warning YAMAHA VX110 2005 Service Manual

E
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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3-3
E
INSP
ADJ
CONTROL SYSTEM
2. Adjust:
Steering cable joint
(steering column end)
NOTE:
Adjust the cable joint at the jet pump end.
Refer to “REMOTE CONTROL CABLES AND
SPEED SENSOR LEAD” in Chapter 8. Adjustment steps:
Set the control grip to the neutral posi-
tion.
Loosen the locknut 1
.
Disconnect the cable joint 2
from the ball
joint 3
.
Turn the cable joint 2
in or out to adjust
the steering cable length c
.
Steering cable length
c:
218.8 mm (8.61 in)
NOTE:
Check that the sum of lengths c
and d
is
581.8 ±
1 mm (22.91 ±
0.04 in).
If the sum of lengths c
and d
is out of
specification, adjust length d
, and then
check the jet thrust nozzle distances
again.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T R..
Locknut:
6.8 N  m (0.68 kgf  m, 4.9 ft  lb)
c
d
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3-5
E
INSP
ADJ
CONTROL SYSTEM
WARNING
After adjusting the free play, turn the han-
dlebar to the right and left and make sure
that the trolling speed does not increase.e. Install the handlebar cover.
T R..
Lower handlebar cover screw:
3.7 N  m (0.37 kgf  m, 2.7 ft  lb)
LOCTITE 242
Upper handlebar cover screw:
1.1 N  m (0.11 kgf  m, 0.8 ft  lb)
Shift cable inspection and adjustment
(Deluxe model only)
1. Check:
Reverse gate stopper lever position
Incorrect →
Adjust.
2. Adjust:
Shift cable joint Checking steps:
Set the shift lever to the reverse position.
Check that the reverse gate 1
contacts
the stopper 2
.
Adjustment steps:
Loosen the locknut 1
.
Disconnect the cable joint 2
from the ball
joint 3
.
Situate the reverse gate to the stopper.
Turn the cable joint in or out to align it
with the ball joint.
Turn in Length is decreased.
Turn out Length is increased.
1
23
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3-6
E
INSP
ADJ
CONTROL SYSTEM
Turn out the cable joint nine times a
to
extend the cable 7 mm (0.28 in) from the
aligned position.
WARNING
The cable joint must be screwed in more
than 8 mm (0.31 in).
Connect the cable joint and tighten the
locknut.
T R..
Locknut:
3.8 N  m (0.38 kgf  m, 2.7 ft  lb)
Trolling speed inspection
1. Inspect:
Trolling speed
Trolling speed:
1,550–1,750 r/min
Checking steps (watercraft in water):
Start the engine and allow it to warm up
for 15 minutes.
Check the engine trolling speed using the
tachometer of the multifunction meter or
using the Yamaha Diagnostic System.
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3-7
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INSP
ADJ
FUEL SYSTEM
FUEL SYSTEM
WARNING
When removing fuel system parts, wrap
them in a cloth and take care that no fuel
spills into the engine compartment.
Fuel line inspection
1. Inspect:
Fuel pump filter
Clog/contaminants →
Clean.
Refer to “FUEL TANK AND FUEL
PUMP MODULE” in Chapter 4.
Fuel hose
Cracks/damage →
Replace.
O-rings (quick connector)
Cracks/damage →
Replace the quick
connector.
Fuel rail
Cracks/damage →
Replace.
Refer to “FUEL INJECTION SYSTEM”
in Chapter 4.
Fuel filler hose
Fuel filler cap
Cracks/damage →
Replace.
2. Inspect:
Fuel tank
Cracks/damage →
Replace.
Water accumulation →
Remove.
NOTE:
To remove water from the fuel tank, remove
the fuel filler hose 1
and use a siphon pump.
Refer to “FUEL TANK AND FUEL PUMP
MODULE” in Chapter 4.
1
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3-16
E
INSP
ADJ
POWER UNIT
Remove the oil tank filler cap again and
check that the oil level is between the
minimum level mark a
and maximum
level mark b
on the dipstick.
If the engine oil is below the minimum
level mark b
, add sufficient oil of the rec-
ommended type to raise it to the correct
level.
If the engine oil is above the maximum
level mark a
, extract sufficient oil using
an oil changer to lower it to the correct
level.
NOTE:
If the oil temperature is low, the reading on
the dipstick will be low, and if the tempera-
ture is high, the reading on the dipstick will
be high.
Engine oil change — using oil changer
WARNING
Avoid changing the engine oil immediately
after turning the engine off. The oil is hot
and should be handled with care to avoid
burns.
CAUTION:
Do not run the engine with too much or
not enough oil in the oil tank. Oil could
spray out or the engine could be dam-
aged.
Do not run the engine for more than 15
seconds without supplying water, when
checking the oil level on land.
The engine could overheat.
Be sure to change the engine oil after the
first 10 hours of operation, and every 100
hours thereafter or at the start of a new
season, otherwise the engine will wear
quickly.
1. Warm the engine up, and then put the
watercraft in a horizontal position.
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3-22
E
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ELECTRICAL
ELECTRICAL
Battery inspection
WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
lyte contains sulfuric acid. Avoid contact
with skin, eyes or clothing.
Antidotes
External: Flush with water.
Internal: Drink large quantities of water or
milk. Follow with milk of magnesia, beaten
egg or vegetable oil. Call physician immedi-
ately.
Eyes: Flush with water for 15 minutes and
get prompt medical attention.
Batteries produce explosive gases. Keep
sparks, flame, cigarettes, etc., well away. If
using or charging the battery in an
enclosed space, make sure that it is well
ventilated. Always shield your eyes when
working near batteries.
KEEP OUT OF THE REACH OF CHILDREN.
CAUTION:
Be careful not to place the battery on its
side.
Make sure to remove the battery from the
battery compartment when adding battery
electrolyte or charging the battery.
When checking the battery, make sure the
breather hose is connected to the battery
and not obstructed.
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3-23
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ELECTRICAL
1. Remove:
Bands
Battery negative lead 1

Battery positive lead 2

Battery
Battery breather hose 3

WARNING
When removing the battery, disconnect
the negative lead first.
Remove the battery to prevent acid loss
during turning the watercraft on its side
for the impeller, etc.
2. Inspect:
Electrolyte level
Low →
Add distilled water.
The electrolyte level should be between
the maximum a
and minimum b
level
marks.
CAUTION:
Use only distilled water. Other types of
water contain minerals which are harmful
to batteries.Filling steps:
Remove each filler cap.
Add distilled water to the maximum level
mark.
When the electrolyte level reaches the
maximum level mark, allow the cell to
stand for 20 minutes. If the electrolyte
level drops, add more distilled water so
the level reaches the maximum level
mark.
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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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