oil YAMAHA VX110 2005 Manual PDF

5-73
EPOWRCRANKCASE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
11 Anode 1
12 Bolt 15
13 Oil pan 1
14 Gasket 1
15 Bolt 2
16 Bolt 1
17 Bolt 7
18 Bolt/washer 10/10
19 Lower crankcase 1
20 Dowel pin 2
21 Dowel pin/O-ring 1/1
Reverse the removal steps for installation.
6
21 20
20 11
10 9
87
23
4
5
16
151718
13 14
1219
1
LT
271
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
LT
572
LT
E
E
AA
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 70 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
20 N •
m (2.0 kgf • m, 14 ft • Ib)
8 × 40 mm
2nd *
3rd 15 N • m (1.5 kgf
• m, 11 ft
• Ib) 1st 7.8 N • m (0.78 kgf
• m, 5.6 ft
• Ib)
9 × 105 mm
4th 49 ± 5˚
8.4 N •
m (0.84 kgf • m, 6.1 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 55 mm
7.6 N •
m (0.76 kgf • m, 5.5 ft • Ib)
6 × 16 mm
15 N •
m (1.5 kgf • m, 11 ft • Ib)
12 N •
m (1.2 kgf • m, 8.7 ft • Ib)
6 × 20 mm
18
AA
1280B
Not reusable
Not reusable
Not reusable
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5-74
EPOWRCRANKCASE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
OIL PIPE AND OIL FILTER BOLT
REMOVALFollow the left “Step” for removal.
Crankshaft Refer to “CRANKSHAFT”.
1Bolt 1
2 Oil pipe 1
3 O-ring 2
4 Oil filter bolt 1
5 Lower crankcase 1
Reverse the removal steps for installation.
E
E
51
2
3
4
AA
6 × 10 mm
12 N • m (1.2 kgf
• m, 8.7 ft
• Ib)
35 N • m (3.5 kgf
• m, 25 ft
• Ib)
Not reusable
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5-75
EPOWRCRANKCASE
SERVICE POINTS
Crankcase disassembly
1. Remove:
Oil pan bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustra-
tion).
The numbers embossed on the oil pan indi-
cate the oil pan tightening sequence.
106
24812
15
11
7
3 1 5 9
13 14
2. Remove:
Crankcase bolts
NOTE:
Loosen each bolt 1/4 of a turn at a time, in
stages and in a crisscross pattern. After all of
the bolts are fully loosened, remove them.
Loosen the bolts in decreasing numerical
order (refer to the numbers in the illustra-
tion).
The numbers embossed on the crankcase
indicate the crankcase tightening sequence.
3. Remove:
Lower crankcase
CAUTION:
Tap on one side of the crankcase with a
soft-face hammer. Tap only on reinforced
portions of the crankcase, not on the
crankcase mating surfaces. Work slowly
and carefully and make sure the crankcase
halves separate evenly.
M9
× 105 mm bolts:
1–
0
M6
× 55 mm bolts:
A–
H,
J
M6
× 70 mm bolts:
I
15397
ICAEG
86240
HFBDJ
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5-76
EPOWRCRANKCASE
4. Remove:
Dowel pins
Crankcase inspection
1. Thoroughly wash the crankcase halves in
a mild solvent.
2. Thoroughly clean all the gasket surfaces
and crankcase mating surfaces.
3. Check:
Crankcase
Cracks/damage →
Replace.
Oil delivery passages
Obstruction →
Blow out with com-
pressed air.
Timing chain inspection
1. Check:
Timing chain 1

Damage/stiffness →
Replace the timing
chain and camshaft sprockets as a set.
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5-77
EPOWRCRANKCASE
Crankcase assembly
1. Lubricate:
Crankshaft journal bearings
(with the recommended lubricant)
2. Apply:
ThreeBond 1280B
(onto the crankcase mating surfaces)
NOTE:
Do not allow any sealant to come into contact
with the oil gallery or crankshaft journal bear-
ings.
Recommended lubricant:
Engine oil
3. Install:
Dowel pins 1

O-ring 2

11
2
1
1280B
4. Install:
Crankcase bolts
NOTE:
Lubricate the bolt 1
–0 threads and wash-
ers with engine oil.
Finger tighten the crankcase bolts.
M9
× 105 mm bolts:
1–
0
M6
× 55 mm bolts:
A–
H,
J
M6
× 70 mm bolts:
I
15397
ICAEG
86240
HFBDJ
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5-79
EPOWRCRANKCASE
CAUTION:
Do not use a torque wrench to tighten
the bolt to the specified angle.
Tighten the bolt until it is at the speci-
fied angle.
NOTE:
When using a hexagonal bolt, note that the
angle from one corner to another is 60°.
6. Tighten:
Crankcase bolts A
–J

NOTE:
Tighten the bolts in the order of the numbers
on the crankcase.
7. Tighten:
Oil pan bolts
NOTE:
Tighten the bolts in the order of the numbers
on the oil pan.
T R..
Crankcase bolt
A–
J:
12 N  m (1.2 kgf  m, 8.7 ft  lb)
LOCTITE 572
T R..
Oil pan bolt:
12 N  m (1.2 kgf  m, 8.7 ft  lb)
LOCTITE 572
15397
ICAEG
86240
HFBDJ
106
24812
15
11
7
3 1 5 9
13 14
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5-81
EPOWRCONNECTING RODS AND PISTONS
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
8Bolt 8
9 Big end upper bearing 4
10 Top ring 4
11 2nd ring 4
12 Oil ring 4
Reverse the removal steps for installation.
EE
E
E
1 2 310
11
12
4
5
6
8
7
9
2nd 120 ± 5˚ 1st 20 N • m (2.0 kgf
• m, 14 ft
• Ib)
MM
MM
4
Not reusable
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5-82
EPOWRCONNECTING RODS AND PISTONS
SERVICE POINTS
Connecting rod and piston removal
The following procedure applies to all of the
connecting rods and pistons.
1. Remove:
Connecting rod cap 1

Big end bearings
NOTE:
Identify the position of each big end bearing so
that it can be reinstalled in its original place.
1
2. Remove:
Piston pin clips 1

Piston pin 2
Piston 3
Connecting rod 4
CAUTION:
Do not use a hammer to drive the piston
pin out.
NOTE:
For reference during installation, put an iden-
tification number a on the piston crown.
Before removing the piston pin, deburr the
piston pin clip’s groove and the piston’s pin
bore area.
3. Remove:
Top ring
2nd ring
Oil ring
NOTE:
When removing a piston ring, open the end
gap with your fingers and lift the other side of
the ring over the piston crown.
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5-84
EPOWRCONNECTING RODS AND PISTONS
If out of specification, replace the piston
and piston rings as a set.
Calculate the piston-to-cylinder clearance
with the following formula.
Piston-to-cylinder clearance = Cylinder
bore “C” – Piston skirt diameter “P”
Piston-to-cylinder clearance:
0.10–0.11 mm (0.0039–0.0043 in)
: 0.17 mm (0.0067 in)
If out of specification, replace the piston
and piston rings as a set.
Piston ring inspection
1. Measure:
Piston ring side clearance
Out of specification →
Replace the pis-
ton and piston rings as a set.
NOTE:
Before measuring the piston ring side clear-
ance, eliminate any carbon deposits from the
piston ring grooves and piston rings.
Side clearance:
Top ring:
0.030–0.065 mm
(0.0012–0.0026 in)
2nd ring:
0.020–0.055 mm
(0.0008–0.0022 in)
Oil ring:
0.040–0.160 mm
(0.0016–0.0063 in)
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5-85
EPOWRCONNECTING RODS AND PISTONS
2. Install:
Piston ring
(into the cylinder)
NOTE:
Level the piston ring in the cylinder with the
piston crown.
a5 mm (0.2 in)
3. Measure:
Piston ring end gap
Out of specification →
Replace the pis-
ton ring.
NOTE:
The oil ring expander spacer’s end gap cannot
be measured. If the oil ring rail’s gap is exces-
sive, replace all three piston rings.
Piston ring end gap:
Top ring:
0.32–0.44 mm
(0.0126–0.0173 in)
2nd ring:
0.43–0.58 mm
(0.0169–0.0228 in)
Oil ring:
0.10–0.35 mm
(0.0039–0.0138 in)
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