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.

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EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
4 Throttle cable 1 Installation steps:
•Install the throttle cable end into the throt-
tle lever.
•Fit the seal 1into the groove in the
bracket.
•Turn the adjuster 2in/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.

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STEERING PAD INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
*1: For California
Step Procedure/Part name Q’ty Service points
STEERING PAD
INSTALLATION
Follow “Step”order for installation.
1Pad 1
2 Upper handlebar cover 1
3Screw
5 ×15 mm (0.20 ×0.59 in)
4
4Screw
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.

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REAR VIEW MIRROR INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
REAR VIEW MIRROR
INSTALLATION
Follow “Step”order for installation.
1 Left mirror (with seal) 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)
2NOTE:
•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
FWD
2
7
6
34
43
1
5
15 N •m (1.5 kgf •m, 11 ft •Ib)
15 N •m (1.5 kgf •m, 11 ft •Ib)

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EXPLODED DIAGRAM
Step Procedure/Part name Q’ty Service points
6 Storage compartment 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.
7Rivet 4
1
FWD
2
7
6
34
43
1
5
15 N •m (1.5 kgf •m, 11 ft •Ib)
15 N •m (1.5 kgf •m, 11 ft •Ib)

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SERVICE POINTS
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 2until 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 awith both hands and push the
rivet pin perpendicularly against a hard
flat surface until the pin protrudes from the
top of the rivet.
21
a

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BATTERY INSTALLATION
EXPLODED DIAGRAM
INSTALLATION CHART
Step Procedure/Part name Q’ty Service points
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

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PREDELIVERY CHECK
CHECKING CHART
Check elements Checking points Reference page
Throttle lever Free play 7
Oil tank Engine oil 13
Battery Battery condition 16
Steering system Handlebar and jet thrust nozzle horizontal
positions
18
Shift system
(Deluxe model only)
Reverse gate 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 checking the engine oil level on
land, supply water to the cooling water
passages.

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•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, perma-
nently damaging the filter and reduc-
ing 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 posi-
tion or launch the watercraft.
•Remove the seat.
•Remove the oil filler cap 1and 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 owner’s 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.

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NOTE:
If the ambient temperature is 20 °C (68 °F)
or less, warm up the engine for an addi-
tional 5 minutes.
• Remove the oil filler cap 1, wipe the dip-
stick 2clean, 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 aand maximum level mark bon
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 the dipstick will
be high.
• Be sure to remove the oil notification tag
3from the intake manifold after checking
the engine oil level.
3

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BATTERY
WARNING
Battery electrolyte is poisonous and dan-
gerous, causing severe burns, etc. Electro-
lyte 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 immedi-
ately.
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.