Engine Removal / Installation
Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
Step 1
2.2 (Below) Remove the flame arrestor
screen from the base.
Battery Removal
2.5 (Below) Remove the two 10mm bolts
from the carburetor brace. Tilt it towards
the center of the boat and remove the two
grease lines from the underside. Remove
the brace.
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).
Step 2
Intake Removal
2.1 (Below) Remove the eight 8mm bolts
from the flame arrestor cover and remove
the top.
2.3 (Above) Remove the three 8mm bolts
securing the velocity stacks and remove the
assemblies.
2.4 (Below,
right)
Remove the
12
10mm
bolts
from
the
flame
arrestor base.
Move
it
towards the
front of the
boat and tilt it towards the center exposing
the oil line fittings. Remove the three oil
lines.
v 1.2
© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
2.12 (Below) Look at each petal-to-cage
surface and check for gap. If a gap of more
than 0.015” is present, replace the petals.
2.6 (Below) Remove the oil pump cable,
throttle cable and choke plate cable from
the front carburetor. Remove the three
10mm bolts from the cable mount and
remove it from the carb.
2.9 (Above) Remove the 16 12mm bolts
securing the intake manifold to the case.
Remove the manifold from the hull.
2.10 (Below) Remove the six screws
securing the reeds to the intake manifold.
2.7 Loosen the gas tank cap to relieve
pressure. Be sure the fuel switch is turned
to the “off” position and be aware of any
fuel that may spill from the hoses. Make
sure the hull is clear of any gasoline fumes
before continuing work, especially with
power tools.
2.8 (Below) Remove the pulse, fuel in and
fuel return lines. Using a wrench, remove
the six 12mm bolts securing the carbs to
the intake manifold. These bolts can be
very tricky to get out due to a lack of
clearance in the hull. A good tool for this
job is a 12mm wrench cut in half.
2.11 (Below) Inspect each reed assembly
for damage and wear. Look at each reed
petal and inspect the edges for signs of
cracking, chipping or any missing parts. If
any damage is present, replace the petals.
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© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
Step 3
3.3 (Below) Detach the pipe exit line from
the fitting.
3.6 (Below) Remove the two 12mm bolts
securing the stinger pipe to the head.
Exhaust Removal
3.1 (Below) Remove the six 14mm bolts
from the exhaust brace.
3.4 (Below) Loosen the waterbox coupler
with a screwdriver and pry off the rubber
fitting from the stinger pipe.
3.2 (Below) Remove the two 10mm bolts
from the temperature sensor mount and
remove the sensor.
3.5 (Below) Remove the head and pipe
water cooling lines.
v 1.2
3.7 (Above) Using a 12mm socket, remove
the four 12mm bolts securing the exhaust
pipe to the exhaust manifold. Wiggle the
pipe towards the front of the boat and pull
it up and out of the hull.
© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
3.8 (Below) Remove the 12 12mm bolts
from the exhaust manifold. NOTE: the
bottom row of bolts does not need to come
out.
Step 4
Engine Removal
4.1 (Below) Using a 10mm socket and a
8mm socket, remove the block electrical
ground and starter wires.
4.3 (Below) Remove the four 12mm motor
mount bolts. If you are unable to break any
of them free, you can also remove the two
respective bolts securing the mount to the
hull.
3.9 (Below) Tilt the exhaust manifold on
its side and remove the cooling line with a
screwdriver.
4.2 (Below) Remove the two 10mm bolts
securing the PTO coupler cover and
remove the cover.
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© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
4.4 (Below) If you have a Venture or XL
hull, and any of the mounts do not come
off the saddles, you must remove the
saddles while the engine is still in the hull.
Tilt the engine towards the front of the
boat, exposing the nine engine support
plate bolts.
4.6 (Below) Tilt the engine over on its
other side to gain access to the flywheel
cover bolts. Remove the eight 10mm bolts
securing the flywheel housing cover and
remove it with the stator and wires. Set it
aside out of the hull.
Step 6
Accessory Removal
With the engine on the ground, workbench
or some other solid surface, begin
removing the external accessories that will
NOT be shipped with the core.
5.1 (Below) Stuff a rag into one of the
exhaust ports.
Make sure the rag
penetrates through the port, into the
combustion chamber on top of the piston.
This will prevent the engine from turning
over while you remove the flywheel nut &
PTO coupler.
4.5 (Below) Remove them with a 14mm
socket and remove the supports.
The engine may now be removed from the
hull.
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© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
5.2 (Right) Remove the flywheel nut with a
17mm socket.
5.3 (Below) Use a universal flywheel puller
to remove the flywheel from the shaft. Do
not ship the flywheel key to SBT.
5.4 (Below) Pull the starter bendix out of
the housing.
5.7 (Below) Using a breaker bar or chain
wrench, remove the PTO flywheel from the
crank.
5.5 (Below) Remove the remaining 10mm
bolt from the starter and pull it back out of
the flywheel housing.
5.8 (Below) Remove the spark plugs, and
with all the external accessories removed,
the engine is now ready to be shipped to
SBT!
5.6 (Below) Remove the pulse lines from
the case.
v 1.2
© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
Engine Installation
Oil Injection
Special Gaskets
Electrical Connections
It is SBT’s recommendation that the oil
injection pump be disabled, and block-off
plate(s) be installed prior to use of the new
engine in your ski.
This is only
recommended to insure reliable lubrication
and extended engine life for all our
customer’s PWCs.
Re-use of your
functioning oil injection pump, if so
equipped, does not void your warranty.
It is SBT’s 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.
It is SBT’s 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.
Bolts
Disclaimer
It is SBT’s recommendation that all bolts
be treated with Loctite® Medium Strength
Threadlocker Blue (242) during assembly.
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.
Paper Gaskets
It is SBT’s 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.
Break-In Oil
It is SBT’s requirement that the new engine
be broken-in with additional oil in the fuel
supply for the first tank. Follow the mixing
chart on the back of the bottle to determine
quantity needed.
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© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
Follow the removal steps in reverse order
to install your new SBT short block
assembly:
5.8 Install new spark plugs.
5.7 Insert a rag into an open exhaust port.
Install the PTO coupler.
•
Torque to 27 ft. lbs.
5.6 Install the pulse line hoses on the case.
5.5 Install the starter and the bottom bolt.
•
•
4.5 Install the engine support plates, if not
done so already.
•
Take a small straight edge and place it on
the coupler. You are looking for an even
match all the way around the coupler.
Place shims where necessary to align the
couplers.
4.2 Install the PTO coupler shield.
Torque to:17 ft. lbs.
•
Torque to 50 ft. lbs.
4.4 Install the engine mounts to the hull if
needed.
•
Torque to 4 ft. lbs.
If you did not need to remove the engine
mounts from the hull, you may now reinstall the engine support plates.
Torque to 12 ft. lbs.
Torque to 12 ft. lbs.
4.1 Install the starter positive and block
ground wires.
•
Torque to 3.6 ft. lbs.
4.3 Install the motor mount bolts if needed.
•
•
Torque to 11 ft. lbs.
Torque to 17 ft. lbs.
5.1 -5.4 Insert the starter bendix into the
housing. Place the flywheel key into the
shaft slot and install the flywheel.
•
4.6 Spin the engine mount nuts onto the
studs, and rock the mounts back & forth
with your hands; try to break them. If any
mount(s) fails, replace it before installing
the new engine. Place the engine in the
hull, PTO side down.
It is SBT’s
recommendation that the oil pump be left
off the new engine, and a block-off plate be
installed at this time. Using a new gasket,
install the flywheel cover.
3.9 Place the exhaust manifold in the hull
and re-attach the cooling line.
Torque to 12 ft. lbs.
Your new engine may require re-shimming.
Shims are necessary between the engine
mounts and brackets to properly align the
engine and pump shafts. If you do not have
enough factory shims with your hull, very
thin, wide washers may be substituted.
3.8 Using a new gasket, bolt the exhaust
manifold to the case.
•
3.7 Install the exhaust pipe to the manifold.
•
v 1.2
Torque to 29 ft. lbs.
Torque to 29 ft. lbs.
© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
3.6 Attach the stinger pipe to the head.
•
Torque to 22 ft. lbs.
3.5 Install the pipe and head cooling lines.
2.5 Install the carburetor brace and its two
grease fittings.
2.4 Install the flame arrestor base and three
oil lines.
•
Torque to 5.8 ft. lbs.
3.4 Re-attach the waterbox coupler.
2.3 Install the velocity stacks.
3.3 Re-attach the pipe water exit line.
3.2 Install the temp sensor.
•
•
Torque to 3 ft. lbs.
2.2 Install the flame arrestor screen.
Torque to 11 ft. lbs.
2.1 Install the flame arrestor cover.
3.1 Install the exhaust brace.
•
•
Torque to 1.4 ft. lbs.
Torque to 29 ft. lbs.
1.1 Install the battery.
2.10 – 2.12 Using new gaskets, install the
reed cage assemblies to the intake
manifold.
•
Torque to 6.5 ft. lbs.
2.9 Attach the intake manifold to the case.
•
Torque to 6.5 ft. lbs.
2.8 – 2.7 Using new gaskets, re-install the
carburetors. Re-attach the fuel and pulse
lines.
2.6 Re-attach the oil pump, throttle and
choke cables to the carb brace. Secure the
brace.
•
Torque to 5.8 ft. lbs.
v 1.2
© 2002 Short Block Technologies
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Engine Removal / Installation
Yamaha 1100 / 1200 non-pv
Tools Needed:
Sockets
•
•
•
•
•
8mm
10mm
12mm
14mm
17mm
Sealers /
Lubricants
•
•
•
•
Loctite® Copper Gasket
Treatment
Loctite® Medium
Threadlocker (Blue)
Loctite® High-Tach Gasket
Treatment
SBT Break-In Oil
Misc.
•
•
•
•
Ratchet
Long socket extension
Short socket extension
Screwdrivers
Parts
•
Installation Gasket Kit
Wrenches
•
•
•
•
Torque wrench
10mm
12mm
Chain wrench
v 1.2
© 2002 Short Block Technologies
10
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