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Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer – PDF DOWNLOAD
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Description
Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
FILE DETAILS:
LANGUAGE:ENGLISH
PAGES:267
DOWNLOADABLE:YES
FILE TYPE:PDF
YAMAHA F40B OUTBOARD SERVICE REPAIR MANUAL PID RANGE 67C 1035037 1044888 MFG APRILL 2005 AND NEWER – PDF DOWNLOAD:
IMAGES PREVIEW OF THE MANUAL:
DESCRIPTION:
Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
PREFACE:
- This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have a basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.
- Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand.
Use the information below as a guide for effective and quality service.
• Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1 in the figure below for an example page).
• The component list consists of part names and quantities, as well as bolt and screw dimensions (see 2 in the figure below).
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point (see 3 in the figure below).
TABLE OF CONTENTS:
Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
Back to Index.................................................................................... 0 F40B SERVICE MANUAL.............................................................................. 1 Important information........................................................................ 2 Contents..................................................................................... 3 General information.......................................................................... 5 How to use this manual................................................................... 6 Manual format........................................................................ 6 Symbol............................................................................... 7 Abbreviation......................................................................... 8 Sealant and locking agent table...................................................... 8 Safety while working..................................................................... 9 Fire prevention...................................................................... 9 Ventilation.......................................................................... 9 Self-protection...................................................................... 9 Part, lubricant, and sealant......................................................... 9 Good working practice................................................................ 10 Disassembling and assembling......................................................... 10 Identification........................................................................... 11 Model................................................................................ 11 Serial number........................................................................ 11 Special service tool..................................................................... 12 Propeller selection...................................................................... 17 Propeller size....................................................................... 17 Selection............................................................................ 17 Predelivery check........................................................................ 18 Checking the outboard motor mounting height.......................................... 18 Checking the fuel system............................................................. 18 Checking the engine oil level........................................................ 18 Checking the gear oil level.......................................................... 19 Checking the battery (E model)....................................................... 19 Connecting the throttle cable and shift cable........................................ 19 Checking the gear shift and throttle operation....................................... 20 Checking the steering system......................................................... 21 Checking the tilt system (D model)................................................... 21 Checking the PTT system (PTT model).................................................. 22 Checking the engine start switch and engine shut-off switch.......................... 22 Checking the cooling water pilot hole................................................ 23 Test run............................................................................. 23 Break-in............................................................................. 24 After the test run................................................................... 24 Precaution when transporting or storing the outboard motor........................... 24 Specification................................................................................ 25 General specification.................................................................... 26 Maintenance specification................................................................ 28 Power unit........................................................................... 28 Fuel system.......................................................................... 32 Lower unit........................................................................... 32 Electrical........................................................................... 33 Dimension............................................................................ 36 Tightening torque........................................................................ 39 Specified torque..................................................................... 39 General torque....................................................................... 41 Periodic check and adjustment................................................................ 43 Maintenance interval chart............................................................... 44 Top cowling.............................................................................. 46 Checking the top cowling............................................................. 46 Fuel system.............................................................................. 46 Checking the fuel joint and fuel hose (fuel joint to carburetor)..................... 46 Checking the fuel filter............................................................. 46 Draining the fuel.................................................................... 47 Power unit............................................................................... 47 Checking the engine oil.............................................................. 47 Changing the engine oil.............................................................. 47 Replacing the oil filter............................................................. 48 Checking the timing belt............................................................. 49 Checking the spark plug.............................................................. 49 Checking the thermostat.............................................................. 50 Checking the cooling water passage................................................... 50 Control system........................................................................... 51 Adjusting the throttle link.......................................................... 51 Adjusting the throttle cable......................................................... 51 Checking the gear shift operation.................................................... 52 Checking the start-in-gear protection (M model)...................................... 53 Checking the engine idle speed....................................................... 54 Checking the ignition timing......................................................... 54 Bracket unit............................................................................. 55 Checking the steering operation (H model)............................................ 55 Checking the tilt operation.......................................................... 55 Checking the PTT fluid level......................................................... 56 Lower unit............................................................................... 56 Checking the gear oil................................................................ 56 Changing the gear oil................................................................ 56 Checking the lower unit for air leakage.............................................. 57 Checking the propeller............................................................... 58 General.................................................................................. 58 Checking the anode................................................................... 58 Checking the battery................................................................. 59 Lubricating the outboard motor....................................................... 60 Fuel system.................................................................................. 61 Hose routing............................................................................. 62 Fuel hose, blowby hose, and cooling water hose....................................... 62 Fuel pump, fuel filter, and fuel joint................................................... 63 Checking the fuel pump............................................................... 65 Checking the fuel filter............................................................. 65 Checking the fuel joint.............................................................. 66 Disassembling the fuel pump.......................................................... 66 Checking the diaphragm and valve..................................................... 66 Assembling the fuel pump............................................................. 67 Carburetor unit.......................................................................... 68 Carburetor........................................................................... 71 Removing the carburetor.............................................................. 73 Disassembling the carburetor......................................................... 73 Checking the carburetor.............................................................. 73 Checking the Prime Start............................................................. 74 Assembling the carburetor............................................................ 75 Installing the carburetor............................................................ 75 Synchronizing the carburetor......................................................... 76 Adjusting the dashpot................................................................ 77 Power unit................................................................................... 78 Power unit (check and adjustment)........................................................ 80 Checking the compression pressure.................................................... 80 Checking the oil pressure............................................................ 80 Checking the valve clearance......................................................... 81 Replacing the timing belt............................................................ 82 Manual starter (M model)................................................................. 86 Disassembling the manual starter..................................................... 88 Checking the manual starter.......................................................... 88 Assembling the manual starter........................................................ 89 Power unit............................................................................... 92 Power unit assembly.................................................................. 92 Starter motor, starter relay, and PTT relay (E and PTT model)........................ 94 Ignition coil, CDI unit, and Rectifier Regulator..................................... 95 Throttle cam......................................................................... 97 Removing the power unit.............................................................. 99 Timing belt and sprocket.................................................................101 Removing the timing belt and sprocket................................................102 Checking the timing belt and sprocket................................................103 Installing the sprocket and timing belt..............................................103 Cylinder head............................................................................105 Removing the cylinder head...........................................................108 Disassembling the cylinder head......................................................108 Checking the cylinder head...........................................................109 Checking the valve spring............................................................109 Checking the valve...................................................................109 Checking the valve guide.............................................................110 Replacing the valve guide............................................................110 Checking the valve seat..............................................................111 Refacing the valve seat..............................................................112 Checking the rocker arm and rocker arm shaft.........................................114 Checking the camshaft................................................................114 Assembling the cylinder head.........................................................115 Installing the cylinder head.........................................................118 Cylinder block...........................................................................119 Disassembling the cylinder block.....................................................121 Checking the piston diameter.........................................................122 Checking the cylinder bore...........................................................122 Checking the piston clearance........................................................122 Checking the piston ring.............................................................122 Checking the piston ring end gap.....................................................123 Checking the piston ring groove......................................................123 Checking the piston ring side clearance..............................................124 Checking the piston pin boss bore....................................................124 Checking the piston pin diameter.....................................................124 Checking the connecting rod small end inside diameter and big end inside diameter....124 Checking the connecting rod big end side clearance...................................125 Checking the crankshaft..............................................................125 Checking the crankpin oil clearance..................................................125 Selecting the connecting rod bearing.................................................126 Checking the crankshaft journal oil clearance........................................127 Selecting the crankshaft main bearing................................................128 Assembling the cylinder block........................................................128 Installing the power unit............................................................131 Lower unit...................................................................................135 Lower unit...............................................................................136 Removing the lower unit..............................................................139 Removing the water pump..............................................................140 Checking the water pump..............................................................140 Propeller shaft housing..................................................................141 Removing the propeller shaft housing assembly........................................142 Disassembling the propeller shaft assembly...........................................142 Disassembling the propeller shaft housing assembly...................................142 Checking the propeller shaft housing.................................................143 Checking the propeller shaft.........................................................143 Assembling the propeller shaft assembly..............................................143 Assembling the propeller shaft housing assembly......................................144 Drive shaft and lower case...............................................................146 Removing the drive shaft, oil seal housing, and shift rod............................148 Disassembling the oil seal housing...................................................148 Disassembling the forward gear.......................................................148 Disassembling the lower case.........................................................149 Checking the pinion and forward gear.................................................149 Checking the bearing.................................................................149 Checking the drive shaft.............................................................149 Checking the shift rod...............................................................150 Checking the lower case..............................................................150 Assembling the lower case............................................................150 Assembling the forward gear..........................................................151 Assembling the oil seal housing......................................................151 Assembling the drive shaft...........................................................151 Installing the shift rod, oil seal housing, and drive shaft..........................151 Installing the propeller shaft housing assembly......................................152 Installing the water pump............................................................153 Installing the lower unit............................................................154 Shimming.................................................................................156 Shimming.............................................................................157 Selecting the pinion shim............................................................157 Selecting the forward gear shim......................................................158 Selecting the reverse gear shim......................................................159 Backlash.................................................................................161 Measuring the forward and reverse gear backlash......................................161 Bracket unit.................................................................................164 Tiller handle (H model)..................................................................166 Removing the tiller handle...........................................................171 Installing the tiller handle.........................................................171 Friction plate (H model).................................................................173 Disassembling the friction plate.....................................................174 Assembling the friction plate........................................................174 Bottom cowling...........................................................................176 Upper case and steering arm..............................................................179 Removing the upper case..............................................................184 Disassembling the upper case.........................................................184 Checking the muffler, exhaust manifold, oil pan, and exhaust guide...................185 Checking the oil strainer............................................................185 Assembling the upper case............................................................186 Removing the steering arm............................................................187 Installing the steering arm..........................................................188 Installing the upper case............................................................188 Hydraulic tilt unit and PTT unit.........................................................190 Clamp bracket and swivel bracket.........................................................191 Removing the hydraulic tilt unit.....................................................193 Removing the PTT unit................................................................193 Removing the clamp bracket...........................................................194 Checking the hydraulic tilt unit.....................................................194 Installing the clamp bracket.........................................................194 Installing the hydraulic tilt unit...................................................195 Installing the PTT unit..............................................................196 Adjusting the trim sensor cam (R model)..............................................197 PTT motor................................................................................199 Disassembling the PTT motor..........................................................200 Checking the PTT motor...............................................................201 Checking the brush holder and brush..................................................202 Assembling the PTT motor.............................................................202 PTT gear pump............................................................................204 Disassembling the gear pump..........................................................207 Checking the gear pump...............................................................208 Checking the gear pump housing.......................................................208 Checking the valve seal..............................................................208 Checking the filter..................................................................209 Assembling the gear pump.............................................................209 PTT cylinder.............................................................................211 Disassembling the PTT cylinder...........................................................212 Checking the tilt cylinder and piston................................................212 Assembling the tilt cylinder.........................................................213 Bleeding the PTT unit................................................................215 Bleeding the PTT unit (installed)....................................................216 PTT electrical system....................................................................217 Checking the fuse....................................................................217 Checking the PTT relay...............................................................217 Checking the PTT switch..............................................................218 Checking the trim sensor.............................................................218 Electrical system............................................................................221 Electrical component and wiring harness routing..........................................222 Top view.............................................................................222 Bow view.............................................................................223 Port view............................................................................224 Tiller handle........................................................................226 Checking the electrical component........................................................227 Measuring the peak voltage...........................................................227 Starter motor (E model)..................................................................228 Removing the starter motor...........................................................229 Checking the starter motor operation.................................................229 Disassembling the starter motor......................................................229 Checking the starter motor pinion....................................................230 Checking the starter motor...........................................................230 Checking the brush holder and brush..................................................231 Assembling the starter motor.........................................................232 Installing the starter motor.........................................................233 Starting system..........................................................................233 Checking the fuse (E model)..........................................................233 Checking the engine start switch.....................................................233 Checking the neutral switch (E model)................................................234 Checking the starter relay (E model).................................................234 Ignition and ignition control system.....................................................235 Checking the ignition spark..........................................................235 Checking the spark plug cap..........................................................236 Checking the ignition coil...........................................................236 Checking the pulser coil.............................................................237 Checking the charge coil.............................................................238 Checking the engine shut-off switch (M model)........................................238 Checking the engine shut-off switch (E model)........................................239 Engine electric control system...........................................................240 Checking the CDI unit................................................................240 Checking the thermo sensor...........................................................240 Checking the oil pressure switch.....................................................241 Checking the warning indicator assembly (H model)....................................242 Checking the power bobbin (for Prime Start)..........................................244 Charging system..........................................................................244 Checking the lighting coil...........................................................244 Checking the Rectifier Regulator (E model)...........................................245 Troubleshooting..............................................................................247 Troubleshooting the outboard motor.......................................................248 Troubleshooting table format.............................................................248 Troubleshooting the power unit...........................................................248 Troubleshooting the PTT unit (PTT model).................................................255 Troubleshooting the lower unit...........................................................256 Index........................................................................................258 Wiring diagram...............................................................................262 F40BMH...................................................................................262 F40BTR...................................................................................263 F40BMH...................................................................................266 F40BTR...................................................................................267
PLEASE NOTE:
- This is the SAME MANUAL used by the dealerships to diagnose your vehicle
- No waiting for couriers / posts as this is a PDF manual and you can download it within 2 minutes time once you make the payment.
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