WaveRunner

VX110 Sport
VX110 Deluxe

SERVICE MANUAL
*LIT186160291*
LIT-18616-02-91 F1K-28197-1H-11
 E

INDEX
A30000-0

GENERAL INFORMATION GEN

INFO
1
SPECIFICATIONS
SPEC 2
PERIODIC INSPECTION AND
ADJUSTMENT INSP
ADJ
3
FUEL SYSTEM
FUEL 4
POWER UNIT
POWR 5
JET PUMP UNIT JET
PUMP
6
– +

ELECTRICAL SYSTEM
ELEC 7
HULL AND HOOD HULL
HOOD
8
TROUBLE ANALYSIS TRBL
ANLS
9
GEN
INFO E

CHAPTER 1
GENERAL INFORMATION

IDENTIFICATION NUMBERS ......................................................................... 1-1

PRIMARY l.D. NUMBER ...........................................................................1-1
ENGINE SERIAL NUMBER ...................................................................... 1-1
JET PUMP UNIT SERIAL NUMBER .........................................................1-1
1
HULL IDENTIFICATION NUMBER (H.l.N.)............................................... 1-1

SAFETY WHILE WORKING...................................................................... 1-2

FIRE PREVENTION .................................................................................. 1-2
VENTILATION ........................................................................................... 1-2
2
SELF-PROTECTION................................................................................. 1-2

3
PARTS, LUBRICANTS, AND SEALANTS ................................................ 1-2
GOOD WORKING PRACTICES ............................................................... 1-3
DISASSEMBLY AND ASSEMBLY ............................................................ 1-4

SPECIAL SERVICE TOOLS ...........................................................................1-5

MEASURING............................................................................................. 1-5
REMOVAL AND INSTALLATION.............................................................. 1-7

4
5
6
7
8
9
GEN
INFO IDENTIFICATION NUMBERS E
A60700-0*

IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Starting primary l.D. number:
F1K: 800101

ENGINE SERIAL NUMBER

The engine serial number is stamped on a
label attached to the engine unit.

Starting serial number:

6D3: 1000001

JET PUMP UNIT SERIAL NUMBER

The jet pump unit serial number is stamped on
a label attached to the intermediate housing.

HULL IDENTIFICATION NUMBER

(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.

1-1
GEN
INFO SAFETY WHILE WORKING E

SAFETY WHILE WORKING

To prevent and accident or injury and to
ensure quality service, follow the safety proce-
dures provided below.

FIRE PREVENTION
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.

VENTILATION
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled in
large quantities they may cause loss of con-
sciousness and death within a short time.
When test running an engine indoors (e.g., in a
water tank), be sure to do so where adequate
ventilation can be maintained.

SELF-PROTECTION
Protect your eyes by wearing safety glasses or
safety goggles during all operation involving
drilling and grinding, or when using an air com-
pressor.
Protect your hands and feet by wearing protec-
tive gloves or safety shoes when necessary.

PARTS, LUBRICANTS, AND

SEALANTS
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the
watercraft.

1-2
GEN
INFO SAFETY WHILE WORKING E

Under normal conditions, the lubricants men-

tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on the
watercraft.
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.

GOOD WORKING PRACTICES

1. The right tools
Use the recommended special service
tools to protect parts from damage. Use
the right tool in the right manner—do not
improvise.
2. Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When
tightening nuts, bolts, and screws, tighten
the large sizes first, and tighten fasteners
starting in the center and moving outward.

1-3
GEN
INFO SAFETY WHILE WORKING E

3. Non-reusable parts
Always use new gaskets, seals, O-rings,
oil seals, cotter pins, circlips, etc., when
installing or assembling parts.

DISASSEMBLY AND ASSEMBLY

1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces of
moving parts during assembly.

3. Install bearings with the manufacture iden-

tification mark in the direction indication in
the installation procedure. In addition, be
sure to lubricate the bearings liberally.
4. Apply a thin coat of water-resistant grease
to the lip and periphery of an oil seal
before installation.
5. Check that moving parts operate normally
after assembly.

1-4
GEN
INFO SPECIAL SERVICE TOOLS E

SPECIAL SERVICE TOOLS

Using the correct special service tools recom-
mended by Yamaha, will aid the work and
enable accurate assembly and tune-up. Impro-
visations and using improper tools can dam-
age the equipment.

NOTE:
• For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-” or
“YW-”.
• For other countries, use part numbers start-
1 90890-06583 2 90890-06584
ing with “90890-”.

MEASURING
1 Dial gauge stand
3 YB-06585 P/N. 90890-06583
90890-06585
2 Dial gauge needle
P/N. 90890-06584
3 Dial gauge stand set
P/N. YB-06585
4 YU-03097 90890-01252
90890-06585
4 Dial indicator gauge
P/N. YU-03097
Dial gauge set
P/N. 90890-01252
5 Pocket tester
P/N. YU-03112
5 YU-03112 6 YU-34899-A
90890-03112
90890-03112
6 Digital multimeter
P/N. YU-34899-A
7 Digital circuit tester
P/N. 90890-03174
8 Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
7 90890-03174 8 YW-06842 9 Fuel pressure gauge
90890-06842 P/N. YB-06766
90890-06786

9 YB-06766 90890-06786

1-5
GEN
INFO SPECIAL SERVICE TOOLS E

0 Compression gauge extension

0 90890-06582 A YU-03017 P/N. 90890-06582
90890-06759 A Cylinder gauge set
P/N. YU-03017
90890-06759
B Compression gauge
P/N. YU-33223-1
90890-03160
C Peak voltage adapter
B YU-33223-1 90890-03160 P/N. YU-39991
D Peak voltage adapter B
P/N. 90890-03172
E Spark checker
P/N. YM-34487
Ignition tester
P/N. 90890-06754
C YU-39991 D 90890-03172 F Test harness (2 pins)
P/N. New: YB-06867
Current: YB-06767
Test harness FWY-2 (2 pins)
P/N. New: 90890-06867
Current: 90890-06767
G Test harness (3 pins)
E YM-34487 F YB-06867 (-06767) P/N. New: YB-06870
90890-06754 90890-06867 (-06767) Current: YB-06770
Test harness SMT250-3 (3 pins)
P/N. New: 90890-06870
Current: 90890-06770
H Test harness (6 pins)
P/N. YB-06848
Test harness FSW-6A (6 pins)
P/N. 90890-06848
G YB-06870 (-06770) H YB-06848 I Test harness (3 pins)
90890-06870 (-06770) 90890-06848
P/N. New: YB-06877
Current: YB-06777
Test harness HM090-3 (3 pins)
P/N. New: 90890-06877
Current: 90890-06777
J Lower unit pressure/vacuum tester
P/N. YB-35956-A
Vacuum/pressure pump gauge set
I YB-06877 (-06777) J YB-35956-A
90890-06877 (-06777) 90890-06756 P/N. 90890-06756

1-6
GEN
INFO SPECIAL SERVICE TOOLS E

K Yamaha diagnostic system

K 60V-85300-02-00 P/N. 60V-85300-02-00
L Yamaha diagnostic system
P/N. 60V-WS853-03

L 60V-WS853-03

REMOVAL AND INSTALLATION

1 Oil filter wrench
1 YB-01426 2 YW-06551 P/N. YB-01426
90890-01426

90890-06551
90890-01426
2 Coupler wrench
P/N. YW-06551
90890-06551
3 Sheave holder
P/N. YS-01880-A
90890-01701
4 Rotor puller
3 YS-01880-A 4 YM-01082
90890-01701 90890-01080 P/N. YM-01082
90890-01080
5 Universal magneto and rotor holder
P/N. YU-01235
Rotor holder
P/N. 90890-01235
6 Bearing housing needle bearing installer
(reduction drive gear)
5 YU-01235 6 YB-06111 P/N. YB-06111
90890-01235

1-7
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GEN
INFO SPECIAL SERVICE TOOLS E

7 Forward gear bearing cup installer

(reduction drive gear)
7 YB-06276-B 8 90890-06657 P/N. YB-06276-B
8 Ball bearing attachment
(reduction drive gear)
P/N. 90890-06657
9 Valve spring compressor
P/N. YM-01253
90890-04019
0 Valve spring compressor attachment
P/N. YM-04114 (ø19 mm)
90890-04114 (ø19 mm)
9 YM-01253 0 YM-04114 (ø19 mm)
90890-04019 90890-04114 (ø19 mm) YM-04108 (ø22 mm)
YM-04108 (ø22 mm)
90890-04108 (ø22 mm) 90890-04108 (ø22 mm)
A Valve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
B Valve guide installer
P/N. YM-04112 (ø4.0 mm)
A YM-04111 (ø4.0 mm) B YM-04112 (ø4.0 mm) 90890-04112 (ø4.0 mm)
90890-04111 (ø4.0 mm) 90890-04112 (ø4.0 mm)
YM-04116 (ø4.5 mm) YM-04117 (ø4.5 mm) YM-04117 (ø4.5 mm)
90890-04116 (ø4.5 mm) 90890-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
C Valve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
D Valve seat cutter
Intake
P/N. 90890-06813 (60°)
C YM-04113 (ø4.0 mm) 90890-06814 (45°)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)

D 90890-06813 (60°) 90890-06315 (60°)

90890-06814 (45°) 90890-06312 (45°)
90890-06815 (30°) 90890-06328 (30°)

1-8
GEN
INFO SPECIAL SERVICE TOOLS E

E Valve seat cutter holder

P/N. 90890-06811 (ø4.0 mm)
E 90890-06811 (ø4.0 mm) F YM-91044
90890-06812 (ø4.5 mm) 90890-06812 (ø4.5 mm)
F Neway valve seat cutter kit
P/N. YM-91044
G Piston ring compressor
P/N. YM-08037
90890-05158
H Drive shaft holder (impeller)
P/N. YB-06151
Drive shaft holder 5 (impeller)
G YM-08037 90890-05158
P/N. 90890-06519
I Slide hammer and adapters
(jet pump bearing and reduction drive
gear)
P/N. YB-06096
J Stopper guide plate (jet pump bearing)
P/N. 90890-06501
K Bearing puller assembly
(jet pump bearing and reduction drive
H YB-06151 I YB-06096 gear)
90890-06519 P/N. 90890-06535
L Stopper guide stand
(jet pump bearing and reduction drive
gear)
P/N. 90890-06538
M Driver rod L3
(jet pump bearing and reduction drive
J 90890-06501 K 90890-06535 gear)
P/N. 90890-06652
N Bearing housing needle bearing remover
(jet pump bearing)
P/N. YB-06112
O Needle bearing attachment
(jet pump bearing, oil seal, and reduction
drive gear)
L 90890-06538 M 90890-06652 P/N. 90890-06614, 90890-06653
Ball bearing attachment
(jet pump oil seal)
P/N. 90890-06634

N YB-06112 O 90890-06614
90890-06653
90890-06634

1-9
GEN
INFO SPECIAL SERVICE TOOLS E

P Outer race installer—forward gear

(jet pump oil seal and reduction drive gear)
P YB-06085 Q 90890-06631 P/N. YB-06085
Q Ball bearing attachment
(jet pump oil seal and reduction drive gear)
P/N. 90890-06631
R Driver handle—large
(intermediate shaft, jet pump, and
R YB-06071 S 90890-06606 reduction drive gear)
P/N. YB-06071
S Driver rod LS
(intermediate shaft, jet pump, and
reduction drive gear)
P/N. 90890-06606
T YB-06552 U YB-06156 90890-06624
T Crankshaft holder (intermediate shaft)
90890-06552 90890-06626 P/N. YB-06552
Crankshaft holder 20 (intermediate shaft)
P/N. 90890-06552
U Bearing outer race attachment
(intermediate shaft and reduction drive
gear)
V YB-06432 P/N. 90890-06624, 90890-06628
V Roller bearing installer/remover
(intermediate shaft bearing and oil seals)
P/N. YB-06432

1-10
SPEC E

CHAPTER 2
SPECIFICATIONS

GENERAL SPECIFICATIONS ....................................................................... 2-1

MAINTENANCE SPECIFICATIONS ............................................................... 2-3

1
ENGINE .................................................................................................... 2-3

2
JET PUMP UNIT ......................................................................................2-6
HULL AND HOOD .................................................................................... 2-6
ELECTRICAL ............................................................................................ 2-7

TIGHTENING TORQUES .............................................................................. 2-10

SPECIFIED TORQUES...........................................................................2-10
GENERAL TORQUE ............................................................................... 2-15

CABLE AND HOSE ROUTING ..................................................................... 2-16

3
4
5
6
7
8
9