Yamaha WaveRunner VX110 Sport User manual

ASSEMBLY MANUAL
WaveRunner
F1K-28107-1G-11LIT-18666-00-36
*LIT186660036*
VX110 Sport
VX110 Deluxe

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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

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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.

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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

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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
3
3
4
5
6
2
1

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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

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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

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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)
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)

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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.
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)

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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.