Yamaha 40V/50H Outboard Service Manual Collection, 1995–2003 (P/N 63B-28197-Z5-11)
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Yamaha Models Covered & Key Technical Specifications
Models: 40VMH, 40VMHO, 40VRO, 40VE, 40VEO, 40VEHTO, 40VETO, 50HMHO, 50HMHD, 50HRO, 50HRDO, 50HEMHD, 50HEDO, 50HEHTO, 50HETO, 40VMHD, 40VMO, 40VWH, 40VET, 50HMO, 50HMDO, 50HWHD, 50HET, F45AE, F45AET, F50AE, F50AET, F50AEHT, F50BET, F45AED, F50AED, FT50BET, F40AET, F40AED, F40AEHT, F40AEHD, F50AEHD, FT50BED, FT50BEHD, FT50CEHD, FT50CED, FT50CET, 40TR, 50TR, F50TH, F50TR, T50TR, F60TR, T60TR
Models & Model Codes:
40VMH — 6H4
40VMHO — 6H4
40VRO — 6H4
40VE — 6H4
40VEO — 6H4
40VEHTO — 6H4
40VETO — 6H4
50HMHO — 6H5
50HMHD — 6H5
50HRO — 6H5
50HRDO — 6H5
50HEMHD — 6H5
50HEDO — 6H5
50HEHTO — 6H5
50HETO — 6H5
40VMHD — 6H4
40VMO — 6H4
40VWH — 6H4
40VET — 6H4
50HMO — 6H5
50HMDO — 6H5
50HWHD — 6H5
50HET — 6H5
F45AE — 62Y
F45AET — 62Y
F50AE — 62Y
F50AET — 62Y
F50AEHT — 62Y
F50BET — 64J
F45AED — 62Y
F50AED — 62Y
FT50BET — 64J
F40AET — 66W
F40AED — 66W
F40AEHT — 66W
F40AEHD — 66W
F50AEHD — 62Y
FT50BED — 64J
FT50BEHD — 64J
FT50CEHD — 64J
FT50CED — 64J
FT50CET — 64J
40TR — 6H4 (40C/50C publication)
50TR — 6H5 (40C/50C publication)
F50TH — 62Y
F50TR — 62Y (carbureted publications); 6C1 (F50D/T50D/F60D/T60D publication)
T50TR — 64J (carbureted publications); 6C2 (F50D/T50D/F60D/T60D publication)
F60TR — 6C5
T60TR — 6C6
Sub-models / Variants: 40MH (40VMHO), 40ER (40VEO), 40TH (40VEHTO), 40TR (40VETO), 50ER (50HEDO), 50TH (50HEHTO), P50TR (50HETO), Tiller control, Remote control, Manual start, Electric start, Oil injection, Pre-mixed fuel, Manual tilt, Hydro tilt, Power trim and tilt (PTT)
Model Years: 1995–2003 (1995, 1996, 1997, 1998, 1999, 2000, 2001, 2002, 2003)
Starting Serial Numbers (40V/50H main manual): 40VMH (S: 010139 ~, L: 310434 ~); 40VMHO (S: 190591 ~, L: 490565 ~); 40VRO (S: 290141 ~, L: 860181 ~); 40VE (S: 060143 ~, L: 360130 ~); 40VEO (S: 110318 ~, L: 840949 ~, UL: 740146 ~); 40VEHTO (L: 430101 ~); 40VETO (S: 880161 ~, L: 541747 ~, UL: 900146 ~); 50HMHO (S: 190351 ~); 50HMHD (S: 010132 ~, L: 310228 ~); 50HRO (S: 260121 ~); 50HRDO (L: 560141 ~); 50HEMHD (L: 850151 ~); 50HEDO (S: 090166 ~, L: 520616 ~); 50HEHTO (L: 590191 ~); 50HETO (S: 210106 ~, L: 441175 ~, UL: 750166 ~)
Starting Serial Numbers (F45A/F50A/F50B supplement): F45AE (L: 500101); F45AET (L: 550101); F50AE (L: 300357); F50AET / F50TR (L: 401901); F50AEHT / F50TH (L: 450251); F50BET / T50TR (L: 400122)
Starting Serial Numbers (F50A/F50T base manual): F50AE (L: 300101); F50AET / F50TR (L: 400101); F50AEHT / F50TH (L: 450101)
Starting Serial Numbers (40W/50W publication): 40VMH / C40MH (S: 010262 ~, L: 310801 ~); 40VMHD (L: 560290 ~); 40VMHO / 40MH (S: 191877 ~, L: 491566 ~); 40VMO (S: 290284 ~, L: 860312 ~); 40VWH (L: 510116 ~); 40VE / C40ER (S: 060285 ~, L: 360173 ~); 40VEO / 40ER (S: 110760 ~, L: 842362 ~, X: 740146 ~); 40VEHTO / P40TH (L: 430386 ~); 40VET / C40TR (L: 921505 ~); 40VETO / 40TR (S: 880367 ~, L: 544974 ~, X: 900196 ~); 50HMHO (S: 190662 ~); 50HMHD (L: 310380 ~); 50HMO (S: 260189 ~); 50HMDO (L: 560258 ~); 50HWHD (L: 850194 ~); 50HEDO / 50ER (S: 090431 ~, L: 521079 ~); 50HET / C50TR (L: 900101 ~); 50HETO / 50TR (S: 210142 ~, L: 444058 ~, X: 750216 ~)
Starting Serial Numbers (F50W/T50W publication): F45AED (L: 500166); F45AET (L: 500231); F50AED (L: 300766); F50AET / F50TR (L: 406877); F50AEHT / F50TH (L: 451017); FT50BET / T50TR (L: 401951)
Starting Serial Numbers (F40X/F50X/T50X publication): F40AET / F40TR (L: 400687); F40AED / F40ER (L: 300135); F40AEHT / F40TH (L: 450201); F40AEHD / F40EH (L: 350101); F45AET (L: 550256); F45AED (L: 500166); F50AET / F50TR (L: 409828); F50AED / F50ER (L: 300837); F50AEHT / F50TH (L: 451272); F50AEHD / F50EH (L: 350330); FT50BET / T50TR (L: 402765); FT50BED (L: 500101); FT50BEHD (L: 600101)
Starting Serial Numbers (F50Z/T50Z publication, USA/Canada): F50TH (L: 451812–); F50TR (L: 421732–); T50TR (L: 406850–)
Starting Serial Numbers (F50Z/T50Z publication, worldwide): F50AEHD (L: 350505–); F50AEHT (L: 451812–); F50AED (L: 301090–); F50AET (L: 421626–); FT50BET (L: 406850–); FT50CEHD (L: 650101–); FT50CED (L: 550101–); FT50CET (L: 450101–)
Starting Serial Numbers (40C/50C publication): 40TR (L: 1005165 ~); 50TR (L: 1004305 ~)
Starting Serial Numbers (F50C/T50C publication): F50TR (L: 1005643–); T50TR (L: 1001978–)
Starting Serial Numbers (F50D/T50D/F60D/T60D publication): F50TR (1000001–); T50TR (1000001–); F60TR (1000001–); T60TR (1000001–)
The technical specifications below apply to the 40V/50H main manual.
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Engine type: 2-stroke, 3-cylinder
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Displacement: 698 cc (42.6 cu. in.)
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Bore x Stroke: 67.0 x 66.0 mm (2.64 x 2.60 in.)
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Max power output: 40 hp (40V); 50 hp (50H), both @ 5,000 RPM
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Idle speed: 800 ± 50 RPM
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Gear ratio: 1.85 (24/13)
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Drive unit: F-N-R, spiral bevel gears, dog clutch
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Starter output: 0.6 kW (electric-start models)
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Spark plug (NGK): B7HS-10 (40hp); B8HS-10 (50hp). Canada and Europe: BR7HS-10 (40hp); BR8HS-10 (50hp)
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Fuel type: Regular gasoline (Min 86 Pump Octane Number)
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Gear oil capacity: 430 cm³ (14.5 US oz)
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Cold cranking amps: 385 A (electric-start models)
Yamaha Manual Features & Selected Content Preview
| Publication | Pages |
|---|---|
| 40V/50H Service Manual, USA/Canada cover designations 40U/50U, 1995–2003 — P/N 63B-28197-Z5-11; LIT-18616-01-38 | 217 |
| F45A/F50A/F50B Supplementary Service Manual, USA/Canada cover designations F50U/T50U — P/N LIT-18616-01-48; 62Y-28197-Z5-1X | 59 |
| F50A/F50T Service Manual — P/N 62Y-28197-Z4-11; LIT-18616-01-23 | 196 |
| 40W/50W Service Manual — P/N LIT-18616-01-81 | 230 |
| F50W/T50W Service Manual — P/N LIT-18616-01-84 | 233 |
| F40X/F50X/T50X Service Manual — P/N 62Y-28197-Z8-11; LIT-18616-01-97 | 274 |
| F50Z/T50Z Service Manual — P/N 62Y-28197-1A-11; LIT-18616-02-33 | 393 |
| 40C/50C Service Manual — P/N 63B-28197-1F-11; LIT-18616-02-65 | 215 |
| F50C/T50C Service Manual — P/N 62Y-28197-1F-11; LIT-18616-02-67 | 355 |
| F50D/T50D/F60D/T60D Service Manual — P/N 6C1-28197-1G-11; LIT-18616-02-85 | 272 |
| Jetdrive Operation and Service Manual — P/N LIT-18619-00-97 | 30 |
The F45A/F50A/F50B supplement is intended for use with the included F50A/F50T base manual. The other service manuals address their own model configurations and starting serial numbers.
The Jetdrive volume covers jetdrive-specific operation and service. General engine operating and repair information requires the corresponding outboard owner’s and service manuals.
Bookmarks, Partial Text Search, and Diagram Detail
Navigation and diagram detail: Embedded PDF bookmarks lead to the individual manuals and many chapter sections. Text search is available in the 40C/50C, F50C/T50C, and F50D/T50D/F60D/T60D volumes; the main manual, other earlier volumes, and Jetdrive manual have no searchable text layer. Small wiring labels and connector numbers require zooming.
The download is one printable 2,475-page PDF containing the 11 publications listed above. The total includes one additional divider page, together with the publications’ covers, contents, indexes, and blank or notes pages.
Powerhead, Gearcase, Electrical, and Jetdrive Service
These selected service topics show part of the material covered rather than the complete contents. Further examples include recoil-starter repair and propeller selection.
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Power unit repair: Step-by-step powerhead removal, crankcase disassembly, crankshaft and piston inspection, reed-valve checks, flywheel magneto removal, and cylinder-head and thermostat service.
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Fuel and oil injection: Carburetor overhaul, Prime Start component tests, fuel-pump inspection, oil-system service, and throttle-link and ignition-timing adjustments.
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Lower unit: Water-pump service, propeller-shaft and gear inspection, seal replacement, leakage checks, shim selection, and forward/reverse backlash measurement.
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Bracket and tilt assemblies: Tiller, clamp, steering, and swivel-bracket work, plus tilt-cylinder, pump-housing, and PTT-motor disassembly and inspection.
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Electrical troubleshooting: CDI, charging, starting, enrichment, and warning-circuit tests, with wiring diagrams, component layouts, and symptom-based trouble-analysis charts.
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Four-stroke service: Valve-train and timing-belt procedures, carburetor synchronization, PTT bleeding, and separate EFI fuel-system and Yamaha Diagnostic System coverage.
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Jetdrive service: Jet-pump assembly and installation, shift-linkage adjustment, bearing-housing overhaul, and liner replacement, with model-specific assembly drawings.
Yamaha wrote the service manuals for dealers and trained mechanics with an understanding of the mechanical and electrical concepts involved in outboard service. The Jetdrive volume also recommends dealer-performed overhauls.
40V/50H Fuel, Lubrication, and Powerhead Service
The maintenance chart distinguishes fuel-line inspection from fuel-filter and carburetor cleaning, alongside oil-pump-link checks and gear-oil changes. Carburetor specifications distinguish manual-start and electric-start configurations.
Prime Start diagnosis includes electrothermal-valve resistance and piston-movement checks. These give a technician specific ways to investigate enrichment faults when assessing a cold-start complaint.
The Oil Line Layout accompanies tank-strainer, check-valve, and oil-pump service information. Powerhead sections pair exploded views with removal and installation charts, then add cylinder-bore wear limits, piston-ring checks, and crankshaft runout measurements.
Carburetor cautions explain how steel wire can enlarge jet openings and how overtightening can damage the pilot-screw tip.
Gearcase Shimming and Tilt Repair
Separate shim-selection procedures cover US/Canadian tooling and the alternative 90890-series tools. Pinion-height-gauge illustrations, including tool 90890-06702, accompany calculations using gearcase markings.
The instructions distinguish reusing the original assembly from replacing the case or internal parts, helping identify which measurements a gearcase repair requires.
Bracket coverage separates manual-tilt hardware from hydro-tilt and power-trim-and-tilt assemblies. Tilt-cylinder service notes identify the risk of deforming the inner cylinder through incorrect clamping during disassembly.
Ignition Tests and Circuit References
The main manual includes Ignition System and Ignition Control System schematics, the ETO-model Electrical Components layout, and the Trouble Analysis Chart. Circuit checks address the charge and pulser coils, oil-level warnings, starter relay, rectifier regulator, and trim controls.
The specified dynamic spark tester is YM-34487/90890-06754. CDI output and resistance checks appear in the main publication; the additional 40W/50W manual includes CDI peak-voltage testing.
Four-Stroke Fuel Systems and Diagnostics
The carbureted four-stroke publications document vacuum-gauge carburetor synchronization. Their power-unit and bracket sections add valve-train inspection, timing-belt service, and PTT bleeding.
The F50D/T50D/F60D/T60D manual covers EFI fuel-pressure checks, vapor-separator service, and Yamaha Diagnostic System troubleshooting. Its diagnostic material explains fault records, sensor monitoring, and stationary and active tests using the separate software, interface, and test equipment described there.
Follow the manuals’ precautions for fuel vapors, rotating components, hydraulic pressure, and supporting a raised outboard during bracket work.
A Preview of Head, Reed-Valve, and Oil-Link Specifications
A few specifications illustrate the detail in the 40V/50H main manual. Cylinder-head tightening is documented in two stages, 15 Nm and 28 Nm, together with a specified bolt sequence.
The reed-valve stopper height is 6.0 ± 0.2 mm. For oil-injection models, the specified 1.0 mm clearance is between the oil-pump lever and its full-open stop with the carburetor throttle fully open.
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