Yamaha E40X - Crankcase and Cylinder Body Exploded Diagram;Removal and Installation Chart

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Symbols10
Index12
General Information14
Identification Serial Number16
Starting Serial Numbers16
Safety While Working18
Good Working Practices20
Disassembly and Assembly Safety22
Special Tools24
Measuring Tools24
Tools for Removal and Installation28
Specifications34
General Specifications36
Specifications38
Maintenance Specifications: Engine40
Maintenance Specifications: Lower44
Maintenance Specifications: Electrical46
Outboard/Bracket Dimensions50
Tightening Torque52
General Tightening Torque54
Periodic Inspection and Adjustment56
Maintenance Interval Chart58
Cowling Periodic Service62
Fuel System Periodic Service62
Control System Periodic Service62
Ignition Timing Adjustment62
Carburetor Cam Roller Adjustment (W, WT)64
Throttle Cable Adjustment (MH, WH)66
Idle Speed Adjustment68
Start-In Gear Protection Adjustment68
Power Trim and Tilt (PTT) System Service and and Adjustments70
Power Trim and Tilt Fluid Check70
Hydraulic System Air Bleeding72
Lower Unit: Gear Oil Check74
Lower Unit Leakage Check76
Anode Inspection76
Battery Check78
Spark Plug Inspection80
Lubrication Points82
Fuel System84
Fuel Joint, Fuel Pump, and Fuel Filter Exploded Diagram/Removal and Installation Chart86
Fuel Joint, Fuel Pump, and Fuel Filter Exploded Diagram/Removal and Installation Chart (Cont)90
Fuel Joint Inspection92
Fuel Filter Inspection92
Fuel Pump Exploded Diagram/Removal and Installation Chart94
Carburetor Exploded Diagram/Removal and Installation Chart96
Carburetor Exploded Diagram/Removal and Installation Chart (Cont)98
Carburetor Exploded Diagram/Removal and Installation Chart (End)100
Carburetor Inspection/Assembly102
Carburetor Inspection/Assembly (Cont)104
Power Unit106
Power Unit Exploded Diagram/Removal and Installation Chart110
Power Unit Exploded Diagram/Removal and Installation Chart (Cont)114
Power Unit Exploded Diagram/Removal and Installation Chart (End)116
Recoil Starter Exploded Diagram/Removal and Installation Chart118
Recoil Starter Exploded Diagram/Removal and Installation Chart (Cont)120
Recoil Starter Exploded Diagram/Removal and Installation Chart (Continued)124
Recoil Starter Exploded Diagram/Removal and Installation Chart (End)126
Sheave Drum Removal128
Spiral Spring Removal128
Starter Rope Installation130
Sheave Drum Installation130
Recoil Starter Checking132
Flywheel Magneto Exploded Diagram/Removal and Installation Chart134
Flywheel Magneto Removal136
Magneto Base Exploded Diagram/Removal and Installation Chart138
Magneto Base Exploded Diagram/Removal and Installation Chart (Cont)140
Starter Motor Unit Exploded Diagram/Removal and Installation Chart142
Electrical Unit Exploded Diagram/Removal and Installation Chart144
Electrical Unit Exploded Diagram/Removal and Installation Chart (Cont)146
Control Unit Exploded Diagram/Removal and Installation Chart148
Intake Manifold and Reed Valve Exploded Diagram/Removal and Installation Chart152
Reed Valve Inspection156
Cylinder Head Cover and Cylinder Head Exploded Diagram/Removal and Installation Chart158
Cylinder Head Cover and Cylinder Head Exploded Diagram/Removal and Installation Chart (Cont)160
Cylinder Head Inspection162
Thermostat Inspection162
Exhaust Cover Exploded Diagram/Removal and Installation Chart164
Crankcase and Cylinder Body Exploded Diagram/Removal and Installation Chart166
Crankcase and Cylinder Body Exploded Diagram/Removal and Installation Chart (Cont)168
Crankcase and Cylinder Body Exploded Diagram/Removal and Installation Chart (End)170
Cylinder Body Inspection172
Piston-To-Cylinder Clearance174
Piston and Crankchaft Exploded Diagram/Removal and Installation Chart176
Piston/Piston Pin Inspection178
Piston Ring Inspection180
Crankshaft Inspection180
Piston Ring Installation182
Piston Installation184
Lower Unit186
Lower Unit Exploded Diagram/Removal and Installation Chart190
Lower Unit Exploded Diagram/Removal and Installation Chart (Cont)192
Lower Unit Exploded Diagram/Removal and Installation Chart (End)194
Water Pump Exploded Diagram/Removal and Installation Chart196
Water Pump Exploded Diagram/Removal and Installation Chart (Cont)198
Propeller Shaft Exploded Diagram/Removal and Installation Chart200
Propeller Shaft Removal204
Propeller Shaft Exploded Diagram/Removal and Installation Chart (Cont)206
Propeller Shaft Housing Exploded Diagram/Removal and Installation Chart208
Propeller Shaft Housing Disassembly210
Propeller Shaft Housing Installation212
Propeller Shaft Housing Installation (Cont)214
Forward Gear and Drive Shaft Exploded Diagram/Removal and Installation Chart216
Forward Gear and Drive Shaft Exploded Diagram/Removal and Installation Chart (Cont)218
Pinion Gear Removal220
Drive Shaft/Forward Gear Disassembly220
Lower Case Disassembly222
Forward Gear/Drive Shaft Assembly224
Lower Case Assembly226
Pinion Gear Installation228
Shimming230
Shim Selection230
Shim Selection (Cont)232
Shim Selection (End)234
Forward Gear Shim234
Forward Gear Shim (Cont)236
Reverse Gear Shim238
Pinion Gear Shim240
Pinion Gear Shim (Cont)242
Forward Gear Shim Check244
Reverse Gear Shim Check246
Backlash Measurement248
Forward Gear Backlash248
Reverse Gear Backlash250
Reverse Gear Measuring Steps252
Reverse Gear Backlash Adjustment252
Bracket Unit254
Steering Handle Exploded Diagram/Removal and Installation Chart258
Steering Handle Exploded Diagram/Removal and Installation Chart (Cont)260
Steering Handle Exploded Diagram/Removal and Installation Chart (End)264
Bottom Cowling Exploded Diagram/Removal and Installation Chart266
Bottom Cowling Exploded Diagram/Removal and Installation Chart (Cont)268
Upper Case Assy Exploded Diagram/Removal and Installation Chart270
Upper Case Assy Exploded Diagram/Removal and Installation Chart (Cont)272
Upper Case Assy Exploded Diagram/Removal and Installation Chart (Continued)274
Upper Case Assy Exploded Diagram/Removal and Installation Chart (End)276
Steering Bracket Exploded Diagram/Removal and Installation Chart278
Power Trim and Tilt (PTT) Unit Exploded Diagram/Removal and Installation Chart282
Power Trim and Tilt (PTT) Unit Exploded Diagram/Removal and Installation Chart (Cont)284
Clamp Bracket (MH, WH, W) Exploded Diagram/Removal and Installation Chart286
Clamp Bracket (MH, WH, W) Exploded Diagram/Removal and Installation Chart (Cont)288
Clamp Bracket (WT) Exploded Diagram/Removal and Installation Chart290
Clamp Bracket (WT) Exploded Diagram/Removal and Installation Chart (Cont)292
Swivel Bracket Exploded Diagram/Removal and Installation Chart294
Swivel Bracket Exploded Diagram/Removal and Installation Chart (Cont)296
Tilt Rod Exploded Diagram/Removal and Installation Chart298
Tilt Rod Exploded Diagram/Removal and Installation Chart (Cont)300
Tilt Rod/Tile Piston Removal302
Tilt Piston/Tilt Rod Installation304
Air Bleeding306
Air Bleeding (Cont)308
PTT Motor, Pump Housing, and Tilt Cylinder Exploded Diagram/Removal and Installation Chart310
PTT Motor, Pump Housing, and Tilt Cylinder Exploded Diagram/Removal and Installation Chart (Cont)312
Pump Housing Exploded Diagram/Removal and Installation Chart314
Pump Housing Exploded Diagram/Removal and Installation Chart (Cont)316
Pump Housing Exploded Diagram/Removal and Installation Chart (End)318
Gear Pump Exploded Diagram/Removal and Installation Chart320
PTT Motor Exploded Diagram/Removal and Installation Chart322
Motor Inspection326
Motor Inspection (Cont)328
PTT Motor Assembly328
Electrical System330
Electrical Components (Top View)334
Electrical Components (Port Side View)336
Electrical Components (Starboard Side View)338
Electrical Components Diagram340
Electrical Components (Cont)342
Electrical Components Diagram (Cont)344
Wire Harness (MH, WH) Diagram346
Wire Harness (W, WT) Diagram348
Electrical Analysis Inspection350
Digital Circuit Tester350
Peak Voltage Measurement350
Peak Voltage Adaptor350
Test Harness (for Pulser and Charge Coils)352
Ignition System (MH, WH) Diagram354
Ignition System (W, WT) Diagram356
Ignition Spark Gap358
Ignition System Peak Voltage360
Spark Plug Gap362
Engine Stop Switch (MH, WH)362
Ignition Control System (MH, WH) Diagram364
Ignition Control System (W, WT)366
Pulser Coil368
Thermo Switch368
Starting System (WH) Diagram370
Starting System (W, WT) Diagram372
Battery374
Fuse374
Wire Harness/Connections374
Starter Relay374
Starter Switch (WH)376
Neutral Switch (WH)376
Choke Solenoid (W, WT)378
Starter Motor Exploded Diagram/Removal and Installation Chart380
Starter Motor Exploded Diagram/Removal and Installation Chart (Cont)382
Pinion Inspection384
Armature Inspection384
Brush Holder Inspection386
Charging System (WH, W, WT) Diagram388
Charging System Peak Voltage390
Power Trim and Tilt (PTT) Conteol System (WT) Diagram392
PTT Relay394
Trouble Analysis396
Trouble Analysis Chart398
Wiring Diagram (MH)406
Wiring Diagram (WH)408
Wiring Diagram (W)410
Wiring Diagram (WT)412

Yamaha E40X - Crankcase and Cylinder Body Exploded Diagram;Removal and Installation Chart

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