Yamaha FX140 User manual

WaveRunner
FX140
F1B-28197-1E-11
*LIT186160238*
LIT-18616-02-38
SERVICE MANUAL

E
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
A10001-0*
WaveRunner FX140
SERVICE MANUAL
©2002 by Yamaha Motor Corporation, USA
1st Edition, February 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-38

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HOW TO USE THIS MANUAL
MANUAL FORMAT
All of the procedures in this manual are organized in a sequential, step-by-step format. The informa-
tion has been compiled to provide the mechanic with an easy to read, handy reference that contains
comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
In this revised format, the condition of a faulty component will precede an arrow symbol and the
course of action required will follow the symbol, e.g.,
•Bearings
Pitting/scratches → Replace.
To assist you in finding your way through this manual, the section title and major heading is given at
the top of every page.
ILLUSTRATIONS
The illustrations within this service manual represent all of the designated models.
CROSS REFERENCES
The cross references have been kept to a minimum. Cross references will direct you to the appropri-
ate section or chapter.

E
IMPORTANT INFORMATION
In this Service Manual particularly important information is distinguished in the following ways.
The Safety Alert Symbol means ATTENTION! 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 repairing the watercraft.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the water-
craft.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
IMPORTANT:
This part has been subjected to change of specification during production.

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HOW TO USE THIS MANUAL
1To help identify parts and clarify procedure steps, there are exploded diagrams at the start of
each removal and disassembly section.
2Numbers are given in the order of the jobs in the exploded diagram.
3Symbols indicate parts to be lubricated or replaced (see “SYMBOLS”).
4A job instruction chart accompanies the exploded diagram, providing the order of jobs, names of
parts, notes in jobs, etc.
5Dimension figures and the number of parts, are provided for fasteners that require a tightening
torque.
Example:
Bolt or screw size : M10 (D) ×25 mm (L)
6Jobs requiring more information (such as special tools and technical data) are described
sequentially.
10 ×25 mm
D
L

E
A50001-1-4
SYMBOLS
Symbols 1to 9are designed as thumb-tabs
to indicate the content of a chapter.
1General Information
2Specifications
3Periodic Inspection and Adjustment
4Fuel System
5Power Unit
6Jet Pump Unit
7Electrical System
8Hull and Hood
9Trouble analysis
Symbols 0to Eindicate specific data:
0Special tool
ASpecified liquid
BSpecified engine speed
CSpecified torque
DSpecified measurement
ESpecified electrical value
[Resistance (Ω), Voltage (V), Electric current (A)]
Symbol Fto Hin an exploded diagram indi-
cate the grade of lubricant and the location of
lubrication point:
FApply YAMALUBE 4-stroke motor oil
GApply water resistant grease
(Yamaha grease A, Yamaha marine grease)
HApply molybdenum disulfide grease
Symbols Ito Nin an exploded diagram indi-
cate the grade of the sealing or locking agent,
and the location of the application point:
IApply Gasket Maker®
JApply Yamabond #4 (Yamaha bond number 4)
KApply LOCTITE®No. 271 (Red LOCTITE)
LApply LOCTITE®No. 242 (Blue LOCTITE)
MApply LOCTITE®No. 572
NApply silicone sealant
NOTE:
In this manual, the above symbols may not be
used in every case.
12
34
56
78
90
AB
CD
EF
GH
IJ
KL
MN
GEN
INFO SPEC
INSP
ADJ FUEL
POWR
JET
PUMP
–+
ELEC
HULL
HOOD
TRBL
ANLS
T
R
.
.
E
A M
GM
4
271
LT
242
LT
572
LT SS

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INDEX
GENERAL INFORMATION 1
GEN
INFO
SPECIFICATIONS 2
SPEC
PERIODIC INSPECTION AND
ADJUSTMENT 3
INSP
ADJ
FUEL SYSTEM 4
FUEL
POWER UNIT 5
POWR
JET PUMP UNIT 6
JET
PUMP
ELECTRICAL SYSTEM 7
ELEC
HULL AND HOOD 8
HULL
HOOD
TROUBLE ANALYSIS 9
TRBL
ANLS
–+
A30000-0

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GEN
INFO
1
2
3
4
5
6
7
8
9
CHAPTER 1
GENERAL INFORMATION
IDENTIFICATION NUMBERS .........................................................................1-1
PRIMARY l.D. NUMBER ...........................................................................1-1
ENGINE SERIAL NUMBER ......................................................................1-1
JET PUMP UNIT SERIAL NUMBER .........................................................1-1
HULL IDENTIFICATION NUMBER (H.l.N.)...............................................1-1
SAFETY WHILE WORKING......................................................................1-2
FIRE PREVENTION .................................................................................. 1-2
VENTILATION ...........................................................................................1-2
SELF-PROTECTION.................................................................................1-2
OILS, GREASES AND SEALING FLUIDS ................................................1-2
GOOD WORKING PRACTICES ...............................................................1-3
DISASSEMBLY AND ASSEMBLY ............................................................1-4
SPECIAL TOOLS ............................................................................................ 1-5
MEASURING.............................................................................................1-5
REMOVAL AND INSTALLATION..............................................................1-8

1-1
E
GEN
INFO IDENTIFICATION NUMBERS
A60700-0*
IDENTIFICATION NUMBERS
PRIMARY l.D. NUMBER
The primary l.D. number is stamped on a label
attached to the inside of the engine compart-
ment.
Starting primary l.D. number:
F1B: 800101
ENGINE SERIAL NUMBER
The engine serial number is stamped on a
label attached to the engine unit.
Starting serial number:
60E: 000101
JET PUMP UNIT SERIAL NUMBER
The jet pump unit serial number is stamped on
a label attached to the intermediate housing.
Starting serial number:
60E: 800058
HULL IDENTIFICATION NUMBER
(H.l.N.)
The H.l.N. is stamped on a plate attached to
the aft deck.

1-2
E
GEN
INFO SAFETY WHILE WORKING
SAFETY WHILE WORKING
The procedures given in this manual are those
recommended by Yamaha to be followed by
Yamaha dealers and their mechanics.
FIRE PREVENTION
Gasoline (petrol) is highly flammable.
Gasoline vapor is explosive if ignited.
Do not smoke while handling gasoline (petrol)
and keep it away from heat, sparks, and open
flames.
VENTILATION
Gasoline vapor is heavier than air and is
deadly if inhaled in large quantities. Engine
exhaust gases are harmful to breathe. When
test-running an engine indoors, maintain good
ventilation.
SELF-PROTECTION
Protect your eyes with suitable safety specta-
cles or safety goggles when grinding or doing
any operation which may cause particles to fly
off.
Protect hands and feet by wearing safety
gloves or protective shoes if appropriate to the
work you are doing.
OILS, GREASES AND SEALING
FLUIDS
Use only genuine Yamaha oils, greases, and
sealing fluids or those recommended by
Yamaha.

1-3
E
GEN
INFO SAFETY WHILE WORKING
Under normal conditions of use there should
be no hazards from the use of the lubricants
mentioned in this manual, but safety is all-
important, and by adopting good safety prac-
tises any risk is minimized. A summary of the
most important precautions is as follows:
1. While working, maintain good standards of
personal and industrial hygiene.
2. Clothing which has become contaminated
with lubricants should be changed as soon
as practicable and laundered before fur-
ther use.
3. Avoid skin contact with lubricants (e.g., do
not place a soiled rag in your pocket).
4. Hands and any other part of the body
which have been in contact with lubricants
or lubricant-contaminated clothing should
be thoroughly washed with hot water and
soap as soon as practicable.
5. To protect the skin, the application of a
suitable barrier cream to the hands before
working is recommended.
6. A supply of clean lint-free cloths should be
available for wiping purposes.
GOOD WORKING PRACTICES
1. The right tools
Use the recommended special tools to
protect parts from damage. Use the right
tool in the right manner –do not improvise.
2. Tightening torque
Follow the tightening torque instructions.
When tightening bolts, nuts and screws,
tighten the larger sizes first and tighten
inner-positioned fixings before outer-posi-
tioned ones.

1-4
E
GEN
INFO SAFETY WHILE WORKING
3. Non-reusable items
Always use new gaskets, packings, O-
rings, oil seals, split-pins, circlips, etc., on
reassembly.
DISASSEMBLY AND ASSEMBLY
1. Clean parts with compressed air when dis-
assembling.
2. Oil the contact surfaces of moving parts
during assembly.
3. After assembly, check that moving parts
operate normally.
4. Install bearings with the manufacturer’s
markings on the side exposed to view and
liberally oil the bearings.
CAUTION:
Do not spin bearings with compressed air
because this will damage their surfaces.
5. When installing oil seals, apply a light coat
of water-resistant grease to the outside
diameter.

1-5
E
GEN
INFO SPECIAL TOOLS
SPECIAL TOOLS
Using the correct special tools recommended
by Yamaha, will aid the work and enable accu-
rate assembly and tune-up. Improvisations
and using improper tools can damage the
equipment.
NOTE:
•For U.S.A. and Canada, use part numbers
starting with “J-”, “YB-”, “YM-”, “YS-”, “YU-”or
“YW-”.
•For other countries, use part numbers start-
ing with “90890-”.
MEASURING
1Dial gauge
P/N. YU-03097
90890-01252
2Dial gauge stand
P/N. 90890-06583
3Dial gauge needle
P/N. 90890-06584
4Dial gauge stand set
P/N. YW-06585
90890-06585
5Pocket tester
P/N. YU-03112
90890-03112
6Digital circuit tester
P/N. YU-34899-A
90890-03174
7Carburetor synchronizer
P/N. YU-08030
8Vacuum gauge
P/N. 90890-03094
Vacuum attachment
P/N. 90890-03060
9Test connector
P/N. YW-06862
90890-06862
0Fuel pressure gauge adapter
P/N. YW-06842
90890-06842
1
23
4
56
78
YU-03097 90890-01252
90890-06583 90890-06584
YW-06585
90890-06585
YU-03112
90890-03112
YU-34899-A
90890-03174
YU-08030 90890-03094 90890-03060
90
YW-06862
90890-06862
YW-06842
90890-06842

1-6
E
GEN
INFO SPECIAL TOOLS
AFuel pressure gauge
P/N. YB-06766
90890-06786
BCompression gauge extension
P/N. 90890-06582
CCylinder gauge set
P/N. YU-03017
90890-06759
DCompression gauge
P/N. YU-33223-1
90890-03160
EPeak voltage adapter
P/N. YU-39991
90890-03172
FSpark gap tester
P/N. YM-34487
90890-06754
GTest harness (2 pins)
P/N. YB-06792
90890-06792
HTest harness (3 pins)
P/N. YB-06791
90890-06791
ITest harness (3 pins)
P/N. YB-06770
90890-06770
JTest harness (6 pins)
P/N. YB-06790
90890-06790
KTest harness (3 pins)
P/N. YB-06793
90890-06793
LTest harness (3 pins)
P/N. YB-06777
90890-06777
A
BC
D
E
F
GH
IJ
YB-06766 90890-06786
90890-06582 YU-03017
90890-06759
YU-33223-1 90890-03160
YU-39991 90890-03172
YM-34487 90890-06754
YB-06792
90890-06792
YB-06791
90890-06791
YB-06770
90890-06770
YB-06790
90890-06790
YB-06793
90890-06793
YB-06777
90890-06777
KL

1-7
E
GEN
INFO SPECIAL TOOLS
MTest harness (3 pins)
P/N. YB-06769
90890-06769
NVacuum/pressure pump gauge set
P/N. YB-35956-A
90890-06756
OYamaha diagnostic system for Watercraft
P/N. 60E-85300-01
PYamaha diagnostic system for Watercraft
(CD-ROM only)
P/N. 60E-WS853-00
M
P
N
YB-06769
90890-06769
YB-35956-A
90890-06756
60E-WS853-00
O60E-85300-01
YAMAHA DIAGNOSTIC SYSTEM
for Watercraft
INSTALLATION MANUAL
60E-2819K-10

1-8
E
GEN
INFO SPECIAL TOOLS
REMOVAL AND INSTALLATION
1Oil filter wrench
P/N. YU-38411
90890-01426
2Coupler wrench
P/N. YW-06551
90890-06551
3Sheave holder
P/N. YS-01880-A
90890-01701
4Rotor puller
P/N. YM-01082
90890-01080
5Rotor holder
P/N. YU-01235
90890-01235
6Valve spring compressor
P/N. YM-04019
90890-04019
7Valve spring compressor attachment
P/N. YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
8Valve guide remover
P/N. YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
9Valve guide installer
P/N. YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
0Valve guide reamer
P/N. YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)
12
34
56
78
90
YU-38411
90890-01426
YW-06551
90890-06551
YS-01880-A
90890-01701
YM-01082
90890-01080
YU-01235
90890-01235
YM-04019
90890-04019
YM-4114 (ø19 mm)
90890-04114 (ø19 mm)
YM-4108 (ø22 mm)
90890-04108 (ø22 mm)
YM-04111 (ø4.0 mm)
90890-04111 (ø4.0 mm)
YM-04116 (ø4.5 mm)
90890-04116 (ø4.5 mm)
YM-04112 (ø4.0 mm)
90890-04112 (ø4.0 mm)
YM-04117 (ø4.5 mm)
90890-04117 (ø4.5 mm)
YM-04113 (ø4.0 mm)
90890-04113 (ø4.0 mm)
YM-04118 (ø4.5 mm)
90890-04118 (ø4.5 mm)

1-9
E
GEN
INFO SPECIAL TOOLS
AValve seat cutter
Intake
P/N. 90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
Exhaust
P/N. 90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
BValve seat cutter holder
P/N. 90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
CValve seat cutter set
P/N. YM-91043-C
DPiston ring compressor
P/N. YM-08037
90890-05158
EDrive shaft holder (impeller)
P/N. YB-06151
90890-06519
FSlide hammer set (jet pump bearing)
P/N. YB-06096
GStopper guide plate (jet pump bearing)
P/N. 90890-06501
HBearing puller (jet pump bearing)
P/N. 90890-06535
IBearing puller claw 1 (jet pump bearing)
P/N. 90890-06536
JStopper guide stand (jet pump bearing)
P/N. 90890-06538
KDrive rod L3 (jet pump bearing)
P/N. 90890-06652
LNeedle bearing attachment
(jet pump bearing and oil seal)
P/N. YB-06112, YB-06196
90890-06614, 90890-06653
90890-06315 (60°)
90890-06312 (45°)
90890-06328 (30°)
YM-08037 90890-05158
YB-06096
90890-06501 90890-06535
90890-06536 90890-06538
90890-06652 YB-06112 90890-06614
B
D
EF
GH
IJ
KL
90890-06811 (ø4.0 mm)
90890-06812 (ø4.5 mm)
YB-06196 90890-06653
YB-06151
90890-06519
A90890-06813 (60°)
90890-06814 (45°)
90890-06815 (30°)
YM-91043-C
C

1-10
E
GEN
INFO SPECIAL TOOLS
MBall bearing attachment
(jet pump oil seal)
P/N. YB-06085
90890-06634
NDriver rod
(intermediate shaft and jet pump)
P/N. YB-06071
90890-06606
OBearing inner/outer race attachment
(jet pump bearing)
P/N. YB-34474
PShaft holder (intermediate shaft)
P/N. YB-06552
90890-06552
QBearing outer race attachment
(intermediate shaft)
P/N. YB-06156
90890-06626
YB-06071 90890-06606 YB-34474
NO
YB-06552
90890-06552
YB-06156 90890-06626
PQ
YB-06085 90890-06634
M