service YAMAHA VX110 2005 Owner's Manual
[x] Cancel search | Manufacturer: YAMAHA, Model Year: 2005, Model line: VX110, Model: YAMAHA VX110 2005Pages: 347, PDF Size: 14.17 MB
Page 81 of 347
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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Page 84 of 347
4-7
EFUELFUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL INJECTION SYSTEM
REMOVALFollow the left “Step” for removal.
1 Cam position sensor coupler 1
2 Fuel injector coupler 4
3 Sensor assembly coupler 1
4 Thermoswitch coupler (exhaust) 1
5 Oil pressure switch coupler 1
6 Ground lead coupler 2
7 Joint connector 4 From fuel rail
8 Throttle body assembly coupler 1
9 Cover 1
17 N m (1.7 kgf m, 12 ft Ib)
5 × 75 mm
1.2 N m (0.12 kgf m, 0.9 ft Ib)
5 × 25 mm
1.5 N m (0.15 kgf m, 1.1 ft Ib)
8 × 35 mm
17 N m (1.7 kgf m, 12 ft Ib)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 × 30 mm
2nd 39 N m (3.9 kgf m, 28 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib)
8 × 20 mm
LT
242
LT
242
LT
271
LT
572
LT
LT
572
LT
22 2320 19
2118 15 1316
14 1712
17
3
2
2
25
4
6
24
24
25 8
26
27
28
29
11 10
9
2.5 N m (0.25 kgf m, 1.8 ft Ib)
6.5 N m (0.65 kgf m, 4.7 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)
3031
30
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Page 85 of 347
4-8
EFUELFUEL INJECTION SYSTEM
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
10 Fuel hose 1
11 Clamp 2
12 Hose screw clamp 1
13 Screw 2
14 Screw 4
15 Air filter case cover 1
16 Air intake duct 1
17 Air intake hose 1
18 Gasket 1
19 Air filter element 1
20 Bolt 4
17 N m (1.7 kgf m, 12 ft Ib)
5 × 75 mm
1.2 N m (0.12 kgf m, 0.9 ft Ib)
5 × 25 mm
1.5 N m (0.15 kgf m, 1.1 ft Ib)
8 × 35 mm
17 N m (1.7 kgf m, 12 ft Ib)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 × 30 mm
2nd 39 N m (3.9 kgf m, 28 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib)
8 × 20 mm
LT
242
LT
242
LT
271
LT
572
LT
LT
572
LT
22 2320 19
2118 15 1316
14 1712
17
3
2
2
25
4
6
24
24
25 8
26
27
28
29
11 10
9
2.5 N m (0.25 kgf m, 1.8 ft Ib)
6.5 N m (0.65 kgf m, 4.7 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)
3031
30
Not reusable
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Page 86 of 347
4-9
EFUELFUEL INJECTION SYSTEM
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
21 Air filter case 1
22 Collar 4
23 Grommet 4
24 Bolt 2
25 Intake assembly 1
26 Bolt 2
27 Throttle cable 1
28 Nut 2
29 Accelerator position sensor 1
30 Nut 4
31 Bracket 2
Reverse the removal steps for installation.
17 N m (1.7 kgf m, 12 ft Ib)
5 × 75 mm
1.2 N m (0.12 kgf m, 0.9 ft Ib)
5 × 25 mm
1.5 N m (0.15 kgf m, 1.1 ft Ib)
8 × 35 mm
17 N m (1.7 kgf m, 12 ft Ib)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 × 30 mm
2nd 39 N m (3.9 kgf m, 28 ft Ib) 1st 15 N m (1.5 kgf m, 11 ft Ib)
8 × 20 mm
LT
242
LT
242
LT
271
LT
572
LT
LT
572
LT
22 2320 19
2118 15 1316
14 1712
17
3
2
2
25
4
6
24
24
25 8
26
27
28
29
11 10
9
2.5 N m (0.25 kgf m, 1.8 ft Ib)
6.5 N m (0.65 kgf m, 4.7 ft Ib)
15 N m (1.5 kgf m, 11 ft Ib)
3031
30
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Page 87 of 347
4-10
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
THROTTLE BODY ASSEMBLY
AND INTAKE MANIFOLD
DISASSEMBLYFollow the left “Step” for disassembly.
1Bolt 4
2 Washer 4
3 Throttle body assembly 1
4Gasket 1
5 Intake manifold 1
6Bolt 2
7 Fuel rail 1
8 × 17 mm
13 N m (1.3 kgf m, 9.4 ft Ib)5 × 15 mm
3.5 N m (0.35 kgf m, 2.5 ft Ib)
8 × 65 mm
13 N m (1.3 kgf m, 9.4 ft Ib)123 4 14151689 107661111
12
13
5
Not reusable
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Page 88 of 347
4-11
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8Gasket 4
9 Fuel injector 4
10 O-ring 4
11 Screw 2
12 Sensor assembly 1
13 O-ring 1
14 Clamp 4
15 Clamp 4
16 Intake manifold joint 4
Reverse the disassembly steps for
assembly.
8 × 17 mm
13 N m (1.3 kgf m, 9.4 ft Ib)5 × 15 mm
3.5 N m (0.35 kgf m, 2.5 ft Ib)
8 × 65 mm
13 N m (1.3 kgf m, 9.4 ft Ib)123 4 14151689 107661111
12
13
5
Not reusable
Not reusable
Not reusable
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Page 89 of 347
4-12
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
SERVICE POINTS
Fuel hose clamps removal
1. Remove:
Fuel hose clamps
CAUTION:
If the fuel hose clamps are removed with-
out cutting the joint first, the fuel hose will
be damaged.
Hose clamps installation
1. Install:
Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones.
NOTE:
Crimp the fuel hose clamps properly to
securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative lead to cut off the elec-
tric current to the electrical systems.
1. Wrap the quick connector with a cloth, and
then rotate the quick connector tab 1
to
the stopper position a
.
WARNING
If the quick connector is removed sud-
denly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
1
a
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Page 97 of 347
EPOWR
1
2
3
4
5
6
7
8
9
CHAPTER 5
POWER UNIT
ENGINE UNIT .................................................................................................. 5-1
EXPLODED DIAGRAM ............................................................................. 5-1
REMOVAL AND INSTALLATION CHART ................................................ 5-1
SERVICE POINTS .................................................................................... 5-4
Compression pressure measurement ................................................. 5-4
Engine unit removal ............................................................................ 5-6
Shim removal ...................................................................................... 5-6
Engine mount inspection ..................................................................... 5-6
Coupling clearance inspection ............................................................ 5-7
EXHAUST PIPES 1 AND 2.............................................................................. 5-8
EXPLODED DIAGRAM ............................................................................. 5-8
REMOVAL AND INSTALLATION CHART ................................................ 5-8
EXHAUST MANIFOLD .................................................................................. 5-11
EXPLODED DIAGRAM ........................................................................... 5-11
REMOVAL AND INSTALLATION CHART .............................................. 5-11
OIL TANK ...................................................................................................... 5-12
EXPLODED DIAGRAM ........................................................................... 5-12
REMOVAL AND INSTALLATION CHART .............................................. 5-12
SERVICE POINTS .................................................................................. 5-17
Oil tank removal ................................................................................ 5-17
Oil strainer inspection........................................................................ 5-18
Oil tank installation ............................................................................ 5-18
OIL PUMP ...................................................................................................... 5-21
EXPLODED DIAGRAM ........................................................................... 5-21
REMOVAL AND INSTALLATION CHART .............................................. 5-21
SERVICE POINTS .................................................................................. 5-23
Oil strainer inspection........................................................................ 5-23
Oil pump installation .......................................................................... 5-23
REDUCTION DRIVE GEAR .......................................................................... 5-24
EXPLODED DIAGRAM ........................................................................... 5-24
REMOVAL AND INSTALLATION CHART .............................................. 5-24
SERVICE POINTS .................................................................................. 5-28
Drive coupling removal...................................................................... 5-28
Drive shaft removal ........................................................................... 5-28
Bearing removal ................................................................................ 5-28
Oil pump drive shaft inspection ......................................................... 5-29
Drive shaft inspection ........................................................................ 5-29
Bearing installing ............................................................................... 5-30
Drive shaft installation ....................................................................... 5-32
Drive coupling installation ................................................................. 5-32
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Page 98 of 347
EPOWR
GENERATOR AND STARTER MOTOR ....................................................... 5-33
EXPLODED DIAGRAM ........................................................................... 5-33
REMOVAL AND INSTALLATION CHART ............................................. 5-33
SERVICE POINTS .................................................................................. 5-38
Flywheel magneto removal ............................................................... 5-38
Starter clutch inspection .................................................................... 5-38
Flywheel magneto installation ........................................................... 5-40
CAMSHAFTS................................................................................................. 5-41
EXPLODED DIAGRAM ........................................................................... 5-41
REMOVAL AND INSTALLATION CHART .............................................. 5-41
SERVICE POINTS .................................................................................. 5-46
Camshaft removal ............................................................................. 5-46
Camshaft inspection.......................................................................... 5-47
Camshaft sprockets inspection ......................................................... 5-49
Timing chain tensioner inspection ..................................................... 5-49
Camshaft installation ......................................................................... 5-50
CYLINDER HEAD.......................................................................................... 5-54
EXPLODED DIAGRAM ........................................................................... 5-54
REMOVAL AND INSTALLATION CHART ............................................. 5-54
SERVICE POINTS .................................................................................. 5-56
Cylinder head removal ...................................................................... 5-56
Cylinder head inspection ................................................................... 5-56
Cylinder head installation .................................................................. 5-57
VALVES AND VALVE SPRINGS .................................................................. 5-59
EXPLODED DIAGRAM ........................................................................... 5-59
REMOVAL AND INSTALLATION CHART ............................................. 5-59
SERVICE POINTS .................................................................................. 5-61
Valve removal ................................................................................... 5-61
Valve spring inspection ..................................................................... 5-62
Valve inspection ................................................................................ 5-62
Valve guide inspection ...................................................................... 5-64
Valve guide replacement................................................................... 5-64
Valve seat inspection ........................................................................ 5-66
Valve seat reface .............................................................................. 5-67
Valve installation ............................................................................... 5-69
CRANKCASE ................................................................................................ 5-71
EXPLODED DIAGRAM ........................................................................... 5-71
REMOVAL AND INSTALLATION CHART .............................................. 5-71
SERVICE POINTS .................................................................................. 5-75
Crankcase disassembly .................................................................... 5-75
Crankcase inspection ........................................................................ 5-76
Timing chain inspection..................................................................... 5-76
Crankcase assembly ......................................................................... 5-77
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Page 99 of 347
EPOWR
CONNECTING RODS AND PISTONS .......................................................... 5-80
EXPLODED DIAGRAM ........................................................................... 5-80
REMOVAL AND INSTALLATION CHART .............................................. 5-80
SERVICE POINTS .................................................................................. 5-82
Connecting rod and piston removal .................................................. 5-82
Cylinder and piston inspection .......................................................... 5-83
Piston ring inspection ........................................................................ 5-84
Piston pin inspection ......................................................................... 5-86
Connecting rod inspection................................................................. 5-87
Connecting rod and piston installation .............................................. 5-89
CRANKSHAFT .............................................................................................. 5-93
EXPLODED DIAGRAM ........................................................................... 5-93
REMOVAL AND INSTALLATION CHART .............................................. 5-93
SERVICE POINTS .................................................................................. 5-94
Crankshaft removal ........................................................................... 5-94
Crankshaft inspection........................................................................ 5-94
Crankshaft installation ....................................................................... 5-97
COOLING WATER HOSE ............................................................................. 5-98
EXPLODED DIAGRAM ........................................................................... 5-98
REMOVAL AND INSTALLATION CHART .............................................. 5-98
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