fuel pressure YAMAHA VX110 2005 Service Manual

1-5
E
GEN
INFO
SPECIAL SERVICE TOOLS
SPECIAL SERVICE TOOLS
Using the correct special service tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up. Impro-
visations and using improper tools can dam-
age the equipment.
NOTE:
For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or
“YW-”.
For other countries, use part numbers start-
ing with “90890-”.
MEASURING
1
Dial gauge stand
P/N. 90890-06583
2
Dial gauge needle
P/N. 90890-06584
3
Dial gauge stand set
P/N. YB-06585
90890-06585
4
Dial indicator gauge
P/N. YU-03097
Dial gauge set
P/N. 90890-01252
5
Pocket tester
P/N. YU-03112
90890-03112
6
Digital multimeter
P/N. YU-34899-A
7
Digital circuit tester
P/N. 90890-03174
8
Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
9
Fuel pressure gauge
P/N. YB-06766
90890-06786
4 12
3
5YU-03097 90890-01252 90890-06583 90890-06584
YB-06585
90890-06585
YU-03112
90890-03112
8YW-06842
90890-06842790890-03174
6YU-34899-A
9YB-06766 90890-06786
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2-6
ESPECMAINTENANCE SPECIFICATIONS
JET PUMP UNIT
HULL AND HOOD
Fuel pump
Pump type Electrical
Fuel pressure kPa
(kgf/cm
2, psi)320–327 (3.2–3.3, 46–47)
Oil filter
Oil filter type Cartridge type
Oil pump
Oil pump type Trochoid
Rotor tip clearance
(scavenge pump)mm (in) 0.09–0.15 (0.0035–0.0059)
Oil pump housing clearance
Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067)
Rotor (scavenge pump) mm (in) 0.09–0.15 (0.0035–0.0059)
Item UnitModel
VX110 Sport VX110 Deluxe
Jet pump
Impeller material Stainless steel
Number of impeller blades 3
Impeller pitch angle Degree 21.2
Impeller clearance mm (in) 0.35–0.45 (0.0138–0.0177)
Impeller clearance limit mm (in) 0.6 (0.0236)
Drive shaft runout limit mm (in) 0.3 (0.0118)
Item UnitModel
VX110 Sport VX110 Deluxe
Free play
Throttle lever free play mm (in) 4–7 (0.16–0.28) Item UnitModel
VX110 Sport VX110 Deluxe
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2-9
ESPECMAINTENANCE SPECIFICATIONS
*1: The figures are for reference only.Accelerator position sensor resis-
tance
*1
@ throttle lever fully closed
Sensor 1 kΩ
0.50–0.90
Sensor 2 kΩ
0.35–10.50
@ throttle lever fully opened
Sensor 1 kΩ
3.75–4.35
Sensor 2 kΩ
3.60–4.50
Cam position sensor
Output voltage (G/O – B/O)
Position A V More than 4.8
Position B V Less than 0.8
Position C V More than 4.8
Fuel sender
Fuel sender resistance
Position AΩ
133.5–136.5
Position BΩ
5–7
Oil pressure switch
Oil pressure switch continuity
pressurekPa
(kgf/cm
2, psi)128 (1.28, 18.2)–167 (1.67, 23.8)
Fuel injector
Fuel injector resistance
*1
@ 20 °C (68 °F)Ω
11.5–12.5
Fuse
Rating
Main V/A 12/30
Main and fuel pump relay V/A 12/20
Main and fuel pump relay V/A 12/10
Electronic control throttle
valve relayV/A 12/10
Remote control unit
(Deluxe model only)V/A 12/3 Item UnitModel
VX110 Sport VX110 Deluxe
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2-25
ESPECCABLE AND HOSE ROUTING
D-D
A-A
B-B
0
8
5
C-C
9
5 Ú
Ù
É
È
Ð
DD
5
6
A
A
1
2
7
34
Î
Ó ÒÌÑÑÌÑ
Ì
Ì
Ë Ë
Ê
Ø×Ö Ô
Õ
Í
Ï
C
CB
B
1Ignition coil
2Fuel rail
3Fuel injector coupler
4Throttle body assembly coupler
5Wiring harness
6Engine temperature sensor lead
7Sensor assembly (intake air pressure and intake
air temperature)
8Cam position sensor coupler
9Cam position sensor lead
0Oil pressure switchÈTo engine temperature sensor
ÉTo thermoswitch (engine)
ÊRoute the engine thermoswitch lead and engine
temperature sensor lead through the corrugated
tube.
ËMore than 10 mm (0.39 in)
ÌDo not leave any slack in the lead.
ÍAttach the thermoswitch (engine) coupler to the
bracket.
ÎAttach a joint connector to the bracket.
ÏPass the fuel injector leads under the fuel rail.
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2-26
ESPECCABLE AND HOSE ROUTING
D-D
A-A
B-B
0
8
5
C-C
9
5 Ú
Ù
É
È
Ð
DD
5
6
A
A
1
2
7
34
Î
Ó ÒÌÑÑÌÑ
Ì
Ì
Ë Ë
Ê
Ø×Ö Ô
Õ
Í
Ï
C
CB
B
ÐInsert the plastic tie completely into the hole in
the engine hanger.
ÑFasten the wiring harness to a bracket on the
fuel rail with a plastic tie.
ÒFasten the wiring harness and cam position
sensor within the range shown in the illustration
with a plastic tie.
ÓSplit in wiring harness
ÔTo cam position sensorÕPass fuel injector lead #4 under the sensor
assembly (intake air pressure and intake air
temperature) lead.
ÖTo oil pressure switch
×To thermoswitch (exhaust)
ØTo ground lead plate
ÙBow end
ÚMake sure that the rubber boot is fitted properly
without any folds.
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EFUEL
1
2
3
4
5
6
7
8
9
CHAPTER 4
FUEL SYSTEM
FUEL TANK AND FUEL PUMP MODULE...................................................... 4-1
EXPLODED DIAGRAM ............................................................................. 4-1
REMOVAL AND INSTALLATION CHART ................................................ 4-1
SERVICE POINTS .................................................................................... 4-4
Fuel hose disconnection ..................................................................... 4-4
Fuel pump module removal................................................................. 4-4
Check valve inspection ....................................................................... 4-4
Fuel sender inspection ........................................................................ 4-5
Fuel tank inspection ............................................................................ 4-5
Fuel hose inspection ........................................................................... 4-5
Fuel pump filter inspection .................................................................. 4-5
Fuel pump module installation ............................................................ 4-6
Fuel hose connect ............................................................................... 4-6
FUEL INJECTION SYSTEM ............................................................................ 4-7
EXPLODED DIAGRAM ............................................................................. 4-7
REMOVAL AND INSTALLATION CHART ................................................ 4-7
THROTTLE BODY ASSEMBLY AND INTAKE MANIFOLD ........................ 4-10
EXPLODED DIAGRAM ........................................................................... 4-10
REMOVAL AND INSTALLATION CHART .............................................. 4-10
SERVICE POINTS .................................................................................. 4-12
Fuel hose clamps removal ................................................................ 4-12
Hose clamps installation ................................................................... 4-12
Fuel hose disconnection ................................................................... 4-12
Fuel line inspection ........................................................................... 4-13
Fuel hose installation (replacing with new fuel hose) ........................ 4-14
Fuel hose connection ........................................................................ 4-14
Fuel injectors inspection.................................................................... 4-15
Throttle body assembly inspection .................................................... 4-15
Accelerator position sensor inspection.............................................. 4-15
Intake assembly installation .............................................................. 4-16
Air filter case assembly installation ................................................... 4-17
Fuel pressure measurement ............................................................. 4-17
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4-7
EFUELFUEL INJECTION SYSTEM
FUEL INJECTION SYSTEM
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL INJECTION SYSTEM
REMOVALFollow the left “Step” for removal.
1 Cam position sensor coupler 1
2 Fuel injector coupler 4
3 Sensor assembly coupler 1
4 Thermoswitch coupler (exhaust) 1
5 Oil pressure switch coupler 1
6 Ground lead coupler 2
7 Joint connector 4 From fuel rail
8 Throttle body assembly coupler 1
9 Cover 1
17 N  m (1.7 kgf  m, 12 ft  Ib)
5 × 75 mm
1.2 N  m (0.12 kgf  m, 0.9 ft  Ib)
5 × 25 mm
1.5 N  m (0.15 kgf  m, 1.1 ft  Ib)
8 × 35 mm
17 N  m (1.7 kgf  m, 12 ft  Ib)2nd 18 N  m (1.8 kgf  m, 13 ft  Ib) 1st 8.8 N  m (0.88 kgf  m, 6.4 ft  Ib)
8 × 30 mm
2nd 39 N  m (3.9 kgf  m, 28 ft  Ib) 1st 15 N  m (1.5 kgf  m, 11 ft  Ib)
8 × 20 mm
LT
242
LT
242
LT
271
LT
572
LT
LT
572
LT
22 2320 19
2118 15 1316
14 1712
17
3
2
2
25
4
6
24
24
25 8
26
27
28
29
11 10
9
2.5 N  m (0.25 kgf  m, 1.8 ft  Ib)
6.5 N  m (0.65 kgf  m, 4.7 ft  Ib)
15 N  m (1.5 kgf  m, 11 ft  Ib)
3031
30
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4-12
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
SERVICE POINTS
Fuel hose clamps removal
1. Remove:
Fuel hose clamps
CAUTION:
If the fuel hose clamps are removed with-
out cutting the joint first, the fuel hose will
be damaged.
Hose clamps installation
1. Install:
Fuel hose clamps
WARNING
Do not reuse the fuel hose clamps, always
replace them with new ones.
NOTE:
Crimp the fuel hose clamps properly to
securely fasten them.
Fuel hose disconnection
WARNING
Before disconnecting the hose, remove the
fuel tank filler cap to reduce any pressure
inside the fuel tank, and then disconnect
the battery negative lead to cut off the elec-
tric current to the electrical systems.
1. Wrap the quick connector with a cloth, and
then rotate the quick connector tab 1
to
the stopper position a
.
WARNING
If the quick connector is removed sud-
denly, pressurized fuel could spray out. To
gradually release the fuel pressure, be sure
to remove the quick connector slowly.
1
a
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4-13
EFUEL
CAUTION:
Do not rotate the quick connector tab
1
past the stopper position, otherwise it
could be damaged.
When the fuel hoses are disconnected,
quickly remove the retainer
2 from the
quick connector, otherwise the retainer
could be lost.
2. Disconnect the fuel hose 1
from the fuel
pipe 2
directly.
WARNING
Always reduce the fuel pressure in the fuel
line before servicing the line or the fuel
pipe. If the fuel pressure is not released,
pressurized fuel could spray out.
21
1
2
3. Cover the quick connector and fuel pipe
with a plastic bag 3 to prevent damage
and to protect them from dirt.
3
Fuel line inspection
1. Inspect:
Fuel hose
Damage/cracks → Replace.
O-rings (quick connector)
Damage/cracks → Replace the quick
connector.
Fuel pipe
Damage/cracks → Replace the fuel
pump.
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
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4-17
EFUEL
THROTTLE BODY ASSEMBLY AND INTAKE
MANIFOLD
Air filter case assembly installation
1. Install:
Air intake duct 1

Air intake hose 2

Air filter case cover
NOTE:
Align the projections a
on the air intake duct
and air intake hose with the projections b
on
the air filter case cover as shown in the illustra-
tion.
2. Adjust:
Throttle lever free play
Refer to “CONTROL SYSTEM” in Chap-
ter 3.
a
b a
b
2
1
Fuel pressure measurement
1. Disconnect:
Fuel hose
Refer to “Fuel hose disconnection”.
2. Install:
Fuel pressure gauge adapter 1

Fuel pressure gauge 2

NOTE:
To connect the fuel pressure gauge adapter,
follow the procedures for connecting a fuel
hose. (Refer to “Fuel hose connection”.)
3. Start the engine and arrow it to warm up
for several minutes.
4. Measure:
Fuel pressure
Out of specification →
Replace the fuel
pump module.
Fuel pressure gauge adapter:
YW-06842/90890-06842
Fuel pressure gauge:
YB-06766/90890-06786
Fuel pressure:
320–327 kPa
(3.2–3.3 kgf/cm
2, 46–47 psi)
2
1
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