tow YAMAHA VX110 2005 Service Manual

2-20
ESPECCABLE AND HOSE ROUTING
12
Ð
Ò
Ó
Õ
Î
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É
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Ñ
Ô
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Ê
Ë
ÏTo ventilation socket
ÐTo fuel tank
ÑPoint the arrow on the cover toward the fuel
tank.
ÒFasten the fuel hose with a plastic tie.
ÓTo fuse box
ÔFasten the wiring harness with a plastic tie at
the white tape.
ÕTo ECM
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2-22
ESPECCABLE AND HOSE ROUTING
A
B
C
D
2
4
2
5
6
7
8
3
2
28
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F
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A
B
2
ÍFasten the oil separator breather hose (to air
intake duct) and cooling water hose with a
holder.
ÎFace the ends of the hose clamp towards the
starboard (right) side of the watercraft.
ÏInsert the cooling water hose to the paint mark.
ÐTo install the cooling water hose, align the white
paint mark on the cooling water hose with the
arrow mark of the hose joint.ÑInstall the cooling water hose with the white
paint mark facing up.
ÒTo cooling water pilot outlet
ÓFace the ends of the hose clamp towards the
bow.
ÔInstall the hose onto the cooling water pipe until
the pipe reaches the curve in the hose.
ÕInsert the plastic tie completely into the hole in
the boss on the cylinder block.
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4-1
EFUELFUEL TANK AND FUEL PUMP MODULE
FUEL TANK AND FUEL PUMP MODULE
EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
FUEL TANK REMOVAL
Follow the left “Step” for removal.
Storage compartment panel Refer to “FRONT HOOD” in Chapter 8.
Ventilation hose From ventilation fitting
Engine unit Refer to “ENGINE UNIT” in Chapter 5.
NOTE:
When removing the pump module only, it is
not necessary to remove the engine unit.
1 Fuel tank breather hose 1
2 Check valve 1
NOTE:
Make sure the arrow direction pointed
toward fuel tank.
7
10
11 3
2
1
18
17121315
16
14
12 6 5
4 8
9
2nd 6.4 N • m (0.64 kgf  m, 4.6 ft  Ib) 1st 3.2 N  m (0.32 kgf  m, 2.3 ft  Ib)
3.7 N  m (0.37 kgf  m, 2.7 ft  Ib)
5.9 N  m (0.59 kgf  m, 4.3 ft  Ib)
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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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5-91
EPOWRCONNECTING RODS AND PISTONS
7. Install:
Big end bearings
Connecting rod assembly 1

(into the cylinder and onto the
crankshaft pin)
Connecting rod cap
(onto the crankshaft pin)
NOTE:
Align the projections on the big end bearings
with the notches in the connecting rods and
connecting rod caps.
Be sure to reinstall each big end bearing in
its original place.
While compressing the piston rings with pis-
ton ring compressor 2
, install the connecting
rod assembly into the cylinder with the other
hand.
Make sure the “Y” marks a
on the connect-
ing rods face towards the front side of the
crankshaft.
Make sure the characters b
on both the con-
necting rod and connecting rod cap are
aligned.
8. Align:
Bolt heads
(with the connecting rod)
Piston ring compressor:
YM-08037/90890-05158
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8-19
E
HULL
HOOD
SERVICE POINTS
Cooling water pilot outlet installation
1. Install:
Cooling water pilot outlet 1

Seal 2

Nut 3

NOTE:
When installing the cooling water pilot outlet,
face the discharge hole toward the stern and
downward at a 30° angle from the horizontal
line as shown in the illustration.
Tighten the nut while holding the cooling
water pilot outlet in place.
30˚
FWD3
12
Grommet installation
1. Install:
Ventilation hose 1

Grommet 2

NOTE:
Install the grommet on the ventilation hose,
making sure that the end of the hose protrudes
the specified length a from the groove around
the outside of the grommet as shown in the
illustration.
Specified length a:
30–40 mm (1.18–1.57 in)
1
2
a
Ventilation hose assembly installation
1. Install:
Ventilation hose assembly
NOTE:
When installing the ventilation hose assembly,
make sure that the grommet is properly seated
in the hole in the inner hull as shown in the
illustration.
HOSES
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