fuel pump YAMAHA VX110 2005 User Guide

3-7
E
INSP
ADJ
FUEL SYSTEM
FUEL SYSTEM
WARNING
When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
Fuel pump filter
Clog/contaminants →
Clean.
Refer to “FUEL TANK AND FUEL
PUMP MODULE” in Chapter 4.
Fuel hose
Cracks/damage →
Replace.
O-rings (quick connector)
Cracks/damage →
Replace the quick
connector.
Fuel rail
Cracks/damage →
Replace.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
Fuel filler hose
Fuel filler cap
Cracks/damage →
Replace.
2. Inspect:
Fuel tank
Cracks/damage →
Replace.
Water accumulation →
Remove.
NOTE:
To remove water from the fuel tank, remove
the fuel filler hose 1
and use a siphon pump.
Refer to “FUEL TANK AND FUEL PUMP
MODULE” in Chapter 4.
1
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EFUEL
1
2
3
4
5
6
7
8
9
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE...................................................... 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ................................................ 4-1
SERVICE POINTS .................................................................................... 4-4
Fuel hose disconnection ..................................................................... 4-4
Fuel pump module removal................................................................. 4-4
Check valve inspection ....................................................................... 4-4
Fuel sender inspection ........................................................................ 4-5
Fuel tank inspection ............................................................................ 4-5
Fuel hose inspection ........................................................................... 4-5
Fuel pump filter inspection .................................................................. 4-5
Fuel pump module installation ............................................................ 4-6
Fuel hose connect ............................................................................... 4-6
FUEL INJECTION SYSTEM ............................................................................ 4-7
EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ................................................ 4-7
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD ........................ 4-10
EXPLODED DIAGRAM ........................................................................... 4-10
REMOVAL AND INSTALLATION CHART .............................................. 4-10
SERVICE POINTS .................................................................................. 4-12
Fuel hose clamps removal ................................................................ 4-12
Hose clamps installation ................................................................... 4-12
Fuel hose disconnection ................................................................... 4-12
Fuel line inspection ........................................................................... 4-13
Fuel hose installation (replacing with new fuel hose) ........................ 4-14
Fuel hose connection ........................................................................ 4-14
Fuel injectors inspection.................................................................... 4-15
Throttle body assembly inspection .................................................... 4-15
Accelerator position sensor inspection.............................................. 4-15
Intake assembly installation .............................................................. 4-16
Air filter case assembly installation ................................................... 4-17
Fuel pressure measurement ............................................................. 4-17
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4-1
EFUELFUEL TANK AND FUEL PUMP MODULE
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL
Follow the left “Step” for removal.
Storage compartment panel Refer to “FRONT HOOD” in Chapter 8.
Ventilation hose From ventilation fitting
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1 Fuel tank breather hose 1
2 Check valve 1
NOTE:
Make sure the arrow direction pointed
toward fuel tank.
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N • m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
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4-2
EFUELFUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
3 Fuel tank breather hose 1
NOTE:
Make sure that the inner seal of the coupler
is installed properly before connecting the
coupler. 4 Fuel sender coupler 1
5 Fuel pump module coupler 1
6 Cover 1
7 Fuel hose 1
8Nut 9
9 Retainer 1
10 Fuel pump module 1
11 Packing 1
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N  m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
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4-3
EFUELFUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
12 Hose clamp 2
13 Fuel filler hose 1
14 Nut 1
15 Fuel filler neck 1
16 Rubber seal 1
17 Fuel tank belt 2
18 Fuel tank assembly 1
Reverse the removal steps for installation.
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N  m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
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4-4
EFUELFUEL TANK AND FUEL PUMP MODULE
SERVICE POINTS
Fuel hose disconnection
1. Disconnect:
Fuel hose
Refer to “FUEL INJECTION SYSTEM”.
Fuel pump module removal
1. Remove:
Nuts
Retainer
NOTE:
Loosen the nuts in the sequence shown.
238
7
5
1 238
7
5
1
4 4
9 6 6
2. Remove:
Fuel pump module 1

NOTE:
Remove the float 2
at an angle because it
could catch on the fuel tank.
12
Check valve inspection
1. Check:
Check valve
Faulty →
Replace.
Checking steps:
Connect a hose to the end of check valve
“A” and blow into it.
Air should come out from end “B”.
Connect the hose to the end of check
valve “B” and blow into it.
Air should come out from end “A”.
A A
B B
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4-5
EFUELFUEL TANK AND FUEL PUMP MODULE
Fuel sender inspection
Refer to “FUEL CONTROL SYSTEM” in
Chapter 7.
Fuel tank inspection
1. Inspect:
Fuel tank
Cracks/damage →
Replace.
Fuel hose inspection
Refer to “FUEL INJECTION SYSTEM”.
Fuel pump filter inspection
1. Inspect:
Fuel pump filter 1

Clog/contaminants →
Wash the fuel
pump filter in kerosene or gasoline.
1
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4-6
EFUEL
Fuel pump module installation
1. Tighten:
Nuts
NOTE:
Tighten the nuts in the sequence shown.
Fuel hose connect
Refer to “FUEL INJECTION SYSTEM”.
T R..
Fuel pump module nut:
1st:
3.2 N  m
(0.32 kgf  m, 2.3 ft  lb)
2nd:
6.4 N  m
(0.64 kgf  m, 4.6 ft  lb)238
7
5
1 872
3
5
9
4 6
1 6 4
FUEL TANK AND FUEL PUMP MODULE
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4-13
EFUEL
CAUTION:
Do not rotate the quick connector tab
1
past the stopper position, otherwise it
could be damaged.
When the fuel hoses are disconnected,
quickly remove the retainer
2 from the
quick connector, otherwise the retainer
could be lost.
2. Disconnect the fuel hose 1
from the fuel
pipe 2
directly.
WARNING
Always reduce the fuel pressure in the fuel
line before servicing the line or the fuel
pipe. If the fuel pressure is not released,
pressurized fuel could spray out.
21
1
2
3. Cover the quick connector and fuel pipe
with a plastic bag 3 to prevent damage
and to protect them from dirt.
3
Fuel line inspection
1. Inspect:
Fuel hose
Damage/cracks → Replace.
O-rings (quick connector)
Damage/cracks → Replace the quick
connector.
Fuel pipe
Damage/cracks → Replace the fuel
pump.
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
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4-17
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
Air filter case assembly installation
1. Install:
Air intake duct 1

Air intake hose 2

Air filter case cover
NOTE:
Align the projections a
on the air intake duct
and air intake hose with the projections b
on
the air filter case cover as shown in the illustra-
tion.
2. Adjust:
Throttle lever free play
Refer to “CONTROL SYSTEM” in Chap-
ter 3.
a
b a
b
2
1
Fuel pressure measurement
1. Disconnect:
Fuel hose
Refer to “Fuel hose disconnection”.
2. Install:
Fuel pressure gauge adapter 1

Fuel pressure gauge 2

NOTE:
To connect the fuel pressure gauge adapter,
follow the procedures for connecting a fuel
hose. (Refer to “Fuel hose connection”.)
3. Start the engine and arrow it to warm up
for several minutes.
4. Measure:
Fuel pressure
Out of specification →
Replace the fuel
pump module.
Fuel pressure gauge adapter:
YW-06842/90890-06842
Fuel pressure gauge:
YB-06766/90890-06786
Fuel pressure:
320–327 kPa
(3.2–3.3 kgf/cm
2, 46–47 psi)
2
1
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