maintenance YAMAHA VX110 2005 Service Manual

E
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
A10001-0*
WaveRunner
VX110 Sport, VX110 Deluxe
SERVICE MANUAL
©2005 by Yamaha Motor Corporation, USA
1st Edition, January 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-91
ProCarManuals.com

ESPEC
1
2
3
4
5
6
7
8
9
CHAPTER 2
SPECIFICATIONS
GENERAL SPECIFICATIONS ....................................................................... 2-1
MAINTENANCE SPECIFICATIONS ............................................................... 2-3
ENGINE .................................................................................................... 2-3
JET PUMP UNIT ...................................................................................... 2-6
HULL AND HOOD .................................................................................... 2-6
ELECTRICAL ............................................................................................ 2-7
TIGHTENING TORQUES .............................................................................. 2-10
SPECIFIED TORQUES ........................................................................... 2-10
GENERAL TORQUE ............................................................................... 2-15
CABLE AND HOSE ROUTING ..................................................................... 2-16
ProCarManuals.com

2-3
ESPECMAINTENANCE SPECIFICATIONS
MAINTENANCE SPECIFICATIONS
ENGINE
Item UnitModel
VX110 Sport VX110 Deluxe
Cylinder head
Warpage limit mm (in) 0.1 (0.004)
Compression pressure
*1 kPa
(kgf/cm2, psi)1,150 (11.5, 164)
Cylinder
Bore size mm (in) 76.000–76.015 (2.9921–2.9927)
Taper limit mm (in) 0.08 (0.003)
Out-of-round limit mm (in) 0.05 (0.002)
Wear limit mm (in) 76.100 (2.9961)
Camshaft
Drive system Chain drive
Intake A mm (in) 31.15 (1.226)
Exhaust A mm (in) 30.75 (1.211)
Intake and exhaust B mm (in) 25.00 (0.984)
Camshaft cap inside diameter mm (in) 24.5 (0.9646)
Camshaft journal diameter
Intake mm (in) 24.46–24.47 (0.9630–0.9634)
Exhaust mm (in) 24.44–24.45 (0.9622–0.9626)
Camshaft-journal-to-camshaft-
cap clearancemm (in) 0.05–0.06 (0.0020–0.0024)
Maximum camshaft runout mm (in) 0.03 (0.0012)
Timing chain
Model/number of links 92RH2015-130/130
Tensioning system Automatic
Valves, valve seats, valve guides
Valve clearance (cold)
Intake mm (in) 0.11–0.20 (0.0043–0.0079)
Exhaust mm (in) 0.25–0.34 (0.0098–0.0134)
Valve dimensions
Valve head diameter A
Intake mm (in) 22.9–23.1 (0.9016–0.9094)
Exhaust mm (in) 24.4–24.6 (0.9606–0.9685)
*1 Measuring conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all
cylinders.
The figures are for reference only.
ProCarManuals.com

2-4
ESPECMAINTENANCE SPECIFICATIONS
Valve face width B
Intake mm (in) 1.91–2.64 (0.0752–0.1039)
Exhaust mm (in) 1.91–2.64 (0.0752–0.1039)
Valve seat width C
Intake mm (in) 0.90–1.10 (0.0354–0.0433)
Exhaust mm (in) 0.90–1.10 (0.0354–0.0433)
Valve margin thickness D
Intake mm (in) 0.85–1.15 (0.0335–0.0453)
Exhaust mm (in) 0.85–1.15 (0.0335–0.0453)
Valve stem diameter
Intake mm (in) 3.975–3.990 (0.1565–0.1571)
Exhaust mm (in) 4.465–4.480 (0.1758–0.1764)
Valve guide inside diameter
Intake mm (in) 4.000–4.012 (0.1575–0.1580)
Exhaust mm (in) 4.500–4.512 (0.1772–0.1776)
Valve-stem-to-valve-guide
clearance
Intake mm (in) 0.010–0.037 (0.0004–0.0015)
Exhaust mm (in) 0.020–0.047 (0.0008–0.0019)
Valve stem runout mm (in) 0.01 (0.0004)
Valve spring
Free length
Intake mm (in) 38.90 (1.53)
Exhaust mm (in) 40.67 (1.60)
Installed length
Intake mm (in) 34.50 (1.36)
Exhaust mm (in) 35.00 (1.38)
Tilt limit
Intake Degree/mm (in) 2.5/1.7 (0.067)
Exhaust Degree/mm (in) 2.5/1.8 (0.071)
Piston
Piston-to-cylinder clearance mm (in) 0.10–0.11 (0.0039–0.0043)
Piston diameter mm (in) 75.895–75.910 (2.9880–2.9886)
Measuring point H* mm (in) 5 (0.2)
Wear limit mm (in) 0.170 (0.0067)
Piston pin boss inside diameter mm (in) 17.002–17.013 (0.6694–0.6698) Item UnitModel
VX110 Sport VX110 Deluxe
ProCarManuals.com

2-5
ESPECMAINTENANCE SPECIFICATIONS
Piston pins
Outside diameter mm (in) 16.991–17.000 (0.6689–0.6693)
Wear limit mm (in) 16.986 (0.6687)
Piston ring
Top ring
Type Barrel
Dimension (B ×
T) mm (in) 0.90 ×
2.75 (0.04 ×
0.11)
End gap (installed) mm (in) 0.32–0.44 (0.0126–0.0173)
Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026)
2nd ring
Type Taper
Dimensions (B ×
T) mm (in) 0.80 ×
2.80 (0.03 ×
0.11)
End gap (installed) mm (in) 0.43–0.58 (0.0169–0.0228)
Ring groove clearance mm (in) 0.020–0.055 (0.0008–0.0022)
Oil ring
Dimensions
(B ×
T)mm (in) 1.50 ×
2.60 (0.06 ×
0.10)
End gap (installed) mm (in) 0.10–0.35 (0.0039–0.0138)
Ring groove clearance mm (in) 0.040–0.160 (0.0016–0.0063)
Connecting rod
Big end oil clearance mm (in) 0.016–0.040 (0.0006–0.0016)
Bearing color code 1. Brown 2. Black 3. Blue 4. Green
Small end inside diameter mm (in) 17.005–17.018 (0.6695–0.6700)
Crankshaft
Crank width A mm (in) 304.8–306.0 (12.00–12.05)
Deflection limit B mm (in) 0.03 (0.0012)
Crankshaft journal oil clearance mm (in) 0.004–0.028 (0.0002–0.0011)
Bearing color code 3. Red/Red 4. Red/Brown 5. Red/Black
6. Red/Blue 7. Red/Green
Throttle body
Type/quantity IM-230/1
Manufacturer Mikuni
ID mark 6D300
Trolling speed r/min 1,550–1,750 Item UnitModel
VX110 Sport VX110 Deluxe
T
B
B
T
B
T
BBB
A
ProCarManuals.com

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
ProCarManuals.com

2-7
ESPECMAINTENANCE SPECIFICATIONS
ELECTRICAL
Item UnitModel
VX110 Sport VX110 Deluxe
Battery
Type Fluid
Capacity V/Ah 12/19
Specific gravity 1.28
ECM unit
(B/R – R/Y, B/W – R/Y,
B/Y – R/Y, B/G – R/Y)
Output peak voltage lower limit
@cranking (loaded) V 90
@2,000 r/min (loaded) V 130
@3,500 r/min (loaded) V 140
Stator
Pickup coil (W/B – B/O)
Output peak voltage
@cranking (unloaded) V 8.0
@cranking (loaded) V 6.9
@2,000 r/min (loaded) V 19.4
@3,500 r/min (loaded) V 25.1
Lighting coil (G – G)
Output peak voltage
@cranking (unloaded) V 7.8
@2,000 r/min (unloaded) V 24.5
@3,500 r/min (unloaded) V 41.6
Pickup coil resistance
(W/B – B/O)Ω
(color) 459–561
Lighting coil resistance (G – G)Ω
(color) 0.23–0.29
Minimum charging current A @ r/min 14 @ 6,000
Ignition coil
Primary coil resistance
@20 °C (68 °F)Ω
1.19–1.61
Secondary coil resistance
@20 °C (68 °F) kΩ
8.5–11.5
Rectifier/regulator (R – B)
Output peak voltage
@3,500 r/min (unloaded) V 13.0
ProCarManuals.com

2-8
ESPECMAINTENANCE SPECIFICATIONS
Starter motor
Type Constant mesh
Output kW 0.8
Rating Seconds 30
Brush length mm (in) 12.5 (0.49)
Wear limit mm (in) 6.5 (0.26)
Commutator undercut mm (in) 0.7 (0.03)
Limit mm (in) 0.2 (0.01)
Commutator diameter mm (in) 28.0 (1.10)
Limit mm (in) 27.0 (1.06)
Starter relay
Rating Seconds 30
Thermoswitch
ON temperature (engine) °C (°F) 84–90 (183–194)
OFF temperature (engine) °C (°F) 70–84 (158–183)
ON temperature (exhaust) °C (°F) 80–86 (176–187)
OFF temperature (exhaust) °C (°F) 66–80 (151–176)
Engine temperature sensor
Engine temperature sensor
resistance (B/Y – B/Y)
@ 20 °C (68 °F) kΩ
54.2–69.0
@ 100 °C (212 °F) kΩ
3.12–3.48
Speed sensor
Output voltage (on pulse) V 11.6
Output pulse/one full turn 2
Throttle position sensor
Output voltage
@ throttle valve fully closed
Sensor 1 V 0.45–0.95
@ throttle valve fully opened
Sensor 2 V 4.60–4.70
Accelerator position sensor
Output voltage
@ throttle lever fully closed
Sensor 1 V 0.50–0.90
Sensor 2 V 0.35–1.05
@ throttle lever fully opened
Sensor 1 V 3.75–4.35
Sensor 2 V 3.50–4.50Item UnitModel
VX110 Sport VX110 Deluxe
ProCarManuals.com

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
ProCarManuals.com

E
INSP
ADJ
1
2
3
4
5
6
7
8
9
CHAPTER 3
PERIODIC INSPECTION AND ADJUSTMENT
MAINTENANCE INTERVAL CHART .............................................................. 3-1
PERIODIC SERVICE ....................................................................................... 3-2
CONTROL SYSTEM ................................................................................. 3-2
Steering column inspection ................................................................. 3-2
Steering cable inspection and adjustment .......................................... 3-2
Throttle cable inspection and adjustment............................................ 3-4
Shift cable inspection and adjustment (Deluxe model only)................ 3-5
Trolling speed inspection .................................................................... 3-6
FUEL SYSTEM.......................................................................................... 3-7
Fuel line inspection ............................................................................. 3-7
Water separator inspection ................................................................. 3-8
POWER UNIT............................................................................................ 3-8
Valve clearance adjustment ................................................................ 3-8
Engine oil level check........................................................................ 3-14
Engine oil change — using oil changer ............................................. 3-16
Air filter element clean....................................................................... 3-18
Spark plug inspection ........................................................................ 3-20
ELECTRICAL .......................................................................................... 3-22
Battery inspection.............................................................................. 3-22
JET PUMP UNIT ..................................................................................... 3-25
Impeller inspection ............................................................................ 3-25
Water inlet strainer inspection ........................................................... 3-25
BILGE PUMP........................................................................................... 3-26
Bilge strainer inspection .................................................................... 3-26
GENERAL ............................................................................................... 3-26
Drain plug inspection......................................................................... 3-26
Lubrication points .............................................................................. 3-26
ProCarManuals.com