Ямаха 40 xws мануал

Related Manuals for Yamaha 40X

Table of Contents

• Contents

• Table of Contents

• Troubleshooting

• Bookmarks

Summary of Contents for Yamaha 40

This manual is also suitable for:

50

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

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

Special service tools / Maintenance interval chart

Maintenance interval chart

Use the following chart as a guideline for general maintenance.
Adjust the maintenance intervals according to the operating conditions of the outboard motor.

Item Remarks

Anodes (external) Check/replace
Anodes (internal) Check/replace
Battery Check/charge
Cooling water passages Clean
Top cowling Check
Fuel filter

(can be disassembled)
Fuel system Check
Fuel tank

(Yamaha portable tank)
Gear oil Change
Lubrication points Lubricate
Engine idle speed
(carburetor models)
Propeller and cotter pin Check/replace
Shift link/shift cable Check/adjust
Thermostat Check
Throttle link/throttle cable/

throttle pick-up timing
Water pump Check
Spark plugs Clean/adjust/

Check/replace

Check/clean

Check/adjust

Check/adjust

replace

Initial Every

10 hours

(1 month)

50 hours

(3 months)

100 hours

(6 months)

200 hours

(1 year)

Refer to

page

3

1
2
3
4
5
6

NOTE:

When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.

66T5F11

3-2

7
8
9

CHK

ADJ

Periodic checks and adjustments

Top cowling

Checking the top cowling

1. Check the fitting by pushing the cowling
with both hands.

S66T3010

2. Check the water separator drain holes for
obstructions. Clean if necessary.

3

Checking the fuel filter

1. Check the fuel filter element 1 for dirt
and residue and check the fuel filter cup

2

for foreign substances and cracks.
Clean the cup with straight gasoline and
replace the element if necessary.

NOTE:

Be sure not to spill any fuel when removing
the fuel filter cup.

Fuel system

Checking the fuel joint and fuel
hoses (fuel joint-to-carburetor)

1. Check the fuel hose connections and fuel
joints for leaks. Replace if necessary.
Also, check the fuel filter 1, fuel pump

2

, and carburetor 3 for leaks or deterio-

ration. Replace if necessary.

1

3

Power unit

3

Checking the spark plugs

1. Disconnect the spark plug caps, and then
remove the spark plugs.

2. Clean the electrodes 1 with a spark plug

3

cleaner or wire brush. Replace the spark
plug if necessary.

3. Check the electrodes for erosion and
excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.

3-3

2

S66T3030

4. Check the spark plug gap a. Adjust if out
of specification.

66T5F11

Specified spark plug:

B7HS (NGK), BR7HS (NGK)

Spark plug gap a:

0.6–0.7 mm (0.024–0.028 in)

5. Install the spark plugs, tighten them fin­ger tight, then to the specified torque
using a spark plug wrench.

Top cowling / Fuel system / Power unit

1

S69J5E40

2

4. Check the thermostat valve opening at
the specified water temperatures.
Replace if out of specification.

3

Spark plug:

T

.

R

.

25 N·m (2.5 kgf·m, 18.4 ft·lb)

Checking the thermostat

1. Remove the cover 1 and thermostat 2.

2

1

2. Suspend the thermostat in a container of
water.

3. Place a thermometer in the water and
slowly heat the water.

S66T3040

Water

temperature

48–52 °C

(118–126 °F)

above

60 °C (140 °F)

5. Install the thermostat and cover, and
then tighten the cover bolts.

Adjusting the start-in-gear
protection

1. Set the gear shift to the neutral position.

Valve lift a

0.05 mm

(0.0020 in)

(valve begins to lift)

more than

3.0 mm (0.12 in)

4
5
6
7
8

66T5F11

9

3-4

CHK

ADJ

Periodic checks and adjustments

2. Loosen the lock nut 1, and then adjust
the start-in-gear protection adjusting nut

2

until the point a on the wire connector
aligned with the mark b on the manual
starter case.

Checking the cooling water passage

1. Check the cooling water inlet cover
and cooling water inlet for clogs. Clean if
necessary.

1

1

Control system

Adjusting the ignition timing

1. Make sure that the engine is stopped
before adjusting the ignition timing.

2. Loosen the throttle cables or remove the
remote control cable.

3. Turn the flywheel magnet clockwise so
that ATDC 2° line a aligns with the mark

b

on the manual starter case.

4. Loosen the locknut 1.

5. Turn the throttle control lever 2 so that
the full-retard screw 3 contacts the stop­per 4.

6. Adjust the full-retard screw 3 so that the
timing indicator c aligns with the mark

d

on the flywheel magnet.

7. Tighten the locknut 1.

3

1

S66T3230

2. Place the lower unit in water, and then
start the engine.

3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passage inside the out­board motor.

8. Adjust the throttle cables or remote con­trol cable.

3-5

S66T3050

66T5F11

9. Shift the remote control lever or shift
lever to forward or reverse, and then
check that the stopper 5 on the throttle
control lever contacts the stopper 6 on
the throttle cable bracket when the throt­tle is fully open.

10. Start the engine and warm it up for 5 min­utes.

11. Check the ignition timing with a timing
light and, if necessary, repeat steps 1–

10.

Power unit / Control system

1
2

6. Turn the throttle grip to the fully closed
position.

7. Loosen the locknut 5.

3

8. Contact the full-retard screw 7 to the
stopper 8, and then turn the adjusting
nut 6 in or out until the specified throttle
cable free play is obtained.

4

9. Tighten the locknut 5.

Ignition timing at engine idle speed:

ATDC 2°

Adjusting the throttle cables
(MH, WH)

NOTE:

Before adjusting the throttle cables, the throt­tle stop screw should be properly adjusted.

1. Loosen the locknut 1.

2. Loosen the throttle-cam-roller adjusting
screw (left-hand threads) 2.

3. Turn the throttle grip to the fully open
position.

4. Adjust the throttle cable adjusting nut
until the center of the throttle cam roller

4

aligns with the mark a on the throttle

cam.

3

5
6

Throttle cable free play:

1 mm (0.04 in)

7
8
9

5. Tighten the locknut.

66T5F11

3-6

CHK

ADJ

10. Align the center of the throttle cam roller

4

with the mark b on the throttle cam,
and then tighten the throttle-cam-roller
adjusting screw 1.

11. Check that the center of the throttle cam
roller 4 aligns with the mark a on the
throttle cam when the throttle grip is
turned to the fully open position.

12. Check that the full-retard screw 7 con­tacts the stopper 8 and that the center of
the throttle cam roller 4 is aligned with
the mark b on the throttle cam when the
throttle grip is turned to the fully closed
position.

Periodic checks and adjustments

5. Adjust the position of the throttle cable
joint until its hole is aligned with the set
pin on the throttle control lever.

13. If necessary, repeat steps 1–12.

Adjusting the throttle cable (W)

NOTE:

Before adjusting the throttle cable, the throt­tle stop screw should be properly adjusted.

1. Loosen the locknut 1, remove the clip

2

, and then disconnect the throttle cable

joint 3.

2. Set the remote control lever to the neu­tral position.

3. Loosen the throttle-cam-roller adjusting
screw (left-hand threads) 4.

4. Check that the full-retard screw 5 con­tacts the stopper 6 and that the center of
the throttle cam roller 7 is aligned with
the mark a on the throttle cam.

b

S66T1050

WARNING

The throttle cable joint must be screwed
in a minimum of 8.0 mm (0.31 in) b.

6. Connect the cable joint, install the clip,
and then tighten the locknut.

7. Align the center of the throttle cam roller

7

with the mark a on the throttle cam,
and then tighten the throttle-cam-roller
adjusting screw 4.

3-7

66T5F11

8. Check that the stopper 8 on the throttle
control lever contacts the stopper 9 on
the throttle cable bracket and that the
center of the throttle cam roller 7 is
aligned with the mark c on the throttle
cam when the remote control lever is
fully open position.

Control system

1

S66T3290

2. Set the gear shift to the neutral position.

3. Check that the neutral switch lever 2 on
the shift lever assembly is pushing the
neutral switch 3. (WH)

N

1
2
3

9. Check that the full-retard screw 5 con­tacts the stopper 6 and that the center of
the throttle cam roller 7 is aligned with
the mark a on the throttle cam when the
remote control lever is fully closed posi­tion.

10. If necessary, repeat steps 1–9.

Checking the gear shift operation
(MH, WH)

1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the adjusting
nut 1 if necessary.

R

N

F

R

F

Checking the gear shift operation
(W)

1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the shift cable
length if necessary.

2. Set the gear shift to the neutral position.

3

2

S66T3260

4
5
6
7
8

66T5F11

S66T3250

9

3-8

CHK

ADJ

3. Loosen the locknut 1, remove the clip

2

, and then disconnect the shift cable

joint 3.

4. Set the shift lever 4 to the neutral posi­tion.

Periodic checks and adjustments

N

R

F

6

23

R

N

F

1

4

S66T3220

5. Adjust the position of the shift cable joint
until its hole is aligned with the set pin.

a

S6D53190

5

S66T3270

Checking the engine idle speed

1. Start the engine and warm it up for 5 min­utes.

2. Attach the special service tool to spark
plug wire #1 1, and then check the
engine idle speed. Adjust if out of specifi­cation.

1

S66T3060

WARNING

The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) a.

6. Connect the cable joint, install the clip,
and then tighten the locknut.

7. Check the gear shift for smooth operation
and, if necessary, repeat steps 2–6.

8. Check that the neutral switch lever on the
shift lever assembly 5 is pushing the
neutral switch 6. (if equipped)

Digital tachometer: 90890-06760

Engine idle speed: 950–1,050 r/min

3. Turn the throttle stop screw 2 in direc­tion a or b until the specified engine
idle speed is obtained.

3-9

66T5F11

Control system / Bracket

NOTE:

• To increase the idle speed, turn the throttle
stop screw in direction a.

• To decrease the idle speed, turn the throttle
stop screw in direction b.

4. If the specified engine idle speed cannot

be obtained, adjust the throttle cable(s).

Checking the ignition timing

1. Start the engine and warm it up for 5 min-

utes.

2. Attach the special service tool to spark

plug wire #1 1, and then check the
engine idle speed.

4. Check that the ATDC 2° line a on the
flywheel magnet is aligned with the mark

b

on the manual starter case. Adjust if

out of specification.

a

b

S66T3100

Ignition timing at engine idle speed:

ATDC 2°

Bracket

Checking the tilt operation

1. Fully tilt the outboard motor up and down
a few times and check the entire tilt
range for smooth operation.

1
2
3

3

4

1

S66T3060

Digital tachometer: 90890-06760

Engine idle speed: 950–1,050 r/min

3. Attach the special service tool to spark
plug wire #1 1.

1

S66T3090

5
6
7
8

S66T3300

9

66T5F11

Timing light: 90890-03141

3-10

CHK

ADJ

Periodic checks and adjustments

Lower unit

Checking the gear oil level

1. Fully tilt the outboard motor down.

2. Remove the check screw 1, and then
check the gear oil level in the lower case.

1

S60V3320

NOTE:

If the oil is at the correct level, the oil should
overflow out of the check hole when the
check screw is removed.

3. If necessary, add sufficient gear oil of the
recommended type until it overflows out
of the check hole.

3

3. Check the oil for metal and discoloration,
and its viscosity. Check the internal parts
of the lower case if necessary.

4. Insert a gear oil tube or gear oil pump
into the drain hole and slowly fill the gear
oil until oil flows out of the check hole and
no air bubbles are visible.

Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90

4. Install the check screw.

Changing the gear oil

1. Tilt the outboard motor up slightly.

2. Place a drain pan under the drain screw

1

, remove the drain screw, then the
check screw 2 and let the oil drain com­pletely.

Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90

Oil quantity:

430 cm

3

(14.54 US oz, 15.17 Imp oz)

5. Install the check screw and quickly install
the drain screw.

3-11

66T5F11

Lower unit / General

Checking the lower unit for air
leakage

1. Remove the check screw 1, and then
install the special service tool.

Leakage tester: 90890-06840

2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.

CAUTION:

Do not over pressurize the lower unit, oth­erwise the oil seals can be damaged.

NOTE:

Cover the check hole with a rag when remov­ing the special service tool from the lower
unit.

General

Checking the anodes

1. Check the anodes and trim tab for
scales, grease, or oil. Clean if necessary.

CAUTION:

Do not oil, grease, or paint the anodes or
the trim tab, otherwise they will be ineffec­tive.

2. Replace the anodes or trim tab if exces­sively eroded.

Checking the battery

1. Check the battery electrolyte level. If the
level is at or below the minimum level
mark a, add distilled water until the level
is between the maximum and minimum
level marks.

3

1
2
3
4
5
6

Lower unit holding pressure:

100 kPa (1.0 kgf/cm

3. If pressure drops below specification,
check the drive shaft and propeller shaft
oil seals for damage.

Checking the propeller

1. Check the propeller blades and splines
for cracks, damage, or wear. Replace if
necessary.

66T5F11

2

, 14 psi)

a

7

S69J3620

8
9

3-12

CHK

ADJ

Periodic checks and adjustments

2. Check the specific gravity of the electro­lyte. Fully charge the battery if below
specification.

WARNING

Battery electrolyte is dangerous; it con­tains sulfuric acid which is poisonous and
highly caustic.
Always follow these preventive measures:

• Avoid bodily contact with electrolyte as

it can cause severe burns or permanent
eye injury.

• Wear protective eye gear when handling

or working near batteries.

Antidote (EXTERNAL):

• SKIN – Wash with water.

• EYES – Flush with water for 15 minutes

and get immediate medical attention.

Antidote (INTERNAL):

• Drink large quantities of water or milk

followed with milk of magnesia, beaten
egg, or vegetable oil. Get immediate

medical attention.
Batteries generate explosive, hydrogen
gas. Always follow these preventive mea­sures:

• Charge batteries in a well-ventilated

area.

• Keep batteries away from fire, sparks or

open flames (e.g., welding equipment,

lighted cigarettes).

• DO NOT SMOKE when charging or han-

dling batteries.
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.

Lubricating the outboard motor

1. Apply water resistant grease to the areas
shown.

AA

S66T3200

AA

S66T3210

È

A

NOTE:

• Batteries vary per manufacturer. The pro­cedures mentioned in this manual may not
always apply, therefore, consult the instruc­tion manual of the battery.

• Disconnect the negative battery lead first,
then the positive battery lead.

Electrolyte specific gravity:

1.280 at 20 °C (68 °F)

3-13

S6D53290

66T5F11

È

Tiller handle model

È

NOTE:

Apply grease to the grease nipples until it
flows from the bushings a.

2. Apply low temperature resistant grease

to the area shown.

General

1
2
3

3. Apply corrosion resistant grease to the

area shown.

4
5
6
7
8

66T5F11

9

3-14

CHK

ADJ

Periodic checks and adjustments

— MEMO —

3-15

66T5F11

FUEL

Fuel system

Special service tools ………………………………………………………………………….4-1

Hose routing………………………………………………………………………………………4-2

Fuel line …………………………………………………………………………………………….4-3

Fuel pump………………………………………………………………………………………….4-5

Checking the fuel pump…………………………………………………………………..4-6

Disassembling the fuel pump …………………………………………………………..4-6

Assembling the fuel pump ……………………………………………………………….4-7

Checking the fuel joint …………………………………………………………………….4-7

Carburetor………………………………………………………………………………………….4-8

Disassembling the carburetor…………………………………………………………4-10

Checking the carburetor ………………………………………………………………..4-10

Assembling the carburetor……………………………………………………………..4-11

Adjusting the throttle stop screw……………………………………………………..4-11

1
2
3
4
5
6
7
8
9

66T5F11

FUEL

Fuel system

Special service tools

Vacuum/pressure pump gauge set
90890-06756

4

4-1

66T5F11

Special service tools / Hose routing

Hose routing

1

4

1
2
3

4

3

4

1

Fuel hose (fuel joint-to-fuel filter)

1

Fuel hose (fuel filter-to-fuel pump)

2

Fuel hose (fuel pump-to-carburetor)

3

Pilot water hose

4

3

2

5

4

6
7

S66T4010

8

66T5F11

9

4-2

FUEL

Fuel system

Fuel line

4

No. Part name Q’ty Remarks

1 Clamp 6
2 Fuel hose 1
3Bolt 1 M6 × 30 mm
4 Fuel joint 1
5Grommet 1
6 Fuel hose 1
7 Fuel hose 1
8Bolt 2 M6 × 40 mm

9 Fuel pump 1
10 Gasket 1
11 Nut 1
12 Bolt 1 M6 × 14 mm
13 Bracket 1
14 Fuel filter assembly 1
15 Fuel filter element 1
16 O-ring 1
17 Cup 1

Not reusable

Not reusable

4-3

66T5F11

Fuel line

4

1
2
3

No. Part name Q’ty Remarks

18 Screw 2 ø6 × 40 mm
19 Collar 2
20 Intake silencer 1
21 O-ring 1
22 Bolt 2 M8 × 100 mm
23 Carburetor 1
24 O-ring 1
25 Solenoid coil 1 W model
26 Bracket 1 W model
27 Grommet 1 W model
28 Spring 1 W model
29 O-ring 1

30 Hook 1 W model
31 Screw 4 W model
32 Bolt 3 M6 × 25 mm / W model
33 Grommet 3 W model
34 Collar 3 W model

Not reusable

Not reusable

Not reusable

W model

4
5
6
7
8
9

66T5F11

4-4

FUEL

Fuel system

Fuel pump

4

No. Part name Q’ty Remarks

1Screw 3 ø5 × 30 mm

2 Cover 1

3 Diaphragm 1

4Gasket 1

5 Fuel pump body assembly 1

6Gasket 2

7 Diaphragm 1

8 Cover 1

Not reusable

Not reusable

4-5

66T5F11