2005 Yamaha WaveRunner VX110 Sport & VX110 Deluxe Service Manual (P/N LIT-18616-02-91)

This Yamaha service manual covers the 2005 WaveRunner VX110 Sport and VX110 Deluxe. The first edition, January 2005, carries publication number LIT-18616-02-91 and cover code F1K-28197-1H-11, with nine chapters covering maintenance, diagnosis, and repair.

• Engine repair: Engine removal, camshaft timing, cylinder-head and valve service, crankcase separation, piston inspection, and crankshaft bearing selection.

• Fuel injection: Fuel pump module service, injector testing, throttle body assembly inspection, and accelerator and throttle position sensor checks.

• Jet pump and driveline: Impeller and drive-shaft service, reduction drive gear disassembly, intermediate-shaft bearing replacement, and coupling alignment.

• Electrical diagnosis: Ignition, starting, and charging tests, multifunction-meter checks, Yamaha Diagnostic System functions, and model-specific wiring diagrams.

• Steering and hull: Steering-column service, control-cable adjustment, hull fittings, exhaust-system service, and Deluxe reverse-gate and shift-lever procedures.

• Scheduled maintenance: Maintenance Interval Chart, valve-clearance adjustment, oil and filter service, cooling-water inlet checks, and bilge-strainer inspection.

Yamaha prepared this manual primarily for its dealers and trained mechanics, assuming an understanding of the mechanical and electrical principles involved.

Engine Repair, Lubrication, and Cooling

Engine work extends to valve-guide replacement and valve-seat refacing, plus connecting-rod and crankshaft bearing selection using stamped codes and color charts. Camshaft timing illustrations, valve-pad selection tables, and component-specific tightening sequences support reassembly.

Bearing identification: The manual warns that mixing crankshaft journal or connecting-rod bearings can alter oil clearance and damage the engine.

Oil-system coverage includes the oil tank, oil strainer, oil pump installation, and oil-filter replacement. Overfilling the dry-sump system can saturate and permanently damage the air filter, a specific caution in the oil-level checking procedure.

Cooling-water hose and wet-exhaust sections cover hose routing, water-lock inspection, and exhaust-joint assembly.

Fuel Injection and Test Equipment

Fuel pump module removal and pressure testing accompany fuel-rail and injector service. The pressure test identifies fuel-pressure gauge YB-06766 and adapter YW-06842.

Throttle body service limit: The throttle body assembly is inspected and replaced as a complete unit; Yamaha specifically prohibits disassembling it.

Electronic checks distinguish throttle position and accelerator position sensors. Computer-based tests require Yamaha Diagnostic System equipment, including for injector Stationary Tests. Connection details and diagnostic functions are covered here; detailed software operation is referred to the separate diagnostic-system instruction manual.

Fuel and high-voltage ignition testing requires the precautions and technical competence described in the manual.

Jet Pump, Steering, and Deluxe Equipment

Press-work details cover pump-shaft and intermediate-drive-shaft bearings and oil seals. Engine installation includes shim identification and coupling-clearance checks, helping preserve driveline alignment after engine removal.

Steering cable inspection and adjustment is documented alongside steering-column removal. The Deluxe-specific sections cover the reverse gate, shift cable, and shift lever.

The Deluxe Yamaha Security System section includes remote-control tests and transmitter registration using an entry box. Registration clears existing transmitter IDs, an important consideration when adding or replacing a remote.

Electrical Fault Isolation and Wiring

Test-harness connection views, stator peak-voltage tables, and rectifier/regulator checks accompany starter-motor inspection and multifunction-meter diagnosis. The Trouble Analysis Chart links symptoms such as poor acceleration, overheating, and charging problems to components and reference chapters, helping narrow the fault before parts are replaced.

Separate Sport and Deluxe color wiring diagrams include connector-pin layouts. Ignition System and Off Throttle Steering System circuit diagrams, plus Cable and Hose Routing drawings, support circuit tracing and harness installation. Exploded views are paired with removal and installation charts throughout the assembly sections.

A Sample of Engine, Fuel, and Ignition Specifications

These examples are a small part of the inspection and test specifications in the manual.

For both covered models, the cylinder-head warpage limit is 0.1 mm. Cold valve clearances are 0.11–0.20 mm for intake valves and 0.25–0.34 mm for exhaust valves.

The fuel-pressure test specifies 320–327 kPa (46–47 psi) with the engine running after warm-up. Ignition-coil primary resistance is 1.19–1.61 ohms at 20°C (68°F), with the electrical chapter explaining how tester internal resistance affects low-resistance measurements.

PDF Search, Navigation, and Page Breakdown

Text search and wiring detail: Searchable text and embedded bookmarks provide access to the nine chapters and wiring diagrams. The Back to Index shortcut targets a separate file that is not included. Small wire-color codes and connector-pin numbers require zooming for comfortable reading.

Supplied as one printable, 341-page English PDF. The total includes seven opening pages, 328 chapter pages, four wiring-diagram and legend pages, one blank page, and the back cover.