Yamaha Outboard 40C 50C 40TLRD 50TLRD* Factory Service / Repair/ Workshop Manual !

40C 50C SERVICE MANUAL 63B-28197-1F-11 LIT-18616-02-65 *LIT186160265*

E NOTICE This manual has been prepared by Yamaha 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 Yamaha 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 succes- sive editions of this manual. 40C, 50C SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, July 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-65

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been complied to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. In this revised format, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol, e.g., ● Bearings Pitting/Damage → Replace. To assist you to find your way about this manual, the Section Title and Major Heading is given at the head of every page. An Index to contents is provided on the first page of each Section. MODEL INDICATION Multiple models are shown in this manual. These indications are noted as follows. THE ILLUSTRATIONS Some illustrations in this manual may differ from the model you have. This is because a procedure described may relate to several models, though only one may be illustrated. (The name of model described will be mentioned in the description). REFERENCES These have been kept to a minimum; however, when you are referred to another section of the manual, you are told the page number to go to. Model name 40VETO 50HETO USA and CANADA name 40TR 50TR Indication 40VETO 50HETO

E WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish important information in this manual in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. SPECIFICATIONS These are given in bold type at each procedure. It is not necessary to leave the section deal- ing with the procedure in order to look up the specifications. It is important to note the differences ispecifications of models. When a procedure relates to more than one model, the main differences in specifications will be shown in a following table. Model name 40VETO 50HETO Starting system Electric Electric Control system Remote Remote Trim/Tilt system PTT PTT Lubrication system Oil injection Oil injection Warning indicator lamp 3 — Enrichment system Prime Start Prime Start

E HOW TO READ DESCRIPTIONS 1. A disassembly installation job mainly consists of the exploded diagram 1. 2. The numerical figures represented by the number 2 indicates the order of the job steps. 3. The symbols represented by the number 3 indicates the contents and notes of the job. For the meanings of the symbols, refer to the next page(s). 4. The REMOVAL AND INSTALLATION CHART 4 is attached to the exploded diagram and explains the job steps, part names, notes for the jobs, etc. 5. The SERVICE POINTS, other than the exploded diagram, explains in detail the items diffi- cult to explain in the exploded diagram or REMOVAL AND INSTALLATION CHART, the Service points requiring the detailed description 5 , etc.

E A50001-1-4 SYMBOLS Symbols 1 to 9 are designed as thumb- tabs to indicate the content of a chapter. 1 General Information 2 Specifications 3 Periodic Inspection and Adjustment 4 Fuel System 5 Power Unit 6 Lower Unit 7 Bracket Unit 8 Electrical System 9 Trouble-analysis Symbols 0 to F indicate specific data: 0 Special tool A Specified liquid B Specified grease C Specified engine speed D Specified torque E Specified measurement F Specified electrical value [Resistance (Ω), Voltage (V), Electric current (A)] Symbol G to J in an exploded diagram indicate grade of lubricant and location of lubrication point: G Apply Yamaha 2-stroke outboard motor oil H Apply Yamaha gear-case lubricant I Apply molybdenum disulfide oil J Apply water resistant grease (Yamaha grease A, Yamaha marine grease) Symbols K to N in an exploded diagram indicate grade of sealing or locking agent, and location of application point: K Apply Gasket maker ® L Apply LOCTITE ® No. 271 (Red LOCTITE) M Apply LOCTITE ® No. 242 (Blue LOCTITE) N Apply LOCTITE ® No. 572 NOTE: In this manual, the above symbols may not be used in every case. 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT – + ELEC TRBL ANLS T R . . E G M A GM 271 LT 242 LT 572 LT

E INDEX GENERAL INFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWER BRACKET UNIT 7 BRKT ELECTRICAL SYSTEM 8 ELEC TROUBLE-ANALYSIS 9 GEN INFO INSP ADJ – + TRBL ANLS A30000-0

E 1 2 3 4 5 6 7 8 9 GEN INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION............................................................................................. 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION .................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS ................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-6 REMOVAL AND INSTALLATION ............................................................ 1-8

1-1 GEN INFO E IDENTIFICATION A60000-1* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. 1 Model name 2 Approved model code 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model Approved model code Starting serial No. 40TR 6H4 L: 1005165 ~ 50TR 6H5 L: 1004305 ~

1-2 GEN INFO E SAFETY WHILE WORKING SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling, and keep it away from heat, sparks, and open flames. VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using com- pressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appro- priate to the work you are doing. OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

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Yamaha Outboard 40C 50C 40TLRD 50TLRD* Factory Service / Repair/ Workshop Manual !

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