service YAMAHA VX110 2005 Service Manual

SERVICE MANUAL
VX110 Sport
WaveRunner
F1K-28197-1H-11 LIT-18616-02-91
*LIT186160291*
VX110 Deluxe
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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
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HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is given at
the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropri-
ate section or chapter.
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IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, passenger(s), a bystander, or a person inspecting or repairing the watercraft.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the water-
craft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.
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A50001-1-4
SYMBOLS
Symbols 1 to 9 are designed to indicate the
content of a chapter.
1General Information
2Specifications
3Periodic Inspection and Adjustment
4Fuel System
5Power Unit
6Jet Pump Unit
7Electrical System
8Hull and Hood
9Trouble Analysis
Symbols 0 to E indicate specific data.
0Special service tool
ASpecified oil or fluid
BSpecified engine speed
CSpecified tightening torque
DSpecified measurement
ESpecified electrical value
(resistance, voltage, electric current)
Symbols F to I in an exploded diagram indi-
cate the grade of lubricant and the lubrication
point.
FApply Yamaha 4-stroke motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply ThreeBond 1104J or ThreeBond 1280B
IApply molybdenum disulfide grease
Symbols J to N in an exploded diagram indi-
cate the type of sealant or locking agent and
the application point.
JApply Gasket Maker
KApply LOCTITE 271 (red)
LApply LOCTITE 242 (blue)
MApply LOCTITE 572
NApply silicone sealant
NOTE:
Additional symbols may be used in this man-
ual.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFOSPEC
INSP
ADJFUEL
POWRJET
PUMP
–+ELECHULL
HOOD
TRBL
ANLS
T R..
E
A1280B1104J
MGM
271
LT
242
LT
572
LTSS
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GEN
INFO
1
2
3
4
5
6
7
8
9
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS ......................................................................... 1-1
PRIMARY l.D. NUMBER ........................................................................... 1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
JET PUMP UNIT SERIAL NUMBER ......................................................... 1-1
HULL IDENTIFICATION NUMBER (H.l.N.) ............................................... 1-1
SAFETY WHILE WORKING...................................................................... 1-2
FIRE PREVENTION .................................................................................. 1-2
VENTILATION ........................................................................................... 1-2
SELF-PROTECTION ................................................................................. 1-2
PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2
GOOD WORKING PRACTICES ............................................................... 1-3
DISASSEMBLY AND ASSEMBLY ............................................................ 1-4
SPECIAL SERVICE TOOLS ........................................................................... 1-5
MEASURING ............................................................................................. 1-5
REMOVAL AND INSTALLATION .............................................................. 1-7
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GEN
INFO
SAFETY WHILE WORKING
SAFETY WHILE WORKING
To prevent and accident or injury and to
ensure quality service, follow the safety proce-
dures provided below.
FIRE PREVENTION
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
VENTILATION
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.
SELF-PROTECTION
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com-
pressor.
Protect your hands and feet by wearing protec-
tive gloves or safety shoes when necessary.
PARTS, LUBRICANTS, AND
SEALANTS
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.
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GEN
INFO
SAFETY WHILE WORKING
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
GOOD WORKING PRACTICES
1.The right tools
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right manner—do not
improvise.
2.Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When
tightening nuts, bolts, and screws, tighten
the large sizes first, and tighten fasteners
starting in the center and moving outward.
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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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GEN
INFO
SPECIAL SERVICE TOOLS
0
Compression gauge extension
P/N. 90890-06582
A
Cylinder gauge set
P/N. YU-03017
90890-06759
B
Compression gauge
P/N. YU-33223-1
90890-03160
C
Peak voltage adapter
P/N. YU-39991
D
Peak voltage adapter B
P/N. 90890-03172
E
Spark checker
P/N. YM-34487
Ignition tester
P/N. 90890-06754
F
Test harness (2 pins)
P/N. New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins)
P/N. New: 90890-06867
Current: 90890-06767
G
Test harness (3 pins)
P/N. New: YB-06870
Current: YB-06770
Test harness SMT250-3 (3 pins)
P/N. New: 90890-06870
Current: 90890-06770
H
Test harness (6 pins)
P/N. YB-06848
Test harness FSW-6A (6 pins)
P/N. 90890-06848
I
Test harness (3 pins)
P/N. New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins)
P/N. New: 90890-06877
Current: 90890-06777
J
Lower unit pressure/vacuum tester
P/N. YB-35956-A
Vacuum/pressure pump gauge set
P/N. 90890-06756
0A
B
C
EF
GH90890-06582 YU-03017
90890-06759
YU-33223-1 90890-03160
YU-39991 90890-03172
YM-34487
90890-06754YB-06867 (-06767)
90890-06867 (-06767)
YB-06870 (-06770)
90890-06870 (-06770)YB-06848
90890-06848
D
IJYB-06877 (-06777)
90890-06877 (-06777)YB-35956-A
90890-06756
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