Yamaha WaveRunner VX110 Sport Bedienungsanleitung

ASSEMBLY MANUAL

WaveRunner

F1K-28107-1G-11LIT-18666-00-36

*LIT186660036*

VX110 Sport

VX110 Deluxe

WaveRunner

VX110 Sport/VX110 Deluxe

ASSEMBLY MANUAL

1st Edition, October 2004

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 informa-

tion needed to assemble the Yamaha water-

craft correctly prior to delivery to the customer.

Since some external parts of the watercraft

have not been assemblied at the Yamaha fac-

tory 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.

NOTICE

Because Yamaha constantly strives for prod-

uct 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 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 must be taken to avoid damage to the

watercraft.

NOTE:

A NOTE provides key information to make pro-

cedures easier or cleaner.

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.

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 criss-

cross fashion, in progressive stages until the

specified torque is reached.

Nut ABolt B

General torque

specifications

N•mkgf•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

–1 –

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

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

–2 –

COMPARTMENT DIAGRAM

COMPARTMENT PART CHART

*1: For California

No. Part name Q’ty Part number

1 Handlebar assembly 1 F1K-U155A-00

2 Engine shut-off cord 1 EW2-68348-00

3 Upper handlebar holder 2 EU0-23814-30

4 Bolt 8

×48 mm (0.31 ×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 mirror (with seal) 1 F1S-U596C-10

–3 –

No. Part name Q’ty Part number

16 Washer 18 ×8 mm (0.71 ×0.31 in) 4 9299R-08200

17 Nut 8 mm (0.31 in) 4 9572R-08300

18 Rivet 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

–4 –

THROTTLE CABLE INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

THROTTLE CABLE

INSTALLATION

Follow “Step”order for installation.

1 Lower handlebar cover 1

2Screw

6 ×13 mm (0.24 ×0.51 in)

3 Grommet 1 NOTE:

Pass the throttle cable and handlebar switch

lead through the grommet, and then fit the

grommet into the steering column.

3.7 N • m (0.37 kgf • m, 2.7 ft • Ib)

3.4 N • m (0.34 kgf • m, 2.5 ft • Ib)

–5 –

EXPLODED DIAGRAM

Step Procedure/Part name Q’ty Service points

4 Throttle cable 1

5 Corrugated tube 1

6 Handlebar switch 1

7Screw

5 ×25 mm (0.20 ×0.98 in)

2NOTE:

Align the handlebar switch projection with the

hole on the handlebar.

3.7 N •m (0.37 kgf •m, 2.7 ft •Ib)

3.4 N •m (0.34 kgf •m, 2.5 ft •Ib)

– 6 –

HANDLEBAR INSTALLATION

EXPLODED DIAGRAM

INSTALLATION CHART

Step Procedure/Part name Q’ty Service points

HANDLEBAR INSTALLATION Follow “Step” order for installation.

1 Upper handlebar holder 2 NOTE:

The upper handlebar holder should be installed

with the punched mark aforward.

2Bolt8×48 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 eshown in the illustra-

tion.

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