Yamaha F40ER Manuals

Manuals and User Guides for Yamaha F40ER. We have 4 Yamaha F40ER manuals available for free PDF download: Service Manual, Rigging Manual

Yamaha F40ER Service Manual (538 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 29 MB

How to Use this Manual
4
Important Information
8
Chapter 1 General Information

12
- Periodic Check and Adjustment
  12
- Specifications
  12
  - Symbols
    12
  - Table of Contents
    14
  - General Information
    16
  - Identification
    18
  - Serial Number
    18
  - Starting Serial Numbers
    18
  - Fire Prevention
    20
  - Oils, Greases and Sealing Fluids
    20
  - Safety While Working
    20
  - Self-Protection
    20
  - Ventilation
    20
  - Good Working Practices
    22
  - Disassembly and Assembly
    24
  - Measuring
    26
  - Special Tools
    26
  - Outillage Special
    27
  - Removing and Installing
    30
  - Outillage Special
    31
  - Specifications
    36
  - General Specifications
    38
  - Mesure
    39
  - Maintenance Specifications
    42
  - Power Unit
    42
  - Electrical
    52
  - Dimensions
    60
  - Specified Torques
    66
  - Tightening Torques
    66
  - General Torques
    70
  - Periodic Check and Adjustment
    72
Chapter 3

76
- Maintenance Interval Chart
  76
  - Checking the Fuel Line
    80
  - Checking the Top Cowling Fit
    80
  - Top Cowling/Fuel System
    80
  - Adjusting the Shift Cable
    82
  - Checking the Fuel Filter
    82
  - Control System
    82
  - Adjusting the Throttle Cable
    84
  - Adjusting the Engine Idling Speed
    86
  - Adjusting the Pilot Screw
    88
  - Exhaust Gas Control Procedures
    90
  - Synchronizing the Carburetor
    94
  - Adjusting the Dash-Pot
    98
  - Start-In-Gear Protection Device Adjustment (Mhd, Whd)
    98
  - Checking the Engine Oil Level
    100
  - Replacing the Engine Oil and Oil Filter
    100
- Power Unit
  100
  - Measuring the Oil Pressure
    102
  - Adjusting the Valve Clearance
    104
  - Measuring the Compression Pressure
    108
  - Checking the Timing Belt
    110
  - Cooling System
    110
  - Checking the Cooling Water Discharge
    110
  - Power Trim and Tilt System
    112
  - Checking the Power Trim and Tilt Fluid Level
    112
- Lower Unit
  114
  - Checking the Gear Oil Level
    114
  - Changing and Checking the Gear Oil
    114
  - Checking the Lower Unit (for Air Leaks)
    116
  - General
    118
  - Checking the Anodes
    118
  - Checking the Battery
    118
  - Checking the Spark Plugs
    120
  - Checking Bolts and Nuts
    124
  - Lubrication Points
    126
- Fuel System
  130
Chapter 4

132
- Hose Routing
  132
- Fuel Joint, Fuel Filter, and Fuel Pump
  134
- Removing/Installing the Fuel Joint, Fuel Filter and Fuel Pump
  134
- Fuel Pump
  136
- Disassembling/Assembling the Fuel Pump Assembly
  136
- Installing the Fuel Filter
  138
- Checking the Fuel Pump
  138
- Carburetor Unit
  140
- Removing/Installing the Carburetor Unit
  140
- Removing/Installing the Carburetors
  144
- Carburetor
  148
Chapter 5

164
- Removing/Installing the Manual Starter
  164
  - Flywheel Magnet Assembly (ED, ET)
    166
  - Removing/Installing the Flywheel Magnet Assembly
    166
  - Removing the Flywheel Magnet Assembly
    168
  - Installing the Flywheel Magnet Assembly
    170
  - Recoil Starter
    172
  - Removing/Installing the Manual Starter
    172
  - Removing/Installing the Manual Starter Assembly
    174
  - Removing the Sheave Drum
    178
  - Removing the Spiral Spring
    178
  - Disassembling Sheave Drum
    180
  - Installing the Spiral Spring
    180
  - Installing the Starter Rope
    180
  - Installing the Sheave Drum
    182
  - Checking the Recoil Starter
    184
  - Disconnecting/Connecting the Leads
    186
  - Power Unit
    186
  - Disconnecting/Connecting the Hoses
    188
  - Removing/Installing the Power Unit
    190
  - Removing/Installing the Stator Assembly
    192
  - Stator Assembly
    192
  - Removing the Sprockets
    198
  - Installing the Timing Belt and Sprockets
    200
    
    Electrical Unit
    202
    
    Removing/Installing the Electrical Unit
    202
  - Electrical Unit
    206
  - Removing/Installing the Electrical Unit 1
    208
  - Removing/Installing the Shift Bracket and Throttle Control Lever
    216
  - Shift Bracket and Throttle Control Lever
    216
  - Cylinder Head
    218
  - Removing/Installing the Cylinder Head
    218
  - Disassembling/Assembling the Oil Pump
    222
  - Removing/Installing the Camshaft and Valve
    224
  - Checking Oil Pump
    228
  - Checking the Cylinder Head
    228
  - Checking the Valve
    230
  - Checking the Rocker Arm and Rocker Shaft
    232
  - Checking the Valve Spring
    232
  - Checking the Cam Shaft
    234
  - Checking the Decompression Actuators (MH)
    234
  - Refacing the Valve Seat
    236
  - Replacing the Valve Guide
    236
  - Installing the Valve
    240
    
    Exhaust Cover
    242
    
    Removing/Installing the Exhaust Cover
    242
  - Checking the Thermostat
    244
  - Installing the Oil Filter
    244
  - Crankshaft and Piston
    246
  - Removing/Installing the Crankshaft and Piston
    246
  - Disassembling/Assembling the Piston
    250
  - Checking the Piston-To-Cylinder Clearance
    252
  - Checking the Piston Pin
    254
  - Checking the Piston Ring
    254
  - Checking the Crankshaft
    256
  - Checking the Main-Bearing Oil Clearance
    258
  - Checking the Big-End Oil Clearance
    262
  - Installing in the Engine
    266
  - Installing the Oil Seal
    266
  - Installing the Piston Ring
    266
  - Removing/Installing the Lower Unit
    274
  - Checking the Propller
    278
  - Installing the Propeller
    278
  - Installing the Trim Tab
    278
  - Removing the Propeller
    278
  - Removing/Installing the Water Pump
    280
  - Water Pump
    280
  - Checking the Impeller and Insert Cartridge
    282
  - Checking the Water Pump Housing
    282
  - Checking the Woodruff Key
    282
  - Installing the Impeller and Water Pump Housing
    282
    
    Removing/Installing the Shift Rod Assembly
    284
    
    Shift Rod Assembly
    284
    
    Propeller Shaft Housing Assembly
    286
    
    Disassembling/Assembling the Propeller Shaft Housing Assembly
    288
    
    Disassembling the Propeller Shaft Housing Assembly
    292
    
    Removing the Propeller Shaft Housing Assembly
    292
    
    Checking the Bearing
    294
    
    Checking the Reverse Gear
    294
    
    Assembling the Propeller Shaft Housing Assembly
    296
    
    Checking the Dog Clutch
    296
    
    Checking the Propeller Shaft
    296
    
    Drive Shaft
    300
    
    Removing/Installing the Drive Shaft
    300
    
    Removing the Drive Shaft
    302
    
    Removing the Drive Shaft Bearing
    302
    
    Assembling the Forward Gear Assembly
    306
    
    Installing the Drive Shaft Bearing
    306
    
    Installing the Drive Shaft
    308
    
    Lower Case Assembly
    310
    
    Checking the Drive Shaft Sleeve
    312
    
    Disassembling the Lower Case Assembly
    312
    
    Assembling the Lower Case Assembly
    314
    
    Checking the Needle Bearing
    314
    
    Shimming
    316
    
    Spezialwerkzeuge
    319
    
    Backlash
    340
    
    Measuring the Forward Gear Backlash
    340
  - 90890-07003 Dial Gauge Set
    344
  - Magnetic Base Attaching Plate
    344
  - Measuring the Reverse Gear Backlash
    344
  - Adjust
    346
  - MM (0.008 In)
    346
  - Shim Thickness
    346
- Bracket Unit
  348
  - Removing/Installing the Steering Friction
    352
  - Tiller Handle Assembly
    352
  - Removing/Installing the Tiller Handle Assembly
    354
  - Disassembling/Assembling the Tiller Handle Assembly
    356
  - MM (0.024 In)
    356
  - Disassembling/Assembling the Link Assembly
    362
  - Bottom Cowling
    364
  - Removing/Installing the Bottom Cowling
    364
  - Removing/Installing the Upper Case Assembly
    366
  - Upper Case Assembly
    366
  - Removing/Installing the Ground Lead
    368
  - Disassembling/Assembling the Upper Case Assembly
    370
  - Removing/Installing the Steering Arm
    376
  - Steering Arm
    376
  - Installing the Bushing
    378
  - Clamp Brackets (MHD, WHD, ED)
    380
  - Removing/Installing the Clamp Brackets
    380
  - Checking the Shock Absorber
    386
  - Removing the Shock Absorber
    386
  - Clamp Brackets (ET)
    388
  - Removing/Installing the Clamp Brackets
    388
  - Power Trim and Tilt Unit
    392
  - Removing/Installing the Power Trim and Tilt Unit
    392
  - Bleeding the Power Trim and Tilt Unit
    396
  - Removing the Power Trim and Tilt Unit
    396
  - Disassembling/Assembling the Tilt Cylinder Assembly
    400
  - Tilt Cylinder Assembly
    400
  - Removing the Tilt Ram Assembly
    402
  - Assembling the Tilt Ram
    404
  - Checking the Tilt Ram
    404
  - Assembling the Tilt Cylinder Assembly
    406
  - Bleeding the Power Trim and Tilt Unit
    408
  - Filling the Reservoir
    408
  - Disassembling/Assembling the Gear Pump Assembly
    412
  - Gear Pump Assembly
    412
  - Disassembling the Gear Pump Assembly
    416
  - Disassembling/Assembling the Pump Housing
    418
  - Pump Housing
    420
  - Disassembly/Assembly the Gear Pump Unit
    424
  - Gear Pump Unit
    424
- Electrical System
  426
  - Electrical Components
    432
  - Starboard and Port View (Port View)
    432
  - Top View
    434
  - Tiller Handle Model (WHD)
    436
  - Wire Harness (MHD)
    438
  - Wire Harness (WHD, ED 10-Pin)
    440
  - Wire Harness (ED 7-Pin)
    442
  - Wire Harness (ET)
    444
  - Digital Circuit Tester
    446
  - Electrical Components Analysis
    446
  - Measuring the Peak Voltage
    446
  - Peak Voltage Adaptor
    446
  - Measuring a Low Resistance
    448
  - Ignition System (MHD)
    450
  - Ignition System (WHD, ED, ET)
    452
  - Checking the Ignition Spark Gap
    454
  - Checking the Ignition Coil
    456
  - Checking the Spark Plug Caps
    456
  - Checking the Charge Coil
    458
  - Checking the Pulser Coil
    458
  - Checking the CDI Unit
    460
  - Ignition Control System (MHD)
    462
  - Ignition Control System (WHD, ED, ET)
    464
  - Checking the Engine Stop Switch
    466
  - Checking the Main Switch
    466
  - Checking the Oil Pressure Switch Continuity
    468
  - Measuring the Pulser Coil Output Peak Voltage
    468
  - Starting System (WHD, ED, ET)
    472
  - Checking the Fuses
    474
  - Checking the Wire Harness Continuity
    474
  - Checking the Starter Relay
    476
  - Checking the Wire Connections
    476
  - Disassembling/Assembling the Starter Motor
    478
  - Starter Motor
    478
  - Checking the Armature
    482
  - Checking the Starter Motor Pinion
    482
  - Removing the Starter Motor Pinion
    482
  - Measuring the Brushes
    484
  - Charging System (WHD, ED, ET)
    488
  - Enrichment Control System
    492
  - Power Trim and Tilt System (ET)
    498
  - Checking the Power Trim and Tilt Relay
    500
  - Checking the Trailer Switch Continuity
    502
  - Measuring the Trim Sensor Resistance
    502
  - Power Trim and Tilt Motor (ET)
    504
  - Checking the Motor
    506
  - Checking the Power Trim and Tilt Motor Assembly
    508
- Trouble Analysis
  510
  - Trouble Analysis Chart
    512
  - Trouble Shooting for Peak Voltage
    524
  - Wiring Diagram
    530

Yamaha F40ER Rigging Manual (226 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7 MB

Table of Contents

5
Propellers

59
- Propeller Specifications
  
  60
  - Propeller Types
    60
  - Propeller Identification
    62
- 2009 Propeller Applications
  
  63
- Propeller Selection
  
  63
- Wot Operation Range Table
  
  69
- Remote Controls
  
  71
  - Remote Control Applications
    72
  - Remote Switch Applications
    85
  - Remote Control Cables
    94
  - Remote Control Attachment Kit
    96
  - Steering Hook
    98
  - Steering Guide Attachment Kit
    101
  - Conventional Wire Harness
    103
  - Digital Electronic Control Wire Harness
    105
Tiller Handles

107
- 6X4 Multi-Function Tiller Handle
  
  108
- Steering Friction Contents
  
  117
Conventional Gauge (6Y5 & 6Y7)

119
- Mounting the Meters
  
  122
  - Meter Mounting Procedure
    122
  - Analog Gauge Illumination (6Y7 Type)
    122
- Analog Tachometer
  
  123
  - Analog Tachometer Applications
    123
  - Analog Tachometer Dimensions
    124
  - Pole Number Set up
    124
- Digital Tachometer
  
  125
  - Digital Tachometer Applications
    125
  - Digital Tachometer Dimensions
    125
  - Pole Number Set up
    126
- Speedometer
  
  127
  - Speedometer Applications
    127
  - Speedometer Dimensions
    128
  - Water Pressure Damper (Op)
    128
  - Speedometer Tube Routing
    129
  - Digital Speedometer Set up
    129
- Fuel Management Gauge
  
  130
  - Fuel Management Gauge Applications
    130
  - Fuel Management Gauge Dimensions
    131
  - Fuel Sender Installation
    132
  - Wiring Description
    133
  - Fuel Management Gauge Set up
    135
  - Fuel Mgt Gauge with Speedometer Set up
    135
- Analog Trim Meter
  
  136
  - Analog Trim Meter Applications
    136
  - Analog Trim Meter Dimensions
    136
  - Trim Sender Adjustment
    136
- Coolant Pressure Meter
  
  137
  - Coolant Pressure Meter Applications
    137
  - Coolant Pressure Meter Dimensions
    137
- Coolant Temp. Meter
  
  138
- Hour Meter
  
  144
  - Hour Meter Applications
    144
  - Wiring the Mechanical Hour Meter
    145
  - Wiring the Digital Hour Meter
    145
- Voltage Meter
  
  146
  - Voltage Meter Applications
    146
  - Voltage Meter Dimensions
    146
  - Wiring the Voltage Meter
    146
- Fuel Meter
  
  147
  - Fuel Meter Applications
    147
  - Fuel Meter Dimensions
    147
- Charge Warning Unit
  
  148
  - Charge Warning Unit Applications
    148
- Wire Harnesses
  
  149
  - Remote-Oil Tank Harness
    149
  - Additional Accessory Lead
    149
  - Meter Harness
    150
  - Lamp Switch
    151
  - Combination Trim and Oil Lead 1
    151
  - Combination Trim and Oil Lead 2
    151
  - Trim Meter Lead
    151
  - Pt/T Switch Lead Extension
    152
  - Trim and Oil Lead
    152
  - Fuel Management Gauge Harness
    152
  - Lighting Coil Extension Harness
    152
  - Rectifier Kit
    152
- Wiring Diagrams
  
  153
  - Wire Color Code
    153
  - Digital Meter
    154
  - Analog Meter (6Y7)
    159
  - Interchangeability between Tachometer and Engine
    161
  - Grommet Description
    164
Digital Network Gauge (6Y8)

167
- Digital Network Gauge Compatible Model
  
  168
- Digital Network Gauge Application
  
  168
  - Square Style Gauge Application
    168
- Digital Network Gauge Dimensions
  
  169
  - Round Style Gauge Application
    169
  - Square Style Gauge Dimensions
    169
  - Round Style Gauge Dimensions
    170
- Optional Equipments
  
  171
  - Multi-Sensor Application
    171
  - Fitting Plate
    171
  - Speed Sensor Kit
    172
  - Coolant Pressure Sensor Kit
    172
- Wire Harness
  
  173
  - Main Bus Wire
    173
  - Pigtail Bus Wire
    173
  - Fuel Tank / Gps Wire
    174
  - Hub
    174
- Wiring Diagrams
  
  175
  - FUEL INJECTED F50-F250 [Mechanical RC] & HPDI ENGINES
    175
  - F350/F300/F250 [Digital Electronic Control]
    178
- Initial Gauge Setup
  
  183
- Troubleshooting
  
  184
- Basic Requirements
  
  185
- Nmea0183 Compatible Equipments Connection
  
  185
Battery

187
- Recommended Battery
  
  188
- Battery Cable Length
  
  189
- Battery Wiring
  
  190
Appendix

195
- Model Name Designation
  
  196
  - Us & Canada Model Identification
    197
  - New Us & Canada Model Identification Code
    197
- Fuel System Vacuum Pressure Standard
  
  198
  - Fuel Hose Routing Resistance Measuring Method
    198
  - Lowest Vacuum Pressure Standard
    199
- Portable Fuel Tanks (Typical)
  
  200
- Fuel Pipes (Typical)
  
  200
- Pre-Delivery Inspection (Pdi) Checks
  
  201
- Conventional Rigging Kit Contents
  
  202
  - Digital Tachometer Kit
    202
  - Digital Tachometer and Speedometer Kit
    202
  - Twin-Motor Kit
    203
  - Remote Oil Tank Kit (for 2-Stroke Engine)
    204
- Digital Network Gauge Rigging Kit Contents
  
  205
- 2009 Manufacturing Start Serial Number
  
  219

Yamaha F40ER Service Manual (299 pages)

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Yamaha F40ER Service Manual (19 pages)

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Yamaha F40ER Service Manual (538 pages)

Table of Contents

Chapter 1 General Information

Chapter 3

Chapter 4

Chapter 5

Yamaha F40ER Rigging Manual (226 pages)

Table of Contents

Table of Contents

Top Cover Pictograph Description

Uncrating Procedure (for Typical Steel Frame)

Mounting the Outboard Motor

Mounting the Remote Oil Tank

Outboard Motor Dimensions

Propellers

Propeller Specifications

2009 Propeller Applications

Propeller Selection

Wot Operation Range Table

Remote Controls

Tiller Handles

6X4 Multi-Function Tiller Handle

Steering Friction Contents

Conventional Gauge (6Y5 & 6Y7)

Mounting the Meters

Analog Tachometer

Digital Tachometer

Speedometer

Fuel Management Gauge

Analog Trim Meter

Coolant Pressure Meter

Coolant Temp. Meter

Hour Meter

Voltage Meter

Fuel Meter

Charge Warning Unit

Wire Harnesses

Wiring Diagrams

Digital Network Gauge (6Y8)

Digital Network Gauge Compatible Model

Digital Network Gauge Application

Digital Network Gauge Dimensions

Optional Equipments

Wire Harness

Wiring Diagrams

Initial Gauge Setup

Troubleshooting

Basic Requirements

Nmea0183 Compatible Equipments Connection

Battery

Recommended Battery

Battery Cable Length

Battery Wiring

Appendix

Model Name Designation

Fuel System Vacuum Pressure Standard

Portable Fuel Tanks (Typical)

Fuel Pipes (Typical)

Pre-Delivery Inspection (Pdi) Checks

Conventional Rigging Kit Contents

Digital Network Gauge Rigging Kit Contents

2009 Manufacturing Start Serial Number

Yamaha F40ER Service Manual (299 pages)

Yamaha F40ER Service Manual (19 pages)

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