Yamaha 40V Service Manual

LIT-18616-01-81 290320 SERVICEMANUAL40V, 50HWORLD WIDE40W, 50WUSA/CANADA

1-1GENINFO E IDENTIFICATION A60000-1* IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor isstamped on a plate attached to the port

5-25POWRECRANKCASE AND CYLINDER BODYCRANKCASE AND CYLINDER BODYEXPLODED DIAGRAM

5-26POWRECRANKCASE AND CYLINDER BODYREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANK CASE AND CYLINDER BODY REMOVALFoll

5-27POWRECRANKCASE AND CYLINDER BODYEXPLODED DIAGRAM

5-28POWRECRANKCASE AND CYLINDER BODYREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsD Hose nipple 1E Hose joint 3F Check val

5-29POWRECRANKCASE AND CYLINDER BODYSERVICE POINTSCylinder body inspection1. Inspect:● Water jacketMaterial deposit/Corrosion → Clean. ● Cylinder inne

5-30POWRECRANKCASE AND CYLINDER BODYPiston to cylinder clearance1. Calculate:● Piston clearanceOut of specification → Replace pistonand piston ring an

5-31POWRECRANK SHAFT AND PISTONCRANK SHAFT AND PISTONEXPLODED DIAGRAM

5-32POWRECRANK SHAFT AND PISTONREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCRANK SHAFT AND PISTON REMOVALFollow the left

5-33POWRECRANK SHAFT AND PISTONSERVICE POINTSPiston pin clip removal1. Remove:● Piston pin clipNOTE:Take care not to damage piston pin holeedge.Piston

5-34POWRECRANK SHAFT AND PISTONMeasuring point “H”Piston diameterStandard10 mm (0.4 in)66.940 ~ 67.000 mm(2.6354 ~ 2.6378 in)Over size piston diameter

1-2GENINFO E SAFETY WHILE WORKINGSAFETY WHILE WORKING The procedures given in this manual arethose recommended by Yamaha to be fol-lowed by Yamaha de

5-35POWRECRANK SHAFT AND PISTONPiston ring inspection1. Inspect:● Piston ringBreakage/Damage → Replace.2. Measure:● End gapUse a feeler gauge.Out of s

5-36POWRECRANK SHAFT AND PISTONCrankshaft inspection1. Measure:● Crank width A ● Crank width BOut of specification → Replace. 2. Measure:● RunoutUse a

5-37POWR E CRANK SHAFT AND PISTON Piston and piston ring installation 1. Install: ● Piston ring (2nd) ● Piston ring (top)CAUTION: ● Take care not to

E 1 2 3 4 5 6 7 8 9 LOWR CHAPTER 6LOWER UNIT LOWER UNIT REMOVAL ... 6-1E

E 1 2 3 4 5 6 7 8 9 LOWR SHIMMING ... 6-19SHIM SELEC

6-1LOWR E LOWER UNIT REMOVALLOWER UNIT REMOVAL EXPLODED DIAGRAM

6-2LOWR E LOWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points LOWER UNIT REMOVAL Follow the left “Step” fo

6-3LOWR E WATER PUMPWATER PUMP EXPLODED DIAGRAM

6-4LOWR E WATER PUMP REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points WATER PUMP REMOVAL Follow the left “Step” for remova

1-3GENINFO E SAFETY WHILE WORKING Under normal conditions of use, thereshould be no hazards from the use of thelubricants mentioned in this manual, b

6-5LOWR E PROPELLER SHAFT AND REVERSE GEARPROPELLER SHAFT AND REVERSE GEAR EXPLODED DIAGRAM

6-6LOWR E PROPELLER SHAFT AND REVERSE GEAR REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points PROPELLER SHAFT AND REVERSE GE

6-7LOWR E PROPELLER SHAFT AND REVERSE GEAR SERVICE POINTS Propeller shaft housing removal 1. Remove: ● Propeller shaft housing ass’y Å For USA and CA

6-8LOWREPROPELLER SHAFT AND REVERSE GEAR3. Remove:● Oil seal 1 ● Needle bearing 2 Driver rod:YB-06071/90890-06652Needle bearing attachment:YB-06112/90

6-9LOWREPROPELLER SHAFT AND REVERSE GEARPropeller shaft housing assembly1. Install:● Needle bearingÅ For USA and CANADAı Except for USA and CANADADept

6-10LOWREPROPELLER SHAFT AND REVERSE GEAR

6-11LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODDRIVE SHAFT, FORWARD GEAR AND SHIFT RODEXPLODED DIAGRAM

6-12LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsDRIVE SHAFT, FORWARD GEAR AN

6-13LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODEXPLODED DIAGRAM

6-14LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsF Forward gear shim *G Scre

1-4GENINFO E SAFETY WHILE WORKING 3. Non-reusable items Always use new gaskets, packings, O-rings, split-pins and circlips etc. onreassembly. DISASSE

6-15LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODSERVICE POINTSPinion nut removal1. Remove:● Pinion nut Forward gear disassembly1. Remove:● Taper rolle

6-16LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT ROD2. Remove:● Drive shaft needle bearingNeedle bearing attachment:YB-06063/90890-06614 ... 1 Drive

6-17LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT RODSleeve inspection1. Inspect:● SleeveWear/Damage → Replace.Lower case inspection1. Clean:● Gear caseUse

6-18LOWREDRIVE SHAFT, FORWARD GEAR AND SHIFT ROD3. Install:● Pinion gear shim● Drive shaft bearing outer raceDrive shaft oil seal housing assembly1. I

6-19LOWRESHIMMINGSHIMMINGNOTE:Shim selection requirement guide:● Not required when;reassembling with original case and innerparts.● Numeric calculatio

6-20LOWRESHIM SELECTION2. Install:● Shimming gauge● Drive shaft● Bearing 1 ● Shim(s) 2 NOTE:● Attach the adapter plate to the gauge baseusing 4 bolts

6-21LOWRESHIMMINGForward gear shimNOTE:Find forward gear shim thickness (T1) byselecting shims until the specified measure-ment (M) is obtained with t

6-22LOWRESHIMMING3. Check:● Specified measurement (M)Out of specified measurement →Adjust.NOTE:Check the fit between the shimming gaugeand lower surfa

6-23LOWRESHIMMINGSHIM SELECTION (EXCEPT FOR USA AND CANADA)Pinion gear shimNOTE:Find pinion gear shim thickness (T3) byselecting shims until the speci

6-24LOWRESHIMMINGNOTE:● Find the average of the measurement (M).● P is the deviation of the lower case dimen-sion from standard. It is stamped on thet

1-5GENINFO E SPECIAL TOOLS A80000-0* SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accu-rate asse

6-25LOWRESHIMMINGForward gear shimNOTE:Find forward gear shim thickness (T1) byselecting shims until the specified measure-ment (M) is obtained with t

6-26LOWRESHIMMING3. Select:● Forward gear shimExample:If T1 is “0.45 mm”, then forward gear shim = 0.42 mmIf T1 is “0.50 mm”, then forward gear shim =

6-27LOWRESHIMMINGForward gear1. Measure:● Forward gear backlashOut of specification → Adjust.Backlash:0.18 ~ 0.45 mm (0.007 ~ 0.018 in)Measuring steps

6-28LOWRESHIMMING2. Adjust:● Forward gear shim(s)NOTE:Adjust the shim(s) to be added or removedaccording to specification.Forward gear backlashShim th

6-29LOWRESHIMMING2. Adjust:● Reverse gear shim(s)NOTE:Adjust the shim(s) to be added or removedaccording to specification.Backlash adjusting plate:YB-

E 1 2 3 4 5 6 7 8 9 BRKT CHAPTER 7BRACKET UNIT TILLER HANDLE REMOVAL ... 7-1

E 1 2 3 4 5 6 7 8 9 BRKT CLAMP BRACKET (Hydro tilt, Power trim and tilt) ... 7-17EXPLODED DIAGRAM ...

7-1BRKT E TILLER HANDLE REMOVALTILLER HANDLE REMOVAL EXPLODED DIAGRAM

7-2BRKT E TILLER HANDLE REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILLER HANDLE REMOVAL Follow the left “St

1-6GENINFO E SPECIAL TOOLS MEASURING Tool nameTool No.Use for:USA and Canada a Except for USA and Canada b 1 Tachometer YU-08036-A 90890-06760 Id

7-3BRKT E TILLER HANDLETILLER HANDLE EXPLODED DIAGRAM

7-4BRKT E TILLER HANDLE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points TILLER HANDLE DISASSEMBLY Follow the left “Step”

7-5BRKT E TILLER HANDLE EXPLODED DIAGRAM

7-6BRKT E TILLER HANDLE REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points35 Collar 136 Wave washer 137 Bracket 138 Steering

7-7BRKT E LINK ASS’Y DISASSEMBLYLINK ASS’Y DISASSEMBLY EXPLODED DIAGRAM

7-8BRKT E LINK ASS’Y DISASSEMBLY REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points LINK ASS’Y DISASSEMBLY Follow the left “

7-9BRKT E SHIFT ACTUATOR AND BOTTOM COWLINGSHIFT ACTUATOR AND BOTTOM COWLING EXPLODED DIAGRAM

7-10BRKT E SHIFT ACTUATOR AND BOTTOM COWLING REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points SHIFT ACTUATOR AND BOT-TOM C

7-11BRKTEUPPER CASE REMOVALUPPER CASE REMOVALEXPLODED DIAGRAM

7-12BRKTEUPPER CASE REMOVALREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsUPPER CASE REMOVAL Follow the left “Step” for rem

1-7GENINFO E SPECIAL TOOLS

7-13BRKTEUPPER CASE AND EXHAUST MANIFOLDUPPER CASE AND EXHAUST MANIFOLDEXPLODED DIAGRAM

7-14BRKTEUPPER CASE AND EXHAUST MANIFOLDREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsUPPER CASE AND EXHAUST MANIFOLDFollo

7-15BRKTECLAMP BRACKETCLAMP BRACKET (Manual tilt)EXPLODED DIAGRAM

7-16BRKTECLAMP BRACKETREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCLAMP BRACKET REMOVAL (Manual tilt)Follow the left “St

7-17BRKTECLAMP BRACKETCLAMP BRACKET (Hydro tilt, Power trim and tilt)EXPLODED DIAGRAM

7-18BRKTECLAMP BRACKETREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCLAMP BRACKET REMOVAL (Hydro tilt, Power trim and tilt

7-19BRKTESTEERING BRACKETSTEERING BRACKETEXPLODED DIAGRAM

7-20BRKTESTEERING BRACKETREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTEERING BRACKET REMOVAL Follow the left “Step” for

7-21BRKTESWIVEL BRACKETSWIVEL BRACKETEXPLODED DIAGRAM

7-22BRKTESWIVEL BRACKETREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSWIVEL BRACKET REMOVAL (Manual tilt)Follow the left “

1-8GENINFO E SPECIAL TOOLS REMOVAL AND INSTALLATION Tool nameTool No.Use for:USA and Canada a Except for USA and Canada b 1Small end bearing need

7-23BRKTESWIVEL BRACKET DISASSEMBLYSWIVEL BRACKET DISASSEMBLYEXPLODED DIAGRAM

7-24BRKTESWIVEL BRACKET DISASSEMBLYREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSWIVEL BRACKET REMOVAL (Hydro tilt, power

7-25BRKTETILT UNIT REMOVALTILT UNIT REMOVALEXPLODED DIAGRAM

7-26BRKTETILT UNIT REMOVALREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTILT UNIT REMOVAL Follow the left “Step” for remov

7-27BRKTETILT CYLINDER, PUMP HOUSING AND MOTOR REMOVALTILT CYLINDER, PUMP HOUSING AND MOTOR REMOVALEXPLODED DIAGRAM

7-28BRKTETILT CYLINDER, PUMP HOUSING AND MOTOR REMOVALREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTILT CYLINDER, PUMP HO

7-29BRKTETILT CYLINDERTILT CYLINDEREXPLODED DIAGRAM

7-30BRKTETILT CYLINDERREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsTILT CYLINDER DISASSEMBLY Follow the left “Step” for r

7-31BRKTETILT CYLINDERSERVICE POINTSTilt cylinder disassembly1. Loosen:● Tilt cylinder end screwTilt cylinder wrench:YB-06175-2B/90890-06544Inner cyli

7-32BRKTETILT CYLINDERInner cylinder assembly1. Fill:● ATF (Dexiron type 2)to inner cylinder.NOTE:Depress the tilt rod fully and fill the innercylinde

1-9GENINFO E SPECIAL TOOLS

7-33BRKTEPUMP HOUSINGPUMP HOUSINGEXPLODED DIAGRAM

7-34BRKTEPUMP HOUSINGREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPUMP HOUSING DISASSEMBLY Follow the left “Step” for rem

7-35BRKTEPTT MOTORPTT MOTOREXPLODED DIAGRAM

7-36BRKTEPTT MOTORREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPOWER TRIM AND TILT MOTOR DISASSEMBLYFollow the left “Step

7-37BRKTEPTT MOTORSERVICE POINTSMotor inspection1. Inspect:● CommutatorDirty → Clean with #600 abrasivepaper.2. Inspect:● Segment undercutClog → Clea

7-38BRKTEPTT MOTOR5. Inspect:● Circuit breakerDiscontinuity → Replace.6. Inspect:● Lead wireDiscontinuity → Replace.7. Measure:● Brush length a Out of

E 1 2 3 4 5 6 7 8 9 –+ELEC CHAPTER 8ELECTRICAL SYSTEM ELECTRICAL COMPONENTS ...

E 1 2 3 4 5 6 7 8 9 –+ELEC STARTER MOTOR ... 8-23EXPLODED DIAGRA

8-1–+ELEC E ELECTRICAL COMPONENTSELECTRICAL COMPONENTS OIL INJECTION MODEL 1 Electrothermal valve 2 Oil level sensorL : BlueB : Black

8-2–+ELEC E ELECTRICAL COMPONENTS MH, MHO, MO, MDO MODEL 1 Oil level sensor 2 Warning lamp 3 Charge coil 4 Lighting coil 5 Pulser coil 6 CDI unit 7 I

1-10GENINFO E SPECIAL TOOLS Tool nameTool No.Use for:USA and Canada a Except for USA and Canada b 23 Bearing outer race puller N.A. 90890-06523 F

8-3–+ELEC E ELECTRICAL COMPONENTS WHD, WH, E, EDO, EO MODEL 1 Oil level sensor 2 Electrothermal valve 3 Oil level warning lamp 4 Charge coil 5 Lighti

8-4–+ELECEELECTRICAL COMPONENTSET, ETO MODEL1 P.T.T. switch2 Oil level sensor3 Electrothermal valve4 Oil level warning lamp5 Charge coil6 Lighting coi

8-5–+ELECEELECTRICAL COMPONENTSEHTO MODEL1 Main switch2 Main switch lead3 Engine stop switch lead4 Battery cable5 Extension wire harness6 Neutral swit

8-6–+ELECEELECTRICAL UNIT COMPONENTSELECTRICAL UNIT COMPONENTSE, EO MODEL1 Starter motor2 Rectifier regulator3 Ignition coil4 Fuse5 Starter relaya Bra

8-7–+ELECEELECTRICAL UNIT COMPONENTSET, ETO MODEL1 Starter motor2 Rectifier regulator3 Ignition coil4 Starter relay5 P.T.T. relay6 Fusea Bracketb Grou

8-8–+ELECEELECTRICAL ANALYSISELECTRICAL ANALYSISINSPECTIONCAUTION:All measuring instruments should be han-dled with special care, or the correct mea-s

8-9–+ELECEIGNITION SYSTEMIGNITION SYSTEM1 Spark plug2 Ignition coil3 Charge coil4 Pulser coil5 Main switch6 Engine stop switch7 10P coupler8 7P couple

8-10–+ELECEIGNITION SYSTEMIGNITION SPARK GAPWARNING● While checking the spark be careful not totouch any connection of lead wires of the“Ignition spar

8-11–+ELECEIGNITION SYSTEM1. Measure:● CDI unit output (test #1)Beyond specification → Replace igni-tion coil.Below specification → Measurecharge coil

8-12–+ELECEIGNITION SYSTEM3. Measure:● Pulser coil output (test #3)Beyond specification → Replace CDIunit.Below specification → Replace pulsercoil. SP

E A20000-0 NOTICE This manual has been prepared by the Yamaha Motor Company primarily for use by Yamahadealers and their trained mechanics when perfo

8-13–+ELECEIGNITION SYSTEMReplacement steps: (Except for Canada and Europe)● Remove the spark-plug cap by pullingthe spark-plug cap.● Remove the plug-

8-14–+ELECEIGNITION SYSTEMMAIN SWITCH1. Check:● ContinuityOut of specification → Replace.Checking leads colorSwitch positionWhite Black Red Yellow Bro

8-15–+ELECEIGNITION CONTROL SYSTEMIGNITION CONTROL SYSTEM1 Thermo switch2 CDI unit3 Warning lamp4 Oil level sensor5 Oil level warning lamp6 Oil level

8-16–+ELECEIGNITION CONTROL SYSTEMTHERMO SWITCH1. Measure:● Thermo switch continuityOut of specification → Replace.1 Discontinuity Å Temperature2 Cont

8-17–+ELECEIGNITION CONTROL SYSTEMFloat positionChecking leads color1 P 2 Ba OFFa ONFloat length:a 56.8 ~ 59.8 mm (2.24 ~ 2.35 in)WARNING LAMP1. Check

8-18–+ELECEIGNITION CONTROL SYSTEMOIL LEVEL WARNING LAMP1. Check:● LED (Light emitting diode) lightingNo lighting → Replace.CAUTION:Use only ordinally

8-19–+ELECESTARTING SYSTEMSTARTING SYSTEM1 Fuse2 10P coupler3 7P coupler4 Main switch5 Starter motor6 Battery7 Neutral switch8 Starter relayÅ Except f

8-20–+ELECESTARTING SYSTEMBATTERYRefer to “GENERAL” in chapter 3.WIRING HARNESS1. Check:● Continuity Discontinuity → Replace.WIRING CONNECTION1. Check

8-21–+ELECESTARTING SYSTEMSTARTER RELAY1. Inspect:● Brown lead terminal● Black lead terminalLoose → Tighten.2. Check:● Relay operationDoes not functio

8-22–+ELECESTARTING SYSTEM

E 1 2 3 4 5 6 7 8 9 SPEC CHAPTER 2SPECIFICATIONS GENERAL SPECIFICATIONS ... 2

8-23–+ELECESTARTER MOTORSTARTER MOTOREXPLODED DIAGRAM

8-24–+ELECESTARTER MOTORREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsSTARTER MOTOR DISASSEMBLY Follow the left “Step” for

8-25–+ELECESTARTER MOTORSERVICE POINTSPinion removal1. Remove:● Clip 1 NOTE:Using a pry-bar, pry off the clip.Pinion inspection1. Inspect:● Pinion tee

8-26–+ELECESTARTER MOTOR3. Check:● Commutator under cutClog/Dirty → Clean.NOTE:Removal all particles of mica and metal bycompressed air.4. Measure:● C

8-27–+ELECESTARTER MOTOR2. Check:● Brush holder continuityOut of specification → Replace.Brush holder continuity:Brush holder 1 - Base 2 Discontinuity

8-28–+ELECECHARGING SYSTEMCHARGING SYSTEM1 Rectifier regulator2 Lighting coil3 Battery4 FuseG : GreenG/W : Green/WhiteR : RedB : Black

8-29–+ELECECHARGING SYSTEMCHARGING SYSTEM PEAK VOLTAGE1. Measure:● Rectifier regulator inputBelow specification → Lighting coilmeasurement.2. Measure:

8-30–+ELECEENRICHMENT CONTROL SYSTEMENRICHMENT CONTROL SYSTEM1 Rectifier regulator2 Lighting coil3 Electrothermal valveG : GreenG/W : Green/WhiteL : B

8-31–+ELECEPOWER TRIM AND TILT CONTROL SYSTEMPOWER TRIM AND TILT CONTROL SYSTEM1 P.T.T. motor2 P.T.T. relay3 P.T.T. switch4 3P coupler (Black)5 10P co

8-32–+ELECEPOWER TRIM AND TILT CONTROL SYSTEMBATTERYRefer to “GENERAL” in chapter 3.FUSERefer to “STARTING SYSTEM”.PTT SWITCH1. Check:● ContinuityOut

2-1SPEC E GENERAL SPECIFICATIONSGENERAL SPECIFICATIONS ItemUnitModel Worldwide 40VMH 40VMHD 40VMHO 40VMO 40VWHUSA, CANADA C40MH — 40MH — — DIMENSION:

8-33–+ELECEPOWER TRIM AND TILT CONTROL SYSTEM● Connect the tester between the termi-nals of the PTT relay as shown.● Connect a 12 V battery.Sky blue (

E 1 2 3 4 5 6 7 8 9 TRBLANLS CHAPTER 9TROUBLE-ANALYSIS TROUBLE ANALYSIS ...

9-1 ETRBLANLS TROUBLE ANALYSISTROUBLE ANALYSISNOTE: Following items should be obtained before “trouble analysis”.1. Battery is charged and its specif

9-2 ETRBLANLS TROUBLE ANALYSIS LOWER UNITNeutral position 6Clutch 6Gear 6Water inlet 6Water pump 6Propeller shaft 6Shifter/Pin 6Shift cam 6Shift shaf

YAMAHA MOTOR Corporation, USA Printed in U.S.A. Printed on recycled paper

2-2SPEC E GENERAL SPECIFICATIONS *1: Pump Octane Number ; (Research octane + Motor octane)/2FUEL AND LUBRICATION:Fuel type Regular gasoline Fuel rati

2-3SPEC E GENERAL SPECIFICATIONS ItemUnitModel Worldwide 40VE 40VEO 40VEHTO 40VET 40VETOUSA, CANADA C40ER 40ER P40TH C40TR 40TR DIMENSION:Over-all le

2-4SPEC E GENERAL SPECIFICATIONS *1: Pump Octane Number ; (Research octane + Motor octane)/2FUEL AND LUBRICATION:Fuel type Regular gasolineFuel ratin

2-5SPECEGENERAL SPECIFICATIONSItemUnitModelWorldwide 50HMHO 50HMHD 50HMO 50HMDO50HWHD50HEDO50HET50HETOUSA, CANADA —————50ER C50TR 50TRDIMENSION:Over-a

2-6SPECEGENERAL SPECIFICATIONS*1: Pump Octane Number ; (Research octane + Motor octane)/2FUEL AND LUBRICA-TION:Fuel typeRegular gasolineFuel ratingP.O

2-7SPECEMAINTENANCE SPECIFICATIONSMAINTENANCE SPECIFICATIONSENGINEItem UnitModel40 hp 50 hpCYLINDER HEAD:Warpage limit mm (in) 0.1 (0.004)CYLINDER:Bor

2-8SPECEMAINTENANCE SPECIFICATIONSTHERMOSTAT:Opening temperature ˚C (˚F) 48 ~ 52 (118 ~ 126)Full-opening temperature ˚C (˚F) 60 (140)Valve lift mm (in

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. Theinformation has be

2-9SPECEMAINTENANCE SPECIFICATIONSLOWERItem UnitModel40 hp 50 hpGEAR BACKLASH:Pinion - forward mm (in) 0.18 ~ 0.45 (0.007 ~ 0.018)Pinion - reverse mm

2-10SPEC E MAINTENANCE SPECIFICATIONS ELECTRICAL Item UnitModel40 hp 50 hpIGNITION TIMING:Ignition timing (full retarded) degree A.T.D.C. 7 ± 1(ful

2-11SPECEMAINTENANCE SPECIFICATIONSCharge coil resistance Ω (color) 368 ~ 552 (Br — L)Charging current (minimum)/rpm A/rpm 3/3,000Charging current (ma

2-12SPECEMAINTENANCE SPECIFICATIONS

2-13SPECEMAINTENANCE SPECIFICATIONSDIMENSION 1

2-14SPECEMAINTENANCE SPECIFICATIONSSymbol UnitModel40VMH40VMHO40VWH50HMHO40VMO50HMO40VE40VEO50HMDO40VMHD50HMHD50HWHD40VEHTO40VET40VETO50HEDO50HET50HET

2-15SPECEMAINTENANCE SPECIFICATIONSDIMENSION 2MANUAL TILT MODELHYDRO TILT/PTT MODEL

2-16SPECEMAINTENANCE SPECIFICATIONSSymbol UnitModelManual tilt Hydro and PTTB1 mm (in) 62.5 (2.5) 126 (5.0)B2 mm (in) 208 (8.2) 254 (10.0)B3 mm (in) 1

2-17SPECETIGHTENING TORQUETIGHTENING TORQUESPECIFIED TORQUEPart to tightenedPart nameThread sizeQ‘tyTightening torque RemarksNm m•kg ft•lbENGINE:Engin

2-18SPECETIGHTENING TORQUEGENERAL TORQUEThis chart specifies the torques for tighten-ing standard fastners with standard cleandry ISO threads at room

E WARNINGS, CAUTIONS AND NOTES Attention is drawn to the various Warnings, Cautions and Notes which distinguish importantinformation in this manual i

E 1 2 3 4 5 6 7 8 9 INSPADJ CHAPTER 3PERIODIC INSPECTION AND ADJUSTMENT MAINTENANCE INTERVAL CHART ...

3-1INSPADJ E MAINTENANCE INTERVAL CHARTMAINTENANCE INTERVAL CHART The following chart should be considered strictly as a guide to general maintenance

3-2INSPADJ E FUEL SYSTEM/CONTROL SYSTEMPERIODIC SERVICE FUEL SYSTEM Fuel line 1. Inspect: ● Fuel lineBreak/Leak/Damage → Replace. CONTROL SYSTEM Th

3-3INSPADJ E CONTROL SYSTEM Throttle cable adjustmentNOTE: Before adjusting the throttle cable, the throttle link should be adjusted.1. Check: ● Full

3-4INSPADJ E CONTROL SYSTEM 3. Check: ● Throttle operationUnsmooth operation → Repair. ● Turn the magneto control lever 3 sothat its adjusting sc

3-5INSPADJECONTROL SYSTEMStart-in-gear protection adjustment1. Check:● Start-in-gear protection operation Incorrect → Adjust.2. Adjust:● Start-in-gear

3-6INSPADJECONTROL SYSTEM/OIL INJECTION SYSTEM● Turn in the pilot screw until it is lightlyseated.● Turn out the pilot screw to specification.Pilot sc

3-7INSPADJEOIL INJECTION SYSTEM/POWER TRIM AND TILT SYSTEM2. Adjust:● Oil pump link joint positionPOWER TRIM AND TILT SYSTEMPower trim and tilt fluid1

3-8INSPADJELOWER UNITLOWER UNITGear oil1. Check:● Gear oilMilky oil → Replace the oil seal.Slag oil → Check the gear, bearingand dog.2. Check:● Gear o

E HOW TO READ DESCRIPTIONS 1. A disassembly installation job mainly consists of the exploded diagram 1 .2. The numerical figures represented by the

3-9INSPADJELOWER UNIT/GENERALNOTE:Do not over-pressurize. Excess pressuremay cause the air to leak out.GENERALAnode1. Inspect:● Anode 1 ● Trim tab 2 ●

3-10INSPADJEGENERALNOTE:● Batteries vary among manufacturers.Therefore the following procedures maynot always apply. Consult your batterymanufacturer’

3-11INSPADJEGENERAL4. Measure:● Electrodes gap a Out of specification → Regap.Gap:0.9 ~1.0 mm (0.035 ~ 0.039 in)5. Tighten:● Spark plugNOTE:Before ins

E 1 2 3 4 5 6 7 8 9 FUEL CHAPTER 4FUEL SYSTEM FUEL JOINT, FUEL FILTER AND FUEL PUMP ... 4-1EXPLODED DIAGR

4-1FUEL E FUEL JOINT, FUEL FILTER AND FUEL PUMPFUEL JOINT, FUEL FILTER AND FUEL PUMP EXPLODED DIAGRAM

4-2FUEL E FUEL JOINT, FUEL FILTER AND FUEL PUMP REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points FUEL JOINT, FUEL FILTER A

4-3FUEL E FUEL JOINT, FUEL FILTER AND FUEL PUMP FUEL LINE LAYOUT M model 1 Fuel pump 2 Fuel filter W, E model 1 Fuel pump 2 Fuel filter 3 Electrother

4-4FUEL E FUEL JOINT, FUEL FILTER AND FUEL PUMP SERVICE POINTS Fuel joint inspection 1. Inspect: ● Fuel jointCrack/Leak/Damage → Replace. 2. Measur

4-5FUEL E CARBURETOR REMOVALCARBURETOR REMOVAL EXPLODED DIAGRAM

4-6FUEL E CARBURETOR REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points CARBURETOR REMOVAL Follow the left “Step” fo

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 Per

4-7FUEL ECARBURETORCARBURETOREXPLODED DIAGRAM

4-8FUELECARBURETORREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCARBURETOR DISASSEMBLY Follow the left “Step” for removal.

4-9FUELECARBURETORSERVICE POINTSCAUTION:Do not use steelwire for cleaning the jets asthis may enlarge the jet diameters and seri-ously affect performa

4-10FUELECARBURETORCarburetor assembly1. Install:● Needle valve● Float 1 ● Float pin 2 ● Screw 3 NOTE:● The float pin should be fit in the slit thecar

4-11FUELEPRIME STARTERPRIME STARTEREXPLODED DIAGRAM

4-12FUELEPRIME STARTERREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsPRIME STARTER DISASSEMBLY Follow the left “Step” for r

4-13FUELEPRIME STARTERSERVICE POINTSFuel enrichment pump inspection1. Inspect:● BodyCrack/Leak/Damage → Replace.2. Inspect:● Seat valveCrack/Distortio

4-14FUELEPRIME STARTER

4-15FUELEOIL TANKOIL TANKEXPLODED DIAGRAM

4-16FUELEOIL TANKREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL TANK REMOVAL Follow the left “Step” for removal.1 Clip

E INDEX GENERAL INFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTION AND ADJUSTMENT 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWE

4-17FUELEOIL TANKOIL LINE LAYOUT1 Electrothermal valve (EM, E model)2 Oil level sensor3 Oil drain hose4 Oil tank5 Oil pump

4-18FUELEOIL TANKSERVICE POINTSOil tank inspection1. Inspect:● Oil tankCrack → Replace.Oil strainer inspection1. Inspect:● Oil strainerCrack/Clog → R

4-19FUELEOIL PUMPOIL PUMPEXPLODED DIAGRAM

4-20FUELEOIL PUMPREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsOIL PUMP REMOVAL Follow the left “Step” for removal.Engine

E 1 2 3 4 5 6 7 8 9 POWR CHAPTER 5POWER UNIT POWER UNIT REMOVAL ... 5-1E

E 1 2 3 4 5 6 7 8 9 POWR CYLINDER HEAD, THERMOSTAT AND EXHAUST COVER ... 5-21EXPLODED DIAGRAM ...

5-1POWR E POWER UNIT REMOVALPOWER UNIT REMOVAL EXPLODED DIAGRAM

5-2POWR E POWER UNIT REMOVAL REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points POWER UNIT REMOVAL Follow the left “Step” fo

5-3POWR E RECOIL STARTERRECOIL STARTER EXPLODED DIAGRAM

5-4POWR E RECOIL STARTER REMOVAL AND INSTALLATION CHART Step Procedure/Part name Q’ty Service points RECOIL STARTER REMOVAL Follow the left “Step” fo

5-5POWR E RECOIL STARTER SERVICE POINTS Sheave drum removal 1. Turn: ● Sheave drum 1 Turn the sheave drum clockwise untilthe spiral spring is free.

5-6POWRERECOIL STARTERDrive pawl and spring inspection1. Inspect:● Drive pawlCrack/Wear/Damage → Replace.● Drive pawl springBroken/Bent/Damage → Repla

5-7POWRERECOIL STARTERStarter rope installation1. Install:● Starter ropeNOTE:● Insert the rope through the rope holes andknot the end.● Wind the rope

5-8POWRERECOIL STARTER

5-9POWREFLYWHEEL MAGNETO AND MAGNETO BASEFLYWHEEL MAGNETO AND MAGNETO BASEEXPLODED DIAGRAM

5-10POWREFLYWHEEL MAGNETO AND MAGNETO BASEREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsFLYWHEEL MAGNETO AND MAGNETO BASE

5-11POWREFLYWHEEL MAGNETO AND MAGNETO BASESERVICE POINTSFlywheel magneto removal1. Remove:● Flywheel nut Å For USA and CANADAı Except for USA and CANA

5-12POWREFLYWHEEL MAGNETO AND MAGNETO BASE

5-13POWREELECTRICAL UNIT REMOVALELECTRICAL UNIT REMOVALEXPLODED DIAGRAMÅ

5-14POWREELECTRICAL UNIT REMOVALREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsELECTRICAL UNIT REMOVAL Follow the left “Ste

E 1 2 3 4 5 6 7 8 9 GENINFO CHAPTER 1GENERAL INFORMATION IDENTIFICATION ...

5-15POWREELECTRICAL UNITELECTRICAL UNITEXPLODED DIAGRAM

5-16POWREELECTRICAL UNITREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsELECTRICAL UNIT DISASSEMBLY Follow the left “Step” f

5-17POWREREED VALVE AND CHECK VALVEREED VALVE AND CHECK VALVEEXPLODED DIAGRAM

5-18POWREREED VALVE AND CHECK VALVEREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsREED VALVE AND CHECK VALVE REMOVALFollow

5-19POWREREED VALVE AND CHECK VALVESERVICE POINTSReed valve inspection1. Inspect:● Reed valveCrack/Damage → Replace.2. Measure:● Valve bending a Out o

5-20POWREREED VALVE AND CHECK VALVE

5-21POWRECYLINDER HEAD, THERMOSTAT AND EXHAUST COVERCYLINDER HEAD, THERMOSTAT AND EXHAUST COVEREXPLODED DIAGRAM

5-22POWRECYLINDER HEAD, THERMOSTAT AND EXHAUST COVERREMOVAL AND INSTALLATION CHARTStep Procedure/Part name Q’ty Service pointsCYLINDER HEAD, THERMOSTA

5-23POWRECYLINDER HEAD, THERMOSTAT AND EXHAUST COVERSERVICE POINTSCylinder head inspection1. Inspect:● Water jacketMaterial deposit/Corrosion → Clean.

5-24POWRECYLINDER HEAD, THERMOSTAT AND EXHAUST COVERThermostat inspection1. Inspect:● ThermostatStick/Damage → Replace.2. Measure:● Valve opening temp