Yamaha F30B 2018 User manual
6BG-28197-ZX-11
LIT-18616-03-84
USA, CAN, AUS, and NZL:
Worldwide:
(6BG)
(6BT)
(6BG)
(6BT)
Preface
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 the Bronze Technical Certificate of the YTA
(Yamaha Technical Academy) marine or the equivalent 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. Also, up-to-date parts information is available on YMBS (Yamaha Marine Business System,
USA only) or YPEC-web (except USA). Additional information and up-to-date information on
Yamaha products and services are available on YMBS, YMPE (Yamaha Multimedia Product Ency-
clopedia, Canada only), or Yamaha Service Portal (except USA and Canada).
Important information
Particularly important information is distinguished in this manual by the following notations:
: This is the safety alert symbol. It is used to alert you to potential personal injury hazards.
Obey all safety messages that follow this symbol to avoid possible injury or death.
A WARNING indicates a hazardous situation which, if not avoided, could result in death or
serious injury.
A NOTICE indicates special precautions that must be taken to avoid damage to the outboard
motor or other property.
TIP:
A TIP provides key information to make procedures easier or clearer.
F30B, F40F
F30A, F40A
SERVICE MANUAL
©2018by Yamaha Motor Co., Ltd.
1st Edition, July 2018
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
6BG-28197-ZX-11
LIT-18616-03-84
0
General information
Model information .............................................................. 0-1
Applicable model ........................................................................ 0-1
Model name designation ............................................................ 0-1
General feature .......................................................................... 0-3
Important safety and service information........................ 0-4
Rotating parts ............................................................................. 0-4
Hot parts..................................................................................... 0-4
Electric shock ............................................................................. 0-4
Propeller ..................................................................................... 0-4
Handling of gasoline................................................................... 0-4
Ventilation................................................................................... 0-4
Self-protection ............................................................................ 0-4
Lifting outboard motors............................................................... 0-5
Handling of gas torch ................................................................. 0-5
Parts, lubricants, and sealants ................................................... 0-5
Handling of lubricants and sealants ........................................... 0-5
Special service tools................................................................... 0-6
Tightening torque ....................................................................... 0-6
Non-reusable parts..................................................................... 0-6
Disassembly and assembly........................................................ 0-6
Disposal of used components and chemicals ............................ 0-6
How to use this manual ..................................................... 0-7
Manual format ............................................................................ 0-7
Conditions when testing and adjusting....................................... 0-8
Abbreviation ............................................................................... 0-8
Color code .................................................................................. 0-8
Specified tightening torque............................................... 0-9
General tightening torque........................................................... 0-9
Symbol .............................................................................. 0-10
Symbol ..................................................................................... 0-10
Lubricant, sealant, and thread locking agent............................ 0-10
Special service tool.......................................................... 0-12
0-1
Model information
Model information
Applicable model
This manual applies to the following models.
Worldwide
USA, CAN, AUS, and NZL
Model name designation
Worldwide
Model name Approved model code Starting serial No.
F30BEHD 6BTK 1000001–
F30BET
F40FEHD
6BGK 1000001–F40FED
F40FET
Model name Approved model code Starting serial No.
F30EHA
6BTK 1000001–F30HA
F30A
F40EHA
6BGK 1000001–F40HA
F40A
1 Model category F: 4-stroke
2 Output horsepower 30/40
3 Model generation B/F
4 Model variation
Level 1: Starting method
E: Electric start
Level 2: Control method
None: Remote control without tiller handle
H: Tiller handle
Level 3: Trim and tilt method
D: Hydraulic tilt
T: PT/T (Power trim and tilt)
5 Motor transom height S: 15 in
L: 20 in
1345
FFEHDL
2
40
0-2
Model information
USA, CAN, AUS, and NZL
1 Model category F: 4-stroke
2 Horsepower 30/40
3 Motor transom height S: 15 in
L: 20 in
4 Starting method/PTT Blank: PTT and E-start
E: Electric start
5 Control method Blank: Remote control
H: Tiller handle
6 Generation A: 1st change on motor
213456
F40LEHA
0-3
Model information
General feature
• Electronic fuel injected, 4-stroke, L3, SOHC, 6-valve, 747 cm³ (45.6 cu. in) engine
• Low exhaust emissions conform to EU1, US EPA, CARB 3-STAR, and JBIA regulations.
• Low fuel evaporative/permeation emissions conform to US EPA regulation.
a. Power unit
• Multipoint electronic fuel injection
• Single throttle body
• Long intake manifold
• Blowby gas reburning system
• Fuel cooler
• Closed fuel vapor gas system
• One piece top cowling with water draining air
intake duct
b. Electrical
• Electronic fuel injection control
• ISC (Idle Speed Control)
• Over-revolution control
• Fail-safe
• Self-diagnosis system with YDIS (1.33 and
later versions)
• Alert systems including low oil pressure,
overheat, and water detection
• High generator output (maximum 17 A)
• Y-COP acceptable (optional)
• Variable troll speed control (650–900 r/min)
• Conventional gauge (6Y5/6Y7) or 6Y8/6YC
Multifunction Meters acceptable
• Speed sensor (optional)
• Water pressure sensor (optional)
c. Bracket unit
• Long span mounts
• Small and compact PTT (PTT model)
• High-pressure gas-assisted hydro tilt (hydro
tilt model)
• Multifunction tiller handle (tiller handle mod-
el)
d. Upper case
• Labyrinth idle exhaust system
e. Lower unit
• Lower unit equivalent to that of a one-class-
higher mode
a
b
c
d
e
0-4
Important safety and service information
Important safety and service in-
formation
To prevent an accident or injury and to provide
quality service, observe the following informa-
tion.
Rotating parts
• Hands, feet, hair, jewelry, clothing, personal
flotation device straps, and so on, can be-
come entangled with internal rotating parts of
the engine, resulting in serious injury or
death.
• Keep the top cowling installed whenever
possible. Do not remove or install the top
cowling when the engine is running.
• Only operate the engine with the top cowling
removed according to the specific instruc-
tions in the manual. Keep hands, feet, hair,
jewelry, clothing, personal flotation device
straps, and so on, away from any exposed
moving parts.
Hot parts
During and after operation, engine parts are
hot enough to cause burns. Do not touch any
parts under the top cowling until the engine has
cooled.
Electric shock
Do not touch any electrical parts while starting
or operating the engine. Otherwise, shock or
electrocution could result.
Propeller
Do not hold the propeller with your hands when
loosening or tightening the propeller nut. Sharp
propeller edges can cause injury. Place a
wood block between gear case and propeller
to hold the propeller for removal and installa-
tion.
Handling of gasoline
• Gasoline is highly flammable. Keep gasoline
and all flammable products away from heat,
sparks, and open flames.
• Gasoline is poisonous and can cause injury
or death. Handle gasoline with care. Never
siphon gasoline by mouth. If you swallow
some gasoline, inhale a lot of gasoline vapor,
or get some gasoline in your eyes, see your
doctor immediately. If gasoline spills on your
skin, wash with soap and water. If gasoline
spills on your clothing, change your clothes.
Ventilation
• Gasoline vapor and exhaust gases are
heavier than air and extremely poisonous. If
gasoline vapor or exhaust gases are inhaled
in large quantities, it may cause loss of con-
sciousness and death within a short time.
• When test running an engine indoors (for ex-
ample, in a water tank) make sure to do so
where adequate ventilation can be main-
tained.
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.
0-5
Important safety and service information
• Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Lifting outboard motors
• Outboard motors weighing 18 kg (40 lb) and
over must be carried by a crane or equiva-
lent.
• Use a wire cable lifting harness of adequate
strength to lift up the outboard motor in a sta-
ble manner.
• Lift and suspend the outboard motor in a sta-
ble manner using the designated lifting at-
tachment points.
• Do not work on or under an outboard motor
while it is suspended from a lifting device. Se-
curely mount the motor on a suitable work
stand or place it on a stable work surface as
soon as possible.
Handling of gas torch
• Improper handling of a gas torch may result
in burns. For information on the proper han-
dling of the gas torch, see the operation man-
ual issued by the manufacturer.
• When using a gas torch, keep it away from
gasoline and oil to prevent a fire.
• Components become hot enough to cause
burns. Do not touch any hot components di-
rectly.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants, or those recommended by Ya-
maha, when servicing or repairing the out-
board motor. Failures caused by the use of
parts, lubricants, or sealants that are not equiv-
alent in design and quality to genuine Yamaha
parts, lubricants, or sealants will not be cov-
ered by warranty.
Handling of lubricants and sealants
• Follow all instructions and safety precautions
provided on the product label and the materi-
al safety data sheet (MSDS/SDS) for lubri-
cants, sealants, and other shop chemicals.
• Wear impervious gloves, eye protection, or
other protective apparel when required.
• Wash skin thoroughly after contact with lubri-
cants, sealants, and other shop chemicals,
and change clothing if contaminated with
them.
0-6
Important safety and service information
Special service tools
For safety and to help protect parts from dam-
age, use the recommended special service
tools.
Tightening torque
When tightening nuts, bolts, and screws, follow
the tightening instructions provided throughout
the manual. If the tightening order is not speci-
fied, tighten the large sizes first, and then tight-
en the small sizes, starting from the center and
moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cotter
pins, and so on, when installing or assembling
parts.
Disassembly and assembly
• Use compressed air to remove dust and dirt
during disassembly.
• Apply engine oil to the contact surfaces of
moving parts before assembly.
• During disassembly, cover all openings,
such as intake and exhaust ports, to prevent
foreign materials from entering the engine.
Foreign materials could cause severe inter-
nal damage when the engine is started.
• Install bearings so that the bearing identifica-
tion mark is facing in the direction indicated in
the installation procedure. In addition, make
sure to lubricate the bearings liberally.
• Apply a thin coat of water resistant grease to
the lip and periphery of an oil seal before in-
stallation.
• Check that moving parts operate normally af-
ter assembly.
• When starting the engine after reassembly,
check for fuel and water leaks from hoses
and pipes that were disconnected or re-
moved while servicing.
• When assembling the PTT/PT unit, do not
use a rag. Otherwise, dust and particles
could get on the PTT/PT unit components,
causing poor performance.
Disposal of used components and
chemicals
Obey all federal, state and local regulations
when disposing of used components and/or
chemicals such as crate frames, replaced
parts, gaskets, oil, and so on.
0-7
How to use this manual
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 following information 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 following figure for an example page).
• The component list consists of the basic removal or disassembly order (“ ”), part names, quantities,
and remarks, which indicate the bolt and screw dimensions and other information (see “2” in the fol-
lowing figure). For the installation or assembly procedure, reverse the order.
• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
the lubrication points (see “3” in the following figure).
• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following fig-
ure), 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 instal-
lation where necessary (see “5” in the following figure for an example page). Detailed explanations of
the procedures are enclosed in (see “6” in the following figure for an example page).
• Numbers enclosed in brackets are used to indicate the removal or tightening order of bolts, screws,
and other parts (see “7” in the following figure).
TIP:
For troubleshooting procedures, see Chapter 4, “Troubleshooting”.
7-25
Cylinder head
Cylinder head
2
1
1
1
3
6
15
16
16
14
11
4
10
8
7
7
13
12
9
9
95
6 N·m (0.6 kgf·m, 4.4 lb·ft)
12 N·m (1.2 kgf·m, 8.9 lb·ft)
90°
17 N·m (1.7 kgf·m, 13 lb·ft)
34 N·m (3.4 kgf·m, 25 lb·ft)
New
New
New
Part name Q’ty Remarks
1 Bolt M6 45 mm 4
2 Oil pump assembly 1
3 Gasket 1
4 Bolt M6 20 mm 7
5 Cylinder head cover 1
6 Gasket 1
7ScrewM4 10 mm 4
8Plate 1
9 Grommet 5
10 Oil filler cap 1
11 O-ring 1
12 Bolt M6 25 mm 4
13 Bolt M9 93 mm 8
14 Cylinder head assem-
bly 1
15 Gasket 1
16 Dowel pin 2
7-27
Cylinder head
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Installingthe cylinder head
Before installing the cylinder head, check the
cylinder head bolts. See “Checking the cylinder
head bolt” (7-26).
1. Check that the hole “a” on the retaining
plate is aligned with the “△” mark “b” on
the cylinder block.
2. Install:
•Dowel pin
• Cylinder head gasket
• Cylinder head
3. Tighten:
• Cylinder head bolt (M9)
• Cylinder head bolt (M6)
▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼▼
a. Tighten the cylinder head bolts (M9) “1” to
the specified torques in 3 stages and in the
order [1], [2], and so on.
TIP:
In the third tightening stage for the cylinder
head bolts (M9) “1”, mark the bolts and cylinder
head with identification marks “a”, and then
tighten the bolts 90 from the marks on the cyl-
inder head.
b. Tighten the cylinder head bolts (M6) “2” to
the specified torques in 2 stages and in the
order [9], [10], and so on.
▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲▲
Cylinder head bolt (M9) diameter
difference limit
“a” – “b” = Less than 0.13 mm
(0.01 in)
Measuring point “c”: 10.0 mm
(0.39 in)
Measuring point “d”: 62.5 mm
(2.46 in)
d
ba
c
b
a
New
Cylinder head bolt (M9) “1” [1]–[8]
1st: 17 N·m (1.7 kgf·m, 13 lb·ft)
2nd: 34 N·m (3.4 kgf·m, 25 lb·ft)
3rd: 90
Cylinder head bolt (M6) “2” [9]–
[12]
1st: 6 N·m (0.6 kgf·m, 4.4 lb·ft)
2nd: 12 N·m (1.2 kgf·m, 8.9 lb·ft)
90 [7]
[3]
[12]
[10]
[9]
[11]
[8]
[4]
[1]
[5]
[2]
[6]
1
2
a
T
R
.
.
143
2
57
6
0-8
How to use this manual
Conditions when testing and adjusting
Conditions can affect specifications when checking, measuring and making certain adjustments. Ser-
vice data in this manual was determined under the following conditions:
• Electrical resistance for components such as ignition coils and sensors was measured at 20 C
(68 F).
• Engine compression was measured at:
• Sea level
• 20 C (68 F)
• All spark plugs removed
• Throttle valve at WOT (depending on model specification)
• Trim/tilt angles shown are when the transom angle is 12 degrees.
Abbreviation
The following abbreviations are used in this service manual.
Color code
TIP:
For example, “R/Y” stands for a Red with Yellow tracer stripe wire.
Abbreviation Description
ECM Electronic Control Module
ISC Idle Speed Control
PTT Power Trim and Tilt
TPS Throttle Position Sensor
VST Vapor Separator Tank
Y-COP Yamaha Customer Outboard Protection
YDIS Yamaha Diagnostic System
B Black Lg Light green Sb Sky blue
Br Brown Or Orange W White
G Green P Pink Y Yellow
Gy Gray Pu Purple
LBlue RRed
0-9
Specified tightening torque
Specified tightening torque
Specified tightening torques are provided for specific nuts, bolts, and screws. Specified tightening
torque specifications are provided in the exploded diagrams and in the related working instructions.
When tightening these fasteners, follow the tightening torque specifications and procedures indicated
throughout the manual to meet the design aims of the outboard motor.
General tightening torque
This chart indicates the tightening torques for standard fasteners with a standard ISO thread pitch.
Width across flats (A) Thread size (B) General torque specifications
N·m kgf·m lb·ft
8 mm M5 5 0.5 3.7
10 mm M6 8 0.8 5.9
12 mm M8 18 1.8 13
14 mm M10 36 3.6 27
17 mm M12 52 5.2 38
0-10
Symbol
Symbol
Symbol
Illustrated symbols are used to identify the specifications which appear.
Lubricant, sealant, and thread locking agent
Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.
Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and
the application points.
Symbol Definition Symbol Definition
Filling fluid Lubricant
Special tool Tightening torque
Wear limit, clearance Engine speed
Electrical data Replace the part with a new one.
Symbol Name Application
YAMALUBE 4 or YAMALUBE 4M FC-W Lubricant
YAMALUBE outboard gear oil or Yamalube Ma-
rine Gearcase Lube Lubricant
Water resistant grease
(Yamaha grease A or Yamalube Marine Grease) Lubricant
Low temperature resistant grease
(Yamaha grease C or Yamalube Molybdenum
Disulfide grease)
Lubricant
Corrosion resistant grease
(Yamaha grease D or Yamalube Marine Grease) Lubricant
Molybdenum disulfide grease
(Yamalube Molybdenum Disulfide grease) Lubricant
Symbol Name Application
Gasket Maker Sealant
ThreeBond 1104J Sealant
ThreeBond 1322D Thread locking agent
ThreeBond 1342J Thread locking agent
T
R
.
.
New
0-11
Symbol
ThreeBond 1377B Thread locking agent
ThreeBond 1901 Lubricant
LOCTITE 242 (blue) Thread locking agent
LOCTITE 271 (red) Thread locking agent
LOCTITE 572 (white) Sealant
Symbol Name Application
0-12
Special service tool
Special service tool
Special service tools with Yamaha part numbers (90890-*****) are distributed by the Parts Division.
Special service tools with USA and Canada tool numbers (YB/YM/YS/YU–*****) are distributed by K&L
Supply Co.
Some of the special service tools are only available from the Marine Service Division.
WW SST No.
YDIS2 Hardware Kit
90890-06884
Digital circuit tester
90890-03243
Peak voltage adapter B
90890-03172
Test harness FWY–6
90890-06872
Vacuum/pressure
pump gauge set
90890-06945
Test harness (3 pins)
90890-06870
Test harness
FW13613–2
90890-06887
Ignition checker (Spark
gap tester)
90890-06754
Test harness
SM6195043
90890-06861
Test harness (3 pins)
90890-06869
Test harness (2 pins)
90890-06867
Fuel pressure gauge
adapter
90890-06946
Fuel pressure gauge
90890-06753
Leakage tester
90890-06840
Fuel injection meter
FIM20000ME
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Crankshaft holder 16
90890-06355
Valve spring compres-
sor
90890-04019
0-13
Special service tool
Valve spring compres-
sor attachment
90890-06320
Valve guide remover/
installer
90890-06801
Valve guide installer
90890-06810
Valve guide reamer
90890-06804
Valve lapper
90890-04101
Valve seat cutter hold-
er
90890-06316
Valve seat cutter 30
90890-06326
Valve seat cutter 45
90890-06312
Valve seat cutter 60
90890-06323
Valve seat cutter 30
90890-06328
Valve seat cutter 45
90890-06325
Valve seat cutter 60
90890-06315
Driver rod LS
90890-06606
Bearing outer race at-
tachment
90890-06626
Oil filter wrench
90890-01426
Piston slider
90890-06529
Stopper guide plate
90890-06501
Bearing separator
90890-06534
Bearing puller assem-
bly
90890-06535
Stopper guide stand
90890-06538
Driver rod L3
90890-06652
Needle bearing attach-
ment
90890-06614
Bearing inner race at-
tachment
90890-06639
Needle bearing attach-
ment
90890-06608
0-14
Special service tool
Drive shaft holder 3
90890-06517
Pinion nut holder
90890-06715
Bearing inner race at-
tachment
90890-06641
Driver rod LL
90890-06605
Bearing outer race at-
tachment
90890-06622
Driver rod SL
90890-06602
Bearing depth plate
90890-06603
Bearing outer race at-
tachment
90890-06627
Bearing inner race at-
tachment
90890-06644
Ball bearing attach-
ment
90890-06634
Shift rod socket
90890-06681
Bearing housing puller
claw L
90890-06502
Center bolt
90890-06504
Backlash indicator
90890-06706
Magnet base plate
90890-07003
Dial gauge set
90890-03238
Magnet base B
90890-06844
Pinion height gauge
90890-06668
Pinion Gear Bushing
Installer
90890-06601
Needle bearing attach-
ment
90890-06611
Cylinder end screw
wrench
90890-06591
0-15
Special service tool
USSST No.
YDIS2 Hardware Kit
LIT-YDIS2-01-KT
Digital multimeter
YU-34899-A
Peak volt adapter
YU-39991
Test harness FWY–6
YB-06872
Pressure/vacuum tes-
ter
YB-35956-B
Test harness (3 pins)
YB-06870
Test harness
FW13613–2
YB-06887
Spark checker
YM-34487
Test harness
SM6195043
YB-06861
Test harness (3 pins)
YB-06869
Test harness (2 pins)
YB-06867
Fuel pressure gauge
adapter
YB-06946
Fuel pressure gauge
YU-03153M
Combination compres-
sion gauge and cylin-
der leakdown test kit
YB-45544-A
Flywheel magneto
holder
YB-06139
Universal Puller
YB-06117
Crankshaft holder
YW-06355
Valve spring compres-
sor
YM-04019
Valve spring compres-
sor adaptor
YB-06320
Valve guide remover
YB-06801
Valve guide installer
YB-06810
Valve guide reamer
YB-06804
Valve lapping tool
YM-A8998
Neway valve seat kit
YB-91044
0-16
Special service tool
Driver handle (large)
YB-06071
Driveshaft bearing in-
staller
YB-06110
Oil filter wrench
YB-01426
Piston ring compressor
YM-08037
Slide hammer
YB-06096
Bearing puller legs
YB-06523
Needle bearing attach-
ment
YB-06112
Bearing housing bear-
ing/oil seal installer
YB-06111
Oil seal installer
YB-06168
Bearing inner race at-
tachment
YB-06639
Bearing cup installer
YB-06167
Driveshaft holder
YB-06079
Pinion nut holder
YB-06715
Bearing splitter plate
YB-06219
Roller bearing installer/
remover
YB-06432
Driveshaft needle
bearing remover and
installer
YB-06063
Forward gear bearing
installer
YB-06270-A
Forward gear outer
race installer
YB-41446
Bearing inner race at-
tachment
YB-06644
Bearing installer-Re-
verse gear bearing
YB-06016
This manual suits for next models
3
Table of contents
Other Yamaha Outboard Motor manuals
