Engine oil YAMAHA VX110 2005 Service Manual

E
A50001-1-4
SYMBOLS
Symbols 1 to 9 are designed to indicate the
content of a chapter.
1General Information
2Specifications
3Periodic Inspection and Adjustment
4Fuel System
5Power Unit
6Jet Pump Unit
7Electrical System
8Hull and Hood
9Trouble Analysis
Symbols 0 to E indicate specific data.
0Special service tool
ASpecified oil or fluid
BSpecified engine speed
CSpecified tightening torque
DSpecified measurement
ESpecified electrical value
(resistance, voltage, electric current)
Symbols F to I in an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
FApply Yamaha 4-stroke motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply ThreeBond 1104J or ThreeBond 1280B
IApply molybdenum disulfide grease
Symbols J to N in an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
JApply Gasket Maker
KApply LOCTITE 271 (red)
LApply LOCTITE 242 (blue)
MApply LOCTITE 572
NApply silicone sealant
NOTE:
Additional symbols may be used in this man-
ual.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFOSPEC
INSP
ADJFUEL
POWRJET
PUMP
–+ELECHULL
HOOD
TRBL
ANLS
T R..
E
A1280B1104J
MGM
271
LT
242
LT
572
LTSS
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1-4
E
GEN
INFO
SAFETY WHILE WORKING
3.Non-reusable parts
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.
DISASSEMBLY AND ASSEMBLY
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces of
moving parts during assembly.
3. Install bearings with the manufacture iden-
tification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.
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2-2
ESPEC
PON*: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2
RON*: Research Octane NumberFuel and oil
Fuel type Regular unleaded gasoline
Minimum fuel rating PON* 86
RON* 90
Fuel tank capacity L
(US gal, Imp gal)60 (15.9, 13.2)
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, SJ, SL
SAE 10W-30, 20W-40, 20W-50
Engine oil quantity L
(US qt, Imp qt)4.3 (4.5, 3.8)
(without oil filter replacement) L
(US qt, Imp qt)2.0 (2.1, 1.8)
(with oil filter replacement) L
(US qt, Imp qt)2.2 (2.3, 1.9) Item UnitModel
VX110 Sport VX110 Deluxe
GENERAL SPECIFICATIONS
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2-10
ESPECTIGHTENING TORQUES
TIGHTENING TORQUES
SPECIFIED TORQUES
Part to tightenedPart
nameThread
sizeQ’tyTightening torque
RemarksRefer to
page
Nmkgfmftlb
Fuel system
Retainer/fuel pump
module1st
Nut—93.20.322.3
4-1
2nd 6.4 0.64 4.6
Fuel filler neck/rubber seal Nut—1 5.9 0.59 4.3 4-1
Fuel filter hose clamp——2 3.7 0.37 2.7 4-1
Air filter case cover Screw M52 1.2 0.12 0.9
572LT4-7
4 1.5 0.15 1.1
Air filter case Bolt M8 4 17 1.7 12 4-7
Air filter case bracket Nut—4 15 1.5 11 4-7
Air intake hose clamp——1 2.5 0.25 1.8 4-7
Throttle cable Nut—1 6.5 0.65 4.7 4-7
Accelerator position sensor Nut—2 17 1.7 12 4-7
Throttle body assembly Bolt M8 4 13 1.3 9.4 4-10
Intake manifold1st
Bolt M6 28.80.886.4
242LT4-7
2nd 18 1.8 13
Intake manifold bracket/
wiring harness bracket 11st
Bolt M8 215 1.5 11
271LT4-7
2nd 39 3.9 28
Fuel rail Bolt M8 2 13 1.3 9.4 4-10
Sensor assembly Screw M5 2 3.5 0.35 2.5 4-10
Engine
Engine unit Bolt M8 4 17 1.7 12
271LT5-1
Oil filter——1171.712
E3-17
Coupling cover Bolt M6 1 7.8 0.78 5.6
572LT5-1
Thermoswitch (exhaust) Bolt M6 2 7.6 0.76 5.5
572LT5-8
Outer exhaust joint
clamp1st
——23.40.342.5
5-8
2nd 3.4 0.34 2.5
Inner exhaust joint clamp1st
——23.40.342.5
5-8
2nd 3.4 0.34 2.5
Exhaust pipe 2
*1 1st
Bolt M10 42.0 0.2 1.4242LT5-9 2nd 15 1.5 11
3rd 39 3.9 28
Exhaust pipe end1st
Bolt M6 33.70.372.7
572LT5-10
2nd 7.6 0.76 5.5
Exhaust pipe 11st
Bolt M8 422 2.2 16
242LT5-10 2nd 22 2.2 16
3rd 35 3.5 25
Exhaust manifold1st
Bolt M8 1122 2.2 16
242LT5-11 2nd 22 2.2 16
3rd 35 3.5 25
*1: For details, refer to the tightening procedures in this manual.
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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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2-12
ESPECTIGHTENING TORQUES
Washer/pickup coil lead and
lighting coil leadBolt M5 1 4.9 0.49 3.5242LT5-36
Pickup coil Bolt M5 2 4.9 0.49 3.5
242LT5-36
Holder (wiring harness) Bolt M6 2 14 1.4 10
242LT5-36
Lighting coil Bolt M6 3 14 1.4 10
242LT5-36
Spark plug——4131.39.4 5-41
Ignition coil Bolt M6 4 7.6 0.76 5.5
572LT5-41
Cam position sensor Bolt M6 1 10 1.0 7.2
572LT5-41
Cooling water pipe1st
Bolt M6 13.70.372.7
5-41
2nd 7.6 0.76 5.5
Cylinder head cover Bolt M6 6 12 1.2 8.7
E5-41
Timing chain tensioner cap bolt Bolt M6 1 10 1.0 7.2 5-43
Timing chain tensioner Bolt M6 2 10 1.0 7.2 5-43
Exhaust camshaft cap Bolt M6 10 10 1.0 7.2
E5-43
Intake camshaft cap Bolt M6 18 10 1.0 7.2
E5-43
Exhaust camshaft sprocket Bolt M7 2 24 2.4 17
E5-43
Intake camshaft sprocket Bolt M7 2 24 2.4 17
E5-43
Cylinder head
*1 Bolt M6 3 10 1.0 7.2
E5-54
1st
Nut—220 2.0 14
E5-54
2nd 140 ±
5°
1st
Nut—320 2.0 14
E5-54
2nd 121 ±
5°
1st
Nut—520 2.0 14
E5-54
2nd 105 ±
5°
Engine temperature sensor——1 15 1.5 11 5-71
Thermoswitch (engine) Bolt M6 2 7.6 0.76 5.5
572LT5-71
Oil pressure switch——1 8.4 0.84 6.1
572LT5-71
Anode cover BoltM6
112 1.2 8.7
271LT5-71
M8 20 2.0 14
Oil pan Bolt M6 15 12 1.2 8.7
572LT5-71
Lower crankcaseBolt M6 10 12 1.2 8.7
572LT5-71
1st
Bolt M9 107.80.785.6
E5-71 2nd Loosen completely
3rd 15 1.5 11
4th 49 ±
5°
Oil pipe Bolt M6 1 12 1.2 8.7
E5-74
Oil filter bolt——1353.525
E5-74
Connecting rod cap1st
Nut—820 2.0 14
M5-80
2nd 120 ±
5°
*1: For details, refer to the tightening procedures in this manual.Part to tightenedPart
nameThread
sizeQ’tyTightening torque
RemarksRefer to
page
Nmkgfmftlb
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2-19
ESPECCABLE AND HOSE ROUTING
12
Ð
Ò
Ó
Õ
Î
ÍÌ
È
É
È
É
Ñ
Ô
3
4
5678
4
B
O
P
5
N
C
D
A09H-H
EFGH
I
P
G
G-G
A
BD
F C
E
JJ
M
C
F
I
I
E
DB
A
A
ÏÐ
H
H
G
G
JK
0
Q
L
Ê
Ë
MWater separator
NElectric fuel pump
OOil separator breather hose (to air intake duct)
PWiring harness
QCooling water inlet hose
ÈFasten the steering sensor lead, handlebar
switch lead, multifunction meter lead, and
buzzer lead with plastic tie 2.ÉFasten the speed sensor lead, fuel sender lead,
wiring harness, and antenna lead (Deluxe
model only) with plastic tie 1 at the white tape on
the wiring harness.
ÊDeluxe model
ËSport model
ÌTo remote control unit (Deluxe model only)
ÍFasten the antenna lead and wiring harness
with a plastic tie at the white tape. (Deluxe
model only)
ÎTo engine unit (Deluxe model only)
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2-25
ESPECCABLE AND HOSE ROUTING
D-D
A-A
B-B
0
8
5
C-C
9
5 Ú
Ù
É
È
Ð
DD
5
6
A
A
1
2
7
34
Î
Ó ÒÌÑÑÌÑ
Ì
Ì
Ë Ë
Ê
Ø×Ö Ô
Õ
Í
Ï
C
CB
B
1Ignition coil
2Fuel rail
3Fuel injector coupler
4Throttle body assembly coupler
5Wiring harness
6Engine temperature sensor lead
7Sensor assembly (intake air pressure and intake
air temperature)
8Cam position sensor coupler
9Cam position sensor lead
0Oil pressure switchÈTo engine temperature sensor
ÉTo thermoswitch (engine)
ÊRoute the engine thermoswitch lead and engine
temperature sensor lead through the corrugated
tube.
ËMore than 10 mm (0.39 in)
ÌDo not leave any slack in the lead.
ÍAttach the thermoswitch (engine) coupler to the
bracket.
ÎAttach a joint connector to the bracket.
ÏPass the fuel injector leads under the fuel rail.
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2-26
ESPECCABLE AND HOSE ROUTING
D-D
A-A
B-B
0
8
5
C-C
9
5 Ú
Ù
É
È
Ð
DD
5
6
A
A
1
2
7
34
Î
Ó ÒÌÑÑÌÑ
Ì
Ì
Ë Ë
Ê
Ø×Ö Ô
Õ
Í
Ï
C
CB
B
ÐInsert the plastic tie completely into the hole in
the engine hanger.
ÑFasten the wiring harness to a bracket on the
fuel rail with a plastic tie.
ÒFasten the wiring harness and cam position
sensor within the range shown in the illustration
with a plastic tie.
ÓSplit in wiring harness
ÔTo cam position sensorÕPass fuel injector lead #4 under the sensor
assembly (intake air pressure and intake air
temperature) lead.
ÖTo oil pressure switch
×To thermoswitch (exhaust)
ØTo ground lead plate
ÙBow end
ÚMake sure that the rubber boot is fitted properly
without any folds.
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E
INSP
ADJ
1
2
3
4
5
6
7
8
9
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE ....................................................................................... 3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering column inspection ................................................................. 3-2
Steering cable inspection and adjustment .......................................... 3-2
Throttle cable inspection and adjustment............................................ 3-4
Shift cable inspection and adjustment (Deluxe model only)................ 3-5
Trolling speed inspection .................................................................... 3-6
FUEL SYSTEM.......................................................................................... 3-7
Fuel line inspection ............................................................................. 3-7
Water separator inspection ................................................................. 3-8
POWER UNIT............................................................................................ 3-8
Valve clearance adjustment ................................................................ 3-8
Engine oil level check........................................................................ 3-14
Engine oil change — using oil changer ............................................. 3-16
Air filter element clean....................................................................... 3-18
Spark plug inspection ........................................................................ 3-20
ELECTRICAL .......................................................................................... 3-22
Battery inspection.............................................................................. 3-22
JET PUMP UNIT ..................................................................................... 3-25
Impeller inspection ............................................................................ 3-25
Water inlet strainer inspection ........................................................... 3-25
BILGE PUMP........................................................................................... 3-26
Bilge strainer inspection .................................................................... 3-26
GENERAL ............................................................................................... 3-26
Drain plug inspection......................................................................... 3-26
Lubrication points .............................................................................. 3-26
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