WaveRunner

VX110 Sport VX110 Deluxe

ASSEMBLY MANUAL
*LIT186660036*
LIT-18666-00-36 F1K-28107-1G-11

WaveRunner VX110 Sport/VX110 Deluxe ASSEMBLY MANUAL 2004 by Yamaha Motor Corporation, USA 1st Edition, October 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA P/N LIT-18666-00-36

PREFACE
This Assembly Manual contains the information needed to assemble the Yamaha watercraft correctly prior to delivery to the customer. Since some external parts of the watercraft have not been assemblied at the Yamaha factory for convenience of packing, assembly by the Yamaha dealer is required. It should be noted that the reassembled watercraft should be thoroughly cleaned, inspected, and adjusted prior to delivery to the customer.

SYMBOLS USED IN THIS ASSEMBLY MANUAL

In order to simplify descriptions in assembly manuals, the following symbols are used: : Coat with water resistant grease. (Yamaha grease A, Yamaha marine grease) : Tightening torque. : Provide clearance. : Install so that the arrow mark faces upward. : Frontword of the watercraft. : Made of rubber or plastics. : Tighten temporarily. : Apply locking agent. LOCTITE 242 (blue) Size: d/D : Diameter of part. l : Length of part.

NOTICE
Because Yamaha constantly strives for product improvement, the service specifications may be subject to change in the future. If any change is introduced into the specifications or assembly procedures, Yamaha dealers will be notified by a technical bulletin.

IMPORTANT MANUAL INFORMATION:

Particularly important information is distinguished in this manual by the following notations. 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 watercraft. NOTE: A NOTE provides key information to make procedures easier or cleaner.

E General torque specifications Nm kgfm ftlb 5.0 0.5 3.6 8.0 0.8 5.8 18 1.8 13 36 3.6 25 43 4.3 31

GENERAL TORQUE SPECIFICATIONS

This chart specifies the torques for tightening standard fasteners with standard clean dry ISO threads at room temperature. Torque specifications for special components or assemblies are given in applicable sections of this manual. To avoid causing warpage, tighten multi-fastener assemblies in a crisscross fashion, in progressive stages until the specified torque is reached.

Nut A 8 mm 10 mm 12 mm 14 mm 17 mm

Bolt B M5 M6 M8 M10 M12

UNPACKING AND CHECKING

Carefully uncrate unit and inventory any missing or damaged parts. NOTE: For USA: If concealed damage is found during uncrating, refer to the Yamaha Warranty Handbook, Chapter 3. Documentation may be required for warranty reimbursement. Do not continue with uncrating or throw the crate away until the requirements in Chapter 3 have been met.

COMPARTMENT DIAGRAM

1 3

5 6

COMPARTMENT PART CHART

No. 1 2 3 4 5 6 Part name Watercraft body Handlebar assembly Vinyl bag Bow locker plate Mirror Basic orientation video Qty 1 1 3 1 2 1 Remarks

COMPARTMENT DIAGRAM

COMPARTMENT PART CHART

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15
*1

Part name Handlebar assembly Engine shut-off cord Upper handlebar holder Bolt 8 48 mm (0.31 1.89 in) Pad Upper handlebar cover Lower handlebar cover Screw 6 13 mm (0.24 0.51 in) Screw 5 15 mm (0.20 0.59 in) Screw 4 9 mm (0.16 0.35 in) Star label tag*1 Grommet Corrugated tube Left mirror (with seal) Right mirror (with seal)

Qty 1 1 2 4 1 1 1 4 4 2 1 1 1 1 1

Part number F1K-U155A-00 EW2-68348-00 EU0-23814-30 90119-089UU F1K-U142D-00 F1K-U143D-01 F1K-U143E-00 90154-06017 90149-05903 90157-04003 F1B-U410M-00 F0M-61469-00 F0D-6773E-00 F1S-U596B-10 F1S-U596C-10

: For California

No. 16 17 18 19 20 21 22 23 24 25 26

Part name Washer 18 8 mm (0.71 0.31 in) Nut 8 mm (0.31 in) Rivet Storage compartment panel Flushing hose connector Tool kit Vinyl bag Owners/Operators manual Riding practice guide Riding instruction card Basic orientation video

Qty 4 4 4 1 1 1 1 1 1 1 1

Part number 9299R-08200 9572R-08300 90269-08801 F1K-U475F-01 67X-E2590-00 F1B-65986-00 EU0-65901-01 F1K-F8199-10 F1K-F819T-10 FN8-U595B-04 F0D-U595A-01

THROTTLE CABLE INSTALLATION

EXPLODED DIAGRAM

3.4 N m (0.34 kgf m, 2.5 ft Ib)

5 3

6 4

6 3 7

3.7 N m (0.37 kgf m, 2.7 ft Ib)

1 5 3

INSTALLATION CHART
Step Procedure/Part name THROTTLE CABLE INSTALLATION Lower handlebar cover Screw 6 13 mm (0.24 0.51 in) Grommet Qty Service points Follow Step order for installation.

1 2 3

1 4 1 NOTE: Pass the throttle cable and handlebar switch lead through the grommet, and then fit the grommet into the steering column.

EXPLODED DIAGRAM

3.4 N m (0.34 kgf m, 2.5 ft Ib)

5 3

6 4

6 3 7

3.7 N m (0.37 kgf m, 2.7 ft Ib)

1 5 3

Step 4 5 6 7

Procedure/Part name Throttle cable Corrugated tube Handlebar switch Screw 5 25 mm (0.20 0.98 in)

Qty 1 1 1 2

Service points

NOTE: Align the handlebar switch projection with the hole on the handlebar.

HANDLEBAR INSTALLATION
EXPLODED DIAGRAM

INSTALLATION CHART
Step 1 Procedure/Part name HANDLEBAR INSTALLATION Upper handlebar holder Qty 2 Service points Follow Step order for installation. NOTE: The upper handlebar holder should be installed with the punched mark a forward. NOTE: Tighten the bolts so that the front clearance b of the upper handlebar holder is smaller than the rear clearance c. b: 1.5 mm (0.06 in) Reference clearance: c: 3.5 mm (0.14 in) NOTE: Be sure to leave some slack in the handlebar switch lead in the area e shown in the illustration.
6

Bolt 8 48 mm (0.31 1.89 in)

Handlebar switch lead

EXPLODED DIAGRAM

Step 4

Procedure/Part name Throttle cable

Qty 1

Service points Installation steps: Install the throttle cable end into the throttle lever. Fit the seal 1 into the groove in the bracket. Turn the adjuster 2 in/out until the specified free play is obtained. Throttle lever free play d: 47 mm (0.160.28 in) Turn in Free play is increased. Turn out Free play is decreased. Tighten the locknut 3.

STEERING PAD INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART
Step Procedure/Part name STEERING PAD INSTALLATION Pad Upper handlebar cover Screw 5 15 mm (0.20 0.59 in) Screw 4 9 mm (0.16 0.35 in) Engine shut-off cord Star label tag*1 Qty Service points Follow Step order for installation.

1 2 3 4 5 6

1 1 4 2 1 1

NOTE: Be sure to attach the star label tag to the handlebar grip after installing all parts.

*1

: For California
8

REAR VIEW MIRROR INSTALLATION

EXPLODED DIAGRAM

7 6
15 N m (1.5 kgf m, 11 ft Ib)

2 3 4
15 N m (1.5 kgf m, 11 ft Ib)

FW

1 5

INSTALLATION CHART
Step Procedure/Part name REAR VIEW MIRROR INSTALLATION Left mirror (with seal) Right mirror (with seal) Washer 18 8 mm (0.71 0.31 in) Nut 8 mm (0.31 in) Remote control transmitter (Deluxe model only) Qty Service points Follow Step order for installation.

1 2 3 4 5

1 1 4 4 2

NOTE: Remove the remote control transmitters (in the vinyl bag). Place the remote control transmitters in the glove compartment. Give the remote control transmitters to the customer at time of delivery.
9

EXPLODED DIAGRAM

7 6
15 N m (1.5 kgf m, 11 ft Ib)

2 3 4
15 N m (1.5 kgf m, 11 ft Ib)

FW

1 5

Step 6

Procedure/Part name Storage compartment panel

Qty 1

Service points NOTE: Before installing the storage compartment panel, fasten the buzzer lead, steering sensor lead, start switch lead, engine shut-off switch lead, and multifunction meter lead with a plastic tie 1.

Rivet

10

SERVICE POINTS
2 1
RIVET INSTALLATION 1. Install: Rivets Installing steps: Insert a rivet completely in the holes in both the storage compartment panel 1 and inner hull. Push in the rivet pin 2 until it clicks and is flush with the top of the rivet. NOTE: To remove a rivet, push the rivet pin in until it clicks and is below the top of the rivet. Before reinstalling a rivet, hold the rivet flange a with both hands and push the rivet pin perpendicularly against a hard flat surface until the pin protrudes from the top of the rivet.

11

BATTERY INSTALLATION
EXPLODED DIAGRAM

INSTALLATION CHART
Step 1 Procedure/Part name BATTERY INSTALLATION Battery Qty 1 Service points Follow Step order for installation. NOTE: Charge the battery before installing it. Refer to PREDELIVERY CHECK.

2 3 4 5

Battery breather hose Battery positive lead (red) Battery negative lead (black) Band

1 1 1 2

CAUTION:
Make sure that the battery breather hose is not pinched.

12

PREDELIVERY CHECK
CHECKING CHART
Check elements Throttle lever Oil tank Battery Steering system Shift system (Deluxe model only) Checking points Free play Engine oil Battery condition Handlebar and jet thrust nozzle horizontal positions Reverse gate position Reference page 7 13 16 18 19

OIL TANK 1. Check: Engine oil level Recommended oil: SAE 10W-30, 20W-40, 20W-50 API SE, SF, SG, SH, SJ, SL NOTE: The engine was filled with the correct amount of oil at the factory. Checking steps:

CAUTION:
When checking the engine oil level on water, be careful of other watercraft, boats, swimmers, or obstacles. The water current or wind can cause the watercraft to move and lead to a collision. When checking the engine oil level on land, supply water to the cooling water passages.

13

Make sure that engine has enough oil but do not overfill. If there is too little oil, the engine can be damaged. If there is too much oil, the air filter can become saturated with oil, permanently damaging the filter and reducing engine performance. Follow the checking procedure carefully. Make sure that debris or water does not enter the oil tank filler hole. Debris or water in the engine oil can cause serious engine damage. Place the watercraft in a horizontal position or launch the watercraft. Remove the seat. Remove the oil filler cap 1 and check for oil on the dipstick 2. If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap. Start the engine.

CAUTION:
When starting the engine make sure the dipstick is securely fitted into the oil tank. NOTE: The engine cannot be started if the Yamaha Security System is in the lock mode. For information on the Yamaha Security System, see the owners manual. Run the engine at trolling speed for 6 minutes or more, and then stop the engine.

CAUTION:
When checking the oil level on land, be sure to connect a garden hose to the watercraft for proper water supply.

14

NOTE: If the ambient temperature is 20 C (68 F) or less, warm up the engine for an additional 5 minutes. Remove the oil filler cap 1, wipe the dipstick 2 clean, and then screw the filler cap into the filler hole completely. Remove the filler cap again to check 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 a, add sufficient oil of the recommended type to raise it to the correct level. If the engine oil is above the maximum level mark b, 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 temperature is high, the reading on the dipstick will be high. Be sure to remove the oil notification tag 3 from the intake manifold after checking the engine oil level.

15

E BATTERY

WARNING
Battery electrolyte is poisonous and dangerous, causing severe burns, etc. Electrolyte 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 immediately. 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. 1. Fill: Battery electrolyte Filling steps: Remove all the filler caps using pliers. Fill with the specified electrolyte from a jug. After the electrolyte is filled up as far as the UPPER LEVEL a, allow the cell to stand for 20 minutes. If after 20 minutes, the electrolyte level has dropped, add more electrolyte up to the UPPER LEVEL mark once again.

16

E 2. Initial battery charging: Battery Charging steps: Connect the charging cable (+) and () of the battery charger to the battery terminals correctly. Charge the battery for 3 to 5 hours with the rate of 1.9 ampere.

WARNING
Turn the battery charger on after the battery is connected to the charger. The sparking by connecting the charging cable to the battery terminal can cause an explosion to the explosive gases coming out from the battery cells.

CAUTION:
Always charge the battery when the electrolyte is poured into the battery for the first time. Otherwise, the battery can cause the lowering of performance earlier. 3. Inspect: Specific gravity of the electrolyte Out of specification Recharge. Specific gravity at 20C (68F): 1.28 NOTE: Replace the battery if there are differences of 0.025 or more on the specific gravity of each cells electrolyte after recharging. 4. Install: Filler caps

CAUTION:
Rinse off any electrolyte from the battery case and wipe the battery dry prior to installation.

17

E STEERING CABLE 1. Check: Distance a, b Out of specification Adjust. Difference of distances a and b: Maximum 5 mm (0.2 in) Checking steps: Set the control grip in the neutral position. Turn the handlebar lock to lock. Measure the distances a and b. If the difference of distances a and b is not within specification, adjust the cable joint.

2. Adjust: Steering cable joint (steering column end) Adjustment steps: Set the control grip in the neutral position. Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Turn the cable joint in or out for adjusting the distances a and b. Turn in Turn out Distance a is increased. Distance b is increased.

WARNING
The cable joint must be screwed in more than 8 mm (0.31 in). Connect the cable joint and tighten the locknut. Locknut: 6.5 N m (0.65 kgf m, 4.7 ft lb)

NOTE: If the steering cable cannot be properly adjusted by the cable joint at the handle end, adjust the cable joint at the jet pump end so that the specified distance is obtained.
18

T.

R.

E SHIFT CABLE (Deluxe model only) 1. Check: Reverse gate stopper lever position Incorrect Adjust. Checking steps: Set the shift lever to the reverse position. Check that the reverse gate 1 contacts the stopper 2. 2. Adjust: Shift cable joint

3 2

Adjustment steps: Loosen the locknut 1. Disconnect the cable joint 2 from the ball joint 3. Situate the reverse gate to the stopper on the bracket and the lever to the reverse gate. Turn the cable joint to align it with the ball joint. Turn in Turn out Shortens. Lengthens.

Turn out the cable joint nine times a to extend 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. Locknut: 3.8 N m (0.38 kgf m, 2.7 ft lb)

T.

R.

19

APPENDICES
SERVICE DATA
Item Trolling speed: Spark plug: Type Gap Fuel and oil: Fuel Engine oil Fuel tank capacity Engine oil quantity Total amount (without oil filter replacement) (with oil filter replacement)
*1 *2

Unit r/min

VX110 Sport/VX110 Deluxe 1,5501,750 CR9EB 0.70.8 (0.0280.031) Regular unleaded gasoline with a minimum octane rating of 86 (PON*1) or 90 (RON*2) SAE 10W-30, 20W-40, 20W-50 API SE, SF, SG, SH, SJ, SL 60 (15.9, 13.2)

mm (in)

L (US gal, Imp gal) L (US qt, Imp qt) L (US qt, Imp qt) L (US qt, Imp qt)

4.3 (4.5, 3.8) 2.0 (2.1, 1.8) 2.2 (2.3, 1.9)

: Pump Octane Number = (Motor Octane Number + Research Octane Number)/2 : Research Octane Number

20

YAMAHA MOTOR CORPORATION, USA

Printed in USA Nov. 2004 0.0 1 CR (E)