2005 YAMAHA VX110 service

4-10
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
THROTTLE BODY ASSEMBLY
AND INTAKE MANIFOLD
DISASSEMBLYFollow the left “Step” for disassembly.
1Bolt 4
2 Washer 4
3 Throttle body assembly 1
4Gasket 1
5 Intake manifold 1
6Bolt 2
7 Fuel rail 1
8 × 17 mm
13 N  m (1.3 kgf  m, 9.4 ft  Ib)5 × 15 mm
3.5 N  m (0.35 kgf  m, 2.5 ft  Ib)
8 × 65 mm
13 N  m (1.3 kgf  m, 9.4 ft  Ib)123 4 14151689 107661111
12
13
5
Not reusable
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4-11
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8Gasket 4
9 Fuel injector 4
10 O-ring 4
11 Screw 2
12 Sensor assembly 1
13 O-ring 1
14 Clamp 4
15 Clamp 4
16 Intake manifold joint 4
Reverse the disassembly steps for
assembly.
8 × 17 mm
13 N  m (1.3 kgf  m, 9.4 ft  Ib)5 × 15 mm
3.5 N  m (0.35 kgf  m, 2.5 ft  Ib)
8 × 65 mm
13 N  m (1.3 kgf  m, 9.4 ft  Ib)123 4 14151689 107661111
12
13
5
Not reusable
Not reusable
Not reusable
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4-12
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
SERVICE POINTS
Fuel hose clamps removal
1. Remove:
Fuel hose clamps
CAUTION:
If the fuel hose clamps are removed with-
out cutting the joint first, the fuel hose will
be damaged.
Hose clamps installation
1. Install:
Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones.
NOTE:
Crimp the fuel hose clamps properly to
securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative lead to cut off the elec-
tric current to the electrical systems.
1. Wrap the quick connector with a cloth, and
then rotate the quick connector tab 1
to
the stopper position a
.
WARNING
If the quick connector is removed sud-
denly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
1
a
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EPOWR
1
2
3
4
5
6
7
8
9
CHAPTER 5
POWER UNIT
ENGINE UNIT .................................................................................................. 5-1
EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ................................................ 5-1
SERVICE POINTS .................................................................................... 5-4
Compression pressure measurement ................................................. 5-4
Engine unit removal ............................................................................ 5-6
Shim removal ...................................................................................... 5-6
Engine mount inspection ..................................................................... 5-6
Coupling clearance inspection ............................................................ 5-7
EXHAUST PIPES 1 AND 2.............................................................................. 5-8
EXPLODED DIAGRAM ............................................................................. 5-8
REMOVAL AND INSTALLATION CHART ................................................ 5-8
EXHAUST MANIFOLD .................................................................................. 5-11
EXPLODED DIAGRAM ........................................................................... 5-11
REMOVAL AND INSTALLATION CHART .............................................. 5-11
OIL TANK ...................................................................................................... 5-12
EXPLODED DIAGRAM ........................................................................... 5-12
REMOVAL AND INSTALLATION CHART .............................................. 5-12
SERVICE POINTS .................................................................................. 5-17
Oil tank removal ................................................................................ 5-17
Oil strainer inspection........................................................................ 5-18
Oil tank installation ............................................................................ 5-18
OIL PUMP ...................................................................................................... 5-21
EXPLODED DIAGRAM ........................................................................... 5-21
REMOVAL AND INSTALLATION CHART .............................................. 5-21
SERVICE POINTS .................................................................................. 5-23
Oil strainer inspection........................................................................ 5-23
Oil pump installation .......................................................................... 5-23
REDUCTION DRIVE GEAR .......................................................................... 5-24
EXPLODED DIAGRAM ........................................................................... 5-24
REMOVAL AND INSTALLATION CHART .............................................. 5-24
SERVICE POINTS .................................................................................. 5-28
Drive coupling removal...................................................................... 5-28
Drive shaft removal ........................................................................... 5-28
Bearing removal ................................................................................ 5-28
Oil pump drive shaft inspection ......................................................... 5-29
Drive shaft inspection ........................................................................ 5-29
Bearing installing ............................................................................... 5-30
Drive shaft installation ....................................................................... 5-32
Drive coupling installation ................................................................. 5-32
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EPOWR
GENERATOR AND STARTER MOTOR ....................................................... 5-33
EXPLODED DIAGRAM ........................................................................... 5-33
REMOVAL AND INSTALLATION CHART ............................................. 5-33
SERVICE POINTS .................................................................................. 5-38
Flywheel magneto removal ............................................................... 5-38
Starter clutch inspection .................................................................... 5-38
Flywheel magneto installation ........................................................... 5-40
CAMSHAFTS................................................................................................. 5-41
EXPLODED DIAGRAM ........................................................................... 5-41
REMOVAL AND INSTALLATION CHART .............................................. 5-41
SERVICE POINTS .................................................................................. 5-46
Camshaft removal ............................................................................. 5-46
Camshaft inspection.......................................................................... 5-47
Camshaft sprockets inspection ......................................................... 5-49
Timing chain tensioner inspection ..................................................... 5-49
Camshaft installation ......................................................................... 5-50
CYLINDER HEAD.......................................................................................... 5-54
EXPLODED DIAGRAM ........................................................................... 5-54
REMOVAL AND INSTALLATION CHART ............................................. 5-54
SERVICE POINTS .................................................................................. 5-56
Cylinder head removal ...................................................................... 5-56
Cylinder head inspection ................................................................... 5-56
Cylinder head installation .................................................................. 5-57
VALVES AND VALVE SPRINGS .................................................................. 5-59
EXPLODED DIAGRAM ........................................................................... 5-59
REMOVAL AND INSTALLATION CHART ............................................. 5-59
SERVICE POINTS .................................................................................. 5-61
Valve removal ................................................................................... 5-61
Valve spring inspection ..................................................................... 5-62
Valve inspection ................................................................................ 5-62
Valve guide inspection ...................................................................... 5-64
Valve guide replacement................................................................... 5-64
Valve seat inspection ........................................................................ 5-66
Valve seat reface .............................................................................. 5-67
Valve installation ............................................................................... 5-69
CRANKCASE ................................................................................................ 5-71
EXPLODED DIAGRAM ........................................................................... 5-71
REMOVAL AND INSTALLATION CHART .............................................. 5-71
SERVICE POINTS .................................................................................. 5-75
Crankcase disassembly .................................................................... 5-75
Crankcase inspection ........................................................................ 5-76
Timing chain inspection..................................................................... 5-76
Crankcase assembly ......................................................................... 5-77
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EPOWR
CONNECTING RODS AND PISTONS .......................................................... 5-80
EXPLODED DIAGRAM ........................................................................... 5-80
REMOVAL AND INSTALLATION CHART .............................................. 5-80
SERVICE POINTS .................................................................................. 5-82
Connecting rod and piston removal .................................................. 5-82
Cylinder and piston inspection .......................................................... 5-83
Piston ring inspection ........................................................................ 5-84
Piston pin inspection ......................................................................... 5-86
Connecting rod inspection................................................................. 5-87
Connecting rod and piston installation .............................................. 5-89
CRANKSHAFT .............................................................................................. 5-93
EXPLODED DIAGRAM ........................................................................... 5-93
REMOVAL AND INSTALLATION CHART .............................................. 5-93
SERVICE POINTS .................................................................................. 5-94
Crankshaft removal ........................................................................... 5-94
Crankshaft inspection........................................................................ 5-94
Crankshaft installation ....................................................................... 5-97
COOLING WATER HOSE ............................................................................. 5-98
EXPLODED DIAGRAM ........................................................................... 5-98
REMOVAL AND INSTALLATION CHART .............................................. 5-98
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5-1
EPOWRENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE UNIT REMOVAL
Follow the left “Step” for removal.
Engine oil Drain.
Refer to “POWER UNIT” in Chapter 3.
Storage compartment panel Refer to “FRONT HOOD” in Chapter 8.
Battery negative and positive lead Refer to “FUSE BOX” in Chapter 7.
Fuel hose Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Water lock and exhaust joint Refer to “EXHAUST SYSTEM” in Chapter 8.
1 Bolt/washer 2/2
2 Fuse box 1
14 10
10
2
113
3
4
11
15
12
8
7
9
6
5
2nd 18 N  m (1.8 kgf  m, 13 ft  Ib) 1st 8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
8 × 35 mm
6 × 25 mm
7.8 N  m (0.78 kgf  m, 5.6 ft  Ib)
8 × 35 mm 17 N  m (1.7 kgf  m, 12 ft  Ib)
17 N  m (1.7 kgf  m, 12 ft  Ib)8 × 40 mm
17 N  m (1.7 kgf  m, 12 ft  Ib)
10LT
242
LT
LT
572
LT
LT
271
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5-2
EPOWRENGINE UNIT
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
3Bolt 2
4 Air filter case assembly 1
5Bolt 1
6 ECM and rectifier/regulator
assembly1
7 Clamp/cooling water hose 1/1 Cooling water pilot outlet
8 Clamp/cooling water hose 1/1 Cooling water inlet
9 Clamp/cooling water hose 1/1 Cooling water outlet
10 Coupler 10
11 Bolt/collar 1/1
12 Coupling cover 1
14 10
10
2
113
3
4
11
15
12
8
7
9
6
5
2nd 18 N  m (1.8 kgf  m, 13 ft  Ib) 1st 8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
8 × 35 mm
6 × 25 mm
7.8 N  m (0.78 kgf  m, 5.6 ft  Ib)
8 × 35 mm 17 N  m (1.7 kgf  m, 12 ft  Ib)
17 N  m (1.7 kgf  m, 12 ft  Ib)8 × 40 mm
17 N  m (1.7 kgf  m, 12 ft  Ib)
10LT
242
LT
LT
572
LT
LT
271
ProCarManuals.com