2000-2005 Yamaha 40hp 4 stroke Outboard Repair Manual
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2000-2005 Yamaha 40hp 4 stroke Outboard Repair Manual
LANGUAGE:ENGLISH
PAGES:535
DOWNLOADABLE:YES
FILE TYPE:PDF
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DESCRIPTION:
- 2000-2005 Yamaha 40hp 4 stroke Outboard Repair Manual
- This manual has been prepared by the Yamaha Motor Company, Ltd. 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 the Yamaha Motor Company, Ltd. 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.
TABLE OF CONTENTS:
2000-2005 Yamaha 40hp 4 stroke Outboard Repair Manual
2000-2005 YAMAHA 40HP 4-STROKE OUTBOARDS........................................ 1 PREFACE..................................................................... 2 TABLE OF CONTENTS........................................................... 14 GENERAL INFORMATION......................................................... 16 IDENTIFICATION.......................................................... 18 SERIAL NUMBER....................................................... 18 STARTING SERIAL NUMBERS............................................. 18 SAFETY WHILE WORKING.................................................... 20 FIRE PREVENTION..................................................... 20 VENTILATION......................................................... 20 SELF-PROTECTION..................................................... 20 OILS, GREASES AND SEALING FLUIDS.................................... 20 GOOD WORKING PRACTICES.............................................. 22 DISASSEMBLY AND ASSEMBLY............................................ 24 SPECIAL TOOLS........................................................... 26 MEASURING........................................................... 26 REMOVING AND INSTALLING............................................. 28 SPECIFICATIONS.............................................................. 36 GENERAL SPECIFICATIONS.................................................. 38 MAINTENANCE SPECIFICATIONS.............................................. 42 POWER UNIT.......................................................... 42 LOWER UNIT.......................................................... 50 ELECTRICAL.......................................................... 52 DIMENSIONS.......................................................... 60 TIGHTENING TORQUES...................................................... 66 SPECIFIED TORQUES................................................... 66 GENERAL TORQUES..................................................... 70 PERIODIC CHECK AND ADJUSTMENT............................................... 72 MAINTENANCE INTERNAL CHART.............................................. 76 TOP COWLING............................................................. 80 CHECKING THE TOP COWLING FIT........................................ 80 FUEL SYSTEM............................................................. 80 CHECKING THE FUEL LINE.............................................. 80 CHECKING THE FUEL FILTER............................................ 82 CONTROL SYSTEM.......................................................... 82 ADJUSTING THE SHIFT CABLE........................................... 82 ADJUSTING THE THROTTLE CABLE........................................ 84 ADJUSTING THE ENGINE IDLING SPEED................................... 86 ADJUSTING THE PILOT SCREW........................................... 88 EXHAUST GAS CONTROL PROCEDURES...................................... 90 SYNCHRONIZED THE CARBURETOR......................................... 94 ADJUSTING THE DASH-POT.............................................. 98 START-IN-GEAR PROTECTION DEVICE ADJUSTMENT (MHD, WHD)............... 98 POWER UNIT..............................................................100 CHECKING THE ENGINE OIL LEVEL.......................................100 REPLACING THE ENGINE OIL AND OIL FILTER.............................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............................................. 74 LUBRICATION POINTS..................................................124 FUEL SYSTEM.................................................................130 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 DISASSEMBLING/ASSEMBLING THE CARBURETOR ASSEMBLY 1..................148 DISASSEMBLING/ASSEMBLING THE CARBURETOR ASSEMBLY 2..................150 CHECKING THE CARBURETOR.............................................154 ASSEMBLING THE CARBURETOR...........................................154 POWER UNIT..................................................................158 FLYWHEEL MAGNET ASSEMBLY................................................164 REMOVING/INSTALLING THE MANUAL STARTER..............................164 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 STARTER ROPE.........................................180 INSTALLING THE SPIRAL SPRING........................................180 INSTALLING THE SHEAVE DRUM..........................................182 CHECKING THE RECOIL STARTER.........................................184 POWER UNIT..............................................................186 DISCONNECTING/CONNECTING THE LEADS..................................186 DISCONNECTING/CONNECTING THE HOSES..................................188 REMOVING/INSTALLING THE POWER UNIT..................................190 STATOR ASSEMBLY.........................................................192 REMOVING/INSTALLING THE STATOR ASSEMBLY.............................192 REMOVING THE SPROCKETS..............................................198 INSTALLING THE TIMING BELT AND SPROCKETS............................200 ELECTRICAL UNIT.........................................................202 REMOVING/INSTALLING THE ELECTRICAL UNIT 1...........................202 REMOVING/INSTALLING THE ELECTRICAL UNIT 2...........................208 REMOVING/INSTALLING THE ELECTRICAL UNIT 3...........................214 SHIFT BRACKET AND THROTTLE CONTROL LEVER................................216 REMOVING/INSTALLING THE 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 VALVE SPRING...........................................232 CHECKING THE ROCKER ARM AND ROCKER SHAFT............................232 CHECKING THE CAM SHAFT..............................................234 CHECKING THE DECOMPRESSION ACTUATURS (MH)...........................234 REPLACING THE VALVE GUIDE...........................................236 REFACING THE VALVE SEAT.............................................236 INSTALLING THE VALVE................................................240 EXHAUST COVER...........................................................242 REMOVING/INSTALLING THE EXHAUST COVER...............................242 INSTALLING THE OIL FILTER...........................................244 CHECKING THE THERMOSTAT.............................................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 CRANKSHAFT.............................................256 CHECKING THE MAIN-BEARING OIL CLEARANCE.............................258 CHECKING THE BIG-END OIL CLEARANCE..................................262 INSTALLING THE PISTON RING..........................................266 INSTALLING IN THE ENGINE............................................266 INSTALLING THE OIL SEAL.............................................266 LOWER UNIT..................................................................268 LOWER UNIT..............................................................274 REMOVING/INSTALLING THE LOWER UNIT..................................274 REMOVING THE PROPELLER..............................................278 CHECKING THE PROPELLER..............................................278 INSTALLING THE PROPELLER............................................278 INSTALLING THE TRIM TAB.............................................278 WATER PUMP..............................................................280 REMOVING/INSTALLING THE WATER PUMP..................................280 CHECKING THE WATER PUMP HOUSING.....................................282 CHECKING THE IMPELLER AND INSERT CARTRIDGE..........................282 CHECKING THE WOODRUFF KEY...........................................282 INSTALLING THE IMPELLER AND WATER PUMP HOUSING......................282 SHIFT ROD ASSEMBLY......................................................284 REMOVING/INSTALLING THE SHIFT ROD ASSEMBLY..........................284 PROPELLER SHAFT HOUSING ASSEMBLY........................................286 REMOVING/INSTALLING THE PROPELLER SHAFT HOUSING ASSEMBLY............286 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY.......288 DISASSEMBLING/ASSEMBLING THE PROPELLER SHAFT ASSEMBLY...............290 REMOVING THE PROPELLER SHAFT HOUSING ASSEMBLY.......................292 DISASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY..................292 CHECKING THE REVERSE GEAR...........................................294 CHECKING THE BEARING................................................294 CHECKING THE PROPELLER SHAFT HOUSING ASSEMBLY.......................294 CHECKING THE DOG CLUTCH.............................................296 CHECKING THE PROPELLER SHAFT........................................296 ASSEMBLING THE PROPELLER SHAFT HOUSING ASSEMBLY.....................296 DRIVE SHAFT.............................................................300 REMOVING/INSTALLING THE DRIVE SHAFT.................................300 REMOVING THE DRIVE SHAFT............................................302 REMOVING THE DRIVE SHAFT BEARING....................................302 DISASSEMBLING THE FORWARD GEAR ASSEMBLY.............................304 CHECKING THE PINION AND FORWARD GEAR................................304 CHECKING THE DRIVE SHAFT............................................304 CHECKING THE BEARINGS...............................................304 ASSEMBLING THE FORWARD GEAR ASSEMBLY................................306 INSTALLING THE DRIVE SHAFT BEARING..................................306 INSTALLING THE DRIVE SHAFT..........................................308 LOWER CASE ASSEMBLY.....................................................310 DISASSEMBLING/INSTALLING THE LOWER CASE ASSEMBLY....................310 DISASSEMBLING THE LOWER CASE ASSEMBLY...............................312 CHECKING THE DRIVE SHAFT SLEEVE.....................................312 CHECKING THE NEEDLE BEARING.........................................314 ASSEMBLING THE LOWER CASE ASSEMBLY..................................314 SHIMMING................................................................316 SHIMMING (FOR USA AND CANADA)...........................................318 SELECTING THE PINION SHIMS..........................................318 SELECTING THE FORWARD GEAR SHIMS....................................322 SELECTING THE REVERSE GEAR SHIMS....................................326 SHIMMING (EXCEPT FOR USA AND CANADA)....................................328 SELECTING THE PINION SHIMS..........................................328 SELECTING THE FORWARD GEAR SHIMS....................................332 SELECTING THE REVERSE GEAR SHIM.....................................334 BACKLASH................................................................340 MEASURING THE FORWARD GEAR BACKLASH.................................340 MEASURING THE REVERSE GEAR BACKLASH.................................344 BRACKET UNIT................................................................348 TILLER HANDLE ASSEMBLY..................................................352 REMOVING/INSTALLING THE STEERING FRICTION...........................352 REMOVING/INSTALLING THE TILLER ASSEMBLY.............................354 DISASSEMBLING/ASSEMBLING THE TILLER HANDLE ASSEMBLY.................356 DISASSEMBLING/ASSEMBLING THE LINK ASSEMBLY..........................362 BOTTOM COWLING..........................................................364 REMOVING/INSTALLING THE BOTTOM COWLING..............................364 UPPER CASE ASSEMBLY.....................................................366 REMOVING/INSTALLING THE UPPER CASE ASSEMBLY.........................366 REMOVING/INSTALLING THE GROUND LEAD.................................368 DISASSEMBLY/ASSEMBLING THE UPPER CASE ASSEMBLY......................370 STEERING ARM............................................................376 REMOVING/INSTALLING THE STEERING ARM................................376 INSTALLING THE BUSHING..............................................378 CLAMP BRACKETS (MHD, WHD, ED)...........................................380 REMOVING/INSTALLING THE CLAMP BRACKETS..............................380 REMOVING THE SHOCK ABSORBER.........................................386 CHECKING 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 REMOVING THE POWER TRIM AND TILT UNIT...............................396 BLEEDING THE POWER TRIM AND TILT UNIT...............................396 TILT CYLINDER ASSEMBLY..................................................400 DISASSEMBLING/ASSEMBLING THE TILT CYLINDER ASSEMBLY.................400 REMOVING THE TILT RAM ASSEMBLY......................................402 CHECKING THE TILT RAM...............................................404 ASSEMBLING THE TILT RAM.............................................404 ASSEMBLING THE TILT CYLINDER ASSEMBLY...............................406 FILLING THE RESERVOIR...............................................408 BLEEDING THE POWER TRIM AND TILT UNIT...............................408 GEAR PUMP ASSEMBLY......................................................412 DISASSEMBLING/ASSEMBLING THE GEAR PUMP ASSEMBLY.....................412 DISASSEMBLING THE GEAR PUMP ASSEMBLY................................416 PUMP HOUSING............................................................418 DISASSEMBLING/ASSEMBLING THE PUMP HOUSING...........................418 GEAR PUMP UNIT..........................................................424 DISASSEMBLY/ASSEMBLY THE GEAR PUMP UNIT.............................424 ELECTRICAL SYSTEM...........................................................426 ELECTRICAL COMPONENTS...................................................432 Starboard and por 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 ELECTRICAL COMPONENTS ANALYSIS..........................................446 DIGITAL CIRCUIT TESTER..............................................446 MEASURING THE PEAK VOLTAGE..........................................446 PEAK VOLTAGE ADAPTOR................................................446 MEASURING A LOW RESISTANCE..........................................448 IGNITION SYSTEM.........................................................450 CHECKING THE SPARK PLUGS............................................454 CHECKING THE IGNITION SPARK GAP.....................................454 CHECKING THE SPARK PLUG CAPS........................................456 CHECKING THE IGNITION COIL..........................................456 CHECKING THE CHARGE COIL............................................458 CHECKING THE PULSER COIL............................................458 CHECKING THE CDI UNIT...............................................460 IGNITION CONTROL SYSTEM.................................................462 CHECKING THE MAIN SWITCH............................................466 CHECKING THE ENGINE STOP SWITCH.....................................466 MEASURING THE PULSER COIL OUTPUT PEAK VOLTAGE.......................468 CHECKING THE OIL PRESSURE SWITCH CONTINUITY.........................468 MEASURING THE ENGINE COOLING WATER TEMPERATURE SENSOR RESISTANCE....468 STARTING SYSTEM (WHD, ED, ET)...........................................472 CHECKING THE BATTERY................................................474 CHECKING THE FUSES..................................................474 CHECKING THE WIRE HARNESS CONTINUITY................................474 CHECKING THE WIRE CONNECTIONS.......................................476 CHECKING THE MAIN SWITCH............................................476 CHECKING THE STARTER RELAY..........................................476 STARTER MOTOR...........................................................478 DISASSEMBLING/ASSEMBLING THE STARTER MOTOR..........................478 REMOVING THE STARTER MOTOR PINION...................................482 CHECKING THE STARTER MOTOR PINION...................................482 CHECKING THE ARMATURE...............................................482 MEASURING THE BRUSHES...............................................484 CHARGING SYSTEM (WHD, ED, ET)...........................................488 CHECKING THE FUSES..................................................490 CHECKING THE BATTERY................................................490 CHEKING THE RECTIFIER/REGULATOR OUTPUT PEAK VOLTAGE.................490 CHECKING THE LIGHTING COIL OUTPUT PEAK VOLTAGE......................490 ENRICHMENT CONTROL SYSTEM...............................................492 CHECKING THE BATTERY................................................494 CHECKING THE FUSE...................................................494 CHECKING THE MAIN SWITCH............................................494 CHECKING THE POWER COIL OUTPUT PEAK VOLTAGE.........................494 CHECKING THE THERMO HEATER PLUNGER..................................494 POWER TRIM AND TILT SYSTEM (ET).........................................498 CHECKING THE FUSES..................................................500 CHECKING THE BATTERY................................................500 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 DISASSEMBLING/ASSEMBLING THE POWER TRIM AND TILT MOTOR..............504 CHECKING THE MOTOR..................................................506 CHECKING THE POWER TRIM AND TILT MOTOR ASSEMBLY.....................508 TROUBLE ANALYSIS............................................................510 TROUBLE ANALYSIS........................................................512 TROUBLE ANALYSIS CHART..............................................512 TROUBLE SHOOTING FOR PEAK VOLTAGE.......................................524
PLEASE NOTE:
⦁ This is the SAME manual used by the dealers to troubleshoot any faults in your vehicle. This can be yours in 2 minutes after the payment is made.
⦁ Contact us at [email protected] should you have any queries before your purchase or that you need any other service / repair / parts operators manual.
