Yamaha WaveRunner FX140 Service Manual
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Yamaha WaveRunner FX140 Service Manual

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  • Page 3 WaveRunner FX140 SERVICE GUIDE 90894-64630-60...
  • Page 4 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...
  • Page 5 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.

  • Page 6: Table Of Contents

    IN TANK FUEL PUMP MODULE ..................9 ENGINE OIL PUMP ..................10 REDUCTION GEAR ......................11 JET PUMP ........................12 HULL ..........13 YAMAHA SOUND SUPPRESSION SYSTEM (YSSS) ........................14 DECK ..........14 LARGE CAPACITY STORAGE COMPARTMENTS ............15 NEWLY DESIGNED MULTIFUNCTION METER ..................16 ELECTRICAL SYSTEM ..............16 YAMAHA DIAGNOSTIC SYSTEM (YDIS) ................16...
  • Page 7 SPECIFICATIONS....................36 ................36 GENERAL SPECIFICATIONS ..............38 MAINTENANCE SPECIFICATIONS ......................38 ENGINE ....................41 JET PUMP UNIT ..................41 HULL AND HOOD ....................42 ELECTRICAL ...................44 TIGHTENING TORQUES ..................44 SPECIFIED TORQUES ..................52 GENERAL TORQUE ................53 CABLE AND HOSE ROUTING WIRING DIAGRAM....................60...

  • Page 8: Outline Of Features

    OUTLINE OF FEATURES 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 •...

  • Page 9: Features And Benefits

    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.

  • Page 10: Cylinder Head

    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.

  • Page 11: Piston And Connecting Rod

    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.

  • Page 12: Crankcase

    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.

  • Page 13: Intake System

    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.

  • Page 14: Exhaust System

    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.

  • Page 15: In Tank Fuel Pump Module

    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.

  • Page 16: Engine Oil Pump

    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.

  • Page 17: Reduction Gear

    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.

  • Page 18: Jet Pump

    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.

  • Page 19: Hull

    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...

  • Page 20: Yamaha Sound Suppression System (Ysss)

    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.

  • Page 21: Deck

    DECK LARGE CAPACITY STORAGE COMPARTMENTS The deck of the FX140 is equipped with three storage compartments. Front storage compartment: 75 L (19.8 gal) Glove compartment: 10 L (2.6 gal) Seat storage compartment: 15 L (3.6 gal) About 100 L (26 gal) of storage space provide adequate storage. The glove compartment is equipped with a removable beverage holder.

  • Page 22: Newly Designed Multifunction Meter

    NEWLY DESIGNED MULTIFUNCTION METER A newly developed multifunction meter provides an easy-to-read and easy-to-operate design. The meter displays speed, engine speed (r/min), fuel level, battery voltage, hours of engine opera- tion, oil pressure warning, fuel warning, overheat warning, and check engine warning. The speedometer display can be switched between kilometers and miles.

  • Page 23: Electrical System

    ELECTRICAL SYSTEM YAMAHA DIAGNOSTIC SYSTEM (YDIS) The Yamaha Diagnostic System (YDIS), which has already been introduced in the outboard motors market, is introduced to the watercraft market for the first time. By connecting a computer to the ECM, quick detection of malfunctions and parts that are difficult to check such as the fuel injectors and fuel pump module can be checked easily.

  • Page 24: Slant Detection Switch

    SLANT DETECTION SWITCH A slant detection switch is installed inside the electric box. If the watercraft overturns 180°, the ring inside the slant detection switch moves to turn the switch When the watercraft is overturned, the slant detection switch turns on and the ECM stops the engine to protect the engine.

  • Page 25: Technical Tips

    TECHNICAL TIPS ENGINE CONTROL The engine control module (ECM) controls ignition timing and fuel injection with information received from six sensors and four switches installed on the engine and on the basis of the 3D map saved in the ECM. The sensors installed on the engine include the cam position sensor, temperature sensor, pulser coil, throttle position sensor, intake air temperature sensor, and intake air pressure sensor.
  • Page 26 Two pulser coils are used: one for cylinders #1 and #4 and one for cylinders #2 and #3. When the projection on the flywheel magnet passes over the pulser coil, the sensor transmits a sig- nal to detect the standard position (BTDC 70°) and initial timing (BTDC 10°) of each cylinder. Pulser coil Pulser coil for cylinders...

  • Page 27: Engine Control Mode

    ENGINE CONTROL MODE The ECM changes the control modes mentioned below for optimum control according to the condi- tions of the engine. Stopping mode If engine speed is less than 50 r/min, fuel injection and ignition are stopped. Starting mode If engine speed is less than 500 r/min, fuel injection and ignition are controlled.
  • Page 28 Fully closed cutoff If engine speed exceeds 6,000 r/min and the throttle angle is near fully closed (below 2.4°), fuel injection is stopped. Engine stop cutoff • If the emergency stop switch is on. • If the slant detection switch is on (i.e., engine speed is less than 3,000 r/min). •...
  • Page 29 Normal mode Except for the controls mentioned earlier, fuel injection is normal sequential injection. Basic ignition timing and each correction value control ignition timing. BTDC 70˚ BTDC 70˚ BTDC 70˚ BTDC 70˚ BTDC 70˚ BTDC 70˚ BTDC 70˚ BTDC 70˚ Injector #1 Injection Stopped...

  • Page 30: Fuel Injection Control

    FUEL INJECTION CONTROL Basic fuel injection volume uses two control systems: The speed density system (D-Jetronic) 3D map, which is calculated from the intake air pressure and engine speed, and the speed throttle speed system (Alpha-N) 3D map, which is calculated from the throttle opening and engine speed. The D-Jetronic and Alpha-N 3D map activity ratio changes according to the throttle opening angle.

  • Page 31: Ignition Control

    IGNITION CONTROL The 3D map of the throttle opening angle and engine speed determines basic ignition timing. Basic ignition timing and each correction value determine actual ignition timing. The ignition range is between 45° BTDC and 10° ATDC. The starting time of ignition is controlled on the basis of 70° BTDC and 10° BTDC of each cylinder. BTDC 70˚CA BTDC 10˚CA BTDC 70˚CA...

  • Page 32: Warning Control

    WARNING CONTROL Overheat warning control The overheat warning control is activated under the following conditions. • If the engine temperature increases from 75 °C (167 °F) to 90 °C (194 °F) within 10 seconds or if the engine temperature exceeds 130 °C (266 °F). •...

  • Page 33: Fail-Safe Function Table

    FAIL-SAFE FUNCTION TABLE Symptom Ignition control Fuel injection control Backup • Only the cylinders inputting signals All cylinders inject simultaneously Incorrect pulser coil ignite initially in Substitute with based on cylinder receiving normal signal the starting mode remaining sensors signal •...

  • Page 34: Cooling System

    COOLING SYSTEM For efficient and excellent cooling, this watercraft is equipped with multiple cooling water passages. Cooling water, which is drawn in by the jet pump, flows to the engine, oil tank, and exhaust pipes. Cooling water, which cools the engine oil in the oil tank, enters the exhaust joint. A pressure control valve limits cooling water pressure that enters the engine.

  • Page 35: Lubrication System

    LUBRICATION SYSTEM The MR-1 engine employs a dry sump lubrication system. A scavenge pump is used to collect oil from the engine and deliver it to the oil tank. A feed oil pump is used to send oil from the oil tank to the various engine components. Cylinder head cover Exhaust camshaft Cylinder head...

  • Page 36: Service Information

    • Start the engine and allow it to warm up for a 15 minutes. • Check the engine trolling speed using the tachometer of the multifunction meter or using the Yamaha Diagnostic System. 2. Adjust: • Trolling speed Adjustment steps: •...

  • Page 37: Steering Cable Inspection And Adjustment

    Steering cable inspection and adjustment 1. Check: • Jet thrust nozzle clearance a, b Difference → Adjust. Checking steps: • Set the control grip in the neutral position. • Turn the handlebar lock to lock. • Measure the clearances a and b. •...

  • Page 38: Qsts Cable Inspection And Adjustment

    QSTS cable inspection and adjustment 1. Measure: • Jet thrust nozzle set length a, b Difference → Adjust. Measurement steps: • Set the control grip in the neutral position. • Set the jet thrust nozzle in the center position. • Measure the jet thrust nozzle set length a and b.

  • Page 39: Shift Cable Inspection And Adjustment

    Shift cable inspection and adjustment 1. Check: • Reverse gate stopper lever position Incorrect → Adjust. Checking steps: • Set the shift lever to the reverse position. • Check that the reverse gate 1 contacts the stopper 2 on the bracket and the lever 3 contacts the reverse gate.

  • Page 40: Engine Oil Inspection

    Engine oil inspection 1. Remove: • Oil filler cap 1 2. Fill: • Oil tank (with the specified amount of the recom- mended engine oil) Recommended oil: SAE 10W-30 API SE, SF, SG, SH, SJ Oil quantity: 2.0 L (2.1 US qt, 1.8 Imp qt) CAUTION: When starting the engine make sure the dipstick is securely fitted into the oil tank.
  • Page 41 • Remove the oil filler cap 1 and check for oil on the dipstick 2. • If there is no oil on the dipstick, pour enough oil so that the tip of the dipstick comes into contact with the oil, and then install the filler cap.
  • Page 42 • If the engine oil is below the minimum level mark a, add sufficient oil of the rec- ommended type to raise it to the correct level. • If the engine oil is above the maximum level mark b, extract sufficient oil using an oil changer to lower it to the correct level.

  • Page 43: Specifications

    SPECIFICATIONS GENERAL SPECIFICATIONS Model Item Unit FX140 Model code Hull Engine/jet Dimensions Length mm (in) 3,340 (131.5) Width mm (in) 1,230 (48.4) Height mm (in) 1,160 (45.7) Dry weight kg (lb) 362 (798) Maximum capacity Person/kg (lb) 3/240 (530) Performance Maximum output kW (PS) @ r/min 103 (140) @ 10,000...
  • Page 44 Model Item Unit FX140 Fuel and oil Fuel type Regular unleaded gasoline Minimum fuel rating PON* RON* Fuel tank capacity l (US gal, 70 (18.5, 15.4) Imp gal) Engine oil type 4-stroke motor oil Engine oil grade SE, SF, SG, SH, or SJ 10W-30 Engine oil capacity l (US qt, Imp qt)

  • Page 45: Maintenance Specifications

    MAINTENANCE SPECIFICATIONS ENGINE Model Item Unit FX140 Cylinder head Warpage limit mm (in) 0.1 (0.004) Compression pressure 1,350 (13.5, 192) (kg/cm , psi) Cylinder Bore size mm (in) 74.060–74.075 (2.9157–2.9163) Taper limit mm (in) 0.08 (0.003) Out-of-round limit mm (in) 0.05 (0.002) Wear limit mm (in)
  • Page 46 Model Item Unit FX140 Valve seat width C Intake mm (in) 0.9–1.1 (0.0354–0.0433) Exhaust mm (in) 0.9–1.1 (0.0354–0.0433) Valve margin thickness D Intake mm (in) 0.5–0.9 (0.0197–0.0354) Exhaust mm (in) 0.5–0.9 (0.0197–0.0354) Valve stem diameter Intake mm (in) 3.975–3.990 (0.1565–0.1571) Exhaust mm (in) 4.460–4.475 (0.1756–0.1762)
  • Page 47 Model Item Unit FX140 Piston ring Top ring Type Barrel Dimension (B × T) 0.90 × 2.75 (0.04 × 0.11) mm (in) End gap (installed) mm (in) 0.19–0.31 (0.0075–0.0122) Ring groove clearance mm (in) 0.030–0.065 (0.0012–0.0026) 2nd ring Type Taper 0.80 ×...

  • Page 48: Jet Pump Unit

    Model Item Unit FX140 Fuel pump Pump type Electrical Output pressure kPa (psi) 320.8–327.2 (45.6–46.5) Oil filter Oil filter type Cartridge type Oil pump Oil pump type Trochoid Rotor tip clearance mm (in) 0.09–0.15 (0.004–0.006) Oil pump housing clearance Rotor (feed pump) mm (in) 0.09–0.17 (0.0035–0.0067) Rotor (scavenge pump)

  • Page 49: Electrical

    ELECTRICAL Model Item Unit FX140 Battery Type Fluid Capacity V/Ah 12/19 ECM unit (B/R – Ground for cylinder #1 and #4) (B/W – Ground for cylinder #2 and #3) Output peak voltage lower limit @cranking @2,000 r/min @3,500 r/min Stator Pulser coil (W –...
  • Page 50 Model Item Unit FX140 Rectifier/regulator (R – B) Output peak voltage (loaded) @3,500 r/min 14.5 Starter motor Type Constant mesh Output Rating Seconds Brush length mm (in) 12.5 (0.49) Wear limit mm (in) 6.5 (0.26) Commutator undercut mm (in) 0.7 (0.03) Limit mm (in) 0.2 (0.01)

  • Page 51: Tightening Torques

    TIGHTENING TORQUES SPECIFIED TORQUES Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Fuel system 0.32 Retainer/fuel pump — assembly – fuel tank 0.64 Fuel filler neck/rubber seal – deck — 0.59 Fuel tank belt/fuel tank – hull Bolt Air filter case cover –...
  • Page 52 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Engine Engine unit – engine mount Bolt Oil filter — — Coupling cover Bolt 0.79 Thermoswitch (exhaust) – Bolt 0.76 exhaust pipe 3 Outer exhaust joint clamp – 0.44 exhaust pipe 3/exhaust —...
  • Page 53 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Exhaust manifold 1 – Bolt cylinder head Exhaust manifold 2 – Bolt cylinder head 0.37 Water jacket – oil tank Bolt 0.76 Oil tank stay/reduction 0.37 drive gear case –...
  • Page 54 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb 0.37 Bolt 0.76 Reduction drive gear case – crankcase Bolt Holder (relief valve) – Bolt reduction drive gear case Bearing housing – Bolt reduction drive gear case Battery negative lead –...
  • Page 55 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Engine temperature sensor – — — crankcase Thermoswitch (engine) – Bolt 0.76 crankcase Oil pressure switch — — 0.84 Anode cover – anode Bolt Anode cover – cylinder head Bolt Oil pan –...
  • Page 56 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Drive shaft nut – drive shaft — Impeller (left-hand threads) – Impeller drive shaft Transom plate – hull — Bilge strainer holder – bulkhead Screw 0.37 Intermediate housing –...
  • Page 57 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Steering cable bracket – — 0.54 steering cable holder Steering cable bracket – deck — 0.54 Speed sensor lead grommet – hull — 0.59 Front hood assembly – deck —...
  • Page 58 Tightening torque Thread Part to tightened Part name Q’ty Remarks size N•m kgf•m ft•lb Electrical Battery box – hull Bolt 0.54 Battery box/spacer – hull Bolt 0.54 Electrical box – bulk head Bolt Tapping Terminal cover – electrical box 0.49 screw Tapping Cover –...

  • Page 59: General Torque

    GENERAL TORQUE General torque This chart specifies tightening torques for stan- Nut A Bolt B specifications dard fasteners with a standard ISO thread N•m kgf•m ft•lb pitch. Tightening torque specifications for spe- 8 mm cial components or assemblies are provided in 10 mm applicable sections of this manual.

  • Page 60: Cable And Hose Routing

    CABLE AND HOSE ROUTING DOWN DOWN 1 Fuel tank breather hose A Battery positive lead 2 QSTS cable B Battery 3 Steering cable C Throttle cable 4 Shift cable D Fuel hose 5 Electrical box lead E Cooling water pilot outlet hose 6 Speed sensor lead F Handlebar switch lead 7 Cooling water pilot outlet...
  • Page 61 0 1 C D MAIN S P A R E 1 Throttle cable A Shift cable 2 Handlebar switch lead B Steering cable 3 QSTS cable C Electrical box lead 4 Buzzer lead D Cooling water pilot outlet hose 5 Fuel tank breather hose E Battery negative lead 6 Ignition coil lead F Battery breather hose...
  • Page 62 È 1 Cooling water hose (cooling water inlet) A Battery positive lead 2 Bilge hose 1 B Speed sensor lead 3 Electric bilge pump C Electric bilge pump lead 4 Bilge hose 4 D Bilge strainer 5 Cooling water hose (from thermostat) E Battery negative lead 6 Bilge hose 3 F Steering cable...
  • Page 63 Ê Î È Ë Ë Ë Ë Í Ì Ï Õ Ö × É Ð Ì Ø Ê Ó Ð Ë Ð Ò Ì Ñ Ô Ò 1 Thermostat Ì To install the hose, align the white paint mark on 2 Pressure control valve the cooling water hose with the projection of 3 Cooling water hose (cooling water inlet)
  • Page 64 Ê Î È Ë Ë Ë Ë Í Ì Ï Õ Ö × É Ð Ì Ø Ê Ó Ð Ë Ð Ò Ì Ñ Ô Ò Ó To install the hose, align the white paint mark on Ö Bundle the cooling water pilot outlet hose and the cooling water hose with the parting line on the cooling water hoses, pass a plastic locking the hose joint.
  • Page 65 Ë É È Ê 1 Wire harness A Oil pressure switch lead 2 Ground lead 3 Wire harness coupler È To electrical box 4 Cam position sensor coupler É To cam position sensor 5 Thermoswitch (exhaust) Ê To oil pressure switch 6 Thermoswitch (exhaust) coupler Ë...
  • Page 66 Ê É È Í Ë Ì Î Ï 1 Engine temperature sensor coupler È To generator 2 Lighting coil coupler É To engine temperature sensor 3 Pulser coil coupler Ê To thermoswitch (engine) 4 Thermoswitch (engine) coupler Ë To thermoswitch (engine) coupler 5 Thermoswitch (engine) Ì...

  • Page 67: Wiring Diagram

    WIRING DIAGRAM FX140 1 Fuse (20A) Color code 2 Fuse (3A) : Black 3 Starter relay : Brown 4 Slant detection switch : Green 5 Main and fuel pump relay : Blue 6 ECM : Orange 7 Rectifier Regulator : Pink 8 Cam position sensor : Red 9 Thermoswitch (exhaust)
  • Page 70 YAMAHA MOTOR CORPORATION, USA Printed in USA × 1 CR Jan. 2002 – 90894-64630-60 (FX1000-A) Printed on recycled paper...

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