lock YAMAHA VX110 2005 User Guide

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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3-15
E
INSP
ADJ
POWER UNIT
Place the watercraft in a horizontal posi-
tion or launch the watercraft.
Remove the seat.
Remove the oil tank filler cap 1
and
check for oil on the dipstick 2
.
If there is no oil on the dipstick, pour
enough oil so that the tip of the dipstick
comes into contact with the oil, and then
install the filler cap.
Start the engine.
CAUTION:
When starting the engine make sure the
dipstick is securely fitted into the oil
tank.
NOTE:
The engine cannot be started if the
Yamaha Security System is in the lock
mode. (Deluxe model only)
For information on the Yamaha Security
System, see the owner’s manual. (Deluxe
model only)
Run the engine at trolling speed for 6
minutes or more, and then turn the
engine off.
CAUTION:
When checking the oil level on land, be
sure to connect a garden hose to the
watercraft for proper water supply.
NOTE:
If the ambient temperature is 20°C (68°F)
or less, warm up the engine for an addi-
tional 5 minutes.
Remove the oil tank filler cap 1
, wipe the
dipstick 2
clean, and then screw the filler
cap into the filler hole completely.
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5-1
EPOWRENGINE UNIT
ENGINE UNIT
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
ENGINE UNIT REMOVAL
Follow the left “Step” for removal.
Engine oil Drain.
Refer to “POWER UNIT” in Chapter 3.
Storage compartment panel Refer to “FRONT HOOD” in Chapter 8.
Battery negative and positive lead Refer to “FUSE BOX” in Chapter 7.
Fuel hose Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Water lock and exhaust joint Refer to “EXHAUST SYSTEM” in Chapter 8.
1 Bolt/washer 2/2
2 Fuse box 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
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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
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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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