YAMAHA OUTBOARD 40VEO Service Repair Manual

LIT-18616-01-81 290320 SERVICE MANUAL 40V, 50H WORLD WIDE 40W, 50W USA/CANADA

E A20000-0 NOTICE This manual has been prepared by the Yamaha Motor Company 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 under- standing of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use. Because the Yamaha Motor Company Ltd. has a policy of continuously improving its prod- ucts, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. A10001-0* 40V/50H SERVICE MANUAL 1997 Yamaha Motor Corporation, USA 1st Edition, August 1997 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 U.S.A. LIT-18616-01-81

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 40VMH 40VMHD 40VMHO 40VMO 40VWH 40VE 40VEO 40VEHTO 40VET USA and CANADA name C40MH 40MH C40ER 40ER P40TH C40TR Indication 40VMH 40VMHD 40VMHO 40VMO 40VWH 40VE 40VEO 40VEHTO 40VET Model name 40VETO 50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO 50HET 50HETO USA and CANADA name 40TR 50ER C50TR 50TR Indication 40VETO 50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO 50HET 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 in specifications 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 40VMH 40VMHD 40VMHO 40VMO 40VWH 40VE 40VEO 40VEHTO 40VET Starting system Manual Manual Manual Manual Manual & Electric Electric Electric Electric Electric Control system Tiller Tiller Tiller Remote Tiller Remote Remote Tiller Remote Trim/Tilt system Manual tilt Hydro tilt Manual tilt Manual tilt Hydro tilt Manual tilt Manual tilt PTT PTT Lubrication system Pre-Mixed Pre-Mixed Oil injection Oil injection Pre-Mixed Pre-Mixed Oil injection Oil injection Pre-Mixed Warning indicator lamp 1 1 1 1 1 1 3 — — Enrichment system Choke Choke Choke Choke Prime Start Prime Start Prime Start Prime Start Prime Start Model name 40VETO 50HMHO 50HMHD 50HMO 50HMDO 50HWHD 50HEDO 50HET 50HETO Starting system Electric Manual Manual Manual Manual Manual & Electric Electric Electric Electric Control system Remote Tiller Tiller Remote Remote Tiller Remote Remote Remote Trim/Tilt system PTT Manual tilt Hydro tilt Manual tilt Hydro tilt Hydro tilt Hydro tilt PTT PTT Lubrication system Oil injection Oil injection Pre-Mixed Oil injection Oil injection Pre-Mixed Oil injection Oil injection Oil injection Warning indicator lamp 3 1 1 1 1 1 3 — — Enrichment system Prime Start Choke Choke Choke Choke Prime Start Prime Start 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 No. 3 Transom height 4 Serial number STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model Approved model code Starting serial No. Model Approved model code Starting serial No. World- wide USA, CANADA World- wide USA, CANADA 40VMH C40MH 6H4 S: 010262 ~ 50HMHO — 6H5 S: 190662 ~ L: 310801 ~ 50HMHD — L: 310380 ~ 40VMHD — L: 560290 ~ 50HMO — S: 260189 ~ 40VMHO 40MH S: 191877 ~ 50HMDO — L: 560258 ~ L: 491566 ~ 50HWHD — L: 850194 ~ 40VMO — S: 290284 ~ 50HEDO 50ER S: 090431 ~ L: 860312 ~ L: 521079 ~ 40VWH — L: 510116 ~ 50HET C50TR L: 900101 ~ 40VE C40ER S: 060285 ~ 50HETO 50TR S: 210142 ~ L: 360173 ~ L: 444058 ~ 40VEO 40ER S: 110760 ~ X: 750216 ~ L: 842362 ~ X: 740146 ~ 40VEHTO P40TH L: 430386 ~ 40VET C40TR L: 921505 ~ 40VETO 40TR S: 880367 ~ L: 544974 ~ X: 900196 ~

YAMAHA OUTBOARD 40VEO Service Repair Manual

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