Yamaha EK40G Service Manual
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Yamaha EK40G Service Manual

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EK40G
EK40J
SERVICE MANUAL
6H9-28197-5G-11

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Summary of Contents for Yamaha EK40G

  • Page 1 EK40G EK40J SERVICE MANUAL 6H9-28197-5G-11...

  • Page 2: Important Information

    NOTICE This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

  • Page 3: Table Of Contents

    Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 5: General Information

    INFO General information How to use this manual ................1-1 Manual format ..................1-1 Symbols ....................1-2 Safety while working ................... 1-3 Fire prevention ..................1-3 Ventilation ....................1-3 Self-protection ..................1-3 Parts, lubricants, and sealants ..............1-3 Good working practices ................1-4 Disassembly and assembly ..............

  • Page 6: How To Use This Manual

    INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list.

  • Page 7: Symbols

    7 Apply Yamaha 2-stroke motor oil q Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 8: Safety While Working

    Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous.

  • Page 9: Good Working Practices

    Safety while working Disassembly and assembly 6. Keep a supply of clean, lint-free cloths for 1. Use compressed air to remove dust and wiping up spills, etc. dirt during disassembly. Good working practices 2. Apply engine oil to the contact surfaces Special service tools of moving parts before assembly.

  • Page 10: Identification

    Propeller size The size of the propeller is indicated on the outside of the propeller boss or the propeller blade. 6F610010 × YAMAHA MOTOR CO., LTD. 6B410030 MADE IN JAPAN PAYS D'ORIGINE JAPON 6B410020 × − 1 Model name...

  • Page 11: Selection

    (4,500–5,500 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. EK40G Propeller size (in) Material 11 3/4 × 7 1/2 - H 11 3/4 × 8 3/4 - H 11 3/4 ×...

  • Page 12: Checking The Outboard Motor Mounting Height

    INFO General information 2. Check that the positive and negative bat- tery leads are securely connected. Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is between the bottom of the boat and a maximum of 25 mm (1 in) a below it. If the mounting height is too high, cavitation will occur and propulsion will be reduced.

  • Page 13: Checking The Steering System

    Predelivery checks Checking the steering system Checking the gear shift and throttle 1. Check the steering friction for proper operation adjustment. 1. Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from neutral to for- ward or reverse.

  • Page 14: Checking The Engine Start Switch, Engine Stop Lanyard Switch And Engine Stop Button

    INFO General information Checking the engine start switch, engine stop lanyard switch and engine stop button 1. Check that the engine starts when the engine start switch is turned to START. (remote control model) 2. Check that the engine turns off when the engine start switch is turned to OFF.

  • Page 15: Break-In

    Predelivery checks Break-in After test run During the test run, perform the break-in 1. Check for water in the gear oil. operation in the following 5 stages. 1. 10 minutes a at the lowest possible 2. Check for fuel leakage in the cowling. speed.
  • Page 16 INFO — MEMO — 1-11 6H95G11...

  • Page 17: Specifications

    SPEC Specifications General specification ................... 2-1 Maintenance specification ................2-3 Power unit ....................2-3 Lower unit ....................2-5 Electrical ....................2-5 Dimensions ....................2-7 Tightening torques ..................2-9 Specified torques ..................2-9 General torques ..................2-10 6H95G11...

  • Page 18: General Specification

    SPEC Specifications General specification Model Item Unit EK40GMH EK40JMH EK40JW Dimensions Overall length mm (in) 997 (39.3) 692 (27.2) Overall width mm (in) 484 (19.1) 363 (14.3) Overall height mm (in) 1,215 (47.8) 1,208 (47.6) mm (in) 1,342 (52.8) 1,335 (52.6) –...
  • Page 19 General specification Model Item Unit EK40GMH EK40JMH EK40JW Fuel and oil Fuel type Regular gasoline and kerosene Engine oil 2-stroke outboard motor oil Engine oil grade NMMA-certified TC-W3 Gear oil type Hypoid gear oil Gear oil grade (*1) GL-4 Gear oil quantity (US oz, 315 (10.65, 11.11) lmp oz)

  • Page 20: Maintenance Specification

    SPEC Specifications Maintenance specification Power unit Model Item Unit EK40GMH EK40JMH EK40JW Power unit Minimum compression 400 (4.0, 58) pressure (*1) (kgf/cm , psi) Cylinder head Warpage limit mm (in) 0.1 (0.0039) (lines indicate straightedge position) Cylinders Bore size mm (in) 78.000–78.020 (3.0709–3.0716) Wear limit mm (in)
  • Page 21 Maintenance specification Model Item Unit EK40GMH EK40JMH EK40JW Piston rings Top ring Dimension B mm (in) 1.970–1.990 (0.0776–0.0783) Dimension T mm (in) 2.500–2.700 (0.0984–0.1063) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) Oversize diameter mm (in) 78.25 (3.0807) mm (in) 78.50 (3.0906)

  • Page 22: Lower Unit

    SPEC Specifications Model Item Unit EK40GMH EK40JMH EK40JW Carburetor ID mark 6F542 6H903 Kerosene Gasoline Kerosene Gasoline Main jet (M.J.) – – Main air jet (M.A.J.) ø1.70 – ø1.70 – Main nozzle (M.N.) mm (in) 3.2 (0.13) – 3.2 (0.13) –...
  • Page 23 Maintenance specification Model Item Unit EK40GMH EK40JMH EK40JW Secondary coil (spark plug wire–spark plug wire) kΩ 6.8–10.2 at 20°C (68°F) CDI unit output peak voltage (O–B) at Cranking (loaded) at 1,500 r/min (loaded) at 3,500 r/min (loaded) Pulser coil output peak voltage (W/R–B, W/B–B) at Cranking (unloaded) 10.0...

  • Page 24: Dimensions

    SPEC Specifications Dimensions Exterior mm (in) S: 784 (30.9) EK40JW L: 897 (35.3) S: 797 (33.4) 427 (16.8) 188 (7.4) 504 (19.8) 72 (2.8) 193 (7.6)* 421 (16.6) EK40JW 478 (18.9) 6H92001M 6H95G11...
  • Page 25 Maintenance specification Clamp bracket mm (in) 6F62002M 6H95G11...

  • Page 26: Tightening Torques

    Spark plug Lower unit Check screw — Drain screw — Lower case mounting bolt 15.5 Lower case cap bolt (EK40G) Cooling water inlet cover (EK40J) Propeller nut (EK40J) 25.3 Propeller shaft housing ring nut (EK40J) — Pinion nut (EK40J) 54.6...

  • Page 27: General Torques

    Tightening torques General torques This chart specifies tightening torques for standard fasteners with a standard ISO thread pitch. Tightening torque specifications for special components or assemblies are provided in applicable sections of this manu- To avoid warpage, tighten multi-fastener assemblies in a crisscross fashion and pro- gressive stages until the specified torque is reached.
  • Page 28 SPEC — MEMO — 2-11 6H95G11...
  • Page 29 Periodic checks and adjustments Special service tools ................... 3-1 Maintenance interval chart ................3-2 Top cowling ....................3-3 Checking the top cowling ................ 3-3 Fuel system ....................3-3 Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ..... 3-3 Checking the fuel filters ................3-3 Power unit .....................

  • Page 30: Chk Adj

    Periodic checks and adjustments Special service tools Digital tachometer 90890-06760 Leakage tester 90890-06840 6H95G11...

  • Page 31: Maintenance Interval Chart

    Check / charge Cooling water passages Clean Cowling clamp Check Fuel filter (can be dis- Check / clean assembled) Fuel system Check Fuel tank (Yamaha por- Check / clean — table tank) Gear oil Change Lubrication points Lubricate 3-10 Idling speed (carbure-...

  • Page 32: Chk Adj

    Periodic checks and adjustments Top cowling NOTE: Be sure not to spill any fuel when removing Checking the top cowling the fuel filter cup. 1. Check the fitting by pushing the cowling with both hands. Power unit Checking the spark plugs 1.

  • Page 33: Checking The Thermostat

    3. Place a thermometer in the water and 6F630060 ∫ slowly heat the water. 6F630070 6B430060 å EK40G ∫ EK40J 4. Check the thermostat valve opening at specified water temperatures. 2. Place the lower unit in water, then start Replace if out of specification.

  • Page 34: Control System

    Periodic checks and adjustments Control system Adjusting the throttle cable (MH) Adjusting the start-in-gear protec- tion NOTE: 1. Set the gear shift to the neutral position. Before adjusting the throttle cables, the throt- tle stop screw should be properly adjusted. 2.

  • Page 35: Adjusting The Throttle Cable (W)

    Control system 4. Adjust the position of the cable end 5 6. Fully open and close the throttle grip and make sure the stopper on the pulley con- until it is aligned with the hole on the pul- tacts the stopper on the bracket (at the ley.

  • Page 36: Checking The Engine Idle Speed

    Periodic checks and adjustments Checking the gear shift operation Checking the engine idle speed 1. Start the engine and warm it up for 5 min- utes. 1. Check that the gear shift operates 2. Attach the special service tool to spark smoothly when shifting it from neutral to plug wire #1 1, and then check the forward or reverse.

  • Page 37: Bracket

    Bracket/Lower unit Bracket Changing the gear oil 1. Fully tilt the outboard motor down. Checking the tilt operation 2. Place a drain pan under the drain screw 1. Fully tilt the outboard motor up and down 1, remove the drain screw, then the a few times and check the entire tilt range check screw 2 and let the oil drain com- for smooth operation.

  • Page 38: Checking The Lower Unit For Air Leakage

    1. Remove the check screw 1, and then install the special service tool. 6F630220 ∫ 6F630310 6F630230 å EK40G Leakage tester: 90890-06840 ∫ EK40J 2. Apply the specified pressure to check Do not oil, grease, or paint the anodes or that the pressure is maintained in the the trim tab, otherwise they will be inef- lower unit for at least 10 seconds.

  • Page 39: Lubricating The Outboard Motor

    General Battery electrolyte is dangerous; it con- tains sulfuric acid which is poisonous and highly caustic. 9 Avoid bodily contact with electrolyte as it can cause severe burns or permanent eye injury. 9 Wear protective eye gear when handling 6F630250 or working near batteries.
  • Page 40 Periodic checks and adjustments 2. Apply low temperature resistant grease to the area shown. 6F630300 3. Apply corrosion resistant grease to the area shown. 6B430300 3-11 6H95G11...

  • Page 41: Fuel

    FUEL Fuel system Special service tools ................... 4-1 Hose routing ....................4-2 Fuel line ......................4-3 Carburetor ..................... 4-5 Disassembling the carburetor ..............4-9 Checking the carburetor ................4-9 Assembling the carburetor ..............4-10 Adjusting the throttle stop screw ............4-11 Fuel pump ....................

  • Page 42: Fuel System

    FUEL Fuel system Special service tools Vacuum/pressure pump gauge set 90890-06756 Digital caliper 90890-06704 6H95G11...

  • Page 43: Hose Routing

    Special service tools/Hose routing Hose routing 6H94010E 1 Fuel hose (Fuel joint-to-fuel filter: For Gasoline) 2 Fuel hose (Fuel joint-to-fuel filter: For Kerosene) 3 Fuel hose (Fuel filter-to-fuel pump: For Gasoline) 4 Fuel hose (Fuel filter-to-fuel pump: For Kerosene) 5 Fuel hose (Fuel pump-to-carburetor: For Gasoline) 6 Fuel hose (Fuel pump-to-carburetor: For Kerosene) 7 Pilot water hose 6H95G11...

  • Page 44: Fuel Line

    FUEL Fuel system Fuel line 6H94020E Part name Q’ty Remarks Clip Fuel hose Fuel hose M6 × 25 mm Bolt Fuel joint Grommet Fuel hose Fuel hose Fuel hose Fuel hose M6 × 55 mm Bolt Fuel pump Gasket Not reusable Bolt Not reusable Bracket...
  • Page 45 Fuel line 6H94020E Part name Q’ty Remarks Fuel filter element O-ring ø6 × 30 mm Screw Intake silencer O-ring Not reusable ø6 × 12 mm Screw Link lever Choke rod Collar Link rod Washer Gasket Not reusable Carburetor assembly Gasket Not reusable 6H95G11...

  • Page 46: Carburetor

    FUEL Fuel system Carburetor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H94040E Part name Q’ty Remarks Damper Hose ø4 × 14 mm Screw Cover Gasket Not reusable Throttle stop screw Spring Pilot screw Spring O-ring ø4 × 5 mm Screw Gasket Not reusable Washer Joint...
  • Page 47 Carburetor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H94040E Part name Q’ty Remarks Lever Pump lever assembly ø4 × 5 mm Screw Gasket Not reusable Drain screw Gasket Not reusable ø5 × 16 mm Screw Main jet Gasket Not reusable Main nozzle Carburetor body Pilot jet Float pin...
  • Page 48 FUEL Fuel system 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H94040E Part name Q’ty Remarks Gasket Not reusable Float chamber Nozzle Gasket Not reusable O-ring Not reusable O-ring Not reusable Stopper Plunger Drain screw Gasket Not reusable Drain screw Gasket Not reusable Check valve Starter jet Gasket...
  • Page 49 Carburetor 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H94040E Part name Q’ty Remarks Float arm Needle valve ø4 × 5 mm Screw Valve seat Gasket Not reusable Ball seat Ball Spring Gasket Not reusable Carburetor body ø5 × 16 mm Screw ø6 ×...

  • Page 50: Disassembling The Carburetor

    FUEL Fuel system Disassembling the carburetor NOTE: 9 Before disassembling the carburetor, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 9 Disassembled jets and other components should be sorted out and kept in order, so 6B440040 that they can be re-assembled in their orig-...

  • Page 51: Assembling The Carburetor

    Carburetor Assembling the carburetor 4. Install the pilot jet w, new gasket and 1. Install the starter jet 1 and check valve cover to the carburetor body of the 2, then install the plunger 3 onto the kerosene side as shown. float chamber of the gasoline side.

  • Page 52: Adjusting The Throttle Stop Screw

    FUEL Fuel system Adjusting the throttle stop screw 7. Install a new O-ring u, and new gasket 1. Start the engine and warm it up for 5 min- i, onto the carburetor body of the gaso- utes. line side, and then install the carburetor body of the kerosene side.

  • Page 53: Fuel Pump

    Carburetor/Fuel pump Fuel pump 6H94030E Part name Q’ty Remarks ø5 × 30 mm Screw Cover Diaphragm Gasket Not reusable Fuel pump body Diaphragm Spring Spring plate Gasket Not reusable Check valve Cover Gasket Not reusable Diaphragm Pump body Gasket Not reusable Diaphragm Cover 6H95G11...
  • Page 54 FUEL Fuel system 6H94030E Part name Q’ty Remarks Check valve ø5 × 24 mm Screw 4-13 6H95G11...

  • Page 55: Checking The Fuel Pump

    Fuel pump Checking the fuel pump 5. Connect the special service tool to the 1. Place a drain pan under the fuel hose fuel pump outlet c or d. connections, and then disconnect the fuel hoses from the fuel pump. 2.

  • Page 56: Disassembling The Fuel Pump

    FUEL Fuel system Disassembling the fuel pump NOTE: Make sure that the gaskets and diaphragms 1. Disassemble the fuel pump. are kept in place through the assembly process. 2. Check the diaphragms for tears or dam- age. Replace if necessary. Checking the fuel joint 3.

  • Page 57: Powr

    POWR Power unit Special service tools ................... 5-1 Power unit ..................... 5-4 Checking the compression pressure ............5-4 Disassembling the manual starter ............5-13 Checking the spiral spring ..............5-13 Checking the drive pawl ................ 5-13 Measuring the starter rope ..............5-13 Assembling the manual starter ..............

  • Page 58: Power Unit

    POWR Power unit Special service tools Compression gauge Driver rod L3 90890-03160 90890-06652 Flywheel holder Driver rod LS 90890-06522 90890-06606 Flywheel puller Bearing Separator 90890-06534 90890-06521 Crankshaft aligner Crank jig set 90890-02422 90890-03107 Needle bearing attachment Flange 90890-06613, 90890-06628, 90890-02351 90890-06631, 90890-06654 6H95G11...
  • Page 59 Special service tools Pressure plate Body 90890-02384 90890-02352 Bolt Press body 90890-02353 90890-02385 Washer Pressure pin B 90890-02354 90890-02390 Bushing-9 (D30) Bearing pressure C 90890-02363 90890-02393 B-12 Bushing-12 (D35) Support 90890-02366 90890-02394 6H95G11...

  • Page 60: Power Unit

    POWR Power unit H-18 Cylinder gauge Height ring (H-18) 90890-06759 90890-02401 Plate C 90890-02402 Pressure pin C 90890-02403 Spacer C 90890-02404 Small end bearing installer 90890-06527 6H95G11...

  • Page 61: Checking The Compression Pressure

    Special service tools/Power unit Power unit 5. If the compression pressure is below specification and the compression pres- Checking the compression pressure sure for each cylinder is unbalanced, add 1. Start the engine, warm it up for 5 min- a small amount of engine oil to the cylin- utes, and then turn it off.
  • Page 62 POWR Power unit 21 N·m (2.1 kgf·m, 15.5 ft·lb) 6H95010E Part name Q’ty Remarks Power unit Manual starter assembly Collar Grommet M8 × 35 mm Bolt Gasket Not reusable M6 × 12 mm Bolt Dowel pin M6 × 25 mm Bolt M8 ×...
  • Page 63 Power unit 160 N·m (16 kgf·m, 115 ft·lb) 6H95030E Part name Q’ty Remarks Flywheel magnet Base assembly M6 × 40 mm Bolt Oil seal Not reusable O-ring Not reusable Woodruff key M8 × 14 mm Bolt Starter pulley Washer Pulser coil ø5 ×...
  • Page 64 POWR Power unit 29 N·m (2.9 kgf·m, 21 ft·lb) 6F65050E Part name Q’ty Remarks Electric starter unit and W model CDI unit assembly CDI unit assembly M8 × 48 mm Bolt M6 × 30 mm Bolt M8 × 25 mm Bolt M6 ×...
  • Page 65 Power unit 29 N·m (2.9 kgf·m, 21 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6F65040E Part name Q’ty Remarks Starter motor Starter relay Bracket M6 × 12 mm Bolt Spiral tube Spring washer Starter motor lead Battery negative lead M8 × 16 mm Bolt Washer Collar...
  • Page 66 POWR Power unit 29 N·m (2.9 kgf·m, 21 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6F65040E Part name Q’ty Remarks Rectifier ø6 × 25 mm Screw M6 × 16 mm Bolt Battery positive lead All components are for W model only. 6H95G11...
  • Page 67 Power unit 6F65060E Part name Q’ty Remarks M6 × 30 mm Bolt Collar Throttle control lever Throttle pulley Throttle cable Bracket M6 × 15 mm Bolt Link rod Joint 6H95G11 5-10...
  • Page 68 POWR Power unit 10 N·m (1.0 kgf·m, 7.2 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6F65020E Part name Q’ty Remarks Manual starter case Spiral spring Washer Sheave drum Spring Drive pawl Spring Washer Drive plate Washer M8 × 30 mm Bolt Collar M6 ×...
  • Page 69 Power unit 10 N·m (1.0 kgf·m, 7.2 ft·lb) 15 N·m (1.5 kgf·m, 11.1 ft·lb) 6F65020E Part name Q’ty Remarks Washer Cover Manual starter handle Damper Starter rope guide Starter rope Start-in-gear protection cable Plunger Spring 6H95G11 5-12...

  • Page 70: Disassembling The Manual Starter

    POWR Power unit Disassembling the manual starter 4. Remove the spiral spring 9 from the 1. Turn the sheave drum 1 clockwise until manual starter case. the spiral spring is free. 6F650040 6F650020 NOTE: 9 Turn the sheave drum so that the notch on The spiral spring can pop out.

  • Page 71: Assembling The Manual Starter

    Power unit Assembling the manual starter 5. Install the spiral spring 4 into the starter 1. Install the starter rope 1 into the sheave case. drum 2. 2. Install the drive pawl and springs. 3. Install the manual starter handle 3. 6F650080 NOTE: Install the outer end c of the spiral spring...

  • Page 72: Removing The Power Unit

    POWR Power unit Removing the power unit 8. Turn the sheave drum 3 times in the direction of the arrow shown, and then NOTE: remove the starter rope from the notch It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency.

  • Page 73: Removing The Flywheel Magnet

    Power unit 4. Disconnect the remote control cables 8. Remove the apron, and then remove the (remote control model) or throttle cables power unit by removing the bolts. (tiller handle model). 5. Disconnect the battery leads and ground leads 5. (W) 6H950180 Removing the flywheel magnet 1.

  • Page 74: Removing The Electrical Components

    POWR Power unit Removing the electrical components 2. Remove the flywheel magnet. 1. Remove the bracket 1. (W: CDI unit, starter motor, starter relay and rectifier) 2. Remove the base assembly 2. 6B450090 6F650210 To prevent damage to the engine or tools, 3.

  • Page 75: Disassembling The Base Assembly

    Power unit Disassembling the base assembly 1. Remove the O-ring and oil seal. 6F650240 Assembling the base assembly 1. Apply grease to a new oil seal, then install it into the base assembly. 6F650250 Needle bearing attachment 1: 90890-06654 Driver rod L3 2: 90890-06652 2.

  • Page 76: Reed Valves

    POWR Power unit Reed valves 6H95070E Part name Q’ty Remarks Intake manifold #1 Reed valve assembly #1 Gasket Not reusable Intake manifold #2 Reed valve assembly #2 Gasket Not reusable Gasket Not reusable Gasket Not reusable M6 × 65 mm Bolt ø5 ×...
  • Page 77 Reed valves 6H95070E Part name Q’ty Remarks M6 × 30 mm Bolt M6 × 15 mm Bolt 6H95G11 5-20...

  • Page 78: Removing The Reed Valve Assembly

    POWR Power unit Removing the reed valve assembly 2. Measure the valve stopper height b and 1. Remove the hoses 1. c. Replace if out of specification. 2. Remove the intake manifold bolts 2, and then remove the intake manifold cover, gasket and reed valve assembly #1 3.
  • Page 79 Cylinder head Cylinder head 25 N·m (2.5 kgf·m, 18 ft·lb) 15 N·m (1.5 kgf·m, 11 ft·lb) 30 N·m (3.0 kgf·m, 22 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6H95080E Part name Q’ty Remarks Gasket Not reusable Cylinder head Thermoswitch...
  • Page 80 POWR Power unit 25 N·m (2.5 kgf·m, 18 ft·lb) 15 N·m (1.5 kgf·m, 11 ft·lb) 30 N·m (3.0 kgf·m, 22 ft·lb) 12 N·m (1.2 kgf·m, 8.7 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6H95080E Part name Q’ty Remarks Anode M6 × 25 mm Bolt Exhaust outer cover Gasket...

  • Page 81: Cylinder Head

    Cylinder head Removing the cylinder head 1. Remove the spark plugs, thermostat cover, thermostat and thermoswitch. 2. Remove the cylinder head cover bolts 1. 3. Remove the cylinder head bolts in the sequence shown. Cylinder head warpage limit: 0.1 mm (0.0039 in) Removing the exhaust cover 1.

  • Page 82: Crankcase

    POWR Power unit Crankcase 20 N·m (2.0 kgf·m, 15 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 6F65090E Part name Q’ty Remarks Crankshaft assembly Cylinder Block Anode M6 × 16 mm Bolt Oil seal Not reusable Oil seal Not reusable O-ring Not reusable O-ring Not reusable...
  • Page 83 Crankcase 6F65100E Part name Q’ty Remarks Crank 3 Washer Roller bearing Connecting rod Needle bearing Circlip Not reusable Piston Piston pin Piston ring set Crank pin Crank 4 Ball bearing Not reusable Labyrinth seal Roller bearing assembly Crank 2 Crank 1 Ball bearing Not reusable 6H95G11...

  • Page 84: Removing The Crankcase

    POWR Power unit Removing the crankcase Removing the crankshaft assembly 1. Remove the crankcase bolts in the and oil seal housing sequence shown. 1. Remove the crankshaft assembly and oil seal housing. 6F650350 6F650360 Checking the cylinder bore 1. Measure the cylinder bore (D —...

  • Page 85: Disassembling The Oil Seal Housing

    Crankcase 2. Calculate the taper limit. Replace or 2. Apply grease to new oil seals, then install rebore the cylinder block if above specifi- them into the oil seal housing. cation. Taper limit: (direction d) — D (direction e) — D 0.08 mm (0.0032 in) 3.

  • Page 86: Checking The Piston Diameter

    POWR Power unit Checking the piston diameter Checking the piston rings 1. Measure the piston outside diameter at 1. Check the piston ring dimensions of B the specified measuring point. Replace if and T. Replace if out of specification. out of specification. 6B450460 Piston ring dimensions Top ring a and 2nd piston ring b:...

  • Page 87: Checking The Piston Ring Side Clearance

    Crankcase Checking the piston ring side clear- ance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. 6B450530 Piston pin diameter: 19.895—19.00 mm (0.7833—0.7835 in) 6F650440 Checking the internal anodes 1.
  • Page 88 POWR Power unit 2. Insert the plate C 1 between crank 1 2 4. Remove the washers, roller bearing and and crank 2 3. Place pressure pin C 4 connecting rod. in the end of the crank pin 5. 5. Insert the support 6 between crank 2 and 3 7 with crank 3 on top.

  • Page 89: Checking The Crankpin

    Crankcase 8. Using the bearing separator to slightly move the inner race off the shaft, and then remove the inner race. Spacer C 1: 90890-02404 Support 2: 90890-02394 6B450600 NOTE: 2. Apply engine oil to the crankpin and Use care not to scratch the shaft. insert it into the crankpin hole by tapping it with a copper hammer, and then install the crankpin using a press.
  • Page 90 POWR Power unit 3. Insert the bushing 3 into the body 4. 6F650530 Spacer C 1: 90890-02404 6. Set crank 2 (or crank 4) on the special service tool. 7. Mount the washers, roller bearing, and connecting rod on the crankpin. Bushing-9 (D30) 3: 90890-02363 Body4: 90890-02352 Flange5: 90890-02351...
  • Page 91 Crankcase 8. Install the bushing 7 on the pressure 11. Insert the press body 9, and install crank plate 8. 1 (or crank 3) onto the crankpin using a press. Do not apply force in excess of 5 tons. NOTE: When installing crank 3 to the pressure plate, do not use the bushing 7.
  • Page 92 POWR Power unit NOTE: 16. Insert plate C q between crank 3 and If any of the measurements are out of speci- crank 4, then place them onto the crank- fication, reassemble the crankshaft. shaft assemblies 1 and 2. Crankshaft width b: 61.40–61.45 mm (2.4173–2.4193 in) 13.

  • Page 93: Checking The Crankshaft

    Crankcase Checking the crankshaft Installing the crankshaft bearings 1. Measure the crankshaft widths a and b. 1. Install the upper and lower bearings using the bearing pressure C 1 and a Repair or disassemble the crankshaft if out of specification. press.

  • Page 94: Assembling The Piston

    POWR Power unit Assembling the piston Assembling the power unit 1. Install the 2nd piston ring 1 and top ring 1. Install the oil seal housing to the crank- 2 onto the pistons. shaft assembly. 2. Install the crankshaft assembly into the cylinder block.
  • Page 95 Crankcase 3. Apply sealant to the mating surface of the crankcase. 6F650640 NOTE: Do not get any sealant on the crankshaft jour- 6F605335 nals. NOTE: Apply LOCTITE 572 to the exhaust cover 4. Install the crankcase onto the cylinder bolts before installation. block, and then tighten the crankcase bolts to the specified torques in two Exhaust outer cover bolt:...

  • Page 96: Installing The Power Unit

    POWR Power unit NOTE: Installing the power unit Apply LOCTITE 572 to the cylinder head 1. Clean the power unit mating surface, and bolts and the cylinder head cover bolts before install the dowels 1 and a new gasket installation. 2.
  • Page 97 Crankcase 7. Tighten the flywheel magnet nut to the 10. Install the manual starter and start-in- gear protection cable 6, and then adjust specified torque. it length. For adjustment procedures, see Chapter 3. 6H950710 Apply force in the direction of the arrows shown, to prevent the flywheel holder 11.

  • Page 98: Lowr

    LOWR LOWR Lower unit Special service tools ................... 6-1 Lower unit (EK40G) ..................6-5 Removing the lower unit ................6-5 Removing the water pump and shift rod ..........6-5 Checking the water pump and shift rod ..........6-5 Propeller shaft housing ................6-11 Removing the propeller shaft housing assembly ........
  • Page 99 Propeller shaft housing ................6-33 Removing the propeller shaft housing assembly ........6-34 Disassembling the propeller shaft assembly ......... 6-34 Disassembling the propeller shaft housing ........... 6-34 Checking the propeller shaft housing ............ 6-35 Checking the propeller shaft ..............6-35 Assembling the propeller shaft assembly ..........

  • Page 100: Lower Unit

    LOWR Lower unit Special service tools Dial gauge set Ring nut wrench extension 90890-01252 90890-06513 Bearing puller assembly Stopper guide plate 90890-06535 90890-06501 Bearing housing puller claw M Drive shaft holder 3 90890-06503 90890-06517 Center bolt Bearing outer race puller assembly 90890-06504 90890-06523 Ring nut wrench...
  • Page 101 Special service tools Stopper guide stand Driver rod LS 90890-06606 90890-06538 Driver rod SL Needle bearing attachment 90890-06602 90890-06608, 90890-06613, 90890-06616, 90890-06653 Needle bearing attachment Bearing depth plate 90890-06603 90890-06614 Driver rod SS Bearing outer race attachment 90890-06604 90890-06622 Driver rod LL Ball bearing attachment 90890-06605 90890-06634, 90890-06637...
  • Page 102 LOWR Lower unit Bearing inner race attachment Digital caliper 90890-06639, 90890-06640 90890-06704 90890-06641, 90890-06644 Ball bearing attachment Pinion height gauge 90890-06631 90890-06710 Driver rod L3 Pinion height gauge plate B 90890-06652 90890-06712 Shimming plate Pinion nut holder 90890-06701 New: 90890-06715 Current: 90890-06505 Pinion height plate Magnet base B...
  • Page 103 Special service tools Backlash indicator 90890-06706 6H95G11...

  • Page 104: Lower Unit (Ek40G)

    LOWR Lower unit Lower unit (EK40G) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6H96050E Part name Q’ty Remarks Lower unit Check screw Gasket Not reusable Drain screw Screw Dowel M6 × 16 mm Bolt Special washer...
  • Page 105 Lower unit (EK40G) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6H96050E Part name Q’ty Remarks Cover Screen Screw 6H95G11...
  • Page 106 LOWR Lower unit 6F66060E Part name Q’ty Remarks Shift rod Holder M6 × 10 mm Bolt Boot Water pump housing M8 × 55 mm Bolt Woodruff key Insert cartridge Impeller Seal Gasket Not reusable Outer plate cartridge Gasket Not reusable Oil seal housing Gasket Not reusable...
  • Page 107 Lower unit (EK40G) 6F66060E Part name Q’ty Remarks M8 × 45 mm Bolt Screw Gasket Not reusable 6H95G11...

  • Page 108: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 3. Loosen the locknut 1, and then remove 1. Drain the gear oil. the adjusting nut 2. 4. Loosen the bolts, and then remove the lower unit from the upper case. 6F660010 2. Shift the shift lever or remote control lever to neutral, place a block of wood between the anti-cavitation plate and pro- peller to keep the propeller from turning,...

  • Page 109: Checking The Water Pump And Shift Rod

    Lower unit (EK40G) Checking the water pump and shift 1. Check the water pump housing for defor- mation. Replace if necessary. 2. Check the impeller and insert cartridge for cracks or wear. Replace if necessary. 3. Check the Woodruff key 1 and the key- way a in the drive shaft for wear.

  • Page 110: Propeller Shaft Housing

    LOWR Lower unit Propeller shaft housing 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6F66070E Part name Q’ty Remarks Lower case cap M6 × 25 mm Bolt Seal Not reusable Taper roller bearing assembly Not reusable Forward gear shim —...
  • Page 111 Propeller shaft housing 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8 N·m (0.8 kgf·m, 5.8 ft·lb) 6F66070E Part name Q’ty Remarks Oil seal Not reusable Propeller shaft housing O-ring Not reusable Dowel 6H95G11 6-12...

  • Page 112: Removing The Propeller Shaft Housing Assembly

    LOWR Lower unit Removing the propeller shaft hous- 2. Remove the ball bearing. ing assembly 1. Remove the bolts, then separate the lower case cap. 6F660600 Do not reuse the bearing, always replace it with a new one. NOTE: Loosen the bolts in sequence as shown. Stopper guide plate 1: 90890-06501 Stopper guide stand 2:...

  • Page 113: Disassembling The Forward Gear

    Propeller shaft housing Disassembling the forward gear 3. Check the dog clutch and shift plunger for 1. Remove the taper roller bearing and cracks or wear. Replace if necessary. shim(s) from the forward gear. Assembling the forward gear 1. Install the original shim(s) 1 and the taper roller bearing 2 into the forward gear 3.

  • Page 114: Assembling The Propeller Shaft Housing

    LOWR Lower unit Assembling the propeller shaft 3. Install the original shim(s) 5 onto pro- housing peller shaft housing 6, then install the reverse gear assembly into the propeller shaft housing. 1. Apply grease to new oil seals, and then install them into the propeller shaft hous- ing to the specified depth.

  • Page 115: Drive Shaft And Lower Case

    Drive shaft and lower case Drive shaft and lower case 6F66080E Part name Q’ty Remarks Drive shaft Circlip Pinion gear Roller bearing assembly Pinion gear shim — Thrust bearing Needle bearing Sleeve Needle bearing Washer Oil seal Not reusable Lower case 6H95G11 6-16...

  • Page 116: Removing The Drive Shaft

    LOWR Lower unit Removing the drive shaft Stopper guide plate 4 : 1. Remove the circlip 1 from the pinion 90890-06501 gear, and then remove the pinion gear Stopper guide stand 5 : and drive shaft assembly. 90890-06538 Bearing puller assembly 6 : 90890-06535 4.

  • Page 117: Checking The Lower Case And Lower Case Cap

    Drive shaft and lower case Checking the lower case and lower Depth b: case cap 2.2—2.8 mm (0.09—0.11 in) 1. Check the skeg and torpedo for cracks or damage. Replace the lower case and 3. Install the sleeve and needle bearing into the lower case to the specified depth.

  • Page 118: Installing The Drive Shaft

    LOWR Lower unit Installing the propeller shaft housing 4. Install the thrust bearing and roller bear- 1. Install the washer 1 and propeller shaft ing assembly. assembly 2 into the propeller shaft housing assembly 3. 2. Install the forward gear assembly to the propeller shaft housing assembly.

  • Page 119: Installing The Water Pump And Shift Rod

    Drive shaft and lower case Installing the water pump and shift 5. Apply sealant to the mating surface of the lower case cap and propeller shaft cap. 1. Install the shift rod assembly 1. 6. Install the propeller shaft housing assem- bly 4 on to the lower case.

  • Page 120: Installing The Lower Unit

    LOWR Lower unit NOTE: 4. Align the groove in the impeller 9 with When installing the pump housing, apply the Woodruff key 0, and then install the grease to the inside of the housing, and then impeller onto the drive shaft. turn the drive shaft clockwise while pushing down the pump housing.
  • Page 121 Drive shaft and lower case 6. Install the propeller, shear pin and pro- peller nut, and then tighten the nut finger tight. Place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then tight- en the nut to the specified torque.

  • Page 122: Shimming

    LOWR Lower unit Shimming 6F660860 6-23 6H95G11...

  • Page 123: Selecting The Pinion Shims

    Shimming Shimming NOTE: 9 Shimming is not required when assembling the original lower case and inner parts. 9 Shimming is required when assembling the original inner parts and a new lower case. 9 Shimming is required when replacing the inner part(s). 6F660880 3.

  • Page 124: Backlash

    LOWR Lower unit Backlash Dial gauge set 1: 90890-01252 Measuring the forward and reverse Magneto base B 2: 90890-06844 gear backlash 7. Hold the drive shaft and slowly turn the 1. Remove the water pump assembly. forward gear clockwise and counter- clockwise, then measure the backlash 2.
  • Page 125 Backlash 10. Adjust the shim(s) to specified thickness (Add or remove). 6F660930 Available shim thicknesses: 1.80, 1.90, 2.00, 2.10, 2.20, 2.30, 2.40, and 2.50 mm 11. Remove the special service tools. Then install the O-ring to the propeller shaft assembly and tighten the lower case cap to specified torque in two stage.

  • Page 126: Lower Unit (Ek40J)

    LOWR Lower unit Lower unit (EK40J) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 35 N·m (3.5 kgf·m, 25.3 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6H96010E Part name Q’ty Remarks Lower unit Check screw Gasket Not reusable Drain screw Screw...
  • Page 127 Lower unit (EK40J) 21 N·m (2.1 kgf·m, 15.5 ft·lb) 35 N·m (3.5 kgf·m, 25.3 ft·lb) 4 N·m (0.4 kgf·m, 3.0 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 6H96010E Part name Q’ty Remarks M8 × 30 mm Bolt Water inlet cover Screw 6H95G11 6-28...
  • Page 128 LOWR Lower unit 6F66020E Part name Q’ty Remarks Shift rod Bushing M6 × 18 mm Bolt Boot Water pump housing M8 × 55 mm Bolt Woodruff key Insert cartridge Impeller Seal Gasket Not reusable Outer plate cartridge Gasket Not reusable Oil seal housing Gasket Not reusable...
  • Page 129 Lower unit (EK40J) 6F66020E Part name Q’ty Remarks Dowel M8 × 45 mm Bolt Screw Gasket Not reusable 6H95G11 6-30...

  • Page 130: Removing The Lower Unit

    LOWR Lower unit Removing the lower unit 3. Mark the trim tab 1 at the area shown, 1. Drain the gear oil. and then remove it. 4. Loosen the locknut 2, and then remove the adjusting nut 3. 5. Loosen the bolts, and then remove the lower unit from the upper case.

  • Page 131: Removing The Water Pump And Shift Rod

    Lower unit (EK40J) Removing the water pump and shift 4. Check the shift rod for cracks or wear. Replace if necessary. 1. Remove the water pump assembly and shift rod assembly 1. 6F660350 NOTE: Before removing the shift rod assembly 1, remove the screw 2.
  • Page 132 LOWR Lower unit Propeller shaft housing 90 N·m (9.0 kgf·m, 65 ft·lb) 6F66030E Part name Q’ty Remarks Shift plunger Dog clutch Cross pin Spring Slider Spring Propeller shaft Reverse gear Reverse gear shim — Washer O-ring Not reusable Ball bearing Not reusable Propeller shaft housing Needle bearing...

  • Page 133: Propeller Shaft Housing

    Propeller shaft housing Removing the propeller shaft hous- Stopper guide plate 4: ing assembly 90890-06501 1. Remove the ring nut from the propeller Bearing housing puller crow M 5: shaft housing, use the special service 90890-06503 tools. Center bolt 6: 90890-06504 Disassembling the propeller shaft assembly 1.

  • Page 134: Checking The Propeller Shaft Housing

    LOWR Lower unit 2. Remove the ball bearing. 3. Check the bearings for pitting or rum- bling. Replace if necessary. Checking the propeller shaft 1. Check the propeller shaft for bends or wear. Replace if necessary. 2. Measure the propeller shaft runout. Do not reuse the bearing, always replace it with a new one.

  • Page 135: Assembling The Propeller Shaft Housing

    Propeller shaft housing Assembling the propeller shaft 3. Install the washer 6 and new ball bear- housing ing 7 onto the reverse gear 8 using a 1. Install the needle bearing into the pro- press. peller shaft housing to the specified depth.

  • Page 136: Drive Shaft And Lower Case

    LOWR Lower unit Drive shaft and lower case 74 N·m (7.4 kgf·m, 54.6 ft·lb) 6F66040E Part name Q’ty Remarks Drive shaft Forward gear Taper roller bearing assembly Not reusable Forward gear shim — Pinion gear Washer Lower case Needle bearing Sleeve Pinion gear shim —...

  • Page 137: Removing The Drive Shaft

    Drive shaft and lower case Removing the drive shaft Disassembling the forward gear 1. Remove the drive shaft assembly and 1. Remove the taper roller bearing from the pinion, and then pull out the forward gear. forward gear using a press. 6F660190 6F660210 Drive shaft holder 3 1:...

  • Page 138: Disassembling The Lower Case

    LOWR Lower unit Disassembling the lower case 1. Remove the taper roller bearing outer race and shim(s). Needle bearing attachment 5 : 90890-06614 6F660230 Driver rod L3 6: 90890-06652 NOTE: Install the claws a as shown. Checking the pinion and forward gear Bearing outer race puller 1.

  • Page 139: Assembling The Oil Seal Housing

    Drive shaft and lower case Assembling the oil seal housing 2. Install the sleeve, original shim(s), and 1. Apply grease to new oil seals, and then drive shaft bearing outer race. install them into the oil seal housing. 6F660270 Ball bearing attachment 1: 90890-06653 6F660290 Driver rod L3 2: 90890-06652...

  • Page 140: Assembling The Forward Gear

    LOWR Lower unit Assembling the forward gear Drive shaft holder 3 1: 1. Install a new taper roller bearing into the 90890-06517 forward gear using a press. Pinion nut holder 2: New: 90890-06715 Current: 90890-06505 Pinion nut: 74 N·m (7.4 kgf·m, 54.6 ft·lb) Installing the oil seal housing 1.

  • Page 141: Installing The Water Pump And Shift Rod

    Drive shaft and lower case Installing the water pump and shift 3. Install the propeller shaft housing assem- bly 5 and lock washer 6 into the lower case, and then tighten the ring nut 7 to 1. Install the shift rod assembly 1. the specified torque.
  • Page 142 LOWR Lower unit 6. Install the seal 9, a new gasket 0 and 3. Install the Woodruff key into the drive pump housing assembly q into the lower shaft. case, tighten the bolts w. 4. Align the groove in the impeller 5 with the Woodruff key 6, and then install the impeller onto the drive shaft.

  • Page 143: Installing The Lower Unit

    Drive shaft and lower case Installing the lower unit 7. Install the propeller and propeller nut, 1. Set the gear shift to the reverse position and then tighten the nut finger tight. at the lower unit. Make sure that the shift Place a block of wood between the anti- rod is in the reverse position.
  • Page 144 LOWR Lower unit 8. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 6F630210 Recommended gear oil: Hypoid gear oil API: GL-4 SAE: 90...

  • Page 145: Shimming

    Drive shaft and lower case/Shimming Shimming ƒ ® π 6F660440 6H95G11 6-46...

  • Page 146: Selecting The Pinion Shims

    LOWR Lower unit Shimming 2. Install the pinion and pinion nut, and then tighten the nut to the specified torque. NOTE: 9 Shimming is not required when assembling Pinion nut: the original lower case and inner parts. 74 N·m (7.4 kgf·m, 54.6 ft·lb) 9 Shimming is required when assembling the original inner parts and a new lower case.

  • Page 147: Selecting The Forward Gear Shims

    Shimming Example: If “M3” is 26.05 mm and “P” is (+5), then T3 = 26.05 – 25.5 – (+5)/100 mm = 0.55 – 0.05 mm = 0.60 mm 5. Select the pinion shim(s) (T3) as follows. Calculated numeral Rounded numeral at 1/100th place 1, 2 3, 4, 5...

  • Page 148: Selecting The Reverse Gear Shims

    LOWR Lower unit Calculation formula: Forward gear shim thickness (T1) = 25.70 + F/100 – M1 Example: If “M1” is 25.30 mm and “F” is (+4), then T1 = 25.70 + (+4)/100 – 25.30 mm = 25.70 + 0.04 – 25.30 mm = 0.44 mm 3.

  • Page 149: Backlash

    Shimming Calculation formula: Reverse gear shim thickness (T2) = M2 – 26.90 – R/100 Example: If “M2” is 27.32 mm and “R” is (+5), then T2 = 27.32 mm – 26.90 mm – (+5)/100 = 27.32 – 26.90 + 0.05 = 0.47 mm 4.
  • Page 150 LOWR Lower unit 5. Slowly turn the drive shaft clockwise and 9. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- counterclockwise and measure the back- lash when the drive shaft stops in each lash when the drive shaft stops in each direction.

  • Page 151: Brkt

    BRKT Bracket unit Special service tools ................... 7-1 Tiller handle (MH) ..................7-2 Assembling the tiller handle ..............7-4 Bottom cowling .................... 7-5 Upper case, pivot shaft ................7-7 Disassembling the upper case .............. 7-11 Checking the upper case ............... 7-11 Assembling the upper case ..............

  • Page 152: Bracket Unit

    BRKT Bracket unit Special service tools Needle bearing attachment 90890-06613 Driver rod L3 90890-06652 6H95G11...

  • Page 153: Tiller Handle (Mh)

    Tiller handle (MH) Tiller handle (MH) 3 N·m (0.3 kgf·m, 2.2 ft·lb) 6H97010E Part name Q’ty Remarks Throttle cable Self locking nut M12 × 68 mm Bolt Washer Collar Plastic washer Metal washer Wave washer Tiller handle bracket Throttle friction adjuster Throttle grip Screw Washer...
  • Page 154 BRKT Bracket unit 3 N·m (0.3 kgf·m, 2.2 ft·lb) 6H97010E Part name Q’ty Remarks M6 × 20 mm Bolt Stay Washer Bushing Pinion M5 × 10 mm Bolt M5 × 10 mm Bolt Rubber grip Pinion Cotter pin Not reusable Stay Wire clip 6H95G11...

  • Page 155: Assembling The Tiller Handle

    Tiller handle (MH) Assembling the tiller handle 1. Install the throttle cables 1 and 2 to the pinion 3. 6F670010 NOTE: Route the throttle cable as shown and clamp the cable protector 4. 2. Install the throttle shaft 5 to the tiller handle bracket.

  • Page 156: Bottom Cowling

    BRKT Bracket unit Bottom cowling 5 N·m (0.5 kgf·m, 3.6 ft·lb) 6H97020E Part name Q’ty Remarks M6 × 25 mm Bolt Cotter pin Not reusable Shift lever Bracket Shift rod lever 1 Shift control lever Shift rod lever 2 Bushing Spring Screw Shift rod...
  • Page 157 Bottom cowling 5 N·m (0.5 kgf·m, 3.6 ft·lb) 6H97020E Part name Q’ty Remarks Rubber seal Collar Choke knob Grommet Retaining plate M6 × 20 mm Bolt Engine stop lanyard switch MH model Grommet M6 × 30 mm Bolt Locknut Adjusting nut Shaft Boot Hose...

  • Page 158: Upper Case, Pivot Shaft

    BRKT Bracket unit Upper case, pivot shaft 6F67040E Part name Q’ty Remarks M6 × 25 mm Bolt Exhaust guide Gasket Not reusable M6 × 20 mm Bolt Exhaust manifold Gasket Not reusable Seal Not reusable Rubber seal Not reusable Pipe 6H95G11...
  • Page 159 Upper case, pivot shaft 28 N·m (2.8 kgf·m, 20 ft·lb) 55 N·m (5.5 kgf·m, 40 ft·lb) 6F67030E Part name Q’ty Remarks Cover Lower mount M12 × 130 mm Bolt Washer M6 × 25 mm Bolt Cover Washer Bracket Upper mount M8 ×...
  • Page 160 BRKT Bracket unit 28 N·m (2.8 kgf·m, 20 ft·lb) 55 N·m (5.5 kgf·m, 40 ft·lb) 6F67030E Part name Q’ty Remarks Protector Upper case assembly Circlip Bushing EK40J: L transom model M8 × 130 mm Bolt Washer Washer Seal Lock tie Seal 6H95G11...
  • Page 161 Upper case, pivot shaft 14 N·m (1.4 kgf·m, 10 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 6F67035E Part name Q’ty Remarks M8 × 30 mm Bolt M8 × 35 mm Bolt Steering bracket Dowel Pivot shaft Washer Bushing Straight key Spring Rubber seal M8 ×...

  • Page 162: Disassembling The Upper Case

    BRKT Bracket unit Disassembling the upper case 4. Remove the circlip 7 and the drive shaft 1. Remove the muffler assembly 1 and bushing 8 from the upper case. (EK40J: gasket 2 from the upper case 3. L transom model) 6F670050 Checking the upper case 1.

  • Page 163: Assembling The Upper Case

    Upper case, pivot shaft Assembling the upper case 3. Install the protector, and then install the 1. Install the drive shaft bushing and the cir- muffler assembly into the uppercase. clip to the upper case. (EK40J: L transom model) 6F670070 Needle bearing attachment 1 : 6F670100 90890-06613...

  • Page 164: Removing The Pivot Shaft

    BRKT Bracket unit 5. Install a new gasket and the muffler assembly into the upper case. 6F670035 Removing the pivot shaft 1. Remove the pivot shaft from the swivel bracket by pulling the shaft off the brack- 2. Remove the oil seal 1 and then remove the bushing 2.

  • Page 165: Clamp Brackets, Swivel Bracket

    Upper case, pivot shaft/Clamp brackets, swivel bracket Clamp brackets, swivel bracket 45 N·m (4.5 kgf·m, 33 ft·lb) 45 N·m (4.5 kgf·m, 33 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 6F67050E Part name Q’ty Remarks Tilt pin Washer M8 ×...
  • Page 166 BRKT Bracket unit 45 N·m (4.5 kgf·m, 33 ft·lb) 45 N·m (4.5 kgf·m, 33 ft·lb) 10 N·m (1.0 kgf·m, 7.2 ft·lb) 24 N·m (2.4 kgf·m, 17.7 ft·lb) 6F67050E Part name Q’ty Remarks Washer Wave washer Circlip Tilt stopper plate (starboard side) Grease nipple Bushing Plate...
  • Page 167 Clamp brackets, swivel bracket 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6F67060E Part name Q’ty Remarks Tilt lock lever Stopper plate (starboard side) Spring M5 × 10 mm Bolt Circlip Tilt lever Tilt lock rod Tilt lock plate Spring Cotter pin Tilt lock arm Tilt lock plate Collar...
  • Page 168 BRKT Bracket unit 4 N·m (0.4 kgf·m, 3.0 ft·lb) 6F67060E Part name Q’ty Remarks Washer Washer Stopper plate (port side) Cover 7-17 6H95G11...

  • Page 169: Removing The Clamp Brackets

    Clamp brackets, swivel bracket Removing the clamp brackets 3. Install the circlip q, spring w and collar 1. Remove the tilt pin, and then remove the e, then install the circlip r. clamp bracket bolt, clamp bracket nut and collar. 2.

  • Page 170: Installing The Pivot Shaft

    BRKT Bracket unit 3. Install the bushing 6, a new oil seal 7, 2. Assemble the clamp brackets, washers, and the washer 8 onto the swivel brack- and swivel bracket, and then install the clamp bracket bolt. 4. Install the dowels 9, steering bracket 0, 3.

  • Page 171: Elec

    ELEC Electrical systems Special service tools ................... 8-1 Checking the electrical components ............8-2 Measuring the peak voltage ..............8-2 Measuring low resistance ................ 8-2 Electrical components ................. 8-3 Top view ....................8-3 Starboard view (MH) ................8-4 Starboard view (W) .................. 8-5 Wiring diagram (MH) ................

  • Page 172: Electrical Systems

    ELEC Electrical systems Special service tools Ignition tester 90890-06754 Digital circuit tester 90890-03174 Peak voltage adaptor B 90890-03172 Test harness (4 pins) New: 90890-06871 Current: 90890-06771 6H95G11...

  • Page 173: Checking The Electrical Components

    Special service tools/Checking the electrical components Checking the electrical Measuring low resistance When measuring a resistance of 10 or less components with the digital circuit tester, the correct mea- Measuring the peak voltage surement cannot be obtained because of the internal resistance of the tester.

  • Page 174: Electrical Components

    ELEC Electrical systems Electrical components Top view 6H980010 1 CDI unit 2 Starter motor (W) 3 Starter relay (W) 4 Spark plug 5 Thermoswitch 6 Engine stop lanyard switch (WH) 7 Engine stop button (MH: if equipped) 6H95G11...

  • Page 175: Starboard View (Mh)

    Electrical components Starboard view (MH) 6F680030 1 Spark plug 2 Ignition coil 3 CDI unit 6H95G11...

  • Page 176: Starboard View (W)

    ELEC Electrical systems Starboard view (W) 6F680040 1 Spark plug 2 Ignition coil 3 Starter relay 4 Starter motor 5 CDI unit 6 Rectifier 7 Fuse 6H95G11...

  • Page 177: Wiring Diagram (Mh)

    Electrical components/Wring diagram Wiring diagram (MH) 6F68010M 1 Thermoswitch : Black W/R: White/Red 2 CDI unit Br : Brown 3 Lighting coil : Green 4 Charge coil : Blue 5 Pulser coil : Orange 6 Engine stop lanyard switch : Pink 7 Ignition coil : White 8 Spark plug...

  • Page 178: Wiring Diagram (W)

    ELEC Electrical systems Wiring diagram (W) 6H98030M 1 Thermoswitch q Ignition coil : Yellow 2 Rectifier w Spark plug B/W : Black/White 3 CDI unit W/B : White/Black 4 Lighting coil : Black W/R: White/Red 5 Charge coil Br : Brown 6 Pulser coil : Green 7 Battery...

  • Page 179: Ignition And Ignition Control System

    Wring diagram/Ignition and ignition control system Ignition and ignition control sys- 3. Measure the ignition coil resistance. Replace if out of specification. Checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool.

  • Page 180: Checking The Cdi Unit

    ELEC Electrical systems Checking the CDI unit Pulser coil output peak voltage: 1. Measure the CDI unit output peak volt- White/red (W/R) — Ground (B) age. If below specification, measure the White/Black (W/B) — Ground (B) pulser coil output peak voltage. Replace Unloaded Loaded the CDI unit if the output peak voltage of...

  • Page 181: Checking The Thermoswitch

    Ignition and ignition control system Checking the thermoswitch Checking the engine stop lanyard 1. Place the thermoswitch in a container of switch (MH) water and slowly heat the water. 1. Check the engine stop lanyard switch for continuity. Replace if there is no continu- ity.

  • Page 182: Starting System

    ELEC Electrical systems Starting system Checking the fuse (W) 1. Check the fuse for continuity. Replace if there is no continuity. Checking the starter relay (W) 1. Connect the digital circuit tester leads to the starter relay terminals. 2. Connect the positive battery terminal to the brown (Br) lead.

  • Page 183: Starter Motor (W)

    Starting system/Starter motor Starter motor (W) 1.0mm 0.15mm 2.0mm 0.25mm 0.25mm 6F68010E Part name Q’ty Remarks Clip Pinion stopper Spring Pinion assembly Bolt Housing Washer set O-ring Not reusable Armature assembly Bracket Brush holder Brush Yoke assembly 6H95G11 8-12...

  • Page 184: Removing The Starter Motor Pinion

    ELEC Electrical systems Removing the starter motor pinion Checking the armature 1. Slide the pinion stopper 1 down as 1. Check the commutator for dirt. Clean with shown, and then remove the clip 2. 600– grit sandpaper and compressed air if necessary.

  • Page 185: Checking The Brushes

    Starter motor/Charging system 4. Check the armature for continuity. 2. Check the brush holder assembly for Replace if out of specifications. continuity. Replace if out of specifica- tions. 6F680190 6F680210 Armature continuity Brush continuity: Commutator segments c Continuity Brush holder 1 — Segment –...

  • Page 186: Checking The Lighting Coil

    ELEC Electrical systems Digital circuit tester: 90890-3174 Peak voltage adaptor B: 90890-03172 Rectifier output peak voltage: Red (R) — Black (B) Unloaded r/min 1,500 3,500 DC V Checking the lighting coil 1. Measure the lighting coil output peak voltage. Replace the lighting coil if below specification.
  • Page 187 TRBL TRBL SHTG SHTG Troubleshooting Power unit ..................... 9-1 Ignition system ..................9-1 Fuel system ..................... 9-3 Compression pressure ................9-4 Lower unit ..................... 9-6 Electrical system ..................9-7 Starting system ..................9-7 Charging system ..................9-8 6H95G11...

  • Page 188: Trbl Shtg

    TRBL TRBL SHTG SHTG Troubleshooting NOTE: 9 To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4–8 for safe maintenance procedures. 9 Check that all electrical connections are tight and free from corrosion. Power unit Symptom: Manual starter turns and or starter motor operate but engine will not start.
  • Page 189 Power unit Ignition system (continued from previous page) Check the CDI unit output peak voltage. Does the out- put peak voltage Check the connection exceed specifi- of the leads from CDI unit. cation values? Check the charge coil output peak voltage. Does the out- put peak voltage Replace the charge coil.

  • Page 190: Fuel System

    TRBL SHTG Troubleshooting Fuel system 9 Consult this chart after the ignition system has been checked. Check for water accumulation or clogging of the fuel filter and inside the carburetor. 9 Clean the fuel system from the Is there water fuel tank to the fuel filter and or residue? carburetor float chamber.

  • Page 191: Compression Pressure

    Power unit Compression pressure 9 Consult this chart after the ignition and fuel systems have been checked. Measure the compression pressure. Does the pressure exceed Check other component again. the specification values? Add a small amount of engine oil into the cylinder through the spark plug hole.
  • Page 192 TRBL SHTG Troubleshooting Symptom: The engine idle speed does not remain steady. Check the throttle cable and link operation. Are they operat- Adjust the throttle cable and ing correctly? throttle link. Check the operation of the carburetor. Is the carburetor operat- Check the ignition system chart.

  • Page 193: Lower Unit

    Power unit/Lower unit Lower unit Symptom: The forward and reverse gear shift mechanism does not operate properly. Check the shift lever operation. Is it operating Check the shift lever shaft. correctly? Check the shift rod connection. Is it connected Connect correctly or replace the properly and in shift rod as necessary.

  • Page 194: Electrical System

    TRBL SHTG Troubleshooting Electrical system Symptom: The starter motor does not operate. (W) 9 Engine stop lanyard switch is operating normally. Starting system Check the fuse for blown. Is there blown? Replace the fuse. Check the battery for fully charged. Fully charge or replae the fully Is the battery fully charged battery.

  • Page 195: Charging System

    Electrical Starting system (continued from previous page) Check the starter relay for continuity. Is there continuity? Replace the starter relay. Disassemble and check the starter motor. Symptom: The battery loses power quickly. (W) 9 Be sure the electrolyte level and gravity are specific condition. 9 Be sure the wireharness, couplers and connectores are good connection.
  • Page 196 Index Checking the drive shaft ....6-17, 6-39 Checking the electrical components ..8-2 Adjusting the start-in-gear protection ..3-5 Checking the engine idle speed ....3-7 Adjusting the throttle cable (MH) ....3-5 Checking the engine start switch, Adjusting the throttle cable (W) ....3-6 engine stop lanyard switch Adjusting the throttle link position .....
  • Page 197 ........6-20, 6-42 Disassembling the fuel pump ....4-15 Disassembling the lower case ..6-17, 6-39 Disassembling the manual starter ..5-13 Lower unit (EK40G) ........6-5 Disassembling the Lower unit (EK40J) ......... 6-27 oil seal housing ......5-28, 6-38 Lower unit ........
  • Page 198 Index Removing the crankcase ......5-27 Removing the crankshaft assembly and Upper case, pivot shaft ......7-7 oil seal housing ........5-27 Removing the cylinder head ....5-24 Removing the drive shaft ....6-17, 6-38 Ventilation ..........1-3 Removing the electrical components ..5-17 Removing the exhaust cover ....
  • Page 200 YAMAHA MOTOR CO., LTD. Printed in Japan Aug. 2004 – 0.3 × 1 ! Printed on recycled paper...

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