2005 YAMAHA VX110 wheel

2-11
ESPECTIGHTENING TORQUES
Oil separator1st
Bolt M6 23.70.372.7572LT5-12
2nd 7.6 0.76 5.5
Ground lead box Bolt M6 3 7.6 0.76 5.5
572LT5-12
Oil tank1st
Bolt M10 515 1.5 11
572LT5-12
2nd 39 3.9 28
Plastic tie/collar1st
Bolt M6 13.70.372.7
5-12
2nd 7.6 0.76 5.5
Oil tank1st
Nut—22.0 0.2 1.4
5-12 2nd 15 1.5 11
3rd 39 3.9 28
Oil tank stay1st
Bolt M10 22.0 0.2 1.4
572LT5-12 2nd 15 1.5 11
3rd 39 3.9 28
Bracket (coupling cover)1st
Bolt M6 23.70.372.7
572LT5-15
2nd 7.6 0.76 5.5
Oil tank cover1st
Bolt M6 83.70.372.7
572LT5-15
2nd 7.6 0.76 5.5
Oil breather plate1st
Bolt M5 91.90.191.4
E5-15
2nd 4.4 0.44 3.2
Baffle plate1st
Bolt M5 31.90.191.4
E5-15
2nd 4.4 0.44 3.2
Oil strainer1st
Bolt M6 23.70.372.7
E5-15
2nd 7.6 0.76 5.5
Oil cooler cover1st
Bolt M6 243.70.372.7
572LT5-15
2nd 7.6 0.76 5.5
Anode Screw M4 1 3.8 0.38 2.7
E5-15
Oil pump assembly BoltM6 6 10 1.0 7.2
572LT5-21 1st
M8 415 1.5 11
2nd 28 2.8 20
Drain plug (engine oil) Bolt M8 1 13 1.3 9.4 5-21
Strainer1st
Bolt M6 23.70.372.7
5-21
2nd 7.6 0.76 5.5
Drive coupling——1282.820
572LT5-24
Reduction drive gear
case1st
Bolt M6 23.70.372.7
572LT5-24
2nd 7.6 0.76 5.5
1st
Bolt M8 515 1.5 11
572LT5-24
2nd 28 2.8 20
Starter motor lead Nut—1 4.9 0.49 3.5
A5-33
Starter motor Bolt M8 2 18 1.8 13 5-33
Generator cover1st
Bolt M10 815 1.5 11
572LT5-33
2nd 50 5.0 36
Flywheel magneto Bolt M10 1 75 7.5 54
E5-33
Starter clutch Bolt M8 6 24 2.4 17 5-33Part to tightenedPart
nameThread
sizeQ’tyTightening torque
RemarksRefer to
page
Nmkgfmftlb
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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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5-33
EPOWRGENERATOR AND STARTER MOTOR
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR COVER AND
FLYWHEEL MAGNETO
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
1 Nut/washer 1/1
2 Starter motor lead 1
3Bolt 2
4 Battery negative lead 1
5 Starter motor 1
6 Band 1
7 Lighting coil coupler 1
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
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5-34
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8 Pickup coil coupler 1
9Bolt 6
10 Bolt 2
11 Generator cover 1
12 Dowel pin 2
13 Gasket 1
14 Idle gear shaft 1
15 Idle gear 1
16 Bolt/washer 1/1
17 Flywheel magneto 1
18 Bolt 6
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
Not reusable
Not reusable
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5-38
EPOWRGENERATOR AND STARTER MOTOR
SERVICE POINTS
Flywheel magneto removal
1. Remove:
Flywheel magneto bolt 1

Washer
NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Flywheel magneto 1

Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2
, remove the flywheel mag-
neto with the rotor puller 3
.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection
1. Check:
Starter clutch rollers 1

Damage/wear →
Replace.
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5-40
EPOWRGENERATOR AND STARTER MOTOR
Flywheel magneto installation
1. Install:
Woodruff key
Flywheel magneto
Washer
Flywheel magneto bolt
NOTE:
Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
Flywheel magneto bolt 1

NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, tighten the flywheel mag-
neto bolt.
CAUTION:
Do not reuse the flywheel magneto bolt and
washer, always replace them with new
ones.
T R..
Flywheel magneto bolt:
75 N  m (7.5 kgf  m, 54 ft  lb)
Sheave holder:
YS-01880-A/90890-01701
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7-54
E
–+ELECINDICATION SYSTEM
Speedometer display
1. Check:
Speedometer display
Does not display → Measure the speed
sensor output voltage and pulses.
2. Measure:
Speed sensor output voltage and pulses
Out of specification → Repair or
replace.
Within specification → Replace the mul-
tifunction meter.
Speed sensor output voltage
(dependant on the paddle wheel
position):
Less than 400 mV/
More than 11.6 V
Output pulse:
2 pulses/one-full turn
Measurement steps:
Apply DC 12 volts to the natural color
three-pin connector (between the red/yel-
low and black/yellow leads).
Rotate the paddle wheel by hand and
measure the voltage between the black/
yellow and yellow leads.
NOTE:
As the paddle wheel is rotated, a square-
wave voltage signal a is produced.
Two pulses occur every time the paddle
wheel makes one-full turn.
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