Yamaha E40J Manuals

Manuals and User Guides for Yamaha E40J. We have 1 Yamaha E40J manual available for free PDF download: Service Manual

Yamaha E40J Service Manual

Yamaha E40J Service Manual (200 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 8.66 MB

Table of Contents

General Information

3
- Table of Contents
  3
- General Information
  5
- How to Use this Manual
  6
- Manual Format
  6
- Symbols
  7
- Safety While Working
  8
- Fire Prevention
  8
- Ventilation
  8
- Self-Protection
  8
- Parts, Lubricants, and Sealants
  8
- Good Working Practices
  9
- Disassembly and Assembly
  9
- Identification
  10
- Applicable Model
  10
- Serial Number
  10
- Propeller Selection
  10
- Propeller Size
  10
- Checking the Gear Oil Level
  11
- Checking the Battery (WH, W)
  11
- Selection
  11
- Checking the Fuel System
  11
- Predelivery Checks
  11
- Checking the Outboard Motor Mounting Height
  12
- Checking the Remote Control Cables (Remote Control Model)
  12
- Checking the Steering System
  13
- Checking the Gear Shift and Throttle Operation
  13
- Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
  14
- Checking the Cooling Water Pilot Hole
  14
- Test Run
  14
- Break-In
  15
- After Test Run
  15
Spec Specifications

17
- Specifications
  17
- General Specification
  18
- Maintenance Specification
  20
- Power Unit
  20
- Electrical
  22
- Lower Unit
  22
- Dimensions
  24
- Specified Torques
  26
- Tightening Torques
  26
- General Torques
  27
Spec - Memo -

29
- Chk Adj
  30
- Periodic Checks and Adjustments
  30
- Special Service Tools
  30
- Maintenance Interval Chart
  31
- Checking the Fuel Filter
  32
- Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
  32
- Checking the Spark Plugs
  32
- Checking the Top Cowling
  32
- Chk Adj
  32
- Fuel System
  32
- Periodic Checks and Adjustments
  32
- Power Unit
  32
- Top Cowling
  32
- Checking the Cooling Water Passages
  33
- Checking the Thermostat
  33
- Adjusting the Start-In-Gear Protection
  34
- Adjusting the Throttle Cable (MH, WH)
  34
- Adjusting the Throttle Link Position
  34
- Control System
  34
- Adjusting the Throttle Cable (W)
  35
- Checking the Gear Shift Operation (MH, WH)
  35
- Checking the Engine Idle Speed
  36
- Checking the Gear Shift Operation (W)
  36
- Bracket
  37
- Changing the Gear Oil
  37
- Checking the Gear Oil Level
  37
- Checking the Tilt Operation
  37
- Lower Unit
  37
- Checking the Anodes
  38
- Checking the Lower Unit for Air Leakage
  38
- Checking the Propeller
  38
- General
  38
- Checking the Battery
  39
- Lubricating the Outboard Motor
  39
Fuel Fuel System

41
- Fuel
  41
- Fuel System
  42
- Special Service Tools
  42
- Hose Routing
  43
- Fuel Line
  44
- Carburetor
  47
- Checking the Carburetor
  49
- Disassembling the Carburetor
  49
- Adjusting the Throttle Stop Screw
  50
- Assembling the Carburetor
  50
- Fuel Pump
  51
- Checking the Fuel Pump
  52
- Disassembling the Fuel Pump
  52
- Assembling the Fuel Pump
  53
- Checking the Fuel Joint
  53
Powr Power Unit

55
- Powr
  55
- Power Unit
  56
- Special Service Tools
  56
- Power Unit
  58
- Checking the Compression Pressure
  59
- Checking the Drive Pawl
  68
- Checking the Spiral Spring
  68
- Disassembling the Manual Starter
  68
- Measuring the Starter Rope
  68
- Assembling the Manual Starter
  69
- Removing the Power Unit
  70
- Removing the Flywheel Magnet
  71
- Removing the Electrical Components
  72
- Removing the Throttle Pulley Assembly
  72
- Assembling the Base Assembly
  73
- Disassembling the Base Assembly
  73
- Reed Valves
  74
- Checking the Reed Valves
  76
- Removing the Reed Valve Assembly
  76
- Checking the Cylinder Head
  79
- Checking the Exhaust Cover
  79
- Cylinder Head
  79
- Installing the Pressure Control Valve
  79
- Removing the Cylinder Head
  79
- Removing the Exhaust Cover
  79
- Crankcase
  80
- Checking the Cylinder Bore
  82
- Removing the Crankcase
  82
- Removing the Crankshaft Assembly and Oil Seal Housing
  82
- Assembling the Oil Seal Housing
  83
- Checking the Oil Seal Housing
  83
- Disassembling the Oil Seal Housing
  83
- Disassembling the Piston
  83
- Checking the Piston Clearance
  84
- Checking the Piston Diameter
  84
- Checking the Piston Rings
  84
- Checking the Internal Anodes
  85
- Checking the Piston Pin
  85
- Checking the Piston Pin Boss Bore
  85
- Checking the Piston Ring Side Clearance
  85
- Disassembling the Crankshaft
  85
- Assembling the Crankshaft
  87
- Checking the Crankpin
  87
- Checking the Crankshaft
  91
- Installing the Crankshaft Bearings
  91
- Assembling the Piston
  92
- Assembling the Power Unit
  92
- Installing the Power Unit
  94
Lowr Lower Unit

96
- Lowr
  96
- Lower Unit
  98
- Special Service Tools
  98
- Lower Unit (E40G)
  102
- Removing the Lower Unit
  106
- Removing the Water Pump and Shift Rod
  106
- Checking the Water Pump and Shift Rod
  107
- Propeller Shaft Housing
  108
- Disassembling the Propeller Shaft Assembly
  110
- Disassembling the Propeller Shaft Housing
  110
- Removing the Propeller Shaft Housing Assembly
  110
- Assembling the Forward Gear
  111
- Assembling the Propeller Shaft Assembly
  111
- Checking the Propeller Shaft
  111
- Checking the Propeller Shaft Housing
  111
- Disassembling the Forward Gear
  111
- Assembling the Propeller Shaft Housing
  112
- Drive Shaft and Lower Case
  113
- Checking the Bearings
  114
- Checking the Drive Shaft
  114
- Checking the Pinion Gear
  114
- Disassembling the Lower Case
  114
- Removing the Drive Shaft
  114
- Assembling the Lower Case
  115
- Checking the Lower Case and Lower Case Cap
  115
- Installing the Drive Shaft
  116
- Installing the Propeller Shaft Housing
  116
- Installing the Water Pump and Shift Rod
  117
- Installing the Lower Unit
  118
- Shimming
  120
- Selecting the Forward and Reverse Gear Shims
  121
- Selecting the Pinion Shims
  121
- Backlash
  122
- Measuring the Forward and Reverse Gear Backlash
  122
- Lower Unit (E40J)
  124
- Removing the Lower Unit
  128
- Checking the Water Pump and Shift Rod
  129
- Removing the Water Pump and Shift Rod
  129
- Disassembling the Propeller Shaft Assembly
  131
- Disassembling the Propeller Shaft Housing
  131
- Propeller Shaft Housing
  131
- Removing the Propeller Shaft Housing Assembly
  131
- Assembling the Propeller Shaft Assembly
  132
- Checking the Propeller Shaft
  132
- Checking the Propeller Shaft Housing
  132
- Assembling the Propeller Shaft Housing
  133
- Drive Shaft and Lower Case
  134
- Disassembling the Drive Shaft
  135
- Disassembling the Forward Gear
  135
- Disassembling the Oil Seal Housing
  135
- Removing the Drive Shaft
  135
- Checking the Bearings
  136
- Checking the Drive Shaft
  136
- Checking the Lower Case
  136
- Checking the Pinion and Forward Gear
  136
- Disassembling the Lower Case
  136
- Assembling the Lower Case
  137
- Assembling the Oil Seal Housing
  137
- Assembling the Drive Shaft
  138
- Assembling the Forward Gear
  138
- Installing the Drive Shaft
  138
- Installing the Oil Seal Housing
  138
- Installing the Propeller Shaft Housing
  138
- Installing the Water Pump and Shift Rod
  139
- Installing the Lower Unit
  141
- Shimming
  143
- Selecting the Pinion Shims
  144
- Selecting the Forward Gear Shims
  145
- Selecting the Reverse Gear Shims
  146
- Backlash
  147
- Measuring the Forward and Reverse Gear Backlash
  147
Brkt Bracket Unit

149
- Brkt
  149
- Bracket Unit
  150
- Special Service Tools
  150
- Tiller Handle (MH, WH)
  151
- Assembling the Tiller Handle
  153
- Bottom Cowling
  154
- Upper Case, Pivot Shaft
  156
- Checking the Upper Case
  160
- Disassembling the Upper Case
  160
- Assembling the Upper Case
  161
- Removing the Pivot Shaft
  162
- Clamp Brackets, Swivel Bracket
  163
- Assembling the Swivel Bracket
  167
- Disassembling the Swivel Bracket
  167
- Installing the Clamp Brackets
  167
- Removing the Clamp Brackets
  167
- Installing the Pivot Shaft
  168
Elec Electrical Systems

169
- Elec
  169
- Electrical Systems
  170
- Special Service Tools
  170
- Checking the Electrical Components
  171
- Measuring Low Resistance
  171
- Measuring the Peak Voltage
  171
- Electrical Components
  172
- Top View
  172
- Port View
  173
- Starboard View (MH)
  174
- Starboard View (WH, W)
  175
- Wiring Diagram (MH)
  176
- Wiring Diagram (WH)
  177
- Wiring Diagram (W)
  178
- Checking the Ignition Coil
  179
- Checking the Ignition Spark Gap
  179
- Checking the Spark Plug Caps
  179
- Ignition and Ignition Control System
  179
- Checking the CDI Unit
  180
- Checking the Charge Coil
  180
- Checking the Pulser Coils
  180
- Checking the Engine Stop Lanyard Switch (MH, WH)
  181
- Checking the Fuse (WH,W)
  181
- Checking the Starter Relay (WH, W)
  181
- Checking the Thermoswitch
  181
- Starting System
  181
- Checking the Choke Solenoid (W)
  182
- Checking the Engine Start Switch (WH)
  182
- Checking the Neutral Switch (WH, W: if Equipped)
  182
- Starter Motor (WH, W)
  183
- Checking the Armature
  184
- Checking the Starter Motor Pinion
  184
- Removing the Starter Motor Pinion
  184
- Charging System
  185
- Checking the Brushes
  185
- Checking the Rectifier (WH, W)
  185
- Checking the Starter Motor Operation
  185
- Checking the Lighting Coil
  186
- Ignition System
  188
- Power Unit
  188
- Trbl Shtg
  188
- Troubleshooting
  188
- Fuel System
  190
- Compression Pressure
  191
- Lower Unit
  193
- Electrical System
  194
- Starting System
  194
- Charging System
  195

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