Printed in JapanApril 2004–0.9 × 1 !Printed on recycled paper40D50DOWNER’S MANUAL63B-28199-1CU.S.A.EditionLIT-18626-05-8463B-9-1C Hyoushi 3/29/04 11
General information 5 Meeting If you are meeting another power vesselhead on, and are close enough to run the riskof collision, neither of you has th
General information 6 or trawls are considered to be “fishing ves-sels” under the International Rules. Vesselswith trolling lines are not considered
General information 7 EMU25540 Fueling instructionsWARNING EWM00010 GASOLINE AND ITS VAPORS ARE HIGH-LY FLAMMABLE AND EXPLOSIVE! ● Do not smoke when
General information 8 dry rags. ● Do not overfill the fuel tank. ● Tighten the filler cap securely after re-fueling. ● If you should swallow some gas
General information 9 speed is too high or too low for good engineperformance, this will have an adverse effecton the engine.Yamaha outboard motors a
10 Basic components EMU25795 Main componentsNOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 40D,
Basic components 11 tions. EMU25830 Fuel joint This joint is used to connect the fuel line. EMU25841 Fuel gauge This gauge is located on either the f
Basic components 12 EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral in-terlock trigger up. EMU26211 Neutral thrott
Basic components 13 EMU25990 Engine stop lanyard switch The lock plate must be attached to the en-gine stop switch for the engine to run. Thelanyard
Basic components 14 EMU26141 Power trim and tilt switch on remote control or tiller handle The power trim and tilt system adjusts theoutboard motor a
EMU25060ZMU01690 Read this owner’s manual carefully before operating your outboard motor.63B-9-1C Hyoushi 3/29/04 11:44 PM Page 2
Basic components 15 protect the engine from electrochemicalcorrosion. Never paint the trim tab as it will become ineffective as an anode. EMU26261 Tr
Basic components 16 EMU26470 Tachometer This gauge shows the engine speed and hasthe following functions. EMU26491 Digital tachometer The tachometer
Basic components 17 rious engine damage will occur. EMU26581 Overheat warning indicator (digital type) If the engine temperature rises too high, thew
Basic components 18 engine has been run. It can be set to showthe total number of hours or the number ofhours for the current trip. The display canal
Basic components 19 clogging. EMU26843 Oil level warning and oil filter clogging warning Oil injection models This engine has an oil level warning sy
Basic components 201. Oil filterZMU033661✼✩✦✯✤✰ ✥✣
21 Operation EMU26901 InstallationCAUTION: ECM00110 Incorrect engine height or obstructionsto smooth water flow (such as the designor condition of t
Operation 22 motor greatly affects the water resistance. Ifthe mounting height is too high, cavitationtends to occur, thus reducing the propulsion;an
Operation 23 board (if packed). For details, consultyour Yamaha dealer.WARNING EWM00650 Avoid using bolts, nuts or washers otherthan those contained
Operation 24 cool.4. Third through tenth hours:Avoid operating at full throttle for morethan 5 minutes at a time. Let the enginecool between full-thr
Important manual information EMU25100 To the owner Thank you for choosing a Yamaha outboardmotor. This Owner’s Manual contains infor-mation needed fo
Operation 25CAUTION: ECM00130 Be sure to take the above steps when op-erating the engine after a long period ofstorage. Otherwise engine seizure cou
Operation 26 EMU27311 Filling oil for electric start modelsWARNING EWM00530 Do not add gasoline into the oil tank. Fire or explosion could result. T
Operation 27 EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27350 Electric start models EMU2
Operation 28 2. If there is a fuel joint on the motor, firmlyconnect the fuel line to the joint. Thenfirmly connect the other end of the fuelline to
Operation 29 to a secure place on your clothing, oryour arm or leg while operating. ● Do not attach the lanyard to clothingthat could tear loose. Do
Operation 30 running, overheating and serious dam-age could occur. Stop the engine andcheck whether the cooling water inlet onthe lower case or the c
Operation 31 EMU27820 Stopping engine Before stopping the engine, first let it cool offfor a few minutes at idle or low speed. Stop-ping the engine i
Operation 32 the boat, sea conditions, and running speed.WARNING EWM00740 Excessive trim for the operating condi-tions (either trim up or trim down)
Operation 33 your boat and operating conditions.NOTE: To adjust the trim angle while the boat ismoving, use the power trim and tilt switch lo-cated o
Operation 34 salt corrosion.WARNING EWM00220 Be sure all people are clear of the out-board motor when tilting up and down,also be careful not to pin
Table of contents General information ... 1 Identification numbers record... 1 Outboard motor serial number ...
Operation 35WARNING EWM00260 After tilting the outboard motor, be sureto support it with the tilt support knob ortilt support lever. Otherwise the o
Operation 36 to allow operation in shallow water.WARNING EWM00660 ● Place the gear shift in neutral beforesetting up for shallow water cruising. ● R
37 Maintenance EMU28216 Specifications Dimension: Overall length: 40TR 646 mm (25.4 in)50TR 670 mm (26.4 in) Overall width: 40TR 350 mm (13.8 in)50TR
Maintenance 38 Tightening torque for engine: Spark plug: 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) Propeller nut: 35.0 Nm (25.8 ft-lb) (3.57 kgf-m) EMU28222
Maintenance 39 with a minimum of tools, can perform the fol-lowing procedures.CAUTION: ECM01411 ● Do not place the outboard motor on itsside before
Maintenance 40 when starting or during operation. ● Keep hands, hair, and clothes awayfrom the flywheel and other rotating parts while the engine is
Maintenance 41 equipment, lighted cigarettes, and soon.) ● DO NOT SMOKE when charging or han-dling batteries.KEEP BATTERIES AND ELECTROLYTIC FLUID OU
Maintenance 42 EMU28521 Maintenance chart Frequency of maintenance operations may be adjusted according to the operating condi-tions, but the followi
Maintenance 43NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. Spark plug(s)C
Maintenance 44 EMU28931 Greasing Yamaha marine grease (Water resistant grease) 40D, 50D EMU28951 Cleaning and adjusting spark plugWARNING EWM00560 W
Table of contents and power trim and tilt models)... 30 Stopping engine ... 31 Procedure ...
Maintenance 45 Yamaha dealer. You should periodically re-move and inspect the spark plug becauseheat and deposits will cause the spark plugto slowly
Maintenance 46 Checkpoints ● Fuel system parts leakage ● Fuel line joint leakage ● Fuel line cracks or other damage ● Fuel connector leakage EMU28980
Maintenance 47 4. Reinstall the filter element in the cup.Make sure the O-ring is in position in thecup. Firmly screw the cup onto the filterhousing.
Maintenance 48 EMU29111 Checking wiring and connectors ● Check that each grounding wire is properlysecured. ● Check that each connector is engaged se
Maintenance 49 is abnormal. EMU29171 Checking propellerWARNING EWM00321 You could be seriously injured if the en-gine accidentally starts when you a
Maintenance 50 EMU29193 Removing the propeller 1. Straighten the cotter pin and pull it outusing a pair of pliers.2. Remove the propeller nut, washer
Maintenance 51 gear case.3. Remove the gear oil drain screw.NOTE: If the magnetic gear oil drain screwequipped: remove all metal particles from the s
Maintenance 52 plosion hazard. ● Dispose of old gasoline according to lo- cal regulations. 1. Empty the fuel tank into an approvedcontainer.2. Pour a
Maintenance 53 EMU29320 Checking battery (for electric start models)WARNING EWM00330 Battery electrolytic fluid is dangerous; itcontains sulfuric ac
Maintenance 54 tion in the boat. Install a fully charged bat- tery in the holder.CAUTION: ECM01121 ● Make sure the main switch (on applica-ble model
1 General information EMU25170 Identification numbers record EMU25182 Outboard motor serial number The outboard motor serial number isstamped on the
55 Trouble Recovery EMU29422 Troubleshooting A problem in the fuel, compression, or igni-tion systems can cause poor starting, loss ofpower, or other
Trouble Recovery 56 Q. Is fuel system obstructed?A. Check for pinched or kinked fuel line orother obstructions in fuel system.Q. Is fuel contaminated
Trouble Recovery 57 A. Have serviced by a Yamaha dealer.Q. Is load on boat improperly distributed?A. Distribute load to place boat on an evenplane.Q.
Trouble Recovery 58 Q. Is heat range of spark plug incorrect?A. Inspect spark plug and replace it with rec-ommended type.Q. Is high pressure fuel pum
Trouble Recovery 59NOTE: Consult your Yamaha dealer if the new fuse immediately blows again. EMU29520 Power trim and tilt will not operate If the eng
Trouble Recovery 60 starter mechanism or top cowling afterthe engine is running. ● Do not touch the ignition coil, sparkplug wire, spark plug cap, or
Trouble Recovery 61NOTE: When the engine does not start with this pro- cedure, see page 61. EMU29670 Engine fails to operate EMU29704 Cold engine fai
Trouble Recovery 62 6. Turn the main switch to “” (start).CAUTION: ECM00191 ● Never turn the main switch to “”(start) while the engine is running. ●
Trouble Recovery 63 3. Drain the fuel from the carburetor, fuelfilter, and fuel line.4. Feed fogging oil or engine oil throughthe carburetor(s) and s
64 Consumer information EMU29811 Important warranty information for U.S.A. and Canada✼✩✦✯✤✰ ✩✧
General information 2 EMU25262 Manufactured date label This label is attached to the clamp bracket orthe swivel bracket. EMU25361 Safety information
Consumer information 65✼✩✦✯✤✰ ✩
Consumer information 66 EMU29820 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY✼✩✦✯✤✰ ✩✩
Consumer information 67✼✩✦✯✤✰ ✩✪
Consumer information 68✼✩✦✯✤✰ ✩✫
Consumer information 69 EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA✼✩✦✯✤✰ ✩✬
Printed in JapanApril 2004–0.9 × 1 !Printed on recycled paper40D50DOWNER’S MANUAL63B-28199-1CU.S.A.EditionLIT-18626-05-8463B-9-1C Hyoushi 3/29/04 11
YAMAHA MOTOR CO., LTD.MADE IN JAPANPAYS D'ORIGINE JAPONOUTBOARD MOTOR WARRANTY REGISTRATIONENREGISTREMENT DE LA GARANTIE DU MOTEUR HORS-BORDPleas
PLACEPOSTAGEHEREATTN: WARRANTY DEPARTMENTWarranty card 2/27/02 11:47 AM Page 2
General information 3 er operation before starting the engine. ● Attach the engine stop switch lanyard cordto a secure place on your clothing, or you
General information 4 cies. You should be aware of these rules,and follow them whenever you encounteranother vessel on the water.Several sets of rule
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