Yamaha F30A User manual
F30A
F40B
SERVICE MANUAL
67C-28197-3K-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 1
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 out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F30A, F40B
SERVICE MANUAL
©2007 by Yamaha Motor Co., Ltd.
1st Edition, August 2007
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in China
Contents
General information 1
GEN
INFO
Specification 2
SPEC
Periodic check and adjustment 3
CHK
ADJ
Fuel system 4
FUEL
Power unit 5
POWR
Lower unit 6
LOWR
Bracket unit 7
BRKT
Electrical system 8
ELEC
Troubleshooting 9
TRBL
SHTG
Index
–+
67C3K11
GEN
INFO
1
2
3
4
5
6
7
8
9
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbol.......................................................................................................1-2
Abbreviation...............................................................................................1-3
Sealant and locking agent table ................................................................1-3
Safety while working......................................................................................1-4
Fire prevention...........................................................................................1-4
Ventilation..................................................................................................1-4
Self-protection ...........................................................................................1-4
Part, lubricant, and sealant........................................................................1-4
Good working practice...............................................................................1-5
Disassembling and assembling .................................................................1-5
Identification...................................................................................................1-6
Model.........................................................................................................1-6
Serial number ............................................................................................1-6
Special service tool .......................................................................................1-7
Propeller selection.......................................................................................1-13
Propeller size...........................................................................................1-13
Selection..................................................................................................1-13
Predelivery check ........................................................................................1-14
Checking the outboard motor mounting height........................................1-14
Checking the fuel system ........................................................................1-14
Checking the engine oil level...................................................................1-14
Checking the gear oil level ......................................................................1-15
Checking the battery (E and W model)....................................................1-15
Connecting the throttle cable and shift cable...........................................1-15
Checking the gear shift and throttle operation.........................................1-16
Checking the steering system .................................................................1-17
Checking the tilt system (D model)..........................................................1-17
Checking the PTT system (PTT model) ..................................................1-17
Checking the engine start switch and engine shut-off switch ..................1-18
Checking the cooling water pilot hole ......................................................1-19
Test run ...................................................................................................1-19
Break-in ...................................................................................................1-19
After the test run ......................................................................................1-20
Precaution when transporting or storing the outboard motor ..................1-20
GEN
INFO General information
1-1 67C3K11
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
•Parts are shown and detailed in an exploded diagram and are listed in the component list (see 1
in the figure below for an example page).
•The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2in the figure below).
•Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3in the figure below).
•Tightening torque specifications are provided in the exploded diagrams (see 4in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
•Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
5
2
3
41
67C3K11 1-2
1
2
3
4
5
6
7
8
9
Symbol
The symbols below are designed to indicate the content of a chapter.
General information
Specification
Periodic check and adjustment
Fuel system
Power unit
Lower unit
Bracket unit
Electrical system
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
–+
Symbols 1to 6indicate specific data.
1Special service tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Cin an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7Apply 4-stroke motor oil
8Apply gear oil
9Apply water resistant grease (Yamaha grease A)
0Apply molybdenum disulfide grease
AApply corrosion resistant grease
(Yamaha grease D)
BApply low temperature resistant grease
(Yamaha grease C)
CApply injector grease
Symbols Dto Iin an exploded diagram or illustration indicate the type of sealant or locking agent
and the application point.
DApply Gasket Maker
EApply ThreeBond 1104J
FApply LOCTITE 271 (red)
GApply LOCTITE 242 (blue)
HApply LOCTITE 572
IApply silicone sealant
123456
T
R
.
.
7890ABC
E G
A M D C I
DEFGHI
GM
1104J
271
LT
242
LT
572
LT SS
How to use this manual
GEN
INFO General information
1-3 67C3K11
Abbreviation
The following abbreviations are used in this service manual.
Sealant and locking agent table
The following table contains sealants, locking agents, and lubricants used in this service manual
that are not listed on page 1-2.
Abbreviation Description
API American Petroleum Institute
ATDC After Top Dead Center
BOW Bow end
CCA Cold Cranking Ampere
CDI Capacitor Discharge Ignition
D model Hydraulic tilt model
E model Electric starter model
EN European Norm (European standard)
EX Exhaust
F position Forward position
H model Tiller handle model
IEC International Electrotechnical Commission
IN Intake
M model Manual starter model
N position Neutral position
PORT Port side
PTT Power trim and tilt
R model Remote control model
R position Reverse position
SAE Society of Automotive Engineers
STBD Starboard side
WD Wiring Diagram
W model Electrical starter with manual starter model
Symbol Name Application Manufacturer
LOCTITE 518 Sealant Henkel
518
67C3K11 1-4
1
2
3
4
5
6
7
8
9
Safety while working
To prevent an accident or injury and to
ensure quality service, follow the safety pro-
cedures 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 ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Part, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned 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.
1. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
2. 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.
3. Change and wash clothing as soon as
possible if soiled with lubricants.
4. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
5. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
How to use this manual / Safety while working
GEN
INFO General information
1-5 67C3K11
6. Maintain good standards of personal and
industrial hygiene.
Good working practice
Special service tool
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable part
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembling and assembling
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply oil or fluid to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indi-
cated 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 nor-
mally after assembly.
67C3K11 1-6
1
2
3
4
5
6
7
8
9
Identification
Model
This manual covers the following models.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
Applicable model
F30AMHD, F30AEHT, F30AET,
F40BMHD, F40BWHD, F40BWHT,
F40BED, F40BET
Model name Approved
model code
Starting
serial No.
F30A 69H 1008205–
F40B 67C 1035037–
S67C1010
Safety while working / Identification
GEN
INFO General information
1-7 67C3K11
Special service tool
Oil filter wrench
90890-01426
Digital tachometer
90890-06760
Timing light
90890-03141
Leakage tester
90890-06840
Vacuum/pressure pump gauge set
90890-06756
Pilot screw adjusting tool
90890-03154
Vacuum gauge
90890-03094
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
67C3K11 1-8
1
2
3
4
5
6
7
8
9
Valve spring compressor
90890-04019
Valve spring compressor attachment
90890-06320
Valve guide remover/installer
90890-06801
Valve guide reamer
90890-06804
Valve seat cutter holder
90890-06316
Valve seat cutter
90890-06312, 90890-06323, 90890-06325,
90890-06327, 90890-06328
Driver rod LS
90890-06606
Ball bearing attachment
90890-06631
Piston slider
90890-06529
Bearing separator
90890-06534
Special service tool
GEN
INFO General information
1-9 67C3K11
Stopper guide plate
90890-06501
Stopper guide stand
90890-06538
Bearing puller assembly
90890-06535
Driver rod L3
90890-06652
Needle bearing attachment
90890-06612, 90890-06614
Driver rod SS
90890-06604
Bearing depth plate
90890-06603
Ball bearing attachment
90890-06637
Bearing inner race attachment
90890-06639, 90890-06640, 90890-06641
Ball bearing attachment
90890-06633
67C3K11 1-10
1
2
3
4
5
6
7
8
9
Drive shaft holder 3
90890-06517
Pinion nut holder
90890-06715
Bearing outer race puller assembly
90890-06523
Driver rod LL
90890-06605
Bearing outer race attachment
90890-06622, 90890-06627
Driver rod SL
90890-06602
Ball bearing attachment
90890-06634
Bearing inner race attachment
90890-06644
Shimming plate
90890-06701
Pinion height gauge
90890-06710
Special service tool
GEN
INFO General information
1-11 67C3K11
Pinion height gauge plate B
90890-06712
Digital caliper
90890-06704
Center bolt
90890-06504
Bearing housing puller claw S
90890-06564
Backlash indicator
90890-06706
Magnet base plate
90890-07003
Dial gauge set
90890-01252
Magnet base B
90890-06844
Bushing installer center bolt
90890-06601
Digital circuit tester
90890-03174
GEN
INFO General information
1-13 67C3K11
Propeller selection
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,
and on the side of the propeller boss.
aPropeller diameter (in inches)
bPropeller pitch (in inches)
cPropeller type (propeller mark)
Selection
When the engine speed is in the full throttle
operating range (4,500–5,500 r/min [F30A] or
5,000–6,000 r/min [F40B]), the ideal propeller
for the boat is one that provides maximum
performance in relation to boat speed and
fuel consumption.
*: This propeller is available in 2 types.
S69W1040
× -
abc
S69W1030
× -
abc
Propeller size (in) Material
10 ×15 - G
Aluminum
10 1/4 ×14 - G*
10 1/4 ×15 - G
10 1/4 ×16 - G
10 3/8 ×13 - G
10 5/8 ×12 - G
10 5/8 ×13 - G
10 3/4 ×16 - G
10 3/4 ×17 - G
11 1/8 ×13 - G
11 1/4 ×14 - G*
11 3/8 ×12 - G*
11 1/2 ×13 - G
11 5/8 ×11 - G
11 3/4 ×12 - G
12 ×11 - G
12 1/4 ×9 - G
S69W1050
× -
abc
67C3K11 1-14
1
2
3
4
5
6
7
8
9
Predelivery check
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
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) abelow it. If
the mounting height is too high, cavita-
tion 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.
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 differ-
ent heights.
2. Check that the clamp brackets are
secured with the clamp bolts.
Checking the fuel system
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel or 2-stroke outboard motor oil.
Checking the engine oil level
1. Check the engine oil level.
NOTE:
If the engine oil is below the minimum level
mark a, add sufficient oil until the level is
between aand b.
S6D51030
a
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, SJ, or SL
SAE: 5W-30, 10W-30, or 10W-40
Engine oil quantity:
Without oil filter replacement:
2.0 L (2.11 US qt, 1.76 Imp qt)
S67C1016
S67C1017
b
a
Propeller selection / Predelivery check
GEN
INFO General information
1-15 67C3K11
Checking the gear oil level
1. Check the gear oil level.
NOTE:
If the oil is at the correct level, a small
amount of oil should overflow out of the
check hole when the gear oil check screw is
removed.
Checking the battery (E and W
model)
1. Check the battery capacity, electrolyte
level, and specific gravity of the electro-
lyte.
2. Check that the positive and negative bat-
tery cables are securely connected.
Connecting the throttle cable and
shift cable
NOTE:
To adjust the throttle cable and shift cable,
see “Adjusting the throttle cable”(3-8) or
“Checking the gear shift operation”(3-9).
1. Set the shift lever or remote control lever
to the N position and the throttle grip or
throttle lever to the fully closed position.
2. Turn the throttle cam 1clockwise until
the cam contacts the fully closed stopper
aon the throttle cam bracket 2and
hold it in that position. Connect the throt-
tle cable 3to the throttle cam, and then
install the clip 4.
3. Check that the shift arm 5is in the N
position as shown. Connect the shift
cable 6to the shift arm, and then install
the clip 7.
WARNING
The shift/throttle cable joint must be
screwed in a minimum depth of 8.0 mm
(0.31 in) b.
Recommended battery capacity:
CCA/EN: 430 A
20HR/IEC: 70 Ah
Electrolyte specific gravity:
1.280 at 20 °C (68 °F)
S67C1019
S67C1020
4
3
2
a
1
S67C1021
7
6
5
d
c
N
RF
S67C1047
b
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1
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