2005 YAMAHA VX110 engine

5-90
EPOWRCONNECTING RODS AND PISTONS
3. Offset:
Piston ring end gaps
aTop ring, oil ring expander spacer
b2nd ring, lower oil ring rail
cUpper oil ring rail
ÈExhaust sidebc
a È
90˚
45˚
90˚
4. Lubricate:
Piston
Piston rings
Cylinder
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5. Lubricate:
Bolt threads
Nut seats
(with the recommended lubricant)
Recommended lubricant:
Molybdenum disulfide grease
6. Lubricate:
Crankshaft pins
Big end bearings
(with the recommended lubricant)
Recommended lubricant:
Engine oil
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5-95
EPOWRCRANKSHAFT
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft
journal oil clearance and prevent engine
damage, the crankshaft journal bearings
must be installed in their original positions.
Measurement steps:
Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase.
Place the upper crankcase upside down
on a bench.
Install the crankshaft journal upper bear-
ings 1
and the crankshaft into the upper
crankcase.
NOTE:
Align the projections a
of the crankshaft
journal upper bearings with the notches b
in the upper crankcase.
Put a piece of Plastigauge 2
on each
crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole
in the crankshaft journal.
Install the crankshaft journal lower bear-
ings into the lower crankcase and assem-
ble the crankcase halves.
NOTE:
Align the projections a
of the crankshaft
journal lower bearings with the notches b
in the lower crankcase.
Do not move the crankshaft until the
clearance measurement has been com-
pleted.
1
a
b
2
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5-97
EPOWRCRANKSHAFT
Crankshaft installation
1. Install:
Crankshaft journal upper bearings
(into the upper crankcase)
Crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
Align the projections a
on the crankshaft
journal upper bearings with the notches b
in
the upper crankcase.
Be sure to install each crankshaft journal
bearing in its original place.
a
b
2. Lubricate:
Crankshaft journals
Crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant:
Engine oil
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6-18
E
JET
PUMPBEARING HOUSING
BEARING HOUSING
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
BEARING HOUSING REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
1 Rubber coupling 1
2Bolt 4
3 Intermediate housing cover 1
4Clamp 2
5 Intermediate drive shaft assembly 1
6 Rubber hose 1
Reverse the removal steps for installation.
2
346
5
1
LT
271
8 × 48 mm
17 N • m (1.7 kgf • m, 12 ft • Ib)
4.2 N • m (0.42 kgf • m, 3.0 ft • Ib)
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E
–+ELEC
1
2
3
4
5
6
7
8
9
CHAPTER 7
ELECTRICAL SYSTEM
ELECTRICAL COMPONENTS........................................................................ 7-1
FUSE BOX ....................................................................................................... 7-2
EXPLODED DIAGRAM ............................................................................. 7-2
REMOVAL AND INSTALLATION CHART ................................................ 7-2
ECM AND RECTIFIER/REGULATOR............................................................. 7-7
EXPLODED DIAGRAM ............................................................................. 7-7
REMOVAL AND INSTALLATION CHART ................................................ 7-7
ELECTRICAL ANALYSIS ............................................................................... 7-9
INSPECTION............................................................................................. 7-9
Digital tester ........................................................................................ 7-9
Low resistance measurement ........................................................... 7-10
Peak voltage measurement .............................................................. 7-10
Peak voltage adapter ........................................................................ 7-11
Test harness .................................................................................... 7-11
IGNITION SYSTEM ....................................................................................... 7-12
WIRING DIAGRAM ................................................................................. 7-12
IGNITION SPARK ................................................................................... 7-14
IGNITION SYSTEM PEAK VOLTAGE .................................................... 7-15
BATTERY ................................................................................................ 7-17
FUSE ....................................................................................................... 7-17
SPARK PLUGS ....................................................................................... 7-17
IGNITION COIL ....................................................................................... 7-18
ENGINE STOP SWITCH ......................................................................... 7-18
ENGINE TEMPERATURE SENSOR ...................................................... 7-19
SENSOR ASSEMBLY ............................................................................. 7-19
THERMOSWITCH (ENGINE).................................................................. 7-20
THERMOSWITCH (EXHAUST) .............................................................. 7-21
MAIN AND FUEL PUMP RELAY............................................................. 7-22
ELECTRONIC CONTROL THROTTLE VALVE RELAY ......................... 7-23
THROTTLE POSITION SENSOR ........................................................... 7-24
ACCELERATOR POSITION SENSOR ................................................... 7-26
CAM POSITION SENSOR ...................................................................... 7-29
SLANT DETECTION SWITCH ................................................................ 7-30
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E
–+ELEC
FUEL CONTROL SYSTEM ........................................................................... 7-31
WIRING DIAGRAM ................................................................................. 7-31
ELECTRIC FUEL PUMP ......................................................................... 7-33
FUEL SENDER ....................................................................................... 7-33
FUEL INJECTOR .................................................................................... 7-34
MAIN AND FUEL PUMP RELAY............................................................. 7-34
OIL PRESSURE SWITCH ....................................................................... 7-34
THERMOSWITCH (ENGINE).................................................................. 7-34
THERMOSWITCH (EXHAUST) .............................................................. 7-34
SLANT DETECTION SWITCH ................................................................ 7-34
REMOTE CONTROL UNIT (DELUXE MODEL ONLY) ........................... 7-34
THROTTLE POSITION SENSOR ........................................................... 7-34
ACCELERATOR POSITION SENSOR ................................................... 7-34
STARTING SYSTEM ..................................................................................... 7-35
WIRING DIAGRAM ................................................................................. 7-35
BATTERY ................................................................................................ 7-37
WIRING CONNECTIONS........................................................................ 7-37
FUSES..................................................................................................... 7-37
START SWITCH...................................................................................... 7-37
STARTER RELAY ................................................................................... 7-38
REMOTE CONTROL UNIT (DELUXE MODEL ONLY) ........................... 7-38
THROTTLE POSITION SENSOR ........................................................... 7-38
ACCELERATOR POSITION SENSOR ................................................... 7-38
STARTER MOTOR ........................................................................................ 7-39
EXPLODED DIAGRAM ........................................................................... 7-39
REMOVAL AND INSTALLATION CHART ............................................. 7-39
SERVICE POINTS .................................................................................. 7-41
Armature inspection .......................................................................... 7-41
Brush holder inspection..................................................................... 7-42
Starter motor front cover inspection .................................................. 7-42
CHARGING SYSTEM .................................................................................... 7-43
WIRING DIAGRAM ................................................................................. 7-43
FUSE ....................................................................................................... 7-44
BATTERY ................................................................................................ 7-44
LIGHTING COIL ...................................................................................... 7-44
RECTIFIER/REGULATOR ...................................................................... 7-44
OFF THROTTLE STEERING SYSTEM......................................................... 7-45
WIRING DIAGRAM ................................................................................. 7-45
STEERING SENSOR .............................................................................. 7-47
ECM......................................................................................................... 7-47
PICKUP COIL .......................................................................................... 7-47
THROTTLE POSITION SENSOR ........................................................... 7-47
ACCELERATOR POSITION SENSOR ................................................... 7-47
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E
–+ELEC
INDICATION SYSTEM .................................................................................. 7-48
WIRING DIAGRAM ................................................................................. 7-48
FUSE ....................................................................................................... 7-50
BATTERY ................................................................................................ 7-50
MAIN AND FUEL PUMP RELAY............................................................. 7-50
ECM......................................................................................................... 7-50
ENGINE TEMPERATURE SENSOR ...................................................... 7-50
THERMOSWITCH (ENGINE).................................................................. 7-50
THERMOSWITCH (EXHAUST) .............................................................. 7-50
REMOTE CONTROL UNIT (DELUXE MODEL ONLY) ........................... 7-50
BUZZER .................................................................................................. 7-50
OIL PRESSURE SWITCH ....................................................................... 7-51
MULTIFUNCTION METER...................................................................... 7-51
Multifunction meter ............................................................................ 7-51
MULTIFUNCTION METER REMOVAL ................................................... 7-51
Display function (Sport model only) .................................................. 7-52
Display function (Deluxe model only) ................................................ 7-53
Speedometer display ........................................................................ 7-54
Tachometer display ........................................................................... 7-55
Hour meter display ............................................................................ 7-55
Voltage meter display........................................................................ 7-55
Low oil pressure warning indicator .................................................... 7-55
Fuel level meter display and fuel warning indicator .......................... 7-55
Overheat warning indicator ............................................................... 7-56
Check engine warning indicator ........................................................ 7-56
Diagnostic display ............................................................................. 7-57
REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY) .......................... 7-58
WIRING DIAGRAM ................................................................................. 7-58
REMOTE CONTROL SYSTEM ............................................................... 7-59
Yamaha Security System indicator ................................................... 7-59
Low-rpm mode indicator.................................................................... 7-59
Checking the remote control transmitter ........................................... 7-60
Transmitter registration ..................................................................... 7-62
Replacing of the transmitter battery .................................................. 7-63
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7-1
E
–+ELECELECTRICAL COMPONENTS
ELECTRICAL COMPONENTS
O
N
M
L
K
J
I
H
G
F
E
D
C
B
A
0
91
2
3
4
5
6
7
8
1Thermoswitch (engine)
2Fuse box
3Slant detection switch
4Starter motor
5Engine temperature sensor
6Spark plugs and ignition coils
7Cam position sensor
8Battery
9Speed sensor
0Sensor assembly (intake air
pressure and intake air tem-
perature)AOil pressure switch
BFuel injectors
CThermoswitch (exhaust)
DRectifier/regulator
EECM
FThrottle body assembly
GLighting coil and pickup coil
HEngine stop switch, engine
shut-off switch, and start
switch
ISteering sensor
JBuzzerKAccelerator position sensor
LElectric fuel pump
MFuel sender
NMultifunction meter
ORemote control unit (Deluxe
model only)
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