2005 YAMAHA VX110 Service Manual

3-8
E
INSP
ADJ
FUEL SYSTEM/POWER UNIT
Water separator inspection
1. Inspect:
Water separator 1

Water accumulation →
Drain.
NOTE:
To drain the water, remove the drain plug.
POWER UNIT
Valve clearance adjustment
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) of the compression stroke.
1. Remove:
Ignition coils
Spark plugs
Cylinder head cover
Cylinder head cover gasket
Refer to “CAMSHAFTS” in Chapter 5.
2. Install:
Dial gauge needle
Dial gauge stand 1

(into spark plug hole #1)
Dial gauge 2

Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YB-06585/90890-06585
Dial indicator gauge:
YU-03097
Dial gauge set:
90890-012522
1
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3-9
E
INSP
ADJ
POWER UNIT
3. Measure:
Valve clearance
Out of specification →
Adjust.
Valve clearance (cold):
Intake valve:
0.11–0.20 mm
(0.0043–0.0079 in)
Exhaust valve:
0.25–0.34 mm
(0.0098–0.0134 in)
Measurement steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC of the compression stroke can be
found when the camshaft lobes are turned
away from each other.
Measure the valve clearance with a thick-
ness gauge 1
.
NOTE:
If the valve clearance is incorrect, record
the measured reading.
Measure the valve clearance in the follow-
ing sequence.
Valve clearance measuring sequence:
Cylinder #1
→ #2
→ #4
→ #3
ÈBow end
To measure the valve clearances of the
other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counter-
clockwise as specified in the following
table.
ÉDegrees that the crankshaft is turned clock-
wise
ÊCylinder
ËCombustion cycle
Cylinder #2 180°
Cylinder #4 360°
Cylinder #3 540°
INEX
1
7205403601800
#4 #3
#2
#1
É
Ê
Ë
Ë
Ë
Ë
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3-10
E
INSP
ADJ
POWER UNIT
4. Remove:
Timing chain tensioner cap bolt 1

Gasket
1
5. Turn the timing chain tensioner rod fully
clockwise with a thin screwdriver 1
.
NOTE:
Make sure that the tensioner rod has been fully
turned clockwise.
1
6. Remove:
Intake camshaft caps
Exhaust camshaft caps
Timing chain
(from the camshaft sprockets)
Intake camshaft
Exhaust camshaft
NOTE:
Refer to “CAMSHAFTS” in Chapter 5.
When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to
prevent it from falling into the crankcase.
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3-11
E
INSP
ADJ
POWER UNIT
7. Adjust:
Valve clearance
Adjustment steps:
Remove the valve lifter 1
and the valve
pad 2
.
NOTE:
Cover the timing chain opening with a rag
to prevent the valve pad from falling into
the crankcase.
Note the position of each valve lifter 3
and valve pad 4
so that they can be
installed in the correct place.
Select the proper valve pad from the fol-
lowing table.
Valve pad thickness
rangeAvailable valve
pads
Nos.
120–2401.20–
2.40 mm25 thicknesses in
0.05 mm increments
NOTE:
The thickness a
of each valve pad is
marked in hundredths of millimeters on
the side that touches the valve lifter.
Since valve pads of various sizes are orig-
inally installed, the valve pad number
must be rounded in order to reach the
closest equivalent to the original.
Round off the original valve pad number
according to the following table.
Last digit Rounded value
0 or 2 0
55
810
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
Locate the rounded number of the origi-
nal valve pad and the measured valve
clearance in the valve pad selection
table. The point where the column and
row intersect is the new valve pad num-
ber.
1
2
148
a
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3-12
E
INSP
ADJ
POWER UNIT
NOTE:
The new valve pad number is only an
approximation. The valve clearance must
be measured again and the above steps
should be repeated if the measurement is
still incorrect.
Install the new valve pad 5
and the valve
lifter 6
.
NOTE:
Lubricate the valve pad with molybdenum
disulfide grease.
Lubricate the valve lifter with molybdenum
disulfide oil.
The valve lifter must turn smoothly when
rotated by hand.
Install the valve lifter and the valve pad in
the correct place.
Install the exhaust and intake camshafts,
timing chain, and camshaft caps.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
NOTE:
Refer to “Camshaft installation — CAM-
SHAFTS” in Chapter 5.
Lubricate the camshafts, camshaft lobes,
and camshaft journals.
Install the exhaust camshaft first.
Align the camshaft marks with the cam-
shaft cap marks.
Turn the crankshaft clockwise several full
turns to seat the parts.
Measure the valve clearance again.
If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
6
5
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3-13
E
INSP
ADJ
POWER UNIT
Intake
Exhaust
MEASURED
CLEARANCEORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00–0.02 120 125 130
135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.03–0.07 120 125 130 135
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.08–0.10 120 125 130 135 140
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.11–0.20 STANDARD CLEARANCE
0.21–0.22 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.23–0.27130135140145150155160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.28–0.32 135 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.33–0.37 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38–0.42 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.43–0.47 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.48–0.52 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53–0.57 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58–0.62 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63–0.67 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68–0.72 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73–0.77 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78–0.82 185 190 195 200 205 210 215 220 225 230 235 240
0.83–0.87 190 195 200 205 210 215 220 225 230 235 240
0.88–0.92 195 200 205 210 215 220 225 230 235 240
Example:
Intake valve clearance (cold)
0.11–0.20 mm (0.0043–0.0079 in)
Rounded value 150
Measured valve clearance is 0.24 mm (0.0094 in)
Replace pad 150 with pad 160
Pad No. 150 = 1.50 mm (0.0591 in)
Pad No. 160 = 1.60 mm (0.0630 in)0.93–0.97 200 205 210 215 220 225 230 235 240
0.98–1.02 205 210 215 220 225 230 235 240
1.03–1.07 210 215 220 225 230 235 240
1.08–1.12 215 220 225 230 235 240
1.13–1.17 220 225 230 235 240
1.18–1.22 225 230 235 240
1.23–1.27 230 235 240
1.28–1.32 235 240
1.33–1.37 240
MEASURED
CLEARANCEORIGINAL VALVE PAD NUMBER
120 125 130 135 140 145 150 155 160 165
170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.00–0.01 120 125 130 135
140 145 150 155 160 165 170 175 180 185 190 195 200 205 210
0.02–0.06 120 125 130 135 140
145 150 155 160 165 170 175 180 185 190 195 200 205 210 215
0.07–0.11 120 125 130 135 140 145
150 155 160 165 170 175 180 185 190 195 200 205 210 215 220
0.12–0.16 120 125 130 135 140 145 150
155 160 165 170 175 180 185 190 195 200 205 210 215 220 225
0.17–0.21 120 125 130 135 140 145 150 155
160 165 170 175 180 185 190 195 200 205 210 215 220 225 230
0.22–0.24 120 125 130 135 140 145 150 155 160
165 170 175 180 185 190 195 200 205 210 215 220 225 230 235
0.25–0.34 STANDARD CLEARANCE
0.35–0.37 125 130 135 140 145 150 155 160 165 170
175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.38–0.42 130 135 140 145 150 155 160 165 170 175
180 185 190 195 200 205 210 215 220 225 230 235 240
0.43–0.47135140145150155160165170175180185 190 195 200 205 210 215 220 225 230 235 240
0.48–0.52 140 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.53–0.57 145 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.58–0.62 150 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.63–0.67 155 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.68–0.72 160 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.73–0.77 165 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.78–0.82 170 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.83–0.87 175 180 185 190 195 200 205 210 215 220 225 230 235 240
0.88–0.92 180 185 190 195 200 205 210 215 220 225 230 235 240
0.93–0.97 185 190 195 200 205 210 215 220 225 230 235 240
0.98–1.02 190 195 200 205 210 215 220 225 230 235 240
1.03–1.07 195 200 205 210 215 220 225 230 235 240
Example:
Exhaust valve clearance (cold)
0.25–0.34 mm (0.0098–0.0134 in)
Rounded value 170
Measured valve clearance is 0.44 mm (0.0173 in)
Replace pad 170 with pad 185
Pad No. 170 = 1.70 mm (0.0669 in)
Pad No. 185 = 1.85 mm (0.0728 in)1.08–1.12 200 205 210 215 220 225 230 235 240
1.13–1.17 205 210 215 220 225 230 235 240
1.18–1.22 210 215 220 225 230 235 240
1.23–1.27 215 220 225 230 235 240
1.28–1.32 220 225 230 235 240
1.33–1.37 225 230 235 240
1.38–1.42 230 235 240
1.43–1.47 235 240
1.48–1.52 240
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3-14
E
INSP
ADJ
POWER UNIT
8. Remove:
Dial gauge
Dial gauge stand
Dial gauge needle
9. Install:
All removed parts
NOTE:
For installation, reverse the removal proce-
dure.
Engine oil level check
1. Check:
Engine oil level
Checking steps:
CAUTION:
When checking the engine oil level on
water, be careful of other watercraft,
boats, swimmers, or obstacles. The
water current or wind can cause the
watercraft to move and lead to a colli-
sion.
When checking the engine oil level on
land, supply water to the cooling water
passages.
Make sure that engine has enough oil
but do not overfill. If there is too little
oil, the engine can be damaged. If there
is too much oil, the air filter can
become saturated with oil, perma-
nently damaging the filter and reduc-
ing engine performance. Follow the
checking procedure carefully.
Make sure that debris or water does
not enter the oil tank filler hole. Debris
or water in the engine oil can cause
serious engine damage.
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3-15
E
INSP
ADJ
POWER UNIT
Place the watercraft in a horizontal posi-
tion or launch the watercraft.
Remove the seat.
Remove the oil tank filler cap 1
and
check for oil on the dipstick 2
.
If there is no oil on the dipstick, pour
enough oil so that the tip of the dipstick
comes into contact with the oil, and then
install the filler cap.
Start the engine.
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil
tank.
NOTE:
The engine cannot be started if the
Yamaha Security System is in the lock
mode. (Deluxe model only)
For information on the Yamaha Security
System, see the owner’s manual. (Deluxe
model only)
Run the engine at trolling speed for 6
minutes or more, and then turn the
engine off.
CAUTION:
When checking the oil level on land, be
sure to connect a garden hose to the
watercraft for proper water supply.
NOTE:
If the ambient temperature is 20°C (68°F)
or less, warm up the engine for an addi-
tional 5 minutes.
Remove the oil tank filler cap 1
, wipe the
dipstick 2
clean, and then screw the filler
cap into the filler hole completely.
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