oil YAMAHA VX110 2005 Manual Online

5-87
EPOWRCONNECTING RODS AND PISTONS
Connecting rod inspection
1. Measure:
Big end oil clearance
Out of specification →
Replace the big
end bearings.
Big end oil clearance:
0.016–0.040 mm
(0.0006–0.0016 in)
Measurement steps:
The following procedure applies to all of the
connecting rods.
CAUTION:
Do not interchange the big end bearings
and connecting rods. To obtain the cor-
rect big end oil clearance and prevent
engine damage, the big end bearings
must be installed in their original posi-
tions.
Clean the big end bearings, crankshaft
pins, and the inside of the connecting rod
halves.
Install the big end upper bearing into the
connecting rod and the big end lower
bearing into the connecting rod cap.
NOTE:
Align the projections a
on the big end bear-
ings with the notches b
in the connecting
rod and connecting rod cap.
Put a piece of Plastigauge 1
on the
crankshaft pin.
Assemble the connecting rod halves.
1
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5-88
EPOWRCONNECTING RODS AND PISTONS
NOTE:
• Do not move the connecting rod or crank-
shaft until the clearance measurement
has been completed.
 Lubricate the bolts threads and nut seats
with molybdenum disulfide grease.
 Make sure the “Y” mark c on the con-
necting rod faces towards the front side of
the crankshaft.
 Make sure the characters d on both the
connecting rod and connecting rod cap
are aligned.
 Tighten the connecting rod nuts.
Refer to “Connecting rod and piston
installation”.
 Remove the connecting rod and big end
bearings.
Refer to “Connecting rod and piston
removal”.
 Measure the compressed Plastigauge
width e on the crankshaft pin.
If the big end oil clearance is out of speci-
fication, select replacement big end bear-
ings.
cd
e
2. Select:
 Big end bearings (P
1–P4)
NOTE:
The numbers stamped into the crankshaft web
and the numbers on the connecting rods are
used to determine the replacement big end
bearing sizes.
P4
P3P2
P1
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5-89
EPOWRCONNECTING RODS AND PISTONS
For example, if the connecting rod “P1” and the
crankshaft web “P
1” numbers are “5” and “1”
respectively, then the bearing size for “P
1” is:
Bearing size of P
1:
“P
1” (connecting rod) –
“P
1” (crankshaft web)
5 – 1 = 4 (green)
BEARING COLOR CODE
1brown
2 black
3blue
4 green5 G
P4P3P2P1
Connecting rod and piston installation
The following procedure applies to all of the
pistons and connecting rods.
1. Install:
Oil ring
2nd ring
Top ring
NOTE:
Be sure to install the piston rings so that the
manufacturer’s marks or numbers face up.
2. Install:
Piston 1

Connecting rod 2

Piston pin 3

Piston pin clips 4

NOTE:
Apply engine oil onto the piston pin.
When installing the connecting rod to the pis-
ton, make sure that the “Y” mark a
on the
connecting rod faces towards the left when
the exhaust valve recesses b
on the piston
face upward. Refer to the illustration.
Reinstall each piston into its original cylinder
(numbering order starting from the front: #1
to #4).
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5-90
EPOWRCONNECTING RODS AND PISTONS
3. Offset:
Piston ring end gaps
aTop ring, oil ring expander spacer
b2nd ring, lower oil ring rail
cUpper oil ring rail
ÈExhaust sidebc
a È
90˚
45˚
90˚
4. Lubricate:
Piston
Piston rings
Cylinder
(with the recommended lubricant)
Recommended lubricant:
Engine oil
5. Lubricate:
Bolt threads
Nut seats
(with the recommended lubricant)
Recommended lubricant:
Molybdenum disulfide grease
6. Lubricate:
Crankshaft pins
Big end bearings
(with the recommended lubricant)
Recommended lubricant:
Engine oil
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5-94
EPOWRCRANKSHAFT
SERVICE POINTS
Crankshaft removal
1. Remove:
Crankshaft 1

Crankshaft journal lower bearings
(from the lower crankcase)
Crankshaft journal upper bearings
(from the upper crankcase)
NOTE:
Identify the position of each crankshaft journal
bearing so that it can be reinstalled in its origi-
nal place.
1
Crankshaft inspection
1. Measure:
Crankshaft runout
Out of specification →
Replace the
crankshaft.
Maximum crankshaft runout:
0.03 mm (0.0012 in)
2. Check:
Crankshaft journal surfaces
Crankshaft pin surfaces
Scratches/wear →
Replace the crank-
shaft.
Bearing surfaces
Scratches/wear →
Replace the crank-
shaft journal bearing.
3. Measure:
Crankshaft journal oil clearance
Out of specification →
Replace the
crankshaft journal bearings.
Crankshaft journal oil clearance:
0.004–0.028 mm
(0.0002–0.0011 in)
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5-95
EPOWRCRANKSHAFT
CAUTION:
Do not interchange the crankshaft journal
bearings. To obtain the correct crankshaft
journal oil clearance and prevent engine
damage, the crankshaft journal bearings
must be installed in their original positions.
Measurement steps:
Clean the crankshaft journal bearings,
crankshaft journals, and bearing portions
of the crankcase.
Place the upper crankcase upside down
on a bench.
Install the crankshaft journal upper bear-
ings 1
and the crankshaft into the upper
crankcase.
NOTE:
Align the projections a
of the crankshaft
journal upper bearings with the notches b
in the upper crankcase.
Put a piece of Plastigauge 2
on each
crankshaft journal.
NOTE:
Do not put the Plastigauge over the oil hole
in the crankshaft journal.
Install the crankshaft journal lower bear-
ings into the lower crankcase and assem-
ble the crankcase halves.
NOTE:
Align the projections a
of the crankshaft
journal lower bearings with the notches b
in the lower crankcase.
Do not move the crankshaft until the
clearance measurement has been com-
pleted.
1
a
b
2
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5-96
EPOWRCRANKSHAFT
Tighten the bolts to specification in the
order of the numbers on the crankcase.
Refer to “Crankcase assembly”—
“CRANKCASE”.
Remove the lower crankcase and the
crankshaft journal lower bearings.
Measure the compressed Plastigauge
width c
on each crankshaft journal.
If the crankshaft journal oil clearance is
out of specification, select replacement
crankshaft journal bearings.
c
4. Select:
Crankshaft journal bearings (J
1–J5)
NOTE:
The numbers stamped into the crankshaft
web and the numbers stamped into the lower
crankcase are used to determine the
replacement crankshaft journal bearing
sizes.
“J
1–J5” refer to the bearings shown in the
crankshaft illustration.
If “J
1–J5” are the same, use the same size
for all of the bearings.
For example, if the crankcase “J
1” and crank-
shaft web “J
1” numbers are “8” and “2” respec-
tively, then the bearing size for “J
1” is:
Bearing size of J
1:
“J
1” (crankcase) – “J1” (crankshaft web)
– 1
8 – 2 – 1 = 5 (Red/black)
BEARING COLOR CODE
3 Red/red
4Red/brown
5 Red/black
6 Red/blue
7Red/green
J5J4J3J2J1
J1J2J3J4J5
J5J4J3J2J1
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5-97
EPOWRCRANKSHAFT
Crankshaft installation
1. Install:
Crankshaft journal upper bearings
(into the upper crankcase)
Crankshaft journal lower bearings
(into the lower crankcase)
NOTE:
Align the projections a
on the crankshaft
journal upper bearings with the notches b
in
the upper crankcase.
Be sure to install each crankshaft journal
bearing in its original place.
a
b
2. Lubricate:
Crankshaft journals
Crankshaft journal bearings
(with the recommended lubricant)
Recommended lubricant:
Engine oil
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5-99
EPOWRCOOLING WATER HOSE
EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
4 Joint 1
5 Clamp/cooling water hose 1/1Ê
To oil tank
6 Clamp/cooling water hose 1/1Ë
From transom plate
7 Joint 1
Reverse the removal steps for installation.
143 2
375
6
ÈÉÊ
Ë
a
2
34
1
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E
JET
PUMP
1
2
3
4
5
6
7
8
9
CHAPTER 6
JET PUMP UNIT
INTAKE GRATE AND RIDE PLATE ............................................................... 6-1
EXPLODED DIAGRAM ............................................................................. 6-1
REMOVAL AND INSTALLATION CHART ................................................ 6-1
JET PUMP UNIT .............................................................................................. 6-3
EXPLODED DIAGRAM ............................................................................. 6-3
REMOVAL AND INSTALLATION CHART ................................................ 6-3
REVERSE GATE (DELUXE MODEL ONLY) .................................................. 6-5
EXPLODED DIAGRAM ............................................................................. 6-5
REMOVAL AND INSTALLATION CHART ................................................ 6-5
JET THRUST NOZZLE, IMPELLER DUCT, AND
IMPELLER HOUSING 1 ................................................................................. 6-6
EXPLODED DIAGRAM ............................................................................. 6-6
REMOVAL AND INSTALLATION CHART ................................................ 6-6
IMPELLER DUCT AND DRIVE SHAFT .......................................................... 6-8
EXPLODED DIAGRAM ............................................................................. 6-8
REMOVAL AND INSTALLATION CHART ................................................ 6-8
SERVICE POINTS .................................................................................. 6-10
Drive shaft removal ........................................................................... 6-10
Impeller inspection ............................................................................ 6-11
Drive shaft inspection ........................................................................ 6-11
Drive shaft installation ....................................................................... 6-12
TRANSOM PLATE AND HOSES .................................................................. 6-15
EXPLODED DIAGRAM ........................................................................... 6-15
REMOVAL AND INSTALLATION CHART .............................................. 6-15
SERVICE POINTS .................................................................................. 6-17
Bilge strainer inspection .................................................................... 6-17
Bilge hose inspection ........................................................................ 6-17
Cooling water hose inspection .......................................................... 6-17
BEARING HOUSING ..................................................................................... 6-18
EXPLODED DIAGRAM ........................................................................... 6-18
REMOVAL AND INSTALLATION CHART .............................................. 6-18
SERVICE POINTS .................................................................................. 6-21
Driven coupling removal and installation........................................... 6-21
Intermediate drive shaft removal ....................................................... 6-21
Bearing removal ................................................................................ 6-22
Bearing and intermediate drive shaft inspection ............................... 6-22
Driven coupling inspection ................................................................ 6-22
Bearing and oil seals installation ....................................................... 6-23
Intermediate drive shaft installation................................................... 6-24
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