Yamaha EK40J Manuals

Manuals and User Guides for Yamaha EK40J. We have 1 Yamaha EK40J manual available for free PDF download: Service Manual

Yamaha EK40J Service Manual

Yamaha EK40J Service Manual (200 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 9 MB

Table of Contents

Table of Contents

3
- Important Information
  2
- General Information
  
  5
  - How to Use this Manual
    6
    
    Manual Format
    6
    
    Symbols
    7
- Contents
  
  7
  - Safety While Working
    8
    
    Fire Prevention
    8
    
    Parts, Lubricants, and Sealants
    8
    
    Self-Protection
    8
    
    Ventilation
    8
    
    Disassembly and Assembly
    9
    
    Good Working Practices
    9
  - Identification
    10
    
    Applicable Model
    10
    
    Serial Number
    10
  - Propeller Selection
    10
    
    Propeller Size
    10
    
    Selection
    11
  - Predelivery Checks
    11
    
    Checking the Battery (W)
    11
    
    Checking the Fuel System
    11
    
    Checking the Gear Oil Level
    11
    
    Checking the Outboard Motor Mounting Height
    12
    
    Checking the Remote Control Cables (Remote Control Model)
    12
    
    Checking the Gear Shift and Throttle Operation
    13
    
    Checking the Steering System
    13
    
    Checking the Cooling Water Pilot Hole
    14
    
    Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
    14
    
    Test Run
    14
    
    After Test Run
    15
    
    Break-In
    15
Spec Specifications

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

29
- Chk Adj
  
  30
- Special Service Tools
  
  30
- Periodic Checks and Adjustments
  
  30
- Maintenance Interval Chart
  
  31
  - Chk Adj
    32
- Top Cowling
  
  32
  - Checking the Top Cowling
    32
- Fuel System
  
  32
  - Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
    32
  - Checking the Fuel Filters
    32
- Power Unit
  
  32
- Control System
  
  34
- Bracket
  
  37
  - Checking the Tilt Operation
    37
- Lower Unit
  
  37
- General
  
  38
  - Checking the Anodes
    38
  - Checking the Battery (W)
    38
  - Lubricating the Outboard Motor
    39
Fuel Fuel System

41
- Fuel
  41
- Special Service Tools
  
  42
- Fuel System
  
  42
- Hose Routing
  
  43
- Fuel Line
  
  44
- Carburetor
  
  46
- Fuel Pump
  
  53
  - Checking the Fuel Pump
    55
  - Disassembling the Fuel Pump
    56
  - Assembling the Fuel Pump
    56
  - Checking the Fuel Joint
    56
Powr Power Unit

57
- Powr
  57
- Special Service Tools
  
  58
- Power Unit
  
  58
- Power Unit
  
  60
- Reed Valves
  
  76
  - Removing the Reed Valve Assembly
    78
  - Checking the Reed Valves
    78
- Cylinder Head
  
  81
- Crankcase
  
  82
Lowr Lower Unit

98
- Lowr
  98
- Lower Unit
  
  100
- Special Service Tools
  
  100
- Lower Unit (EK40G)
  
  104
- Propeller Shaft Housing
  
  110
- Drive Shaft and Lower Case
  
  115
  - Removing the Drive Shaft
    116
  - Disassembling the Lower Case
    116
  - Checking the Pinion Gear
    116
  - Checking the Bearings
    116
  - Checking the Drive Shaft
    116
  - Checking the Lower Case and Lower Case Cap
    117
  - Assembling the Lower Case
    117
  - Installing the Drive Shaft
    118
  - Installing the Propeller Shaft Housing
    118
  - Installing the Water Pump and Shift Rod
    119
  - Installing the Lower Unit
    120
- Shimming
  
  122
- Lower Unit (EK40J)
  
  126
- Propeller Shaft Housing
  
  133
- Drive Shaft and Lower Case
  
  136
  - Removing the Drive Shaft
    137
  - Disassembling the Drive Shaft
    137
  - Disassembling the Forward Gear
    137
  - Disassembling the Oil Seal Housing
    137
  - Disassembling the Lower Case
    138
  - Checking the Pinion and Forward Gear
    138
  - Checking the Bearings
    138
  - Checking the Drive Shaft
    138
  - Checking the Lower Case
    138
  - Assembling the Oil Seal Housing
    139
  - Assembling the Lower Case
    139
  - Assembling the Forward Gear
    140
  - Assembling the Drive Shaft
    140
  - Installing the Drive Shaft
    140
  - Installing the Oil Seal Housing
    140
  - Installing the Propeller Shaft Housing
    140
  - Installing the Water Pump and Shift Rod
    141
  - Installing the Lower Unit
    143
- Shimming
  
  145
  - Selecting the Pinion Shims
    146
  - Selecting the Forward Gear Shims
    147
  - Selecting the Reverse Gear Shims
    148
  - Backlash
    149
  - Measuring the Forward and Reverse Gear Backlash
    149
Brkt Bracket Unit

151
- Brkt
  151
- Special Service Tools
  
  152
- Bracket Unit
  
  152
- Tiller Handle (MH)
  
  153
  - Assembling the Tiller Handle
    155
- Bottom Cowling
  
  156
- Upper Case, Pivot Shaft
  
  158
  - Disassembling the Upper Case
    162
  - Checking the Upper Case
    162
  - Assembling the Upper Case
    163
  - Removing the Pivot Shaft
    164
- Clamp Brackets, Swivel Bracket
  
  165
  - Removing the Clamp Brackets
    169
  - Disassembling the Swivel Bracket
    169
  - Assembling the Swivel Bracket
    169
  - Installing the Clamp Brackets
    169
  - Installing the Pivot Shaft
    170
Elec Electrical Systems

171
- Elec
  171
- Special Service Tools
  
  172
- Electrical Systems
  
  172
- Checking the Electrical Components
  
  173
  - Measuring the Peak Voltage
    173
  - Measuring Low Resistance
    173
- Electrical Components
  
  174
  - Top View
    174
  - Starboard View (MH)
    175
  - Starboard View (W)
    176
  - Wiring Diagram (MH)
    177
  - Wiring Diagram (W)
    178
- Ignition and Ignition Control System
  
  179
  - Checking the Ignition Spark Gap
    179
  - Checking the Ignition Coil
    179
  - Checking the Spark Plug Caps
    179
  - Checking the CDI Unit
    180
  - Checking the Pulser Coils
    180
  - Checking the Charge Coil
    180
  - Checking the Thermoswitch
    181
  - Checking the Engine Stop Lanyard Switch (MH)
    181
- Starting System
  
  182
  - Checking the Fuse (W)
    182
  - Checking the Starter Relay (W)
    182
- Starter Motor (W)
  
  183
  - Removing the Starter Motor Pinion
    184
  - Checking the Starter Motor Pinion
    184
  - Checking the Armature
    184
  - Checking the Brushes
    185
  - Checking the Starter Motor Operation
    185
- Charging System
  
  185
  - Checking the Rectifier (W)
    185
  - Checking the Lighting Coil
    186
  - Trbl Shtg
    188
    
    Ignition System
    188
    
    Power Unit
    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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