service YAMAHA VX110 2005 Workshop Manual

5-27
EPOWRREDUCTION DRIVE GEAR
EXPLODED DIAGRAM
*1: EPNOC grease AP #0 Step Procedure/Part name Q’ty Service points
9 Circlip 1
10 Bearing 1
11 Reduction drive gear case 1
Reverse the disassembly steps for
assembly.
E
E
E
E
3
4
8
6
5
10
9
1
*1
AA
*1
E
2
11
7
*1
Not reusable
Not reusable
ProCarManuals.com

5-28
EPOWRREDUCTION DRIVE GEAR
SERVICE POINTS
Drive coupling removal
1. Remove:
Reduction drive gear housing
2. Remove:
Drive coupling 1

NOTE:
While holding the drive shaft 2
with the rotor
holder 3
, loosen the drive coupling with the
coupler wrench 4
.
Coupler wrench:
YW-06551/90890-06551
Universal magneto and rotor
holder:
YU-01235
Rotor holder:
90890-01235
1
4
23
Drive shaft removal
1. Remove:
Drive shaft
NOTE:
Press in the direction of the arrow.
Bearing removal
1. Remove:
Circlip
Rear bearing
Collar
Front bearing
NOTE:
Remove the front bearing, spacer, and rear
bearing using a press.
ÈFor USA and Canada
ÉFor worldwide
Driver handle—large:
YB-06071
Driver rod L3:
90890-06652
Bearing housing needle bearing
installer:
YB-06111
Needle bearing attachment:
90890-06653
È
É
ProCarManuals.com

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
ProCarManuals.com

5-34
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8 Pickup coil coupler 1
9Bolt 6
10 Bolt 2
11 Generator cover 1
12 Dowel pin 2
13 Gasket 1
14 Idle gear shaft 1
15 Idle gear 1
16 Bolt/washer 1/1
17 Flywheel magneto 1
18 Bolt 6
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
Not reusable
Not reusable
ProCarManuals.com

5-35
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
19 Starter clutch 1
20 Starter gear 1
21 Woodruff key 1
Reverse the removal steps for installation.
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
ProCarManuals.com

5-36
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
GENERATOR DISASSEMBLY
Follow the left “Step” for disassembly.
1 Bolt/washer 1/1
2Bolt 2
3 Pickup coil 1
NOTE:
There washer hold the pickup coil lead.
Make sure to not pitch the lead between the
projection and the washer when installing
the bolt.
4Bolt 2
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 35 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
ProCarManuals.com

5-37
EPOWRGENERATOR AND STARTER MOTOR
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
5 Holder 1
6Bolt 3
7 Lighting coil 1
Reverse the disassembly steps for
assembly.
1
7
6
3
2
45
LT
242
LT
242
LT
242LT
242
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 14 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 14 mm
14 N 
m (1.4 kgf  m, 10 ft  Ib)
6 × 35 mm
4.9 N 
m (0.49 kgf  m, 3.5 ft  Ib)
5 × 10 mm
ProCarManuals.com

5-38
EPOWRGENERATOR AND STARTER MOTOR
SERVICE POINTS
Flywheel magneto removal
1. Remove:
Flywheel magneto bolt 1

Washer
NOTE:
While holding the flywheel magneto 2
with the
sheave holder 3
, loosen the flywheel magneto
bolt.
Sheave holder:
YS-01880-A/90890-01701
2. Remove:
Flywheel magneto 1

Woodruff key
NOTE:
While holding the flywheel magneto with
sheave holder 2
, remove the flywheel mag-
neto with the rotor puller 3
.
Rotor puller:
YM-01082/90890-01080
Starter clutch inspection
1. Check:
Starter clutch rollers 1

Damage/wear →
Replace.
ProCarManuals.com

5-41
EPOWRCAMSHAFTS
CAMSHAFTS
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
CYLINDER HEAD COVER
REMOVALFollow the left “Step” for removal.
1Bolt 4
2 Ignition coil 4
3 Spark plug 4
4 Clamp/breather hose 1/1È
To oil tank
Paint mark a

5Bolt 1
6 Cam position sensor 1
7 Clamp/cooling water hose 1/1É
To transom plate
8 Rubber seal 1
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 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)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
ProCarManuals.com

5-42
EPOWRCAMSHAFTS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
9Bolt 1
10 Cooling water pipe 1
11 O-ring 1
12 Bolt 6
13 Rubber mount 6
14 Cylinder head cover 1
15 Cylinder head cover gasket 1
16 Timing chain guide (top side) 1
Reverse the removal steps for installation.
E
4
65
7 8
10
11
12
13 9
LT
572
LT
14
16
15
3
13 N 
m (1.3 kgf  m, 9.4 ft  Ib)
10 N 
m (1.0 kgf  m, 7.2 ft  Ib)
6 × 16 mm 6 × 16 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)
12 N 
m (1.2 kgf  m, 8.7 ft  Ib)
6 × 22 mm
aÈ
É
1
2
7.6 N 
m (0.76 kgf  m, 5.5 ft  Ib)
6 × 16 mm
LT
572
LTAA
1280B
1280B
Not reusable
Not reusable
ProCarManuals.com