Yamaha FX140 User manual

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

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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.

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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

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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
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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.