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Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
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Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
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Description
Yamaha F40b Outboard Service Repair Manual Pid Range 67c-1035037 1044888 Mfg Aprill 2005 And Newer
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YAMAHA F40B OUTBOARD SERVICE REPAIR MANUAL PID RANGE 67C 1035037 1044888 MFG APRILL 2005 AND NEWER:
DESCRIPTION:
Yamaha F40b Outboard Service Repair Manual Pid Range 67c-1035037 1044888 Mfg Aprill 2005 And Newer
- 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). • Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below for an example), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees.
- • Separate procedures and illustrations are used to explain the details of removal
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 exact manual used by your dealers to fix your vehicle.
- The same can be yours in the next 2-3 mins as you will be directed to the download page immediately after paying for the manual.
- Any queries / doubts regarding your purchase, please feel free to contact [email protected]
1 review for Yamaha F40b Outboard Service Repair Manual Pid Range 67c 1035037 1044888 Mfg Aprill 2005 And Newer
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Roman Maximus –
It is just PDF, not paper manual.