1990-1997 Yamaha 40HP 2-Stroke Outboard Repair Manual

1990 - 1997 OUTBOARD SERVICE MANUAL Model : C40ELRP, C40ELRQ, C40ELRR, C40ELRS, C40ELRT, C40ELRU, C40ELRV, C40MLHQ, C40MLHR, C40MLHS, C40MLHT, C40MLHU, C40MLHV, C40MSHQ, C40MSHR, C40MSHS, C40MSHT, C40PLRU, C40PLRV, CV40ELD 6R6281972011 *6R6281972011*

AIO000-O* CV40 SERVICE MANUAL © 1989 Yamaha Motor Co., Ltd. 1st Edition, December 1989 All rights reserved. No part of this publication may be reproduced or transmitted in any form or by any means including photocopying and recording without the written permission of the copyright holder. Such written permission must also be obtained before any part of this publication is stored in a retrieval system of any nature. Printed in Japan PIN 8R6-28197.20.11

A20000-0 NOTICE This manualhas been prepared by theYamahaMotor Company primarily for use by Yamahadeal- ersand their trained mechanics when performing maintenance proceduresand repairs to Yamaha equipment.Ithas been written to suit theneeds of persons who have a basic under- standing of the mechanical and electrical conceptsand proceduresinherent in the work, for without such knowledge attempted repairsor serviceto theequipment could render it unsafeor unfit for use. Because the Yamaha Motor Company Ltd hasa policy ofcontinuously 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.Authorised Yamahadealersare notified periodically of modifi- cations and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual.

A30000-0 INDEX GENERAL INFORMATION -ir GEN INFO g.. SPECIFICATION SC-E'C _'J GENERAL SERVICE _![_ FUEL SYSTEM FUEL POWER UNIT P_WW R_. _ LOWER UNIT L_; BRACKET UNIT BRKT ELECTRICALSYSTEM ELEC 1 _ l? TROUBLE-SHOOTING T_L SHTG

CHAPTER 1. GENERAL INFORMATION HOWTO USE THIS MANUAL ........................................................... 1-1 MANUAL FORMAT ..................................................................... 1-1 THE ILLUSTRATIONS ................................................................. 1-1 REFERENCES............................................................................. 1-1 WARNINGS, CAUTIONS and NOTES ............................................ 1-1 SYMBOLS ................................................................................. 1-2 IDENTIFICATION ............................................................................. 1-3 SERIAL NUMBER ........................................................................ 1-3 ENGINE SERIAL NUMBER ............................................................ 1-3 STARTING SERIAL NUMBERS ...................................................... 1-3 SAFETY WHILE WORKING ............................................................... 1-4 SPECIAL TOOLS ............................................................................. 1-6 SPECIAL TOOLS FOR TUNE-UP ................................................... 1-6 SPECIAL TOOLS FOR ENGINE SERVICE ........................................ 1-6 SPECIAL TOOLS FOR LOWER UNIT SERVICE ................................ 1-7 SEALING AGENTS ANDLUBRICANTS .......................................... 1-7 CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS .............................................................. 2-1 MAINTENANCE SPECIFICATIONS ..................................................... 2-3 TIGHTENING TORQUE ................................................................... 2-1 1

CHAPTER 3 GENERAL SERVICE PREDELIVERY SERVICE ............................................................................... 3-1 CONTENTS ............................................................................................... 3-1 ELECTRIC WIRING ..................................................................................3-2 FUELLINE ................................................................................................ 3-3 GEAROILLEVEL .....................................................................................3-4 OPERATION OFCONTROLS AND MOVING PARTS .......................... 3-4 FUEL LEAKAGE ....................................................................................... 3-5 WATER LEAKAGE ...................................................................................3-5 EXHAUST LEAKAGE ............................................................................... 3-5 ENGINEAND LOWER UNIT NOISE ...................................................... 3-5 IDLE-SPEED.............................................................................................. 3-5 IGNITION TIMING ........................................ ' ........... '. ................................ 3-5 MOTOR EXTERIOR .................................................................................. 3-5 INSTRUCTING THE NEW OWNER ........................................................ 3-5 PERIODIC SERVICE ...................................................................................... 3-6 MAINTENANCE SCHEDULE ................................................................... 3-6 ANODE ...................................................................................................... 3-6 BATFERY................................................................................................... 3-7 CARBURETOR ...................i ...................................................................... 3-8 CARBURETOR LINK ADJUSTMENT ...................................................... 3-8 CHOKE SOLENOID .................................................................................. 3-8 CYLINDER HEADBOLTS, ENGINE MOUNTINGBOLTS, AND FLYWHEELNUT ...................................................................................... 3-9 FUEL FILTER ............................................................................................ 3-9 FUEL TANK AND FUEL LINE ................................................................ 3-9 GEAROIL................................................................................................... 3-9 IDLE-SPEED.............................................................................................. 3-9 IGNITION TIMING ADJUSTMENT ........................................................ 3-10 PROPELLER ............................................................................................ 3-14 SPARK PLUG.......................................................................................... 3-15 START-IN-GEAR PROTECTION ADJUSTMENT .................................. 3-15

CHAPTER 4 FUEL SYSTEM FUEL SYSTEM ................................................................................ 4-1 CLEANING AND INSPECTION ...................................................... 4-2 INSTALLATION .......................................................................... 4-4 CARBURETOR ................................................................................ 4-5 EXPLODED DIAGRAM ................................................................. 4-5 REMOVAL AND DISASSEMBLY ................................................... 4-6 INSPECTION .............................................................................. 4-7 ASSEMBLY ............................................................................... 4-8 INSTALLATION .......................................................................... 4-9 CHAPTER 5 POWER UNIT EXPLODED DIAGRAM ..................................................................... 5-1 PREPARATION FOR OVERHAUL ........................................................ 5-1 REMOVAL ...................................................................................... 5-2 DISASSEMBLY ............................................................................... 5-3 INSPECTION ................................................................................... 5-4 CYLINDER HEAD .................. ; ..................................................... 5-4 CYLINDER BLOCK ...................................................................... 5-5 PISTON ..................................................................................... 5-6 PISTON RING ............................................................................ 5-7 PISTON PIN AND SMALL END BEARING ....................................... 5-8 CRANKSHAFT ........................................................................... 5-8 REED VALVE ............................................................................. 5-8 THERMOSTAT ........................................................................... 5-9 BALL BEARING .......................................................................... 5-9 ASSEMBLY AND ADJUSTMENT ..................................................... 5-10 BEARING, OILSEAL AND O-RING ............................................... 5-10 PISTON ................................................................................... 5-10 SMALL END BEARINGS AND PISTON ASSEMBLY ........................ 5-1 1

CRANK CYLINDER ASSEMBLY ................................................... 5-12 CYLINDER HEAD AND EXHAUST COVER .................................... 5-12 INTAKE MANIFOLD .................................................................. 5-1 3 FUEL SYSTEM AND ELECTRICAL SYSTEM .................................. 5-13 INSTALLATION ............................................................................. 5-1 3 RECOIL STARTER ......................................................................... 5-14 EXPLODED DIAGRAM ............................................................... 5-14 REMOVAL AND DISASSEMBLY ................................................. 5-1 5 INSPECTION ............................................................................ 5-1 6 ASSEMBLY ............................................................................. 5-1 7 INSTALLATION ........................................................................ 5-1 9 CHAPTER 6 LOWER UNIT EXPLODED DIAGRAM ..................................................................... 6-1 REMOVAL ...................................................................................... 6-2 DISASSEMBLY ............................................................................... 6-2 INSPECTION ................................................................................... 6-6 GEAR CASE .............................................................................. 6-6 BEARING HOUSING .................................................................... 6-6 WATER PUMP HOUSING ............................................................ 6-6 IMPELLER .................................................................................. 6-7 OIL-SEAL COVER ....................................................................... 6-7 GEARS ..................................................................................... 6-7 BEARINGS ................................................................................ 6-7 CLUTCH DOG AND COMPONENTS .............................................. 6-7 i DRIVE SHAFT AND PROPELLER SHAFT ........................................ 6-8 ,- DRIVE SHAFT SLEEVE ................................................................ 6-8 SHIFT-PLUNGER, SHIFT-SHAFT, AND BOOT ................................. 6-8 PROPELLER/TRIM TAB/ANODE .................................................... 6-8

ASSEMBLY AND ADJUSTMENT ....................................................... 6-9 SHIMSELECTION ....................................................................... 6-9 BACKLASH ............................................................................. 6-13 ASSEMBLY ............................................................................. 6-16 WATERPUMP INSTALLATION ................................................... 6-19 LOWER UNITLEAKAGECHECK ................................................. 6-20 INSTALLATION ............................................................................. 6-20 K_ooo2o. CHAPTER 7 BRACKET UNIT EXPLODED DIAGRAM ..................................................................... 7-1 REMOVAL ...................................................................................... 7-2 DISASSEMBLY ............................................................................... 7-3 INSPECTION ................................................................................... 7-4 MOUNTING-BOLT ...................................................................... 7-4 RUBBER MOUNTS ...................................................................... 7-4 COLLAR .................................................................................... 7-4 TILT LOCK PLATES .................................................................... 7-4 LEVERS .................................................................................... 7-4 ASSEMBLY .................................................................................... 7-5 INSTALLATION ............................................................................... 7-5 .,oooo. CHAPTER8 ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ............................................................. 8-1 WIRING DIAGRAM .......................................................................... 8-3 REMOTE CONTROLBOX ................................................................. 8-4 REMOVAL ...................................................................................... 8-5 CLEANING, INSPECTION AND REPAIR ............................................... 8-7 SPARK PLUG ............................................................................ 8-7 PULSER COIL ............................................................................ 8-7 CHARGECOIL ........................................................................... 8-7

1990-1997 Yamaha 40HP 2-Stroke Outboard Repair Manual

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