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Outboard Motor
F40D
Yamaha F40D Service Manual
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BRKT
Bracket unit
7-9
6C13G11
Bottom cowling
7
No.
Part name
Q
’
ty
Remark
s
1
Washer
1
2
Bushing
1
3B
r
a
c
k
e
t
1
4
Bushing
1
5B
o
l
t
1
M
5
×
14 mm
6
Shift rod
1
7
Bushing
1
8
Cotter pin
1
Not reusable
9B
o
l
t
1
10
Spring
1
11
Ball
1
12
Flushing hose
1
13
Hose joint
1
14
Adapter
1
15
Screw
2
ø
6
×
19 mm
16
Stay
1
17
Bolt
1
M6
×
15 mm
S6C17060
T
R
.
.
2 N
·
m (0.2 kgf
·
m, 1.5 ft
·
Ib)
A
A
A
A
1
2
3
4
5
7
A
A
6
8
9
10
11
12
13
14
16
15
17
18
19
20
21
22
24
25
23
27
33
32
34
31
30
29
28
26
T
R
.
.
18 N
·
m (1.8 kgf
·
m, 13.3 ft
·
Ib)
LT
242
205
207
Table of Contents
Gen Info General Information
5
Default Chapter
2
Important Information
2
General Information
5
Table of Contents
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
9
Applicable Models
9
Serial Number
10
Outline of Features
11
Features and Benefits
12
Fuel System
12
Solenoid Valve
13
Electronic Control System
14
ECM (Electric Control Module)
15
Variable Trolling RPM Switch (Optional)
16
Propeller Selection
17
Propeller Size
17
Selection
17
Predelivery Checks
18
Checking the Fuel System
18
Checking the Engine Oil Level
18
Checking the Gear Oil Level
18
Checking the Battery
18
Checking the Outboard Motor Mounting Height
19
Checking the Remote Control Cables
19
Checking the Steering System
19
Checking the Gear Shift and Throttle Operation
20
Checking the Power Trim and Tilt System
20
Checking the Hydro Tilt System
20
Checking the Engine Start Switch and Engine Stop Lanyard Switch
21
Checking the Cooling Water Pilot Hole
21
Test Run
22
Break-In
22
After Test Run
22
Spec Specifications
23
General Specifications
24
Specifications
24
Maintenance Specification
28
Power Unit
28
Lower Unit
31
Electrical
32
Power Unit
34
Lower Unit
37
Electrical
38
Dimensions
40
Tightening Torques
44
Specified Torques
44
General Torques
47
Chk Adj/Chk Adj
49
Chk Adj
50
Special Service Tools
50
Periodic Checks and Adjustments
50
Maintenance Interval Chart
51
Top Cowling
52
Checking the Top Cowling
52
Fuel System
52
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Fuel Injector)
52
Checking the Fuel Filter
52
Power Unit
52
Checking the Engine Oil Level
52
Changing the Engine Oil Using an Oil Changer
53
Changing the Engine Oil by Draining It
53
Replacing the Oil Filter
54
Checking the Timing Belt
55
Replacing the Timing Belt
55
Checking the Spark Plugs
57
Checking the Thermostat
58
Checking the Cooling Water Passage
59
Control System
59
Checking the Engine Idle Speed
59
Adjusting the Throttle Link and Throttle Cable
59
Checking the Gear Shift Operation
61
Bracket Unit
62
Checking the Power Trim and Tilt Operation
62
Checking the Hydro Tilt Unit Operation
62
Checking the Power Trim and Tilt Fluid Level
63
Lower Unit
63
Checking the Gear Oil Level
63
Changing the Gear Oil
64
Checking the Lower Unit for Air Leakage
64
Checking the Propeller
65
General
65
Checking the Anodes
65
Checking the Battery
66
Lubricating the Outboard Motor
67
Fuel Fuel System
69
Special Service Tools
70
Fuel System
70
Hose Routing
71
Fuel and Blowby Hoses
71
Cooling Water Pilot Hoses
72
Fuel Filter and Fuel Pump
73
Checking the Fuel Pump
75
Disassembling the Fuel Pump
75
Checking the Diaphragm and Valves
76
Assembling the Fuel Pump
76
Checking the Fuel Joint
76
Intake Manifold
77
Checking the Throttle Position Sensor
80
Installing the Throttle Position Sensor
80
Checking the Idle Speed Control
80
Vapor Separator
83
Disconnecting the Quick Connector
85
Measuring the Fuel Pressure
85
Checking the Pressure Regulator
86
Draining the Fuel
87
Disassembling the Vapor Separator
87
Checking the Vapor Separator
88
Adjusting the Float
88
Assembling the Vapor Separator
89
Powr Power Unit
90
Special Service Tools
92
Power Unit
92
Power Unit
94
Checking the Compression Pressure
94
Checking the Oil Pressure
94
Checking the Valve Clearance
95
Removing the Power Unit
105
Removing the Timing Belt and Sprockets
106
Checking the Timing Belt and Sprockets
107
Installing the Timing Belt and Sprockets
108
Cylinder Head
110
Removing the Cylinder Head
114
Checking the Valve Springs
115
Checking the Valves
115
Checking the Valve Guides
116
Replacing the Valve Guides
116
Checking the Valve Seat
117
Refacing the Valve Seat
118
Checking the Rocker Arms and Rocker Arm Shaft
120
Checking the Camshaft
120
Checking the Cylinder Head
121
Checking the Oil Pump
122
Installing the Valves
122
Installing the Camshaft
123
Installing the Rocker Arm Shaft Assembly
123
Installing the Oil Pump
124
Installing the Cylinder Head
125
Exhaust Cover
126
Cylinder Block
128
Disassembling the Cylinder Block
129
Checking the Piston Diameter
130
Checking the Cylinder Bore
130
Checking the Piston Clearance
130
Checking the Piston Rings
130
Checking the Piston Ring Grooves
131
Checking the Piston Ring Side Clearance
132
Checking the Piston Pin Boss Bore
132
Checking the Piston Pin
132
Checking the Connecting Rod Small End Inside Diameter
132
Checking the Connecting Rod Big End Side Clearance
132
Checking the Crankshaft
133
Checking the Crankpin Oil Clearance
133
Selecting the Connecting Rod Bearing
134
Checking the Crankshaft Journal Oil Clearance
135
Selecting the Main Bearings
136
Assembling the Power Unit
137
Installing the Power Unit
140
Lowr Lower Unit
142
Special Service Tools
144
Lower Unit
144
Lower Unit (F50, F60)
148
Removing the Lower Unit
150
Removing the Water Pump
150
Checking the Water Pump
150
Propeller Shaft Housing (F50, F60)
151
Removing the Propeller Shaft Housing Assembly
152
Disassembling the Propeller Shaft Assembly
152
Disassembling the Propeller Shaft Housing
152
Checking the Propeller Shaft Housing
153
Checking the Propeller Shaft
153
Assembling the Propeller Shaft Assembly
153
Assembling the Propeller Shaft Housing
153
Drive Shaft and Lower Case (F50, F60)
157
Removing the Drive Shaft
157
Disassembling the Drive Shaft
157
Disassembling the Forward Gear
157
Disassembling the Oil Seal Housing
157
Disassembling the Lower Case
158
Checking the Shift Rod and Shift Cam
158
Checking the Pinion and Forward Gear
158
Checking the Bearings
158
Checking the Drive Shaft
158
Checking the Lower Case
159
Assembling the Oil Seal Housing
159
Assembling the Lower Case
159
Assembling the Forward Gear
160
Assembling the Drive Shaft
160
Installing the Pinion
160
Installing the Oil Seal Housing
161
Installing the Propeller Shaft Housing
161
Installing the Water Pump
162
Installing the Lower Unit
162
Shimming (F50, F60)
165
Shimming
166
Selecting the Pinion Shims
166
Selecting the Forward Gear Shims
167
Selecting the Reverse Gear Shims
168
Backlash (F50, F60)
168
Measuring the Forward and Reverse Gear Backlash
168
Lower Unit (FT50, FT60)
170
Removing the Lower Unit
174
Removing the Water Pump and Shift Rod
174
Checking the Water Pump and Shift Rod
175
Propeller Shaft Housing (FT50, FT60)
177
Removing the Propeller Shaft Housing Assembly
177
Disassembling the Propeller Shaft Assembly
177
Disassembling the Propeller Shaft Housing
177
Checking the Propeller Shaft Housing
178
Checking the Propeller Shaft
178
Assembling the Propeller Shaft Assembly
178
Assembling the Propeller Shaft Housing
178
Drive Shaft and Lower Case (FT50, FT60)
180
Removing the Drive Shaft
182
Disassembling the Drive Shaft
182
Disassembling the Forward Gear
182
Disassembling the Oil Seal Housing
182
Disassembling the Lower Case
183
Checking the Pinion and Forward Gear
183
Checking the Bearings
183
Checking the Drive Shaft
183
Checking the Lower Case
183
Assembling the Lower Case
184
Assembling the Forward Gear
184
Assembling the Drive Shaft
185
Installing the Pinion
185
Installing the Propeller Shaft Housing
185
Installing the Water Pump and Shift Rod
186
Installing the Lower Unit
187
Shimming (FT50, FT60)
190
Shimming
191
Selecting the Pinion Shims
191
Selecting the Forward Gear Shims
192
Backlash (FT50, FT60)
193
Measuring the Forward Gear Backlash
193
Brkt Bracket Unit
196
Bracket Unit
198
Special Service Tools
198
Tiller Handle
199
Checking the Throttle Cable and Shift Cable
205
Assembling the Tiller Handle
205
Lubricating the Tiller Handle Bracket
205
Adjusting the Friction Plate
205
Bottom Cowling
206
Upper Case
210
Removing the Upper Case
215
Disassembling the Upper Case
215
Checking the Drive Shaft Bushing
215
Disassembling the Oil Pan
215
Checking the Oil Strainer
215
Assembling the Oil Pan
216
Assembling the Upper Case
217
Installing the Upper Case
218
Steering Arm
219
Removing the Steering Arm
220
Installing the Steering Arm
220
Clamp Brackets and Swivel Bracket
222
Removing the Clamp Brackets
224
Installing the Clamp Brackets
224
Adjusting the Trim Sensor
224
Power Trim and Tilt Unit
226
Removing the Power Trim and Tilt Unit/Hydro Tilt Unit
227
Power Trim and Tilt Motor
228
Disassembling the Power Trim and Tilt Motor
229
Checking the Power Trim and Tilt Motor
229
Assembling the Power Trim and Tilt Motor
230
Gear Pump
232
Disassembling the Gear Pump
235
Checking the Gear Pump
235
Assembling the Gear Pump
235
Tilt Cylinder and Trim Cylinder
237
Disassembling the Trim Cylinder
239
Disassembling the Tilt Cylinder
239
Checking the Tilt Cylinder and Trim Cylinder
240
Checking the Valves
240
Assembling the Tilt Cylinder
240
Assembling the Power Trim and Tilt Unit
242
Bleeding the Power Trim and Tilt Unit
243
Installing the Power Trim and Tilt Unit/Hydro Unit
244
Bleeding the Power Trim and Tilt Unit (Built-In)
245
Power Trim and Tilt Electrical System
246
Checking the Fuse
246
Checking the Power Trim and Tilt Relay
246
Checking the Power Trim and Tilt Switch
247
Checking the Trim Sensor
248
Elec Electrical Systems
250
Special Service Tools
252
Electrical Systems
252
Checking the Electrical Components
253
Measuring the Peak Voltage
253
Measuring the Lower Resistance
253
Electrical Components
254
Port View
254
Bow View
255
Starboard View
256
Top View
257
Tiller Handle Model
258
Ignition and Ignition Control System
259
Checking the Ignition Spark
259
Checking the Spark Plug Wires
259
Checking the Ignition Coils
259
Checking the ECM
260
Checking the Pulser Coil
260
Checking the Pulser Coil Air Gap
261
Checking the Sensor Assembly
261
Checking the Oil Pressure Switch
261
Checking the Cooling Water Temperature Sensor
262
Checking the Shift Position Switch
262
Checking the Neutral Switch (Tiller Handle Model)
262
Checking the Main and Fuel Pump Relay (Main Control)
262
Checking the Engine Start Switch (Tiller Handle Model)
263
Checking the Engine Stop Lanyard Switch (Tiller Handle Model)
263
Checking the Warning Indicators (Tiller Handle Model)
264
Fuel Control System
264
Checking the Injectors
264
Checking the Electric Fuel Pump
264
Checking the Main and Fuel Pump Relay (Fuel Control)
265
Checking the Solenoid Valve
265
Starting System
266
Checking the Fuses
266
Checking the Starter Relay
266
Starter Motor
269
Disassembling the Starter Motor
269
Checking the Starter Motor Pinion
269
Checking the Armature
269
Checking the Brushes
270
Checking the Magnet Switch
270
Checking the Starter Motor Operation
270
Charging System
271
Checking the Stator Coil
271
Checking the Rectifier Regulator
271
Trbl Shtg Troubleshooting
273
Special Service Tools
274
Trbl Shtg
274
Troubleshooting
274
Yamaha Diagnostic System
274
Diagnosing the Electronic Control System
278
Self-Diagnosis
278
Power Unit
280
Power Trim and Tilt Unit
295
Other manuals for Yamaha F40D
Owner's Manual
110 pages
4
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Yamaha F40D Specifications
General
Brand
Yamaha
Model
F40D
Category
Outboard Motor
Language
English
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