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WORLD WIDE

40V, 50H USA/CANADA

40W, 50W SERVICE MANUAL LIT-18616-01-81

290320


E A30000-0

INDEX

GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTION AND ADJUSTMENT FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT

GEN INFO

SPEC

INSP ADJ

FUEL

POWR

LOWER

BRKT –

ELECTRICAL SYSTEM TROUBLE-ANALYSIS

+

ELEC

TRBL ANLS

1 2 3 4 5 6 7 8 9


GEN INFO

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CHAPTER 1 GENERAL INFORMATION IDENTIFICATION............................................................................................. 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION.................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-6 REMOVAL AND INSTALLATION ............................................................ 1-8

1 2 3 4 5 6 7 8 9


GEN INFO

IDENTIFICATION

E A60000-1*

IDENTIFICATION SERIAL NUMBER The serial number of the outboard motor is stamped on a plate attached to the port side of the clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor serial number is stamped is bonded to the portside of the clamp bracket. The label is specially treated so that peeling it off causes cracks across the serial number. 1 2 3 4

Model name Approved model No. Transom height Serial number

STARTING SERIAL NUMBERS The starting serial number blocks are as follows: Model Worldwide 40VMH

USA, CANADA

Starting serial No.

6H4

S: 010262 ~ L: 310801 ~ L: 560290 ~ S: 191877 ~ L: 491566 ~ S: 290284 ~ L: 860312 ~ L: 510116 ~ S: 060285 ~ L: 360173 ~ S: 110760 ~ L: 842362 ~ X: 740146 ~ L: 430386 ~ L: 921505 ~ S: 880367 ~ L: 544974 ~ X: 900196 ~

C40MH

40VMHD

40VMHO

40MH

40VMO

40VWH

40VE

C40ER

40VEO

40ER

40VEHTO 40VET

P40TH C40TR

40VETO

40TR

Model

Approved model code

Worldwide 50HMHO 50HMHD 50HMO 50HMDO 50HWHD

USA, CANADA — — — — —

50HEDO

50ER

50HET

C50TR

50HETO

50TR

1-1

Approved model code

Starting serial No.

6H5

S: 190662 ~ L: 310380 ~ S: 260189 ~ L: 560258 ~ L: 850194 ~ S: 090431 ~ L: 521079 ~ L: 900101 ~ S: 210142 ~ L: 444058 ~ X: 750216 ~


GEN INFO

SAFETY WHILE WORKING

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SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be followed by Yamaha dealers and their mechanics.

FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling, and keep it away from heat, sparks, and open flames.

VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation.

SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles when using compressed air, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing.

OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha.

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GEN INFO

SAFETY WHILE WORKING

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Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precautions is as follows: 1. While working, maintain good standards of personal and industrial hygiene. 2. Clothing which has become contaminated with lubricants should be changed as soon as practicable, and laundered before further use. 3. Avoid skin contact with lubricants; do not, for example, place a soiled wipingrag in one’s pocket. 4. Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as soon as practicable. 5. To protect the skin, the application of a suitable barrier cream to the hands before working is recommended. 6. A supply of clean lint-free cloths should be available for wiping purposes.

GOOD WORKING PRACTICES 1. The right tools Use the special tools that are advised to protect parts from damage. Use the right tool in the right manner — don’t improvise. 2. Tightening torque Follow the torque tightening instructions. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.

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GEN INFO

SAFETY WHILE WORKING

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3. Non-reusable items Always use new gaskets, packings, Orings, split-pins and circlips etc. on reassembly.

DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed-air on disassembling them. 2. Oil the contact surfaces of moving parts on assembly.

3. After assembly, check that moving parts operate normally.

4. Install bearings with the manufacturer’s markings on the side exposed to view, and liberally oil the bearings. 5. When installing oil seals, apply a light coating of water-resistant grease to the outside diameter.

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GEN INFO

SPECIAL TOOLS

E

A80000-0*

SPECIAL TOOLS The use of correct special tools recommended by Yamaha will aid the work and enable accurate assembly and tune-up. Improvisations and use of improper tools can cause damage to the equipment. NOTE: ● For U.S.A. and Canada, use part number starting with “YB-”, “YU-” or “YW-”. ● For others, use part number starting with “90890-”.

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GEN INFO

SPECIAL TOOLS

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MEASURING Tool name 1 2 3 4 5 6 7 8 9 10 11

Tachometer Dynamic spark tester C.D.I. tester Mity Vac Pressure tester Dial indicator Backlash indicator Magnetic flexible stand Backlash adjusting plate Thickness gauge Pinion height gauge

12

Digital caliper

13 14 15 16 17 18 19 20 21 22 23 24

Gauge block Adapter plate Gauge base Clamp Shimming plate Base plate Compression spring Press plate Gauge pin Digital multimeter Pocket tester Spins test harness

Tool No. Except for USA and USA and Canada a Canada b YU-08036-A 90890-06760 YM-34487 90890-06754 YU-91022-B N.A. YB-35956 90890-06756 YB-35956 90890-06762 YU-03097 90890-01252 YB-06265 90890-06706 YU-34481 90890-06705 YB-07003 N.A. YU-26900-9 N.A. N.A. 90890-06702 N.A.

90890-06704

YB-34432-9 YB-34432-10 YB-34432-11 YB-34432-17 N.A. YB-34446-1 YB-34446-3 YB-34446-4 YB-34446-7 YU-34899-A YU-03112 YB-06757

N.A. N.A. N.A. N.A. 90890-06701 N.A. N.A. N.A. N.A. 90890-06752 90890-03112 90890-06757

1-6

Use for: Idle speed Ignition system Ignition system Fuel joint Lower case Backlash Backlash Backlash Backlash Shimming Pinion shimming Pinion Forward shimming shimming Pinion shimming Pinion shimming Pinion shimming Pinion shimming Forward shimming Forward shimming Forward shimming Forward shimming Forward shimming Electrical Electrical Peak voltage measurement


GEN INFO

SPECIAL TOOLS

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GEN INFO

SPECIAL TOOLS

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REMOVAL AND INSTALLATION Tool name

1

Small end bearing needle installer

Tool No. Except for USA and USA and Canada a Canada b YB-06106

90890-06526

2

Bearing separator

YB-06219

90890-06534

3 4

Flywheel holder Flywheel puller

YB-06139 YB-06117

90890-06522 90890-06521

5

Stopper guide plate

N.A.

90890-06501

6 7 8 9

Bearing housing puller Center bolt Universal puller Oil seal installer

YB-06234 N.A. YB-06117 YB-06168

90890-06503 90890-06504 N.A. N.A.

10

Needle bearing remover

YB-06112

90890-06614

11

Needle bearing installer

YB-06111

90890-06614

12

Bearing outer race puller clow

N.A.

90890-06535

Use for:

Small end Reverse gear bearing Crank shaft Forward bearing gear inner bearing Flywheel Flywheel Reverse gear bearing Propeller shaft housing Drive shaft outer bearing Propeller shaft housing Propeller shaft housing Propeller shaft housing Propeller shaft oil seal Propeller shaft needle bearing Propeller shaft needle bearing Reverse gear bearing

13

Stopper guide stand

14

Slide hammer set

YB-06096

15 16 17

Pinion nut wrench Socket adapter Drive shaft holder Needle bearing attachment Drive shaft needle bearing depth stop Bearing installer Bearing installer Bearing installer

N.A. N.A. YB-06079

Forward Reverse gear 90890-06538 gear outer bearing bearing Drive shaft outer bearing Reverse gear N.A. Forward bearing gear outer bearing 90890-06505 Pinion nut 90890-06506 Pinion nut 90890-06517 Pinion nut

YB-06063

90890-06614

Drive shaft needle bearing

YB-34473

N.A.

Drive shaft needle bearing

YB-06167 YB-06110 YB-06270-A

90890-06628 90890-06627 90890-06640

Drive shaft oil seal Drive shaft outer bearing Forward gear inner bearing

18 19 20 21 22

N.A.

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GEN INFO

SPECIAL TOOLS

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GEN INFO

SPECIAL TOOLS

Tool name 23

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Tool No. Except for USA and USA and Canada a Canada b N.A. 90890-06523

25 26 27

Bearing outer race puller Bearing outer race puller clow Bearing installer Shift rod wrench Tilt cylinder wrench

28

Bearing depth plate

N.A.

90890-06603

29

Driver rod - SL

N.A.

90890-06602

30

Driver rod - SS

N.A.

90890-06604

31 32 33

Driver rod - L Driver rod - S Driver rod - M10

YB-06071 N.A. N.A.

90890-06605 90890-06606 90890-06652

24

N.A.

Use for: Forward gear outer bearing

90890-06532

Forward gear outer bearing

YB-41446 90890-06626 YB-06052 N.A. YB-06175-2B 90890-06544

Forward gear outer bearing Shift rod PTT Propeller Drive shaft shaft needle needle bearbearing ing Drive shaft needle bearing Propeller shaft needle bearing Bearing and oil seal Bearing and oil seal Bearing and oil seal

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SPEC

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CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS .......................................................................... 2-1 MAINTENANCE SPECIFICATIONS................................................................ 2-7 ENGINE..................................................................................................... 2-7 LOWER...................................................................................................... 2-9 ELECTRICAL ........................................................................................... 2-10 DIMENSION 1......................................................................................... 2-13 DIMENSION 2......................................................................................... 2-15 TIGHTENING TORQUE................................................................................. 2-17 SPECIFIED TORQUE .............................................................................. 2-17 GENERAL TORQUE ............................................................................... 2-18

1 2 3 4 5 6 7 8 9


SPEC

GENERAL SPECIFICATIONS

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GENERAL SPECIFICATIONS Item

Model Unit

Worldwide USA, CANADA

DIMENSION: Over-all length Over-all width Over-all height

40VMH C40MH

40VMHD — 1,281 (50.4)

mm (in)

mm (in)

40VMO —

40VWH —

670 (26.4)

1,281 (50.4)

349 (13.7)

mm (in)

S L X

40VMHO 40MH

1,223 (48.1)

360 (14.2)

1,223 (48.1)

mm (in)

1,350 (53.1)

mm (in)

Boat transom height S L X WEIGHT: (with aluminum propeller) S L X PERFORMANCE: Output (ISO) Full throttle operating range Maximum fuel consumption ENGINE: Type Number of cylinder Total displacement Bore × Stroke Compression ratio Number of carburetor Intake system Scavenging system Control system Starting system Ignition system Alternator output Enrichment system Advance type Spark plug (NGK) For CANADA and Europe Exhaust system Cooling system Lubrication system

mm (in)

381 (15.0)

381 (15.0)

mm (in)

508 (20.0)

mm (in)

381 (15.0)

kg (lb)

74 (163)

75.8 (167)

71.5 (158)

kg (lb)

76.5 (169)

84 (185.2)

77.5 (171)

74 (163)

81.5 (179.7)

kg (lb)

kW (hp)/rpm

29.4 (40)/5,000

rpm

4,500 ~ 5,500

L (US gal, Imp gal)/ h at rpm

18.5 (4.9, 4.1) at 5,500

2 stroke - L 3 3

cm (cu. in)

698 (42.6)

mm (in)

67.0 × 66.0 (2.64 × 2.60) 6.00 3 Reed valve Loop charge Tiller control

Remote control

Tiller control Manual & Electric

Manual CDI 80W

12-80

80W

Choke valve

12-6A Prime start

Electric automatic B7HS-10 BR7HS-10 Through propeller boss Water Pre-mixed fuel & oil

2-1

Oil injection

Pre-mixed fuel & oil


SPEC

GENERAL SPECIFICATIONS

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Item Worldwide USA, CANADA

FUEL AND LUBRICATION: Fuel type Fuel rating Engine oil type/grade Mixing ratio Engine oil tank capacity Gear oil type Gear oil quantity BRACKET: Trim/tilt system Tilt angle Tilt-up angle Trim angle Shallow water crushing angle Steering angle DRIVE UNIT: Gear shift position Gear ratio Gear type Clutch type Propeller direction Propeller drive system Propeller series mark ELECTRICAL: Battery capacity Cold cranking

Model Unit

40VMH C40MH

40VMHD —

40VMHO 40MH

40VMO —

40VWH —

Regular gasoline 1

P.O.N.*

Min. 86 2-stroke outboard motor oil / TC-W3 50 : 1

50 : 1

1.5 (1.6, 1.3)

L (US qt, Imp qt)

Hypoid gear oil-SAE#90 cm3 (US oz, Imp oz)

430 (14.5, 15.1)

Manual tilt degree

8, 12, 16, 20, 24

degree

66

69

8, 12, 16, 20, 24 66

degree at 12˚ transom

–4 ~ 20

degree

Tilt angle +18

Tilt angle +18

degree (left + right)

Tilt angle +18

40 + 40

F-N-R 1.85 (24/13) Spiral bevel gear Dog clutch Clockwise Spline G

Ah (kC)

70 (252)

Amps

380

*1: Pump Octane Number ; (Research octane + Motor octane)/2

2-2

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YAMAHA OUTBOARD 50HMDO Service Repair Manual L 560258 -  

YAMAHA OUTBOARD 50HMDO Service Repair Manual L 560258 -  

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