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Outboard Motor
E40G
Yamaha E40G User Manual
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BRKT
7-5
6F65G1
1
Bracket unit
6F67020E
5 N
·
m (0.5 kgf
·
m, 3.6 ft
·
lb)
W
WH
No.
Part name
Q
’
ty
Remarks
1
Bolt
2
M6
×
25 mm
2
Cotter pin
1
3
Shift lever
1
4
Bracket
1
5
Shift rod lever 1
1
6
Shift control lever
1
7
Shift rod lever 2
1
8
Bushing
1
9
Spring
2
10
Screw
2
1
1
Shift rod
1
12
Bolt
1
M6
×
10 mm
13
Lever
1
14
Bushing
1
15
W
ave washer
1
16
Cowling lock lever
1
17
Bottom cowling
1
Not reusable
Bottom cowling
153
155
Table of Contents
General Information
3
Table of Contents
3
General Information
5
How to Use this Manual
6
Manual Format
6
Symbols
7
Safety While Working
8
Fire Prevention
8
Ventilation
8
Self-Protection
8
Parts, Lubricants, and Sealants
8
Good Working Practices
9
Disassembly and Assembly
9
Identification
10
Applicable Model
10
Serial Number
10
Propeller Selection
10
Propeller Size
10
Checking the Gear Oil Level
11
Checking the Battery (WH, W)
11
Selection
11
Checking the Fuel System
11
Predelivery Checks
11
Checking the Outboard Motor Mounting Height
12
Checking the Remote Control Cables (Remote Control Model)
12
Checking the Steering System
13
Checking the Gear Shift and Throttle Operation
13
Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
14
Checking the Cooling Water Pilot Hole
14
Test Run
14
Break-In
15
After Test Run
15
Spec Specifications
17
Specifications
17
General Specification
18
Maintenance Specification
20
Power Unit
20
Electrical
22
Lower Unit
22
Dimensions
24
Specified Torques
26
Tightening Torques
26
General Torques
27
Spec - Memo -
29
Chk Adj
30
Periodic Checks and Adjustments
30
Special Service Tools
30
Maintenance Interval Chart
31
Checking the Fuel Filter
32
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
32
Checking the Spark Plugs
32
Checking the Top Cowling
32
Chk Adj
32
Fuel System
32
Periodic Checks and Adjustments
32
Power Unit
32
Top Cowling
32
Checking the Cooling Water Passages
33
Checking the Thermostat
33
Adjusting the Start-In-Gear Protection
34
Adjusting the Throttle Cable (MH, WH)
34
Adjusting the Throttle Link Position
34
Control System
34
Adjusting the Throttle Cable (W)
35
Checking the Gear Shift Operation (MH, WH)
35
Checking the Engine Idle Speed
36
Checking the Gear Shift Operation (W)
36
Bracket
37
Changing the Gear Oil
37
Checking the Gear Oil Level
37
Checking the Tilt Operation
37
Lower Unit
37
Checking the Anodes
38
Checking the Lower Unit for Air Leakage
38
Checking the Propeller
38
General
38
Checking the Battery
39
Lubricating the Outboard Motor
39
Fuel Fuel System
41
Fuel
41
Fuel System
42
Special Service Tools
42
Hose Routing
43
Fuel Line
44
Carburetor
47
Checking the Carburetor
49
Disassembling the Carburetor
49
Adjusting the Throttle Stop Screw
50
Assembling the Carburetor
50
Fuel Pump
51
Checking the Fuel Pump
52
Disassembling the Fuel Pump
52
Assembling the Fuel Pump
53
Checking the Fuel Joint
53
Powr Power Unit
55
Powr
55
Power Unit
56
Special Service Tools
56
Power Unit
58
Checking the Compression Pressure
59
Checking the Drive Pawl
68
Checking the Spiral Spring
68
Disassembling the Manual Starter
68
Measuring the Starter Rope
68
Assembling the Manual Starter
69
Removing the Power Unit
70
Removing the Flywheel Magnet
71
Removing the Electrical Components
72
Removing the Throttle Pulley Assembly
72
Assembling the Base Assembly
73
Disassembling the Base Assembly
73
Reed Valves
74
Checking the Reed Valves
76
Removing the Reed Valve Assembly
76
Checking the Cylinder Head
79
Checking the Exhaust Cover
79
Cylinder Head
79
Installing the Pressure Control Valve
79
Removing the Cylinder Head
79
Removing the Exhaust Cover
79
Crankcase
80
Checking the Cylinder Bore
82
Removing the Crankcase
82
Removing the Crankshaft Assembly and Oil Seal Housing
82
Assembling the Oil Seal Housing
83
Checking the Oil Seal Housing
83
Disassembling the Oil Seal Housing
83
Disassembling the Piston
83
Checking the Piston Clearance
84
Checking the Piston Diameter
84
Checking the Piston Rings
84
Checking the Internal Anodes
85
Checking the Piston Pin
85
Checking the Piston Pin Boss Bore
85
Checking the Piston Ring Side Clearance
85
Disassembling the Crankshaft
85
Assembling the Crankshaft
87
Checking the Crankpin
87
Checking the Crankshaft
91
Installing the Crankshaft Bearings
91
Assembling the Piston
92
Assembling the Power Unit
92
Installing the Power Unit
94
Lowr Lower Unit
96
Lowr
96
Lower Unit
98
Special Service Tools
98
Lower Unit (E40G)
102
Removing the Lower Unit
106
Removing the Water Pump and Shift Rod
106
Checking the Water Pump and Shift Rod
107
Propeller Shaft Housing
108
Disassembling the Propeller Shaft Assembly
110
Disassembling the Propeller Shaft Housing
110
Removing the Propeller Shaft Housing Assembly
110
Assembling the Forward Gear
111
Assembling the Propeller Shaft Assembly
111
Checking the Propeller Shaft
111
Checking the Propeller Shaft Housing
111
Disassembling the Forward Gear
111
Assembling the Propeller Shaft Housing
112
Drive Shaft and Lower Case
113
Checking the Bearings
114
Checking the Drive Shaft
114
Checking the Pinion Gear
114
Disassembling the Lower Case
114
Removing the Drive Shaft
114
Assembling the Lower Case
115
Checking the Lower Case and Lower Case Cap
115
Installing the Drive Shaft
116
Installing the Propeller Shaft Housing
116
Installing the Water Pump and Shift Rod
117
Installing the Lower Unit
118
Shimming
120
Selecting the Forward and Reverse Gear Shims
121
Selecting the Pinion Shims
121
Backlash
122
Measuring the Forward and Reverse Gear Backlash
122
Lower Unit (E40J)
124
Removing the Lower Unit
128
Checking the Water Pump and Shift Rod
129
Removing the Water Pump and Shift Rod
129
Disassembling the Propeller Shaft Assembly
131
Disassembling the Propeller Shaft Housing
131
Propeller Shaft Housing
131
Removing the Propeller Shaft Housing Assembly
131
Assembling the Propeller Shaft Assembly
132
Checking the Propeller Shaft
132
Checking the Propeller Shaft Housing
132
Assembling the Propeller Shaft Housing
133
Drive Shaft and Lower Case
134
Disassembling the Drive Shaft
135
Disassembling the Forward Gear
135
Disassembling the Oil Seal Housing
135
Removing the Drive Shaft
135
Checking the Bearings
136
Checking the Drive Shaft
136
Checking the Lower Case
136
Checking the Pinion and Forward Gear
136
Disassembling the Lower Case
136
Assembling the Lower Case
137
Assembling the Oil Seal Housing
137
Assembling the Drive Shaft
138
Assembling the Forward Gear
138
Installing the Drive Shaft
138
Installing the Oil Seal Housing
138
Installing the Propeller Shaft Housing
138
Installing the Water Pump and Shift Rod
139
Installing the Lower Unit
141
Shimming
143
Selecting the Pinion Shims
144
Selecting the Forward Gear Shims
145
Selecting the Reverse Gear Shims
146
Backlash
147
Measuring the Forward and Reverse Gear Backlash
147
Brkt Bracket Unit
149
Brkt
149
Bracket Unit
150
Special Service Tools
150
Tiller Handle (MH, WH)
151
Assembling the Tiller Handle
153
Bottom Cowling
154
Upper Case, Pivot Shaft
156
Checking the Upper Case
160
Disassembling the Upper Case
160
Assembling the Upper Case
161
Removing the Pivot Shaft
162
Clamp Brackets, Swivel Bracket
163
Assembling the Swivel Bracket
167
Disassembling the Swivel Bracket
167
Installing the Clamp Brackets
167
Removing the Clamp Brackets
167
Installing the Pivot Shaft
168
Elec Electrical Systems
169
Elec
169
Electrical Systems
170
Special Service Tools
170
Checking the Electrical Components
171
Measuring Low Resistance
171
Measuring the Peak Voltage
171
Electrical Components
172
Top View
172
Port View
173
Starboard View (MH)
174
Starboard View (WH, W)
175
Wiring Diagram (MH)
176
Wiring Diagram (WH)
177
Wiring Diagram (W)
178
Checking the Ignition Coil
179
Checking the Ignition Spark Gap
179
Checking the Spark Plug Caps
179
Ignition and Ignition Control System
179
Checking the CDI Unit
180
Checking the Charge Coil
180
Checking the Pulser Coils
180
Checking the Engine Stop Lanyard Switch (MH, WH)
181
Checking the Fuse (WH,W)
181
Checking the Starter Relay (WH, W)
181
Checking the Thermoswitch
181
Starting System
181
Checking the Choke Solenoid (W)
182
Checking the Engine Start Switch (WH)
182
Checking the Neutral Switch (WH, W: if Equipped)
182
Starter Motor (WH, W)
183
Checking the Armature
184
Checking the Starter Motor Pinion
184
Removing the Starter Motor Pinion
184
Charging System
185
Checking the Brushes
185
Checking the Rectifier (WH, W)
185
Checking the Starter Motor Operation
185
Checking the Lighting Coil
186
Ignition System
188
Power Unit
188
Trbl Shtg
188
Troubleshooting
188
Fuel System
190
Compression Pressure
191
Lower Unit
193
Electrical System
194
Starting System
194
Charging System
195
5
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Yamaha E40G Specifications
General
Brand
Yamaha
Model
E40G
Category
Outboard Motor
Language
English
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