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Yamaha 40X Owner's Manual

Other manuals for 40X: Owner's Manual, Service Manual, Owner's Manual

Summary of 40X

  • Page 1

    Owner’s manual e40x 40x 66t-28199-29-e0

  • Page 2

    Emu25051 read this owner’s manual carefully before operating or working on your outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold..

  • Page 3: Important Manual Information

    Important manual information emu25103 to the owner thank you for choosing a yamaha outboard motor. This owner’s manual contains infor- mation needed for proper operation, mainte- nance and care. A thorough understanding of these simple instructions will help you ob- tain maximum enjoyment from your ...

  • Page 4: Table of Contents

    Table of contents general information .......................... 1 identification numbers record .......... 1 outboard motor serial number .......... 1 key number....................................... 1 ec label........................................... 1 c-tick label ................................

  • Page 5: Table of Contents

    Table of contents chart (25:1) ................................... 24 procedure for pre-mixed models..... 24 pre-operation checks .................... 25 fuel ................................................. 25 oil.................................................... 25 controls........................

  • Page 6: Table of Contents

    Table of contents treatment of submerged motor..... 73 procedure ....................................... 73.

  • Page 7: General Information

    1 general information emu25170 identification numbers record emu25183 outboard motor serial number the outboard motor serial number is stamped on the label attached to the port side of the clamp bracket. Record your outboard motor serial number in the spaces provided to assist you in ordering spare ...

  • Page 8: General Information

    General information 2 emu25213 c-tick label engines affixed with this label conform to certain portion(s) of the australian radio communications act. Emu25221 emission control information emu25310 u.S. Insular areas engines affixed with the label pictured below conform to u.S. Environmental protecti...

  • Page 9: General Information

    General information 3 emu25382 important labels emu25395 warning labels emu25401 label warning ewm01260 ● be sure shift control is in neutral before starting engine. (except 2hp) ● do not touch or remove electrical parts when starting or during operation. ● keep hands, hair, and clothes away from fl...

  • Page 10: General Information

    General information 4 emu30480 label caution: ecm01450 use premix fuel only..

  • Page 11: Safety Information

    5 safety information emu33621 safety information observe these precautions at all times. Emu33630 rotating parts hands, feet, hair, jewelry, clothing, pfd straps, etc. Can become entangled with inter- nal rotating parts of the engine, resulting in serious injury or death. Keep the top cowling in pla...

  • Page 12: Safety Information

    Safety information 6 emu33900 carbon monoxide this product emits exhaust gases which contain carbon monoxide, a colorless, odor- less gas which may cause brain damage or death when inhaled. Symptoms include nau- sea, dizziness, and drowsiness. Keep cock- pit and cabin areas well ventilated. Avoid bl...

  • Page 13: Safety Information

    Safety information 7 ● avoid sharp turns or other maneuvers that make it hard for others to avoid you or un- derstand where you are going. ● avoid areas with submerged objects or shallow water. ● ride within your limits and avoid aggres- sive maneuvers to reduce the risk of loss of control, ejection...

  • Page 14: Basic Requirements

    8 basic requirements emu25540 fueling instructions warning ewm00010 gasoline and its vapors are high- ly flammable and explosive! ● do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. ● stop engine before refueling. ● refuel in a well-ventilated area. Refuel...

  • Page 15: Basic Requirements

    Basic requirements 9 22. Warning ewm01570 ● improper mounting of the outboard mo- tor could result in hazardous condi- tions such as poor handling, loss of control, or fire hazards. ● because the motor is very heavy, spe- cial equipment and training is required to mount it safely. Emu33580 remote co...

  • Page 16: Basic Requirements

    Basic requirements 10 your outboard motor came with a yamaha propeller chosen to perform well over a range of applications, but there may be uses where a different propeller would be more appropriate. Your yamaha dealer can help you select the right propeller for your boating needs. Select a propell...

  • Page 17: Basic Components

    11 basic components emu2579b main components note: * may not be exactly as shown; also may not be included as standard equipment on all mod- els. E40x, 40x 9 8 3 1 2 19 4 5 6 7 20 10 18 11 12 13 14 17 16 15 21 20 22 13 11 23 24 25 26 27 zmu03031 1. Top cowling 2. Top cowling lock lever 3. Anode 4. A...

  • Page 18: Basic Components

    Basic components 12 emu25802 fuel tank if your model was equipped with a portable fuel tank, its function is as follows. Warning ewm00020 the fuel tank supplied with this engine is its dedicated fuel reservoir and must not be used as a fuel storage container. Com- mercial users should conform to rel...

  • Page 19: Basic Components

    Basic components 13 emu26201 neutral interlock trigger to shift out of neutral, first pull the neutral in- terlock trigger up. Emu26211 neutral throttle lever to open the throttle without shifting into ei- ther forward or reverse, put the remote con- trol lever in the neutral position and lift the n...

  • Page 20: Basic Components

    Basic components 14 emu25922 gear shift lever pulling the gear shift lever towards you puts the engine in forward gear so that the boat moves ahead. Pushing the lever away from you puts the engine in reverse gear so that the boat moves astern. Emu25941 throttle grip the throttle grip is on the tille...

  • Page 21: Basic Components

    Basic components 15 there is too much resistance, it could be difficult to move the remote control lever or throttle grip, which could result in an accident. When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. Emu25991 engine shut-off switch the clip must...

  • Page 22: Basic Components

    Basic components 16 emu26001 engine stop button to open the ignition circuit and stop the en- gine, push this button. Emu26011 choke knob for pull type to supply the engine with the rich fuel mix- ture required to start, pull out this knob. Emu26070 manual starter handle to start the engine, first g...

  • Page 23: Basic Components

    Basic components 17 emu31432 steering friction adjuster a friction device provides adjustable resis- tance to the steering mechanism, and can be set according to operator preference. An ad- juster lever is located on the bottom of the tiller handle bracket. To increase resistance, turn the lever to ...

  • Page 24: Basic Components

    Basic components 18 to increase resistance, turn the adjuster clockwise. To decrease resistance, turn the adjuster counterclockwise. Warning ewm00040 do not overtighten the friction adjuster. If there is too much resistance, it could be difficult to steer, which could result in an accident. Emu32051...

  • Page 25: Basic Components

    Basic components 19 relation to the transom. Emu30530 tilt lock mechanism the tilt lock mechanism is used to prevent the outboard motor from lifting out of the wa- ter when in reverse gear. To lock it, set the tilt lock lever in the lock po- sition. To release, push the tilt lock lever in the releas...

  • Page 26: Basic Components

    Basic components 20 tilt position. Emu26372 top cowling lock lever(s) (turn type) to remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- stalling the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the lever...

  • Page 27: Basic Components

    Basic components 21 emu26817 overheat warning this engine has an overheat-warning de- vice. If the engine temperature rises too high, the warning device will activate. Activation of warning device ● the engine speed will automatically de- crease to about 2000 r/min. ● if equipped with an overheat-wa...

  • Page 28: Operation

    22 operation emu26902 installation the information presented in this section is intended as reference only. It is not possible to provide complete instructions for every possible boat and motor combination. Prop- er mounting depends in part on experience and the specific boat and motor combination. ...

  • Page 29: Operation

    Operation 23 caution: ecm01630 ● during water testing, check the buoy- ancy of the boat, at rest, with its maxi- mum load. Check that the static water level on the exhaust housing is low enough to prevent water entry into the power head when water rises due to waves when the outboard is not run- nin...

  • Page 30: Operation

    Operation 24 if it accidentally falls off the transom. 3. Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your yamaha dealer. Warning ewm00650 avoid using bolts, nuts or washers other than those contained in the engine pack- agin...

  • Page 31: Operation

    Operation 25 3. Next two hours: accelerate at full throttle onto plane, then reduce engine speed to three-quar- ter throttle (approximately 4000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three- quarter throttle or less to...

  • Page 32: Operation

    Operation 26 sources of ignition. 1. Remove the fuel tank cap. 2. Fill the fuel tank carefully. 3. Close the cap securely after refueling. Wipe up any spilled fuel. Emu27405 gasoline and oil mixing (100:1) if equipped with a portable fuel tank 1. Pour oil into the portable fuel tank, and then add ga...

  • Page 33: Operation

    Operation 27 built-in fuel tank. Caution: ecm00811 ● avoid using any oil other than the spec- ified type. ● use a thoroughly blended fuel-oil mix- ture. ● if the mixture is not thoroughly mixed, or if the mixing ratio is incorrect, the following problems could occur. ● low oil ratio: lack of oil cou...

  • Page 34: Operation

    Operation 28 3. If a steering friction adjuster is provided on your outboard motor, securely attach the fuel line to the fuel line clamp. Note: during engine operation place the tank hori- zontally, otherwise fuel cannot be drawn from the fuel tank. 4. Squeeze the primer pump, with the ar- row point...

  • Page 35: Operation

    Operation 29 3. Place the throttle grip in the “ ” (start) position. 4. Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position. Note: ● it is not necessary to use the choke when starting a warm engine. ● if the choke knob is left in the “ ” (sta...

  • Page 36: Operation

    Operation 30 amount and try to start the engine again. If the engine still fails to start, see page 67. Emu27563 electric start models 1. Place the gear shift lever in neutral. Note: the start-in-gear protection device prevents the engine from starting except when in neu- tral. 2. Attach the engine ...

  • Page 37: Operation

    Operation 31 ● if the choke knob is left in the “ ” (start) position while the engine is running, the engine will run poorly or stall. 5. Push the starter button to start the mo- tor. (repeat if necessary.) 6. Immediately after the engine starts, re- lease the starter button to allow it to re- turn ...

  • Page 38: Operation

    Operation 32 cure place on your clothing, or your arm or leg. Then install the clip on the other end of the cord into the engine shut-off switch. Warning ewm00121 ● attach the engine shut-off cord to a se- cure place on your clothing, or your arm or leg while operating. ● do not attach the cord to c...

  • Page 39: Operation

    Operation 33 6. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it. Note: ● when the engine is cold, it needs to be warmed up. For further information, see page 35. ● if the engine does not start on the first try, repeat the procedure. If ...

  • Page 40: Operation

    Operation 34 4. Open the throttle slightly without shifting using the neutral throttle lever or free ac- celerator. You may need to change the throttle opening slightly depending on engine temperature. After the engine starts, return the throttle to the original position. Note: ● on remote controls ...

  • Page 41: Operation

    Operation 35 possible to start the engine. The starter can also be damaged. If the engine will not start after 5 seconds of cranking, return the main switch to “ ” (on), wait 10 seconds, then crank the engine again. Emu27670 warming up engine emu27681 choke start models 1. After starting the engine,...

  • Page 42: Operation

    Operation 36 to shift from in gear (forward/reverse) to neutral 1. Close the throttle so that the engine slows to idle speed. 2. After the engine is at idle speed in gear move the remote control lever / gear shift lever firmly and crisply into the neu- tral position. Zmu03060 zmu05737 r n f zmu02030

  • Page 43: Operation

    Operation 37 emu31742 stopping boat warning ewm01510 ● do not use the reverse function to slow down or stop the boat as it could cause you to lose control, be ejected, or im- pact the steering wheel or other parts of the boat. This could increase the risk of serious injury. It could also damage the ...

  • Page 44: Operation

    Operation 38 4. Remove the key if the boat will be left unattended. Note: the engine can also be stopped by pulling the cord and removing the clip from the en- gine shut-off switch, then turning the main switch to “ ” (off). Emu27861 trimming outboard motor the trim angle of the outboard motor helps...

  • Page 45: Operation

    Operation 39 3. Reposition the rod in the desired hole. To raise the bow (“trim-out”), move the rod away from the transom. To lower the bow (“trim-in”), move the rod to- ward the transom. Make test runs with the trim set to different angles to find the position that works best for your boat and oper...

  • Page 46: Operation

    Operation 40 angles to find the position that works best for your boat and operating conditions. Emu27911 adjusting boat trim when the boat is on plane, a bow-up attitude results in less drag, greater stability and effi- ciency. This is generally when the keel line of the boat is up about 3 to 5 deg...

  • Page 47: Operation

    Operation 41 duce salt corrosion. Warning ewm00221 be sure all people are clear of the out- board motor when tilting up and down, body parts can be crushed between the motor and the clamp bracket when the motor is trimmed or tilted. Warning ewm00250 leaking fuel is a fire hazard. If there is a fuel ...

  • Page 48: Operation

    Operation 42 emu32722 procedure for tilting up (power trim and tilt models) 1. Place the remote control lever in neutral. 2. Press the power trim and tilt switch “ ” (up) until the outboard motor has tilted up completely. 3. Push the tilt support knob into the clamp bracket to support the engine. Wa...

  • Page 49: Operation

    Operation 43 emu33120 procedure for tilting down (power trim and tilt models) 1. Push the power trim and tilt switch “ ” (up) until the outboard motor is support- ed by the tilt rod and the tilt support knob becomes free. 2. Pull out the tilt support knob. 3. Push the power trim and tilt switch “ ” ...

  • Page 50: Operation

    Operation 44 position as soon as the boat is back in deeper water. Caution: ecm00260 do not tilt the outboard motor up so that the cooling water inlet on the lower unit is above the surface of the water when set- ting up for and cruising in shallow water. Otherwise severe damage from overheat- ing c...

  • Page 51: Operation

    Operation 45 5. Slightly tilt the outboard motor up until the tilt support bar automatically returns to the free position. 6. Slowly lower the outboard motor to the normal position. Emu32850 power trim and tilt models the outboard motor can be tilted up partially to allow operation in shallow water....

  • Page 52: Operation

    Operation 46 sediment in it, such as muddy or other turbid (cloudy) water. Cruising in acidic water water in some areas can be acidic. After op- erating in such water, flush the cooling pas- sages with fresh water to prevent corrosion. Also rinse the outside of the outboard motor with fresh water..

  • Page 53: Maintenance

    47 maintenance emu31480 specifications note: “(al)” stated in the specification data below represents the numerical value for the alumi- num propeller installed. Likewise, “(sus)” represents the value for stainless steel propeller installed and “(pl)” for plastic propeller installed. Emu28219 dimens...

  • Page 54: Maintenance

    Maintenance 48 40xwt 6.0 a e40xwh 6.0 a drive unit: gear positions: forward-neutral-reverse gear ratio: 2.00 (26/13) trim and tilt system: 40xwt power trim and tilt e40xmh manual tilt e40xwh manual tilt propeller mark: g fuel and oil: recommended fuel: regular unleaded gasoline fuel tank capacity: 2...

  • Page 55: Maintenance

    Maintenance 49 ered in the normal running position, use an additional support device to secure it in the tilt position. The outboard motor should be trailered and stored in the normal running position. If there is insufficient road clearance in this position, then trailer the outboard motor in the t...

  • Page 56: Maintenance

    Maintenance 50 4. Install the outboard motor on the test tank. Fill the tank with fresh water to above the level of the anti-cavitation plate. Caution: ecm00290 if the fresh water level is below the level of the anti-cavitation plate, or if the water supply is insufficient, engine seizure may occur....

  • Page 57: Maintenance

    Maintenance 51 oil and procedures for your engine. Emu28431 battery care warning ewm00330 battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures: ● avoid bodily contact with electrolytic fluid as it ...

  • Page 58: Maintenance

    Maintenance 52 emu28507 periodic maintenance warning ewm01071 be sure to turn off the engine when you perform maintenance unless otherwise specified. If you are not familiar with ma- chine servicing, this work should be done by your yamaha dealer or other qualified mechanic. Maintenance, replacement...

  • Page 59: Maintenance

    Maintenance 53 emu28522 maintenance chart frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. Refer to the sections in this chapter for explanations of each owner-specific action. Note: when operating in salt ...

  • Page 60: Maintenance

    Maintenance 54 emu28874 maintenance chart (additional) water pump inspection / replace- ment spark plug(s) cleaning / adjustment / replacement item actions every 500 hours (2.5 years) 1000 hours (5 years) exhaust guide, exhaust manifold inspection / replace- ment item actions initial every 10 hours ...

  • Page 61: Maintenance

    Maintenance 55 emu28941 greasing yamaha grease a (water resistant grease) yamaha grease d (corrosion resistant grease; for propeller shaft) e40xmh, e40xwh zmu03074.

  • Page 62: Maintenance

    Maintenance 56 40xwt emu28953 cleaning and adjusting spark plug warning ewm00560 when removing or installing a spark plug, be careful not to damage the insulator. A damaged insulator could allow external sparks, which could lead to explosion or fire. Warning ewm01550 the engine will still be very ho...

  • Page 63: Maintenance

    Maintenance 57 other deposits are excessive, you should re- place the spark plug with another of the cor- rect type. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; adjust the gap to specification if necessary. When fitting the plug, always clean the gas- ket su...

  • Page 64: Maintenance

    Maintenance 58 checkpoints ● fuel system parts leakage ● fuel line joint leakage ● fuel line cracks or other damage ● fuel connector leakage emu28980 inspecting fuel filter warning ewm00310 gasoline is highly flammable, and its va- pors are flammable and explosive. ● if you have any question about p...

  • Page 65: Maintenance

    Maintenance 59 4. Reinstall the filter element in the cup. Make sure the o-ring is in position in the cup. Firmly screw the cup onto the filter housing. 5. Attach the filter assembly to the bracket so that the fuel hoses are attached to the filter assembly. 6. Run the engine and check the filter and...

  • Page 66: Maintenance

    Maintenance 60 leaks from the joints between the exhaust cover, cylinder head, and body cylinder. Emu34580 checking power trim and tilt system warning ewm00431 ● never get under the lower unit while it is tilted, even when the tilt support lever is locked. Severe injury could occur if the outboard m...

  • Page 67: Maintenance

    Maintenance 61 checkpoints ● check each of the propeller blades for wear, erosion from cavitation or ventila- tion, or other damage. ● check the propeller shaft for damage. ● check the splines for wear or damage. ● check for fish line tangled around the pro- peller shaft. ● check the propeller shaft...

  • Page 68: Maintenance

    Maintenance 62 specified torque. 4. Align the propeller nut with the propeller shaft hole. Insert a new cotter pin in the hole and bend the cotter pin ends. Note: if the propeller nut does not align with the propeller shaft hole after tightening to the specified torque, tighten the nut further to al...

  • Page 69: Maintenance

    Maintenance 63 the gear oil drain screw hole. 6. Put a new gasket on the oil level plug. When the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. 7. Put a new gasket on the gear oil drain screw. Insert and tighten the gear oil drain screw. Emu29302 cleaning ...

  • Page 70: Maintenance

    Maintenance 64 them ineffective. Note: inspect ground leads attached to external anodes on equipped models. Consult a yamaha dealer for inspection and replace- ment of internal anodes attached to the pow- er unit. Emu29320 checking battery (for electric start models) warning ewm00330 battery electro...

  • Page 71: Maintenance

    Maintenance 65 2. Always keep the battery in a good state of charge. Installing a voltmeter will help you monitor your battery. If you will not use the boat for a month or more, re- move the battery from the boat and store it in a cool, dark place. Completely re- charge the battery before using it. ...

  • Page 72: Maintenance

    Maintenance 66 emu29400 coating the boat bottom a clean hull improves boat performance. The boat bottom should be kept as clean of ma- rine growth as possible. If necessary, the boat bottom can be coated with an anti-foul- ing paint approved for your area to inhibit marine growth. Do not use anti-fo...

  • Page 73: Trouble Recovery

    67 trouble recovery emu29425 troubleshooting a problem in the fuel, compression, or igni- tion systems can cause poor starting, loss of power, or other problems. This section de- scribes basic checks and possible remedies, and covers all yamaha outboard motors. Therefore some items may not apply to ...

  • Page 74: Trouble Recovery

    Trouble recovery 68 a. Check for pinched or kinked fuel line or other obstructions in fuel system. Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Have ignition parts failed? A. Have serviced by a yamaha dealer. Q. Has ...

  • Page 75: Trouble Recovery

    Trouble recovery 69 q. Is load on boat improperly distributed? A. Distribute load to place boat on an even plane. Q. Is water pump or thermostat faulty? A. Have serviced by a yamaha dealer. Q. Is there excess water in fuel filter cup? A. Drain filter cup. Engine power loss. Q. Is propeller damaged? ...

  • Page 76: Trouble Recovery

    Trouble recovery 70 q. Is fuel joint connection incorrect? A. Connect correctly. Q. Is heat range of spark plug incorrect? A. Inspect spark plug and replace it with rec- ommended type. Q. Is high pressure fuel pump drive belt bro- ken? A. Have serviced by a yamaha dealer. Q. Is engine not responding...

  • Page 77: Trouble Recovery

    Trouble recovery 71 emu29512 power trim and tilt will not operate if the engine cannot be tilted up or down with the power trim and tilt because of a dis- charged battery or a failure with the power trim and tilt unit , the engine can be tilted manually. 1. Loosen the manual valve screw by turn- ing...

  • Page 78: Trouble Recovery

    Trouble recovery 72 the engine is running. ● do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor. You could get an electrical shock. Emu29562 emergency starting engine 1. Remove the top cowling. 2. Remove the start-...

  • Page 79: Trouble Recovery

    Trouble recovery 73 6. Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise. 7. Give a strong pull straight out to crank and start the engine. Repeat if neces- sary. Emu29760 treatment of submerged mot...

  • Page 80: Trouble Recovery

    Trouble recovery 74 dealer as soon as possible. Caution: ecm00400 do not attempt to run the outboard motor until it has been completely inspected..

  • Page 82

    Yamaha motor co., ltd. Printed on recycled paper printed in japan april 2007–0.5 × 1 !.