Yamaha F40D Owner'S Manual Download Page 72

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Maintenance

EMU34450

Maintenance chart 2

Wire harness connec-
tions/Wire coupler con-
nections

Inspection or replace-
ment as necessary

(Yamaha) Meter/gauge

Inspection

(Yamaha) Fuel tank

Inspection and clean-
ing as necessary

Item

Actions

Every

1000 hours

Guide exhaust/exhaust
manifold

Inspection or replace-
ment as necessary

Timing belt

Replacement

Item

Actions

Initial

Every

20 hours

months)

100

hours (1

years)

300

hours (3

years)

500

hours (5

years)

Summary of Contents for F40D

Page 1: ...OWNER S MANUAL F40D F50F FT50G F60C FT60D 6C1 28199 74 E0 ...

Page 2: ...51 Read this owner s manual carefully before operating or working on your outboard motor Keep this manual onboard in a waterproof bag when boating This manual should stay with the outboard motor if it is sold ...

Page 3: ... your machine and this manual If there is any question concerning this manu al please consult your Yamaha dealer To ensure long product life Yamaha recom mends that you use the product and perform the specified periodic inspections and main tenance by correctly following the instruc tions in the owner s manual Any damage resulting from neglect of these instructions is not covered by warranty Some ...

Page 4: ...protection 11 Basic components 12 Main components 12 Fuel tank 13 Fuel joint 13 Fuel gauge 14 Fuel tank cap 14 Air vent screw 14 Remote control 14 Remote control lever 14 Neutral interlock trigger 14 Neutral throttle lever 14 Tiller handle 15 Gear shift lever 15 Throttle grip 15 Throttle indicator 15 Throttle friction adjuster 16 Engine shut off switch 16 Engine stop button 17 Main switch 17 Steer...

Page 5: ...Adjusting trim angle for hydro tilt models 48 Adjusting boat trim 48 Tilting up and down 49 Procedure for tilting up hydro tilt models 49 Procedure for tilting up power trim and tilt models 50 Procedure for tilting down hydro tilt models 52 Cruising in shallow water 52 Hydro tilt models 52 Power trim and tilt models models 53 Cruising in other conditions 54 Maintenance 56 Specifications 56 Transpo...

Page 6: ...g the battery 78 Checking top cowling 78 Coating the boat bottom 78 Trouble Recovery 80 Troubleshooting 80 Temporary action in emergency 83 Impact damage 83 Replacing fuse 83 Power trim and tilt will not operate 84 Water separator warning indicator blinks while cruising 84 Starter will not operate 86 Emergency starting engine 87 Treatment of submerged motor 87 ...

Page 7: ...our outboard motor is sto len EMU25190 Key number If a main key switch is equipped with the mo tor the key identification number is stamped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key EMU25202 EC label Engines affixed with this label conform to certain portions of the European Parliament directive relating to machinery ...

Page 8: ... the label pictured below conform to SAV the Swiss exhaust emission regulations for Swiss inshore waters Approval label of emission control certif icate Fuel requirement label ZMU01696 ZMU05466 YAMAHA MOTOR CO LTD Motorfamilie Abgastypenpruf Nummer ZMU04492 1 Fuel requirement label location 1 ZMU04031 ...

Page 9: ...r Read this manual Read any manuals supplied with the boat Read all labels on the outboard motor and the boat If you need any additional information contact your Yamaha dealer EMU33830 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements 1 2 3 ZMU05676 ...

Page 10: ...lothing away from rotating parts while the engine is running Do not touch or remove electrical parts when starting or during operation 3 WARNING EWM01670 Read Owner s Manuals and labels Wear an approved personal flotation device PFD Attach engine shut off cord lanyard to your PFD arm or leg so the engine stops if you accidentally leave the helm which could prevent a runaway boat EMU33841 Symbols T...

Page 11: ...Operator s Manual Hazard caused by continuous rotation Electrical hazard Remote control lever gear shift lever operat ing direction dual direction Engine start Engine cranking ZMU05696 ZMU05664 ZMU05665 ZMU05666 ZMU05667 ZMU05668 ...

Page 12: ...it is tilt ed even when the tilt support lever is locked Severe injury could occur if the outboard mo tor accidentally falls EMU33670 Engine shut off cord Attach the engine shut off cord so that the engine stops if the operator falls overboard or leaves the helm This prevents the boat from running away under power and leaving people stranded or running over people or objects Always attach the engi...

Page 13: ...he water near the boat shift into neutral and shut off the motor Stay away from swimming areas Swimmers can be hard to see The propeller can keep moving even when the motor is in neutral Shut off the engine when a person is in the water near you EMU33750 Passengers Consult your boat manufacturer s instruc tions for details about appropriate passenger locations in your boat and be sure all pas seng...

Page 14: ...tting an obstacle apply throttle and turn in another direction EMU33790 Weather Stay informed about the weather Check weather forecasts before boating Avoid boating in hazardous weather EMU33880 Passenger training Make sure at least one other passenger is trained to operate the boat in the event of an emergency EMU33890 Boating safety publications Be informed about boating safety Additional public...

Page 15: ...g if gasoline spills on it Touch the fuel nozzle to the filler open ing or funnel to help prevent electro static sparks CAUTION ECM00010 Use only new clean gasoline which has been stored in clean containers and is not contaminated with water or foreign mat ter EMU25580 Gasoline If knocking or pinging occurs use a different brand of gasoline or premium unleaded fuel EMU25683 Engine oil NOTE If the ...

Page 16: ...board mo tor could result in hazardous condi tions such as poor handling loss of control or fire hazards Because the motor is very heavy spe cial equipment and training is required to mount it safely EMU33580 Remote control requirements The remote control unit must be equipped with a start in gear protection device s This device prevents the engine from starting un less it is in neutral WARNING EW...

Page 17: ...ll allow the engine to reach the middle or upper half of the operating range at full throttle with the maximum boat load Generally chose a larger pitch propel ler for a smaller operating load and a smaller pitch propeller for a heavier load If you carry loads that vary widely chose the propeller that lets the engine run in the proper range for your maximum load but remember that you may need to re...

Page 18: ...9 11 12 13 10 2 6 7 5 8 15 16 14 19 17 18 20 21 ZMU05106 1 Top cowling 2 Water separator 3 Top cowling lock lever 4 Drain screw 5 Anode 6 Anti cavitation plate 7 Trim tab anode 8 Propeller 9 Cooling water inlet 10 Anode s 11 Tilt rod 12 Tilt lock lever 13 Tilt support lever 14 Tiller handle 15 Flushing device 16 Remote control box side mount type 17 Digital tachometer 18 Digital speedometer 19 Tac...

Page 19: ...age container Com mercial users should conform to relevant licensing or approval authority regula tions EMU25830 Fuel joint This joint is used to connect the fuel line 1 4 6 3 2 5 ZMU05429 1 Tachometer unit Square type 2 Tachometer unit Round type 3 Speedometer unit Square type 4 Speed fuel meter unit Square type 5 Speed fuel meter unit Round type 6 Fuel management meter Square type 1 Fuel joint 2...

Page 20: ...g the lever forward from the neutral po sition engages forward gear Pulling the le ver back from neutral engages reverse The engine will continue to run at idle until the le ver is moved about 35 a detent can be felt Moving the lever farther opens the throttle and the engine will begin to accelerate EMU26201 Neutral interlock trigger To shift out of neutral first pull the neutral in terlock trigge...

Page 21: ... shift lever towards you puts the engine in forward gear so that the boat moves ahead Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern EMU25941 Throttle grip The throttle grip is on the tiller handle Turn the grip counterclockwise to increase speed and clockwise to decrease speed EMU25961 Throttle indicator The fuel consumption curve on the throttle ind...

Page 22: ...gine shut off switch for the engine to run The cord should be attached to a secure place on the operator s clothing or arm or leg Should the operator fall overboard or leave the helm the cord will pull out the clip stopping ignition to the engine This will prevent the boat from running away under power WARNING EWM00121 Attach the engine shut off cord to a se cure place on your clothing or your arm...

Page 23: ...lectrical circuits are off and the key can be removed on With the main switch in the on posi tion the electrical circuits are on and the key cannot be removed start With the main switch in the start po sition the starter motor turns to start the en gine When the key is released it returns automatically to the on position EMU31432 Steering friction adjuster A friction device provides adjustable res...

Page 24: ...ed when the adjuster lever is set to the A position Check the tiller handle for smooth move ment when the lever is turned to the star board side B Do not apply lubricants such as grease to the friction areas of the steering friction ad juster EMU26142 Power trim and tilt switch on remote control or tiller handle The power trim and tilt system adjusts the outboard motor angle in relation to the tra...

Page 25: ...ase the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an obsta cle NOTE For instructions on using the power trim and tilt switch see page 49 EMU30900 Variable trolling RPM switches The trolling speed can be adjusted when the outboard motor is trolling Press the switch to increase the trolling speed and press the switch to decrease t...

Page 26: ...the left port side turn the trim tab rear end to the port side A in the figure If the boat tends to veer to the right starboard side turn the trim tab end to the starboard side B in the figure CAUTION ECM00840 The trim tab also serves as an anode to protect the engine from electrochemical corrosion Never paint the trim tab as it will become ineffective as an anode EMU26261 Trim rod tilt pin The po...

Page 27: ... up position lock the tilt support lever to the clamp bracket EMU26372 Top cowling lock lever s turn type To remove the engine top cowling turn the lock lever s and lift off the cowling When in stalling the cowling check to be sure it fits properly in the rubber seal Then lock the cowling again by returning the lever s to the lock position EMU26460 Flushing device This device is used to clean the ...

Page 28: ...stem has activated stop the engine and consult a Yamaha dealer immediately EMU26302 Warning indicator If the engine develops a condition which is cause for warning the indicator lights up For details on how to read the warning indicator see page 33 EMU26470 Tachometer This gauge shows the engine speed and has the following functions EMU26491 Digital tachometer The tachometer shows the engine speed...

Page 29: ...nfor mation see page 38 EMU26523 Low oil pressure warning indicator If oil pressure drops too low the warning in dicator will start to blink For further informa tion see page 33 CAUTION ECM00021 Do not continue to run the engine if the low oil pressure warning indicator is on and the engine oil level is lower Seri ous engine damage will occur The low oil pressure warning indicator does not indicat...

Page 30: ...ng indicator is on Serious engine damage will occur EMU26601 Speedometer digital type This gauge shows the boat speed NOTE After the main switch is first turned on all segments of the display come on as a test After a few seconds the gauge will change to normal operation Watch the gauge when turning on the main switch to make sure all segments come on NOTE The speedometer displays km h mph or knot...

Page 31: ...the trim angle of your motor exceeds the trim operating range the top segment on the trim meter display will blink EMU26650 Hour meter digital type This meter shows the number of hours the engine has been run It can be set to show the total number of hours or the number of hours for the current trip The display can also be turned on and off Changing the display format Pressing the mode button chan...

Page 32: ...is in the time mode Press the set button the hour display will begin blinking Press the mode button until the desired hour is displayed Press the set button again the minute display will begin blinking Press the mode button until the desired minute is dis played Press the set button again to start the clock NOTE The clock operates on battery power Dis connecting the battery will stop the clock Res...

Page 33: ... speed fuel meter unit square or round types and fuel management meter square type The indicator system is slightly differ ent between the round and square types Check the model and type of your unit care fully This manual describes mainly the warning indicators For more details on set ting meters or changing indicator systems see the attached operation manual EMU31681 Tachometer unit The tachomet...

Page 34: ...eter 3 Multifunction display 4 Cooling water pressure 5 Cooling water engine temperature 6 Water detection warning indicator 7 Battery voltage 8 Oil pressure 4 stroke models 2 1 ZMU05415 2 3 1 4 5 6 7 8 ZMU05416 1 Set button 2 Mode button 1 Tachometer 2 Trim meter 3 Multifunction display 4 Water detection warning indicator 5 Engine trouble warning maintenance indica tor 6 Cooling water pressure 7 ...

Page 35: ...mediately if the buzzer sounds and the low oil pressure warning in dicator blinks Check the engine oil quantity and replenish oil if necessary If the warning device has activated while the appropriate engine oil quantity is maintained consult your Yamaha dealer CAUTION ECM01600 Do not continue to run the engine if the low oil pressure warning device has acti vated Serious engine damage will occur ...

Page 36: ...and consult a Yamaha dealer immediately CAUTION ECM00910 Gasoline mixed with water could cause damage to the engine Engine trouble warning This indicator will blink when the engine mal functions while cruising Get back to the port soon and consult a Yamaha dealer immedi ately CAUTION ECM00920 In such an event the engine will not oper ate properly Consult a Yamaha dealer immediately Low battery vol...

Page 37: ...rs are connected to the unit trip display water surface temperature display depth display and clock will be available For the optional sensor consult your Yamaha dealer The speed fuel meter unit is avail able in round or square types Check your speed fuel meter unit type ZMU05427 ZMU05428 1 Set button 2 Mode button 1 Speedometer 2 Fuel meter 3 Multifunction display 1 Set button 2 Mode button 2 1 Z...

Page 38: ...ay water surface tempera ture display depth display and clock will be available For the optional sensor consult your Yamaha dealer NOTE After the main switch is first turned on all the displays come on as a test After a few sec onds the gauge will change to normal oper ation NOTE The speedometer unit shows various kinds of information according to the setting made using the set and mode but tons I...

Page 39: ...ee the attached operation man ual EMU26801 Warning system CAUTION ECM00090 Do not continue to operate the engine if a warning device has activated Consult your Yamaha dealer if the problem can not be located and corrected EMU26817 Overheat warning This engine has an overheat warning de vice If the engine temperature rises too high the warning device will activate Activation of warning device The e...

Page 40: ...r clogging EMU30168 Low oil pressure warning If the oil pressure drops too low the warning device will activate Activation of warning device The engine speed will automatically de crease to about 2000 r min If equipped with a low oil pressure warning indicator it will light or blink The buzzer will sound if equipped on the tiller handle remote control box or main switch panel ZMU03604 ZMU04587 ZMU...

Page 41: ...s safe to do so Check the oil level and add oil as needed If the oil level is correct and the warning device does not switch off consult your Yamaha dealer CAUTION ECM00101 Do not continue to run the engine if the low oil pressure warning indicator is on Serious engine damage could occur ...

Page 42: ...is well balanced Otherwise the boat could be hard to steer For single en gine boats mount the outboard motor on the centerline keel line of the boat EMU26931 Mounting height boat bottom The mounting height of your outboard motor affects its efficiency and reliability If it is mounted too high propeller ventilation may occur which will reduce propulsion due to excessive propeller slip and the water...

Page 43: ...engine life CAUTION ECM00800 Failure to follow the break in procedure could result in reduced engine life or even severe engine damage EMU27083 Procedure for 4 stroke models Your new engine requires a period of ten hours break in to allow mating surfaces of moving parts to wear in evenly Correct break in will help ensure proper performance and longer engine life NOTE Failure to follow the break in...

Page 44: ...ealer immediately EMU27130 Controls Check throttle shift and steering for prop er operation before starting the engine The controls should work smoothly with out binding or unusual free play Look for loose or damaged connections Check operation of the starter and stop switches when the outboard motor is in the water EMU31721 Stop switches Confirm that turning the main switch to the off position st...

Page 45: ...an steer clear of any obstructions Be sure there are no swimmers in the water near you When the air vent screw is loosened gasoline vapor will be released Gaso line is highly flammable and its vapors are flammable and explosive Refrain from smoking and keep away from open flames and sparks while loosen ing the air vent screw This product emits exhaust gases which contain carbon monoxide a col orle...

Page 46: ...ine to the fuel line clamp NOTE During engine operation place the tank hori zontally otherwise fuel cannot be drawn from the fuel tank 4 Squeeze the primer pump with the ar row pointing up until you feel it become firm EMU27491 Starting engine WARNING EWM01600 Before starting the engine make sure that the boat is tightly moored and that you can steer clear of any obstructions Be sure there are no ...

Page 47: ...l Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward 3 Place the throttle grip in the start position After the engine starts return the throttle to the fully closed po sition 4 Turn the main switch to start and hold it for a maximum of 5 seconds 5 Immediately after the engine starts re lease the main switch and allow it to re ...

Page 48: ... cure place on your clothing or your arm or leg while operating Do not attach the cord to clothing that could tear loose Do not route the cord where it could become entangled pre venting it from functioning Avoid accidentally pulling the cord dur ing normal operation Loss of engine power means the loss of most steering control Also without engine power the boat could slow rapidly This could cause ...

Page 49: ...engine Otherwise serious en gine damage could occur Check the oil level and add oil if necessary Consult your Yamaha dealer if the cause for the low oil pressure warning indicator can not be found A continuous flow of water from the pi lot hole shows that the water pump is pumping water through the cooling passages If water is not flowing out of the pilot hole at all times while the en gine is run...

Page 50: ...gear about 35 a detent can felt for re mote control models To shift from in gear forward reverse to neutral 1 Close the throttle so that the engine slows to idle speed 2 After the engine is at idle speed in gear move the remote control lever gear shift lever firmly and crisply into the neu tral position 1 Neutral interlock trigger ...

Page 51: ...80 Trolling EMU30890 Adjusting trolling speed The trolling speed on outboard motors equipped with the variable trolling RPM switches can be adjusted approximately 50 r min with each press of a switch To increase the trolling speed press the switch To decrease the trolling speed press the switch NOTE The trolling speed changes approximately 50 r min each time a switch is pressed If the trolling spe...

Page 52: ...e the position of the bow of the boat in the water Correct trim angle will help im prove performance and fuel economy while reducing strain on the engine Correct trim angle depends upon the combination of boat engine and propeller Correct trim is also affected by variables such as the load in the boat sea conditions and running speed WARNING EWM00740 Excessive trim for the operating condi tions ei...

Page 53: ...y signs of instabil ity or control problems Improper trim angle can cause loss of control If equipped with a power trim and tilt switch located on the bottom cowling use the switch only when the boat is at a complete stop with the engine off Do not adjust the trim angle with this switch while the boat is moving Adjust the outboard motor trim angle using the power trim and tilt switch To raise the ...

Page 54: ... engine To raise the bow trim out tilt the engine up To lower the bow trim in tilt the engine down Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions EMU27911 Adjusting boat trim When the boat is on plane a bow up attitude results in less drag greater stability and effi ciency This is generally when the keel line of the ...

Page 55: ...obstructions and also to re duce salt corrosion WARNING EWM00221 Be sure all people are clear of the out board motor when tilting up and down Body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted WARNING EWM00250 Leaking fuel is a fire hazard If there is a fuel joint on the outboard motor discon nect the fuel line or close the fuel cock if the engine...

Page 56: ... the tilt support lever or knob when trailering the boat The outboard motor could shake loose from the tilt sup port and fall If the motor cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position For more detailed in formation see page 58 EMU32721 Procedure for tilting up power trim and tilt models 1 Place the remote control lever gear ...

Page 57: ...ard motor could shake loose from the tilt sup port and fall If the motor cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position For more detailed in formation see page 58 4 Models equipped with trim rods Once the outboard motor is supported with the tilt support lever press the power trim and tilt switch down to retract the trim rods ...

Page 58: ...on in shallow water WARNING EWM00270 Place the gear shift in neutral before us ing the shallow water cruising system Run the boat at the lowest possible speed when using the shallow water cruising system Use extra care when operating in re verse Too much reverse thrust can cause the outboard motor to lift out of the water increasing the chance of ac cident and personal injury Return the outboard m...

Page 59: ...sition EMU32850 Power trim and tilt models models The outboard motor can be tilted up partially to allow operation in shallow water WARNING EWM00660 Place the gear shift in neutral before setting up for shallow water cruising Return the outboard motor to its normal position as soon as the boat is back in deeper water CAUTION ECM00260 Do not tilt the outboard motor up so that the cooling water inle...

Page 60: ...perating in salt water flush the cooling water passages with fresh water to prevent them from becoming clogged Also rinse the outside of the outboard motor with fresh wa ter and if possible rinse the power head un der the cowling Cruising in muddy or turbid water Yamaha strongly recommends that you use the optional chromium plated water pump kit available for V4 and large engines if you use the ou...

Page 61: ...ruising in acidic water Water in some areas can be acidic After op erating in such water flush the cooling pas sages with fresh water to prevent corrosion Also rinse the outside of the outboard motor with fresh water ...

Page 62: ...27 mm 20 7 in F50FED 527 mm 20 7 in F50FET 527 mm 20 7 in F60CET 527 mm 20 7 in FT50GET 530 mm 20 9 in FT60DET 530 mm 20 9 in Transom height X F50FET 644 mm 25 4 in F60CET 644 mm 25 4 in FT60DET 644 mm 25 4 in Weight AL L F40DET 110 0 kg 243 lb F50FED 107 0 kg 236 lb F50FET 110 0 kg 243 lb F60CET 110 0 kg 243 lb FT50GET 115 0 kg 254 lb FT60DET 115 0 kg 254 lb Weight AL X F50FET 114 0 kg 251 lb F60...

Page 63: ...er trim and tilt Propeller mark F40DET G F50FED G F50FET G F60CET G FT50GET K FT60DET K Fuel and oil Recommended fuel Regular unleaded gasoline Min research octane 90 Fuel tank capacity 25 L 6 60 US gal 5 50 Imp gal Recommended engine oil 4 stroke outboard motor oil Recommended engine oil group 1 SAE 10W 30 10W 40 5W 30 API SE SF SG SH SJ SL Recommended engine oil group 2 SAE 15W 40 20W 40 20W 50 ...

Page 64: ...r cannot be trail ered in the normal running position use an additional support device to secure it in the tilt position The outboard motor should be trailered and stored in the normal running position If there is insufficient road clearance in this position then trailer the outboard motor in the tilt po sition using a motor support device such as a transom saver bar Consult your Yamaha dealer for...

Page 65: ...to the cooling water passag es CAUTION ECM00310 Avoid running the outboard motor at high speed while on the flushing attachment otherwise overheating could occur 5 Cooling system flushing is essential to prevent the cooling system from clog ging up with salt sand or dirt In addi tion fogging lubricating the engine is mandatory to prevent excessive engine damage due to rust Perform the flush ing an...

Page 66: ...ur Yamaha dealer EMU28402 Lubrication 1 Install the spark plug s and torque to proper specification For information on spark plug installation see page 67 2 Change the gear oil For instructions see page 74 Inspect the oil for the pres ence of water that indicates a leaky seal Seal replacement should be performed by an authorized Yamaha dealer prior to use 3 Grease all grease fittings For further d...

Page 67: ...attery manufacturer s instructions Procedure 1 Disconnect and remove the battery from the boat Always disconnect the black negative cable first to prevent the risk of shorting 2 Clean the battery casing and terminals Fill each cell to the upper level with dis tilled water 3 Store the battery on a level surface in a cool dry well ventilated place out of di rect sunlight 4 Once a month check the spe...

Page 68: ...ns see page 58 EMU28450 Cleaning the outboard motor After use wash the exterior of the outboard motor with fresh water Flush the cooling system with fresh water NOTE For cooling system flushing instructions see page 58 EMU28460 Checking painted surface of motor Check the motor for scratches nicks or flak ing paint Areas with damaged paint are more likely to corrode If necessary clean and paint the...

Page 69: ...e the engine has reached proper operating temperature Frequent quick acceleration and decelera tion Frequent shifting Frequently starting and stopping the en gine s Operation that fluctuates often between light and heavy cargo loads Outboard motors operating under any of these above conditions require more fre quent maintenance Yamaha recommends that you do this service twice as often as specified...

Page 70: ...l Every 20 hours 3 months 100 hours 1 years 300 hours 3 years 500 hours 5 years Anode s external Inspection or replace ment as necessary Anode s cylinder head thermostat cover Inspection or replace ment as necessary Anodes exhaust cover cooling water passage cover Rectifier Regula tor cover Replacement Anode s exhaust cover cover joint Replacement Battery Inspection or charging replacement as nece...

Page 71: ...tion adjustment or replacement as nec essary Spark plug s Inspection adjustment or replacement as nec essary Spark plug caps high tention cordes Inspection or replace ment as necessary Pilot water Inspection Throttle link Throttle cable Throttle pick up timing Inspection adjustment or replacement as nec essary Thermostat Inspection or replace ment as necessary Timing belt Inspection or replace men...

Page 72: ...t as necessary Yamaha Meter gauge Inspection Yamaha Fuel tank Inspection and clean ing as necessary Item Actions Every 1000 hours Guide exhaust exhaust manifold Inspection or replace ment as necessary Timing belt Replacement Item Actions Initial Every 20 hours 3 months 100 hours 1 years 300 hours 3 years 500 hours 5 years ...

Page 73: ...remely care so that neither you nor anyone else gets burnt To avoid burns work on the engine when it has cooled down The spark plug is an important engine com ponent and is easy to inspect The condition of the spark plug can indicate something about the condition of the engine For exam ple if the center electrode porcelain is very white this could indicate an intake air leak or carburetion problem...

Page 74: ...justed to the correct torque as soon as possible with a torque wrench EMU28962 Checking fuel system WARNING EWM00060 Gasoline and its vapors are highly flam mable and explosive Keep away from sparks cigarettes flames or other sources of ignition WARNING EWM00910 Leaking fuel can result in fire or explo sion Check for fuel leakage regularly If any fuel leakage is found the fuel system must be repai...

Page 75: ...eutral until it is running smooth ly NOTE Correct idling speed inspection is only possi ble if the engine is fully warmed up If not warmed up fully the idle speed will measure higher than normal If you have difficulty ver ifying the idle speed or the idle speed re quires adjustment consult a Yamaha dealer or other qualified mechanic 2 Verify whether the idle speed is set to specification For idle ...

Page 76: ...completely Wipe up any spilled oil immediately 3 Put a new gasket on the oil drain screw Apply a light coat of oil to the gasket and install the drain screw NOTE If a torque wrench is not available when you are installing the drain screw finger tighten the screw just until the gasket comes into contact with the surface of the drain hole Then tighten 1 4 to 1 2 turn more Tighten the drain screw to ...

Page 77: ...it is above the upper mark 7 Dispose of used oil according to local regulations NOTE For more information on the disposal of used oil consult your Yamaha dealer Change the oil more often when operating the engine under adverse conditions such as extended trolling EMU29112 Checking wiring and connectors Check that each grounding wire is properly secured Check that each connector is engaged se curel...

Page 78: ...pushed out completely 4 Check that the trim and tilt rod the tilt rod is free of corrosion or other flaws 5 Tilt the outboard motor down Check that the trim and tilt rod the tilt rod oper ates smoothly NOTE Consult your Yamaha dealer if any operation is abnormal EMU32110 Checking propeller WARNING EWM01610 You could be seriously injured if the en gine accidentally starts when you are near the prop...

Page 79: ...EMU30661 Removing propeller EMU29195 Spline models 1 Straighten the cotter pin and pull it out using a pair of pliers 2 Remove the propeller nut washer and spacer if equipped 3 Remove the propeller and thrust wash er EMU30671 Installing propeller EMU29231 Spline models CAUTION ECM00340 Be sure to install the thrust washer be ZMU01897 1 Cotter pin 2 Propeller nut 3 Washer 4 Spacer 5 Propeller 6 Thr...

Page 80: ...le EMU29282 Changing gear oil WARNING EWM00800 Be sure the outboard motor is securely fastened to the transom or a stable stand You could be severely injured if the outboard motor falls on you Never get under the lower unit while it is tilted even when the tilt support lever or knob is locked Severe injury could occur if the outboard motor accidental ly falls 1 Tilt the outboard motor so that the ...

Page 81: ...es or other sources of ignition when cleaning the fuel tank Remove the fuel tank from the boat be fore cleaning it Work only outdoors in an area with good ventilation Wipe up any spilled fuel immediately Reassemble the fuel tank carefully Im proper assembly can result in a fuel leak which could result in a fire or ex plosion hazard Dispose of old gasoline according to lo cal regulations 1 Empty th...

Page 82: ...s are protected from corrosion by sacrificial anodes Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a Yamaha dealer for replacement of external anodes CAUTION ECM00720 Do not paint anodes as this would render them ineffective NOTE Inspect ground leads attached to external anodes on equipped models Consult a Yamaha dealer for inspection and replace me...

Page 83: ...d so on DO NOT SMOKE when charging or han dling batteries KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN CAUTION ECM00360 A poorly maintained battery will quickly deteriorate Ordinary tap water contains minerals harmful to a battery and should not be used for topping up 1 Check the electrolyte level at least once a month Fill to the manufacturer s rec ommended level when necessary ...

Page 84: ...g the battery Disconnect the BLACK cable from the NEG ATIVE terminal first Then disconnect the RED cable from the POSITIVE terminal EMU29391 Checking top cowling CAUTION ECM01650 Be sure the cowling is closed securely and that there are no gaps A loose or im properly fitting cover could allow water into the engine Check the fitting of the top cowling by push ing it with both hands If it is loose h...

Page 85: ...Maintenance 79 ZMU01943 ...

Page 86: ...rviced by a Yamaha dealer Q Is shift lever in gear A Shift to neutral Engine will not start starter operates Q Is fuel tank empty A Fill tank with clean fresh fuel Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is fuel filter clogged A Clean or replace filter Q Is starting procedure incorrect A See page 40 Q Has fuel pump malfunctioned A Have serviced by a Yamaha dealer Q Are ...

Page 87: ...Yamaha dealer Q Is air vent screw on fuel tank closed A Open air vent screw Q Is choke knob pulled out A Return to home position Q Is motor angle too high A Return to normal operating position Q Is carburetor clogged A Have serviced by a Yamaha dealer Q Is fuel joint connection incorrect A Connect correctly Q Is throttle valve adjustment incorrect A Have serviced by a Yamaha dealer Q Is battery ca...

Page 88: ...t type A Inspect spark plug s Clean or replace with recommended type Q Are weeds or other foreign matter tangled on gear housing A Remove foreign matter and clean lower unit Q Is fuel system obstructed A Check for pinched or kinked fuel line or other obstructions in fuel system Q Is fuel filter clogged A Clean or replace filter Q Is fuel contaminated or stale A Fill tank with clean fresh fuel Q Is...

Page 89: ...ncy EMU29440 Impact damage WARNING EWM00870 The outboard motor can be seriously damaged by a collision while operating or trailering Damage could make the out board motor unsafe to operate If the outboard motor hits an object in the wa ter follow the procedure below 1 Stop the engine immediately 2 Inspect the control system and all com ponents for damage Also inspect the boat for damage 3 Whether ...

Page 90: ... va pors are flammable and explosive Do not perform this procedure on a hot or running engine Allow the engine to cool There will be fuel in the fuel filter Keep away from sparks cigarettes flames or other sources of ignition This procedure will allow some fuel to spill Catch fuel in a rag Wipe up any spilled fuel immediately The fuel filter must be reassembled carefully with the O ring filter cup...

Page 91: ...using NOTE Be careful not to twist the water detection switch lead when unscrewing the filter cup 6 Drain the water in the filter cup by soak ing it up with a rag NOTE Properly dispose of the rag 7 Firmly screw the filter cup onto the filter housing NOTE Be careful not to twist the water detection switch lead when screwing the filter cup onto 1 Water separator warning indicator 1 Plastic tie 1 ZMU...

Page 92: ...tart the engine the start in gear protection device does not oper ate Make sure the remote control lever is in neutral Otherwise the boat could unexpectedly start to move which could result in an accident Attach the engine shut off cord to a se cure place on your clothing or your arm or leg while operating the boat Do not attach the cord to clothing that could tear loose Do not route the cord wher...

Page 93: ... in neutral and that the clip is attached to the engine shut off switch 4 Turn on the main switch 5 Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope around the fly wheel several turns clockwise 6 Give a strong pull straight out to crank the engine Repeat if necessary WARNING EWM00620 Do not install the top cowling when en gine is running E...

Page 94: ...YAMAHA MOTOR CO LTD Printed on recycled paper Printed in Japan April 2007 0 1 1 ...

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Yamaha F40D, Owner'S Manual

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