Yamaha 40x User Manual
40X
E40X
290545
SERVICE MANUAL
66T-28197-5F-11
NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
1
40X, E40X
SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st Edition, December 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
Contents
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
1
2
3
4
5
Lower unit
Bracket unit
Electrical systems
Troubleshooting
Index
LOWR
BRKT
–+
ELEC
TRBL
SHTG
6
7
8
9
GEN
INFO
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbols.....................................................................................................1-2
Safety while working......................................................................................1-3
Fire prevention...........................................................................................1-3
Ventilation..................................................................................................1-3
Self-protection ...........................................................................................1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly .......................................................................1-4
1
2
Identification...................................................................................................1-5
Applicable models .....................................................................................1-5
Serial number ............................................................................................1-5
Propeller selection.........................................................................................1-5
Propeller size.............................................................................................1-5
Selection....................................................................................................1-6
Predelivery checks ........................................................................................1-6
Checking the fuel system ..........................................................................1-6
Checking the gear oil level ........................................................................1-6
Checking the battery (WH, W)...................................................................1-6
Checking the outboard motor mounting height..........................................1-7
Checking the remote control cables (remote control model) .....................1-7
Checking the steering system ...................................................................1-8
Checking the gear shift and throttle operation...........................................1-8
Checking the engine start switch and engine stop lanyard switch ............1-9
Checking the cooling water pilot hole ........................................................1-9
Test run .....................................................................................................1-9
Break-in ...................................................................................................1-10
After test run ............................................................................................1-10
3
4
5
6
7
66T5F11
8
9
GEN
INFO
General information
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to understand. Use the information below as a guide for effective and quality service.
1
Parts are shown and detailed in an exploded diagram and are listed in the components list.
2
Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3
Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4
The components list consists of part names and part quantities, as well as bolt and screw dimensions.
5
Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
1
LOWR
Lower unit
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1
3Hose 1
4 Check screw 1
5 Gasket 2
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1
17 Propeller nut 1
18 Trim tab 1
6-5
Lower unit
Not reusable
Not reusable
Not reusable
3
4
2
62Y5A11
1
LOWR
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2 using a press.
CAUTION:
• Do not press the drive shaft threads
directly.
• Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
Lower unit
S62Y6850K
Drive shaft holder 4 1: 90890-06518
Pinion nut holder 2: 90890-06505
Socket adapter 2 3: 90890-06507
Bearing inner race attachment 3:
90890-06639
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Bearing separator 1: 90890-06534
2. Remove the needle bearing from the forward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
a
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
S62Y6740K
1-1
5
6-19
62Y5A11
66T5F11
Symbols
T
R
.
.
D
242
LT
The symbols below are designed to indicate the content of a chapter.
How to use this manual
General information
GEN
INFO
Specifications
SPEC
Periodic checks and adjustments
CHK
ADJ
Symbols 1 to 6 indicate specific data.
123456
Fuel system
FUEL
Power unit
POWR
Lower unit
LOWR
Bracket unit
BRKT
Electrical systems
ELEC
Troubleshooting
– +
TRBL
SHTG
1
2
3
4
Special tool
1
Specified oil or fluid
2
Specified engine speed
3
Specified tightening torque
4
Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point.
7890ABC
A M
E G
Apply 2-stroke outboard motor oil
7
Apply gear oil
8
Apply water resistant grease (Yamaha grease A)
9
Apply molybdenum disulfide grease
0
Symbols D to I in an exploded diagram indicate the type of sealant or locking agent and the application point.
DEFGHI
GM
4
LT
271
Specified measurement
5
Specified electrical value
6
(resistance, voltage, electric current)
C I
Apply corrosion resistant grease
A
(Yamaha grease D)
Apply low temperature resistant grease
B
(Yamaha grease C)
Apply injector grease
C
LT
572
SS
5
6
7
8
9
Apply Gasket Maker
D
Apply Yamabond No. 4
E
Apply LOCTITE 271 (red)
F
66T5F11
Apply LOCTITE 242 (blue)
G
Apply LOCTITE 572
H
Apply silicon sealant
I
1-2
GEN
INFO
General information
Safety while working
To prevent an accident or injury and to
ensure quality service, follow the safety procedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where adequate ventilation can be maintained.
1
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the outboard motor.
Under normal conditions, the lubricants mentioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.
1-3
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
66T5F11
Safety while working
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practices
Special service tools
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tightening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normally after assembly.
1
2
3
4
5
6
7
8
9
66T5F11
1-4
GEN
INFO
General information
Identification
Applicable models
This manual covers the following models.
Applicable models
40XWH, 40XW, E40XMH, E40XW
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1
Propeller selection
1
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and
could also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size
The size of the propeller is indicated on a
propeller blade, on the propeller boss end, on
the side of the propeller boss.
Model name
1
Approved model code
2
Transom height
3
Serial number
4
Model name
40XWH
40XW
E40XMH
E40XW
Approved
model code
Starting
serial No.
66TK 1008141–
× -
a
bc
× -
× -
a
bc
S69W1030
S69W1040
1-5
a
bc
S69W1050
66T5F11
Identification / Propeller selection / Predelivery checks
Propeller diameter (in inches)
a
Propeller pitch (in inches)
b
Propeller type (propeller mark)
c
Selection
When the engine speed is at the full throttle
operating range (4,500–5,500 r/min), the
ideal propeller for the boat is one that provides maximum performance in relation to
boat speed and fuel consumption.
1
Propeller size (in) Material
10 1/4 × 14 - G
10 1/4 × 15 - G
10 1/4 × 16 - G
10 3/4 × 16 - G
10 3/4 × 17 - G
11 × 15 - G
11 1/8 × 13 - G
11 1/4 × 14 - G
Aluminum
11 3/8 × 12 - G
11 1/2 × 13 - G
11 5/8 × 11 - G
11 3/4 × 10 - G
11 3/4 × 12 - G
12 × 11 - G
12 1/4 × 8 - G
12 1/4 × 9 - G
CAUTION:
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 50:1. For
break-in period, 25:1 mixture shall be
used.
Checking the gear oil level
1. Check the gear oil level.
2
3
4
5
6
Predelivery checks
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the fuel system
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
66T5F11
1
7
S60V1290
Checking the battery (WH, W)
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
Recommended battery capacity:
CCA/EN: 430 A
20HR/IEC: 70 Ah
Electrolyte specified gravity:
1.280 at 20 °C (68 °F)
1-6
8
9
GEN
INFO
2. Check that the positive and negative battery leads are securely connected.
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate is
between the bottom of the boat and a
maximum of 25 mm (1 in) a below it. If
the mounting height is too high, cavitation will occur and propulsion will be
reduced. Also, the engine speed will
increase abnormally and cause the
engine to overheat. If the mounting
height is too low, water resistance will
increase and reduce engine efficiency.
General information
a
S6D51030
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at different heights.
2. Check that the clamp brackets are
secured with the clamp screws.
Checking the remote control cables
(remote control model)
1. Set the remote control lever to the neutral position and fully close the throttle
lever.
2. Check that the throttle cam 1 is in its
fully closed position and align the center
of the throttle cam roller 2 with the mark
a
on the throttle cam.
3. Check that the shift link lever 3 is in the
neutral position.
N
R
b
3
F
S66T1030
S66T1050
WARNING
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
b
.
1-7
66T5F11
Predelivery checks
Checking the steering system
1. Check the steering friction for proper
adjustment.
NOTE:
• To increase the friction, turn the friction
adjusting bolt in direction a.
• To decrease the friction, turn the friction
adjusting bolt in direction b.
2. Check that the steering operates
smoothly.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the remote control lever
or shift lever is shifted from neutral to forward or reverse.
2. Check that the throttle operates smoothly
when the throttle grip (tiller handle
model) is turned from the fully closed
position to the fully open position a.
Check that the throttle operates smoothly
when the remote control lever (remote
control model) is shifted from forward or
reverse to the fully open positions a.
R
N
F
0 100%
1
2
3
4
S66T1060
S66T1040
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
a
S66T1070
a
5
N
F
R
a
S69J1210
6
7
8
9
66T5F11
1-8
GEN
INFO
Checking the engine start switch and
engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check that the engine turns off when the
engine start switch is turned to OFF.
3. Check that the engine turns off when the
engine stop lanyard switch is pushed or
the engine stop lanyard is pulled from the
engine stop lanyard switch.
General information
S60V1070
Checking the cooling water pilot
hole
1. Check that cooling water is discharged
from the cooling water pilot hole.
S66T1080
S66T1090
S66T3050
Test run
1. Start the engine, and then check that the
gear shift operates smoothly.
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.
4. Run the outboard motor for 1 hour at
3,000 r/min or at half throttle, then for
another hour at 4,000 r/min or at 3/4
throttle.
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
NOTE:
The test run is part of the break-in operation.
1-9
66T5F11
Break-in
During the test run, perform the break-in
operation in the following four stages.
1. First 10 minutes a of operation at idle
Predelivery checks
2. Fifty minutes b at 3,000 r/min or less
3. One hour c at 4,000 r/min or less
4. Eight hours d at 5,000 r/min or less with
repeated wide-open-throttle operation for
5 minutes or less
cdaÈb
0
È
Hour
After test run
1. Check for water in the gear oil.
1
210
S60V1120
1
2
3
4
5
2. Check for fuel leakage in the cowling.
3. Flush the cooling water passage with
fresh water using the flushing kit and with
the engine running at idle.
6
7
8
9
66T5F11
1-10
GEN
INFO
General information
— MEMO —
1-11
66T5F11
SPEC
Specifications
General specifications...................................................................................2-1
Maintenance specification ............................................................................2-3
Power unit..................................................................................................2-3
Lower unit ..................................................................................................2-5
Electrical ....................................................................................................2-5
Dimensions................................................................................................2-7
Tightening torques.........................................................................................2-9
Specified torques.......................................................................................2-9
General torques.......................................................................................2-10
1
2
3
4
5
6
7
8
9
66T5F11
SPEC
Specifications
General specifications
Item Unit
40XWH 40XW E40XMH E40XW
Dimension
Overall length mm (in)
1,073 (42.2)
675 (26.6)
Overall width mm (in) 402 (15.8) 362 (14.3) 402 (15.8) 362 (14.3)
Overall height
(S) mm (in) — 1,237 (48.7) —
(L) mm (in)
1,364 (53.7)
(X) mm (in) —
Boat transom height
(S) mm (in) — 381 (15.0) —
(L) mm (in) 508 (20.0) — 508 (20.0)
(X) mm (in) — 635 (25.0) —
Weight
(with aluminum propeller)
(S) kg (lb) —
(L) kg (lb)
78.0 (172.0)
74.6 (164.5) 72.0 (158.8)
(X) kg (lb) —
Performance
Maximum output kW (hp) 29.4 (40) at 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L (US gal,
20 (5.3, 4.4) at 5,500 r/min
Imp gal)/hr
Engine idle speed r/min 950–1,050
Power unit
Type 2-stroke
Cylinder quantity L2
Total displacement cm
3
(cu. in) 703 (42.9)
Bore × stroke mm (in) 80.0 × 70.0 (3.15 × 2.76)
Compression ratio 6.0
Intake system Reed valve
Scavenging system Loop charge
Control system Tiller
handle
Remote
control
Starting system Manual and electric Manual Manual and
Fuel system Carburetor
Ignition control system CDI
Maximum generator output V, A 12, 6.0 — 12, 6.0
Starting enrichment Choke valve
Spark plug B7HS (NGK), BR7HS (NGK)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Pre-mixed fuel
Model
1,073 (42.2)
675 (26.6)
— 1,364 (53.7)
1,476 (58.1)
—
73.6 (162.3) 76.2 (168.0)
76.7 (169.1)
Tiller
handle
Remote
control
electric
2
—
—
—
2-1
66T5F11
General specifications
Item Unit
Fuel and oil
Fuel type Regular gasoline
Engine oil 2-stroke outboard motor oil
Engine oil grade
Fuel and oil mixing ratio 50:1
Gear oil type Hypoid gear oil
Gear oil grade
Gear oil quantity cm
Bracket unit
Tilt angle Degree 8, 12, 16, 20, 24
(at 12° boat transom)
Tilt-up angle Degree 68
Steering angle Degree 45 + 45
Drive unit
Gear shift positions F-N-R
Gear ratio 2.00 (26/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller mark G
Electrical
Battery minimum capacity
CCA/EN A 430 — 430
20HR/IEC Ah 70 — 70
(*1)
Meeting both API and SAE requirements
(*2)
CCA: Cold Cranking Ampere
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
(*1)
API
(*2)
NMMA-certified
SAE
3
Imp oz)
(US oz,
40XWH 40XW E40XMH E40XW
430 (14.54, 15.17)
Model
TC-W3
GL-4
90
1
2
3
4
5
6
7
66T5F11
8
9
2-2
SPEC
Specifications
Maintenance specification
Power unit
Item Unit
40XWH 40XW E40XMH E40XW
Power unit
Minimum compression
pressure
(*1)
kPa
(kgf/cm2, psi)
Cylinder heads
Warpage limit
mm (in) 0.1 (0.0039)
(lines indicate straightedge
position)
Cylinders
Bore size mm (in) 80.000–80.020 (3.1496–3.1504)
Bore size limit mm (in) 80.100 (3.1535)
Taper limit mm (in) 0.08 (0.0032)
Out-of-round limit mm (in) 0.05 (0.0020)
Pistons
Piston diameter (D) mm (in) 79.910–79.934 (3.1461–3.1470)
Measuring point (H) mm (in) 10 (0.39)
Piston-to-cylinder clearance mm (in) 0.085–0.090 (0.0033–0.0035)
(Limit) mm (in) 0.14 (0.0055)
Piston pin boss bore mm (in) 19.904–19.915 (0.7836–0.7841)
Oversize piston
1st mm (in) 0.25 (0.010)
2nd mm (in) 0.50 (0.020)
Oversize piston diameter
1st mm (in) 80.160–80.184 (3.1559–3.1568)
2nd mm (in) 80.410–80.434 (3.1657–3.1667)
Piston pins
Outside diameter mm (in) 19.895–19.900 (0.7833–0.7835)
(*1)
Measure conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
Model
630 (6.3, 91)
2
2-3
66T5F11
Maintenance specification
Item Unit
Piston rings
Top ring
Dimension B mm (in) 1.97–1.99 (0.0776–0.0783)
Dimension T mm (in) 2.40–2.60 (0.0945–0.1024)
End gap mm (in) 0.30–0.50 (0.0118–0.0197)
Side clearance mm (in) 0.04–0.08 (0.0015–0.0031)
Oversize diameter
1st mm (in) 80.250 (3.1594)
2nd mm (in) 80.500 (3.1693)
2nd piston ring
Dimension B mm (in) 1.97–1.99 (0.0776–0.0783)
Dimension T mm (in) 2.40–2.60 (0.0945–0.1024)
End gap mm (in) 0.30–0.50 (0.0118–0.0197)
Side clearance mm (in) 0.03–0.07 (0.0012–0.0028)
Oversize diameter
1st mm (in) 80.250 (3.1594)
2nd mm (in) 80.500 (3.1693)
Connecting rods
Small-end inside diameter mm (in) 24.900–24.912 (0.9803–0.9808)
Big-end side clearance mm (in) 0.200–0.700 (0.0079–0.0276)
Small-end axial play limit mm (in) 2.0 (0.08)
Crankshaft
Crankshaft width A mm (in) 63.90–63.95 (2.5157–2.5177)
Crankshaft width B mm (in) 40.88–41.10 (1.6094–1.6181)
Crankpin diameter mm (in) 26.995–27.000 (1.0628–1.0630)
Runout limit mm (in) 0.03 (0.0012)
40XWH 40XW E40XMH E40XW
Model
1
2
3
4
5
6
Thermostats
Opening temperature °C (°F) 48–52 (118–126)
Fully open temperature °C (°F) 60 (140)
Valve open lower limit mm (in) 3.0 (0.12)
Reed valves
Valve stopper height limit mm (in) 10.2–10.4 (0.40–0.41)
Valve bending limit mm (in) 0.2 (0.008)
66T5F11
7
8
9
2-4
SPEC
Specifications
Item Unit
Carburetor
ID mark 66T02 66T12 66T02 66T12
Main jet # 170
Main air jet # 160
Pilot jet # 70
Pilot air jet # 60
Pilot screw turns out 1 3/8–1 7/8
Float height mm (in) 16.5–18.5 (0.65–0.73)
40XWH 40XW E40XMH E40XW
Model
Lower unit
Item Unit
Gear backlash
Pinion-to-forward gear mm (in) 0.19–0.56 (0.0075–0.0220)
Pinion-to-reverse gear mm (in) 0.75–1.13 (0.0295–0.0445)
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
40XWH 40XW E40XMH E40XW
Model
Electrical
Item Unit
Ignition and ignition control
system
Ignition timing (cylinder #1) Degree
Degree
Spark plug gap mm (in) 0.6–0.7 (0.024–0.028)
Spark plug cap resistance
(with resister type)
Ignition coil resistance
Primary coil (B/W – B)
at 20 °C (68 °F)
Secondary coil
(B/W – spark plug wire)
at 20 °C (68 °F) kΩ 5.4–7.4
CDI unit output peak voltage
(B/O – B, B/W – B)
at cranking (loaded) V 180
at 1,500 r/min (loaded) V 180
at 3,500 r/min (loaded) V 170
kΩ 4.0–6.0
Ω
0.32–0.44
40XWH 40XW E40XMH E40XW
ATDC2 at engine idle speed
BTDC23 at 5,000 r/min
Model
2-5
66T5F11
Maintenance specification
Item Unit
Pulser coil output peak voltage
(W/R – W/B)
at cranking (unloaded) V 7.0
at cranking (loaded) V 4.0
at 1,500 r/min (loaded) V 10.0
at 3,500 r/min (loaded) V 17.0
Pulser coil resistance
Starter motor
Type Bendix — Bendix
Brushes
Length limit mm (in) 6.4 (0.25) — 6.4 (0.25)
Armature
Commutator undercut limit mm (in) 0.8 (0.03) — 0.8 (0.03)
Charging system
Fuse A 10
Charge coil output peak
voltage (Positive side: Br –
Negative side: L)
at cranking (unloaded) V 330
at cranking (loaded) V 190
at 1,500 r/min (loaded) V 190
at 3,500 r/min (loaded) V 190
Charge coil resistance (Br – L)
Lighting coil output peak
voltage
Lighting coil resistance
Rectifier output peak voltage
(*1)
The figures are for reference only.
(*1)
(G – G)
at cranking (unloaded) V 6.0 — 6.0
at 1,500 r/min (unloaded) V 16.0 — 16.0
at 3,500 r/min (unloaded) V 33.0 — 33.0
at 1,500 r/min (unloaded) V 14.0 — 14.0
at 3,500 r/min (unloaded) V 32.0 — 32.0
(*1)
(W/R – W/B)
(*1)
(G – G)
(R – B)
Ω
311.4–380.6
Ω
684–836
Ω
0.31–0.37 — 0.31–0.37
40XWH 40XW E40XMH E40XW
Model
1
2
3
4
5
6
7
8
66T5F11
9
2-6
SPEC
Specifications
Dimensions
Exterior
* Tiller handle model only
mm (in)
45˚
221 (8.7)*
702 (27.6)
592 (23.3)* 369 (14.5)
159 (6.3)
523 (20.6)*
397 (15.6)
294 (11.6)*
118 (4.7)
190 (7.5)*
182 (7.2)
S: 826 (32.5)
L: 940 (37.0)
X:1,043 (41.1)
553 (21.8)
65 (2.6)
2-7
S: 424 (16.7)
X: 1,007 (39.7)
S: 767 (30.2)
L: 893 (35.2)
S: 25 (1.0)
L: 24 (0.9)
X: 24 (0.9)
L: 550 (21.7)
X: 664 (26.1)
175 (6.9) 471 (18.5)
43 (1.7)
38 (1.5)*
S: 65 (2.6)
L: 91 (3.6)
X: 91 (3.6)
S: 3 (0.1)
L: 8 (0.3)
X:16 (0.6)
12
˚
˚
4
522 (20.6)
64
˚
S: 626 (24.7)
L: 697 (27.4)
X: 761 (30.0)
S66T2010
66T5F11
Clamp bracket
Maintenance specification
1
2
3
4
5
6
7
8
66T5F11
9
2-8
SPEC
Specifications
Tightening torques
2
Specified torques
Part to be tightened Thread size
Fuel system
Intake silencer screw M6 2 0.2 1.5
Power unit
Power unit mounting bolt M8 21 2.1 15.5
Engine start button nut M16 5 0.5 3.7
Starter rope guide bolt M6 8 0.8 5.9
Manual starter roller bolt M6 3 0.3 2.2
Sheave drum bolt M6 5 0.5 3.7
Flywheel magnet nut M20 157 15.7 115.8
Starter motor bolt M8 21 2.1 15.5
Starter motor terminal nut M8 7 0.7 5.2
Starter relay terminal nut M6 4 0.4 3.0
Ignition coil bolt M6 8 0.8 5.9
Rectifier screw M5 3 0.3 2.2
Intake manifold bolt
1st
2nd 12 1.2 8.9
M6
Reed valve screw M5 2 0.2 1.5
Cylinder head bolt
Cylinder head cover bolt
Exhaust cover bolt
1st
2nd 30 3.0 22.1
1st
2nd 12 1.2 8.9
1st
2nd 12 1.2 8.9
M8
M6
M6
Spark plug — 25 2.5 18.4
Crankcase bolt
1st
2nd 40 4.0 29.5
M10
Lower unit
Gear oil drain screw — 90.96.6
Gear oil check screw — 90.96.6
Lower case mounting bolt M10 40 4.0 29.5
Cooling water inlet cover screw M5 4 0.4 3.0
Propeller nut M16 40 4.0 29.5
Propeller shaft housing bolt M8 16 1.6 11.8
Pinion nut M12 74 7.4 54.6
Tightening torques
N·mkgf·mft·lb
60.64.4
15 1.5 11.1
60.64.4
60.64.4
20 2.0 14.8
2-9
66T5F11
Tightening torques
Part to be tightened Thread size
Bracket unit
Tiller handle bracket nut M10 10 1.0 7.4
Self-locking nut M10 41 4.1 30.2
Engine stop lanyard switch nut — 20.21.5
Battery lead holder screw M6 2 0.2 1.5
Throttle grip screw M5 3 0.3 2.2
Neutral switch nut — 70.75.2
Upper mounting nut M8 24 2.4 17.7
Upper mount bolt M8 27 2.7 20.0
Mount housing nut M10 54 5.4 39.8
Steering friction adjusting bolt M8 4 0.4 3.0
Upper case bolt M8 21 2.1 15.5
Exhaust manifold bolt M8 21 2.1 15.5
Self-locking nut M22 45 4.5 33.2
Tilt stopper plate nut M8 24 2.4 17.7
Grease nipple — 30.32.2
Clamp bracket nut M8 18 1.8 13.3
Tilt lever screw M5 4 0.4 3.0
Tightening torques
N·mkgf·mft·lb
1
2
3
4
General torques
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. Tightening torque specifications
for special components or assemblies are
provided in applicable sections of this manual. To avoid warpage, tighten multi-fastener
assemblies in a crisscross fashion and progressive stages until the specified torque is
reached. Unless otherwise specified, torque
specifications require clean, dry threads.
Components should be at room temperature.
General torque
Nut (A) Bolt (B)
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 25
17 mm M12 43 4.3 31
specifications
N·mkgf·mft·lb
5
6
7
8
9
66T5F11
2-10
SPEC
Specifications
— MEMO —
2-11
66T5F11
CHK
ADJ
Periodic checks and adjustments
Special service tools .....................................................................................3-1
Maintenance interval chart............................................................................3-2
Top cowling ....................................................................................................3-3
Checking the top cowling...........................................................................3-3
Fuel system ....................................................................................................3-3
Checking the fuel joint and fuel hoses (fuel joint-to-carburetor) ................3-3
Checking the fuel filter ...............................................................................3-3
Power unit.......................................................................................................3-3
Checking the spark plugs ..........................................................................3-3
Checking the thermostat............................................................................3-4
Adjusting the start-in-gear protection.........................................................3-4
Checking the cooling water passage.........................................................3-5
Control system...............................................................................................3-5
Adjusting the ignition timing.......................................................................3-5
Adjusting the throttle cables (MH, WH) .....................................................3-6
Adjusting the throttle cable (W) .................................................................3-7
Checking the gear shift operation (MH, WH).............................................3-8
Checking the gear shift operation (W) .......................................................3-8
Checking the engine idle speed ................................................................3-9
Checking the ignition timing.....................................................................3-10
1
2
3
4
5
Bracket..........................................................................................................3-10
Checking the tilt operation .......................................................................3-10
Lower unit.....................................................................................................3-11
Checking the gear oil level ......................................................................3-11
Changing the gear oil ..............................................................................3-11
Checking the lower unit for air leakage ...................................................3-12
Checking the propeller.............................................................................3-12
General..........................................................................................................3-12
Checking the anodes...............................................................................3-12
Checking the battery................................................................................3-12
Lubricating the outboard motor................................................................3-13
6
7
8
9
66T5F11
CHK
ADJ
Periodic checks and adjustments
Special service tools
Timing light
90890-03141
Digital tachometer
90890-06760
3
Leakage tester
90890-06840
3-1
66T5F11
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