oil YAMAHA VX110 2005 Owner's Guide

3-19
E
INSP
ADJ
POWER UNIT
5. Remove the air filter element and check it
for dirt and oil. Replace the air filter ele-
ment if there is any oil buildup.
CAUTION:
Do not start the engine with the air filter
case removed, otherwise the engine
could be damaged.
If cleaning the air filter element, use cold
or lukewarm water and let it air dry com-
pletely. Do not use detergent or a solvent
to clean the air filter element, or dry it with
heat or compressed air, otherwise it
could be damaged.
6. Install:
Air filter element
NOTE:
Install the air filter element with its projections
a
facing away from the projections b
on the
air filter case.
7. Install:
Air filter case cover
8. Install:
Air filter case
T R..
Air filter case cover screw (short):
1.5 N  m (0.15 kgf  m, 1.1 ft  lb)
LOCTITE 572
Air filter case cover screw (long):
1.2 N  m (0.12 kgf  m, 0.9 ft  lb)
LOCTITE 572
T R..
Air filter case:
17 N  m (1.7 kgf  m, 12 ft  lb)
a
b
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3-20
E
INSP
ADJ
POWER UNIT
Spark plug inspection
1. Remove:
Ignition coils
CAUTION:
Be careful not to get any foreign sub-
stances or water in spark plug hole.
2. Inspect:
Electrodes 1

Damage/wear →
Replace.
Insulator color 2

Distinctly different color →
Check the
engine condition.
Color guide:
Medium to light tan color:
Normal
Whitish color:
Lean fuel mixture
Air leak
Incorrect settings
Blackish color:
Overly rich mixture
Electrical malfunction
Defective spark plug
3. Clean:
Spark plug
(with a spark plug cleaner or wire brush)
4. Measure:
Spark plug gap a

Out of specification →
Regap.
Spark plug gap:
0.7–0.8 mm (0.028–0.031 in)
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3-21
E
INSP
ADJ
POWER UNIT
5. Tighten:
Spark plug
NOTE:
Before installing the spark plug, clean the
gasket surface and spark plug surface. Also,
it is suggested to apply a thin film of anti-
seize compound to the spark plug threads to
prevent thread seizure.
If a torque wrench is not available, a good
estimate of the correct tightening torque for a
new spark plug is to finger tighten a
the
spark plug and then tighten it another 1/4 to
1/2 of a turnb
.
T R..
Spark plug:
13 N  m (1.3 kgf  m, 9.4 ft  lb)
6. Install:
Ignition coils
T R..
Ignition coil bolt:
7.6 N  m (0.76 kgf  m, 5.5 ft  lb)
LOCTITE 572
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3-22
E
INSP
ADJ
ELECTRICAL
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
lyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immedi-
ately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away. If
using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery.
When checking the battery, make sure the
breather hose is connected to the battery
and not obstructed.
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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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4-14
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
Fuel hose installation (replacing with new
fuel hose)
1. Install:
Fuel hose 1

NOTE:
To install the fuel hose, be sure to align the
white mark a
of the fuel hose with the
checker tab 2
of the quick connector.
When replacing the fuel hose with a new
one, a checker tab 2
that has half engage-
ment prevention is attached to the quick con-
nector of the hose. If the quick connector is
completely installed to the fuel pipe, it is
removable.
2
1a
2
Fuel hose connection
1. Apply a thin coat of engine oil to the con-
tact surfaces of the fuel pipe.
2. Insert the quick connector into the fuel
pipe until you hear a “click.”
3. To check the connection of the quick con-
nector, push and pull on the quick connec-
tor several times until there is free play of
2–3 mm (0.08–0.12 in).
NOTE:
If free is not obtained, disconnect the fuel hose
and check the O-ring for damage and that it is
properly installed.
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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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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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5-4
EPOWRENGINE UNIT
SERVICE POINTS
Compression pressure measurement
The following procedure applies to all of the
cylinders.
NOTE:
Insufficient compression pressure will result in
a loss of performance.
1. Measure:
Valve clearance
Out of specification →
Adjust.
Refer to “POWER UNIT” in Chapter 3.
2. Warm the engine up, and then put the
watercraft in a horizontal position.
3. Remove:
Ignition coils
Spark plugs
CAUTION:
Before removing the spark plugs, use com-
pressed air to blow away any dirt accumu-
lated in the spark plug wells to prevent it
from falling into the cylinders.
4. Install:
Compression gauge extension 1

Compression gauge 2

Compression gauge extension:
90890-06582
Compression gauge:
YU-33223-1/90890-03160
2
1
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5-5
EPOWRENGINE UNIT
5. Measure:
Compression pressure
Out of specification →
Refer to steps (b)
and (c).
6. Install:
Spark plug
Minimum compression pressure
(reference data):
1,150 kPa
(11.5 kgf/cm
2, 164 psi)
Measurement steps:
a. With the throttle wide open, crank the
engine until the reading on the compres-
sion gauge stabilizes.
NOTE:
The difference in compression pressure
between cylinders should not exceed 100
kPa (1 kgf/cm2, 14 psi).
b. If the compression pressure is extremely
high, check the cylinder head, valve sur-
faces and piston crown for carbon depos-
its.
Carbon deposits →
Eliminate.
c. If the compression pressure is below the
minimum specification, squirt a few drops
of oil into the cylinder and measure
again.
Refer to the following table.
Compression pressure
(with oil applied into the cylinder)
Reading Diagnosis
Higher than
without oilPiston ring wear,
piston wear or
damage
→ Repair.
Same as without
oilValves, cylinder
head gasket or pis-
ton possibly defec-
tive
→ Repair.
T R..
Spark plug:
13 N  m (1.3 kgf  m, 9.4 ft  lb)
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