Table Of Contents - Yamaha F40BMHD Service Manual

Table of Contents

How To Use This Manual4
Important Information8
Symbols12
Specifications12
Periodic Check And Adjustment12
General Information12
Table Of Contents14
Identification18
Serial Number18
Starting Serial Numbers18
Safety While Working20
Fire Prevention20
Ventilation20
Self-Protection20
Oils, Greases And Sealing Fluids20
Good Working Practices22
Disassembly And Assembly24
Special Tools26
Measuring26
Outillage Special27
Removing And Installing30
General Specifications38
Mesure39
Maintenance Specifications42
Power Unit42
Electrical52
Dimensions60
Tightening Torques66
Specified Torques66
General Torques70
Maintenance Interval Chart76
Top Cowling/Fuel System80
Checking The Top Cowling Fit80
Checking The Fuel Line80
Checking The Fuel Filter82
Control System82
Adjusting The Shift Cable82
Adjusting The Throttle Cable84
Adjusting The Engine Idling Speed86
Adjusting The Pilot Screw88
Exhaust Gas Control Procedures90
Synchronizing The Carburetor94
Adjusting The Dash-Pot98
Start-In-Gear Protection Device Adjustment (Mhd, Whd)98
Checking The Engine Oil Level100
Replacing The Engine Oil And Oil Filter100
Measuring The Oil Pressure102
Adjusting The Valve Clearance104
Measuring The Compression Pressure108
Checking The Timing Belt110
Cooling System110
Checking The Cooling Water Discharge110
Power Trim And Tilt System112
Checking The Power Trim And Tilt Fluid Level112
Lower Unit114
Checking The Gear Oil Level114
Changing And Checking The Gear Oil114
Checking The Lower Unit (For Air Leaks)116
General118
Checking The Anodes118
Checking The Battery118
Checking The Spark Plugs120
Checking Bolts And Nuts124
Lubrication Points126
Fuel System130
Hose Routing132
Fuel Joint, Fuel Filter, And Fuel Pump134
Removing/Installing The Fuel Joint, Fuel Filter And Fuel Pump134
Fuel Pump136
Disassembling/Assembling The Fuel Pump Assembly136
Installing The Fuel Filter138
Checking The Fuel Pump138
Carburetor Unit140
Removing/Installing The Carburetor Unit140
Removing/Installing The Carburetors144
Carburetor148
Disassembling/Assembling The Carburetor Assembly148
Disassembling/Assembling The Carburetor Assembly 2150
Checking The Carburetor154
Assembling The Carburetor154
Flywheel Magnet Assembly164
Removing/Installing The Manual Starter164
Flywheel Magnet Assembly (Ed, Et)166
Removing/Installing The Flywheel Magnet Assembly166
Removing The Flywheel Magnet Assembly168
Installing The Flywheel Magnet Assembly170
Recoil Starter172
Removing/Installing The Manual Starter Assembly174
Removing The Sheave Drum178
Removing The Spiral Spring178
Disassembling Sheave Drum180
Installing The Starter Rope180
Installing The Spiral Spring180
Installing The Sheave Drum182
Checking The Recoil Starter184
Disconnecting/Connecting The Leads186
Disconnecting/Connecting The Hoses188
Removing/Installing The Power Unit190
Stator Assembly192
Removing/Installing The Stator Assembly192
Removing The Sprockets198
Installing The Timing Belt And Sprockets200
Electrical Unit202
Removing/Installing The Electrical Unit202
Removing/Installing The Electrical Unit 1208
Shift Bracket And Throttle Control Lever216
Removing/Installing The Shift Bracket And Throttle Control Lever216
Cylinder Head218
Removing/Installing The Cylinder Head218
Disassembling/Assembling The Oil Pump222
Removing/Installing The Camshaft And Valve224
Checking Oil Pump228
Checking The Cylinder Head228
Checking The Valve230
Checking The Valve Spring232
Checking The Rocker Arm And Rocker Shaft232
Checking The Cam Shaft234
Checking The Decompression Actuators (Mh)234
Replacing The Valve Guide236
Refacing The Valve Seat236
Installing The Valve240
Exhaust Cover242
Removing/Installing The Exhaust Cover242
Installing The Oil Filter244
Checking The Thermostat244
Crankshaft And Piston246
Removing/Installing The Crankshaft And Piston246
Disassembling/Assembling The Piston250
Checking The Piston-To-Cylinder Clearance252
Checking The Piston Pin254
Checking The Piston Ring254
Checking The Crankshaft256
Checking The Main-Bearing Oil Clearance258
Checking The Big-End Oil Clearance262
Installing The Piston Ring266
Installing In The Engine266
Installing The Oil Seal266
Removing/Installing The Lower Unit274
Removing The Propeller278
Checking The Propller278
Installing The Propeller278
Installing The Trim Tab278
Water Pump280
Removing/Installing The Water Pump280
Checking The Water Pump Housing282
Checking The Impeller And Insert Cartridge282
Checking The Woodruff Key282
Installing The Impeller And Water Pump Housing282
Shift Rod Assembly284
Removing/Installing The Shift Rod Assembly284
Propeller Shaft Housing Assembly286
Disassembling/Assembling The Propeller Shaft Housing Assembly288
Removing The Propeller Shaft Housing Assembly292
Disassembling The Propeller Shaft Housing Assembly292
Checking The Reverse Gear294
Checking The Bearing294
Checking The Dog Clutch296
Checking The Propeller Shaft296
Assembling The Propeller Shaft Housing Assembly296
Drive Shaft300
Removing/Installing The Drive Shaft300
Removing The Drive Shaft302
Removing The Drive Shaft Bearing302
Assembling The Forward Gear Assembly306
Installing The Drive Shaft Bearing306
Installing The Drive Shaft308
Lower Case Assembly310
Disassembling The Lower Case Assembly312
Checking The Drive Shaft Sleeve312
Checking The Needle Bearing314
Assembling The Lower Case Assembly314
Shimming316
Spezialwerkzeuge319
Backlash340
Measuring The Forward Gear Backlash340
Measuring The Reverse Gear Backlash344
Magnetic Base Attaching Plate344
90890-07003 Dial Gauge Set344
Adjust346
Shim Thickness346
Mm (0.008 In)346
Bracket Unit348
Tiller Handle Assembly352
Removing/Installing The Steering Friction352
Removing/Installing The Tiller Handle Assembly354
Disassembling/Assembling The Tiller Handle Assembly356
Mm (0.024 In)356
Disassembling/Assembling The Link Assembly362
Bottom Cowling364
Removing/Installing The Bottom Cowling364
Upper Case Assembly366
Removing/Installing The Upper Case Assembly366
Removing/Installing The Ground Lead368
Disassembling/Assembling The Upper Case Assembly370
Steering Arm376
Removing/Installing The Steering Arm376
Installing The Bushing378
Clamp Brackets (Mhd, Whd, Ed)380
Removing/Installing The Clamp Brackets380
Removing The Shock Absorber386
Checking The Shock Absorber386
Clamp Brackets (Et)388
Power Trim And Tilt Unit392
Removing/Installing The Power Trim And Tilt Unit392
Removing The Power Trim And Tilt Unit396
Bleeding The Power Trim And Tilt Unit396
Tilt Cylinder Assembly400
Disassembling/Assembling The Tilt Cylinder Assembly400
Removing The Tilt Ram Assembly402
Checking The Tilt Ram404
Assembling The Tilt Ram404
Assembling The Tilt Cylinder Assembly406
Filling The Reservoir408
Gear Pump Assembly412
Disassembling/Assembling The Gear Pump Assembly412
Disassembling The Gear Pump Assembly416
Disassembling/Assembling The Pump Housing418
Pump Housing420
Gear Pump Unit424
Disassembly/Assembly The Gear Pump Unit424
Electrical System426
Electrical Components432
Starboard And Port View (Port View)432
Top View434
Tiller Handle Model (Whd)436
Wire Harness (Mhd)438
Wire Harness (Whd, Ed 10-Pin)440
Wire Harness (Ed 7-Pin)442
Wire Harness (Et)444
Electrical Components Analysis446
Digital Circuit Tester446
Measuring The Peak Voltage446
Peak Voltage Adaptor446
Measuring A Low Resistance448
Ignition System (Mhd)450
Ignition System (Whd, Ed, Et)452
Checking The Ignition Spark Gap454
Checking The Spark Plug Caps456
Checking The Ignition Coil456
Checking The Charge Coil458
Checking The Pulser Coil458
Checking The Cdi Unit460
Ignition Control System (Mhd)462
Ignition Control System (Whd, Ed, Et)464
Checking The Main Switch466
Checking The Engine Stop Switch466
Measuring The Pulser Coil Output Peak Voltage468
Checking The Oil Pressure Switch Continuity468
Starting System (Whd, Ed, Et)472
Checking The Fuses474
Checking The Wire Harness Continuity474
Checking The Wire Connections476
Checking The Starter Relay476
Starter Motor478
Disassembling/Assembling The Starter Motor478
Removing The Starter Motor Pinion482
Checking The Starter Motor Pinion482
Checking The Armature482
Measuring The Brushes484
Charging System (Whd, Ed, Et)488
Enrichment Control System492
Power Trim And Tilt System (Et)498
Checking The Power Trim And Tilt Relay500
Checking The Trailer Switch Continuity502
Measuring The Trim Sensor Resistance502
Power Trim And Tilt Motor (Et)504
Checking The Motor506
Checking The Power Trim And Tilt Motor Assembly508
Trouble Analysis510
Trouble Analysis Chart512
Trouble Shooting For Peak Voltage524
Wiring Diagram530