2012 Yamaha F40 HP outboard service repair manual

2009 OUTBOARD SERVICE MANUAL Model : F40JEA, F40JEA-(6BG1), F40JEA-(6BG2), F40JEHA, F40JEHA-(6BG1), F40JEHA-(6BG2), F40LA, F40LA-(6BG1), F40LA-(6BG2), F40LEHA, F40LEHA-(6BG1), F40LEHA-(6BG2) 6BG281972L11 *6BG281972L11*

Preface 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 the Bronze Technical Certificate of YTA (Yamaha Technical Academy) marine or the equivalent 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 successive editions of this manual. Also, up-to-date parts information is available on YPEC-web. Additional information and up- to-date information on Yamaha products and services are available on Yamaha Service Portal. Important information Particularly important information is distinguished in this manual by the following notations: The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury. A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property. TIP: A TIP provides key information to make procedures easier or clearer. F40H SERVICE MANUAL ©2010 by Yamaha Motor Co., Ltd. 2 nd Edition, December 2010 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Canada

Contents General information 0 Specification 1 Technical features and description 2 Rigging information 3 Troubleshooting 4 Electrical system 5 Fuel system 6 Power unit 7 Lower unit 8 Bracket unit 9 Maintenance 10 Index Appendix A GEN INFO SPEC TECH FEA RIG GING TRBL SHTG ELEC FUEL POWR LOWR BRKT MNT

GEN INFO 0 1 2 3 4 5 6 7 8 9 10 A General information 0 Safety while working ........................................................... 0-1 Rotating part .............................................................................. 0-1 Hot part ...................................................................................... 0-1 Electric shock ............................................................................ 0-1 Propeller .................................................................................... 0-1 Handling of gasoline .................................................................. 0-1 Ventilation .................................................................................. 0-1 Self-protection ........................................................................... 0-2 Working with crane .................................................................... 0-2 Handling of burner ..................................................................... 0-2 Part, lubricant, and sealant ........................................................ 0-2 Handling of sealant .................................................................... 0-2 Special service tool ................................................................... 0-3 Tightening torque ...................................................................... 0-3 Non-reusable part ...................................................................... 0-3 Disassembly and assembly ....................................................... 0-3 How to use this manual ........................................................... 0-4 Manual format ........................................................................... 0-4 Abbreviation .............................................................................. 0-5 Sealant and locking agent ...................................................... 0-6 Symbol ...................................................................................... 0-6 Special service tool .................................................................. 0-7

0-1 GEN INFO General information Safety while working To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Rotating part • Hands, feet, hair, jewelry, clothing, Personal flotation device straps, and so on can become entangled with internal rotating parts of the engine, resulting in serious injury or death. • Keep the top cowling in place whenever possible. Do not remove or replace the cowling with the engine running. • Only operate the engine with the cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, Personal flotation device straps, and so on away from any exposed moving parts. Hot part During and after operation, engine parts are hot enough to cause burns. Avoid touching any parts under the top cowling until the engine has cooled. Electric shock Do not touch any electrical parts while starting or operating the engine. They can cause shock or electrocution. Propeller Do not hold the propeller with your hands when loosening or tightening it. Handling of gasoline • Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. • Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you happen to swallow some gasoline or inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes. Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. • When test running an engine indoors (example: in a water tank), make sure to do so where adequate ventilation can be main- tained.

0-2 Safety while working 0 1 2 3 4 5 6 7 8 9 10 A Self-protection • Protect your eyes by wearing safety glasses or safety goggles during all opera- tions involving drilling and grinding, or when using an air compressor. • Protect your hands and feet by wearing protective gloves and safety shoes when necessary. Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane. • Use a wire rope of adequate strength, and lift up the outboard motor with the three point suspension. • If the outboard motor does not have three or more points to be suspended, support it with additional ropes or the like so that the outboard motor can be lifted and carried in a stable manner. Handling of burner • Incorrect handling of burner may result in burns. Refer to the operation manual issued by the manufacturer to assure the correct handling. • When using a burner, keep it away from the gasoline and oil, to prevent a fire. • Components become hot enough to cause burns. Do not touch them directly. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor. Handling of sealant • Wear protective gloves to protect your skin, when using the sealants. • Refer to the material data sheet issued by the manufacturer. Some of the sealants may be harmful for human health.

0-3 GEN INFO General information Special service tool Use the recommended special service tools to work safety, and to protect parts from dam- age. Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts. Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly. • Apply engine oil to the contact surfaces of moving parts before assembly. • Install bearings with the manufacture identi- fication mark in the direction indicated in the installation procedure. In addition, be sure to lubricate the bearings liberally. • Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. • Check that moving parts operate normally after assembly.

0-4 0 1 2 3 4 5 6 7 8 9 10 A How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. • Parts are shown and detailed in an exploded diagram and are listed in the component list (see a in the figure below for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see b in the figure below). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point (see c in the figure below). • Tightening torque specifications are provided in the exploded diagrams (see d in the figure below for an example), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees. • Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see e in the figure below for an example page). TIP: For troubleshooting procedures, see Chapter 4, “Troubleshooting.” 8-1 LOWR Lower unit Lower unit No. Part name Q’ty Remarks 1 Drain screw 1 2 Gasket 2 Not reusable 3 Bolt 4 M10 x 40 mm 4 Check screw 1 5 Dowel 2 6 Hose nipple 1 7 Plastic tie 2 Not reusable 8 Hose 1 9 Nipple 1 10 Bolt 1 M8 x 35 mm 11 Lower unit 1 12 Anode 1 13 Propeller nut 1 14 Cotter pin 1 Not reusable 15 Washer 1 16 Washer 1 17 Propeller 1 12 18 19 20 21 3 3 11 1 3 3 4 6 5 2 7 8 9 7 5 10 2 17 16 15 14 13 9 N·m (0.9 kgf·m, 6.6 ft·lb) 40 N·m (4.0 kgf·m, 29.5 ft·lb) 35 N·m (3.5 kgf·m, 25.8 ft·lb) 9 N·m (0.9 kgf·m, 6.6 ft·lb) 8-16 Drive shaft and lower case 0 1 2 3 4 5 6 7 8 9 10 A TIP: • Install a new needle bearing with the identi- fication mark b facing toward the water pump side. When using the driver rod, do not strike the special service tool in a manner that will force the stopper c out of place. 5. Heat the installation area of the taper roller bearing outer race in the lower case with a gas torch, and then install the drive shaft sleeve i, original shim(s) (T3) j and a new taper roller bearing outer race k. NOTICE: When heating the lower case, heat the entire installation area evenly. Otherwise, the paint on the lower case could be burned. TIP: Install the drive shaft sleeve with the protru- sion d facing forward. Do not reuse a shim if deformed or scratched. 6. While holding the special service tool c, strike the tool to check that the taper roller bearing outer race is installed properly. If a high-pitched metallic sound is produced when the special service tool is struck, the outer race is installed properly. 7. Install the water inlet covers m, n, the nut o and the water inlet cover screw p, and then tighten the water inlet cover screw p to the specified torque. Assembling the forward gear 1. Install a new taper roller bearing a. Driver rod SL f: 90890-06602 Needle bearing attachment g: 90890-06614 Bearing depth plate h: 90890-06603 Installation depth a: 182.5–183.0 mm (7.19–7.20 in) a b c f f g h g e i j k d Driver rod LL c: 90890-06605 Bearing outer race attachment l: 90890-06627 Water inlet cover screw p: 1 N·m (0.1 kgf·m, 0.7 ft·lb) c l c l m n o p e b c d a Safety while working / How to use this manual

0-5 GEN INFO General information Abbreviation The following abbreviations are used in this service manual. Abbreviation Description ABYC American Boat and Yacht Council API American Petroleum Institute ATDC After Top Dead Center BTDC Before Top Dead Center CARB California Air Resources Board CCA Cold Cranking Ampere C/E Check Engine ECM Electronic Control Module EPA Environmental Protection Agency EX Exhaust F Forward IC Integrated Circuit IN Intake ISC Idle Speed Control MCA Marine Cranking Ampere N Neutral P.O.N. Pump Octane Number = (RON+Motor Octane Number) / 2 PORT Port side PTT Power Trim and Tilt R Reverse RC Reserve Capacity SAE Society of Automotive Engineers SOHC Single Overhead Camshaft STBD Starboard side TDC Top Dead Center TPS Throttle Position Sensor W/F Water in Fuel http://ReadManuals.com

0-6 0 1 2 3 4 5 6 7 8 9 10 A Sealant and locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points. Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points. Symbol Name Application Yamaha 4-stroke motor oil Lubricant Gear oil Lubricant Water resistant grease (Yamaha grease A) Lubricant Molybdenum disulfide grease Lubricant Corrosion resistant grease (Yamaha grease D) Lubricant Low temperature resistant grease (Yamaha grease C) Lubricant Symbol Name Application Gasket Maker Sealant ThreeBond 1104J Sealant ThreeBond 1322 Sealant ThreeBond 1377B Thread locking agent ThreeBond 1401 Thread locking agent LOCTITE 271 (red) Thread locking agent LOCTITE 242 (blue) Thread locking agent How to use this manual / Sealant and locking agent http://ReadManuals.com

2012 Yamaha F40 HP outboard service repair manual

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