Yamaha F40F Owner'S Manual Download

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Trouble Recovery

hazard.

If the water separator-alert indicator on the
6Y8 Multifunction tachometer blinks, perform
the following procedure.

Stop the engine.

Remove the top cowling.

Remove the holder.

Disconnect the water detection switch
coupler.

NOTICE:

Be careful not to get

any water on the water detection
switch coupler, otherwise a malfunc-
tion could occur.

[ECM01950]

Unscrew the filter cup from the filter
housing.

NOTICE:

Be careful not to

twist the water detection switch lead
when unscrewing the filter cup.

[ECM01960]

Drain the water in the filter cup by soak-
ing it up with a rag.

Firmly screw the filter cup onto the filter
housing.

NOTICE:

Be careful not to

twist the water detection switch lead
when screwing the filter cup onto the
filter housing.

[ECM01970]

Connect the water detection switch cou-
pler securely until a click is heard.

1. Water separator-alert indicator

1. Holder

ZMU06424

1. Water detection switch coupler

1. Filter cup
2. Water detection switch lead

ZMU06425

ZMU06426

Summary of Contents for F40F

Page 1: ...q q q q Read this manual carefully before operating this outboard motor OWNER S MANUAL F40F 6BG 28199 20 E0 ...

Page 2: ...EMU25052 Read this manual carefully before operating this 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: ... ing there may be minor discrepancies between 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 ...

Page 4: ... Multiple batteries 11 Propeller selection 11 Start in gear protection 11 Engine oil requirements 12 Fuel requirements 12 Gasoline 12 Muddy or acidic water 12 Anti fouling paint 13 Motor disposal requirements 13 Emergency equipment 13 Components 14 Components diagram 14 Fuel tank 15 Fuel joint 15 Fuel gauge 16 Fuel tank cap 16 Air vent screw 16 Remote control box 16 Remote control lever 16 Neutral...

Page 5: ...e cowling 39 Fuel system 39 Controls 39 Engine shut off cord lanyard 40 Engine oil 40 Engine 41 Flushing device 41 Install cowling 41 Power trim and tilt system 42 Battery 42 Filling fuel 42 Operating engine 43 Sending fuel portable tank 43 Starting engine 44 Checks after starting engine 47 Cooling water 47 Warming up engine 47 Manual start and electric start models 47 Checks after engine warm up ...

Page 6: ...g wiring and connectors 73 Checking propeller 74 Removing propeller 74 Installing propeller 75 Changing gear oil 75 Cleaning fuel tank 76 Inspecting and replacing anode s 77 Checking battery for electric start models 78 Connecting the battery 78 Disconnecting the battery 79 Trouble Recovery 80 Troubleshooting 80 Temporary action in emergency 83 Impact damage 83 Replacing fuse 83 Power trim and til...

Page 7: ... mo tor and the clamp bracket when the motor is trimmed or tilted Keep body parts out of this area at all times Be sure no one is in this area before operating the power trim and tilt mechanism The power trim and tilt switches operate even when the main switch is off Keep peo ple be away from the switches whenever working around the motor Never get under the lower unit while it is tilt ed even whe...

Page 8: ...for every occupant Yamaha recommends that you must wear a PFD whenever boating At a minimum children and non swimmers should always wear PFDs and everyone should wear PFDs when there are potentially hazardous boat ing conditions EMU33730 People in the water Always watch carefully for people in the wa ter such as swimmers skiers or divers whenever the engine is running When someone is in the water ...

Page 9: ...id collisions Re member boats do not have brakes and stopping the engine or reducing throttle can reduce the ability to steer If you are not sure that you can stop in time before hitting 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 ...

Page 10: ...mped on your key as shown in the illustration Record this number in the space provided for reference in case you need a new key EMU37290 EC Declaration of Conformity DoC This outboard motor conforms to certain por tions of the European Parliament directive relating to machinery Each conformed outboard motor accompa nied with EC DoC EC DoC contains the fol lowing information Name of Engine Manufact...

Page 11: ...ion 5 EMU25213 C Tick label Engines affixed with this label conform to certain portion s of the Australian Radio Communications Act 1 CE marking location 1 C Tick label location 1 ZMU06391 ZMU06040 1 ZMU06391 ZMU01697 ...

Page 12: ...ead 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 EMU33831 Warning labels If these labels are damaged or missing contact your Yamaha dealer for replacements F40F ZMU06393 1 3 2 ...

Page 13: ...RNING EWM01681 Keep hands hair and clothing away from rotating parts while the engine is running Do not touch or remove electrical parts when starting or during operation 3 WARNING EWM01671 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 preve...

Page 14: ...mean as follows Notice Warning Read Owner 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 15: ... Bore stroke 65 0 75 0 mm 2 56 2 95 in Ignition system CDI Spark plug NGK DPR6EB 9 Spark plug gap 0 8 0 9 mm 0 031 0 035 in Control system F40FEHD Tiller F40FEHT Tiller F40FET Remote control Starting system Electric Starting carburetion system Electronic fuel injection Valve clearance cold engine IN 0 15 0 25 mm 0 0059 0 0098 in Valve clearance cold engine EX 0 25 0 35 mm 0 0098 0 0138 in Min cold...

Page 16: ...f your mo tor s does not exceed the boats maximum horsepower rating See the boat s capacity plate or contact the manufacturer EMU33571 Mounting motor WARNING EWM01570 Improper mounting of the outboard 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 Your ...

Page 17: ...to perform well over a range of applications but there may be uses where a different propeller would be more appropriate Your Yamaha dealer can help you select the right propeller for your boating needs Select a propeller that will 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 sm...

Page 18: ...g methanol Ethanol can be used if the ethanol content does not exceed 10 and the fuel meets the minimum octane ratings All etha nol blends containing more than 10 etha nol can cause fuel system damage or cause engine starting and running problems Yamaha does not recommend gasohol con taining methanol because it can cause fuel system damage or engine performance problems EMU36880 Muddy or acidic wa...

Page 19: ... These paints can cause more rapid engine corrosion EMU36341 Motor disposal requirements Never illegally discard dump the motor Yamaha recommends consulting the dealer about discarding the motor EMU36351 Emergency equipment Keep the following items onboard in case there is trouble with the motor A tool kit with assorted screwdrivers pli ers wrenches including metric sizes and electrical tape Water...

Page 20: ... separator 3 Top cowling lock lever 4 Anode 5 Anti cavitation plate 6 Trim tab anode 7 Propeller 8 Cooling water inlet 9 Clamp bracket 10 Power trim and tilt switch 11 Variable trolling RPM switch 12 Gear shift lever 13 Tiller handle 14 Engine stop button Engine shut off switch 15 Main switch 16 Flushing device 17 Tilt support knob 18 Steering friction adjuster 19 Alert indicator 20 Tilt lock leve...

Page 21: ...ervoir and must not be used as a fuel storage 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 3 2 ZMU05484 1 Tachometer unit Square type 2 Speedometer unit Square type 3 Fuel management meter Square type 1 Fuel joint 2 Fuel gauge 3 Fuel tank cap 4 Air vent screw ZMU02284 3 1 4 2 ...

Page 22: ...Moving 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 t...

Page 23: ...ift 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 indica...

Page 24: ...lip must be attached to the engine 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 At tach the engine shut off cord to a secure place on your...

Page 25: ...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 resis tance to the steering mechan...

Page 26: ...d 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 EMU26143 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 tran...

Page 27: ... use this switch while the boat is moving could increase the risk of falling overboard and could distract the operator increasing the risk of collision with another boat or an obsta cle 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 the trolling speed TIP...

Page 28: ...CM00840 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 EMU26312 Tilt lock mechanism The tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa ter when in reverse gear To lock it set the tilt lock lever in the lock position To release push the tilt lock lever ...

Page 29: ...etails on usage see page 63 EMU35561 Fuel filter Water separator This engine has a combination fuel filter wa ter separator and associated alert system If water separated from the fuel exceeds a specific volume the alert device of 6Y8 Mul tifunction Tachometer will activate Activation of alert device The water separator alert indicator of 6Y8 Multifunction Tachometer will blink The buzzer will sou...

Page 30: ...Components 24 details on how to read the alert indicator see page 34 1 Alert indicator ...

Page 31: ... too high this indicator will light up For further information on reading the indicator see page 34 NOTICE ECM00052 Do not continue to run the engine if the overheat alert indicator is on Serious en gine damage will occur EMU26493 Digital tachometer The tachometer shows the engine speed and has the following functions All segments of the display will light momen tarily after the main switch is tur...

Page 32: ...ours for the current trip The display can also be turned on and off To change the display format press the mode button The display can show total hours or trip hours or turn off To reset the trip hours simultaneously press the set and mode buttons for more than 1 second while the trip hours are displayed This resets the trip counter to 0 zero The total number of hours the engine has been run canno...

Page 33: ...e display will light momen tarily after the main switch is turned on and will return to normal thereafter EMU36061 Speedometer The speedometer displays km h mph or knots according to operator preference Se lect the desired units of measurement by set ting the selector switch on the back of the gauge See the illustration for settings EMU26712 Fuel gauge Eight segments indicate the fuel level When 1...

Page 34: ...o trip meter clock or voltmeter EMU26691 Trip meter This gauge displays the distance the boat has traveled since the gauge was last reset The trip distance is shown in kilometers or miles depending upon the unit of measure ment selected for the speedometer To reset the trip meter to zero press the set and mode buttons at the same time The trip distance is kept in memory by bat tery power The store...

Page 35: ... 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 alert indicators For more details on setting meters or changing indicator systems see the attached operation manual EMU36183 6Y8 Multifunction tachometers T...

Page 36: ...peed will automatical ly decrease to about 3000 r min Stop the engine immediately if the buzzer sounds and the low oil pressure alert indica tor blinks Check the engine oil quantity and replenish oil if necessary If the alert device has activated while the appropriate engine oil quantity is maintained consult your Yamaha dealer NOTICE ECM01601 Do not continue to run the engine if the low oil press...

Page 37: ...ilter while cruising In such an event stop the engine immediately and see page 83 of this manual to drain the water from the fuel filter Get back to the port soon and consult a Yamaha dealer immediately NOTICE ECM00910 Gasoline mixed with water could cause damage to the engine EMU36160 Engine trouble alert This indicator will blink if the engine malfunc tions while cruising Get back to the port so...

Page 38: ...emperature dis play depth display and clock will also be available For the optional sensors consult your Yamaha dealer 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 For more information see the operation manual originally supplied with the meter EMU36250 6Y8 Multifunction fuel management meters The fuel m...

Page 39: ...uments and indicators 33 ation For more information see the operation manual originally supplied with the meter 1 Set button 2 Mode button 1 Fuel flow meter 2 Multifunction display 2 1 ZMU05438 1 2 ZMU05439 ...

Page 40: ...tomatically de crease to about 3000 r min The overheat alert indicator will light or blink The buzzer will sound If the alert system has activated stop the en gine and check the cooling water inlets Check trim angle to be sure that the cool ing water inlet is submerged Check the cooling water inlet for clogging EMU26865 Low oil pressure alert If the oil pressure drops too low the alert de vice wil...

Page 41: ... 35 The buzzer will sound If the alert system has activated stop the en gine as soon as it is safe to do so Check the oil level and add oil as needed If the oil level is correct consult your Yamaha dealer ZMU04254 ZMU05232 ...

Page 42: ...t 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 EMU26932 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 wat...

Page 43: ...w of water such as the design or condition of the boat or ac cessories such as transom ladders or depth finder transducers can create airborne water spray while the boat is cruising If the motor is operated con tinuously in the presence of airborne water spray enough water could enter the engine through the intake opening on the cowling to cause severe engine damage Eliminate the cause of the air ...

Page 44: ...lure to follow the break in procedure could result in reduced engine life or even severe engine damage Run the engine in the water under load in gear with a propel ler installed as follows For ten hours for breaking in engine avoid extended idling rough water and crowded areas 1 For the first hour of operation Run the engine at varying speeds up to 2000 r min or approximately half throttle 2 For t...

Page 45: ... leakage is found the fuel system must be repaired by a qualified mechanic Improper repairs can make the outboard unsafe to operate EMU36450 Check for fuel leaks Check under top cowling and in the boat for fuel leaks or gasoline fumes Check fuel line connections to be sure they are tight Check fuel lines for cracks swelling or other damage EMU36470 Check the fuel filter Check that the fuel filter ...

Page 46: ...ff cord for damage such as cuts breaks and wear EMU37051 Engine oil 1 Put the outboard motor in an upright po sition not tilted NOTICE If the motor is not level the oil level indicated on the dipstick may not be accurate ECM01790 2 Remove the top cowling 3 Remove oil dipstick and wipe it clean 4 Insert the dipstick and remove it again Be sure to completely insert the dipstick into the dipstick gui...

Page 47: ...k lever is re leased 2 Be sure that the rubber seal is seated all the way around the engine 3 Place the cowling on top of the seal 4 Check to be sure the rubber seal fits cor rectly all the way around the engine 5 Move the lever to lock the cowling as shown NOTICE If the cowling is not installed correctly water spray under the cowling can damage the engine or the cowling can blow off at high speed...

Page 48: ...e of corrosion or other flaws 5 Tilt the outboard motor down Check that the trim and tilt rod operates smoothly EMU36581 Battery Check that the battery is in good condition and fully charged Check that the battery connections are clean secure and covered by insulating covers The electrical contacts of the battery and cables must be clean and properly connected or the battery will not start the eng...

Page 49: ...o local laws or regulations EMU27451 Operating engine EMU27465 Sending fuel portable tank WARNING EWM00420 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 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 flamma...

Page 50: ...art models WARNING EWM01840 Failure to attached engine shut off cord could result in a runaway boat if opera tor is ejected Attach the engine shut off cord to a secure place on your cloth ing 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...

Page 51: ...gine is running Do not keep the starter motor turning for more than 5 seconds If the starter motor is turned continuously for more than 5 seconds the battery will be quickly discharged thus making it impossible to start the engine The starter can also be damaged If the engine will not start after 5 seconds of cranking return the main switch to on wait 10 seconds then crank the engine again ECM0019...

Page 52: ...shut off cord to a se cure place on your clothing or your arm or leg Then install the clip on the other end of the cord into the engine shut off switch 3 Turn the main switch to on 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 turn to on NOTICE Never turn the main switch to start while the en...

Page 53: ...exhaust cover cylinder head and body cylinder EMU27670 Warming up engine EMU27715 Manual start and electric start models 1 After starting the engine allow it to idle for 3 minutes to warm up Failure to do so will shorten engine life 2 Be sure the low oil pressure alert indica tor goes off after starting the engine NOTICE If the low oil pressure alert indicator blinks after the engine starts stop t...

Page 54: ...low it to warm up To shift out of neutral 1 Pull the neutral interlock trigger up if equipped 2 Move the remote control lever gear shift lever firmly and crisply forward for forward gear or backward for reverse gear about 35 a detent can felt for re mote control models Be sure to check that the tilt lock lever is in the lock down position if equipped before operating in reverse To shift from in ge...

Page 55: ...ury It could also damage the shift mechanism Do not shift into reverse while traveling at planing speeds Loss of control boat swamping or damage to the boat could occur The boat is not equipped with a separate braking system Water resistance stops it af ter the throttle lever is moved back to idle The stopping distance varies depending on gross weight water surface conditions and wind direction EM...

Page 56: ...engine is stopped and restarted or when the engine speed exceeds ap proximately 3000 r min EMU27821 Stopping engine Before stopping the engine first let it cool off for a few minutes at idle or low speed Stop ping the engine immediately after operating at high speed is not recommended EMU27845 Procedure 1 Push and hold the engine stop button or turn the main switch to off 2 After stopping the engi...

Page 57: ...rect 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 EMU27885 Adjusting trim angle Power trim and tilt WARNING EWM00753 Be sure all people are clear of the out board motor...

Page 58: ...im angle Be sure all people are clear of the out board motor when adjusting the trim angle also be careful not to pinch any body parts between the drive unit and clamp bracket Use caution when trying a trim position for the first time Increase speed gradu ally and watch for any signs of instabil ity or control problems Improper trim angle can cause loss of control 1 Stop the engine 2 Place the til...

Page 59: ...formance and econ omy are decreased because the hull of the boat is pushing the water and there is more air drag Excessive trim out can also cause the propeller to ventilate which reduces per formance further and the boat may por poise hop in the water which could throw the operator and passengers overboard Bow Down Too much trim in causes the boat to plow through the water decreasing fuel economy...

Page 60: ...ndle if equipped because this could break the handle EMU33152 Procedure for tilting up hydro tilt models 1 Place the gear shift lever in neutral 2 Place the tilt lock lever in the release po sition 3 Hold the rear of the top cowling with one hand tilt the engine up and turn the tilt support lever toward you or tilt support knob into the clamp bracket and then place the tilt lock lever back into th...

Page 61: ...erwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the pow er tilt unit loses pressure EWM00262 NO TICE Do not use the tilt support lever or knob when trailering the boat The outboard motor could shake loose from the tilt support and fall If the motor cannot be trailered in the nor mal running position use an addi tional support device to secure it...

Page 62: ...for tilting down hydro tilt models 1 Release the tilt lock lever 2 Hold the rear of the top cowling with one hand tilt the outboard motor up slightly and pull out the tilt support knob or re turn the tilt support lever 3 Slowly tilt the outboard motor down 4 Place the tilt lock lever in the lock posi tion EMU33120 Procedure for tilting down power trim and tilt models 1 Push the power trim and tilt...

Page 63: ...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 NOTICE ECM00260 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set ting up for and cruising in shallow water Otherwise severe damage from over...

Page 64: ...TICE ECM00260 Do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set ting up for and cruising in shallow water Otherwise severe damage from overheat ing can result EMU32912 Procedure for power trim and tilt models 1 Place the remote control lever gear shift lever in neutral 2 Slightly tilt the outboard motor up to the desired ...

Page 65: ...outside of the outboard motor with fresh wa ter and if possible rinse the power head un der the cowling Cruising in muddy turbid or acidic water Yamaha strongly recommends that you use the optional chromium plated water pump kit see page 12 if you use the outboard motor in acidic water or water with a lot of sediment in it such as muddy or turbid cloudy water After operating in such water flush th...

Page 66: ...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 further details EMU28290 Storing outboard motor When storing your Yamaha outboard motor for prolonged periods of time 2 months or longer several important procedures must be performed to prevent excessive damage It is advisable to have your ...

Page 67: ...late or if the water supply is in sufficient engine seizure may occur ECM00291 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 of the engine is mandatory to prevent excessive engine damage due to rust Perform the flush ing and fogging at the same time WARNING Do not touch or remove electrical parts when ...

Page 68: ... water to the cooling water passages Avoid run ning the outboard motor at high speed while on the flushing attach ment otherwise overheating could occur ECM02000 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 69: ...spark plug s and torque to proper specification For information on spark plug installation see page 70 2 Change the gear oil For instructions see page 75 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 de tails see page 69 TIP For long term storage foggin...

Page 70: ...the engine which can cause serious overheating Be sure the con nector is tightened securely on the fitting after flushing the engine ECM00541 TIP When flushing the engine with the boat in the water tilting up the outboard motor un til it is completely out of the water will achieve better results For cooling system flushing instructions see page 60 EMU28450 Cleaning the outboard motor After use was...

Page 71: ...rts are necessary use only genuine Yamaha parts or parts of equivalent design and quality Any part of inferior quality may malfunction and the resulting loss of control could endanger the operator and passengers Yamaha genuine parts and ac cessories are available from your Yamaha dealer EMU34150 Severe operating conditions Severe operating conditions involve one or more of the following types of o...

Page 72: ...er the engine should be flushed with clean water after each use The symbol indicates the check ups which you may carry out yourself The symbol indicates work to be carried out by your Yamaha dealer Item Actions Initial Every 20 hours 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years Anode s external Inspection or replace ment as necessary Anode s cylinder head thermostat cover Inspecti...

Page 73: ... trim tilt unit Inspection Propeller Propeller nut Cotter pin Inspection or replace ment as necessary PCV Pressure Con trol Valve Inspection or replace ment as necessary Shift link shift cable Inspection adjustment or replacement as nec essary Spark plug s Inspection or replace ment as necessary Spark plug caps high tension cords Inspection or replace ment as necessary Water from the cooling water...

Page 74: ...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 3 months 100 hours 1 year 300 hours 3 years 500 hours 5 years ...

Page 75: ...Maintenance 69 EMU28941 Greasing Yamaha grease A water resistant grease Yamaha grease D corrosion resistant grease for propeller shaft F40FEHD F40FEHT ZMU06417 ...

Page 76: ...iagnose any problems yourself Instead take the outboard motor to a Yamaha dealer You should periodically re move and inspect the spark plug because heat and deposits will cause the spark plug to slowly break down and erode If electrode erosion becomes excessive or if carbon and other deposits are excessive you should re place the spark plug with another of the cor rect type 1 Remove the spark plug...

Page 77: ... Keep hands hair and clothes away from the flywheel and other rotating parts while the engine is running NOTICE ECM00490 This procedure must be performed while the outboard motor is in the water A flushing attachment or test tank can be used A diagnostic tachometer should be used for this procedure Results may vary depending on whether testing is conducted with the flushing attachment in a test ta...

Page 78: ...ipstick may not be accurate ECM01860 2 Start the engine Warm it up and keep the idle speed for 5 10 minutes 3 Stop the engine and leave it for 5 10 minutes 4 Remove the top cowling 5 Remove the oil filler cap Pull out the dip stick and use the oil changer to extract the oil completely 6 Add the correct amount of oil through the filler hole Put back the filler cap and the dipstick NOTICE Overfillin...

Page 79: ...ere engine damage Consult your Yamaha dealer if the problem cannot be located and corrected ECM01622 12 Dispose of used oil according to local regulations TIP 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 ground...

Page 80: ...Put a wood block between the anti cavi tation plate and the propeller to prevent the propeller from turning Checkpoints Check each of the propeller blades for wear erosion from cavitation or ventila tion or other damage Check the propeller shaft for damage Check the splines for wear or damage Check for fish line tangled around the pro peller shaft Check the propeller shaft oil seal for dam age EMU...

Page 81: ...stalled Otherwise the propeller can come off during operation ECM01890 TIP If the propeller nut does not align with the propeller shaft hole after tightening to the specified torque tighten the nut further to align it with the hole EMU29287 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 outboa...

Page 82: ...g When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug 7 Put a new gasket on the gear oil drain screw Insert and tighten the gear oil drain screw EMU29302 Cleaning fuel tank WARNING EWM00920 Gasoline is highly flammable and its va pors are flammable and explosive If you have any question about properly doing this procedure consult your Yamaha dealer Keep...

Page 83: ... cleaning sol vent Allow the filter to dry 5 Replace the gasket with a new one Re install the fuel joint assembly and tighten the screws firmly EMU29312 Inspecting and replacing anode s Yamaha outboard motors 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 a...

Page 84: ...el 2 Check the battery s charge If your boat is equipped with the digital speedome ter the voltmeter and low battery alert functions will help you monitor the bat tery s charge If the battery needs charg ing consult your Yamaha dealer 3 Check the battery connections They should be clean secure and covered by an insulating cover WARNING Bad connections can produce shorting or arcing and cause an ex...

Page 85: ...switch NOTICE If they are left on the electrical system can be damaged ECM01930 2 Disconnect the negative cable s from the negative terminal NOTICE Al ways disconnect all negative ca bles first to avoid a short circuit and damage to the electrical system ECM01940 3 Disconnect the positive cable s and re move the battery from the boat 4 Clean maintain and store the battery according to the manufact...

Page 86: ...A Have serviced 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 44 Q Has fuel pump malfunctioned A Have serviced by a Yamaha deal...

Page 87: ...erviced by a 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 ...

Page 88: ...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 s...

Page 89: ...ion in emergency 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 dama...

Page 90: ...0 Gasoline is highly flammable and its 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 reassemble...

Page 91: ...from the filter housing NOTICE Be careful not to twist the water detection switch lead when unscrewing the filter cup ECM01960 6 Drain the water in the filter cup by soak ing it up with a rag 7 Firmly screw the filter cup onto the filter housing NOTICE Be careful not to twist the water detection switch lead when screwing the filter cup onto the filter housing ECM01970 8 Connect the water detection...

Page 92: ...ould 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 where it could become entangled pre venting it from functioning Avoid accidentally pulling the cord dur ing normal operation Loss of engine pow...

Page 93: ...ormation see page 44 Be sure the engine is 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 Do not install the top ...

Page 94: ... submerged motor If the outboard motor is submerged immedi ately take it to a Yamaha dealer Otherwise some corrosion may begin almost immedi ately NOTICE Do not attempt to run the outboard motor until it has been com pletely inspected ECM00401 ...

Page 95: ......

Page 96: ...YAMAHA MOTOR CO LTD Printed on recycled paper Printed in Japan September 2008 0 1 1 ...

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Yamaha F40F, Owner'S Manual

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