Yamaha VX110Deluxe Manuel de service

SERVICE MANUALVX110 SportWaveRunnerF1K-28197-1H-11LIT-18616-02-91*LIT186160291*VX110 Deluxe

1-1EGENINFOIDENTIFICATION NUMBERSA60700-0*IDENTIFICATION NUMBERSPRIMARY l.D. NUMBERThe primary l.D. number is stamped on a labelattached to the inside

5-1EPOWRENGINE UNITENGINE UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE UNIT REMOVALFollow the

5-2EPOWRENGINE UNITEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points3Bolt 24 Air filter case assembly 15Bolt 16 ECM and rectifier/regulator

5-3EPOWRENGINE UNITEXPLODED DIAGRAM*: As required.Step Procedure/Part name Q’ty Service points13 Bolt/washer 4/414 Shim *15 Engine unit 1Reverse the r

5-4EPOWRENGINE UNITSERVICE POINTSCompression pressure measurementThe following procedure applies to all of thecylinders.NOTE:Insufficient compression

5-5EPOWRENGINE UNIT5. Measure:• Compression pressureOut of specification → Refer to steps (b)and (c).6. Install:• Spark plugMinimum compression pressu

5-6EPOWRENGINE UNIT7. Install:• Ignition coilsT R..Ignition coils bolt:7.6 N • m (0.76 kgf • m, 5.5 ft • lb)LOCTITE 572Engine unit removal1. Remove:•

5-7EPOWRENGINE UNITCoupling clearance inspection1. Measure:• Clearance a • Clearance b Out of specification → Adjust.NOTE:Measure the clearances with

5-8EPOWREXHAUST PIPES 1 AND 2EXHAUST PIPES 1 AND 2EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST PI

5-9EPOWREXHAUST PIPES 1 AND 2EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points7Bolt 1NOTE:Tighten the bolts in the sequence indicated.8Bolt

5-10EPOWREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points11 Exhaust pipe 2 112 Bolt 313 Exhaust pipe end 114 Gasket 215 Silencer 116 Inner

1-2EGENINFO SAFETY WHILE WORKING SAFETY WHILE WORKINGTo prevent and accident or injury and toensure quality service, follow the safety proce-dures pro

5-11EPOWREXHAUST MANIFOLDEXHAUST MANIFOLDEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST MANIFOLD RE

5-12EPOWROIL TANKOIL TANKEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL TANK REMOVALFollow the left “St

5-13EPOWROIL TANKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9 Oil separator 110 Clamp/breather hose 1/1Ê To air intake pipe11 Clamp/b

5-14EPOWROIL TANKEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points20 Nut 221 Bolt 522 Oil tank 123 Oil tank stay 124 Pin 225 O-ring 426 Con

5-15EPOWROIL TANKEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL TANK DISASSEMBLYFollow the left “Step”

5-16EPOWROIL TANKEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points11 Bolt 312 Baffle plate 113 Bolt 214 Oil strainer 115 Bolt 2416 Oil coo

5-17EPOWROIL TANKSERVICE POINTSOil tank removal1. Remove:• Oil tankNOTE:Loosen the oil tank bolts and nuts in thesequence shown.3597642182. Remove:• O

5-18EPOWROIL TANK4. Remove:• Oil cooler covers• GasketsNOTE:Loosen the oil cooler cover bolts in thesequence shown.819127651110342Oil strainer inspect

5-19EPOWR2. Install:• Gasket• Oil breather plateNOTE:Tighten the oil breather plate bolts in thesequence shown.T R..Oil breather plate bolt:1st:1.9 N

5-20EPOWROIL TANK4. Install:• Oil tankNOTE:Tighten the oil tank nuts and bolts in thesequence shown.T R..Bolt 1:1st:15 N • m (1.5 kgf • m, 11 ft • lb)

1-3EGENINFO SAFETY WHILE WORKINGUnder normal conditions, the lubricants men-tioned in this manual should not harm or behazardous to your skin. However

5-21EPOWROIL PUMPOIL PUMPEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP ASSEMBLY REMOVALFollow th

5-22EPOWROIL PUMPEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8Bolt 29 Strainer 1Reverse the removal steps for installation.2nd 28 N

5-23EPOWROIL PUMPSERVICE POINTSOil strainer inspection1. Check:• Oil strainer 1 Damage → Replace.Contaminants → Clean.1Oil pump installation1. Install

5-24EPOWRREDUCTION DRIVE GEARREDUCTION DRIVE GEAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsREDUCTION D

5-25EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Reduction drive gear case assembly17Gasket 18Pin 29 Circlip

5-26EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART*1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service pointsREDUCTIO

5-27EPOWRREDUCTION DRIVE GEAREXPLODED DIAGRAM*1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service points9 Circlip 110 Bearing 111 Reduction dri

5-28EPOWRREDUCTION DRIVE GEARSERVICE POINTSDrive coupling removal1. Remove:• Reduction drive gear housing2. Remove:• Drive coupling 1 NOTE:While holdi

5-29EPOWRREDUCTION DRIVE GEAR2. Remove:• Circlip• Reduction drive gear bearingÈFor USA and CanadaÉFor worldwideSlide hammer and adapters:YB-06096Stopp

5-30EPOWRREDUCTION DRIVE GEARBearing installing1. Install:• Reduction drive gear bearingNOTE:Install the reduction driver gear bearing usinga press.Dr

1-4EGENINFO SAFETY WHILE WORKING3.Non-reusable partsAlways use new gaskets, seals, O-rings,oil seals, cotter pins, circlips, etc., wheninstalling or a

5-31EPOWRREDUCTION DRIVE GEAR3. Install:• Collar• Rear bearingNOTE:• Install the front bearing using a press.• Before installing the rear bearing, hol

5-32EPOWRREDUCTION DRIVE GEARDrive shaft installation1. Install:• Drive shaft• CollarNOTE:Press the into the reduction drive gear caseusing a pipe tha

5-33EPOWRGENERATOR AND STARTER MOTORGENERATOR AND STARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service po

5-34EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Pickup coil coupler 19Bolt 610 Bolt 211 Generator co

5-35EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points19 Starter clutch 120 Starter gear 121 Woodruff key 1

5-36EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsGENERATOR DISASSEMBLYFo

5-37EPOWRGENERATOR AND STARTER MOTOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points5 Holder 16Bolt 37 Lighting coil 1Reverse the disasse

5-38EPOWRGENERATOR AND STARTER MOTORSERVICE POINTSFlywheel magneto removal1. Remove:• Flywheel magneto bolt 1 • WasherNOTE:While holding the flywheel

5-39EPOWRGENERATOR AND STARTER MOTOR2. Check:• Starter clutch 1 • Starter gear 2 Burrs/chips/roughness/wear → Replacethe defective part(s).3. Check:•

5-40EPOWRGENERATOR AND STARTER MOTORFlywheel magneto installation1. Install:• Woodruff key• Flywheel magneto• Washer• Flywheel magneto boltNOTE:• Clea

1-5EGENINFOSPECIAL SERVICE TOOLSSPECIAL SERVICE TOOLSUsing the correct special service tools recom-mended by Yamaha, will aid the work andenable accur

5-41EPOWRCAMSHAFTSCAMSHAFTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCYLINDER HEAD COVER REMOVALFollow

5-42EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9Bolt 110 Cooling water pipe 111 O-ring 112 Bolt 613 Rubber mount 614 Cy

5-43EPOWRCAMSHAFTSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCAMSHAFT REMOVALFollow the left “Step” for

5-44EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Timing chain tensioner 17 Timing chain tensioner gasket 18 Timing chai

5-45EPOWRCAMSHAFTSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Exhaust camshaft 119 Bolt 220 Exhaust camshaft sprocket 121 Pin 122 T

5-46EPOWRCAMSHAFTSSERVICE POINTSCamshaft removal1. Install:• Dial gauge needle• Dial gauge stand 1 (into spark plug hole #1)• Dial gauge 2 2. Turn the

5-47EPOWRCAMSHAFTS5. Remove:• Camshaft caps• Dowel pinsNOTE:Loosen the intake and exhaust camshaft capbolts in the sequence shown.11076321418151141075

5-48EPOWRCAMSHAFTS3. Measure:• Camshaft runoutOut of specification → Replace.Maximum camshaft runout:0.03 mm (0.0012 in)4. Measure:• Camshaft-journal-

5-49EPOWRCAMSHAFTS5. Measure:• Camshaft journal diameter a Out of specification → Replace the cam-shaft.Within specification → Replace the cyl-inder h

5-50EPOWRCAMSHAFTSCamshaft installation1. Install:• Exhaust camshaft sprocket 1 • Intake camshaft sprocket 2 (with the special service tool 3)NOTE:Ins

1-6EGENINFOSPECIAL SERVICE TOOLS0Compression gauge extensionP/N. 90890-06582ACylinder gauge setP/N. YU-0301790890-06759BCompression gaugeP/N. YU-33223

5-51EPOWRCAMSHAFTS• Install the exhaust and intake camshaftcaps.NOTE:Gradually tighten the intake and exhaustcamshaft cap bolts in 2–3 steps in theseq

5-52EPOWRCAMSHAFTST R..Timing chain tensioner bolt:10 N • m (1.0 kgf • m, 7.2 ft • lb)• Remove the screwdriver, make sure thetiming chain tensioner ro

5-53EPOWRCAMSHAFTS7. Install:• Cylinder head cover gasket• Cylinder head coverNOTE:• Apply sealant onto the mating surfaces of thecylinder head cover

5-54EPOWRCYLINDER HEADCYLINDER HEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsCYLINDER HEAD REMOVALFol

5-55EPOWRCYLINDER HEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Nut/washer 2/25 Nut/washer 3/36 Nut/washer 5/57 Cylinder head 18 C

5-56EPOWRCYLINDER HEADSERVICE POINTSCylinder head removal1. Remove:• Cylinder head bolts 1 2. Remove:• Cylinder head nutsNOTE:Loosen the cylinder head

5-57EPOWRCYLINDER HEAD3. Measure:• Cylinder head warpageOut of specification → Replace the cyl-inder head.Cylinder head warpage limit:0.1 mm (0.004 in

5-58EPOWRCYLINDER HEAD2. Tighten:• Cylinder head bolts 1 NOTE:Lubricate the cylinder head bolts with engineoil.T R..Cylinder head bolt:10 N • m (1.0 k

5-59EPOWRVALVES AND VALVE SPRINGSVALVES AND VALVE SPRINGSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service pointsVA

5-60EPOWRVALVES AND VALVE SPRINGSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Exhaust valve lifter 811 Exhaust valve pad 812 Exhaust

1-7EGENINFOSPECIAL SERVICE TOOLSKYamaha diagnostic systemP/N. 60V-85300-02-00LYamaha diagnostic systemP/N. 60V-WS853-03L60V-WS853-03K60V-85300-02-00RE

5-61EPOWRVALVES AND VALVE SPRINGSSERVICE POINTSValve removal1. Remove:• Valve lifter 1 • Valve pad 2 NOTE:Make a note of the position of each valve li

5-62EPOWRVALVES AND VALVE SPRINGSValve spring inspection1. Measure:• Valve spring free length a Out of specification → Replace thevalve spring.2. Meas

5-63EPOWRVALVES AND VALVE SPRINGS4. Measure:• Valve stem diameter a Out of specification → Replace thevalve.Valve stem diameter a:Intake valve:3.975–3

5-64EPOWRVALVES AND VALVE SPRINGSValve guide inspectionNOTE:Before checking the valve guide make surethat the valve stem diameter is within specifi-ca

5-65EPOWRVALVES AND VALVE SPRINGS2. Install the new valve guide 2 by strikingthe special service tool from the camshaftside until the valve guide clip

5-66EPOWRVALVES AND VALVE SPRINGSValve seat inspection1. Eliminate carbon deposits from the valvewith a scraper.2. Apply a thin, even layer of Mechani

5-67EPOWRVALVES AND VALVE SPRINGSValve seat reface1. Reface the valve seat with the valve seatcutter.2. Cut the surface of the valve seat with a 45°cu

5-68EPOWRVALVES AND VALVE SPRINGS4. Use a 60° cutter to adjust the contact widthof the bottom edge of the valve seat.bPrevious contact width60˚b5. Use

5-69EPOWRVALVES AND VALVE SPRINGS9. Apply a thin, even layer of lapping com-pound onto the valve seat, and then lapthe valve using a valve lapper (com

5-70EPOWRVALVES AND VALVE SPRINGS2. Compress the valve spring, and theninstall the valve cotter 1 using a thinscrewdriver with a small amount of greas

1-8EGENINFOSPECIAL SERVICE TOOLS7Forward gear bearing cup installer(reduction drive gear)P/N. YB-06276-B8Ball bearing attachment(reduction drive gear)

5-71EPOWRCRANKCASECRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PAN AND CRANKCASE REMOVALFoll

5-72EPOWRCRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service pointsReduction drive gear case Refer to “REDUCTION DRIVE GEAR”.Cylinder head

5-73EPOWRCRANKCASEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points11 Anode 112 Bolt 1513 Oil pan 114 Gasket 115 Bolt 216 Bolt 117 Bolt 718

5-74EPOWRCRANKCASEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PIPE AND OIL FILTER BOLT REMOVALFollow

5-75EPOWRCRANKCASESERVICE POINTSCrankcase disassembly1. Remove:• Oil pan boltsNOTE:• Loosen each bolt 1/4 of a turn at a time, instages and in a criss

5-76EPOWRCRANKCASE4. Remove:• Dowel pinsCrankcase inspection1. Thoroughly wash the crankcase halves ina mild solvent.2. Thoroughly clean all the gaske

5-77EPOWRCRANKCASECrankcase assembly1. Lubricate:Crankshaft journal bearings(with the recommended lubricant)2. Apply:• ThreeBond 1280B (onto the crank

5-78EPOWRCRANKCASE5. Tighten:• Crankcase bolts 1–0 NOTE:• Do not reuse crankcase bolts 1–0.• The tightening procedure of crankcase bolts1–0 is angle c

5-79EPOWRCRANKCASECAUTION:• Do not use a torque wrench to tightenthe bolt to the specified angle.• Tighten the bolt until it is at the speci-fied angl

5-80EPOWRCONNECTING RODS AND PISTONSCONNECTING RODS AND PISTONSEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service poi

1-9EGENINFOSPECIAL SERVICE TOOLSEValve seat cutter holderP/N. 90890-06811 (ø4.0 mm)90890-06812 (ø4.5 mm)FNeway valve seat cutter kitP/N. YM-91044GPist

5-81EPOWRCONNECTING RODS AND PISTONSEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Bolt 89 Big end upper bearing 410 Top ring 411 2nd ri

5-82EPOWRCONNECTING RODS AND PISTONSSERVICE POINTSConnecting rod and piston removalThe following procedure applies to all of theconnecting rods and pi

5-83EPOWRCONNECTING RODS AND PISTONSCylinder and piston inspectionThe following procedure applies to all of thecylinders and pistons.1. Check: • Pisto

5-84EPOWRCONNECTING RODS AND PISTONS• If out of specification, replace the pistonand piston rings as a set. • Calculate the piston-to-cylinder clearan

5-85EPOWRCONNECTING RODS AND PISTONS2. Install:• Piston ring (into the cylinder)NOTE:Level the piston ring in the cylinder with thepiston crown. a5 mm

5-86EPOWRCONNECTING RODS AND PISTONSPiston pin inspectionThe following procedure applies to all of thepiston pins.1. Check: • Piston pin Bluediscolora

5-87EPOWRCONNECTING RODS AND PISTONSConnecting rod inspection1. Measure: • Big end oil clearance Out of specification → Replace the bigend bearings.Bi

5-88EPOWRCONNECTING RODS AND PISTONSNOTE:• Do not move the connecting rod or crank-shaft until the clearance measurementhas been completed. • Lubricat

5-89EPOWRCONNECTING RODS AND PISTONSFor example, if the connecting rod “P1” and thecrankshaft web “P1” numbers are “5” and “1”respectively, then the b

5-90EPOWRCONNECTING RODS AND PISTONS3. Offset: • Piston ring end gaps aTop ring, oil ring expander spacerb2nd ring, lower oil ring railcUpper oil ring

1-10EGENINFOSPECIAL SERVICE TOOLSPOuter race installer—forward gear(jet pump oil seal and reduction drive gear)P/N. YB-06085QBall bearing attachment (

5-91EPOWRCONNECTING RODS AND PISTONS7. Install: • Big end bearings • Connecting rod assembly 1 (into the cylinder and onto the crankshaft pin)• Connec

5-92EPOWRCONNECTING RODS AND PISTONS9. Tighten: • Connecting rod nuts WARNING• Replace the connecting rod bolts andnuts with new ones. • Clean the con

5-93EPOWRCRANKSHAFTCRANKSHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANKSHAFT REMOVALFollow the le

5-94EPOWRCRANKSHAFTSERVICE POINTSCrankshaft removal1. Remove: • Crankshaft 1 • Crankshaft journal lower bearings (from the lower crankcase)• Crankshaf

5-95EPOWRCRANKSHAFTCAUTION:Do not interchange the crankshaft journalbearings. To obtain the correct crankshaftjournal oil clearance and prevent engine

5-96EPOWRCRANKSHAFT• Tighten the bolts to specification in theorder of the numbers on the crankcase.Refer to “Crankcase assembly”—“CRANKCASE”.• Remove

5-97EPOWRCRANKSHAFTCrankshaft installation1. Install: • Crankshaft journal upper bearings (into the upper crankcase)• Crankshaft journal lower bearing

5-98EPOWRCOOLING WATER HOSECOOLING WATER HOSEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCOOLING WATER H

5-99EPOWRCOOLING WATER HOSEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4 Joint 15 Clamp/cooling water hose 1/1ÊTo oil tank6 Clamp/cool

EJETPUMP123456789CHAPTER 6JET PUMP UNITINTAKE GRATE AND RIDE PLATE ...6-1EXPLODED DIAGRAM

ENOTICEThis manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trainedmechanics when performing maintenance procedures a

6-1EJETPUMPINTAKE GRATE AND RIDE PLATEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsINTAKE GRATE, RIDE PLA

6-2EJETPUMPINTAKE GRATE AND RIDE PLATEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6Bolt 47 Ride plate 1Reverse the removal steps for i

6-3EJETPUMPJET PUMP UNITJET PUMP UNITEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsJET PUMP UNIT REMOVALFo

6-4EJETPUMPJET PUMP UNITEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9 Collar 210 Bolt 211 Rubber plate 212 Bolt 113 Bolt 214 Bolt 415

6-5EJETPUMPREVERSE GATE (DELUXE MODEL ONLY)REVERSE GATE (DELUXE MODEL ONLY)EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty

6-6EJETPUMPJET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1JET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1EXPLODED DIAGRAMREMOVAL AND

6-7EJETPUMPJET THRUST NOZZLE, IMPELLER DUCT, AND IMPELLER HOUSING 1EXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Bolt 411 Water inlet

6-8EJETPUMPIMPELLER DUCT AND DRIVE SHAFTIMPELLER DUCT AND DRIVE SHAFTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART*1: EPNOC grease AP #0Step Procedur

6-9EJETPUMPIMPELLER DUCT AND DRIVE SHAFTEXPLODED DIAGRAM*1: EPNOC grease AP #0Step Procedure/Part name Q’ty Service points8 Oil seal 19 Rear bearing

6-10EJETPUMPIMPELLER DUCT AND DRIVE SHAFTSERVICE POINTSDrive shaft removal1. Remove:• ImpellerNOTE:Hold the impeller duct assembly in a visebetween tw

ESPEC123456789CHAPTER 2SPECIFICATIONSGENERAL SPECIFICATIONS ...2-1MAINTENANCE SP

6-11EJETPUMPIMPELLER DUCT AND DRIVE SHAFT4. Remove:• Oil sealsNOTE:Remove the oil seals using a flat head screw-driver.5. Remove:• Front bearingNOTE:R

6-12EJETPUMPIMPELLER DUCT AND DRIVE SHAFTDrive shaft installation1. Install:• Oil sealsDriver handle—large:YB-06071Driver rod LS:90890-06606Outer race

6-13EJETPUMPIMPELLER DUCT AND DRIVE SHAFT5. Install:• Front bearingNOTE:Press the spacer and the front bearing using apipe that is more than 60 mm (2.

6-14EJETPUMP8. Install:• Impeller NOTE:Hold the impeller duct assembly in a visebetween two aluminum plates a.T R..Impeller:75 N • m (7.5 kgf • m, 54

6-15EJETPUMPTRANSOM PLATE AND HOSESTRANSOM PLATE AND HOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTR

6-16EJETPUMPTRANSOM PLATE AND HOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Bilge strainer 17 Nut/washer 2/28 Nut/washer 2/29 Tra

6-17EJETPUMPTRANSOM PLATE AND HOSESSERVICE POINTSBilge strainer inspectionRefer to “JET PUMP UNIT” in Chapter 3.Bilge hose inspection1. Inspect:• Bilg

6-18EJETPUMPBEARING HOUSINGBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING RE

6-19EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsBEARING HOUSING DISASSEMBLYFollow

6-20EJETPUMPBEARING HOUSINGEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Oil seal 17 Bearing 18 Oil seal 19 Oil seal 110 Bearing housi

2-1ESPECGENERAL SPECIFICATIONSGENERAL SPECIFICATIONS Item UnitModelVX110 Sport VX110 DeluxeModel codeHull F1KEngine/jet 6D3DimensionsLength mm (in) 3,

6-21EJETPUMPBEARING HOUSINGSERVICE POINTSDriven coupling removal and installation1. Remove and install:• Driven coupling NOTE:• Install the driven cou

6-22EJETPUMPBEARING HOUSINGBearing removal1. Remove:• Circlip• Bearing • Oil sealsÈFor USA and CanadaÉFor worldwideNOTE:Remove the bearing and oil sea

6-23EJETPUMPBEARING HOUSINGBearing and oil seals installation1. Install:• Oil seals• BearingNOTE:Install the bearing using a press. Driver handle—larg

6-24EJETPUMPBEARING HOUSINGIntermediate drive shaft installation1. Install:• Intermediate drive shaftNOTE:Install the intermediate drive shaft using a

E– +ELEC123456789CHAPTER 7ELECTRICAL SYSTEMELECTRICAL COMPONENTS...7-1FUSE BOX..

E– +ELECFUEL CONTROL SYSTEM ...7-31WIRING DIAGRAM ...

E– +ELECINDICATION SYSTEM ... 7-49WIRING DIAGRAM ...

7-1E– +ELECELECTRICAL COMPONENTSELECTRICAL COMPONENTSONMLKJIHGFEDCBA09123456781 Thermoswitch (engine)2 Fuse box3 Slant detection switch4 Starter motor

7-2E– +ELECFUSE BOXFUSE BOXEXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFUSE BOX REMOVALFollow the left

2-2ESPECPON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2RON*: Research Octane NumberFuel and oilFuel type Regular unleaded

7-3E– +ELECFUSE BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points9Bracket 110 Rubber mount 111 Main and fuel pump relay 112 Electronic

7-4E– +ELECFUSE BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points20 Plate 121 Bolt 222 Cover 223 Positive battery lead 124 Starter moto

7-5E– +ELECFUSE BOXEXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points30 Wiring harness 1 Black31 Holder 232 Pipe 133 Battery 134 Battery bo

7-6E– +ELECFUSE BOX1265431 Positive battery lead2 Starter motor lead (white tape)3 Starter relay4 Wiring harness (black)5 Wiring harness (brown)6 Wiri

7-7E– +ELECECM AND RECTIFIER/REGULATORECM AND RECTIFIER/REGULATOREXPLODED DIAGRAM REMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service

7-8E– +ELECECM AND RECTIFIER/REGULATOREXPLODED DIAGRAM Step Procedure/Part name Q’ty Service points8Bolt 29Bracket 110 Grommet 211 Collar 2Reverse the

7-9E– +ELECELECTRICAL ANALYSISELECTRICAL ANALYSISINSPECTIONCAUTION:• All measuring instruments should be han-dled with special care. Damaged or mis-ha

7-10E– +ELECELECTRICAL ANALYSISLow resistance measurementNOTE:• When measuring a resistance of 10 Ω or lessusing a digital tester, the correct measure

7-11E– +ELECELECTRICAL ANALYSISPeak voltage adapterNOTE:• Throughout this chapter the part numbers ofthe specified peak voltage adapters havebeen omit

7-12E– +ELECIGNITION SYSTEMIGNITION SYSTEMWIRING DIAGRAM10A10A3A30A20AWBrBRFREEPUSHBWFREEPUSHBr BrFREEPUSHBWWBrBr BrBrRWB/WB/OB/OB/OB/RP/RP/RW/BP/WP/W

2-3ESPECMAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINE Item UnitModelVX110 Sport VX110 DeluxeCylinder headWarpage limit mm (in) 0.1 (0.004

7-13E– +ELECIGNITION SYSTEMWIRING DIAGRAM10A10A3A30A20AWBrBRFREEPUSHBWFREEPUSHBr BrFREEPUSHBWWBrBr BrBrRWB/WB/OB/OB/OB/RP/RP/RW/BP/WP/WB/OL/BB/WB/RB/O

7-14E– +ELECIGNITION SYSTEMIGNITION SPARK WARNING• When checking the spark gap, do nottouch any of the connections of the sparkchecker/ignition tester

7-15E– +ELECIGNITION SYSTEMIGNITION SYSTEM PEAK VOLTAGE WARNINGWhen checking the electrical components,do not touch any of the connections of thedigit

7-16E– +ELECIGNITION SYSTEM2. Measure:• Pickup coil output peak voltageBelow specification → Replace thepickup coil.Above specification → Replace theE

7-17E– +ELECNOTE:To crank the engine, connect the engine shut-off cord (lanyard) to the engine shut-off switch,and then press the start switch and eng

7-18E– +ELECIGNITION COIL1. Measure:• Primary coil resistanceOut of specification → Replace.NOTE:When measuring a resistance of 10 Ω or lessusing a di

7-19E– +ELECIGNITION SYSTEMENGINE TEMPERATURE SENSOR1. Measure:• Engine temperature sensor resistance(at the specified temperature)Out of specificatio

7-20E– +ELECIGNITION SYSTEMTHERMOSWITCH (ENGINE)1. Check:• Thermoswitch (engine) continuity(at the specified temperature)Out of specification → Replac

7-21E– +ELECTHERMOSWITCH (EXHAUST)1. Check:• Thermoswitch (exhaust) continuity(at the specified temperature)Out of specification → Replace. 1 No conti

7-22E– +ELECIGNITION SYSTEMMAIN AND FUEL PUMP RELAY1. Check:• Main and fuel pump relay continuityFaulty → Replace. Checking steps:• Connect the tester

2-4ESPECMAINTENANCE SPECIFICATIONSValve face width BIntake mm (in) 1.91–2.64 (0.0752–0.1039)Exhaust mm (in) 1.91–2.64 (0.0752–0.1039)Valve seat width

7-23E– +ELECELECTRONIC CONTROL THROTTLE VALVE RELAY1. Check:• Electronic control throttle valve relaycontinuityFaulty → Replace.Checking steps:• Conne

7-24E– +ELECIGNITION SYSTEMTHROTTLE POSITION SENSOR1. Measure:• Throttle position sensor output voltageOut of specification → Replace thethrottle body

7-25E– +ELECIGNITION SYSTEM• Squeeze the throttle lever to the fullyopen position and hold it.• Check the output voltage of throttle posi-tion sensor

7-26E– +ELECIGNITION SYSTEMACCELERATOR POSITION SENSOR1. Measure:• Accelerator position sensor output volt-ageOut of specification → Replace theaccele

7-27E– +ELECAccelerator position sensor 1 output voltage at throttle lever fully opened position:3.75–4.35 VAccelerator position sensor 2 output volta

7-28E–+ELEC2. Measure:• Accelerator position sensor resistanceOut of specification → Replace theaccelerator position sensor.Checking steps:• Connect t

7-29E– +ELECCAM POSITION SENSOR1. Measure:• Cam position sensor output voltageOut of specification → Replace.NOTE:• The cam position sensor consists o

7-30E– +ELECSLANT DETECTION SWITCH1. Check:• Slant detection switch operationOut of specification → Replace.NOTE:When checking the slant detection swi

7-31E– +ELECFUEL CONTROL SYSTEMFUEL CONTROL SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRB/WB/OB/OB/RP/RP/RP/WP/WB/OL/BB/WB/RB/OP/RP/WGOWOOLGWR/YP/GY/GBOLP

7-32E– +ELECFUEL CONTROL SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRB/WB/OB/OB/RP/RP/RP/WP/WB/OL/BB/WB/RB/OP/RP/WGOWOOLGWR/YP/GY/GBOLPBPu/RPu/BPu/GPu/YP/

2-5ESPECMAINTENANCE SPECIFICATIONSPiston pinsOutside diameter mm (in) 16.991–17.000 (0.6689–0.6693)Wear limit mm (in) 16.986 (0.6687)Piston ringTop ri

7-33E– +ELECFUEL CONTROL SYSTEMELECTRIC FUEL PUMP1. Check:• Fuel pump operating soundFuel pump does not sound → Measurethe fuel pressure.Refer to “FUE

7-34E– +ELECFUEL CONTROL SYSTEMFUEL INJECTORRefer to “FUEL INJECTION SYSTEM”in Chapter 4.MAIN AND FUEL PUMP RELAYRefer to “IGNITION SYSTEM”.OIL PRESSU

7-35E– +ELECSTARTING SYSTEMSTARTING SYSTEMWIRING DIAGRAMWBrBRFREEPUSHBWFREEPUSHBr BrFREEPUSHBWWBrBr BrBrRRB/O10A10A3A30A20ARRBBBRB BrBBrBB/WB/OB/OB/RP

7-36E– +ELECWIRING DIAGRAMWBrBRFREEPUSHBWFREEPUSHBr BrFREEPUSHBWWBrBr BrBrRRB/O10A10A3A30A20ARRBBBRB BrBBrBB/WB/OB/OB/RP/RP/RP/WP/WB/OB/WB/RB/OP/RP/WW

7-37E– +ELECSTARTING SYSTEMBATTERYRefer to “ELECTRICAL” in Chapter 3.WIRING CONNECTIONS1. Check:• Wiring connectionsPoor connections → Properly connec

7-38E– +ELECSTARTING SYSTEMSTARTER RELAY1. Inspect:• Brown lead terminal• Black lead terminalLoose → Tighten.2. Check:• Starter relayFaulty → Replace.

7-39E– +ELECSTARTER MOTORSTARTER MOTOREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHART *: As requiredStep Procedure/Part name Q’ty Service pointsSTARTER

7-40E– +ELECSTARTER MOTOREXPLODED DIAGRAM*: As requiredStep Procedure/Part name Q’ty Service points8 Starter motor rear cover 19 O-ring 110 Shim * t =

7-41E– +ELECSTARTER MOTOREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points18 Spacer 119 Holder 120 Starter motor yoke 1Reverse the disassem

7-42E– +ELECSTARTER MOTORSERVICE POINTSArmature inspection1. Inspect:• Armature shaft 1 Damage/wear → Replace.12. Inspect:• CommutatorDirt → Clean wit

2-6ESPECMAINTENANCE SPECIFICATIONSJET PUMP UNIT HULL AND HOOD Fuel pumpPump type ElectricalFuel pressure kPa (kgf/cm2, psi)320–327 (3.2–3.3, 46–47)Oil

7-43E– +ELECSTARTER MOTOR6. Inspect:• Armature coil continuityOut of specification → Replace.Armature coil continuity:Commutator segments 1 Continuity

7-44E– +ELECCHARGING SYSTEMCHARGING SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRGGGGGGRGGGBRB453211 Battery2 Fuse (30 A)3 Fuse (20 A)4 Rectifier/regulator

7-45E– +ELECCHARGING SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in Chapter 3.LIGHTING COILRefer to “IGNITION SYSTEM”.RECTIFIER/

7-46E– +ELECOFF THROTTLE STEERING SYSTEMOFF THROTTLE STEERING SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRB/WB/OB/OB/OB/RP/RP/RB/OW/BP/WP/WB/WB/RB/OP/RP/W

7-47E– +ELECWIRING DIAGRAM10A10A3A30A20AR RBBRB/WB/OB/OB/OB/RP/RP/RB/OW/BP/WP/WB/WB/RB/OP/RP/WGOOWBWOOLGWW/BR/YW/LY/GR/YBLBPu/RPu/BPu/GPu/YR/YY/WL/RR/

7-48E– +ELECOFF THROTTLE STEERING SYSTEMSTEERING SENSOR1. Check:• Steering sensorMalfunction → Replace the steeringsensor.Checking steps:• Turn the ha

7-49E– +ELECINDICATION SYSTEMINDICATION SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRB BrBBrB/OW/BB/OB/OWRYGOBWYWG/OW/BY/GR/YBPBPu/RPu/BPu/GPu/YP/WB/GR/YW/

7-50E– +ELECINDICATION SYSTEMWIRING DIAGRAM10A10A3A30A20AR RBBRB BrBBrB/OW/BB/OB/OWRYGOBWYWG/OW/BY/GR/YBPBPu/RPu/BPu/GPu/YP/WB/GR/YW/BB/YY/WL/RB/RB/WB

7-51E– +ELECINDICATION SYSTEMFUSERefer to “STARTING SYSTEM”.BATTERYRefer to “ELECTRICAL” in Chapter 3.MAIN AND FUEL PUMP RELAYRefer to “IGNITION SYSTE

7-52E– +ELECINDICATION SYSTEMOIL PRESSURE SWITCH1. Measure: • Oil pressure switch continuityOut of specification → Replace.Lower unit pressure/vacuum

2-7ESPECMAINTENANCE SPECIFICATIONSELECTRICALItem UnitModelVX110 Sport VX110 DeluxeBatteryType FluidCapacity V/Ah 12/19Specific gravity 1.28ECM unit(B/

7-53E– +ELECDisplay function (Sport model only)1. Check:• Display functionDoes not operate → Replace the multi-function meter.L/BBB/YR/WB/YPB/GR/WYYRR

7-54E– +ELECDisplay function (Deluxe model only)1. Check:• Display functionDoes not operate → Replace the multi-function meter.1Remote control unit2Bu

7-55E– +ELECINDICATION SYSTEMSpeedometer display1. Check:• Speedometer displayDoes not display → Measure the speedsensor output voltage and pulses.2.

7-56E– +ELECINDICATION SYSTEMTachometer display1. Check:• Tachometer displayDoes not display → Check the enginespeed using the “Engine monitor” of the

7-57E– +ELECINDICATION SYSTEMOverheat warning indicator1. Check:• Overheat warning indicatorDoes not come on → Replace the multi-function meter. Check

7-58E– +ELECDiagnostic display1. Check:• Diagnostic displayDoes not display → Replace the multi-function meter. Checking steps:• Start the engine.• Di

7-59E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)REMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)WIRING DIAGRAMWBrBRFREEPUSHBWFREEPUSHBr BrFREEPUSHBWBrBr

7-60E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)REMOTE CONTROL SYSTEMYamaha Security System indicator1. Check:• Yamaha Security System indicatorC

7-61E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)Checking the remote control transmitter1. Check:• Remote control transmitterDoes not operate → Re

7-62E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)NOTE:• If the start switch or the remote controltransmitter is not operated for more than25 secon

2-8ESPECMAINTENANCE SPECIFICATIONSStarter motorType Constant meshOutput kW 0.8Rating Seconds 30Brush length mm (in) 12.5 (0.49)Wear limit mm (in) 6.5

7-63E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)Transmitter registration1. Register:• Remote control transmitter 1 ID codes can be added or re-re

7-64E– +ELECREMOTE CONTROL SYSTEM (DELUXE MODEL ONLY)Replacing of the transmitter batteryCAUTION:• Do not allow any water, dust, or dirt toenter the r

EHULLHOODCHAPTER 8HULL AND HOODHANDLEBAR ... 8-1EXPLOD

EHULLHOOD123456789REMOTE CONTROL CABLES AND SPEED SENSOR LEAD ...8-23EXPLODED DIAGRAM ...

8-1EHULLHOODHANDLEBARHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR REMOVALFollow the le

8-2EHULLHOODHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR REMOVALFollow the left “Step”

8-3EHULLHOODHANDLEBAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Throttle cable 1NOTE:Pass the throttle cable and wiring harnessthro

8-4EHULLHOODHANDLEBAREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHANDLEBAR DISASSEMBLYFollow the left “S

8-5EHULLHOODHANDLEBAREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points6 Throttle lever assembly 17 Handlebar grip 2NOTE:Apply adhesive to t

8-6EHULLHOODHANDLEBARSERVICE POINTSHandlebar inspection1. Inspect:• HandlebarBends/cracks/damage → Replace.Handlebar switch inspectionRefer to “STARTI

EHOW TO USE THIS MANUALMANUAL FORMATAll of the procedures in this manual are organized in a sequential, step-by-step format. The informa-tion has been

2-9ESPECMAINTENANCE SPECIFICATIONS*1: The figures are for reference only.Accelerator position sensor resis-tance*1@ throttle lever fully closedSensor

8-7EHULLHOODHANDLEBAR3. Install:• Throttle cableNOTE:Fit the seal into the groove in the bracket.4. Install:• Pad 1 NOTE:Make sure that the handlebar

8-8EHULLHOODFRONT HOODFRONT HOODEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFRONT HOOD REMOVALFollow the

8-9EHULLHOODFRONT HOODEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points9 Right mirror/seal 1/1 Deluxe model only10 Rivet 411 Storage compar

8-10EHULLHOODFRONT HOODSERVICE POINTSRivet Installation1. Install:• RivetsInstalling steps:• Insert a rivet completely in the holes inboth the storage

8-11EHULLHOODENGINE HATCH COVERENGINE HATCH COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE HATC

8-12EHULLHOODENGINE HATCH COVEREXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Shift lever handle 1 Deluxe model only9 Engine hatch cove

8-13EHULLHOODSERVICE POINTSDamper stopper inspection (Deluxe modelonly)1. Install:• Damper stopper 1 • Shift lever handle 2 NOTE:To install the damper

8-14EHULLHOODENGINE HATCH COVEREXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsGLOVE COMPARTMENT REMOVAL Fol

8-15EHULLHOODSERVICE POINTSGlove compartment assembly installation1. Install:• Hinge assemblyNOTE:When installing the hinge assembly, makesure that th

8-16EHULLHOODSHIFT LEVER (DELUXE MODEL ONLY)SHIFT LEVER (DELUXE MODEL ONLY)EXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty

2-10ESPECTIGHTENING TORQUESTIGHTENING TORQUESSPECIFIED TORQUESPart to tightenedPart nameThread sizeQ’tyTightening torqueRemarksRefer to pageN•mkgf•mft

8-17EHULLHOODHOSESHOSESEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsHOSES REMOVALFollow the left “Step” f

8-18EHULLHOODHOSESEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points3 Ventilation hose 24 Fuel tank breather hose 25Clamp 16 Cooling water h

8-19EHULLHOODSERVICE POINTSCooling water pilot outlet installation1. Install:• Cooling water pilot outlet 1 • Seal 2 • Nut 3 NOTE:• When installing th

8-20EHULLHOODSTEERING COLUMNSTEERING COLUMNEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING COLUMN R

8-21EHULLHOODSTEERING COLUMNEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING COLUMN DISASSEMBLYFollo

8-22EHULLHOODSTEERING COLUMNSERVICE POINTSSteering column inspection1. Inspect:• Seal rubber• Steering housing assemblyCracks/damage/wear → Replace th

8-23EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep

8-24EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points4Nut 15 Steering cable 16 Seal 17

8-25EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points14 Shift cable end 1 Deluxe model

8-26EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADSERVICE POINTS WARNINGWhen routing the cables, do not grasp thecable by the outer crimped shea

2-11ESPECTIGHTENING TORQUESOil separator1stBolt M6 23.70.372.7572LT5-122nd 7.6 0.76 5.5Ground lead box Bolt M6 3 7.6 0.76 5.5572LT5-12Oil tank1stBolt

8-27EHULLHOODREMOTE CONTROL CABLES AND SPEED SENSOR LEADShift cable (jet pump end) installation (Deluxe model only)1. Install:• Shift cable (jet pump

8-28EHULLHOODSEAT AND HAND GRIPSEAT AND HAND GRIPEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSEAT AND HA

8-29EHULLHOODSEAT AND HAND GRIPEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8 Spring washer/washer 1/19 Projection 110 Nut/washer 2/211

8-30EHULLHOODSEAT AND HAND GRIPSERVICE POINTSSeat lock assembly inspection1. Inspect:• Seat lock assemblyDamage/wear → Replace.

8-31EHULLHOODEXHAUST SYSTEMEXHAUST SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsEXHAUST SYSTEM REMO

8-32EHULLHOODEXHAUST SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points5 Joint clamp 2 16 Joint 17 Joint clamp 3 18 Joint clamp 4 19 J

8-33EHULLHOODEXHAUST SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points15 Hose clamp 2 116 Water tank 117 Rubber hose 118 Plate 1Rever

8-34EHULLHOODEXHAUST SYSTEMSERVICE POINTSExhaust system inspection1. Inspect:• Water lock bandCracks/damage → Replace.2. Inspect:• Rubber hosesBurns/c

8-35EHULLHOODEXHAUST SYSTEMExhaust system installation1. Install:• Exhaust jointNOTE:Be sure to install the projections a on theexhaust pipe and exhau

8-36EHULLHOODDECK AND HULLDECK AND HULLEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsDECK AND HULL DISASSE

2-12ESPECTIGHTENING TORQUESWasher/pickup coil lead and lighting coil leadBolt M5 1 4.9 0.49 3.5242LT5-36Pickup coil Bolt M5 2 4.9 0.49 3.5242LT5-36Hol

8-37EHULLHOODDECK AND HULLEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points12 Nut 4NOTE:To remove the cleat, remove the exhaustsystem first

8-38EHULLHOODENGINE MOUNTENGINE MOUNTEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsENGINE MOUNT REMOVALFol

ETRBLANLS123456789CHAPTER 9TROUBLE ANALYSISINTRODUCTION...

9-1ETRBLANLSINTRODUCTIONINTRODUCTIONFEATURESThe newly developed Yamaha Diagnostic System provides quicker detection and analysis of enginemalfunctions

9-2ETRBLANLSINTRODUCTIONHARDWARE REQUIREMENTSMake sure that your computer meets the following requirements before using this software.Computer: IBM PC

9-3ETRBLANLSOPERATINGOPERATINGCONNECTING THE COMMUNICATION CABLE TO THE WATERCRAFTTop view13-pin communication coupler2Wiring harness coupler3Meter co

9-4ETRBLANLSTROUBLE ANALYSISTROUBLE ANALYSISNOTE:Before consulting the “TROUBLE ANALYSIS CHART,” check the following items.1. Check that the battery i

9-5ETRBLANLSTROUBLE ANALYSISPOWER UNITCompression 5Cylinder head gaskets 5Cylinder block 5Crankcase 5Piston rings 5Pistons 5Bearings 5Valve(s) and val

9-6ETRBLANLSTROUBLE ANALYSISJET PUMP UNITDuct 6Impeller 6Intake grate 6Bearings 6Water inlet hose 6Bilge hose 6Bilge strainer 3Bilge hose joint 6ELECT

2-13ESPECTIGHTENING TORQUESJet pump unitSteering cable joint Nut — 1 6.8 0.68 4.9242LT6-3Ride plate Bolt M8 4 17 1.7 12572LT6-1Intake grate BoltM627.6

9-7ETRBLANLSTROUBLE ANALYSISStarting system• Start switch 7• Starter relay 7• Starter motor 7Charging system• Lighting coil 7• Rectifier/regulator 7•

9-8ETRBLANLSTROUBLE ANALYSISSELF-DIAGNOSISWith the engine running, press the select but-ton 1 for 8 seconds and check if an error codeis indicated on

WIRING DIAGRAMVX110 Sport1 Battery2 Starter motor3 Fuse (30 A)4 Fuse (20 A)5 Fuse (3 A)6 Fuse (10 A)7 Fuse (10 A)8 Starter relay9 Main and fuel pump r

WIRING DIAGRAMVX110 Deluxe1 Battery2 Starter motor3 Fuse (30 A)4 Fuse (20 A)5 Fuse (3 A)6 Fuse (10 A)7 Fuse (10 A)8 Starter relay9 Main and fuel pump

YAMAHA MOTOR CORPORATION, USAPrinted in USAJan. 2005 – 0.0 × 1 CR(E)

VX110 Sport4 2 3 1123 1 1 21 21 21 21 21 21 21 21 21 21 2123456784 2 1 3 5 6 1 2 3 5 6 7 4 8 9 10 11 12 13 141 2 3 4 5 6 7 8 9 10 11 12

VX110 Deluxe4 2 3 1123 11 1 21 21 21 21 21 21 21 21 21 21 2123456784 2 1 3 5 613 14 12 18 15 11 3 4 7 6 16 910 1 2 3

2-14ESPECTIGHTENING TORQUESShift cable locknut (Deluxe model only)Nut — 1 3.8 0.38 2.7572LT8-23Steering cable locknut (steering column side)Nut — 1 6.

2-15ESPECTIGHTENING TORQUESElectricalFuse box Nut — 2 17 1.7 12 7-2Fuse box bracket Nut — 4 15 1.5 11 7-2ECM Bolt M6 4 4.0 0.4 2.9572LT7-7Bracket1stBo

2-16ESPECCABLE AND HOSE ROUTINGCABLE AND HOSE ROUTINGKE2134567890DCABÊÈÉ125676JAAHIGF0627K-KJ-JI-IH-HG-GA-AB-BC-CD-DE-EF-FBBCCEEFF DDIIIIGGHHKKJJAABB1

2-17ESPECCABLE AND HOSE ROUTINGKE2134567890DCABÊÈÉ125676JAAHIGF0627K-KJ-JI-IH-HG-GA-AB-BC-CD-DE-EF-FBBCCEEFF DDIIIIGGHHKKJJAABBÈ Fasten the speed sens

2-18ESPECCABLE AND HOSE ROUTING1 2ÐÒÓÕÎÍ ÌÈÉÈÉÑÔ34567 84BOP5NCDA09H-HEFGHIPGG-GABDFCEJJMCFIIEDBAAÏÐHHGGJK0QLÊË1 Multifunction meter2 Handlebar switch

EIMPORTANT INFORMATIONIn this Service Manual particularly important information is distinguished in the following ways.The Safety Alert Symbol means A

2-19ESPECCABLE AND HOSE ROUTING1 2ÐÒÓÕÎÍ ÌÈÉÈÉÑÔ34567 84BOP5NCDA09H-HEFGHIPGG-GABDFCEJJMCFIIEDBAAÏÐHHGGJK0QLÊËM Water separatorN Electric fuel pumpO O

2-20ESPECCABLE AND HOSE ROUTING1 2ÐÒÓÕÎÍ ÌÈÉÈÉÑÔ34567 84BOP5NCDA09H-HEFGHIPGG-GABDFCEJJMCFIIEDBAAÏÐHHGGJK0QLÊËÏ To ventilation socketÐ To fuel tankÑ P

2-21ESPECCABLE AND HOSE ROUTINGABCD24256783228ÑÊÓÒÊÊÍÉËF-F E-E21 2 2222ÕÈ ÐÔÎÌÏFFEEDCAB21 Cooling water inlet hose2 Cooling water hose3 Cooling water

2-22ESPECCABLE AND HOSE ROUTINGABCD24256783228ÑÊÓÒÊÊÍÉËF-F E-E21 2 2222ÕÈ ÐÔÎÌÏFFEEDCAB2Í Fasten the oil separator breather hose (to airintake duct) a

2-23ESPECCABLE AND HOSE ROUTING139 0 ACB8 84 5 6 72EDFÈÉÍÊËÌA-AAAÎ1 Oil separator breather hose (to air intake duct)2 Wiring harness3 Ignition coil le

2-24ESPECCABLE AND HOSE ROUTING139 0 ACB8 84 5 6 72EDFÈÉÍÊËÌA-AAAÎÌ To generatorÍ Fasten the thermoswitch (exhaust) lead at theprotective sleeve, the

2-25ESPECCABLE AND HOSE ROUTINGD-DA-AB-B085C-C95ÚÙÉÈÐDD56AA12734ÎÓÒÌÑÑÌÑÌÌËËÊØ×ÖÔÕÍÏCCBB1 Ignition coil2 Fuel rail3 Fuel injector coupler4 Throttle bo

2-26ESPECCABLE AND HOSE ROUTINGD-DA-AB-B085C-C95ÚÙÉÈÐDD56AA12734ÎÓÒÌÑÑÌÑÌÌËËÊØ×ÖÔÕÍÏCCBBÐ Insert the plastic tie completely into the hole inthe engine

EINSPADJ123456789CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENTMAINTENANCE INTERVAL CHART ...

EHOW TO USE THIS MANUAL1 To help identify parts and clarify procedure steps, there are exploded diagrams at the start ofeach removal and disassembly s

3-1EINSPADJMAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHARTThe following chart should be considered strictly as a guide to general maintenance int

3-2EINSPADJCONTROL SYSTEMPERIODIC SERVICECONTROL SYSTEMSteering column inspection1. Inspect:• Steering columnExcessive play → Replace the steeringcolu

3-3EINSPADJCONTROL SYSTEM2. Adjust:• Steering cable joint (steering column end)NOTE:Adjust the cable joint at the jet pump end.Refer to “REMOTE CONTRO

3-4EINSPADJCONTROL SYSTEMThrottle cable inspection and adjustmentNOTE:Before adjusting the throttle lever free play,check the trolling speed.1. Measur

3-5EINSPADJCONTROL SYSTEM WARNINGAfter adjusting the free play, turn the han-dlebar to the right and left and make surethat the trolling speed does no

3-6EINSPADJCONTROL SYSTEM• Turn out the cable joint nine times a toextend the cable 7 mm (0.28 in) from thealigned position. WARNINGThe cable joint mu

3-7EINSPADJFUEL SYSTEMFUEL SYSTEM WARNINGWhen removing fuel system parts, wrapthem in a cloth and take care that no fuelspills into the engine compart

3-8EINSPADJFUEL SYSTEM/POWER UNITWater separator inspection1. Inspect:• Water separator 1 Water accumulation → Drain.NOTE:To drain the water, remove t

3-9EINSPADJPOWER UNIT3. Measure:• Valve clearanceOut of specification → Adjust.Valve clearance (cold):Intake valve:0.11–0.20 mm (0.0043–0.0079 in)Exha

3-10EINSPADJPOWER UNIT4. Remove:• Timing chain tensioner cap bolt 1 • Gasket15. Turn the timing chain tensioner rod fullyclockwise with a thin screwdr

EA50001-1-4SYMBOLSSymbols 1 to 9 are designed to indicate thecontent of a chapter.1General Information2Specifications3Periodic Inspection and Adjustme

3-11EINSPADJPOWER UNIT7. Adjust:• Valve clearanceAdjustment steps:• Remove the valve lifter 1 and the valvepad 2.NOTE:• Cover the timing chain opening

3-12EINSPADJPOWER UNITNOTE:The new valve pad number is only anapproximation. The valve clearance mustbe measured again and the above stepsshould be re

3-13EINSPADJPOWER UNITIntakeExhaustMEASURED CLEARANCEORIGINAL VALVE PAD NUMBER120 125 130 135 140 145150 155 160 165 170 175 180 185 190 195 200 205 2

3-14EINSPADJPOWER UNIT8. Remove:• Dial gauge• Dial gauge stand• Dial gauge needle9. Install:• All removed partsNOTE:For installation, reverse the remo

3-15EINSPADJPOWER UNIT• Place the watercraft in a horizontal posi-tion or launch the watercraft.• Remove the seat.• Remove the oil tank filler cap 1 a

3-16EINSPADJPOWER UNIT• Remove the oil tank filler cap again andcheck that the oil level is between theminimum level mark a and maximumlevel mark b on

3-17EINSPADJPOWER UNIT2. Remove:• Oil tank filler cap 1 3. Insert the tube of an oil changer into the oilfiller hole.4. Operate the oil changer to ext

3-18EINSPADJPOWER UNIT7. Fill:• Oil tank (with the specified amount of the recom-mended engine oil)CAUTION:When starting the engine make sure thedipst

3-19EINSPADJPOWER UNIT5. Remove the air filter element and check itfor dirt and oil. Replace the air filter ele-ment if there is any oil buildup.CAUTI

3-20EINSPADJPOWER UNITSpark plug inspection1. Remove:• Ignition coilsCAUTION:Be careful not to get any foreign sub-stances or water in spark plug hole

EINDEXGENERAL INFORMATION1GEN INFOSPECIFICATIONS2SPECPERIODIC INSPECTION AND ADJUSTMENT3INSP ADJFUEL SYSTEM4FUELPOWER UNIT5POWRJET PUMP UNIT6JETPUMPEL

3-21EINSPADJPOWER UNIT5. Tighten:• Spark plugNOTE:• Before installing the spark plug, clean thegasket surface and spark plug surface. Also,it is sugge

3-22EINSPADJELECTRICALELECTRICALBattery inspection WARNINGBattery electrolyte is poisonous and dan-gerous, causing severe burns, etc. Electro-lyte con

3-23EINSPADJELECTRICAL1. Remove:• Bands• Battery negative lead 1 • Battery positive lead 2 • Battery• Battery breather hose 3 WARNING• When removing

3-24EINSPADJELECTRICAL3. Inspect:• Specific gravityOut of specification → Charge.4. Install:• Filler capsCAUTION:Before installation, rinse off any fl

3-25EINSPADJJET PUMP UNITJET PUMP UNITImpeller inspection1. Check:• Impeller 1 Damage/wear → Replace.Nicks/scratches → File or grind.2. Measure:• Impe

3-26EINSPADJBILGE PUMP/GENERALBILGE PUMPBilge strainer inspection1. Inspect:• Bilge strainer 1 Contaminants → Clean.Cracks/damage → Replace.1GENERALDr

3-27EINSPADJGENERAL2. Lubricate:• Nozzle pivot shaft • Steering cable (nozzle end)Recommended grease:Yamaha marine grease, Yamaha grease A (Water resi

EFUEL123456789CHAPTER 4FUEL SYSTEMFUEL TANK AND FUEL PUMP MODULE...4-1EXPLODED DIAGRAM ...

4-1EFUELFUEL TANK AND FUEL PUMP MODULEFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Servic

4-2EFUELFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points3 Fuel tank breather hose 1NOTE:Make sure that the i

4-3EFUELFUEL TANK AND FUEL PUMP MODULEEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points12 Hose clamp 213 Fuel filler hose 114 Nut 115 Fuel

4-4EFUELFUEL TANK AND FUEL PUMP MODULESERVICE POINTSFuel hose disconnection1. Disconnect:• Fuel hoseRefer to “FUEL INJECTION SYSTEM”.Fuel pump module

4-5EFUELFUEL TANK AND FUEL PUMP MODULEFuel sender inspectionRefer to “FUEL CONTROL SYSTEM” inChapter 7.Fuel tank inspection1. Inspect:• Fuel tankCrack

4-6EFUELFuel pump module installation1. Tighten:• NutsNOTE:Tighten the nuts in the sequence shown.Fuel hose connectRefer to “FUEL INJECTION SYSTEM”.T

4-7EFUELFUEL INJECTION SYSTEMFUEL INJECTION SYSTEMEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFUEL INJEC

4-8EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points10 Fuel hose 111 Clamp 212 Hose screw clamp 113 Screw 214 Scr

4-9EFUELFUEL INJECTION SYSTEMEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points21 Air filter case 122 Collar 423 Grommet 424 Bolt 225 Intake

4-10EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDEXPLODED DIAGRAMREMOVAL AND INSTALLATION CHARTStep Proced

4-11EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDEXPLODED DIAGRAMStep Procedure/Part name Q’ty Service points8Gasket 49 Fuel injector 410 O-ring 411

4-12EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDSERVICE POINTSFuel hose clamps removal1. Remove:• Fuel hose clampsCAUTION:If the fuel hose clamps a

EGENINFO123456789CHAPTER 1GENERAL INFORMATIONIDENTIFICATION NUMBERS ...1-1PRIMA

4-13EFUELCAUTION:• Do not rotate the quick connector tab 1past the stopper position, otherwise itcould be damaged.• When the fuel hoses are disconnect

4-14EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDFuel hose installation (replacing with new fuel hose)1. Install:• Fuel hose 1 NOTE:• To install the

4-15EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDFuel injectors inspectionNOTE:Do not remove the throttle body assembly.1. Check:• Fuel injectorsDir

4-16EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDIntake assembly installation1. Install:• Intake screw clamp• Intake manifold joint• Intake assembly

4-17EFUELTHROTTLE BODY ASSEMBLY AND INTAKE MANIFOLDAir filter case assembly installation1. Install:• Air intake duct 1 • Air intake hose 2 • Air filte

4-18EFUEL5. Remove:• Fuel pressure gauge• Fuel pressure gauge adapterNOTE:To disconnect the fuel pressure gaugeadapter, follow the procedures for disc

EPOWR123456789CHAPTER 5POWER UNITENGINE UNIT...5-1EXPL

EPOWRGENERATOR AND STARTER MOTOR.....5-33EXPLODED DIAGRAM ....

EPOWRCONNECTING RODS AND PISTONS ...............5-80EXPLODED DIAGRAM ..........