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Yamaha F40B - Service Manual

Yamaha F40B
285 pages
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F30A
F40B
SERVICE MANUAL
67C-28197-3K-11

Table of Contents

Other manuals for Yamaha F40B

Questions and Answers

Summary

General Information

How to Use This Manual

Explains the manual's format, symbols, and conventions for service procedures.

Safety While Working

Details safety precautions, fire prevention, ventilation, and self-protection measures.

Special Service Tool

Lists and illustrates specialized tools required for servicing Yamaha outboard motors.

Predelivery Check

Outlines essential checks to ensure smooth and efficient delivery of the outboard motor.

Specification

General Specification

Provides overall dimensional, weight, performance, and power unit specifications for various models.

Maintenance Specification

Details technical specifications for engine components, valves, pistons, and other parts requiring maintenance.

Tightening Torque

Lists specified tightening torques for fasteners across different systems, ensuring correct assembly.

Periodic Check and Adjustment

Maintenance Interval Chart

Provides a schedule for regular maintenance tasks based on operating hours or time intervals.

Fuel System Checks

Covers checks for fuel joints, hoses, filters, and fuel pump for leaks and proper function.

Power Unit Checks

Details procedures for checking engine oil level, changing oil, replacing oil filter, timing belt, spark plugs, and thermostat.

Control System Checks

Outlines adjustments and checks for throttle links, cables, gear shift operation, and idle speed.

Lower Unit Checks

Includes checks for gear oil, air leakage, and propeller condition in the lower unit.

General Checks

Covers checks for anodes, battery condition, and lubrication points on the outboard motor.

Fuel System

Hose Routing

Illustrates the correct routing of fuel, blowby, and cooling water hoses for proper connection.

Fuel Pump, Fuel Filter, and Fuel Joint

Details the components and procedures for checking, disassembling, and assembling the fuel pump, filter, and joint.

Carburetor Unit

Covers the assembly, disassembly, and adjustment of the carburetor system, including jets and pilot screws.

Power Unit

Power Unit (Check and Adjustment)

Explains procedures for checking compression pressure, oil pressure, valve clearance, and replacing the timing belt.

Manual Starter (M and W Model)

Covers the disassembly, checking, and assembly of the manual starter mechanism.

Ignition Coil, CDI Unit, and Rectifier Regulator

Covers checks and procedures for the ignition system components like coils, CDI unit, and rectifier regulator.

Timing Belt and Sprocket

Covers the removal, checking, and installation of the timing belt and sprockets for engine timing.

Cylinder Head

Details the disassembly, checking, and assembly of the cylinder head, valves, springs, and camshaft.

Cylinder Block

Covers the disassembly and checking of critical engine block components like pistons, rings, connecting rods, and crankshaft.

Lower Unit

Lower Unit

Provides an exploded view and part list for the lower unit assembly, including propeller and trim tab.

Propeller Shaft Housing

Covers the removal, disassembly, checking, and assembly of the propeller shaft housing and its components.

Drive Shaft and Lower Case

Details procedures for removing, disassembling, checking, and assembling the drive shaft, lower case, and associated parts.

Shimming

Explains the process of selecting and calculating shim thicknesses for proper gear and pinion alignment.

Backlash

Describes how to measure and adjust gear backlash for forward and reverse gears.

Bracket unit

Tiller Handle (H model)

Covers the removal, installation, and adjustment of the tiller handle assembly for H model outboards.

Friction Plate (H model)

Details the disassembly and assembly procedures for the friction plate mechanism on H model tiller handles.

Bottom Cowling

Explains the removal and installation of bottom cowling components, including clamps and brackets.

Upper Case and Steering Arm

Covers the disassembly and assembly of the upper case, steering arm, and related components.

Hydraulic Tilt Unit and PTT Unit

Comprehensive guide to the hydraulic tilt and Power Trim and Tilt (PTT) systems, including disassembly, checking, and assembly.

PTT Motor

Procedures for disassembling, checking, and assembling the PTT motor, including brushes and commutator.

PTT Gear Pump

Detailed instructions for the disassembly, checking, and assembly of the PTT gear pump system.

PTT Cylinder

Covers the disassembly, checking, and assembly of the PTT cylinder, including seals and pistons.

PTT Electrical System

Explains checks for fuses, PTT relays, switches, and trim sensors to diagnose electrical issues.

Electrical System

Electrical Component and Wiring Harness Routing

Provides diagrams showing the location and routing of electrical components and wiring harnesses.

Starter Motor (E and W model)

Covers the removal, checking, disassembly, and assembly of the starter motor for E and W models.

Starting System

Explains checks for fuses, engine start switches, neutral switches, and starter relays related to the starting system.

Ignition and Ignition Control System

Covers checks for ignition spark, spark plug caps, ignition coils, pulser coils, charge coils, and engine shut-off switches.

Engine Electric Control System

Details checks for CDI units, thermo sensors, oil pressure switches, warning indicators, and power bobbins.

Charging System

Procedures for checking lighting coils and the Rectifier Regulator to ensure proper charging system function.

Troubleshooting

Troubleshooting the Outboard Motor

General guidelines and tables for diagnosing and resolving common outboard motor issues.

Troubleshooting the Power Unit

Specific troubleshooting steps for power unit issues like engine not cranking or not starting.

Troubleshooting the PTT Unit (PTT model)

Diagnoses problems related to the PTT unit not operating or the tilt ram not extending.

Troubleshooting the Lower Unit

Addresses issues with the shift mechanism of the forward and reverse gears not operating correctly.

Summary

General Information

How to Use This Manual

Explains the manual's format, symbols, and conventions for service procedures.

Safety While Working

Details safety precautions, fire prevention, ventilation, and self-protection measures.

Special Service Tool

Lists and illustrates specialized tools required for servicing Yamaha outboard motors.

Predelivery Check

Outlines essential checks to ensure smooth and efficient delivery of the outboard motor.

Specification

General Specification

Provides overall dimensional, weight, performance, and power unit specifications for various models.

Maintenance Specification

Details technical specifications for engine components, valves, pistons, and other parts requiring maintenance.

Tightening Torque

Lists specified tightening torques for fasteners across different systems, ensuring correct assembly.

Periodic Check and Adjustment

Maintenance Interval Chart

Provides a schedule for regular maintenance tasks based on operating hours or time intervals.

Fuel System Checks

Covers checks for fuel joints, hoses, filters, and fuel pump for leaks and proper function.

Power Unit Checks

Details procedures for checking engine oil level, changing oil, replacing oil filter, timing belt, spark plugs, and thermostat.

Control System Checks

Outlines adjustments and checks for throttle links, cables, gear shift operation, and idle speed.

Lower Unit Checks

Includes checks for gear oil, air leakage, and propeller condition in the lower unit.

General Checks

Covers checks for anodes, battery condition, and lubrication points on the outboard motor.

Fuel System

Hose Routing

Illustrates the correct routing of fuel, blowby, and cooling water hoses for proper connection.

Fuel Pump, Fuel Filter, and Fuel Joint

Details the components and procedures for checking, disassembling, and assembling the fuel pump, filter, and joint.

Carburetor Unit

Covers the assembly, disassembly, and adjustment of the carburetor system, including jets and pilot screws.

Power Unit

Power Unit (Check and Adjustment)

Explains procedures for checking compression pressure, oil pressure, valve clearance, and replacing the timing belt.

Manual Starter (M and W Model)

Covers the disassembly, checking, and assembly of the manual starter mechanism.

Ignition Coil, CDI Unit, and Rectifier Regulator

Covers checks and procedures for the ignition system components like coils, CDI unit, and rectifier regulator.

Timing Belt and Sprocket

Covers the removal, checking, and installation of the timing belt and sprockets for engine timing.

Cylinder Head

Details the disassembly, checking, and assembly of the cylinder head, valves, springs, and camshaft.

Cylinder Block

Covers the disassembly and checking of critical engine block components like pistons, rings, connecting rods, and crankshaft.

Lower Unit

Lower Unit

Provides an exploded view and part list for the lower unit assembly, including propeller and trim tab.

Propeller Shaft Housing

Covers the removal, disassembly, checking, and assembly of the propeller shaft housing and its components.

Drive Shaft and Lower Case

Details procedures for removing, disassembling, checking, and assembling the drive shaft, lower case, and associated parts.

Shimming

Explains the process of selecting and calculating shim thicknesses for proper gear and pinion alignment.

Backlash

Describes how to measure and adjust gear backlash for forward and reverse gears.

Bracket unit

Tiller Handle (H model)

Covers the removal, installation, and adjustment of the tiller handle assembly for H model outboards.

Friction Plate (H model)

Details the disassembly and assembly procedures for the friction plate mechanism on H model tiller handles.

Bottom Cowling

Explains the removal and installation of bottom cowling components, including clamps and brackets.

Upper Case and Steering Arm

Covers the disassembly and assembly of the upper case, steering arm, and related components.

Hydraulic Tilt Unit and PTT Unit

Comprehensive guide to the hydraulic tilt and Power Trim and Tilt (PTT) systems, including disassembly, checking, and assembly.

PTT Motor

Procedures for disassembling, checking, and assembling the PTT motor, including brushes and commutator.

PTT Gear Pump

Detailed instructions for the disassembly, checking, and assembly of the PTT gear pump system.

PTT Cylinder

Covers the disassembly, checking, and assembly of the PTT cylinder, including seals and pistons.

PTT Electrical System

Explains checks for fuses, PTT relays, switches, and trim sensors to diagnose electrical issues.

Electrical System

Electrical Component and Wiring Harness Routing

Provides diagrams showing the location and routing of electrical components and wiring harnesses.

Starter Motor (E and W model)

Covers the removal, checking, disassembly, and assembly of the starter motor for E and W models.

Starting System

Explains checks for fuses, engine start switches, neutral switches, and starter relays related to the starting system.

Ignition and Ignition Control System

Covers checks for ignition spark, spark plug caps, ignition coils, pulser coils, charge coils, and engine shut-off switches.

Engine Electric Control System

Details checks for CDI units, thermo sensors, oil pressure switches, warning indicators, and power bobbins.

Charging System

Procedures for checking lighting coils and the Rectifier Regulator to ensure proper charging system function.

Troubleshooting

Troubleshooting the Outboard Motor

General guidelines and tables for diagnosing and resolving common outboard motor issues.

Troubleshooting the Power Unit

Specific troubleshooting steps for power unit issues like engine not cranking or not starting.

Troubleshooting the PTT Unit (PTT model)

Diagnoses problems related to the PTT unit not operating or the tilt ram not extending.

Troubleshooting the Lower Unit

Addresses issues with the shift mechanism of the forward and reverse gears not operating correctly.

Yamaha F40B Specifications

General IconGeneral
Engine Type4-stroke
Displacement747 cc
Cylinder ConfigurationInline 3
Full Throttle RPM Range5000-6000 RPM
Fuel Induction SystemEFI (Electronic Fuel Injection)
Starting SystemElectric
Lubrication SystemWet sump
Shaft Length20 inches
ExhaustThrough propeller
Trim MethodPower trim and tilt
Ignition SystemTCI
Recommended FuelRegular unleaded gasoline
Gear ShiftF-N-R
SteeringRemote
Warranty3 years
Bore x Stroke65.0 mm x 75.0 mm (2.56 in x 2.95 in)
Recommended OilYamalube 4M (10W-30 or 20W-40)

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