clock YAMAHA VX110 2005 Service Manual

2-1
ESPECGENERAL SPECIFICATIONS
GENERAL SPECIFICATIONS
Item UnitModel
VX110 Sport VX110 Deluxe
Model code
Hull F1K
Engine/jet 6D3
Dimensions
Length mm (in) 3,220 (126.8)
Width mm (in) 1,170 (46.1)
Height mm (in) 1,150 (45.3)
Dry weight kg (lb) 325 (716)
Maximum capacity Person/kg (lb) 3/240 (530)
Performance
Maximum output kW (PS) @ r/min 81.0 (110) @ 8,000
Maximum fuel consumption l/h (US gal/h,
lmp gal/h)28.0 (7.4, 6.2)
Cruising range h 2.1
Engine
Engine type 4-stroke, L4, DOHC
Displacement cm
3 (cu. in) 1,052 (64.2)
Bore ×
stroke mm (in) 76.0 ×
58.0 (2.99 ×
2.28)
Compression ratio 11.4:1
Exhaust system Wet exhaust
Lubrication system Dry sump
Cooling system Water cooled
Starting system Electric starter
Ignition system TCI
Ignition timing Degree BTDC 5–BTDC 35
Spark plug model
(manufacturer)CR9EB (NGK)
Spark plug gap mm (in) 0.7–0.8 (0.028–0.031)
Battery capacity V/Ah 12/19
Generator output A @ r/min 12–21 @ 6,000
Drive unit
Propulsion system Jet pump
Jet pump type Axial flow, single stage
Impeller rotation Counterclockwise (viewed from rear)
Transmission Constant mesh 1-speed
Jet thrust nozzle horizontal
angleDegree 24 + 24
Jet thrust nozzle trim angle Degree 3
Reverse system—Reverse gate
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3-9
E
INSP
ADJ
POWER UNIT
3. Measure:
Valve clearance
Out of specification →
Adjust.
Valve clearance (cold):
Intake valve:
0.11–0.20 mm
(0.0043–0.0079 in)
Exhaust valve:
0.25–0.34 mm
(0.0098–0.0134 in)
Measurement steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC of the compression stroke can be
found when the camshaft lobes are turned
away from each other.
Measure the valve clearance with a thick-
ness gauge 1
.
NOTE:
If the valve clearance is incorrect, record
the measured reading.
Measure the valve clearance in the follow-
ing sequence.
Valve clearance measuring sequence:
Cylinder #1
→ #2
→ #4
→ #3
ÈBow end
To measure the valve clearances of the
other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counter-
clockwise as specified in the following
table.
ÉDegrees that the crankshaft is turned clock-
wise
ÊCylinder
ËCombustion cycle
Cylinder #2 180°
Cylinder #4 360°
Cylinder #3 540°
INEX
1
7205403601800
#4 #3
#2
#1
É
Ê
Ë
Ë
Ë
Ë
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3-10
E
INSP
ADJ
POWER UNIT
4. Remove:
Timing chain tensioner cap bolt 1

Gasket
1
5. Turn the timing chain tensioner rod fully
clockwise with a thin screwdriver 1
.
NOTE:
Make sure that the tensioner rod has been fully
turned clockwise.
1
6. Remove:
Intake camshaft caps
Exhaust camshaft caps
Timing chain
(from the camshaft sprockets)
Intake camshaft
Exhaust camshaft
NOTE:
Refer to “CAMSHAFTS” in Chapter 5.
When removing the timing chain and cam-
shafts, fasten the timing chain with a wire to
prevent it from falling into the crankcase.
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3-12
E
INSP
ADJ
POWER UNIT
NOTE:
The new valve pad number is only an
approximation. The valve clearance must
be measured again and the above steps
should be repeated if the measurement is
still incorrect.
Install the new valve pad 5
and the valve
lifter 6
.
NOTE:
Lubricate the valve pad with molybdenum
disulfide grease.
Lubricate the valve lifter with molybdenum
disulfide oil.
The valve lifter must turn smoothly when
rotated by hand.
Install the valve lifter and the valve pad in
the correct place.
Install the exhaust and intake camshafts,
timing chain, and camshaft caps.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
NOTE:
Refer to “Camshaft installation — CAM-
SHAFTS” in Chapter 5.
Lubricate the camshafts, camshaft lobes,
and camshaft journals.
Install the exhaust camshaft first.
Align the camshaft marks with the cam-
shaft cap marks.
Turn the crankshaft clockwise several full
turns to seat the parts.
Measure the valve clearance again.
If the valve clearance is still out of specifi-
cation, repeat all of the valve clearance
adjustment steps until the specified clear-
ance is obtained.
6
5
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5-39
EPOWRGENERATOR AND STARTER MOTOR
2. Check:
Starter clutch 1

Starter gear 2

Burrs/chips/roughness/wear →
Replace
the defective part(s).
3. Check:
Starter clutch gear’s contacting surfaces
a

Damage/pitting/wear →
Replace the
starter clutch gear.
12
a
4. Check:
Starter clutch operation
Checking steps:
Install the starter gear 1
onto the starter
clutch 2
and hold the starter clutch.
When turning the starter gear clockwise
È, it should turn freely, otherwise the
starter clutch is faulty and must be
replaced.
When turning the starter gear counter-
clockwise É, the starter clutch and the
starter gear should engage, otherwise
the starter clutch is faulty and must be
replaced.
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5-46
EPOWRCAMSHAFTS
SERVICE POINTS
Camshaft removal
1. Install:
Dial gauge needle
Dial gauge stand 1

(into spark plug hole #1)
Dial gauge 2

2. Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC on the compression stroke can be found
when the camshaft lobes are turned away from
each other.
Dial gauge stand:
90890-06583
Dial gauge needle:
90890-06584
Dial gauge stand set:
YB-06585/90890-06585
Dial indicator gauge:
YU-03097
Dial gauge set:
90890-01252
2
1
INEX
3. Make the alignment marks a on the timing
chain and camshaft sprockets.
a
4. Remove:
Timing chain tensioner 1
Gasket
1
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5-49
EPOWRCAMSHAFTS
5. Measure:
Camshaft journal diameter a

Out of specification →
Replace the cam-
shaft.
Within specification →
Replace the cyl-
inder head and the camshaft caps as a
set.
Camshaft journal diameter:
Intake:
24.46–24.47 mm
(0.9630–0.9634 in)
Exhaust:
24.44–24.45 mm
(0.9622–0.9626 in)
Camshaft sprockets inspection
1. Check:
Camshaft sprocket
Wear/damage →
Replace the camshaft
sprockets and timing chain as a set.
a
1/4 of a tooth
b
Correct
1Timing chain
2Camshaft sprocket
Timing chain tensioner inspection
1. Check:
Timing chain tensioner
Cracks/damage/rough movement →

Replace.
Checking steps:
While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1
.
Remove the screwdriver and slowly
release the timing chain tensioner rod.
Make sure that the timing chain tensioner
rod comes out of the timing chain ten-
sioner housing smoothly. If there is rough
movement, replace the timing chain ten-
sioner.
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5-50
EPOWRCAMSHAFTS
Camshaft installation
1. Install:
Exhaust camshaft sprocket 1

Intake camshaft sprocket 2

(with the special service tool 3
)
NOTE:
Install the camshaft sprocket with the punch
mark a
facing outside.
Universal magneto and rotor
holder:
YU-01235
Rotor holder:
90890-01235
T R..
Camshaft sprocket bolt:
24 N  m (2.4 kgf  m, 17 ft  lb)
2. Install:
Exhaust camshaft
Intake camshaft
Exhaust camshaft caps
Intake camshaft caps
Installation steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
Install the timing chain onto both cam-
shaft sprockets, and then install the cam-
shaft.
CAUTION:
Do not turn the crankshaft when install-
ing the camshaft to avoid damage or
improper valve timing.
NOTE:
Make sure that the punch marks a
on the
camshafts face up.
Be sure to align the alignment marks b
made during removal to install the timing
chain and camshaft sprockets.
b
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5-51
EPOWRCAMSHAFTS
Install the exhaust and intake camshaft
caps.
NOTE:
Gradually tighten the intake and exhaust
camshaft cap bolts in 2–3 steps in the
sequence shown.
T R..
Camshaft cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
NOTE:
Make sure that the punch marks c
on the
camshafts are aligned with the arrow marks
d
on the camshaft caps.
Out of alignment →
Reinstall.
Remove the wire from the timing chain.
10 1 4 5 8
17 5 1 4 8 15 9 12 149 3 2
7 6
18 7 3 2 6
13 11 10 16
3. Install:
Timing chain tensioner
Installation steps:
While lightly pressing the timing chain
tensioner rod by hand, turn the tensioner
rod fully clockwise with a thin screwdriver
1
.
NOTE:
Make sure that the tensioner rod has been
fully set clockwise.
With the timing chain tensioner rod
turned all the way into the timing chain
tensioner housing (with the thin screw-
driver still installed), install the gasket and
the timing chain tensioner 2
onto the cyl-
inder block.
WARNING
Always use a new gasket.
Tighten the timing chain tensioner bolts
3
to the specified torque.
NOTE:
The “UP” mark on the timing chain ten-
sioner should face up.
33
2
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5-52
EPOWRCAMSHAFTS
T R..
Timing chain tensioner bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
Remove the screwdriver, make sure the
timing chain tensioner rod releases, and
then tighten the cap bolt to the specified
torque.
T R..
Cap bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
4. Turn:
Drive coupling
(several turns counterclockwise)
5. Check:
Turn the drive coupling counterclock-
wise, and then check if cylinder #1 is at
TDC of the compression stroke with a
dial gauge.
Camshaft punch marks a

Make sure that the camshaft punch
marks are aligned with the arrow marks
b
on the camshaft caps.
Out of alignment →
Adjust.
Refer to the installation steps above.
6. Measure:
Valve clearance
Out of specification →
Adjust.
Refer to “POWER UNIT” in Chapter 3.
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