engine YAMAHA VX110 2005 Workshop Manual

5-8
EPOWREXHAUST PIPES 1 AND 2
EXHAUST PIPES 1 AND 2
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
EXHAUST PIPES 1 AND 2
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
È
For cooling water pilot outlet on port side
É
From water jacket
1 Clamp/cooling water hose 1/1
2 Clamp/cooling water hose 1/1
3Bolt 2
4 Thermoswitch (exhaust) 1
5 Exhaust joint clamp 2 Slide the outer exhaust joint for exhaust
manifold side
6 Exhaust joint clamp 2
6
64 3
É
5
2
È 6 × 16 mm
7.6 N  m (0.76 kgf  m, 5.5 ft  Ib)
2nd 3.4 N  m (0.34 kgf  m, 2.5 ft  Ib) 1st 3.4 N  m (0.34 kgf  m, 2.5 ft  Ib)LT
242
LT
242
LT
572
LT
LT
572
LT
LT
242
1
LT
242
LT
242
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5-12
EPOWROIL TANK
OIL TANK
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL TANK REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Intake assembly Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
1 Clamp/cooling water hose 1/1È
To exhaust pipe 1
2Bolt 4
3 Water jacket 1
4Gasket 1
5 Clamp/breather hose 2/1
6 Clamp/breather hose 2/1É
To oil pump
7Bolt 2
8 Collar 2
Ì
LT
572
LT
572
LT
572
LT
572
LT
572
LT
572
23 1925 24
26
25
2116 17 15
14
1220 22
3
4
6 8
9
72
6
AA
6 × 30 mm
2nd 7.6 N  m (0.76 kgf
 m, 5.5 ft
 Ib) 1st 3.7 N  m (0.37 kgf
 m, 2.7 ft
 Ib)
2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)
2nd 39 N  m (3.9 kgf
 m, 28 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
10 × 85 mm2nd 15 N  m (1.5 kgf
 m, 11 ft
 Ib) 1st 2.0 N  m (0.2 kgf
 m, 1.4 ft
 Ib)
10 × 70 mm
3rd 39 N  m (3.9 kgf
 m, 28 ft
 Ib)7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 35 mm
È
ÉÌ13
LT
572
LT
572
LT
572
LT
572
18
102nd 7.6 N  m (0.76 kgf  m, 5.5 ft  Ib)
1st 3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
6 × 20 mm
Ê
Ë
a
1
5
1111
5
6 × 35 mm
Not reusable
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5-21
EPOWROIL PUMP
OIL PUMP
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PUMP ASSEMBLY
REMOVALFollow the left “Step” for removal.
Oil tank Refer to “OIL TANK”.
1 Drain plug/washer 1/1 Drain engine oil.
2Bolt 6
3Bolt 2
4Bolt 2
5 Oil pump assembly 1
6Gasket 1
7Pin 2
2nd 28 N  m (2.8 kgf  m, 20 ft  Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
8 × 112 mm
6 × 25 mm
10 N  m (1.0 kgf  m, 7.2 ft  Ib)
2nd 7.6 N  m (0.76 kgf  m, 5.5 ft  Ib) 1st 3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
6 × 16 mm
LT
572
LT
LT
572
LT
13 N  m (1.3 kgf  m, 9.4 ft  Ib)
8 × 12 mm
LT
572
LT
1
5
7 73
4
2
6
8
8
9
2nd 28 N  m (2.8 kgf  m, 20 ft  Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
8 × 95 mm
Not reusable
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5-33
EPOWRGENERATOR AND STARTER MOTOR
GENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR COVER AND
FLYWHEEL MAGNETO
REMOVALFollow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
1 Nut/washer 1/1
2 Starter motor lead 1
3Bolt 2
4 Battery negative lead 1
5 Starter motor 1
6 Band 1
7 Lighting coil coupler 1
4 3
2 1
5
7
89
1113 12
18 16171920 21
15 14
AA
E
E
E
LT
572
LT
572
AA
AA
8 × 30 mm
18 N  m (1.8 kgf
 m, 13 ft
 Ib)
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
10 × 47 mm
75 N  m (7.5 kgf
 m, 54 ft
 Ib) 8 × 20 mm
24 N  m (2.4 kgf
 m, 17 ft
 Ib)
10 × 60 mm
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf
 m, 11 ft
 Ib)
6
2nd 50 N  m (5.0 kgf
 m, 36 ft
 Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
10 × 135 mm
10
LT
572
LT
572
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5-40
EPOWRGENERATOR AND STARTER MOTOR
Flywheel magneto installation
1. Install:
Woodruff key
Flywheel magneto
Washer
Flywheel magneto bolt
NOTE:
Clean the tapered portion of the crankshaft
and the flywheel magneto hub.
When installing the flywheel magneto, make
sure the woodruff key is properly seated in
the keyway of the crankshaft.
Lubricate the flywheel magneto bolt and
washer with engine oil.
2. Tighten:
Flywheel magneto bolt 1

NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, tighten the flywheel mag-
neto bolt.
CAUTION:
Do not reuse the flywheel magneto bolt and
washer, always replace them with new
ones.
T R..
Flywheel magneto bolt:
75 N  m (7.5 kgf  m, 54 ft  lb)
Sheave holder:
YS-01880-A/90890-01701
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5-43
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CAMSHAFT REMOVAL
Follow the left “Step” for removal.
Cylinder head cover
Reduction drive gear case Refer to “REDUCTION DRIVE GEAR”.
NOTE:
When removing camshafts it is not neces-
sary to remove the reduction drive gear
case.
1 Thermoswitch (engine) coupler 1
2 Engine temperature sensor coupler 1
3 Cap bolt 1
4Gasket 1
5Bolt 2
M
E
EE
E
E
E
M
12
13
12
13
12
13
141819
10
20
10
10
15
11
16
9
17
822
21
3 4
5 6 7
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 35 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 25 mm
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 8 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
24 N 
m (2.4 kgf  m, 17 ft  Ib)
7 × 11 mm
2324
25
26
27
12
6 × 16 mm
AA
Not reusable
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5-54
EPOWRCYLINDER HEAD
CYLINDER HEAD
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CYLINDER HEAD REMOVAL
Follow the left “Step” for removal.
Engine unit Refer to “ENGINE UNIT”.
Intake assembly Refer to “FUEL INJECTION SYSTEM” in
Chapter 4.
Exhaust pipes 1 and 2 Refer to “EXHAUST PIPES 1 AND 2”.
Oil tank Refer to “OIL TANK”.
Intake and exhaust camshaft Refer to “CAMSHAFTS”.
1Bolt 2
2 Hunger 1
3Bolt 3
EEE
E
2 4
1
855
7
9 3 6
6
LT
271
2nd 121 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
2nd 140 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
10 N •
m (1.0 kgf • m, 7.2 ft • Ib)
6 × 12 mm
10 N •
m (1.0 kgf • m, 7.2 ft • Ib)
6 × 55 mm
8 × 20 mm
6
2nd 105 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
2nd 105 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
2nd 105 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
2nd 105 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
E6
4
66
6
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5-57
EPOWRCYLINDER HEAD
3. Measure:
Cylinder head warpage
Out of specification →
Replace the cyl-
inder head.
Cylinder head warpage limit:
0.1 mm (0.004 in)
Measurement steps:
Place a straightedge 1
and a thickness
gauge 2
across the cylinder head.
Measure the warpage.
If the limit is exceeded, replace the cylin-
der head.
Cylinder head installation
1. Install:
Cylinder head
NOTE:
Pass the timing chain through the timing
chain cavity.
Lubricate the cylinder head nuts with engine
oil.
Tighten the cylinder head nuts in the
sequence shown.
T R..
Cylinder head nut
1:
1st:
20 N  m (2.0 kgf  m, 14 ft  lb)
2nd:
121
± 5°
Cylinder head nut
2:
1st:
20 N  m (2.0 kgf  m, 14 ft  lb)
2nd:
105
± 5°
Cylinder head nut
3:
1st:
20 N  m (2.0 kgf  m, 14 ft  lb)
2nd:
140
± 5°
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5-58
EPOWRCYLINDER HEAD
2. Tighten:
Cylinder head bolts 1

NOTE:
Lubricate the cylinder head bolts with engine
oil.
T R..
Cylinder head bolt:
10 N  m (1.0 kgf  m, 7.2 ft  lb)
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5-65
EPOWRVALVES AND VALVE SPRINGS
2. Install the new valve guide 2
by striking
the special service tool from the camshaft
side until the valve guide clip 3
contacts
the cylinder head.
NOTE:
Apply engine oil to the surface of the new
valve guide.
Valve guide remover:
Intake (ø4.0 mm):
YM-04111/90890-04111
Exhaust (ø4.5 mm):
YM-04116/90890-04116
Valve guide installer:
Intake (ø4.0 mm):
YM-04112/90890-04112
Exhaust (ø4.5 mm):
YM-04117/90890-04117
3
E
2
3. Insert the special service tool into the
valve guide 2
, and then ream the valve
guide.
NOTE:
Turn the valve guide reamer clockwise to
ream the valve guide.
Do not turn the reamer counterclockwise
when removing the reamer.
4. Measure:
Valve guide inside diameter
Valve guide reamer:
Intake (ø4.0 mm):
YM-04113/90890-04113
Exhaust (ø4.5 mm):
YM-04118/90890-04118
Valve guide inside diameter:
Intake:
4.000–4.012 mm
(0.1575–0.1580 in)
Exhaust:
4.500–4.512 mm
(0.1772–0.1776 in)
2
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