Yamaha 40X Owner's Manual
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- Service manual (417 pages) ,
- Owner's manual (140 pages) ,
- Owner's manual (82 pages)
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Summary of Contents for Yamaha 40X
- Page 1 E40X OWNER’S MANUAL Read this manual carefully before operating this outboard motor. 66T-28199-2B-E0...
- Page 2 EMU25052 Read this manual carefully before operating this outboard motor. Keep this manual onboard in a waterproof bag when boating. This manual should stay with the outboard motor if it is sold.
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Page 3: Important Manual Information
Any damage tain maximum enjoyment from your new resulting from neglect of these instructions is Yamaha. If you have any question about the not covered by warranty. operation or maintenance of your outboard Some countries have laws or regulations re- motor, please consult a Yamaha dealer. -
Page 4: Table Of Contents
Table of contents Safety information......1 Propeller selection ......11 Start-in-gear protection ....12 Outboard motor safety ....1 Engine oil requirements ....12 Propeller..........1 Fuel requirements ......12 Rotating parts........1 Gasoline .......... 12 Hot parts ........... 1 Muddy or acidic water .... - Page 5 Table of contents Instruments and indicators .... 25 Adjusting trim angle for manual tilt models........48 Analog tachometer ......25 Adjusting trim angle Analog speedometer ..... 25 (Power trim and tilt)....... 48 Hour meter ........25 Adjusting boat trim ......49 Engine control system....
- Page 6 Table of contents Inspecting and replacing anode(s)........69 Checking battery (for electric start models) ....69 Connecting the battery ....70 Disconnecting the battery ....70 Trouble Recovery ......72 Troubleshooting ......72 Temporary action in emergency ........75 Impact damage ....... 75 Replacing fuse ........
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Page 7: Safety Information
Safety information EMU33622 tor and the clamp bracket when the motor is Outboard motor safety trimmed or tilted. Keep body parts out of this Observe these precautions at all times. area at all times. Be sure no one is in this EMU36501 area before operating the power trim and tilt Propeller... -
Page 8: Gasoline Exposure And Spills
Personal flotation devices cording to the boat manufacturers instruc- Have an approved personal flotation device tions. Overloading or incorrect weight (PFD) on board for every occupant. Yamaha distribution can compromise the boats han-... -
Page 9: Avoid Collisions
Safety information dling and lead to an accident, capsizing or boating in hazardous weather. swamping. EMU33880 Passenger training EMU33772 Avoid collisions Make sure at least one other passenger is Scan constantly for people, objects, and oth- trained to operate the boat in the event of an er boats. -
Page 10: General Information
Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number... -
Page 11: C-Tick Label
General information ZMU04866 ZMU04902 1. CE marking location 1. C-Tick label location ZMU06081 ZMU06081 1. CE marking location 1. C-Tick label location ZMU01697 ZMU06040 EMU25213 C-Tick label Engines affixed with this label conform to certain portion(s) of the Australian Radio Communications Act. -
Page 12: Read Manuals And Labels
Read any manuals supplied with the boat. Read all labels on the outboard motor and the boat. If you need any additional information, contact your Yamaha dealer. EMU33831 Warning labels If these labels are damaged or missing, contact your Yamaha dealer for replacements. 40X, E40X ZMU06080... - Page 13 General information ZMU05670 EMU33912 Contents of labels EWM01671 The above warning labels mean as follows. WARNING Read Owner’s Manuals and labels. EWM01691 Wear an approved personal flotation WARNING device (PFD). Emergency starting does not have start- Attach engine shut-off cord (lanyard) to in-gear protection.
- Page 14 General information EMU33843 Electrical hazard Symbols The following symbols mean as follows. Notice/Warning ZMU05666 Remote control lever/gear shift lever operat- ing direction, dual direction ZMU05696 Read Owner’s Manual ZMU05667 Engine start/ Engine cranking ZMU05664 Hazard caused by continuous rotation ZMU05668 ZMU05665...
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Page 15: Specifications And Requirements
Specifications and requirements EMU31480 Performance: Specifications Full throttle operating range: TIP: 4500–5500 r/min Maximum output: “(AL)” stated in the specification data below 29.4 kW@5000 r/min represents the numerical value for the alumi- (40 HP@5000 r/min) num propeller installed. Idling speed (in neutral): Likewise, “(SUS)”... -
Page 16: Installation Requirements
Specifications and requirements Maximum generator output: E40XMH 92.2 dB(A) 40XWT 6 A Sound power level E40XWH 6 A (ICOMIA 39/94 and 40/94): Drive unit: E40XMH 100.0 dB(A) Gear positions: Vibration on tiller handle (ICOMIA 38/94): Forward-neutral-reverse E40XMH Vibration on tiller handle is Gear ratio: under 2.5 m/s 2.00 (26/13) -
Page 17: Battery Requirements
[EWM01820] appropriate. EMU36300 Multiple batteries Your Yamaha dealer can help you select the To connect multiple batteries, such as for right propeller for your boating needs. Select multiple engine configurations or for an ac- a propeller that will allow the engine to reach... -
Page 18: Start-In-Gear Protection
Yamaha re- speed range when carrying lighter loads. comends that you use alcohol-free (see For instructions on propeller removal and in- Gasohol) gasoline whenever possible. -
Page 19: Anti-Fouling Paint
Specifications and requirements motor in muddy or acidic water conditions. Consult your Yamaha dealer for details. However, depending on the model it might EMU25221 Emission control information not be required. EMU25310 EMU36330 U.S. insular areas Anti-fouling paint Engines affixed with the label pictured below A clean hull improves boat performance. - Page 20 Specifications and requirements ZMU04904 1. Manufactured date label location ZMU06081 1. Manufactured date label location...
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Page 21: Components
Components EMU2579M Components diagram TIP: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 40X, E40X 11 12 ZMU03031 1. Top cowling 16. Throttle friction adjuster* 2. Cowling lock lever 17. -
Page 22: Fuel Tank
Components EMU25802 EMU25860 Fuel tank Air vent screw If your model was equipped with a portable This screw is on the fuel tank cap. To loosen fuel tank, its function is as follows. the screw, turn it counterclockwise. EWM00020 EMU26181 Remote control box WARNING The remote control lever actuates both the... -
Page 23: Neutral Interlock Trigger
Components when the remote control lever is in neutral. The remote control lever will operate only when the neutral throttle lever is in the closed position. 1. Neutral “ ” 2. Forward “ ” 3. Reverse “ ” 4. Shift 5. -
Page 24: Gear Shift Lever
Components ZMU03034 ZMU03032 EMU25922 EMU25961 Gear shift lever Throttle indicator Pulling the gear shift lever towards you puts The fuel consumption curve on the throttle the engine in forward gear so that the boat indicator shows the relative amount of fuel moves ahead. -
Page 25: Engine Shut-Off Cord (Lanyard) And Clip
Components or throttle grip, which could result in an tangled, preventing it from functioning. accident. Avoid accidentally pulling the cord dur- [EWM00032] ing normal operation. Loss of engine power means the loss of most steering control. Also, without engine power, the boat could slow rapidly. -
Page 26: Choke Knob For Pull Type
Components EMU26080 Starter button To start the engine with the electric starter, push the starter button. ZMU02083 EMU26011 Choke knob for pull type To supply the engine with the rich fuel mix- ZMU03038 ture required to start, pull out this knob. EMU26090 Main switch The main switch controls the ignition system;... -
Page 27: Steering Friction Adjuster
Components 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 the port side “A”. -
Page 28: Power Trim And Tilt Switch On Remote Control
Components To increase resistance, turn the adjuster sure you have tightened the bolt after ad- clockwise. justing the trim tab. To decrease resistance, turn the adjuster The trim tab should be adjusted so that the counterclockwise. steering control can be turned to either the EWM00040 right or left by applying the same amount of WARNING... -
Page 29: Tilt Lock Mechanism
Components ZMU03042 ZMU03040 ECM00660 EMU30530 Tilt lock mechanism NOTICE The tilt lock mechanism is used to prevent Do not use the tilt support lever or knob the outboard motor from lifting out of the wa- when trailering the boat. The outboard ter when in reverse gear. -
Page 30: Cowling Lock Lever(S) (Turn Type)
Components tilt position. EMU26373 Cowling lock lever(s) (turn type) To remove the engine top cowling, turn the cowling lock lever(s) and lift off the cowling. When installing the cowling, check to be sure it fits properly in the rubber seal. Then lock the cowling again by returning the cowling lock lever(s) to the lock position. -
Page 31: Instruments And Indicators
The gauge shows the engine speed. time elapsed either when the main switch is on or only when the engine is running. For in- structions on how to select the counting mode, consult your Yamaha dealer. ZMU04579 EMU26591 Analog speedometer This gauge shows the boat speed in km/h and mph. -
Page 32: Engine Control System
NOTICE Check the cooling water inlet for clogging. Do not continue to operate the engine if a alert device has activated. Consult your Yamaha dealer if the problem cannot be located and corrected. EMU2681A Overheat alert This engine has an overheat-alert device. If the engine temperature rises too high, the alert device will activate. -
Page 33: Installation
Installation 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. EWM01590 WARNING ZMU01760... -
Page 34: Clamping The Outboard Motor
Consult your Yamaha dealer or boat man- ufacturer for further information on deter- mining the proper mounting height. For instructions on setting the trim angle of... - Page 35 Secure the clamp bracket to the transom using the bolts provided with the out- board (if packed). For details, consult your Yamaha dealer. WARNING! Avoid using bolts, nuts or washers other than those contained in the engine packaging. If used, they must be of at...
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Page 36: Operation
Operation EMU36381 plane, then immediately reduce the First-time operation throttle to 3000 r/min or less. EMU30174 Next two hours: Breaking in engine Accelerate at full throttle onto plane, Your new engine requires a period of break- then reduce engine speed to three-quar- in to allow mating surfaces of moving parts to ter throttle (approximately 4000 r/min). -
Page 37: Fuel Level
If any water is found in the fuel, or if a gine top cowling, release the lock lever and significant amount of debris is found, the fuel lift off the cowling. tank should be checked and cleaned by a Yamaha dealer. ZMU06090 ZMU06082 EMU36442 Fuel system... -
Page 38: Engine Shut-Off Cord (Lanyard)
3. Engine shut-off switch ZMU06115 After installing, check the fitting of the top ZMU02003 cowling by pushing it with both hands. If the top cowling is loose, have it repaired by your 1. Cord Yamaha dealer. 2. Clip 3. Engine shut-off switch... -
Page 39: Power Trim And Tilt System
Operation ZMU02828 ZMU04678 1. Trim and tilt rod EMU34581 Power trim and tilt system Check that the trim and tilt rod is free of EWM01930 WARNING corrosion or other flaws. Tilt the outboard motor down. Check Never get under the lower unit while it that the trim and tilt rod operates is tilted, even when the tilt support lever smoothly. -
Page 40: Gasoline And Oil Mixing (100:1)
Operation inhale a lot of gasoline vapor, or get Touch the fuel nozzle to the filler open- some gasoline in your eyes, see your ing or funnel to help prevent electrostatic doctor immediately. If gasoline spills sparks. on your skin, wash with soap and wa- Fill the fuel tank, but do not overfill. - Page 41 Operation Gasoline to engine oil ratio Break-in period See page 30 After break-in 100:1 100:1 12 L 14 L 24 L (0.26 US gal, (3.2 US gal, (3.7 US gal, (6.3 US gal, 0.22 Imp gal) 2.6 Imp gal) 3.1 Imp gal) 5.3 Imp gal) 0.01 L 0.12 L...
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Page 42: Operating Engine
Operation the oil gradually as the gasoline is being add- connect the fuel line to the joint. Then ed to the tank. firmly connect the other end of the fuel EMU27451 line to the joint on the fuel tank. Operating engine EMU27466 Sending fuel (portable tank) EWM00420... -
Page 43: Starting Engine
Operation Place the gear shift lever in neutral. ZMU03045 1. Arrow TIP: EMU27493 The start-in-gear protection device prevents Starting engine the engine from starting except when in neu- EWM01600 tral. WARNING Attach the engine shut-off cord to a se- Before starting the engine, make sure cure place on your clothing, or your arm that the boat is tightly moored and that or leg. - Page 44 Operation ZMU02954 After the engine starts, slowly return the Pull out / turn the choke knob fully. After manual starter handle to its original po- the engine starts, replace / return the sition before releasing it. knob to the home position. Slowly return the throttle grip to the fully closed position.
- Page 45 Operation EMU27565 Electric start models EWM01840 WARNING Failure to attached engine shut-off cord could result in a runaway boat if opera- tor is ejected. Attach the engine shut- off cord to a secure place on your cloth- ing, or your arm or leg while operating. Do not attach the cord to clothing that ZMU02026 could tear loose.
- Page 46 Operation If the choke knob is left in the “ ” (start) position while the engine is running, the engine will run poorly or stall. Push the starter button to start the mo- tor. (Repeat if necessary.) ZMU02962 TIP: When the engine is cold, it needs to be warmed up.
- Page 47 Operation be thrown forward. Place the remote control lever in neutral. ZMU02314 TIP: As a starting point, lift the lever just until you feel resistance, then lift slightly more. TIP: The neutral throttle lever can only be used The start-in-gear protection device prevents when the remote control lever is in neutral.
- Page 48 Operation control. Also, without engine power, the boat could slow rapidly. This could cause people and objects in the boat to be thrown forward. Place the remote control lever in neutral. After the engine starts, slowly return the manual starter handle to its original po- sition before releasing it.
- Page 49 Operation pressed in. START ZMU01880 ZMU02315 Open the throttle slightly without shifting TIP: using the neutral throttle lever or free ac- celerator. You may need to change the It is not necessary to use the choke when throttle opening slightly depending on starting a warm engine.
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Page 50: Checks After Starting Engine
Confirm that removing the clip from the en- blocked. Consult your Yamaha dealer if gine shut-off switch stops the engine. the problem cannot be located and cor- Confirm that the engine cannot be started rected. - Page 51 Operation engine and allow it to warm up. To shift out of neutral Pull the neutral interlock trigger up (if equipped). 1. Neutral interlock trigger Move the remote control lever / gear shift lever firmly and crisply forward (for forward gear) or backward (for reverse ZMU05737 gear) [about 35°...
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Page 52: Stopping Boat
Operation EMU31742 Stopping boat EWM01510 WARNING 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 ZMU02030 serious injury. -
Page 53: Trimming Outboard Motor
Operation gine shut-off switch, then turning the main switch to “ ” (off). EMU27862 Trimming outboard motor EWM00740 WARNING Excessive trim for the operating condi- tions (either trim up or trim down) can cause boat instability and can make steering the boat more difficult. This in- creases the possibility of an accident. -
Page 54: Adjusting Trim Angle For Manual Tilt Models
Operation ZMU03063 1. Trim rod 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 ZMU03062 angles to find the position that works best for your boat and operating conditions. -
Page 55: Adjusting Boat Trim
Operation board motor when adjusting the trim the boat is up about 3 to 5 degrees. With the angle. Body parts can be crushed be- bow up, the boat may have a greater tenden- tween the motor and the clamp bracket cy to steer to one side or the other. -
Page 56: Tilting Up And Down
Operation and making it hard to increase speed. Oper- few minutes. Otherwise fuel may leak. ating with excessive trim-in at higher speeds ECM00241 also makes the boat unstable. Resistance at NOTICE the bow is greatly increased, heightening the Before tilting the outboard motor, stop danger of “bow steering”... -
Page 57: Procedure For Tilting Up (Power Trim And Tilt Models)
Operation ZMU04851 ZMU03065 EMU32723 Place the tilt lock lever (if equipped) in Procedure for tilting up (power trim the release/up position. and tilt models) Place the remote control lever in neutral. ZMU03066 Pull up the shallow water lever (if equipped). Press the power trim and tilt switch “... -
Page 58: Procedure For Tilting Down (Power Trim And Tilt Models)
Operation tilt support knob or tilt support lever. Pull out the tilt support knob. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit or in the pow- er tilt unit loses pressure. [EWM00262] TICE: Do not use the tilt support lever or knob when trailering the boat. -
Page 59: Shallow Water
Operation If equipped with a tilt support knob: Pull EMU28125 Procedure it out, then slowly tilt the engine down. Place the remote control lever / gear EMU28061 shift lever in neutral. Shallow water EMU28073 Cruising in shallow water (manual tilt models) EWM01781 WARNING... -
Page 60: Power Trim And Tilt Models
Operation cruising. ing can result. EMU32922 Procedure for power trim and tilt models Place the remote control lever in neutral. ZMU04851 To return the outboard motor to the nor- mal running position, place the remote control lever / gear shift lever in neutral. Slightly tilt the outboard motor up to the Place the tilt lock lever in the lock/down desired position using the power trim... -
Page 61: Cruising In Other Conditions
Cruising in muddy, turbid, or acidic water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (see page 12) if you use the outboard motor in acidic water or water with a lot of sediment in it, such as muddy or turbid (cloudy) water. -
Page 62: Maintenance
Consult your Yamaha ECM01411 NOTICE dealer for further details. -
Page 63: Procedure
Maintenance water may enter the cylinder through the exhaust port and cause engine trou- ble. Store the outboard motor in a dry, well- ventilated place, not in direct sunlight. EMU28304 Procedure EMU28334 Flushing in a test tank ZMU02051 ECM00300 NOTICE 1. -
Page 64: Lubrication
EWM01871 WARNING Seal replacement should be performed by an authorized Yamaha dealer prior to These procedures require mechanical use. skills, tools, and supplies. If you do not Grease all grease fittings. For further de- have the proper skills, tools, or supplies tails, see page 63. -
Page 65: Replacement Parts
Yamaha marine dealership. EMU28511 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of equivalent design and quality. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. -
Page 66: Maintenance Chart 1
The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 20 hours Item... - Page 67 Maintenance Initial Every 20 hours Item Actions hours hours hours months) (1 year) (3 years) (5 years) Fuel line(High pres- Inspection or replace- sure) ment as necessary Fuel line(Low pres- Inspection sure) Fuel line(Low pres- Inspection or replace- sure) ment as necessary Inspection or replace- Fuel pump ment as necessary...
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Page 68: Maintenance Chart 2
Actions hours hours hours months) (1 year) (3 years) (5 years) (Yamaha) Meter/gauge Inspection Inspection and clean- (Yamaha) Fuel tank ing as necessary EMU34451 Maintenance chart 2 Every Item Actions 1000 hours Exhaust guide/exhaust Inspection or replace- manifold ment as necessary... -
Page 69: Greasing
Maintenance EMU28941 Greasing Yamaha grease A (water resistant grease) Yamaha grease D (corrosion resistant grease; for propeller shaft) E40XMH, E40XWH ZMU03074... -
Page 70: Cleaning And Adjusting Spark Plug
Instead, take the outboard motor to a lead to explosion or fire. [EWM00561] Yamaha dealer. You should periodically re- Standard spark plug: move and inspect the spark plug because B7HS heat and deposits will cause the spark plug BR7HS to slowly break down and erode. -
Page 71: Checking Fuel Filter
Maintenance Be sure to use the specified spark plug, fuel filter, consult your Yamaha dealer. otherwise the engine may not operate properly. Before fitting the spark plug, measure the electrode gap with a wire thickness gauge; replace it if out of spec- ification. -
Page 72: Checking Wiring And Connectors
Maintenance quires adjustment, consult a Yamaha dealer or other qualified mechanic. EMU29113 Checking wiring and connectors Check that each connector is engaged se- curely. Check that each ground lead is properly secured. ZMU01897 Checkpoints Check each of the propeller blades for ero- sion from cavitation or ventilation, or other damage. -
Page 73: Installing Propeller
Changing gear oil tion and be lost. EWM00800 WARNING Apply Yamaha marine grease or a cor- rosion resistant grease to the propeller Be sure the outboard motor is securely shaft. fastened to the transom or a stable Install the spacer (if equipped), thrust stand. -
Page 74: Cleaning Fuel Tank
If the oil is milky, water EMU29302 is getting into the gear case which Cleaning fuel tank can cause gear damage. Consult a EWM00920 Yamaha dealer for repair of the lower WARNING unit seals. [ECM00711] Gasoline is highly flammable, and its va- TIP: pors are flammable and explosive. -
Page 75: Inspecting And Replacing Anode(S)
Consult a when cleaning the fuel tank. Yamaha dealer for replacement of external Remove the fuel tank from the boat be- anodes. fore cleaning it. Work only outdoors in... -
Page 76: Connecting The Battery
If the battery needs charg- The electrical contacts of the battery and ing, consult your Yamaha dealer. cables must be clean and properly con- Check the battery connections. They nected, or the battery will not start the should be clean, secure, and covered by engine. - Page 77 Maintenance they are left on, the electrical system can be damaged. [ECM01930] Disconnect the negative cable(s) from the negative (-) terminal. NOTICE: Al- ways disconnect all negative (-) ca- bles first to avoid a short circuit and damage to the electrical system. [ECM01940] Disconnect the positive cable(s) and re- move the battery from the boat.
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Page 78: Trouble Recovery
Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble-alert indicator is flash- Q. Are spark plug(s) fouled or of incorrect ing, consult your Yamaha dealer. - Page 79 Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
- Page 80 Q. Is fuel system obstructed? Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or A. Have serviced by a Yamaha dealer. other obstructions in fuel system. Q. Is there excess water in fuel filter cup? Q.
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Page 81: Temporary Action In Emergency
Q. Is steering pivot loose or damaged? EWM00631 A. Tighten or have serviced by a Yamaha WARNING dealer. Substituting an incorrect fuse or a piece EMU29433... -
Page 82: Power Trim And Tilt Will Not Operate
Trouble Recovery er), the engine can be started with an emer- gency starter rope. EWM01022 WARNING Use this procedure only in an emergen- cy to return to the nearest port for re- pairs. When the emergency starter rope is used to start the engine, the start-in- ZMU03081 gear protection device does not oper- ate. -
Page 83: Emergency Starting Engine
Trouble Recovery the engine is running. equipped. 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 Remove the top cowling. -
Page 84: Treatment Of Submerged Motor
EMU33501 Treatment of submerged motor If the outboard motor is submerged, immedi- ately take it to a Yamaha dealer. Otherwise some corrosion may begin almost immedi- ately. NOTICE: Do not attempt to run the outboard motor until it has been com- pletely inspected. - Page 86 YAMAHA MOTOR CO., LTD. Printed in Japan March 2009–0.6 × 1 ! Printed on recycled paper...