cooling YAMAHA VX110 2005 User Guide

EPOWR
CONNECTING RODS AND PISTONS .......................................................... 5-80
EXPLODED DIAGRAM ........................................................................... 5-80
REMOVAL AND INSTALLATION CHART .............................................. 5-80
SERVICE POINTS .................................................................................. 5-82
Connecting rod and piston removal .................................................. 5-82
Cylinder and piston inspection .......................................................... 5-83
Piston ring inspection ........................................................................ 5-84
Piston pin inspection ......................................................................... 5-86
Connecting rod inspection................................................................. 5-87
Connecting rod and piston installation .............................................. 5-89
CRANKSHAFT .............................................................................................. 5-93
EXPLODED DIAGRAM ........................................................................... 5-93
REMOVAL AND INSTALLATION CHART .............................................. 5-93
SERVICE POINTS .................................................................................. 5-94
Crankshaft removal ........................................................................... 5-94
Crankshaft inspection........................................................................ 5-94
Crankshaft installation ....................................................................... 5-97
COOLING WATER HOSE ............................................................................. 5-98
EXPLODED DIAGRAM ........................................................................... 5-98
REMOVAL AND INSTALLATION CHART .............................................. 5-98
ProCarManuals.com

5-2
EPOWRENGINE UNIT
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
3Bolt 2
4 Air filter case assembly 1
5Bolt 1
6 ECM and rectifier/regulator
assembly1
7 Clamp/cooling water hose 1/1 Cooling water pilot outlet
8 Clamp/cooling water hose 1/1 Cooling water inlet
9 Clamp/cooling water hose 1/1 Cooling water outlet
10 Coupler 10
11 Bolt/collar 1/1
12 Coupling cover 1
14 10
10
2
113
3
4
11
15
12
8
7
9
6
5
2nd 18 N  m (1.8 kgf  m, 13 ft  Ib) 1st 8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
8 × 35 mm
6 × 25 mm
7.8 N  m (0.78 kgf  m, 5.6 ft  Ib)
8 × 35 mm 17 N  m (1.7 kgf  m, 12 ft  Ib)
17 N  m (1.7 kgf  m, 12 ft  Ib)8 × 40 mm
17 N  m (1.7 kgf  m, 12 ft  Ib)
10LT
242
LT
LT
572
LT
LT
271
ProCarManuals.com

5-8
EPOWREXHAUST PIPES 1 AND 2
EXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST PIPES 1 AND 2
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
È
For cooling water pilot outlet on port side
É
From water jacket
1 Clamp/cooling water hose 1/1
2 Clamp/cooling water hose 1/1
3Bolt 2
4 Thermoswitch (exhaust) 1
5 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust
manifold side
6 Exhaust joint clamp 2
6
64 3
É
5
2
È 6 × 16 mm
7.6 N  m (0.76 kgf  m, 5.5 ft  Ib)
2nd 3.4 N  m (0.34 kgf  m, 2.5 ft  Ib) 1st 3.4 N  m (0.34 kgf  m, 2.5 ft  Ib)LT
242
LT
242
LT
572
LT
LT
572
LT
LT
242
1
LT
242
LT
242
ProCarManuals.com

5-11
EPOWREXHAUST MANIFOLD
EXHAUST MANIFOLD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST MANIFOLD REMOVAL
Follow the left “Step” for removal.
Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.
1 Clamp/cooling hose 2/1È
To cylinder block
2Bolt 5
3Bolt 6
4 Exhaust manifold 1
5Gasket 1
6 Dowel pin 2
Reverse the removal steps for installation.
6
5 3È
6
2
4
1
1
1
2nd 22 N  m (2.2 kgf  m, 16 ft  Ib) 1st
22 N  m (2.2 kgf  m, 16 ft  Ib)
3rd 35 N  m (3.5 kgf  m, 25 ft  Ib)
8 × 75 mm
2nd 22 N  m (2.2 kgf  m, 16 ft  Ib) 1st 22 N  m (2.2 kgf  m, 16 ft  Ib)
3rd 35 N  m (3.5 kgf  m, 25 ft  Ib)
8 × 155 mm
LT
242
LT
242
Not reusable
ProCarManuals.com

5-12
EPOWROIL TANK
OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL TANK REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Intake assembly Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
1 Clamp/cooling water hose 1/1È
To exhaust pipe 1
2Bolt 4
3 Water jacket 1
4Gasket 1
5 Clamp/breather hose 2/1
6 Clamp/breather hose 2/1É
To oil pump
7Bolt 2
8 Collar 2
Ì
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
23 1925 24
26
25
2116 17 15
14
1220 22
3
4
6 8
9
72
6
AA
6 × 30 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)
2nd 39 N  m (3.9 kgf
 m, 28 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
10 × 85 mm2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
10 × 70 mm
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 35 mm
È
ÉÌ13
LT
572
LT
572
LT
572
LT
572
18
102nd 7.6 N  m (0.76 kgf  m, 5.5 ft  Ib)
1st 3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
6 × 20 mm
Ê
Ë
a
1
5
1111
5
6 × 35 mm
Not reusable
ProCarManuals.com

5-13
EPOWROIL TANK
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9 Oil separator 1
10 Clamp/breather hose 1/1Ê
To air intake pipe
11 Clamp/breather hose 1/1Ë
From cylinder head cover
Mark a

12 Clamp/cooling water hose 1/1Ì
From cooling water inlet
13 Bolt 1
14 Collar 1
15 Band 1
16 Bolt 3
17 Ground lead box 1
18 O-ring 1
19 Bolt 2
Ì
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
23 1925 24
26
25
2116 17 15
14
1220 22
3
4
6 8
9
72
6
AA
6 × 30 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)
2nd 39 N  m (3.9 kgf
 m, 28 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
10 × 85 mm2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
10 × 70 mm
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 35 mm
È
ÉÌ13
LT
572
LT
572
LT
572
LT
572
18
102nd 7.6 N  m (0.76 kgf  m, 5.5 ft  Ib)
1st 3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
6 × 20 mm
Ê
Ë
a
1
5
1111
5
6 × 35 mm
Not reusable
ProCarManuals.com

5-41
EPOWRCAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CYLINDER HEAD COVER
REMOVALFollow the left “Step” for removal.
1Bolt 4
2 Ignition coil 4
3 Spark plug 4
4 Clamp/breather hose 1/1È
To oil tank
Paint mark a

5Bolt 1
6 Cam position sensor 1
7 Clamp/cooling water hose 1/1É
To transom plate
8 Rubber seal 1
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
ProCarManuals.com

5-42
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9Bolt 1
10 Cooling water pipe 1
11 O-ring 1
12 Bolt 6
13 Rubber mount 6
14 Cylinder head cover 1
15 Cylinder head cover gasket 1
16 Timing chain guide (top side) 1
Reverse the removal steps for installation.
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
Not reusable
Not reusable
ProCarManuals.com

5-98
EPOWRCOOLING WATER HOSE
COOLING WATER HOSE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
COOLING WATER HOSE
REMOVALFollow the left “Step” for removal.
Exhaust manifold Refer to “EXHAUST MANIFOLD”.
1 Clamp/cooling water hose 1/1È
To cylinder block
NOTE:
To install the cooling water hose, align the
white paint mark a
water hose with the pro-
jection of the hose joint.
2 Clamp/cooling water hose 1/1É
To exhaust manifold
3 Clamp/cooling water hose 2/1
143 2
375
6
ÈÉÊ
Ë
a
2
34
1
ProCarManuals.com

5-99
EPOWRCOOLING WATER HOSE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
4 Joint 1
5 Clamp/cooling water hose 1/1Ê
To oil tank
6 Clamp/cooling water hose 1/1Ë
From transom plate
7 Joint 1
Reverse the removal steps for installation.
143 2
375
6
ÈÉÊ
Ë
a
2
34
1
ProCarManuals.com