Yamaha WaveRunner VX110 Deluxe, Assembly Manual

Page 1: ...ASSEMBLY MANUAL WaveRunner F1K 28107 1G 11 LIT 18666 00 36 LIT186660036 VX110 Sport VX110 Deluxe ...

Page 2: ...Y 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 ...

Page 3: ...mportant information is distin guished in this manual by the following nota tions The safety Alert Symbol means ATTEN TION 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 repair ing the watercraft CAUTION A CAUTION indicates special precautions that m...

Page 4: ...special components or assemblies are given in applicable sections of this manual To avoid causing warpage tighten multi fastener assemblies in a criss cross fashion in progressive stages until the specified torque is reached Nut A Bolt B General torque specifications N m kgf m ft lb 8 mm M5 5 0 0 5 3 6 10 mm M6 8 0 0 8 5 8 12 mm M8 18 1 8 13 14 mm M10 36 3 6 25 17 mm M12 43 4 3 31 ...

Page 5: ...y 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 COMPARTMENT PART CHART No Part name Q ty Remarks 1 Watercraft body 1 2 Handlebar assembly 1 3 Vinyl bag 3 4 Bow locker plate 1 5 Mirror 2 6 Basic orientation video 1 3 3 4 5 6 2 1 ...

Page 6: ...31 1 89 in 4 90119 089UU 5 Pad 1 F1K U142D 00 6 Upper handlebar cover 1 F1K U143D 01 7 Lower handlebar cover 1 F1K U143E 00 8 Screw 6 13 mm 0 24 0 51 in 4 90154 06017 9 Screw 5 15 mm 0 20 0 59 in 4 90149 05903 10 Screw 4 9 mm 0 16 0 35 in 2 90157 04003 11 Star label tag 1 1 F1B U410M 00 12 Grommet 1 F0M 61469 00 13 Corrugated tube 1 F0D 6773E 00 14 Left mirror with seal 1 F1S U596B 10 15 Right mir...

Page 7: ... 4 90269 08801 19 Storage compartment panel 1 F1K U475F 01 20 Flushing hose connector 1 67X E2590 00 21 Tool kit 1 F1B 65986 00 22 Vinyl bag 1 EU0 65901 01 23 Owner s Operator s manual 1 F1K F8199 10 24 Riding practice guide 1 F1K F819T 10 25 Riding instruction card 1 FN8 U595B 04 26 Basic orientation video 1 F0D U595A 01 ...

Page 8: ...BLE INSTALLATION Follow Step order for installation 1 Lower handlebar cover 1 2 Screw 6 13 mm 0 24 0 51 in 4 3 Grommet 1 NOTE Pass the throttle cable and handlebar switch lead through the grommet and then fit the grommet into the steering column 1 2 3 4 5 3 3 7 N m 0 37 kgf m 2 7 ft Ib 5 3 5 6 6 7 3 4 N m 0 34 kgf m 2 5 ft Ib ...

Page 9: ...ice points 4 Throttle cable 1 5 Corrugated tube 1 6 Handlebar switch 1 7 Screw 5 25 mm 0 20 0 98 in 2 NOTE Align the handlebar switch projection with the hole on the handlebar 1 2 3 4 5 3 3 7 N m 0 37 kgf m 2 7 ft Ib 5 3 5 6 6 7 3 4 N m 0 34 kgf m 2 5 ft Ib ...

Page 10: ...pper handlebar holder should be installed with the punched mark a forward 2 Bolt 8 48 mm 0 31 1 89 in 4 NOTE Tighten the bolts so that the front clearance b of the upper handlebar holder is smaller than the rear clearance c Reference clearance b 1 5 mm 0 06 in c 3 5 mm 0 14 in 3 Handlebar switch lead 1 NOTE Be sure to leave some slack in the handlebar switch lead in the area e shown in the illustr...

Page 11: ...s Install the throttle cable end into the throt tle lever Fit the seal 1 into the groove in the bracket Turn the adjuster 2 in out until the speci fied free play is obtained Throttle lever free play d 4 7 mm 0 16 0 28 in Turn in Free play is increased Turn out Free play is decreased Tighten the locknut 3 ...

Page 12: ... ty Service points STEERING PAD INSTALLATION Follow Step order for installation 1 Pad 1 2 Upper handlebar cover 1 3 Screw 5 15 mm 0 20 0 59 in 4 4 Screw 4 9 mm 0 16 0 35 in 2 5 Engine shut off cord 1 6 Star label tag 1 1 NOTE Be sure to attach the star label tag to the han dlebar grip after installing all parts ...

Page 13: ... 1 2 Right mirror with seal 1 3 Washer 18 8 mm 0 71 0 31 in 4 4 Nut 8 mm 0 31 in 4 5 Remote control transmitter Deluxe model only 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 1 FW D 2 7 6 3 4 4 3 1 5 15 N m 1 5 kgf m 11 ft Ib 15 N m 1 5 kgf m 11 ...

Page 14: ...t panel 1 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 7 Rivet 4 1 FW D 2 7 6 3 4 4 3 1 5 15 N m 1 5 kgf m 11 ft Ib 15 N m 1 5 kgf m 11 ft Ib ...

Page 15: ...ll 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 2 1 a ...

Page 16: ...ints BATTERY INSTALLATION Follow Step order for installation 1 Battery 1 NOTE Charge the battery before installing it Refer to PREDELIVERY CHECK 2 Battery breather hose 1 CAUTION Make sure that the battery breather hose is not pinched 3 Battery positive lead red 1 4 Battery negative lead black 1 5 Band 2 ...

Page 17: ...e position 19 OIL TANK 1 Check Engine oil level NOTE The engine was filled with the correct amount of oil at the factory Recommended oil SAE 10W 30 20W 40 20W 50 API SE SF SG SH SJ SL 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 colli sion When c...

Page 18: ...rcraft 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...

Page 19: ...k b on the dipstick If the engine oil is below the minimum level mark a 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 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 tempera ture is high the reading on ...

Page 20: ...ce 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 ...

Page 21: ...attery can cause the lowering of performance earlier 3 Inspect Specific gravity of the electrolyte Out of specification Recharge NOTE Replace the battery if there are differences of 0 025 or more on the specific gravity of each cell s electrolyte after recharging 4 Install Filler caps CAUTION Rinse off any electrolyte from the battery case and wipe the battery dry prior to installation Charging st...

Page 22: ...f 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 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 Distance a is incre...

Page 23: ...connect 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 Shortens Turn out 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 cab...

Page 24: ...EB Gap mm in 0 7 0 8 0 028 0 031 Fuel and oil Fuel Regular unleaded gasoline with a minimum octane rating of 86 PON 1 or 90 RON 2 Engine oil SAE 10W 30 20W 40 20W 50 API SE SF SG SH SJ SL Fuel tank capacity L US gal Imp gal 60 15 9 13 2 Engine oil quantity Total amount L US qt Imp qt 4 3 4 5 3 8 without oil filter replacement L US qt Imp qt 2 0 2 1 1 8 with oil filter replacement L US qt Imp qt 2 ...

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Page 26: ...YAMAHA MOTOR CORPORATION USA Printed in USA Nov 2004 0 0 1 CR E ...