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Manuals
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Yamaha Manuals
Outboard Motor
E40G
Service manual
Yamaha E40G Service Manual
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Contents
Table of Contents
Troubleshooting
Bookmarks
Table of Contents
General Information
Table of Contents
General Information
How to Use this Manual
Manual Format
Symbols
Safety While Working
Fire Prevention
Ventilation
Self-Protection
Parts, Lubricants, and Sealants
Good Working Practices
Disassembly and Assembly
Identification
Applicable Model
Serial Number
Propeller Selection
Propeller Size
Checking the Gear Oil Level
Checking the Battery (WH, W)
Selection
Checking the Fuel System
Predelivery Checks
Checking the Outboard Motor Mounting Height
Checking the Remote Control Cables (Remote Control Model)
Checking the Steering System
Checking the Gear Shift and Throttle Operation
Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
Checking the Cooling Water Pilot Hole
Test Run
Break-In
After Test Run
Spec Specifications
Specifications
General Specification
Maintenance Specification
Power Unit
Electrical
Lower Unit
Dimensions
Specified Torques
Tightening Torques
General Torques
Spec - Memo -
Chk Adj
Periodic Checks and Adjustments
Special Service Tools
Maintenance Interval Chart
Checking the Fuel Filter
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
Checking the Spark Plugs
Checking the Top Cowling
Chk Adj
Fuel System
Periodic Checks and Adjustments
Power Unit
Top Cowling
Checking the Cooling Water Passages
Checking the Thermostat
Adjusting the Start-In-Gear Protection
Adjusting the Throttle Cable (MH, WH)
Adjusting the Throttle Link Position
Control System
Adjusting the Throttle Cable (W)
Checking the Gear Shift Operation (MH, WH)
Checking the Engine Idle Speed
Checking the Gear Shift Operation (W)
Bracket
Changing the Gear Oil
Checking the Gear Oil Level
Checking the Tilt Operation
Lower Unit
Checking the Anodes
Checking the Lower Unit for Air Leakage
Checking the Propeller
General
Checking the Battery
Lubricating the Outboard Motor
Fuel Fuel System
Fuel
Fuel System
Special Service Tools
Hose Routing
Fuel Line
Carburetor
Checking the Carburetor
Disassembling the Carburetor
Adjusting the Throttle Stop Screw
Assembling the Carburetor
Fuel Pump
Checking the Fuel Pump
Disassembling the Fuel Pump
Assembling the Fuel Pump
Checking the Fuel Joint
Powr Power Unit
Powr
Power Unit
Special Service Tools
Power Unit
Checking the Compression Pressure
Checking the Drive Pawl
Checking the Spiral Spring
Disassembling the Manual Starter
Measuring the Starter Rope
Assembling the Manual Starter
Removing the Power Unit
Removing the Flywheel Magnet
Removing the Electrical Components
Removing the Throttle Pulley Assembly
Assembling the Base Assembly
Disassembling the Base Assembly
Reed Valves
Checking the Reed Valves
Removing the Reed Valve Assembly
Checking the Cylinder Head
Checking the Exhaust Cover
Cylinder Head
Installing the Pressure Control Valve
Removing the Cylinder Head
Removing the Exhaust Cover
Crankcase
Checking the Cylinder Bore
Removing the Crankcase
Removing the Crankshaft Assembly and Oil Seal Housing
Assembling the Oil Seal Housing
Checking the Oil Seal Housing
Disassembling the Oil Seal Housing
Disassembling the Piston
Checking the Piston Clearance
Checking the Piston Diameter
Checking the Piston Rings
Checking the Internal Anodes
Checking the Piston Pin
Checking the Piston Pin Boss Bore
Checking the Piston Ring Side Clearance
Disassembling the Crankshaft
Assembling the Crankshaft
Checking the Crankpin
Checking the Crankshaft
Installing the Crankshaft Bearings
Assembling the Piston
Assembling the Power Unit
Installing the Power Unit
Lowr Lower Unit
Lowr
Lower Unit
Special Service Tools
Lower Unit (E40G)
Removing the Lower Unit
Removing the Water Pump and Shift Rod
Checking the Water Pump and Shift Rod
Propeller Shaft Housing
Disassembling the Propeller Shaft Assembly
Disassembling the Propeller Shaft Housing
Removing the Propeller Shaft Housing Assembly
Assembling the Forward Gear
Assembling the Propeller Shaft Assembly
Checking the Propeller Shaft
Checking the Propeller Shaft Housing
Disassembling the Forward Gear
Assembling the Propeller Shaft Housing
Drive Shaft and Lower Case
Checking the Bearings
Checking the Drive Shaft
Checking the Pinion Gear
Disassembling the Lower Case
Removing the Drive Shaft
Assembling the Lower Case
Checking the Lower Case and Lower Case Cap
Installing the Drive Shaft
Installing the Propeller Shaft Housing
Installing the Water Pump and Shift Rod
Installing the Lower Unit
Shimming
Selecting the Forward and Reverse Gear Shims
Selecting the Pinion Shims
Backlash
Measuring the Forward and Reverse Gear Backlash
Lower Unit (E40J)
Removing the Lower Unit
Checking the Water Pump and Shift Rod
Removing the Water Pump and Shift Rod
Disassembling the Propeller Shaft Assembly
Disassembling the Propeller Shaft Housing
Propeller Shaft Housing
Removing the Propeller Shaft Housing Assembly
Assembling the Propeller Shaft Assembly
Checking the Propeller Shaft
Checking the Propeller Shaft Housing
Assembling the Propeller Shaft Housing
Drive Shaft and Lower Case
Disassembling the Drive Shaft
Disassembling the Forward Gear
Disassembling the Oil Seal Housing
Removing the Drive Shaft
Checking the Bearings
Checking the Drive Shaft
Checking the Lower Case
Checking the Pinion and Forward Gear
Disassembling the Lower Case
Assembling the Lower Case
Assembling the Oil Seal Housing
Assembling the Drive Shaft
Assembling the Forward Gear
Installing the Drive Shaft
Installing the Oil Seal Housing
Installing the Propeller Shaft Housing
Installing the Water Pump and Shift Rod
Installing the Lower Unit
Shimming
Selecting the Pinion Shims
Selecting the Forward Gear Shims
Selecting the Reverse Gear Shims
Backlash
Measuring the Forward and Reverse Gear Backlash
Brkt Bracket Unit
Brkt
Bracket Unit
Special Service Tools
Tiller Handle (MH, WH)
Assembling the Tiller Handle
Bottom Cowling
Upper Case, Pivot Shaft
Checking the Upper Case
Disassembling the Upper Case
Assembling the Upper Case
Removing the Pivot Shaft
Clamp Brackets, Swivel Bracket
Assembling the Swivel Bracket
Disassembling the Swivel Bracket
Installing the Clamp Brackets
Removing the Clamp Brackets
Installing the Pivot Shaft
Elec Electrical Systems
Elec
Electrical Systems
Special Service Tools
Checking the Electrical Components
Measuring Low Resistance
Measuring the Peak Voltage
Electrical Components
Top View
Port View
Starboard View (MH)
Starboard View (WH, W)
Wiring Diagram (MH)
Wiring Diagram (WH)
Wiring Diagram (W)
Checking the Ignition Coil
Checking the Ignition Spark Gap
Checking the Spark Plug Caps
Ignition and Ignition Control System
Checking the CDI Unit
Checking the Charge Coil
Checking the Pulser Coils
Checking the Engine Stop Lanyard Switch (MH, WH)
Checking the Fuse (WH,W)
Checking the Starter Relay (WH, W)
Checking the Thermoswitch
Starting System
Checking the Choke Solenoid (W)
Checking the Engine Start Switch (WH)
Checking the Neutral Switch (WH, W: if Equipped)
Starter Motor (WH, W)
Checking the Armature
Checking the Starter Motor Pinion
Removing the Starter Motor Pinion
Charging System
Checking the Brushes
Checking the Rectifier (WH, W)
Checking the Starter Motor Operation
Checking the Lighting Coil
Ignition System
Power Unit
Trbl Shtg
Troubleshooting
Fuel System
Compression Pressure
Lower Unit
Electrical System
Starting System
Charging System
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E40G
E40J
SERVICE MANUAL
6F6-28197-5G-11
Table of
Contents
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1
2
3
4
5
Advertisement
Chapters
General Information
3
Spec Specifications
17
Spec - Memo -
29
Fuel Fuel System
41
Powr Power Unit
55
Lowr Lower Unit
96
Brkt Bracket Unit
149
Elec Electrical Systems
169
Table of Contents
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