Yamaha F40A 2018 Manuals

Manuals and User Guides for Yamaha F40A 2018. We have 1 Yamaha F40A 2018 manual available for free PDF download: Service Manual

Yamaha F40A 2018 Service Manual

Yamaha F40A 2018 Service Manual (348 pages)

6BT, 6BG

Brand: Yamaha | Category: Outboard Motor | Size: 12.38 MB

Table of Contents

Table of Contents

3
- General Information
  4
- Model Information
  5
- Applicable Model
  5
- Model Name Designation
  5
- General Feature
  7
- Propeller
  8
- Self-Protection
  8
- Ventilation
  8
- Handling of Gasoline
  8
- Electric Shock
  8
- Hot Parts
  8
- Rotating Parts
  8
- Important Safety and Service Information
  8
- Lifting Outboard Motors
  9
- Handling of Gas Torch
  9
- Parts, Lubricants, and Sealants
  9
- Handling of Lubricants and Sealants
  9
- Special Service Tools
  10
- Tightening Torque
  10
- Non-Reusable Parts
  10
- Disassembly and Assembly
  10
- Disposal of Used Components and Chemicals
  10
- Manual Format
  11
- How to Use this Manual
  11
- Conditions When Testing and Adjusting
  12
- Abbreviation
  12
- Color Code
  12
- Specified Tightening Torque
  13
- General Tightening Torque
  13
- Symbol
  14
- Lubricant, Sealant, and Thread Locking Agent
  14
- Special Service Tool
  16
- Specification
  22
Technical Feature and Description

32
- Electronic Control System
  33
- Electrical Components
  35
- Fail-Safe
  37
- Engine ECM
  39
- Intake Silencer
  39
- Fuel Diagram
  40
- Fuel System
  40
- Lubrication Diagram
  42
- Lubrication System
  42
- Cooling Diagram
  44
- Cooling System
  44
- Intake and Exhaust Diagram
  46
- Intake and Exhaust System
  46
- Fuel Hose
  47
- Hose Routing
  47
- Vapor Gas Hose and Blowby Hose
  48
- Cooling Water Hose
  49
Rigging Information

50
Troubleshooting

63
Electrical System

77
- Electrical Component and Wire Harness Routing
  79
- Port
  79
- Starboard
  81
- Front
  83
- Rear
  84
- Top
  85
- Bottom Cowling (Tiller Handle Model)
  86
- Bottom Cowling (Remote Control Model)
  87
- Tiller Handle (Tiller Handle Model)
  89
- ECM Circuit Diagram
  91
- ECM Coupler Layout
  93
- Checking the Electrical Component
  94
- Measuring the Peak Voltage
  94
- Using the YDIS
  94
- Checking the Main Relay
  95
- Engine Control Unit and Component
  95
- Using the Digital Tester
  95
- Checking the Engine ECM Circuit
  96
- Checking the TPS
  97
- Checking the ISC Valve
  98
- Checking the Oil Pressure Switch
  98
- Checking the Alert Indicator (Tiller Handle Model)
  99
- Checking the Alert Buzzer
  100
- Checking the Trolling Switch (Tiller Handle Model)
  100
- Checking the Water Detection Switch
  100
- Fuel Control Unit and Component
  100
- Checking the Fuel Injector
  101
- Checking the High-Pressure Fuel Pump
  102
- Checking the Vapor Shut-Off Valve
  103
- Charging Unit and Component
  104
- Checking the Lighting Coil (Stator Assembly)
  104
- Checking the Rectifier/Regulator
  105
- Checking the Ignition Spark
  106
- Ignition Unit and Component
  106
- Checking the Engine ECM
  107
- Checking the Ignition Coil
  107
- Checking the Pulser Coil
  108
- Checking the Spark Plug Cap
  108
- Checking the Intake Air Pressure Sensor
  109
- Checking the Intake Air Temperature Sensor
  109
- Checking the Shift Position Switch
  110
- Checking the Thermo Sensor
  110
- Checking the Engine Shut-Off Switch
  111
- Checking the Starter Relay
  112
- Starting Unit and Component
  112
- Checking the Engine Start Switch
  113
- Starter Motor
  114
- Checking the Starter Motor Pinion
  115
- Disassembling the Starter Motor
  115
- Removing the Starter Motor
  115
- Checking the Armature (Starter Motor)
  116
- Checking the Brush Holder
  116
- Assembling the Starter Motor
  117
- Installing the Starter Motor
  119
- 6Y8 Multifunction Meters Sensor
  120
- Checking the Water Pressure Sensor
  120
- Checking the Speed Sensor
  121
- Checking the PTT Relay
  122
- PTT System
  122
- Checking the PTT Switch (on Bottom Cowling)
  123
- Checking the PTT Switch (Tiller Handle Model)
  124
- Checking the Trim Sensor
  124
Fuel System

126
- Disconnecting the Quick Connector
  128
- Measuring the Fuel Pressure
  128
- Reducing the Fuel Pressure
  128
- Checking the Pressure Regulator
  130
- Fuel Filter
  131
- Checking the Fuel Cup Assembly
  132
- Checking the Fuel Filter Assembly
  132
- Checking the Fuel Filter Element
  132
- Removing the Fuel Filter Assembly
  132
- Assembling the Fuel Filter Assembly
  133
- Checking the Fuel Joint
  133
- Checking the Primer Pump
  133
- Installing the Fuel Filter Assembly
  134
- Fuel Pump Assembly
  135
- Checking the Fuel Pump Assembly
  136
- Disassembling the Fuel Pump
  136
- Assembling the Fuel Pump
  137
- Checking the Diaphragm and Valve
  137
- Installing the Fuel Pump Assembly
  138
- Intake Silencer, Intake Manifold and Throttle Body
  139
- Checking the Intake Manifold
  140
- Checking the Throttle Body
  140
- Checking the Vapor Shut-Off Valve
  140
- Installing the Intake Manifold
  140
- Throttle Link Rod
  141
- Adjusting the Throttle Link Rod
  142
- Installing the Throttle Link
  142
- Vapor Separator
  144
- Draining the Fuel
  145
- Installing the Vapor Separator
  145
- Removing the Vapor Separator
  145
- Fuel Cooler
  147
- Vapor Separator and High-Pressure Fuel Pump
  148
- Adjusting the Float Height
  149
- Checking the Fuel Strainer
  149
- Checking the Vapor Separator
  149
- Assembling the Vapor Separator
  150
- Fuel Injector
  152
- Checking the Fuel Rail and Fuel Injector
  153
- Installing the Fuel Injector
  153
- Removing the Fuel Injector
  153
Power Unit

154
- Checking the Compression Pressure
  156
- Checking the Oil Pressure
  156
- Power Unit (Check and Adjustment)
  156
- Adjusting the Pulser Coil Air Gap
  157
- Checking the Pulser Coil Air Gap
  157
- Checking the Valve Clearance
  157
- Adjusting the Valve Clearance
  160
- Power Unit Assembly
  161
- Removing the Power Unit
  162
- Installing the Power Unit
  164
- Flywheel Magneto and Timing Belt
  168
- Removing the Flywheel Magneto
  169
- Checking the Timing Belt and Sprocket
  170
- Removing the Timing Belt and Sprocket
  170
- Installing the Sprocket and Timing Belt
  171
- Installing the Stator Assembly
  172
- Installing the Flywheel Magneto
  173
- Engine ECM, Rectifier/Regulator, and Ignition Coil
  174
- Installing the Wire Harness
  176
- Wire Harness
  176
- Installing the Starter Motor
  180
- Starter Motor
  180
- Cylinder Head
  182
- Removing the Cylinder Head
  182
- Checking the Cylinder Head Bolt
  183
- Installing the Cylinder Head
  183
- Camshaft and Valve
  185
- Disassembling the Cylinder Head
  186
- Checking the Cylinder Head
  187
- Checking the Valve
  188
- Checking the Valve Spring
  188
- Checking the Valve Guide
  189
- Replacing the Valve Guide
  189
- Checking the Valve Seat
  191
- Refacing the Valve Seat
  191
- Checking the Rocker Arm and Rocker Arm Shaft
  194
- Checking the Camshaft
  195
- Checking the Spark Plug
  195
- Assembling the Cylinder Head
  196
- Checking the Cylinder Head Anode
  196
- Exhaust Cover
  199
- Removing the Exhaust Cover
  200
- Removing the Oil Filter
  200
- Checking the Exhaust Cover Anode
  201
- Checking the Thermostat
  201
- Installing the Oil Filter
  201
- Installing the Exhaust Cover
  202
- Installing the Thermo Sensor
  202
- Cylinder Block
  204
- Disassembling the Cylinder Block
  205
- Checking the Cylinder Bore
  206
- Checking the Piston Diameter
  206
- Checking the Piston Clearance
  207
- Checking the Piston Ring
  207
- Checking the Piston Ring End Gap
  207
- Checking the Piston Ring Groove
  208
- Checking the Piston Ring Side Clearance
  208
- Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
  209
- Checking the Piston Pin Boss Inside Diameter
  209
- Checking the Piston Pin Diameter
  209
- Checking the Connecting Rod Big End Side Clearance
  210
- Checking the Crankshaft
  210
- Checking the Big End Oil Clearance
  211
- Selecting the Crankshaft Pin Bearing
  212
- Checking the Journal Oil Clearance
  213
- Selecting the Crankshaft Journal Bearing
  214
- Assembling the Cylinder Block
  215
Lower Unit

219
- Lower Unit
  221
- Checking the Lower Unit Anode
  222
- Checking the Propeller
  222
- Removing the Lower Unit
  222
- Water Pump
  223
- Checking the Water Pump
  224
- Disassembling the Propeller Shaft Assembly
  226
- Disassembling the Propeller Shaft Housing Assembly
  226
- Propeller Shaft Housing
  226
- Removing the Propeller Shaft Housing Assembly
  226
- Assembling the Propeller Shaft Assembly
  228
- Checking the Dog Clutch
  228
- Checking the Propeller Shaft
  228
- Checking the Propeller Shaft Housing
  228
- Checking the Reverse Gear
  228
- Assembling the Propeller Shaft Housing Assembly
  229
- Disassembling the Drive Shaft Assembly
  232
- Disassembling the Forward Gear
  232
- Drive Shaft and Lower Case
  232
- Removing the Drive Shaft
  232
- Disassembling the Lower Case
  233
- Checking the Drive Shaft
  234
- Checking the Forward Gear
  234
- Checking the Lower Case
  234
- Checking the Pinion
  234
- Checking the Shift Rod
  234
- Assembling the Forward Gear
  235
- Assembling the Lower Case
  235
- Assembling the Drive Shaft
  238
- Assembling the Oil Seal Housing
  238
- Installing the Shift Rod, Drive Shaft, and Oil Seal Housing
  239
- Installing the Propeller Shaft Housing Assembly
  240
- Installing the Water Pump
  240
- Checking the Lower Unit for Air Leakage
  241
- Installing the Lower Unit
  242
- Lower Unit
  242
- Shimming
  244
- Shimming Workflow
  244
- Shimming Check Sheet
  245
- Measuring the Forward Gear Backlash and Reverse Gear Backlash before Disassembly
  247
- Shim Location
  251
- Shimming Procedure
  251
- Selecting the Pinion Shim (T3)
  252
- Measuring the Forward Gear Backlash
  254
- Adjusting the Forward Gear Shim Thickness (T1)
  255
- Adjusting the Reverse Gear Shim Thickness (T2)
  256
- Measuring the Reverse Gear Backlash
  256
Bracket Unit

259
- Friction Plate (Tiller Handle Model)
  262
- Installing the Friction Plate
  262
- Assembling the Tiller Handle
  265
- Tiller Handle (Tiller Handle Model)
  265
- Assembling the Electrical Component
  269
- Electrical Component (Tiller Handle)
  269
- Shift Rod and Shift Bracket
  270
- Bottom Cowling
  271
- Installing the Upper Case
  274
- Removing the Upper Case
  274
- Upper Case Assembly and Mount
  274
- Upper Case
  275
- Assembling the Upper Case
  276
- Checking the Drive Shaft Bushing
  276
- Disassembling the Upper Case
  276
- Assembling the Oil Pan and Exhaust Guide
  279
- Checking the Exhaust Guide Anode
  279
- Checking the Oil Pan and Exhaust Guide
  279
- Checking the Oil Strainer
  279
- Oil Pan and Exhaust Guide
  279
- Steering Arm
  281
- Installing the Steering Arm
  282
- Removing the Steering Arm
  282
- Hydro Tilt
  284
- Checking the Hydro Tilt
  285
- Checking the Hydro Tilt Anode
  285
- Installing the Hydro Tilt Assembly
  285
- Removing the Hydro Tilt Assembly
  285
- PTT Unit
  286
- Bleeding the PTT Unit
  287
- Removing the PTT Unit
  287
- Installing the PTT Unit
  288
- Adjusting the Trim Sensor Cam
  291
- Checking the Clamp Bracket Anode
  291
- Clamp Bracket and Swivel Bracket
  291
- Installing the Clamp Bracket
  291
- PTT Motor
  293
- Checking the Armature (PTT Motor)
  294
- Disassembling the PTT Motor
  294
- Removing the PTT Motor
  294
- Checking the Brush
  295
- Assembling the PTT Motor
  296
- Installing the PTT Motor
  297
- PTT Gear Pump
  298
- Checking the Filter
  300
- Checking the Gear Pump
  300
- Checking the Gear Pump Housing
  300
- Checking the Valve Seal
  300
- PTT Cylinder
  301
- Checking the PTT Cylinder and Piston
  302
- Removing the Trim and Tilt Ram Assembly
  302
- Assembling the Trim and Tilt Ram Assembly
  303
- Checking the Absorber Valve
  303
- Installing the Trim and Tilt Ram Assembly
  303
Maintenance

305
- Maintenance Interval Chart 1
  306
- Outline
  306
- Maintenance Interval Chart 2
  308
- Predelivery Check
  309
- Checking the Battery
  312
- Checking the Engine Oil Level
  312
- Checking the Cooling Water Pilot Hole
  313
- Checking the Gear Oil Level
  313
- Checking the Hydro Tilt Unit
  314
- Checking the Outboard Motor Mounting Height
  314
- Checking the Power Trim and Tilt Unit
  314
- General Periodic Maintenance
  316
- Changing the Engine Oil Using an Oil Changer
  319
- Checking the Cooling Water Inlet
  319
- Checking the Engine Idle Speed/Noise
  319
- Changing the Engine Oil by Removing the Drain Bolt
  320
- Replacing the Oil Filter
  322
- Changing the Gear Oil
  323
- Checking the Gear Oil Level
  324
- Greasing Points
  324
- Checking the PTT Fluid Level
  325
- Greasing the Clamp Bracket Bolt (through Tube)
  325
- Checking the Cowling Lock Lever
  326
- Specification
  328
- Charging Unit, Starting Unit, and PTT Unit
  341
- Engine Control Unit, Fuel Unit, and Ignition Unit
  341
- How to Use the Wiring Diagram
  341
- Wiring Diagram
  341
- Control Unit
  345
- Pinion Shim (T3) Selection Table
  346
- Shim Selection Table and Chart
  346
- Forward Gear Shim (T1) Selection Chart
  347
- Reverse Gear Shim (T2) Selection Chart
  347

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