40tlrb

[DougBradlow]

Hello I have a 2003 40HP Yamaha outboard I'm about to totally rebuild,I have reviewed the manual and can not seem to find out how to remove the spacer collar for the oil pump.If some one can tell me the proper way to separate the crank case and remove the driven gear and spacer collar.I purchased a complete crankshaft assembly and I want to install all new stock pistons and rings with new wrist pins and bearings.The engine has a knock the lower unit is brand new so I want to go all out and rebuild this engine.I want to keep the engine as the factory designed it so it will remain oil injected and that will be all new as well.I never seen an outboard were the crank and pistons come out from the crank case before as the rods are a permanent fixture to the crank,This brings to question when installing the new crank and pistons how is that done properly?The manual does not go into detail of reassembly,if someone can guide me as how I can do this it would be greatly appreciated.Thank you

[boscoe99]

Welcome to the world of crap Yamaha data.

Excellant craftsmanship.
Good design.
Shit data.

Wish I could help you but I am not familiar with this particular model.

[99yam40]

I will find a thread I started not long ago and post a link as it may give you a little guidance.
I have not opened mine up yet and it is not an oil injected one so not much help there

Here it is http://www.yamahaoutboardparts.com/f...e-th24566.html

[DougBradlow]

40tlrb

Thank you that helped.

[rodbolt17]

remove the oil pump.
use needle nosed pliers and remove the driven shaft.
it juts pulls out.
yep
that simple.
maybe that's why its not in the manual.

best bet is once you remove the crank is to send the block and the crank to a machine shop to see if the block will be ok with standard pistons or does it need boring.
the crank to have the bearings replaced.
I use Carolina machine and tool(formerly Ackermanns) in Wilmington NC for my cranks and Rons marine in Portsmouth VA for my blocks.
its the difference in a REBUILD or a patchemup.