Yamaha E40J - Installing the Power Unit

POWR
5-39
6F65G11
Power unit
NOTE:
Apply LOCTITE 572 to the cylinder head
bolts and the cylinder head cover bolts before
installation.
8. Install the thermostat, a new gasket and
thermostat cover.
9. Install the spark plugs, tighten them fin-
ger tight, then to the specified torque with
a spark plug wrench.
10. Install the reed valve assembly and the
intake manifold assembly, and then tight-
en the intake manifold bolts 4 to the
specified torques in two stages.
11. Connect the hoses 5.
12. Install the throttle pulley assembly, and
the electrical components to the power
unit.
Installing the power unit
1. Clean the power unit mating surface, and
install the dowels 1 and a new gasket
2.
2. Install the power unit 3, and then tighten
the power unit mounting bolts 4 to the
specified torque.
3. Install the apron 5.
NOTE:
Apply LOCTITE 572 to the power unit mount-
ing bolts before installation.
4. Connect the fuel hose and pilot water
hose.
5. Connect the engine stop lanyard switch
leads (MH, WH).
6. Connect the neutral switch connectors
(WH).
7. Install the Woodruff key and flywheel
magnet.
6F650680
4
5
6F650690
5
4
1
1
2
3
Cylinder head bolt:
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd:30 N·m (3.0 kgf·m, 22 ft·lb)
Cylinder head cover bolt 3:
12 N·m (1.2 kgf·m, 8.7 ft·lb)
Spark plug:
25 N·m (2.5 kgf·m, 18 ft·lb)
Power unit mounting bolt 4:
21 N·m (2.1 kgf·m, 15.5 ft·lb)