E40G/EK40G

E40J/EK40J

SERVICE GUIDE

038005
 NOTICE
This service guide has been prepared to provide Yamaha dealers with information regarding the
product concept, technical features, benefits, technical tips and new servicing points of a new model.

The information contained in this guide is essential to Yamaha dealer service staff for their daily
customer service.

It is our hope that you will use this guide to train your service staff and that it will help answer any
questions concerning this new model.

This guide mainly features the modification points from previous E40G, EK40G, E40J, and EK40J
outboard motors.

NOTE:
• The descriptions herein are based on the information officially announced by Yamaha Motor Co.,
Ltd. as of the end of April 2004.
• For further information, refer to the appropriate service manual.

The specifications, features, descriptions and servicing points are subject to change without notice.

E40G, EK40G, E40J, EK40J

SERVICE GUIDE
(c) 2004 by Yamaha Motor Co., Ltd.
1st Edition, June 2004
All right reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
 CONTENTS
OUTLINE OF FEATURES ......................................................................................... 1

TECHNICAL FEATURES AND DESCRIPTIONS ...................................................... 2

1. AIR DUCT ON TOP COWLING .................................................................................... 2
2. CRANKSHAFT BIGEND BEARING .............................................................................. 3
3. STEERING BRACKET .................................................................................................. 4
4. IGNITION SYSTEM ...................................................................................................... 5
5. ELECTRICAL CONTROL SYSTEM .............................................................................. 6

RIGGING INFORMATION ......................................................................................... 7

1. DIMENSIONS ............................................................................................................... 7
1) EXTERIOR ............................................................................................................... 7
2) CLAMP BRACKET ................................................................................................... 8
2. PROPELLER SELECTION ........................................................................................... 9
1) WOT SPEED RANGE .............................................................................................. 9
2) PROPELLER APPLICATIONS ............................................................................... 10

SERVICE INFORMATION....................................................................................... 11
1. GENERAL SPECIFICATIONS .................................................................................... 11
2. SERVICE DATA .......................................................................................................... 15
3. TIGHTENING TORQUES ........................................................................................... 16
1) SPECIFIED TORQUES (EXTRACTED) ................................................................. 16
2) GENERAL TORQUES ............................................................................................ 16
4. WIRING DIAGRAM ..................................................................................................... 17
 OUTLINE OF FEATURES
The E40G, EK40G, E40J, EK40J outboard motors have been minorly changed and have the
following features:
∑ Reliable ignition system
∑ Durable components
∑ Better waterproof

POWER UNIT
∑ Newly designed bigend bearing washer
∑ Special air duct cover on top cowling

BRACKET
∑ Durable steering bracket
∑ Usable throtte friction device

ELECTRICAL
∑ Electronic advance controlled ignition system

Fig. 1 Outboard motor outline

1
 TECHNICAL FEATURES AND DESCRIPTIONS
1. AIR DUCT ON TOP COWLING
The special air duct cover is used on the rear of top cowling, on a model spec.
The air entrances are located on both sides of the cover to avoid wave water from entering backward
directly.
The storage base on rear of bottom cowling has been extended 15mm(0.6in) because of the projec-
tion cover on the rear of top cowling.

Special air duct cover

15
mm

Long storage base

(Bottom cowling)
Fig. 2 Top cowling

2
2. CRANKSHAFT BIGEND BEARING
The bigend washer on crankshaft pin has changed.
The oil dimple arrangement on the surface of washer has been changed to the constant from ran-
dom, causing durability increased.

(mm)

Previous model
New model

Fig. 3 Big-end bearing washer

3
3. STEERING BRACKET
To obtain more durability, the following improvement has been carried out.

∑ The portion for mounting the tiller handle has been changed to bigger size.
∑ Also, the stopping aria for tiller handle has been changed to larger size.
∑ The number of rib has been increased.

Rib

11.5mm 27.5mm
(0.45in) (1.08in)

Previous model New model

Fig. 4 Steering bracket

The throttle friction adjustment structure has been changed for easier operation.

Previous model New model

Fig. 5 Throttle friction device

4
4. IGNITION SYSTEM
The ignition advance system has been changed to the electrical from the mechanical, which obtains
simple structure and reliability.
The CDI unit has been changed to match to new ignition system, and combined the control unit.
The connector of CDI unit has been changed to couplers from bullet terminals for easier connection.

CDI unit Control unit

Model CDI identification
E40G, E40J 6F6-00

6F5-21
EK40G, EK40J 6F5-30
6F5-22

6F6-00

Previous model New model

Fig. 6 CDI unit

The flywheel magneto design has been changed because of automatically electrical ignition advance
system. Twin pulser coils are used for the electrical ignition advance system.

NOTE:
The location for the lighting coil and charge coil has been reversed between previous model and new
model.

Lighting coil Charge coil Charge coil Lighting coil

Pulser coil Pulser coil

Previous model New model
Fig. 7 Flywheel magneto base
5
5. ELECTRICAL CONTROL SYSTEM
OVER REVOLUTION CONTROL
When the engine speed exceeds 5850 rpm, the
ignition is shut-off.
When the engine speed is dropped below 5850
rpm, the ignition is resumed.
Engine RPM Below 5850 Above 2850
Activated ignition #1, #2 Non

OVERHEAT CONTROL
When the overheat switch is turned on for 2 sec-
onds and the engine is over 3000 rpm, the over-
heat control system is activated.
The ignition is shut-off and the engine speed is
limited to 3000 rpm.
If the overheat switch is turned off or the engine
speed is dropped below 2800 rpm, the ignition
is resumed.
Engine RPM
Overheat switch Below 2800 Above 3000
Normal Shut-off ignition
ON
operation #1, #2
Normal Normal
OFF
operation operation
NOTE:
On new models, the warning indicator on bot-
tom cowling has been deleted.

6
 RIGGING INFORMATION
1. DIMENSIONS
1) EXTERIOR

7
2) CLAMP BRACKET

8
2. PROPELLER SELECTION
Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applica-
tions, but there may be uses where a propeller with a different pitch would be more appropriate.
For a greater operating load, a smaller pitch propeller is more suitable as enables the correct engine
speed at WOT (Wide-Open-Throttle) to be maintained.
Conversely, a larger pitch propeller is more suitable for a smaller operating load.

1) WOT SPEED RANGE

With WOT operation and under a maximum boat load, the engine should be within the upper half of
the WOT speed range.
Select a propeller which fulfills this requirement.

WOT speed range:

4,500-5,500 r/min

CAUTION:
Do not run the engine which exceeds the WOT speed range.
Otherwise, an overheat or engine damage could occur.
If the engine exceeds the WOT speed range, replace the propeller to a larger pitch.
Conversely if not reached to the specified range, a smaller pitch propeller is suitable.

NOTE:
∑ The engine speed at WOT makes a change of approximately 200 - 300 rpm if the propeller pitch is
changed one inch.
∑ The maximum engine speed can increase when the outboard motor is maintained in trimmed up
position.

9
2) PROPELLER APPLICATIONS
Diameter Pitch
Model Mark Material Part number Remarks
(in) (in)
12 1/4 8 G Aluminum 63D-45941-00-EL
12 1/4 9 G Aluminum 68U-45941-00-EL Dual thrust
12 1/4 9 G Aluminum 663-45956-01-EL
11 3/4 10 G Aluminum 663-45954-01-EL
11 5/8 11 G Aluminum 69W-45947-00-EL
12 11 G SST 663-45972-60-98
10 5/8 12 G Aluminum 6H5-45952-00-EL
11 3/8 12 G Aluminum 69W-45952-00-EL
12 12 G SST 663-45970-60-98
40J 10 3/8 13 G Aluminum 6H5-45945-00-EL
E40J 11 1/8 13 G Aluminum 69W-45945-00-EL
EK40J 11 1/2 13 G SST 663-45974-60-98
10 1/4 14 G Aluminum 6H5-45958-00-EL
11 1/4 14 G Aluminum 69W-45958-00-EL
11 1/4 14 G SST 697-45970-00-98
10 15 G Aluminum 6H5-45943-00-EL
10 1/4 15 G SST 663-45976-00-98
11 15 G Aluminum 69W-45943-00-EL
10 1/4 16 G SST 663-45978-00-98
10 3/4 16 G Aluminum 663-45949-01-EL
10 3/4 17 G Aluminum 663-45941-01-EL
11 3/4 7 1/2 H Aluminum 676-45956-61-EL
11 3/4 8 3/4 H Aluminum 676-45947-62-EL
11 3/4 10 H Aluminum 676-45945-62-EL
E40G
11 1/2 11 H Aluminum 676-45941-62-EL
EK40G
11 1/2 12 H Aluminum 676-45943-62-EL
11 1/2 13 H Aluminum 676-45952-62-EL
11 1/2 13 1/2 H Aluminum 676-45949-62-EL

10
 SERVICE INFORMATION
1. GENERAL SPECIFICATIONS
Model
Item Unit
E40GMH E40GWH EK40GMH
Prefix model cord 6F6K 6F5K
Starting serial number 1013723 1006117
Dimension
Overall length mm (in) 1012 (39.8)
Overall width mm (in) 484 (19.1)
S mm (in) 1215 (47.8)
Overall height L mm (in) 1342 (52.8)
Y mm (in) 1392 (54.8)
S mm (in) 444 (17.5)
Transom height L mm (in) 571 (22.5)
Y mm (in) 622 (24.5)
Dry weight
S kg (lb) 65 (143) 65 (143)
L kg (lb) 67 (148) 71 (157) 68 (150)
Y kg (lb) 68 (150)
Performance
Maximum output kW (HP) 29.4 (40)@5,000rpm
Full throttle operating range r/min 4,500-5,500
Maximum fuel consumption L (US gal, Imp gal)/hr 20 (5.3, 4.4)@5,000rpm
Idle speed r/min 1,150 1,100
Power unit
Engine type Loop charged 2-stroke, 2-cylinder
3
Total displacement cm (cu.in) 669 (40.8)
Bore Stroke mm (in) 78.0 × 70.0 (3.07 × 2.76)
Compression ratio 6.25 5.00
Control system Tiller handle
Starting system Manual Manual/Electric Manual
Enrichment system Choke valve
Ignition control system CDI
Ignition timing Degree BTDC23-BTDC4 BTDC23-BTDC9
Maximum generator output (*1) V-A (W) 12-6 (80)
Spark plug / Gap NGK/mm (in) B7HS / 0.6 (0.024)
Cooling system Water
Exhaust system Under water
Lubrication system Premixed fuel
Fuel and oil
Premixed gasoline (50/1)
Fuel type Premixed gasoline (50/1)
Premixed kerosene (30/1)
Fuel minimum rating RON (*2) 84
Engine oil YAMALUBE 2 stroke outboard oil
Engine oil grade NMMA-certified TC-W3
Gear oil type Hypoid gear oil
Gear oil grade (*3) API/SAE GL-4/90
3
Gear oil quantity cm (US oz, Imp oz) 315 (10.7, 11.1)

(*1)Lighting coil equipped model

(*2) RON; Research Octane Number
(*3) Meeting the API and SAE requirements

11
 Model
Item Unit
E40GMH E40GWH EK40GMH
Bracket unit
Trim angle (*4) Degree 8, 12, 16, 20, 24
Shallow water tilting angle Degree
Tilt-up angle Degree 67
Steering angle Degree 45+45
Drive unit
Gear shift positions F-N-R
Gear ratio 1.85 (24/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Drive pin
Propeller direction Rear view Clockwise
Propeller ID mark H
Electrical (*5)
CCA/SAE Amps 245
MCA/ABYC Amps 323
RC/SAE Mins 52
Battery minimum capacity
CCA/EN Amps 347
20HR/IEC Ah 40
JIS 32C24-65D31
Battery cable length Grommet to terminal m (ft) 1.43 (4.7)

(*4) At 12-degree boat transom

(*5) For Electric start model
CCA: Cold Cranking Amperage
SAE: Society of Automotive Engineering
MCA: Marine Cold Cranking
ABYC: American Boat and Yacht Counsel
RC: Reserve Capacity
EN: European Norm (European standard)
IEC: International Electro-technical Commission
JIS: Japanese Industry Standard

12
 Model
Item Unit
E40JMH E40JWH E40JW/40JW EK40JMH EK40JW
Prefix model cord 6J4K 6H9K
Starting serial number 1006736 1001748
Dimension
Overall length mm (in) 1012 (39.8) 707 (27.8) 1012 (39.8) 707 (27.8)
Overall width mm (in) 484 (19.1) 363 (14.3) 484 (19.1) 363 (14.3)
S mm (in) 1208 (47.6)
Overall height L mm (in) 1335 (25.6)
Y mm (in) 1386 (54.6)
S mm (in) 421 (16.6)
Transom height L mm (in) 548 (21.6)
Y mm (in) 598 (23.5)
Dry weight
S kg (lb) 65 (143) 68 (150) 70 (154) 70 (154)
L kg (lb) 67 (148) 71 (157) 70 (154) 72 (159) 72 (159)
Y kg (lb) 68 (150) 73 (161)
Performance
Maximum output kW (HP) 29.4 (40)@5,000rpm
Full throttle operating range r/min 4,500-5,500
Maximum fuel consumption L (US gal, Imp gal)/hr 19.5 (5.2, 4.3)@5,000rpm
Idle speed r/min 1,150 1,100
Power unit
Engine type Loop charged 2-stroke, 2-cylinder
3
Total displacement cm (cu.in) 669 (40.8)
Bore Stroke mm (in) 78.0 × 70.0 (3.07 × 2.76)
Compression ratio 6.25 5.00
Control system Tiller handle Remote control Tiller handle Remote control
Starting system Manual Manual/Electric Manual Manual/Electric
Enrichment system Choke valve
Ignition control system CDI
Ignition timing Degree BTDC23-BTDC4 BTDC23-BTDC9
Maximum generator output (*1) V-A (W) 12-6 (80)
Spark plug / Gap NGK / mm (in) B7HS / 0.6 (0.024)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Premixed fuel
Fuel and oil
Premixed gasoline (50/1)
Fuel type Premixed gasoline (50/1)
Premixed kerosene (30/1)
Fuel minimum rating RON (*2) 84
Engine oil YAMALUBE 2 stroke outboard oil
Engine oil grade NMMA-certified TC-W3
Gear oil type Hypoid gear oil
Gear oil grade (*3) API/SAE GL-4/90
Gear oil quantity cm3 (US oz, Imp oz) 315 (10.7, 11.1)
(*1)Lighting coil equipped model
(*2) RON; Research Octane Number
(*3) Meeting the API and SAE requirements

13
 Model
Item Unit
E40JMH E40JWH E40JW/40JW EK40JMH EK40JW
Bracket unit
Trim angle (*4) Degree 8, 12, 16, 20, 24
Shallow water tilting angle Degree
Tilt-up angle Degree 67
Steering angle Degree 45+45
Drive unit
Gear shift positions F-N-R
Gear ratio 2.00 (26/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Rear view Clockwise
Propeller ID mark G
Electrical (*5)
CCA/SAE Amps 245
MCA/ABYC Amps 323
RC/SAE Mins 52
Battery minimum capacity
CCA/EN Amps 347
20HR/IEC Ah 40
JIS 32C24-65D31
Battery cable length Grommet to terminal m (ft) 1.43 (4.7)

(*4) At 12-degree boat transom

(*5) For Electric start model
CCA: Cold Cranking Amperage
SAE: Society of Automotive Engineering
MCA: Marine Cold Cranking
ABYC: American Boat and Yacht Counsel
RC: Reserve Capacity
EN: European Norm (European standard)
IEC: International Electro-technical Commission
JIS: Japanese Industry Standard

14
2. SERVICE DATA
Item Unit Data Note
E40G, E40J compression pressure At sea level and
kPa (Kgf/cm2, psi) 670 (6.8, 97)
(for reference) room temperature.
ID 6F605
Main jet #150
E40G carburetor
Pilot jet #88
Pilot screw 1 1/4
For Worldwide M: 6F605, E: 6J404 M: Manual start
ID
For China M: 6F613, E: 6J413 E: Electric start
Main jet #150
E40J carburetor
Pilot jet #88
For Worldwide 1 1/4
Pilot screw Permissible range 1/4
For China 3/4
EK40G, EK40J compression pressure At sea level and
kPa (Kgf/cm2, psi) 560 (5.7, 81)
(for reference) room temperature.
ID 6F542
Main jet #145
EK40G carburetor
Pilot jet #60
Pilot screw 1 1/4
ID 6H903
Main jet #140
EK40J carburetor Kerosene : #90
Pilot jet
Gasoline : #60
Pilot screw 1 1/4 Permissible range 1/4

15
3. TIGHTENING TORQUES
1) SPECIFIED TORQUES (EXTRACTED)
Tightening torques
Part to be tightened Thread size
N·m kgf·m lb·ft
POWER UNIT
1st 20 2.0 14
Crankcase bolt M8
2nd 39 3.9 29
Cylinder head bolt M6 11 1.1 8
1st 15 1.5 11
Cylinder head bolt M8
2nd 30 3.0 22
Exhaust outer cover bolt M6 8 0.8 5.6
Flywheel nut (M20) 157 16 116
Spark plug M14 25 2.5 18
DRIVE UNIT (E40J, EK40J)
Exhaust guide bolt M8 21 2.1 15
Gear oil plug M8 8.5 0.9 6.3
Lower case mount bolt M8 21 2.1 15
Pinion nut (M12) 69 6.9 51
Propeller nut (M16) 34 3.4 25
Ring nut (M79.5) 91 9.1 67
DRIVE UNIT (E40G, EK40G)
Exhaust guide bolt M8 21 2.1 15
Gear oil plug M8 8.5 0.9 6
1st 4 0.4 3
Lower case cover bolt M6
2nd 8 0.8 6
Lower case mount bolt M8 21 2.1 15
BRACKET UNIT
Bracket thru stud nut (M8) 24 2.4 18
Grease nipple M6 3 0.3 2.2
1st 14 1.4 10
Lower mount cover bolt M8
2nd 24 2.4 18
Lower rubber mount cover nut (M10) 55 5.5 41
Thru tube nut (M20) 45 4.5 33
Upper rubber mount nut (M10) 29 2.9 21

2) GENERAL TORQUES General torques

This chart shows the general tightening torques Nut (A) Bolt (B)
N·m Kgf·m lb·ft
for standard fasteners such as a bolt or nut with 8 mm M5 4.4 0.4 3.2
a standard thread pitch of ISO (International 10 mm M6 7.6 0.8 5.6
Organization for Standardization). To avoid 12 mm M8 18 1.8 13
warpage of the components, tighten the fasten-
14 mm M10 36 3.6 27
ers with a crisscross pattern and progressive
17 mm M12 43 4.3 32
stages until the specified tightening torque is
obtained.
Unless otherwise specified, the specific tighten-
A B
ing torque is required clean and dry threads at
room temperature.

16
4. WIRING DIAGRAM
E40GMH/EK40GMH/E40JMH

17
E40GWH/E40JWH

18
E40JW/EK40JW/40JW

19
 YAMAHA
YAMAHA MOTOR
MOTOR CO.,
CO., LTD.
LTD.
Printed in Japan
June 2004 - 0.3 ¥ 1E
(E) Printed on recycled paper