steering YAMAHA VX110 2005 User Guide

6-3
E
JET
PUMPJET PUMP UNIT
JET PUMP UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
JET PUMP UNIT REMOVAL
Follow the left “Step” for removal.
1 Shift cable joint 1 Deluxe model only
2 Bilge hose 1
3 Nut/washer 1/2
4 Steering cable joint 1
5 Hose clamp/spout hose 1/1
6Bolt 4
7 Collar 4
8Nut 2
8 × 24 mm
14 N • m (1.4 kgf
• m, 10 ft
• Ib)
6 × 22 mm
6.8 N • m (0.68 kgf
• m, 4.9 ft
• Ib)
2.2 N • m (0.22 kgf
• m, 1.6 ft
• Ib)
6.8 N • m (0.68 kgf
• m, 4.9 ft
• Ib)
10 × 45 mm
40 N • m (4.0 kgf
• m, 29 ft
• Ib)
11
76
5
3
16
312 1 15
LT
572
LT
572
LT
572
LT
572
LT
242
AA
LT
271
LT
4
14
2
10
13
6.8 N • m (0.68 kgf
• m, 4.9 ft
• Ib)
8
9
6 × 30 mm
7.8 N •
m (0.78 kgf • m, 5.6 ft • Ib) 8 × 18 mm
17 N • m (1.7 kgf
• m, 12 ft
• Ib)
6 × 25 mm
1104J
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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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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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7-45
E
–+ELECOFF THROTTLE STEERING SYSTEM
OFF THROTTLE STEERING SYSTEM
WIRING DIAGRAM
10A
10A
3A
30A20A
RR
BBR
B/W
B/O
B/O
B/O
B/R
P/R
P/R
B/O
W/B
P/W
P/W
B/WB/R
B/O
P/RP/W
G
O
O
W
BW
O
OLG
W
W/BR/Y
W/LY/G
R/Y
BL
BPu/RPu/B
Pu/GPu/Y
R/Y
Y/WL/R
R/Y
R/Y
R/Y
R/YPu/G
Pu/Y
Pu/B
Pu/RR/Y
R/Y
R/Y
R/YY/W
Y/G
L/R
R
R
R
B
W/LBOW/LB/OO
R
98
0
0 0 0 ABC D E1
4
5
67 32
1Battery
2Starter motor
3Fuse (30 A)
4Fuse (20 A)
5Fuse (10 A)
6Fuse (10 A)
7Starter relay
8Main and fuel pump relay
9Electronic control throttle valve relay0Fuel injector
AECM
BThrottle body assembly
CAccelerator position sensor
DPickup coil
ESteering sensor
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7-46
E
–+ELEC
WIRING DIAGRAM
10A
10A
3A
30A20A
RR
BBR
B/W
B/O
B/O
B/O
B/R
P/R
P/R
B/O
W/B
P/W
P/W
B/WB/R
B/O
P/RP/W
G
O
O
W
BW
O
OLG
W
W/BR/Y
W/LY/G
R/Y
BL
BPu/RPu/B
Pu/GPu/Y
R/Y
Y/WL/R
R/Y
R/Y
R/Y
R/YPu/G
Pu/Y
Pu/B
Pu/RR/Y
R/Y
R/Y
R/YY/W
Y/G
L/R
R
R
R
B
W/LBOW/LB/OO
R
98
0
0 0 0 ABC D E1
4
5
67 32
B: Black
G: Green
L: Blue
O : Orange
R: Red
W: White
B/O : Black/orange
B/R : Black/red
B/W : Black/whiteL/R : Blue/red
P/R : Pink/red
P/W : Pink/white
Pu/B : Purple/black
Pu/G : Purple/green
Pu/R : Purple/red
Pu/Y : Purple/yellow
R/Y : Red/yellow
W/B : White/blackW/L : White/blue
Y/G : Yellow/green
Y/W : Yellow/white
OFF THROTTLE STEERING SYSTEM
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7-47
E
–+ELECOFF THROTTLE STEERING SYSTEM
STEERING SENSOR
1. Check:
Steering sensor
Malfunction → Replace the steering
sensor.
Checking steps:
Turn the handlebar all the way to the left
or right, and then release it.
Install a plastic tie 1 loosely around the
center of the handlebar grip as shown.
Hook a spring gauge 2 onto the plastic
tie.
Hold the spring gauge at a 90° angle
from the handlebar, and then pull the
spring gauge with a force of 10 kgf
(22 lb).
When handlebar
pulledWhen handlebar
not pulled
ON OFF
Check that the following is displayed in
the “Engine Monitor” window of the
Yamaha Diagnostic System.
Use the same procedure to check that
the steering sensor operates correctly
when the handlebar is turned to both the
left and right. Replace the steering sen-
sor if it is a malfunction.
1
2
ECM
Refer to “IGNITION SYSTEM”.
PICKUP COIL
Refer to “IGNITION SYSTEM”.
THROTTLE POSITION SENSOR
Refer to “IGNITION SYSTEM”.
ACCELERATOR POSITION SENSOR
Refer to “IGNITION SYSTEM”.
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E
HULL
HOOD
CHAPTER 8
HULL AND HOOD
HANDLEBAR .................................................................................................. 8-1
EXPLODED DIAGRAM ............................................................................. 8-1
REMOVAL AND INSTALLATION CHART ................................................ 8-1
SERVICE POINTS .................................................................................... 8-6
Handlebar inspection .......................................................................... 8-6
Handlebar switch inspection ............................................................... 8-6
Handlebar assembly installation ......................................................... 8-6
FRONT HOOD ................................................................................................. 8-8
EXPLODED DIAGRAM ............................................................................. 8-8
REMOVAL AND INSTALLATION CHART ................................................ 8-8
SERVICE POINTS .................................................................................. 8-10
Rivet Installation ................................................................................ 8-10
ENGINE HATCH COVER .............................................................................. 8-11
EXPLODED DIAGRAM ........................................................................... 8-11
REMOVAL AND INSTALLATION CHART .............................................. 8-11
SERVICE POINTS .................................................................................. 8-13
Damper stopper inspection (Deluxe model only) .............................. 8-13
EXPLODED DIAGRAM ........................................................................... 8-14
REMOVAL AND INSTALLATION CHART .............................................. 8-14
SERVICE POINTS .................................................................................. 8-15
Glove compartment assembly installation......................................... 8-15
SHIFT LEVER (DELUXE MODEL ONLY) ..................................................... 8-16
EXPLODED DIAGRAM ........................................................................... 8-16
REMOVAL AND INSTALLATION CHART .............................................. 8-16
HOSES .......................................................................................................... 8-17
EXPLODED DIAGRAM ........................................................................... 8-17
REMOVAL AND INSTALLATION CHART .............................................. 8-17
SERVICE POINTS .................................................................................. 8-19
Cooling water pilot outlet installation ................................................. 8-19
Grommet installation ......................................................................... 8-19
Ventilation hose assembly installation .............................................. 8-19
STEERING COLUMN .................................................................................... 8-20
EXPLODED DIAGRAM ........................................................................... 8-20
REMOVAL AND INSTALLATION CHART .............................................. 8-20
SERVICE POINTS .................................................................................. 8-22
Steering column inspection ............................................................... 8-22
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E
HULL
HOOD
1
2
3
4
5
6
7
8
9
REMOTE CONTROL CABLES AND SPEED SENSOR LEAD .................... 8-23
EXPLODED DIAGRAM ........................................................................... 8-23
REMOVAL AND INSTALLATION CHART .............................................. 8-23
SERVICE POINTS .................................................................................. 8-26
Remote control cables inspection ..................................................... 8-26
Steering cable (jet pump end) installation ......................................... 8-26
Steering cable stopper installation .................................................... 8-26
Shift cable (jet pump end) installation (Deluxe model only) .............. 8-27
Shift cable (shift lever end) installation (Deluxe model only)............. 8-27
Remote control cables adjustment .................................................... 8-27
SEAT AND HAND GRIP................................................................................ 8-28
EXPLODED DIAGRAM ........................................................................... 8-28
REMOVAL AND INSTALLATION CHART .............................................. 8-28
SERVICE POINTS .................................................................................. 8-30
Seat lock assembly inspection .......................................................... 8-30
EXHAUST SYSTEM ...................................................................................... 8-31
EXPLODED DIAGRAM ........................................................................... 8-31
REMOVAL AND INSTALLATION CHART .............................................. 8-31
SERVICE POINTS .................................................................................. 8-34
Exhaust system inspection................................................................ 8-34
Exhaust component parts sub-assembly .......................................... 8-34
Exhaust system installation ............................................................... 8-35
DECK AND HULL.......................................................................................... 8-36
EXPLODED DIAGRAM ........................................................................... 8-36
REMOVAL AND INSTALLATION CHART .............................................. 8-36
ENGINE MOUNT ........................................................................................... 8-38
EXPLODED DIAGRAM ........................................................................... 8-38
REMOVAL AND INSTALLATION CHART .............................................. 8-38
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8-2
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
HANDLEBAR REMOVAL
Follow the left “Step” for removal.
1 Handlebar switch coupler 2
2 Plastic tie 1
NOTE:
Fasten the buzzer lead, steering sensor
lead, start switch lead, engine shut-off
switch lead, and multifunction meter lead
with a plastic tie.
3 Corrugated tube 1
4 Grommet 1
4 5
3
4
3
7
2
FWD
6
11
6
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8-3
E
HULL
HOODHANDLEBAR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Throttle cable 1
NOTE:
Pass the throttle cable and wiring harness
through the grommet, and then fit the grom-
met into the steering column.
6 Handlebar switch lead 1
7 Handlebar assembly 1
Reverse the removal steps for installation.
4 5
3
4
3
7
2
FWD
6
11
6
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