Yamaha 40X Owner's Manual
Yamaha outboard motor
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- Service manual (417 pages) ,
- Owner's manual (140 pages) ,
- Owner's manual (82 pages)
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Summary of Contents for Yamaha 40X
- Page 1 E40X OWNER’S MANUAL Read this manual carefully before operating this outboard motor. 66T-28199-2C-E0...
- Page 2 EMU25052 Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.
- Page 3 Any damage tain maximum enjoyment from your new resulting from neglect of these instructions is Yamaha. If you have any question about the not covered by warranty. operation or maintenance of your outboard Some countries have laws or regulations re- motor, please consult a Yamaha dealer.
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Page 4: Table Of Contents
Table of contents Safety information......1 Propeller selection ......11 Start-in-gear protection ....12 Outboard motor safety ..... 1 Engine oil requirements ....12 Propeller..........1 Fuel requirements ......12 Rotating parts........1 Gasoline .......... 12 Hot parts ........... 1 Muddy or acidic water .... - Page 5 Table of contents Hour meter ........24 Adjusting boat trim ......46 Engine control system....25 Tilting up and down......47 Procedure for tilting up (manual tilt Alert system ........25 models) ......... 47 Overheat alert ......... 25 Procedure for tilting up (power trim Installation ........
- Page 6 Table of contents Connecting the battery ....67 Disconnecting the battery ....67 Trouble Recovery ......69 Troubleshooting ......69 Temporary action in emergency..72 Impact damage ....... 72 Replacing fuse ........ 72 Power trim and tilt will not operate.......... 73 Starter will not operate ....
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Page 7: Safety Information
Safety information tor and the clamp bracket when the motor is EMU33622 Outboard motor safety trimmed or tilted. Keep body parts out of this Observe these precautions at all times. area at all times. Be sure no one is in this EMU36501 area before operating the power trim and tilt Propeller... -
Page 8: Gasoline Exposure And Spills
Have an approved personal flotation device tions. Overloading or incorrect weight (PFD) on board for every occupant. Yamaha distribution can compromise the boats han- recommends that you must wear a PFD dling and lead to an accident, capsizing or... -
Page 9: Avoid Collisions
Safety information swamping. EMU33880 Passenger training EMU33772 Avoid collisions Make sure at least one other passenger is Scan constantly for people, objects, and oth- trained to operate the boat in the event of an er boats. Be alert for conditions that limit your emergency. -
Page 10: General Information
Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number... -
Page 11: C-Tick Label
General information ZMU04866 ZMU04902 1. CE marking location 1. C-Tick label location ZMU06081 ZMU06081 1. CE marking location 1. C-Tick label location ZMU01697 ZMU06040 EMU25213 C-Tick label Engines affixed with this label conform to certain portion(s) of the Australian Radio Communications Act. -
Page 12: Read Manuals And Labels
Read all labels on the outboard motor and the boat. ● If you need any additional information, contact your Yamaha dealer. EMU33832 Warning labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. 40X, E40X ZMU06080... - Page 13 General information ZMU05670 EMU33912 Contents of labels EWM01671 The above warning labels mean as follows. WARNING Read Owner’s Manuals and labels. ● EWM01691 Wear an approved personal flotation ● WARNING device (PFD). Emergency starting does not have start- Attach engine shut-off cord (lanyard) to ●...
- Page 14 General information Electrical hazard EMU33843 Symbols The following symbols mean as follows. Notice/Warning ZMU05666 Remote control lever/gear shift lever operat- ing direction, dual direction ZMU05696 Read Owner’s Manual ZMU05667 Engine start/ Engine cranking ZMU05664 Hazard caused by continuous rotation ZMU05668 ZMU05665...
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Page 15: Specifications And Requirements
Specifications and requirements 29.4 kW@5000 r/min EMU31480 Specifications (40 HP@5000 r/min) TIP: Idle speed (in neutral): 1000 50 r/min “(AL)” stated in the specification data below Engine: represents the numerical value for the alumi- Type: num propeller installed. 2-stroke L Likewise, “(SUS)”... -
Page 16: Installation Requirements
Specifications and requirements E40XMH Manual tilt EMU33554 Installation requirements Propeller mark: EMU33564 Boat horsepower rating Fuel and oil: EWM01560 Recommended fuel: WARNING Regular unleaded gasoline Overpowering a boat can cause severe Fuel tank capacity: instability. 24 L (6.34 US gal, 5.28 Imp.gal) Recommended engine oil: Before installing the outboard motor(s), con- YAMALUBE 2-stroke outboard motor... -
Page 17: Battery Requirements
Fire, explosion or sparks could result. appropriate. [EWM01820] Your Yamaha dealer can help you select the EMU36300 right propeller for your boating needs. Select Multiple batteries a propeller that will allow the engine to reach... -
Page 18: Start-In-Gear Protection
EMU25651 Engine oil requirements engine starting and running problems. Yamaha does not recommend gasohol con- Recommended engine oil: taining methanol because it can cause fuel YAMALUBE 2-stroke outboard motor system damage or engine performance problems. -
Page 19: Motor Disposal Requirements
(including metric sizes), and electrical tape. Waterproof flashlight with extra batteries. ● An extra engine shut-off cord (lanyard) ● with clip. Spare parts, such as an extra set of spark ● plugs. Consult your Yamaha dealer for details. -
Page 20: Components
EMU2579T Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all mod- els (order from dealer). 40X, E40X 12 13 16 15 ZMU05259 1. Top cowling 16. Engine stop button/Engine shut-off switch* 2. -
Page 21: Fuel Joint
Components EWM00020 EMU26181 Remote control box WARNING The remote control lever actuates both the The fuel tank supplied with this engine is shifter and the throttle. The electrical switch- its dedicated fuel reservoir and must not es are mounted on the remote control box. be used as a fuel storage container. -
Page 22: Neutral Interlock Trigger
Components 1. Neutral “ ” 1. Fully open 2. Fully closed 2. Forward “ ” 3. Reverse “ ” TIP: 4. Shift 5. Fully closed The neutral throttle lever will operate only 6. Throttle when the remote control lever is in neutral. 7. -
Page 23: Gear Shift Lever
Components the left or right as necessary. ZMU03034 ZMU03032 EMU25961 Throttle indicator EMU25923 Gear shift lever The fuel consumption curve on the throttle Move the gear shift lever forward to engage indicator shows the relative amount of fuel the forward gear or rearward to engage the consumed for each throttle position. -
Page 24: Engine Shut-Off Cord (Lanyard) And Clip
Components or throttle grip, which could result in an tangled, preventing it from functioning. accident. Avoid accidentally pulling the cord dur- [EWM00032] ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. -
Page 25: Choke Knob For Pull Type
Components its operation is described below. ” (off) “ ● With the main switch in the “ ” (off) posi- tion, the electrical circuits are off, and the key can be removed. ” (on) “ ● With the main switch in the “ ”... -
Page 26: Steering Friction Adjuster
Components tance to the steering mechanism, and can be set according to operator preference. An ad- justing screw or bolt is located on the swivel bracket. ZMU02810 If the resistance does not increase even when the lever is turned to the port side “A”, make sure that the nut is tightened to the ZMU03039 specified torque. -
Page 27: Trim Tab With Anode
Components ZMU02822 EMU26244 1. Trim tab Trim tab with anode 2. Bolt EWM00840 WARNING Bolt tightening torque: An improperly adjusted trim tab could 18.0 Nm (1.8 kgf-m, 13 ft-lb) cause difficult steering. Always test run after the trim tab has been installed or re- EMU26262 Trim rod (tilt pin) placed to be sure steering is correct. -
Page 28: Tilt Support Knob
Components EMU26333 Tilt support bar The tilt support bar keeps the outboard motor in the tilted up position. ZMU03041 1. Tilt lock lever To lock it, set the tilt lock lever in the lock po- ZMU03043 sition. To release, push the tilt lock lever in ECM01660 the release position. - Page 29 Components ZMU02009 1. Cowling lock lever(s)
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Page 30: Instruments And Indicators
The gauge shows the engine speed. time elapsed either when the main switch is on or only when the engine is running. For in- structions on how to select the counting mode, consult your Yamaha dealer. ZMU04579 EMU26591 Analog speedometer This gauge shows the boat speed in km/h and mph. -
Page 31: Engine Control System
Check the cooling water inlet for clogging. ● Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU2681C Overheat alert This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate. -
Page 32: Installation
Installation EMU26902 Installation The information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Proper mounting depends in part on experience and the specific boat and motor combination. EWM01590 WARNING ZMU01760... -
Page 33: Clamping The Outboard Motor
Test runs at different heights can help de- off the transom. termine the optimum mounting height. Consult your Yamaha dealer or boat man- ufacturer for further information on deter- mining the proper mounting height. For instructions on setting the trim angle of ●... - Page 34 Installation packaging. If used, they must be of at least the same quality of material and strength and must be tightened se- curely. After tightening, test run the engine and check their tightness. [EWM00651] ZMU02637 1. Bolts...
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Page 35: Operation
Operation plane, then immediately reduce the EMU36381 First-time operation throttle to 3000 r/min or less. Next two hours: EMU30174 Breaking in engine Accelerate at full throttle onto plane, Your new engine requires a period of break- then reduce engine speed to three-quar- in to allow mating surfaces of moving parts to ter throttle (approximately 4000 r/min). -
Page 36: Fuel Level
If any water is found in the fuel, or if a the top cowling, release the cowling lock le- significant amount of debris is found, the fuel ver and lift off the top cowling. tank should be checked and cleaned by a Yamaha dealer. ZMU06090 ZMU06082 EMU36442 Fuel system... -
Page 37: Engine Shut-Off Cord (Lanyard)
[ECM01991] ZMU06115 ZMU02003 After installing, check the fitting of the top 1. Cord cowling by pushing it with both hands. If the 2. Clip top cowling is loose, have it repaired by your 3. Engine shut-off switch Yamaha dealer. -
Page 38: Power Trim And Tilt System
Operation ZMU02828 ZMU04678 1. Trim and tilt rod EMU34581 Power trim and tilt system Check that the trim and tilt rod is free of EWM01930 WARNING corrosion or other flaws. Tilt the outboard motor down. Check that Never get under the lower unit while it ●... -
Page 39: Gasoline And Oil Mixing (100:1)
Operation some gasoline in your eyes, see your ing or funnel to help prevent electrostatic doctor immediately. If gasoline spills sparks. on your skin, wash with soap and wa- Fill the fuel tank, but do not overfill. ter. If gasoline spills on your clothing, WARNING! Do not overfill. - Page 40 Operation Gasoline to engine oil ratio Break-in period See page 29 After break-in 100:1 100:1 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal) 0.01 L 0.12 L...
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Page 41: Operating Engine
Operation the oil gradually as the gasoline is being add- the fuel joint on the fuel line with the fuel ed to the tank. joint on the motor and firmly connect the fuel line to the joint while pinching the EMU27452 Operating engine joint. -
Page 42: Starting Engine
Operation Place the gear shift lever in neutral. ZMU03045 1. Arrow TIP: EMU27493 The start-in-gear protection device prevents Starting engine the engine from starting except when in neu- EWM01600 tral. WARNING Attach the engine shut-off cord to a se- Before starting the engine, make sure cure place on your clothing, or your arm that the boat is tightly moored and that or leg. - Page 43 Operation ZMU02954 After the engine starts, slowly return the Pull out / turn the choke knob fully. After manual starter handle to its original posi- the engine starts, replace / return the tion before releasing it. knob to the home position. Slowly return the throttle grip to the fully closed position.
- Page 44 Operation EMU27636 Manual start models (remote control) EWM01840 WARNING Failure to attached engine shut-off cord ● could result in a runaway boat if opera- tor is ejected. Attach the engine shut- off cord to a secure place on your cloth- ing, or your arm or leg while operating.
- Page 45 Operation gine is warm and fails to start, open the throttle a small amount and try to start the engine again. If the engine still fails to start, see page 69. EMU27645 Electric start / remote control models EWM01840 WARNING Failure to attached engine shut-off cord ●...
- Page 46 Operation or leg. Then install the clip on the other TIP: end of the cord into the engine shut-off On remote controls equipped with a neu- ● switch. tral throttle lever, a good starting point is to lift the lever just until you feel resistance, then lift slightly more.
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Page 47: Checks After Starting Engine
Confirm that the engine cannot be started ● case or the cooling water pilot hole is with the clip removed from the engine blocked. Consult your Yamaha dealer if shut-off switch. the problem cannot be located and cor- EMU34530 rected. - Page 48 Operation swimmers or obstacles in the water near you. ECM01610 NOTICE Warm up the engine before shifting into gear. Until the engine is warm, the idle speed may be higher than normal. High idle speed can prevent you from shifting back to neutral.
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Page 49: Stopping Boat
Operation ZMU03064 EMU31742 Stopping boat EWM01510 WARNING Do not use the reverse function to slow ● down or stop the boat as it could cause you to lose control, be ejected, or im- pact the steering wheel or other parts of the boat. -
Page 50: Trimming Outboard Motor
Operation ZMU02083 ZMU02301 Remove the key if the boat will be left un- attended. TIP: The engine can also be stopped by pulling the cord and removing the clip from the en- gine shut-off switch, then turning the main switch to “ ”... -
Page 51: Adjusting Trim Angle For Manual Tilt Models
Operation ZMU03063 1. Trim rod Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to- ward the transom. Make test runs with the trim set to different angles to find the position that works best for ZMU03062 your boat and operating conditions. -
Page 52: Adjusting Boat Trim
Operation board motor when adjusting the trim the boat is up about 3 to 5 degrees. With the angle. Body parts can be crushed be- bow up, the boat may have a greater tenden- tween the motor and the clamp bracket cy to steer to one side or the other. -
Page 53: Tilting Up And Down
Operation also makes the boat unstable. Resistance at ECM00241 NOTICE the bow is greatly increased, heightening the Before tilting the outboard motor, stop danger of “bow steering” and making opera- ● the engine by following the procedure tion difficult and dangerous. on page 43. -
Page 54: Procedure For Tilting Up (Power Trim And Tilt Models)
Operation ZMU03065 ZMU04851 Place the tilt lock lever (if equipped) in EMU32724 Procedure for tilting up (power trim the release/up position. and tilt models) Place the remote control lever in neutral. ZMU03066 Pull up the shallow water lever (if equipped). Press the power trim and tilt switch “... -
Page 55: Procedure For Tilting Down (Power Trim And Tilt Models)
Operation tilt support knob or tilt support lever. Pull out the tilt support knob. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the pow- er tilt unit loses pressure. [EWM00262] NOTICE: Do not use the tilt support lever or knob when trailering the... -
Page 56: Shallow Water
Operation If equipped with a tilt support knob: Pull EMU28125 Procedure it out, then slowly tilt the engine down. Place the remote control lever / gear EMU28061 Shallow water shift lever in neutral. EMU28073 Cruising in shallow water (manual tilt models) EWM01781 WARNING... -
Page 57: Power Trim And Tilt Models
Operation cruising. ing can result. EMU32922 Procedure for power trim and tilt models Place the remote control lever in neutral. ZMU04851 To return the outboard motor to the nor- mal running position, place the remote control lever / gear shift lever in neutral. Place the tilt lock lever in the lock/down Slightly tilt the outboard motor up to the position, then slightly tilt the outboard... -
Page 58: Cruising In Other Conditions
Cruising in muddy, turbid, or acidic water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 12) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. -
Page 59: Maintenance
Leaking fuel is a fire hazard. When ● such as a transom saver bar. Consult your transporting and storing the outboard Yamaha dealer for further details. motor, disconnect the fuel line from the outboard motor to prevent fuel from EMU28236 Clamp screw mounting models leaking. -
Page 60: Storing Outboard Motor
EMU30272 Storing outboard motor plate. NOTICE: If the fresh water level When storing your Yamaha outboard motor is below the level of the anti-cavita- for prolonged periods of time (2 months or tion plate, or if the water supply is in- longer), several important procedures must sufficient, engine seizure may occur. -
Page 61: Lubrication
Seal replacement should be performed to perform a maintenance procedure, by an authorized Yamaha dealer prior to have a Yamaha dealer or other qualified use. mechanic do the work. -
Page 62: Replacement Parts
Yamaha marine dealership. EMU28511 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. -
Page 63: Maintenance Chart 1
The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 20 hours Item... - Page 64 Maintenance Initial Every 20 hours Item Actions hours (1 hours (3 hours (5 months) year) years) years) Fuel line (High pres- Inspection or replace- sure) ment as necessary Fuel line (Low pres- Inspection sure) Fuel line (Low pres- Inspection or replace- sure) ment as necessary Inspection or replace-...
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Page 65: Maintenance Chart 2
Item Actions hours (1 hours (3 hours (5 months) year) years) years) (Yamaha) Meter/gauge Inspection Fuel tank (Yamaha por- Inspection and clean- table tank) ing as necessary EMU34451 Maintenance chart 2 Every Item Actions 1000 hours Exhaust guide/exhaust Inspection or replace-... -
Page 66: Greasing
Maintenance EMU28943 Greasing Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft) E40XMH ZMU03074... -
Page 67: Cleaning And Adjusting Spark Plug
Instead, take the outboard motor to a lead to explosion or fire. [EWM00561] Yamaha dealer. You should periodically re- Standard spark plug: move and inspect the spark plug because BR7HS heat and deposits will cause the spark plug to slowly break down and erode. -
Page 68: Checking Fuel Filter
9. If you have difficulty verifying the or foreign matter is found in the filter, clean or idle speed, or the idle speed requires ad- replace it. For cleaning or replacement of the justment, consult a Yamaha dealer or fuel filter, consult your Yamaha dealer. -
Page 69: Inspecting Wiring And Connectors
Maintenance other qualified mechanic. EMU29114 Inspecting wiring and connectors Inspect that each connector is engaged ● securely. Inspect that each ground lead is properly ● secured. ZMU01897 Checkpoints Check each of the propeller blades for ero- ● sion from cavitation or ventilation, or other damage. -
Page 70: Installing Propeller
Changing gear oil ation and be lost. EWM00800 WARNING Apply Yamaha marine grease or a corro- sion resistant grease to the propeller Be sure the outboard motor is securely ● shaft. fastened to the transom or a stable Install the spacer (if equipped), thrust stand. -
Page 71: Cleaning Fuel Tank
EMU29302 amount of metal particles, the gear Cleaning fuel tank case may be damaged. Have a EWM00920 Yamaha dealer check and repair the WARNING outboard motor. Gasoline is highly flammable, and its va- [ECM00713] TIP: pors are flammable and explosive. -
Page 72: Inspecting And Replacing Anode(S)
● flames, or other sources of ignition from the surfaces of the anodes. Consult a when cleaning the fuel tank. Yamaha dealer for replacement of external Remove the fuel tank from the boat be- anodes. ● fore cleaning it. Work only outdoors in... -
Page 73: Connecting The Battery
1. Red cable tery’s charge. If the battery needs charg- 2. Black cable ing, consult your Yamaha dealer. 3. Battery Check the battery connections. They should be clean, secure, and covered by The electrical contacts of the battery and an insulating cover. - Page 74 Maintenance equipped) and main switch. NOTICE: If they are left on, the electrical system can be damaged. [ECM01930] Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al- ways disconnect all negative (-) ca- bles first to avoid a short circuit and damage to the electrical system.
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Page 75: Trouble Recovery
Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble-alert indicator is flash- Q. Are spark plug(s) fouled or of incorrect ing, consult your Yamaha dealer. - Page 76 Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
- Page 77 Q. Is fuel system obstructed? Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or A. Have serviced by a Yamaha dealer. other obstructions in fuel system. Q. Is there excess water in fuel filter cup? Q.
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Page 78: Temporary Action In Emergency
A. Tighten bolt. holder, and replace the fuse with a new one of the proper amperage. Q. Is steering pivot loose or damaged? EWM00631 A. Tighten or have serviced by a Yamaha WARNING dealer. Substituting an incorrect fuse or a piece EMU29433... -
Page 79: Power Trim And Tilt Will Not Operate
Trouble Recovery gency starter rope. EWM01022 WARNING Use this procedure only in an emergen- ● cy to return to the nearest port for re- pairs. When the emergency starter rope is ● used to start the engine, the start-in- gear protection device does not oper- ZMU03081 ate. -
Page 80: Emergency Starting Engine
Trouble Recovery plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor. You could get an electrical shock. EMU29562 Emergency starting engine Remove the top cowling. Remove the start-in-gear protection ca- ble from the starter, if equipped. ZMU02026 ZMU03082 ZMU02334... -
Page 81: Treatment Of Submerged Motor
EMU33501 Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. NOTICE: Do not attempt to run the outboard motor until it has been com- pletely inspected. - Page 82 YAMAHA MOTOR CO., LTD. Printed in Japan March 2010–0.3 1 ! Printed on recycled paper...