Yamaha C40ER Manuals

Manuals and User Guides for Yamaha C40ER. We have 1 Yamaha C40ER manual available for free PDF download: Service Manual

Yamaha C40ER Service Manual

Yamaha C40ER Service Manual (224 pages)

Marine Outboard

Brand: Yamaha | Category: Outboard Motor | Size: 5.73 MB

Table of Contents

Info Chapter 1 General Information

9
- How to Use this Manual
  3
- Table of Contents
  9
- Chapter 1
  10
- Identification
  10
- Serial Number
  10
- Starting Serial Numbers
  10
- Safety While Working
  11
  - Fire Prevention
    11
  - Ventilation
    11
  - Self-Protection
    11
  - Oils, Greases and Sealing Fluids
    11
  - Good Working Practices
    12
  - Disassembly and Assembly
    13
- Special Tools
  14
  - Measuring
    15
  - Removal and Installation
    17
Specifications

21
- Chapter 2 Specifications
  22
- General Specifications
  22
- Maintenance Specifications
  28
  - Engine
    28
  - Lower
    30
  - Electrical
    31
  - Dimension 1
    34
  - Dimension 2
    36
- Tightening Torque
  38
  - Specified Torque
    38
  - General Torque
    39
Table of Contents

41
- Chapter 3
  42
- Maintenance Interval Chart
  42
- Periodic Service
  43
  - Fuel System
    43
    
    Fuel Line
    43
  - Control System
    43
    
    Throttle Link Adjustment
    43
    
    Throttle Cable Adjustment
    44
    
    Shift Cable Adjustment
    45
    
    Start-In-Gear Protection Adjustment
    46
    
    Idle Speed Adjustment
    46
  - Oil Injection System
    47
    
    Oil Tank Water Drain
    47
    
    Oil Pump Link Adjustment
    47
  - Power Trim and Tilt System
    48
    
    Power Trim and Tilt Fluid
    48
  - Lower Unit
    49
    
    Gear Oil
    49
    
    Lower Unit Leakage Check
    49
  - General
    50
    
    Anode
    50
    
    Battery
    50
    
    Spark Plug
    51
    
    Grease Points
    52
Table of Contents

53
- Chapter 4
  54
- Exploded Diagram
  54
- Fuel Joint, Fuel Filter and Fuel Pump
  54
- Removal and Installation Chart
  55
- Fuel Line Layout
  56
  - M Model
    56
- Service Points
  57
  - Fuel Joint Inspection
    57
  - Fuel Filter Inspection
    57
  - Fuel Pump Inspection
    57
- Carburetor Removal
  58
  - Exploded Diagram
    58
  - Removal and Installation Chart
    59
- Carburetor
  60
  - Exploded Diagram
    60
  - Removal and Installation Chart
    61
  - Service Points
    62
    
    Carburetor Inspection
    62
    
    Carburetor Assembly
    63
- Prime Starter
  64
  - Exploded Diagram
    64
  - Removal and Installation Chart
    65
  - Service Points
    66
    
    Fuel Enrichment Pump Inspection
    66
    
    Fuel Enrichment Valve Inspection
    66
- Oil Tank
  68
  - Exploded Diagram
    68
  - Removal and Installation Chart
    69
  - Oil Line Layout
    70
  - Service Points
    71
    
    Oil Tank Inspection
    71
    
    Oil Strainer Inspection
    71
    
    Check Valve Inspection
    71
- Oil Pump
  72
  - Exploded Diagram
    72
  - Removal and Installation Chart
    73
Powr Chapter 5 Power Unit

74
- Chapter 5 Power Unit
  76
- Power Unit Removal
  76
  - Exploded Diagram
    76
  - Removal and Installation Chart
    77
- Recoil Starter
  78
  - Exploded Diagram
    78
  - Removal and Installation Chart
    79
  - Service Points
    80
    
    Sheave Drum Removal
    80
    
    Spiral Spring Removal
    80
    
    Starter Stopping Plunger Inspection
    80
    
    Drive Pawl and Spring Inspection
    81
    
    Rope Roller and Collar Inspection
    81
    
    Bushing Inspection
    81
    
    Sheave Drum Inspection
    81
    
    Spiral Spring Inspection
    81
    
    Starter Rope Inspection
    81
    
    Starter Rope Installation
    82
    
    Sheave Drum Installation
    82
    
    Spiral Spring Setting
    82
    
    Recoil Starter Checking
    82
- Flywheel Magneto and Magneto Base
  84
  - Exploded Diagram
    84
  - Removal and Installation Chart
    85
  - Service Points
    86
    
    Flywheel Magneto Removal
    86
- Electrical Unit Removal
  88
  - Exploded Diagram
    88
  - Removal and Installation Chart
    89
- Electrical Unit
  90
  - Exploded Diagram
    90
  - Removal and Installation Chart
    91
- Reed Valve and Check Valve
  92
  - Exploded Diagram
    92
  - Removal and Installation Chart
    93
  - Service Points
    94
    
    Reed Valve Inspection
    94
- Cylinder Head, Thermostat and Exhaust Cover
  96
  - Exploded Diagram
    96
  - Removal and Installation Chart
    97
  - Service Points
    98
    
    Cylinder Head Inspection
    98
    
    Thermostat Inspection
    99
- Crankcase and Cylinder Body
  100
  - Exploded Diagram
    100
  - Removal and Installation Chart
    101
  - Exploded Diagram
    102
  - Removal and Installation Chart
    103
  - Service Points
    104
    
    Cylinder Body Inspection
    104
    
    Piston to Cylinder Clearance
    105
    
    Oil Pump Driven Gear Inspection
    105
    
    Cylinder Body and Crankcase Installation
    105
- Crank Shaft and Piston
  106
  - Exploded Diagram
    106
  - Removal and Installation Chart
    107
  - Service Points
    108
    
    Piston Pin Clip Removal
    108
    
    Piston Pin and Small End Bearing Removal
    108
    
    Piston Ring Removal
    108
    
    Bearing Removal
    108
    
    Piston Inspection
    108
    
    Piston Pin and Small End Bearing Inspection
    109
    
    Piston Ring Inspection
    110
    
    Crankshaft Inspection
    111
    
    Piston and Piston Ring Installation
    112
    
    Crankshaft and Piston Installation
    112
Lowr Chapter 6 Lower Unit

114
- Chapter 6 Lower Unit
  116
- Lower Unit Removal
  116
  - Exploded Diagram
    116
  - Removal and Installation Chart
    117
  - Service Points
    117
    
    Propeller Inspection
    117
- Water Pump
  118
  - Exploded Diagram
    118
  - Removal and Installation Chart
    119
  - Service Points
    119
    
    Water Pump Housing Inspection
    119
    
    Impeller and Insert Cartridge Inspection
    119
- Propeller Shaft and Reverse Gear
  120
  - Exploded Diagram
    120
  - Removal and Installation Chart
    121
  - Service Points
    121
    
    Propeller Shaft Housing Removal
    121
    
    Propeller Shaft Housing Disassembly
    121
    
    Reverse Gear Inspection
    123
    
    Bearing Inspection
    123
    
    Propeller Shaft Housing Inspection
    123
    
    Dog Clutch Inspection
    123
    
    Propeller Shaft Inspection
    123
    
    Propeller Shaft Housing Assembly
    124
- Drive Shaft, Forward Gear and Shift Rod
  126
  - Exploded Diagram
    126
  - Removal and Installation Chart
    127
  - Exploded Diagram
    128
  - Removal and Installation Chart
    129
  - Service Points
    130
    
    Pinion Nut Removal
    130
    
    Forward Gear Disassembly
    130
    
    Lower Case Disassembly
    130
    
    Pinion and Forward Gear Inspection
    131
    
    Drive Shaft Inspection
    131
    
    Shift Cam Inspection
    131
    
    Bearing Inspection
    131
    
    Sleeve Inspection
    132
    
    Lower Case Inspection
    132
    
    Lower Case Assembly
    132
    
    Drive Shaft Oil Seal Housing Assembly
    133
    
    Forward Gear Assembly
    133
    
    Pinion Nut Installation
    133
- Shimming
  134
  - Shim Selection (for Usa and Canada)
    134
    
    Pinion Gear Shim
    134
    
    Forward Gear Shim
    136
    
    Forward Gear
    143
    
    Reverse Gear
    143
Table of Contents

146
- Chapter 7
  148
- Exploded Diagram
  148
- Tiller Handle Removal
  148
- Removal and Installation Chart
  149
- Tiller Handle
  150
  - Exploded Diagram
    150
  - Removal and Installation Chart
    151
  - Exploded Diagram
    152
  - Removal and Installation Chart
    153
  - Service Points
    153
    
    Control Cable Inspection
    153
    
    Bushing Inspection
    153
    
    Shift Lever Inspection
    153
    
    Friction Piece Inspection
    153
    
    Steering Handle Inspection
    153
- Link Ass'y Disassembly
  154
  - Exploded Diagram
    154
  - Removal and Installation Chart
    155
  - Service Points
    155
    
    Throttle Arm Inspection
    155
    
    Throttle Shift Ass'y Inspection
    155
    
    Cam Plate Inspection
    155
    
    Bushing Inspection
    155
- Shift Actuator and Bottom Cowling
  156
  - Exploded Diagram
    156
  - Removal and Installation Chart
    157
- Upper Case Removal
  158
  - Exploded Diagram
    158
  - Removal and Installation Chart
    159
  - Service Points
    159
    
    Rubber Mount Inspection
    159
    
    Mount Bolt Inspection
    159
- Upper Case and Exhaust Manfold
  160
  - Exploded Diagram
    160
  - Removal and Installation Chart
    161
- CLAMP BRACKET (Manual Tilt)
  162
  - Exploded Diagram
    162
- CLAMP BRACKET (Hydro Tilt, Power Trim and Tilt)
  164
  - Exploded Diagram
    164
  - Removal and Installation Chart
    165
- Steering Bracket
  166
  - Exploded Diagram
    166
  - Removal and Installation Chart
    167
- Swivel Bracket
  168
  - Exploded Diagram
    168
  - Removal and Installation Chart
    169
- Swivel Bracket Disassembly
  170
  - Exploded Diagram
    170
  - Removal and Installation Chart
    171
- Tilt Unit Removal
  172
  - Exploded Diagram
    172
  - Removal and Installation Chart
    173
- Tilt Cylinder, Pump Housing and Motor Removal
  174
  - Exploded Diagram
    174
  - Removal and Installation Chart
    175
  - Service Points
    175
- Tilt Cylinder
  176
  - Exploded Diagram
    176
  - Removal and Installation Chart
    177
  - Service Points
    177
    
    Tilt Cylinder Disassembly
    177
    
    Inner Cylinder Disassembly
    178
    
    Tilt Rod Inspection
    178
    
    Tilt Cylinder Inspection
    178
    
    Tilt Piston Inspection
    178
    
    Spring Inspection
    178
    
    Free Piston Inspection
    178
    
    Inner Cylinder Assembly
    179
    
    Tilt Cylinder Assembly
    179
- Pump Housing
  180
  - Exploded Diagram
    180
  - Removal and Installation Chart
    181
- Ptt Motor
  182
  - Exploded Diagram
    182
  - Removal and Installation Chart
    183
  - Service Points
    184
    
    Motor Inspection
    184
    
    Motor Assembly
    185
Table of Contents

186
- Chapter 8 Oil Injection Model
  188
- Electrical Components
  188
- Mh, Mho, Mo, Mdo Model
  189
- Whd, Wh, E, Edo, Eo Model
  190
- Et, Eto Model
  191
- Ehto Model
  192
- Electrical Unit Components
  193
  - E, Eo Model
    193
  - Et, Eto Model
    194
- Electrical Analysis
  195
  - Inspection
    195
    
    Low Resistance Measurement
    195
- Ignition System
  196
  - Ignition Spark Gap
    197
  - CDI System Peak Voltage
    197
  - Spark Plug
    199
  - Spark Plug Cap
    199
  - Engine Stop Switch
    200
  - Main Switch
    201
- Ignition Control System
  202
  - Thermo Switch
    203
  - Oil Level Sensor
    203
  - Warning Lamp
    204
  - Oil Level Warning Lamp
    205
  - CDI Unit
    205
- Starting System
  206
  - Battery
    207
  - Wiring Harness
    207
  - Wiring Connection
    207
  - Engine Stop Switch
    207
  - Main Switch
    207
  - Neutral Switch
    207
  - Starter Relay
    208
  - Fuse
    208
- Starter Motor
  210
  - Exploded Diagram
    210
  - Removal and Installation Chart
    211
  - Service Points
    212
    
    Pinion Removal
    212
    
    Pinion Inspection
    212
    
    Armature Inspection
    212
    
    Brush Holder Inspection
    213
    
    Cover Inspection
    214
- Charging System
  215
  - Charging System Peak Voltage
    216
  - Fuse
    216
  - Battery
    216
- Enrichment Control System
  217
  - Lighting Coil
    217
  - Electrothermal Valve
    217
  - Rectifier Regulator
    217
- Power Trim and Tilt Control System
  218
  - Battery
    219
  - Fuse
    219
  - Ptt Switch
    219
  - Ptt Relay
    219
  - Trim Sensor
    220
  - Trouble Analysis
    222

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