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  1. #1

    Rebuilding an FX-140 Motor

    I recently acquired a 2002 FX-140 with severe motor damage. There were chards of metal in the bottom of the ski along with a ton of oil. I got the motor pulled today, and I'll be tearing into it shortly. I've never worked on a ski before, but I've done a lot of automotive work. My first question is about mounting the motor on an engine stand for tear down. I have the factory manual and supplement, plus some other instructions from pulling the motor, but none of them say anything about where to mount the block.

    Here's the engine stand:

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    And here's where I was thinking about mounting. Does anyone have any better recommendations or think that these two taps are too weak or know where else I can use to get more than just two contact points to the crankcase?

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    And for the curious few, here's what she looked like coming out:

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    And what I'll be having fun repairing. Anyone brave enough to venture a guess on a starting parts list from what you can see here. I'm sure I'll be finding more as I pull the bottom end out further:
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  2. #2
    cigarlust's Avatar
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    Man, have those cases professionally done by a pwc company. Thats some crazy repair work. Compare that to a price of a lower set of good cases...

  3. #3
    MR-1 X 2's Avatar
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    You would be better off purchasing a complete used engine if the cylinder head is damaged. Unfortunately the parts you will probably need total more than what the current resale value is of that year ski.

  4. #4
    YoYamma's Avatar
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    Quote Originally Posted by MR-1 X 2 View Post
    You would be better off purchasing a complete used engine if the cylinder head is damaged. Unfortunately the parts you will probably need total more than what the current resale value is of that year ski.
    +1 you might want to hold up right there and do a complete cost analysis on paper before you proceed any further. The parts alone on Marine 4 strokes can be expensive; you may be better off putting the money in a well-maintained used ski. Hope you get it sorted out.

  5. #5
    Ya, until I got it out of the ski, I wasn't sure what the condition of the case was gonna be. I agree that if the head is damaged in any way, its worth finding a complete engine somewhere. But I won't know that until I start tearing it down further. Any advice on putting it on the stand?

    I do plan on itemizing parts/costs before I invest anything other than labor in this project. I'd rather not part out the ski, but if it comes to that, I knew it was an option when I started.

  6. #6
    dhoad's Avatar
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    I know nobody likes the SBT engines and I am leery of them myself, but if you buy a premium version of there replacement engine you get a 2 year warranty. I think that is an option worth researching at very least if your cases and head are toast

  7. #7
    Are there any engine upgrades I should consider instead of limiting my rebuild to a direct stock replacement? FX140HO or FX160 motor perhaps. I don't want to have to buy any extra electronics or much in the way of added cost, but if I'm spending the money, it'd be nice to know whats available. The bore/stroke and heads are different, I'm pretty sure, so I'd be looking at longblocks at that point, but curious what else would be required to make the swap.

    So, I finished the tear down today. The stand worked just fine using the exhaust mounting holes.

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    The head looked to be in pretty good shape, though the valves are bent on the #1 cylinder. So I am budgeting my shopping list:

    - Both crankcase halves
    - Crankshaft
    - One piston/con rod assembly
    - Rings
    - Bearings
    - Oil Pan
    OR Short block - makes sense if I can find one affordably since I could really only reuse 3 piston/con rod assemblies and some bolts. If I had to buy individually, I don't think this build is cost effective.

    Plus:
    - Cam Chain
    - Set of 5 valves + hardware
    - Gasket set
    - Misc hoses/hose clamps that I don't think I want to reuse
    - Possibly starter motor since it looks to be a PITA to replace later.

    If I do go for it, I'll strip down the head and have it hot tanked. Is there anything else I should have hot tanked to clean dirt, grime, salt? I was thinking just soak the exhaust parts/bolts in water, degrease them, and maybe some wire brush to get rid of the salt layers.


    Exhaust removed:
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    Oil pan removed:

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    Knarled crankshaft:

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    Pistons:

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    Top end looked good:

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    Pistons with damage to #1 from valve impact:

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    Camshafts removed:

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    Head with bent valves on #1 cylinder:

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  8. #8
    volltrex's Avatar
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    Great to see posts like this.......keep us informed on how it goes.

    If you have any queries, it may be worth getting in touch with david3aces over at pwctoday.......he just rebuilt a 140 motor & found a few pitfalls along the way.

  9. #9
    2000 1200 gpr 2001 800 bb gpr ddg101's Avatar
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  10. #10
    2000 1200 gpr 2001 800 bb gpr ddg101's Avatar
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    I have a Fx 140 motor for sale pm me or call me @ 405 919 4566 or 243 4566

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