Yamaha FX140 User manual

WaveRunner
FX140
SERVICE GUIDE
90894-64630-60

WaveRunner FX140
SERVICE GUIDE
©2002 by Yamaha Motor Corporation, USA
1st Edition, January 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA

PREFACE
This Service Guide has been prepared to provide Yamaha dealers with information about a new
model (e.g., product concept, features, technical details).
The information contained in this guide is essential to Yamaha dealer service staff for their daily
customer service.
It is our hope that you will use this guide to train your dealer service staff about this model and that it
will help answer questions about this new model.
NOTE:
• The descriptions herein are based on the information officially announced by Yamaha Motor Com-
pany Limited as of the end of December 2001.
• For detailed service information, refer to the appropriate service manual.

CONTENTS
OUTLINE OF FEATURES .........................................................................................1
FEATURES AND BENEFITS ....................................................................................2
POWER UNIT......................................................................................................2
CYLINDER HEAD.............................................................................................3
PISTON AND CONNECTING ROD ........................................................................4
CRANKCASE ..................................................................................................5
INTAKE SYSTEM .............................................................................................6
EXHAUST SYSTEM ..........................................................................................7
IN TANK FUEL PUMP MODULE ...........................................................................8
ENGINE OIL PUMP ..........................................................................................9
REDUCTION GEAR ........................................................................................10
JET PUMP.........................................................................................................11
HULL ................................................................................................................12
YAMAHA SOUND SUPPRESSION SYSTEM (YSSS)................................................13
DECK................................................................................................................14
LARGE CAPACITY STORAGE COMPARTMENTS ..................................................14
NEWLY DESIGNED MULTIFUNCTION METER ......................................................15
ELECTRICAL SYSTEM......................................................................................16
YAMAHA DIAGNOSTIC SYSTEM (YDIS) ..............................................................16
ELECTRICAL BILGE PUMP ..............................................................................16
SLANT DETECTION SWITCH............................................................................17
TECHNICAL TIPS ...................................................................................................18
ENGINE CONTROL ...........................................................................................18
ENGINE CONTROL MODE ...............................................................................20
FUEL INJECTION CONTROL.............................................................................23
IGNITION CONTROL .........................................................................................24
IGNITION COIL LOCK CONTROL .......................................................................24
WARNING CONTROL........................................................................................25
Overheat warning control ..................................................................................25
Oil pressure warning control...............................................................................25
Slant detection control......................................................................................25
FAIL-SAFE FUNCTION TABLE...........................................................................26
COOLING SYSTEM ...........................................................................................27
LUBRICATION SYSTEM ....................................................................................28
SERVICE INFORMATION.......................................................................................29
PERIODIC SERVICE .........................................................................................29
Trolling speed check and adjustment ....................................................................29
Steering cable inspection and adjustment ..............................................................30
QSTS cable inspection and adjustment .................................................................31
Shift cable inspection and adjustment ...................................................................32
Engine oil inspection........................................................................................33

SPECIFICATIONS...................................................................................................36
GENERAL SPECIFICATIONS ............................................................................36
MAINTENANCE SPECIFICATIONS ....................................................................38
ENGINE ......................................................................................................38
JET PUMP UNIT ............................................................................................41
HULL AND HOOD ..........................................................................................41
ELECTRICAL ................................................................................................42
TIGHTENING TORQUES ...................................................................................44
SPECIFIED TORQUES ....................................................................................44
GENERAL TORQUE .......................................................................................52
CABLE AND HOSE ROUTING............................................................................53
WIRING DIAGRAM..................................................................................................60

1
OUTLINE OF FEATURES
Fig. 1
The FX140 watercraft features:
•High-performance, 4-stroke, 4-cylinder engine (total displacement: 998 cc [60.9 cu. in.], maxi-
mum output: 103 kW [140 PS] at 10,000 r/min) with electronic fuel injection
•Low-pollution and low-noise engine conforming to 2006 U.S. Environmental Protection Agency
(EPA) regulations
•Large hull to provide nimble handling and stability
Large capacity front
storage compartment:
75 L (19.8 gal)
Large bow gunwale
Newly designed V-shaped hull
with foam floatation
Lightweight, compact, high-power, high-
reliability 4-stroke engine
Large sponsons
Five-position QSTS
Multifunction LCD meter
Mechanical and electrical
bilge pump
Big jet pump with large stainless
steel impeller and water strainer
High efficiency
reverse gate
Five-position adjustable tilt steering
Large fuel tank: 70 L (18.5 gal)
Lid with damping mechanism, beverage holder,
and large capacity glove compartment: 10 L (2.6 gal)

2
FEATURES AND BENEFITS
POWER UNIT
The MR-1 engine is a newly developed 4-stroke, in-line 4-cylinder, DOHC, 20-valve engine.
Based on the YZF-R1 engine, the optimum engine for watercraft has been designed to realize high
performance, compactness, lightweight, and low noise.
With electronic fuel injection, this engine meets 2006 U.S. Environmental Protection Agency (EPA)
emission regulations and is considerate to the environment.
The MR-1 engine employs a dry sump lubrication system. As a result, the oil pan is compact and the
overall height of the engine is low.
Fig. 2

3
CYLINDER HEAD
The cylinder head is based on the YZF-R1 for a compact design.
DOHC with 5 valves (intake: 3, exhaust: 2) per cylinder accomplishes a high combustion ratio and
high performance.
A timing chain drives the intake and exhaust camshafts and a timing chain tensioner provides the
optimum tension of the timing chain at all times. As a result, the camshafts open and close the
valves with optimum timing.
A cam position sensor is installed to the cylinder head cover of cylinder #4 to distinguish each cylin-
der and to control the engine more precisely.
Fig. 3

4
PISTON AND CONNECTING ROD
The pistons, piston pins, and connecting rods have been made lightweight to reduce reciprocating
mass for high performance.
The shape of the piston has been exclusively developed for watercraft.
Both ends of the piston pin are tapered to make the piston pin lightweight.
Fig. 4

5
CRANKCASE
Like the YZF-R1, the cylinder block and upper crankcase are cast in one piece.
Integral casting reinforces the crankcase and makes it compact and lightweight.
The crankcase body is aluminum, however, the cylinder sleeves are cast with cast iron.
Fig. 5

6
INTAKE SYSTEM
This intake system is equipped with four independent throttle bodies and injectors.
The intake system supplies the optimum air-fuel mixture to each cylinder to obtain high performance
and driveability.
A large air cleaner box and air filter allow large volumes of clean air intake with low noise.
A throttle position sensor, an intake air pressure sensor, and an intake air temperature sensor are
installed to the throttle bodies. Signals transmitted from these sensors help to control the optimum
fuel injection.
Fig. 6

7
EXHAUST SYSTEM
Four exhaust pipes of equal length are connected to each cylinder and are combined midway to
form a single exhaust pipe. This pipe is called a “collecting pipe”and it contributes to high perfor-
mance.
In addition, the exhaust pipes are the same length as those of the YZF-R1.
All the exhaust pipes utilize a double-pipe construction.
Cooling water passes around the exhaust pipes to cool the pipes and to prevent heat from transmit-
ting to surrounding areas.
Fig. 7

8
IN TANK FUEL PUMP MODULE
A fuel pump is integrated in the fuel tank, which is the same type system used in automobiles.
A fuel sender is installed to the side of the pump module.
A pressure regulator at the fuel pump outlet control pressure to the fuel line.
Remaining fuel returns to the bottom of the fuel pump, and then reenter the fuel pump inlet nearby.
With the suction generated at this time, fuel in the fuel tank is fed into the fuel pump module. As a
result, fuel is supplied to the fuel pump inlet without interruption for reliable fuel pressure.
Fig. 8
Delivery pipe
Fuel tank
Fuel line
Engine
Injector
Return
Fuel pump
module
Pressure
regulator
To fuel pump
From pressure
regulator
From fuel tank
Fuel pump
module
Float
Fuel sender
Fuel line
Fuel sender
connector
Fuel pump connector
Pressure
regulator
Fuel pump

9
ENGINE OIL PUMP
Because the MR-1 engine employs a dry sump lubrication system, it is equipped with two oil pumps:
a scavenge oil pump and a feed oil pump.
The scavenge oil pump extracts oil from the engine and sends it to the oil tank.
The feed oil pump sends oil from the oil tank to the engine.
In addition, the same axle drives both oil pumps.
Cooling water circulates around the oil tank to cool the oil.
Fig. 9

10
REDUCTION GEAR
Because the maximum engine speed of the MR-1 engine is high, the impeller would over rotate.
The reduction gear reduces the engine speed until the maximum speed of the impeller is in an effi-
cient range.
The reduction ratio is 1.47:1.
Fig. 10

11
JET PUMP
A large jet pump with a 155 mm (6.1 in) diameter, three-blade, stainless steel impeller provides
more power and thrust.
With the jet pump mounted on the vertical plane of the hull, servicing is made easier.
A cooling water strainer is incorporated into the jet pump, which prevents the cooling water pas-
sages from clogging.
The jet thrust nozzle has a 5°trimmed up angle, which allows higher straight line cruising perfor-
mance.
A newly designed reverse gate raises efficiency of water flow in the reverse position for easier han-
dling when operating the watercraft in reverse.
Fig. 11

12
HULL
A newly designed V-shaped hull provides excellent maneuverability and stability.
Foam filling in the inner hull reinforces the hull and also serves as a floatation.
Fig. 12

13
YAMAHA SOUND SUPPRESSION SYSTEM (YSSS)
To reduce noise, the sound suppression system is installed to the intake and exhaust systems.
To reduce intake noise, intake boxes are equipped near the hood.
To reduce exhaust noise, a resonator is equipped to the exhaust system.
Fig. 13