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Table Of Contents - Yamaha 40X Service Manual

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Table of Contents

General Information14

Identification Serial Number16

Starting Serial Numbers16

Safety While Working18

Good Working Practices20

Disassembly And Assembly Safety22

Special Tools24

Measuring Tools24

Tools For Removal And Installation28

Specifications34

General Specifications36

Maintenance Specifications: Engine40

Maintenance Specifications: Lower44

Maintenance Specifications: Electrical46

Outboard/Bracket Dimensions50

Tightening Torque52

General Tightening Torque54

Periodic Inspection And Adjustment56

Maintenance Interval Chart58

Cowling Periodic Service62

Fuel System Periodic Service62

Control System Periodic Service62

Ignition Timing Adjustment62

Carburetor Cam Roller Adjustment (W, Wt)64

Throttle Cable Adjustment (Mh, Wh)66

Idle Speed Adjustment68

Start-In Gear Protection Adjustment68

Power Trim And Tilt (Ptt) System Service And And Adjustments70

Power Trim And Tilt Fluid Check70

Hydraulic System Air Bleeding72

Lower Unit: Gear Oil Check74

Lower Unit Leakage Check76

Anode Inspection76

Battery Check78

Spark Plug Inspection80

Lubrication Points82

Fuel Joint, Fuel Pump, And Fuel Filter Exploded Diagram/Removal And Installation Chart86

Fuel Joint, Fuel Pump, And Fuel Filter Exploded Diagram/Removal And Installation Chart (Cont)90

Fuel Joint Inspection92

Fuel Filter Inspection92

Fuel Pump Exploded Diagram/Removal And Installation Chart94

Carburetor Exploded Diagram/Removal And Installation Chart96

Carburetor Exploded Diagram/Removal And Installation Chart (Cont)98

Carburetor Exploded Diagram/Removal And Installation Chart (End)100

Carburetor Inspection/Assembly102

Carburetor Inspection/Assembly (Cont)104

Power Unit Exploded Diagram/Removal And Installation Chart110

Power Unit Exploded Diagram/Removal And Installation Chart (Cont)114

Power Unit Exploded Diagram/Removal And Installation Chart (End)116

Recoil Starter Exploded Diagram/Removal And Installation Chart118

Recoil Starter Exploded Diagram/Removal And Installation Chart (Cont)120

Recoil Starter Exploded Diagram/Removal And Installation Chart (Continued)124

Recoil Starter Exploded Diagram/Removal And Installation Chart (End)126

Sheave Drum Removal128

Spiral Spring Removal128

Starter Rope Installation130

Sheave Drum Installation130

Recoil Starter Checking132

Flywheel Magneto Exploded Diagram/Removal And Installation Chart134

Flywheel Magneto Removal136

Magneto Base Exploded Diagram/Removal And Installation Chart138

Magneto Base Exploded Diagram/Removal And Installation Chart (Cont)140

Starter Motor Unit Exploded Diagram/Removal And Installation Chart142

Electrical Unit Exploded Diagram/Removal And Installation Chart144

Electrical Unit Exploded Diagram/Removal And Installation Chart (Cont)146

Control Unit Exploded Diagram/Removal And Installation Chart148

Intake Manifold And Reed Valve Exploded Diagram/Removal And Installation Chart152

Reed Valve Inspection156

Cylinder Head Cover And Cylinder Head Exploded Diagram/Removal And Installation Chart158

Cylinder Head Cover And Cylinder Head Exploded Diagram/Removal And Installation Chart (Cont)160

Cylinder Head Inspection162

Thermostat Inspection162

Exhaust Cover Exploded Diagram/Removal And Installation Chart164

Crankcase And Cylinder Body Exploded Diagram/Removal And Installation Chart166

Crankcase And Cylinder Body Exploded Diagram/Removal And Installation Chart (Cont)168

Crankcase And Cylinder Body Exploded Diagram/Removal And Installation Chart (End)170

Cylinder Body Inspection172

Piston-To-Cylinder Clearance174

Piston And Crankchaft Exploded Diagram/Removal And Installation Chart176

Piston/Piston Pin Inspection178

Piston Ring Inspection180

Crankshaft Inspection180

Piston Ring Installation182

Piston Installation184

Lower Unit Exploded Diagram/Removal And Installation Chart190

Lower Unit Exploded Diagram/Removal And Installation Chart (Cont)192

Lower Unit Exploded Diagram/Removal And Installation Chart (End)194

Water Pump Exploded Diagram/Removal And Installation Chart196

Water Pump Exploded Diagram/Removal And Installation Chart (Cont)198

Propeller Shaft Exploded Diagram/Removal And Installation Chart200

Propeller Shaft Removal204

Propeller Shaft Exploded Diagram/Removal And Installation Chart (Cont)206

Propeller Shaft Housing Exploded Diagram/Removal And Installation Chart208

Propeller Shaft Housing Disassembly210

Propeller Shaft Housing Installation212

Propeller Shaft Housing Installation (Cont)214

Forward Gear And Drive Shaft Exploded Diagram/Removal And Installation Chart216

Forward Gear And Drive Shaft Exploded Diagram/Removal And Installation Chart (Cont)218

Pinion Gear Removal220

Drive Shaft/Forward Gear Disassembly220

Lower Case Disassembly222

Forward Gear/Drive Shaft Assembly224

Lower Case Assembly226

Pinion Gear Installation228

Shim Selection230

Shim Selection (Cont)232

Shim Selection (End)234

Forward Gear Shim234

Forward Gear Shim (Cont)236

Reverse Gear Shim238

Pinion Gear Shim240

Pinion Gear Shim (Cont)242

Forward Gear Shim Check244

Reverse Gear Shim Check246

Backlash Measurement248

Forward Gear Backlash248

Reverse Gear Backlash250

Reverse Gear Measuring Steps252

Reverse Gear Backlash Adjustment252

Bracket Unit254

Steering Handle Exploded Diagram/Removal And Installation Chart258

Steering Handle Exploded Diagram/Removal And Installation Chart (Cont)260

Steering Handle Exploded Diagram/Removal And Installation Chart (End)264

Bottom Cowling Exploded Diagram/Removal And Installation Chart266

Bottom Cowling Exploded Diagram/Removal And Installation Chart (Cont)268

Upper Case Assy Exploded Diagram/Removal And Installation Chart270

Upper Case Assy Exploded Diagram/Removal And Installation Chart (Cont)272

Upper Case Assy Exploded Diagram/Removal And Installation Chart (Continued)274

Upper Case Assy Exploded Diagram/Removal And Installation Chart (End)276

Steering Bracket Exploded Diagram/Removal And Installation Chart278

Power Trim And Tilt (Ptt) Unit Exploded Diagram/Removal And Installation Chart282

Power Trim And Tilt (Ptt) Unit Exploded Diagram/Removal And Installation Chart (Cont)284

Clamp Bracket (Mh, Wh, W) Exploded Diagram/Removal And Installation Chart286

Clamp Bracket (Mh, Wh, W) Exploded Diagram/Removal And Installation Chart (Cont)288

Clamp Bracket (Wt) Exploded Diagram/Removal And Installation Chart290

Clamp Bracket (Wt) Exploded Diagram/Removal And Installation Chart (Cont)292

Swivel Bracket Exploded Diagram/Removal And Installation Chart294

Swivel Bracket Exploded Diagram/Removal And Installation Chart (Cont)296

Tilt Rod Exploded Diagram/Removal And Installation Chart298

Tilt Rod Exploded Diagram/Removal And Installation Chart (Cont)300

Tilt Rod/Tile Piston Removal302

Tilt Piston/Tilt Rod Installation304

Air Bleeding306

Air Bleeding (Cont)308

Ptt Motor, Pump Housing, And Tilt Cylinder Exploded Diagram/Removal And Installation Chart310

Ptt Motor, Pump Housing, And Tilt Cylinder Exploded Diagram/Removal And Installation Chart (Cont)312

Pump Housing Exploded Diagram/Removal And Installation Chart314

Pump Housing Exploded Diagram/Removal And Installation Chart (Cont)316

Pump Housing Exploded Diagram/Removal And Installation Chart (End)318

Gear Pump Exploded Diagram/Removal And Installation Chart320

Ptt Motor Exploded Diagram/Removal And Installation Chart322

Motor Inspection326

Motor Inspection (Cont)328

Ptt Motor Assembly328

Electrical System330

Electrical Components (Top View)334

Electrical Components (Port Side View)336

Electrical Components (Starboard Side View)338

Electrical Components Diagram340

Electrical Components (Cont)342

Electrical Components Diagram (Cont)344

Wire Harness (Mh, Wh) Diagram346

Wire Harness (W, Wt) Diagram348

Electrical Analysis Inspection350

Digital Circuit Tester350

Peak Voltage Measurement350

Peak Voltage Adaptor350

Test Harness (For Pulser And Charge Coils)352

Ignition System (Mh, Wh) Diagram354

Ignition System (W, Wt) Diagram356

Ignition Spark Gap358

Ignition System Peak Voltage360

Spark Plug Gap362

Engine Stop Switch (Mh, Wh)362

Ignition Control System (Mh, Wh) Diagram364

Ignition Control System (W, Wt)366

Thermo Switch368

Starting System (Wh) Diagram370

Starting System (W, Wt) Diagram372

Wire Harness/Connections374

Starter Relay374

Starter Switch (Wh)376

Neutral Switch (Wh)376

Choke Solenoid (W, Wt)378

Starter Motor Exploded Diagram/Removal And Installation Chart380

Starter Motor Exploded Diagram/Removal And Installation Chart (Cont)382

Pinion Inspection384

Armature Inspection384

Brush Holder Inspection386

Charging System (Wh, W, Wt) Diagram388

Charging System Peak Voltage390

Power Trim And Tilt (Ptt) Conteol System (Wt) Diagram392

Trouble Analysis396

Trouble Analysis Chart398

Wiring Diagram (Mh)406

Wiring Diagram (Wh)408

Wiring Diagram (W)410

Wiring Diagram (Wt)412

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