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.