2005 YAMAHA VX110 engine

5-58
EPOWRCYLINDER HEAD
2. Tighten:
Cylinder head bolts 1

NOTE:
Lubricate the cylinder head bolts with engine
oil.
T R..
Cylinder head bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
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5-65
EPOWRVALVES AND VALVE SPRINGS
2. Install the new valve guide 2
by striking
the special service tool from the camshaft
side until the valve guide clip 3
contacts
the cylinder head.
NOTE:
Apply engine oil to the surface of the new
valve guide.
Valve guide remover:
Intake (ø4.0 mm):
YM-04111/90890-04111
Exhaust (ø4.5 mm):
YM-04116/90890-04116
Valve guide installer:
Intake (ø4.0 mm):
YM-04112/90890-04112
Exhaust (ø4.5 mm):
YM-04117/90890-04117
3
E
2
3. Insert the special service tool into the
valve guide 2
, and then ream the valve
guide.
NOTE:
Turn the valve guide reamer clockwise to
ream the valve guide.
Do not turn the reamer counterclockwise
when removing the reamer.
4. Measure:
Valve guide inside diameter
Valve guide reamer:
Intake (ø4.0 mm):
YM-04113/90890-04113
Exhaust (ø4.5 mm):
YM-04118/90890-04118
Valve guide inside diameter:
Intake:
4.000–4.012 mm
(0.1575–0.1580 in)
Exhaust:
4.500–4.512 mm
(0.1772–0.1776 in)
2
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5-70
EPOWRVALVES AND VALVE SPRINGS
2. Compress the valve spring, and then
install the valve cotter 1
using a thin
screwdriver with a small amount of grease
applied to it.
Valve spring compressor:
YM-01253/90890-04019
Valve spring compressor
attachment:
(for the intake valve):
YM-04114/90890-04114
(for the exhaust valve):
YM-04108/90890-04108
3. Lightly tap the valve spring retainer with a
plastic hammer to set the valve cotter
securely.
NOTE:
Apply engine oil to the valve pads and valve
lifters before installation.
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5-71
EPOWRCRANKCASE
CRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PAN AND CRANKCASE
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Intake assembly Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.
Exhaust manifold Refer to “EXHAUST MANIFOLD”.
Generator cover Refer to “GENERATOR AND STARTER
MOTOR”.
Oil tank Refer to “OIL TANK”.
Oil pump Refer to “OIL PUMP”.
*: Loosen completely
6
21 20
20 11
10 9
87
23
4
5
16
151718
13 14
1219
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 N •
m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
2nd *
3rd 15 N • m (1.5 kgf
• m, 11 ft
• Ib) 1st 7.8 N • m (0.78 kgf
• m, 5.6 ft
• Ib)
9 × 105 mm
4th 49 ± 5˚
8.4 N •
m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
m (1.5 kgf • m, 11 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
18
AA
1280B
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5-72
EPOWRCRANKCASE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.
Cylinder head Refer to “CAMSHAFTS”.
1 Timing chain 1
2 Engine temperature sensor 1
3 Washer 1
4Bolt 2
5 Thermoswitch (engine) 1
6 Oil pressure switch 1
7Bolt 1
8Bolt 1
9 Anode cover 1
10 Grommet 1
6
21 20
20 11
10 9
87
23
4
5
16
151718
13 14
1219
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 N •
m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
2nd *
3rd 15 N • m (1.5 kgf
• m, 11 ft
• Ib) 1st 7.8 N • m (0.78 kgf
• m, 5.6 ft
• Ib)
9 × 105 mm
4th 49 ± 5˚
8.4 N •
m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
m (1.5 kgf • m, 11 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
18
AA
1280B
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5-77
EPOWRCRANKCASE
Crankcase assembly
1. Lubricate:
Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:
ThreeBond 1280B
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings.
Recommended lubricant:
Engine oil
3. Install:
Dowel pins 1

O-ring 2

11
2
1
1280B
4. Install:
Crankcase bolts
NOTE:
Lubricate the bolt 1
–0 threads and wash-
ers with engine oil.
Finger tighten the crankcase bolts.
M9
× 105 mm bolts:
1–
0
M6
× 55 mm bolts:
A–
H,
J
M6
× 70 mm bolts:
I
15397
ICAEG
86240
HFBDJ
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5-87
EPOWRCONNECTING RODS AND PISTONS
Connecting rod inspection
1. Measure:
Big end oil clearance
Out of specification →
Replace the big
end bearings.
Big end oil clearance:
0.016–0.040 mm
(0.0006–0.0016 in)
Measurement steps:
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the cor-
rect big end oil clearance and prevent
engine damage, the big end bearings
must be installed in their original posi-
tions.
Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves.
Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a
on the big end bear-
ings with the notches b
in the connecting
rod and connecting rod cap.
Put a piece of Plastigauge 1
on the
crankshaft pin.
Assemble the connecting rod halves.
1
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5-89
EPOWRCONNECTING RODS AND PISTONS
For example, if the connecting rod “P1” and the
crankshaft web “P
1” numbers are “5” and “1”
respectively, then the bearing size for “P
1” is:
Bearing size of P
1:
“P
1” (connecting rod) –
“P
1” (crankshaft web)
5 – 1 = 4 (green)
BEARING COLOR CODE
1brown
2 black
3blue
4 green5 G
P4P3P2P1
Connecting rod and piston installation
The following procedure applies to all of the
pistons and connecting rods.
1. Install:
Oil ring
2nd ring
Top ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Install:
Piston 1

Connecting rod 2

Piston pin 3

Piston pin clips 4

NOTE:
Apply engine oil onto the piston pin.
When installing the connecting rod to the pis-
ton, make sure that the “Y” mark a
on the
connecting rod faces towards the left when
the exhaust valve recesses b
on the piston
face upward. Refer to the illustration.
Reinstall each piston into its original cylinder
(numbering order starting from the front: #1
to #4).
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