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EK40G
User Manuals: Yamaha EK40G Kerosene Outboard Motor
Manuals and User Guides for Yamaha EK40G Kerosene Outboard Motor. We have
1
Yamaha EK40G Kerosene Outboard Motor manual available for free PDF download: Service Manual
Yamaha EK40G Service Manual (200 pages)
Brand:
Yamaha
| Category:
Outboard Motor
| Size: 9 MB
Table of Contents
Table of Contents
3
Important Information
2
General Information
5
How to Use this Manual
6
Manual Format
6
Symbols
7
Contents
7
Safety While Working
8
Fire Prevention
8
Parts, Lubricants, and Sealants
8
Self-Protection
8
Ventilation
8
Disassembly and Assembly
9
Good Working Practices
9
Identification
10
Applicable Model
10
Serial Number
10
Propeller Selection
10
Propeller Size
10
Selection
11
Predelivery Checks
11
Checking the Battery (W)
11
Checking the Fuel System
11
Checking the Gear Oil Level
11
Checking the Outboard Motor Mounting Height
12
Checking the Remote Control Cables (Remote Control Model)
12
Checking the Gear Shift and Throttle Operation
13
Checking the Steering System
13
Checking the Cooling Water Pilot Hole
14
Checking the Engine Start Switch, Engine Stop Lanyard Switch and Engine Stop Button
14
Test Run
14
After Test Run
15
Break-In
15
Spec Specifications
17
Specifications
17
General Specification
18
Fuel
18
Maintenance Specification
20
Power Unit
20
Lower Unit
22
Electrical
22
Dimensions
24
Tightening Torques
26
Specified Torques
26
General Torques
27
Spec - Memo -
29
Chk Adj
30
Special Service Tools
30
Periodic Checks and Adjustments
30
Maintenance Interval Chart
31
Chk Adj
32
Top Cowling
32
Checking the Top Cowling
32
Fuel System
32
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Carburetor)
32
Checking the Fuel Filters
32
Power Unit
32
Checking the Spark Plugs
32
Checking the Thermostat
33
Checking the Cooling Water Passages
33
Control System
34
Adjusting the Start-In-Gear Protection
34
Adjusting the Throttle Link Position
34
Adjusting the Throttle Cable (MH)
34
Adjusting the Throttle Cable (W)
35
Checking the Gear Shift Operation (MH)
35
Checking the Engine Idle Speed
36
Checking the Gear Shift Operation (W)
36
Bracket
37
Checking the Tilt Operation
37
Lower Unit
37
Checking the Gear Oil Level
37
Changing the Gear Oil
37
Checking the Lower Unit for Air Leakage
38
Checking the Propeller
38
General
38
Checking the Anodes
38
Checking the Battery (W)
38
Lubricating the Outboard Motor
39
Fuel Fuel System
41
Fuel
41
Special Service Tools
42
Fuel System
42
Hose Routing
43
Fuel Line
44
Carburetor
46
Disassembling the Carburetor
50
Checking the Carburetor
50
Assembling the Carburetor
51
Adjusting the Throttle Stop Screw
52
Fuel Pump
53
Checking the Fuel Pump
55
Disassembling the Fuel Pump
56
Assembling the Fuel Pump
56
Checking the Fuel Joint
56
Powr Power Unit
57
Powr
57
Special Service Tools
58
Power Unit
58
Power Unit
60
Checking the Compression Pressure
61
Disassembling the Manual Starter
70
Checking the Spiral Spring
70
Checking the Drive Pawl
70
Measuring the Starter Rope
70
Assembling the Manual Starter
71
Removing the Power Unit
72
Removing the Flywheel Magnet
73
Removing the Electrical Components
74
Removing the Throttle Pulley Assembly
74
Disassembling the Base Assembly
75
Assembling the Base Assembly
75
Reed Valves
76
Removing the Reed Valve Assembly
78
Checking the Reed Valves
78
Cylinder Head
81
Removing the Cylinder Head
81
Checking the Cylinder Head
81
Removing the Exhaust Cover
81
Checking the Exhaust Cover
81
Crankcase
82
Removing the Crankcase
84
Removing the Crankshaft Assembly and Oil Seal Housing
84
Checking the Cylinder Bore
84
Disassembling the Oil Seal Housing
85
Checking the Oil Seal Housing
85
Assembling the Oil Seal Housing
85
Disassembling the Piston
85
Checking the Piston Diameter
86
Checking the Piston Clearance
86
Checking the Piston Rings
86
Checking the Piston Ring Side Clearance
87
Checking the Piston Pin Boss Bore
87
Checking the Piston Pin
87
Checking the Internal Anodes
87
Disassembling the Crankshaft
87
Checking the Crankpin
89
Assembling the Crankshaft
89
Checking the Crankshaft
93
Installing the Crankshaft Bearings
93
Assembling the Piston
94
Assembling the Power Unit
94
Installing the Power Unit
96
Lowr Lower Unit
98
Lowr
98
Lower Unit
100
Special Service Tools
100
Lower Unit (EK40G)
104
Removing the Lower Unit
108
Removing the Water Pump and Shift Rod
108
Checking the Water Pump and Shift Rod
109
Propeller Shaft Housing
110
Removing the Propeller Shaft Housing Assembly
112
Disassembling the Propeller Shaft Assembly
112
Disassembling the Propeller Shaft Housing
112
Disassembling the Forward Gear
113
Checking the Propeller Shaft Housing
113
Checking the Propeller Shaft
113
Assembling the Forward Gear
113
Assembling the Propeller Shaft Assembly
113
Assembling the Propeller Shaft Housing
114
Drive Shaft and Lower Case
115
Removing the Drive Shaft
116
Disassembling the Lower Case
116
Checking the Pinion Gear
116
Checking the Bearings
116
Checking the Drive Shaft
116
Checking the Lower Case and Lower Case Cap
117
Assembling the Lower Case
117
Installing the Drive Shaft
118
Installing the Propeller Shaft Housing
118
Installing the Water Pump and Shift Rod
119
Installing the Lower Unit
120
Shimming
122
Selecting the Pinion Shims
123
Selecting the Forward and Reverse Gear Shims
123
Backlash
124
Measuring the Forward and Reverse Gear Backlash
124
Lower Unit (EK40J)
126
Removing the Lower Unit
130
Removing the Water Pump and Shift Rod
131
Checking the Water Pump and Shift Rod
131
Propeller Shaft Housing
133
Removing the Propeller Shaft Housing Assembly
133
Disassembling the Propeller Shaft Assembly
133
Disassembling the Propeller Shaft Housing
133
Checking the Propeller Shaft Housing
134
Checking the Propeller Shaft
134
Assembling the Propeller Shaft Assembly
134
Assembling the Propeller Shaft Housing
135
Drive Shaft and Lower Case
136
Removing the Drive Shaft
137
Disassembling the Drive Shaft
137
Disassembling the Forward Gear
137
Disassembling the Oil Seal Housing
137
Disassembling the Lower Case
138
Checking the Pinion and Forward Gear
138
Checking the Bearings
138
Checking the Drive Shaft
138
Checking the Lower Case
138
Assembling the Oil Seal Housing
139
Assembling the Lower Case
139
Assembling the Forward Gear
140
Assembling the Drive Shaft
140
Installing the Drive Shaft
140
Installing the Oil Seal Housing
140
Installing the Propeller Shaft Housing
140
Installing the Water Pump and Shift Rod
141
Installing the Lower Unit
143
Shimming
145
Selecting the Pinion Shims
146
Selecting the Forward Gear Shims
147
Selecting the Reverse Gear Shims
148
Backlash
149
Measuring the Forward and Reverse Gear Backlash
149
Brkt Bracket Unit
151
Brkt
151
Special Service Tools
152
Bracket Unit
152
Tiller Handle (MH)
153
Assembling the Tiller Handle
155
Bottom Cowling
156
Upper Case, Pivot Shaft
158
Disassembling the Upper Case
162
Checking the Upper Case
162
Assembling the Upper Case
163
Removing the Pivot Shaft
164
Clamp Brackets, Swivel Bracket
165
Removing the Clamp Brackets
169
Disassembling the Swivel Bracket
169
Assembling the Swivel Bracket
169
Installing the Clamp Brackets
169
Installing the Pivot Shaft
170
Elec Electrical Systems
171
Elec
171
Special Service Tools
172
Electrical Systems
172
Checking the Electrical Components
173
Measuring the Peak Voltage
173
Measuring Low Resistance
173
Electrical Components
174
Top View
174
Starboard View (MH)
175
Starboard View (W)
176
Wiring Diagram (MH)
177
Wiring Diagram (W)
178
Ignition and Ignition Control System
179
Checking the Ignition Spark Gap
179
Checking the Ignition Coil
179
Checking the Spark Plug Caps
179
Checking the CDI Unit
180
Checking the Pulser Coils
180
Checking the Charge Coil
180
Checking the Thermoswitch
181
Checking the Engine Stop Lanyard Switch (MH)
181
Starting System
182
Checking the Fuse (W)
182
Checking the Starter Relay (W)
182
Starter Motor (W)
183
Removing the Starter Motor Pinion
184
Checking the Starter Motor Pinion
184
Checking the Armature
184
Checking the Brushes
185
Checking the Starter Motor Operation
185
Charging System
185
Checking the Rectifier (W)
185
Checking the Lighting Coil
186
Trbl Shtg
188
Ignition System
188
Power Unit
188
Troubleshooting
188
Fuel System
190
Compression Pressure
191
Lower Unit
193
Electrical System
194
Starting System
194
Charging System
195
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