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Yamaha 40X Service Manual

Yamaha 40X
416 pages
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290301
SERVICE MANUAL
MANUEL D’ENTRETIEN
WARTUNGSHANDBUCH
MANUAL DE SERVICIO
E
F
D
ES
40X, E40X

Table of Contents

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Yamaha 40X Specifications

General IconGeneral
Horsepower40 hp
Number of Cylinders3
Starting SystemElectric
Fuel TypeGasoline
Maximum Output5500 RPM
Shaft Length Options20 in

Summary

Chapter 1: General Information

Identification

Provides information on identifying the outboard motor's serial number and model.

Safety While Working

Outlines safety precautions and procedures for working on the outboard motor.

Good Working Practices

Details best practices for performing maintenance and repairs on the outboard motor.

Special Tools

Lists and describes specialized tools required for specific maintenance and repair tasks.

Removal and Installation

Provides procedures for removing and installing various components of the outboard motor.

Chapter 2: Specifications

General Specifications

Details the overall technical specifications for the outboard motor models.

Maintenance Specifications

Outlines specific maintenance-related data for engine, gear, and electrical components.

Dimensions

Provides detailed dimensional data for outboard and bracket configurations.

Tightening Torque

Lists required torque specifications for various parts and assemblies.

Chapter 3: Periodic Inspection and Adjustment

Maintenance Interval Chart

Provides a schedule for routine inspections and maintenance intervals based on hours or time.

Periodic Service

Details the periodic service checks for cowling, fuel system, and control systems.

Control System

Covers adjustments and checks for the ignition and throttle control systems.

Power Trim and Tilt (PTT) System

Explains procedures for checking and servicing the Power Trim and Tilt system.

Lower Unit

Outlines checks and maintenance for the lower unit, including gear oil and leakage.

General

Covers general inspections and maintenance tasks such as anode, battery, spark plugs, and lubrication.

Chapter 4: Fuel System

Fuel Joint, Fuel Pump, and Fuel Filter

Details the removal, installation, and service points for fuel system components.

Fuel Pump

Provides exploded views and service procedures for the fuel pump assembly.

Carburetor

Covers exploded views, removal, installation, and inspection of the carburetor.

Chapter 5: Power Unit

Power Unit

Details exploded views and service procedures for the main power unit assembly.

Recoil Starter

Covers exploded views, removal, installation, and checking of the recoil starter.

Flywheel Magneto

Provides exploded views and service procedures for the flywheel magneto assembly.

Magneto Base

Details exploded views and service procedures for the magneto base assembly.

Starter Motor Unit

Explains exploded views and service procedures for the starter motor unit.

Electrical Unit

Details exploded views and service procedures for the electrical unit components.

Control Unit

Provides exploded views and service procedures for the control unit assembly.

Chapter 6: Lower Unit

Lower Unit

Details exploded views and service procedures for the lower unit assembly.

Water Pump

Covers exploded views and service procedures for the water pump assembly.

Propeller Shaft

Provides exploded views and service procedures for the propeller shaft assembly.

Propeller Shaft Housing

Details exploded views and service procedures for the propeller shaft housing assembly.

Forward Gear and Drive Shaft

Explains exploded views and service procedures for the forward gear and drive shaft.

Chapter 7: Bracket Unit

Steering Handle

Details exploded views and service procedures for the steering handle assembly.

Support of Direction

Covers exploded views and service procedures for the support of direction.

Steering Bracket

Provides exploded views and service procedures for the steering bracket.

Power Trim and Tilt (PTT) Unit

Explains exploded views and service procedures for the Power Trim and Tilt (PTT) unit.

Clamp Bracket (MH, WH, W)

Details exploded views and service procedures for the clamp bracket assembly.

Clamp Bracket (WT)

Covers exploded views and service procedures for the clamp bracket (WT) assembly.

Swivel Bracket

Provides exploded views and service procedures for the swivel bracket assembly.

Tilt Rod

Details exploded views and service procedures for the tilt rod assembly.

Chapter 8: Electrical Systems

Electrical Components

Illustrates and identifies electrical components in various views of the outboard motor.

Wire Harness (MH, WH)

Shows the wiring diagram for the wire harness (MH, WH) with connection details.

Wire Harness (W, WT)

Details the wiring diagram for the wire harness (W, WT) and color codes.

Electrical Analysis

Covers procedures for testing electrical circuits, peak voltage, and test harnesses.

Ignition System

Explains the ignition system wiring, spark plug gap, and peak voltage measurements.

Ignition Control System

Details the ignition control system wiring and components like CDI and thermo switch.

Starting System

Covers wiring diagrams, battery, fuse, starter relay, and motor checks.

Chapter 9: Trouble Analysis

Trouble Analysis

Provides an overview of troubleshooting procedures and common issues.

Trouble Analysis Chart

A chart that correlates engine problems with specific components to check for diagnosis.

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