Yamaha VX110 Deluxe WaveRunner 2006 Service Manual

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WAVERUNNER
®
WATERCRAFT
4/10/08 WR2008-001R
Yamaha Motor Corporation, U.S.A. has determined
that a possible defect which relates to safety may
exist in all 2003 through 2007 and certain 2008 model
GP1300 (GP1300R) WaveRunners and also in all 2005
through 2007 and certain 2008 model VX1100 (VX)
WaveRunners. In the affected units, there is a possibility
that the outer throttle cable could corrode and become
cracked or kinked. If the outer cable is damaged in this
way, it could cause the inner cable (throttle wire) to fray
over time from wear. If the frayed inner cable catches
on the damaged outer cable, throttle movement can be
increasingly impaired which may eventually lead to the
throttle being incapable of returning to the idle position.
This could result in an accident with the potential of
personal injury or death to the operator, passenger, or
bystanders.
To correct this defect, Yamaha is initiating a Factory Modification Campaign. Affected watercraft must have
the throttle cable replaced with one of a new material.
Yamaha is notifying all registered owners of affected units by first-class mail. A copy of this letter is included in
this bulletin. The customer should take the letter along with the affected unit to an authorized Yamaha dealer
for throttle cable replacement.
A computer report listing all affected units invoiced to your dealership is included in this bulletin. Use the list
to help ensure all units are modified. All sold units that have been registered with Yamaha will show the cus-
tomer’s name and address. Your dealership must notify the owner of any affected unit that was actually sold
but is listed as “unsold” on the report.
You must correct all affected units in your inventory, as well as all customer-owned units brought to you for this
service. Before modifying a unit, check for a black circle mark under the Primary ID label inside the engine
compartment (see Identification Procedure in this bulletin) which indicates a unit has already been modified.
If you purchase an affected unit from another dealer in the future, check for this black circle mark and then
perform the procedures in this bulletin if no mark is present before you sell the unit.
Affected WaveRunners should not be operated until they are modified. It is a violation of federal law and
Yamaha policy for your dealership to deliver any new affected units to customers until the procedures in this
bulletin are performed.
When the modification on each unit has been performed, follow the Warranty information section of this
bulletin to receive reimbursement. Be sure to use the Factory Modification Campaign procedures in
Chapter 8 of the Warranty and Y.E.S. Handbook (LIT-11760-00-05).
PAGE 1 of 20
©2008 YAMAHA MOTOR CORPORATION, U.S.A.
2003~2008 GP1300 and 2005~2008 VX1100
FACTORY MODIFICATION CAMPAIGN Throttle Cable Corrosion
RECALL
This modification has top priority. This bulletin must be
performed immediately to ensure customer safety.
NOTE: Bulletins that announce a recall will have an R at the end of the bulletin number from now on.
GP1300 SHOWN
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Summary of Contents

Page 1 - Throttle Cable Corrosion

WAVERUNNER® WATERCRAFT 4/10/08 WR2008-001RYamaha Motor Corporation, U.S.A. has determined that a possible defect which relates to safety may

Page 2

PAGE 10 of 2018. Pull the throttle lever to its fully open position and adjust the clearance of the oil pump. Adjust the positions of the locknut for

Page 3

PAGE 11 of 204. Replace the gasket with a new part. NOTE: Exhaust manifold bolt must be installed with Chamber assembly. No. 1 Bolt, No. 2 Bolt, No.

Page 4

9. Install the exhaust cover. Tighten the 3 bolts to the specifi ed torque.Exhaust cover retaining bolt:12 Nm (1.2 kgf-m, 8.7 ft-lb)Loctite® 24210. Ti

Page 5

VX1100Refer to the VX1100 Service Manual (LIT-18616-02-91), if necessary, when performing these procedures.1. Remove the seat and disconnect the batt

Page 6

6. Remove the grommet from the steering column, and pull the throttle cable inboard. NOTE: Do not reuse the grommet that has been removed.7. Replac

Page 7 - PAGE 7 of 20

10. Route the throttle cable and the lead for the handlebar switch assembly through the cutout in the new grommet, which is included in the kit. Then,

Page 8 - PAGE 8 of 20

12. Connect the cable end to the throttle lever. Then, adjust the throttle lever free play.Throttle lever free play “A:”4~7 mm (0.16~0.28 in) After ad

Page 9 - PAGE 9 of 20

13. Install the pad.NOTE: Before installing the long pad a, cut off 57.8mm (2.3 in) from its lower end, thus setting its overall length to 139.4mm (5.

Page 10 - PAGE 10 of 20

PAGE 18 of 20When the modifi cation is complete, put a black circle with permanent marker under the Primary ID label which will make it easy to identif

Page 11 - PAGE 11 of 20

PAGE 19 of 20The owner of each warranty-registered unit will receive a letter announcing this campaign. The letter has a label which includes the Prim

Page 12 - PAGE 12 of 20

Sold Units: Modify all watercraft in the affected range. Before modifying a unit, check to be sure it has not already been performed. See “Identifica

Page 13 - CAUTION:

PAGE 20 of 20Dear Yamaha WaveRunner® Owner:Yamaha Motor Corporation, U.S.A. has determined that a possible defect which relates to safety may exist in

Page 14

Exhaust System Removal1. Remove the seat and disconnect the battery.2. Remove all the spark plug caps.3. Disconnect the exhaust temperature sensor

Page 15 - PAGE 15 of 20

8. Remove the cooling water pipe from below the outer exhaust joint and loosen the 2 screw clamp.9. Slide the outer exhaust joint forward. Then, loo

Page 16 - PAGE 16 of 20

PAGE 5 of 2013. Remove the exhaust chamber assembly as shown in the illustration.NOTE: To remove the bolt from the exhaust cham-ber assembly, use a so

Page 17 - PAGE 17 of 20

PAGE 6 of 203. Disconnect the engine temperature sensor cou-pler and remove the plastic tie at the top of the throttle body assembly.4. Loosen the 3

Page 18

PAGE 7 of 204. Remove the steering pad. 5. Disconnect the throttle cable from the throttle lever. 6. From the inside of the watercraft, remove the

Page 19 - PAGE 19 of 20

PAGE 8 of 209. Replace the throttle cable with the new throttle cable.NOTE: Identify the part by its part number. Previous: 60T5200 Ne

Page 20 - SAFETY RECALL NOTICE

PAGE 9 of 2014. Measure the installation length “A” of the throttle cable. Adjust it if this measurement is out of specifi cation. Apply grease to the

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