YAMAHA VX110 2005 Workshop Manual

3-2
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INSP
ADJ
CONTROL SYSTEM
PERIODIC SERVICE
CONTROL SYSTEM
Steering column inspection
1. Inspect:
Steering column
Excessive play →
Replace the steering
column.
Refer to “STEERING COLUMN” in
Chapter 8.
Inspection steps:
Move the handlebar up and down and
back and forth.
Check the excessive play of the handle-
bar.
Steering cable inspection and adjustment
1. Inspect:
Jet thrust nozzle distances a
and b

Out of specification →
Adjust.
Difference of distances
a and
b:
Maximum 5 mm (0.2 in)
Measurement steps:
Set the control grip to the neutral posi-
tion.
Turn the handlebar lock to lock.
Measure distances a
and b
.
If the difference of distances a
and b
is
not within specification, adjust the cable
joint.
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3-3
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CONTROL SYSTEM
2. Adjust:
Steering cable joint
(steering column end)
NOTE:
Adjust the cable joint at the jet pump end.
Refer to “REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD” in Chapter 8. Adjustment steps:
Set the control grip to the neutral posi-
tion.
Loosen the locknut 1
.
Disconnect the cable joint 2
from the ball
joint 3
.
Turn the cable joint 2
in or out to adjust
the steering cable length c
.
Steering cable length
c:
218.8 mm (8.61 in)
NOTE:
Check that the sum of lengths c
and d
is
581.8 ±
1 mm (22.91 ±
0.04 in).
If the sum of lengths c
and d
is out of
specification, adjust length d
, and then
check the jet thrust nozzle distances
again.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T R..
Locknut:
6.8 N  m (0.68 kgf  m, 4.9 ft  lb)
c
d
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3-4
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INSP
ADJ
CONTROL SYSTEM
Throttle cable inspection and adjustment
NOTE:
Before adjusting the throttle lever free play,
check the trolling speed.
1. Measure:
Throttle lever free play a

Out of specification →
Adjust.
Throttle cable length b

Out of specification →
Adjust.
NOTE:
Check that the throttle cable length b
is 18.4
±
1 mm (0.72 ±
0.04 in). Adjust if necessary.
Adjust the throttle lever free play at the throt-
tle lever end of the throttle cable.
Throttle lever free play
a:
4–7 mm (0.16–0.28 in)
Throttle cable length
b:
18.4
± 1 mm (0.72
± 0.04 in)
b
2. Adjust:
Throttle lever free play a
Adjustment steps:
a. Remove the handlebar cover.
b. Loosen the locknut 1
.
c. Turn the adjuster 2
in or out until the
specified free play is obtained.
Turn in Free play is increased.
Turn out Free play is decreased.
d. Tighten the locknut 1
.
NOTE:
If the throttle cable free play cannot be
adjusted properly, replace the throttle cable.
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3-5
E
INSP
ADJ
CONTROL SYSTEM
WARNING
After adjusting the free play, turn the han-
dlebar to the right and left and make sure
that the trolling speed does not increase.e. Install the handlebar cover.
T R..
Lower handlebar cover screw:
3.7 N  m (0.37 kgf  m, 2.7 ft  lb)
LOCTITE 242
Upper handlebar cover screw:
1.1 N  m (0.11 kgf  m, 0.8 ft  lb)
Shift cable inspection and adjustment
(Deluxe model only)
1. Check:
Reverse gate stopper lever position
Incorrect →
Adjust.
2. Adjust:
Shift cable joint Checking steps:
Set the shift lever to the reverse position.
Check that the reverse gate 1
contacts
the stopper 2
.
Adjustment steps:
Loosen the locknut 1
.
Disconnect the cable joint 2
from the ball
joint 3
.
Situate the reverse gate to the stopper.
Turn the cable joint in or out to align it
with the ball joint.
Turn in Length is decreased.
Turn out Length is increased.
1
23
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3-6
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INSP
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CONTROL SYSTEM
Turn out the cable joint nine times a
to
extend the cable 7 mm (0.28 in) from the
aligned position.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T R..
Locknut:
3.8 N  m (0.38 kgf  m, 2.7 ft  lb)
Trolling speed inspection
1. Inspect:
Trolling speed
Trolling speed:
1,550–1,750 r/min
Checking steps (watercraft in water):
Start the engine and allow it to warm up
for 15 minutes.
Check the engine trolling speed using the
tachometer of the multifunction meter or
using the Yamaha Diagnostic System.
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3-7
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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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3-8
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INSP
ADJ
FUEL SYSTEM/POWER UNIT
Water separator inspection
1. Inspect:
Water separator 1

Water accumulation →
Drain.
NOTE:
To drain the water, remove the drain plug.
POWER UNIT
Valve clearance adjustment
The following procedure applies to all of the
valves.
NOTE:
Valve clearance adjustment should be made
on a cold engine, at room temperature.
When the valve clearance is to be measured
or adjusted, the piston must be at top dead
center (TDC) of the compression stroke.
1. Remove:
Ignition coils
Spark plugs
Cylinder head cover
Cylinder head cover gasket
Refer to “CAMSHAFTS” in Chapter 5.
2. Install:
Dial gauge needle
Dial gauge stand 1

(into spark plug hole #1)
Dial gauge 2

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:
90890-012522
1
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3-9
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POWER UNIT
3. Measure:
Valve clearance
Out of specification →
Adjust.
Valve clearance (cold):
Intake valve:
0.11–0.20 mm
(0.0043–0.0079 in)
Exhaust valve:
0.25–0.34 mm
(0.0098–0.0134 in)
Measurement steps:
Turn the drive coupling counterclockwise,
and then check if cylinder #1 is at TDC of
the compression stroke with a dial gauge.
NOTE:
TDC of the compression stroke can be
found when the camshaft lobes are turned
away from each other.
Measure the valve clearance with a thick-
ness gauge 1
.
NOTE:
If the valve clearance is incorrect, record
the measured reading.
Measure the valve clearance in the follow-
ing sequence.
Valve clearance measuring sequence:
Cylinder #1
→ #2
→ #4
→ #3
ÈBow end
To measure the valve clearances of the
other cylinders, starting with cylinder #1
at TDC, turn the drive coupling counter-
clockwise as specified in the following
table.
ÉDegrees that the crankshaft is turned clock-
wise
ÊCylinder
ËCombustion cycle
Cylinder #2 180°
Cylinder #4 360°
Cylinder #3 540°
INEX
1
7205403601800
#4 #3
#2
#1
É
Ê
Ë
Ë
Ë
Ë
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3-10
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INSP
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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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3-11
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INSP
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POWER UNIT
7. Adjust:
Valve clearance
Adjustment steps:
Remove the valve lifter 1
and the valve
pad 2
.
NOTE:
Cover the timing chain opening with a rag
to prevent the valve pad from falling into
the crankcase.
Note the position of each valve lifter 3
and valve pad 4
so that they can be
installed in the correct place.
Select the proper valve pad from the fol-
lowing table.
Valve pad thickness
rangeAvailable valve
pads
Nos.
120–2401.20–
2.40 mm25 thicknesses in
0.05 mm increments
NOTE:
The thickness a
of each valve pad is
marked in hundredths of millimeters on
the side that touches the valve lifter.
Since valve pads of various sizes are orig-
inally installed, the valve pad number
must be rounded in order to reach the
closest equivalent to the original.
Round off the original valve pad number
according to the following table.
Last digit Rounded value
0 or 2 0
55
810
EXAMPLE:
Original valve pad number = 148 (thickness
= 1.48 mm)
Rounded value = 150
Locate the rounded number of the origi-
nal valve pad and the measured valve
clearance in the valve pad selection
table. The point where the column and
row intersect is the new valve pad num-
ber.
1
2
148
a
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