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Yamaha 40 Owner's Manual
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Yamaha 40 Owner's Manual

Outboard motor
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OWNER'S MANUAL
U.S.A.Edition
LIT-18626-06-58
63B-28199-1E

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  • Page 1 OWNER’S MANUAL U.S.A.Edition LIT-18626-06-58 63B-28199-1E...
  • Page 2 EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.

  • Page 3: Important Manual Information

    EMU25110 tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. 40, 50 In this Owner’s Manual particularly important...

  • Page 4: Table Of Contents

    Table of contents General information ......1 Trim tab with anode......16 Trim rod (tilt pin) ......17 Identification numbers record... 1 Tilt support lever for power trim Outboard motor serial number ..1 and tilt or hydro tilt model....17 Key number........
  • Page 5 Procedure for tilting up ....38 Connecting the battery ....58 Procedure for tilting down ....39 Disconnecting the battery....59 Cruising in shallow water ....40 Checking top cowling ...... 59 Power trim and tilt models / Coating the boat bottom ....59 power tilt models......

  • Page 6: General Information

    Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number...

  • Page 7: Safety Information

    General information should give you an understanding of the motor and its operation. Before operating the boat, read any own- EMISSION CONTROL INFORMATION er’s or operator’s manuals supplied with it ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

  • Page 8: Important Labels

    Never illegally discard (dump) the product. Attach the engine stop switch lanyard cord Yamaha recommends consulting the deal- to a secure place on your clothing, or your er on discarding the product. arm or leg while operating. If you acciden- Be informed about boating safety.

  • Page 9: Basic Boating Rules (Rules Of The Road)

    General information EMU25401 These rules determine which vessel has the Label right-of-way, and what each vessel should EWM01260 WARNING Stand-on vessel Be sure shift control is in neutral before The vessel with the right-of-way has the duty starting engine. (except 2HP) to continue its course and speed, except to Do not touch or remove electrical parts avoid an immediate collision.

  • Page 10: Other Special Situations

    General information sel head-on) Crossing When two power driven vessels are crossing Crossing: (you are traveling across the oth- each other’s path close enough to run the er vessel’s path) risk of collision, the vessel which has the oth- Overtaking: (you are passing or being er on the starboard (right) side must keep out passed by another vessel) of the way of the other.
  • Page 11 General information bend that may obstruct the view of other wa- er is going towards the port). This means that ter vessels, the operator should sound a pro- red buoys are passed on the starboard longed blast on the whistle (4 to 6 seconds). (right) side when proceeding from open wa- If another vessel is around the bend, it too ter into port, and black buoys are to port (left)

  • Page 12: Fueling Instructions

    General information ZMU01708 EMU25540 away from sparks, flames, or other Fueling instructions sources of ignition. EWM00010 Stop engine before refueling. WARNING Refuel in a well-ventilated area. Refuel GASOLINE AND ITS VAPORS ARE HIGH- portable fuel tanks off the boat. LY FLAMMABLE AND EXPLOSIVE! Take care not to spill gasoline.

  • Page 13: Gasoline

    The performance of your outboard motor will the fuel meets minimum octane ratings. be critically affected by your choice of propel- Yamaha does not recommended gasohol ler, as an incorrect choice could adversely containing methanol because it can cause affect performance and could also seriously fuel system damage or engine performance damage the motor.

  • Page 14: Start-In-Gear Protection

    53. on the engine. EMU25770 Start-in-gear protection Yamaha outboard motors are fitted with pro- Yamaha outboard motors or Yamaha-ap- pellers chosen to perform well over a range proved remote control units are equipped of applications, but there may be uses where with start-in-gear protection device(s).

  • Page 15: Basic Components

    Basic components EMU25796 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. 40, 50 ZMU05014 1. Battery cable 15. Fuel tank* 2. Anode(s) EMU25802 3. Propeller* Fuel tank 4.

  • Page 16: Fuel Joint

    Basic components tions. ZMU03157 1. Power trim and tilt switch 2. Remote control lever 1. Fuel joint 3. Neutral interlock trigger 2. Fuel gauge 4. Neutral throttle lever 3. Fuel tank cap 5. Main switch / choke switch 4. Air vent screw 6.

  • Page 17: Neutral Interlock Trigger

    Basic components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral in- terlock trigger up. 1. Fully open 2. Fully closed EMU25911 Tiller handle To change direction, move the tiller handle to the left or right as necessary.

  • Page 18: Throttle Grip

    Basic components 1. Throttle indicator 1. Forward “ ” 2. Neutral “ ” EMU25970 3. Reverse “ ” Throttle friction adjuster A friction device provides adjustable resis- EMU25941 tance to movement of the throttle grip or the Throttle grip remote control lever, and can be set accord- The throttle grip is on the tiller handle.

  • Page 19: Engine Stop Lanyard Switch

    Basic components NOTE: The engine cannot be started with the lock plate removed. When constant speed is desired, tighten the adjuster to maintain the desired throttle set- ting. EMU25990 Engine stop lanyard switch 1. Lanyard 2. Lock plate The lock plate must be attached to the en- gine stop switch for the engine to run.

  • Page 20: Main Switch

    Basic components EMU26090 EMU26141 Main switch Power trim and tilt switch on remote The main switch controls the ignition system; control or tiller handle its operation is described below. The power trim and tilt system adjusts the “ ” (off) outboard motor angle in relation to the tran- With the main switch in the “...

  • Page 21: Power Trim And Tilt Switch On Bottom Engine Cowling

    Basic components DOWN ZMU03096 EMU26151 NOTE: Power trim and tilt switch on bottom For instructions on using the power trim and engine cowling tilt switch, see page 37. The power trim and tilt switch is located on EMU26241 the side of the bottom engine cowling. Press- Trim tab with anode ing the switch “...

  • Page 22: Trim Rod (Tilt Pin)

    Basic components ZMU03097 ZMU03194 EMU26372 1. Trim tab Top cowling lock lever(s) (turn type) 2. Bolt To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- EMU26261 Trim rod (tilt pin) stalling the cowling, check to be sure it fits The position of the trim rod determines the properly in the rubber seal.

  • Page 23: Tachometer

    Basic components EMU26470 7. Engine trouble warning indicator Tachometer 8. Set button This gauge shows the engine speed and has 9. Mode button the following functions. NOTE: The water separator and engine trouble warning indicators only operate when the en- gine is equipped with the appropriate func- tions.

  • Page 24: Overheat Warning Indicator (Digital Type)

    Basic components rious engine damage will occur. ZMU04581 NOTE: ZMU01867 Memorize the trim angles that work best for 1. Oil level indicator your boat under different conditions. Adjust the trim angle to the desired setting with the EMU26581 Overheat warning indicator (digital power trim and tilt switch.

  • Page 25: Warning System

    Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU26814 Overheat warning ZMU03025 This engine has an overheat warning device.

  • Page 26: Oil Level Warning And Oil Filter Clogging Warning

    Basic components ZMU03942 ZMU03026 The buzzer will sound (if equipped on the EMU26845 Oil level warning and oil filter tiller handle, remote control box, or main clogging warning switch panel). Oil injection models This engine has an oil level warning system. If the oil level falls below the lower limit, the warning system will activate.
  • Page 27 Basic components ZMU03366 1. Oil filter...

  • Page 28: Operation

    Operation EMU26901 specific boat and motor combination. Installation EWM00830 ECM00110 WARNING CAUTION: Improper mounting of the outboard mo- Incorrect engine height or obstructions tor could result in hazardous conditions to smooth water flow (such as the design such as poor handling, loss of control, or or condition of the boat, or accessories fire hazards.

  • Page 29: Clamping The Outboard Motor

    Other- mine the optimum mounting height. Con- wise the engine could be completely lost sult your Yamaha dealer boat if it accidentally falls off the transom. manufacturer for further information on de- termining the proper mounting height.

  • Page 30: Breaking In Engine

    Operation board (if packed). For details, consult EMU27060 Gasoline and engine oil mixing chart your Yamaha dealer. (50:1) EWM00650 WARNING Avoid using bolts, nuts or washers other than those contained in the engine pack- aging. If used, they must be of at least the same quality of material and strength and must be tightened securely.

  • Page 31: Preoperation Checks

    Keep hands, hair, and clothes away Check fuel line connections to be sure they from the flywheel and other rotating are tight (if equipped Yamaha fuel tank or parts while the engine is running. boat tank). Be sure the fuel tank is positioned on a se-...

  • Page 32: Filling Fuel And Engine Oil

    Fuel tank capacity (if equipped Yamaha Ring Free Fuel Additive, available from fuel tank): your Yamaha dealer. Ring Free Fuel Addi- 25 L (6.60 US gal) (5.50 Imp.gal) tive has repeatedly proven its ability to clean combustion deposits from inside the engine, notably the critical piston-ring-land area, and fuel system components.

  • Page 33: Filling Oil For Electric Start Models

    EWM00530 WARNING Do not add gasoline into the oil tank. Fire or explosion could result. This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ZMU03370 ing conditions. No fuel premixing is needed.

  • Page 34: Oil Level Indicator Operation

    450 No refilling necessary. (0.48 US qt, 0.40 Imp qt) Yellow from 450 cm (0.48 US qt, 0.40 Imp qt) down to Add oil; see page 28. 200 cm (0.21 US qt, 0.18 Imp qt) Buzzer sounds in...

  • Page 35: Starting Engine

    Operation tank cap, loosen it 2 or 3 turns. zontally, otherwise fuel cannot be drawn from the fuel tank. Squeeze the primer pump with the outlet end up until you feel it become firm. ZMU02295 If there is a fuel joint on the motor, firmly connect the fuel line to the joint.
  • Page 36 Operation gine stop switch. Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds. EWM00120 WARNING Attach the engine stop switch lanyard to a secure place on your clothing, or your arm or leg while operating. Do not attach the lanyard to clothing that could tear loose.
  • Page 37 Operation EMU27662 Electric start and remote control models Place the remote control lever in neutral. Turn the main switch to “ ” (on). Turn the main switch to “ ” (start), and hold it for a maximum of 5 seconds. NOTE: The start-in-gear protection device prevents the engine from starting except when in neu-...

  • Page 38: Warming Up Engine

    Place the throttle grip in the fully closed the lower case or the cooling water pilot position. hole is blocked. Consult your Yamaha dealer if the problem cannot be located and corrected. Move the gear shift lever quickly and...

  • Page 39: Reverse (Automatic Reverse Lock And Power Trim And Tilt Models)

    Operation firmly from neutral to forward. Move the gear shift lever quickly and firmly from neutral to reverse. Remote control models Pull up the neutral interlock trigger (if equipped) and move the remote control lever quickly and firmly from neutral to forward.

  • Page 40: Procedure

    Operation ping the engine immediately after operating at high speed is not recommended. EMU27844 Procedure Push and hold the engine stop button or turn the main switch to “ ” (off). ZMU02301 Remove the key if the boat will be left unattended.

  • Page 41: Adjusting Trim Angle

    Operation Adjust the outboard motor trim angle using the power trim and tilt switch. ZMU03110 1. Power trim and tilt switch ZMU03109 1. Trim operating angle DOWN EMU27881 Adjusting trim angle ZMU03096 Power trim and tilt models EWM00750 1. Power trim and tilt switch WARNING Be sure all people are clear of the out- board motor when adjusting the tilt an-...

  • Page 42: Adjusting Boat Trim

    Operation “ ” (down). the operator and passengers overboard. Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions. NOTE: To adjust the trim angle while the boat is moving, use the power trim and tilt switch lo- cated on the remote control device or tiller handle, if equipped.

  • Page 43: Procedure For Tilting Up

    Operation sion with obstructions, and also to reduce salt corrosion. EWM00220 WARNING Be sure all people are clear of the out- board motor when tilting up and down, also be careful not to pinch any body parts between the drive unit and engine bracket.

  • Page 44: Procedure For Tilting Down

    Operation ZMU01935 ZMU03115 EWM00260 WARNING After tilting the outboard motor, be sure to support it with the tilt support knob or tilt support lever. Otherwise the outboard motor could fall back down suddenly if oil in the power trim and tilt unit loses pres- sure.

  • Page 45: Cruising In Shallow Water

    Operation ZMU02569 EMU28060 Push the power tilt / power trim and tilt Cruising in shallow water switch “ ” (down) to lower the outboard The outboard motor can be tilted up partially motor to the desired position. to allow operation in shallow water. EMU28090 Power trim and tilt models / power tilt models...

  • Page 46: Cruising In Other Conditions

    ZMU01935 For cooling system flushing instructions, see page 43. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit (not available for some models) if you use the outboard motor in turbid (muddy) water...

  • Page 47: Maintenance

    Gear ratio: Full throttle operating range: 1.85 (24/13) 4500–5500 r/min Trim and tilt system: Maximum output: Power trim and tilt 40TR 29.4 kW@5000 r/min (40 Propeller mark: HP@5000 r/min) 50TR 36.8 kW@5000 r/min (50 Fuel and oil: HP@5000 r/min) Recommended fuel:...

  • Page 48: Transporting And Storing Outboard Motor

    Maintenance Spark plug: sition using a motor support device such as 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) a transom saver bar. Consult your Yamaha Propeller nut: dealer for further details. 35.0 Nm (25.8 ft-lb) (3.57 kgf-m) EMU28235 Clamp screw mounting models...

  • Page 49: Procedure

    NOTE: Cooling system flushing is essential to prevent the cooling system from clog- The use of “Yamaha Fuel Conditioner and ging up with salt, sand, or dirt. In addi- Stabilizer” eliminates the need to drain the tion, fogging of the engine is mandatory fuel system.

  • Page 50: Lubrication (Oil Injection Models)

    Seal replacement should be per- follow these preventive measures: formed by an authorized Yamaha dealer Charge batteries in a well-ventilated ar- prior to use. Grease all grease fittings. For further de- Keep batteries away from fire, sparks, tails, see page 49.

  • Page 51: Cleaning The Outboard Motor

    EMU28510 Replacement parts If replacement parts are necessary, use only genuine Yamaha parts or parts of the same type and of equivalent strength and materi- als. Any part of inferior quality may malfunc- ZMU03223 tion, and the resulting loss of control could endanger the operator and passengers.

  • Page 52: Maintenance Chart

    When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 50 hours Item...
  • Page 53 Maintenance Initial Every 50 hours Item Actions 10 hours hours (6 hours (1 (1 month) months) months) year) Inspection / replace- Water pump ment Oil pump Inspection / adjustment Oil tank water drain Inspection / cleaning Cleaning / adjustment / Spark plug(s) replacement...

  • Page 54: Greasing

    Maintenance EMU28931 Greasing Yamaha marine grease (Water resistant grease) 40, 50 ZMU03414 The spark plug is an important engine com- EMU28952 Cleaning and adjusting spark plug ponent and is easy to inspect. The condition EWM00560 of the spark plug can indicate something WARNING about the condition of the engine.

  • Page 55: Checking Fuel System

    Improper repairs can make the outboard unsafe to operate. Check the fuel lines for leaks, crack, or mal- function. If a problem is found, your Yamaha dealer or other qualified mechanic should re- 1. Spark plug gap pair it immediately.

  • Page 56: Inspecting Fuel Filter

    If any water is found in the If you have any question about properly fuel, the Yamaha portable fuel tank or doing this procedure, consult your other fuel tanks should be checked and Yamaha dealer.

  • Page 57: Inspecting Idling Speed

    If you have difficulty ver- 1. Filter cup ifying the idle speed, or the idle speed re- 2. Filter element quires adjustment, consult a Yamaha dealer 3. Filter housing or other qualified mechanic. 4. O-ring Verify whether the idle speed is set to Reinstall the filter element in the cup.

  • Page 58: Exhaust Leakage

    Never get under the lower unit while it NOTE: is tilted, even when the tilt support lever Consult your Yamaha dealer if any operation is locked. Severe injury could occur if is abnormal. the outboard motor accidentally falls.

  • Page 59: Removing The Propeller

    Maintenance move the key, and remove the lanyard from the engine stop switch. Turn off the battery cut-off switch if your boat has one. Do not use your hand to hold the pro- peller when loosening or tightening the propeller nut. Put a wood block be- tween the anti-cavitation plate and the propeller to prevent the propeller from turning.

  • Page 60: Installing The Propeller

    Apply Yamaha marine grease or a cor- Tilt the outboard motor so that the gear rosion resistant grease to the propeller oil drain screw is at the lowest point pos- shaft.

  • Page 61: Cleaning Fuel Tank

    NOTE: Remove the fuel tank from the boat be- For disposal of used oil consult your Yamaha fore cleaning it. Work only outdoors in dealer. an area with good ventilation.

  • Page 62: Inspecting And Replacing Anode(S)

    EMU29312 Inspecting and replacing anode(s) Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the ZMU03135 external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

  • Page 63: Connecting The Battery

    (for example: welding charge the battery when it is low. equipment, lighted cigarettes, and so NOTE: on.) Consult a Yamaha dealer when charging or DO NOT SMOKE when charging or han- re-charging batteries. dling batteries. EMU29331 KEEP BATTERIES AND ELECTROLYTIC Connecting the battery FLUID OUT OF REACH OF CHILDREN.

  • Page 64: Disconnecting The Battery

    EMU29390 Checking top cowling Check the fitting of the top cowling by push- ing it with both hands. If it is loose have it re- paired by your Yamaha dealer. ZMU04678 EMU29400 Coating the boat bottom A clean hull improves boat performance. The boat bottom should be kept as clean of ma- rine growth as possible.

  • Page 65: Trouble Recovery

    Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble warning indicator is Q. Are spark plug(s) fouled or of incorrect flashing, consult your Yamaha dealer.
  • Page 66 Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
  • Page 67 Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on gear housing? Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower A. Distribute load to place boat on an even unit.

  • Page 68: Temporary Action In Emergency

    EWM00630 Q. Is steering pivot loose or damaged? WARNING A. Tighten or have serviced by a Yamaha Be sure to use the specified fuse. An in- dealer. correct fuse or a piece of wire could allow EMU29432 excessive current flow.

  • Page 69: Power Trim And Tilt / Power Tilt Will Not Operate

    NOTE: ate. Make sure the remote control lever Consult your Yamaha dealer if the new fuse is in neutral. Otherwise the boat could immediately blows again. unexpectedly start to move, which EMU29522 could result in an accident.

  • Page 70: Emergency Starting Engine

    Trouble Recovery wheel or other moving parts when the main switch must be “ ” (on), if engine is running. Do not install the equipped. starter mechanism or top cowling after the engine is running. Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor.

  • Page 71: Engine Fails To Operate

    Trouble Recovery NOTE: When the engine does not start with this pro- cedure, see page 66. EMU29670 Engine fails to operate EMU29704 Cold engine fails to start If the engine fails to start when it is cold, use the following procedure. ZMU03142 EWM00410 WARNING...

  • Page 72: Treatment Of Submerged Motor

    Do not keep the starter motor turning If the outboard motor is submerged, immedi- for more than 5 seconds. If the starter ately take it to a Yamaha dealer. Otherwise motor is turned continuously for more some corrosion may begin almost immedi- than 5 seconds, the battery will be ately.
  • Page 73 Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope. ZMU01911 Take the outboard motor to a Yamaha dealer as soon as possible. ECM00400 CAUTION: Do not attempt to run the outboard motor...

  • Page 74: Consumer Information

    Consumer information EMU29811 Important warranty information for U.S.A. and Canada...
  • Page 75 Consumer information...

  • Page 76: Yamaha Motor Corporation, U.s.a. Outboard Motor Two Year Limited Warranty

    Consumer information EMU29820 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY...
  • Page 77 Consumer information...
  • Page 78 Consumer information...

  • Page 79: Important Warranty Information If You Use Your Yamaha Outside The Usa Or Canada

    Consumer information EMU29841 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE THE USA OR CANADA...
  • Page 80 Printed in Japan May 2005–0.8 × 1 ! Printed on raecycled paper...
  • Page 81 (A l’usage du concessionnaire) MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation) YAMAHA DEALER NUMBER NO. DU CONCESSIONNAIRE YAMAHA DEALER NAME YAMAHA MOTOR CO., LTD. NOM DU MADE IN JAPAN CONCESSIONNAIRE PAYS D'ORIGINE JAPON USAGE...
  • Page 82 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT...

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