Part Number: F1B-U2103-00-00
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Yamaha FX140-2002, size: 9.4 MB
Yamaha Waverunner FX 140 (2002)
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Engine Removal / Installation
Yamaha FX140 / HO
2.2 Wiggle & remove the flame arrestors by loosening the 4 flame arrestor bolts. Remove the two allen bolts on each throttle body. Remove the three retaining screws from the airbox base and raise it.
2.4 Loosen the outer then inner hose clamps on the pipe and separate. Remove the cooling fitting.
1.1 (Above) Remove the two retaining straps, disconnect the battery and remove it from the hull. Disconnect the negative (black) cable first, then the positive (red).
2.3 Disconnect the hose and wire connector under the base to remove it.
2.5 Remove the PTO shroud.
Removal From Hull
2.1 Remove the center screws and outer retaining clips from the airbox cover and remove.
2006 Short Block Technologies
2.6 Remove the relay cover on the electrical box and disconnect the starter lead.
2.8 Using an engine hoist, raise the engine to access the remaining hoses and connections.
3.2 Remove the rail connections and cooling lines from the block.
3.3 Remove the exhaust collector.
3.1 Remove the coil pack and ignition wires from the block.
2.7 Disconnect the wiring harness connections. Remove motor mount bolts.
3.4 Remove the exhaust manifold and knock sensor. 3.7 Remove the head bracket. 3.9 Loosen the clamps and remove the intake adaptors.
3.5 Remove the oil line and head sensor.
3.10 Pry the rubber plug back and remove the retaining bolt and tube on the head.
3.8 Remove the gear reduction assembly.
3.6 Remove the two retaining bolts on top and 4 on the bottom for the oil tank and remove it from the block.
3.11 Remove the case sensor. 3.14 Remove the starter.
3.12 Remove the case bracket.
3.13 Remove the flywheel and bendix gear assembly.
Engine Installation Notes
It is SBTs recommendation that all paper gaskets be treated with Loctite HighTack Gasket Sealer prior to installation. Read and follow all instructions on the product canister to insure good gasket sealing on your new engine.
It is SBTs recommendation that all electrical connections be sanded, cleaned and secured during the assembly process. It is a common problem to not have solid connections due to corrosion, paint, poor wire condition, etc.
Disclaimer Special Gaskets
It is SBTs recommendation that all exhaust gaskets be sealed with Loctite Copper Gasket Adhesive prior to installation. Read and follow all instructions on the product canister to insure good gasket sealing on your new engine. While every precaution has been taken in the preparation of these guides, SBT assumes no responsibility for errors or omissions. Neither is any Liability assumed for damages resulting from use of the information contained herein. Publication of the procedures in these guides does not imply approval of the manufacturers of the products covered. Persons engaging in the procedures herein do so at their own risk.
It is SBTs recommendation that all bolts be treated with Loctite Medium Strength Threadlocker Blue (242) during assembly.
Follow the removal steps in reverse order to install your new SBT short block assembly: 1.1 Reinstall battery. 3.3 Torque exhaust collector to 28 ft./lbs.
3.14 Torque the starter to 13 ft./lbs.
3.2 Reattach rail connectors and cooling lines.
3.13 Torque the flywheel bolt to 54 ft./lbs.
3.1 Torque coil pack to 11 ft./lbs.
3.12 Torque the case bracket to 13 ft./lbs.
3.11 Torque the case sensor to 11 ft./lbs.
2.8 Hoist the engine back into the hull far enough to reconnect the bottom fittings and lines.
3.10 Torque the head tube to 4.5 ft./lbs.
2.7 Drop the engine fully in the hull and reattach the electrical harnesses. Torque motor mounts to 12 ft./lbs.
3.9 Tighten the intake adaptor clamps to snug.
2.6 Reattach starter lead and cover.
3.8 Torque the gear reduction unit bolts to 20 ft./lbs.
2.5 Install PTO shroud to snug.
3.7 Torque the head bracket bolt to 23 ft./lbs.
2.4 Install exhaust clamps to snug.
3.6 Torque the top oil tank bolts to 20 ft./lbs. Torque the bottom 4 bolts to 28 ft./lbs.
2.3 Reattach airbox hose and connector. Torque to 4.7 ft./lbs.
2.2 Torque airbox base to 12 ft./lbs. Torque Flame arrestor bolts to snug.
3.5 Tighten the head sensor to snug. 2.1 Torque airbox cover screws to snug and snap outer connectors shut.
3.4 Torque the exhaust manifold to 28 ft./lbs. Torque the knock sensor to 11 ft./lbs.
Tools Needed: Sockets
17mm socket 14mm socket 13mm socket 12mm socket 10mm socket 8mm socket
Sealers / Lubricants
Loctite Copper Gasket Adhesive Loctite Medium Threadlocker (Blue) 242
External Gasket Kit Zip-Ties
Ratchet Long socket extension Short socket extension Screwdrivers Yamaha Rotor (flywheel) Puller Part # YM01082 / 40890-01080 from any Yamaha Dealer
12mm wrench 10mm wrench Torque wrench
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