Yamaha 40V refurb/restoration

[Livid]

Been a busy bee the past few weeks. Got my Yamaha exhaust tuner cut and welded to a similar style of the hydrotec marine one. Difference is the hydrotec is about £500 to get in the UK and I spent £160 on mine

To fit these funnel tuners you need to cut about a foot off the silencer, interested to see how much more antisocial it's going to bed. It was already quite smoky and noisy. I'll never have the most antisocial boat in the family because my uncles have a Mariah and a faery which both sounds like Shrek gargling bricks and broken glass.
I gave the exposed metal a quick coat of zinc based primer to stop it corroding, i don't want my shiny new exhaust manifold falling off

After the paint had dried it's finally time to stop taking it apart and start putting it back together. Helicoiled a broken stud hole in the top brakcet. Replaced all engine mounts whilst it was all torn apart too, don't want the engine falling off.

I had to get the lower unit off the leg to get the whole thing back together and my idiot brain forgot to remove a bolt and I ended up chipping the brand new paint which I'm never going to forgive myself for 😂😂 but it's reasonably hard to see so it should be fine.
Finally got the whole assembly back on the engine bracket. This is the first big bit of progress on getting this back together.

I gave up on getting my carbs bored out and sniped some Yamaha pro50 ones on eBay that'll do a fine job. My original carb bodies are lost in the post still and I gave up waiting. Still waiting on parts to get the block back together but I'm going to be able to service and install the lower unit and strip and clean the new carbs

[ollyit]

love your work mate

[Spreu-boote]

Wow nice update! Cant wait ro see it in the water

[Livid]

Been another few weeks and a lot more work. This is starting to get very close to being finished.
Got the leg on the bracket. Serviced the impeller whilst I was at it, no better time to do it. Only service thing left is the gear oil which I'll leave until I have slightly better access to the bottom because there's so many other engine bits around the garage I can't really get to it.

Stripped back my eBay carbs to check their condition, they were alright but quite worn, I'll need to get a proper rebuild kit into them before I properly run it. Was missing an o ring too.

My last parts order finally arrived so I was able to get the pistons on the crank. I decided in my infinite wisdom to not buy the correct tool for the job and had to hunt around the house for a bit of pipe the right size to hold the needles in place as I slid in the pin. Ended up using a bit from a old torch which did the trick. The little clips that hold the pins in were fun to deal with, one went flying into my hair at one point

Then I dropped the crank into the cylinder body. Hopefully it's the last time I see it but knowing my luck this time next week I'll be ripping it all apart because it exploded. Got all the bolts torqued down and sealed up.

Still to do is a lot of small things. I need to fit the oil seals onto the block as well as drill out a few broken bolts, get the flywheel on etc. I'll probably attach most of the accoutrements whilst the block Is off the leg, will make things a bit easier. I need to purge the oil system with fresh fully synthetic because what's in there now is not trustworthy at all. I also need to clean the gasket surface on the bottom of the block because I didn't do it earlier for some reason best known to the octopus that lives in my head.

[Spreu-boote]

Wow very nice to see your work again

[Livid]

Another month and I've been hard at work. Finishing touches now but I need to be careful to not overlook anything.
The block is back together now and I've been mounting ancillaries. Flywheel pickups, flywheel, CDI box, electrical unit etc. The wiring is a mess but I don't have to look at it so it's all ok haha.

Remaining jobs are fuel pump, oil pump and rebuild the carbs. The parts are on their way on a slow boat from the USA so god knows when they'll arrive. The fuel pump seems ok but it's a cheap part so I might as well replace it, the oil pump left lots of metal particles when I purged it so I'm rebuilding it so I can be confident in its quality. I really don't want to seize the engine up.

I also went and got the stickers put on the cowl, it looks really sharp now, can't wait to turn the key, getting very close now

[jeffstevens763@g]

looking sweet with the new decals

[Livid]

Been very busy, final parts arrived so I've been reassembling the carbs, oil pump and getting the engine on the block.
Attachment 136524
Carbs got rebuilt from the ground up with new seals, floats, needle valves and seats and with the main jets enlarged a touch. Now at 135.
Attachment 136525
Next up was getting the block on the leg and hooking up the tilt motor and switch and oil indicator hooked up as well as some temporary control cables. The battery I had earmarked didn't work so I had to jump start it off my car haha. But it fired first time and after I fixed the mixture screws it started up no problem! Ran for a little and the cooling water came through so that's all good
Attachment 136526
Finishing touches now, I've got to get the bottom carb roller moved and welded because my new carbs are off a pro50 and the roller is in a different spot and jams. Easy enough fix though. The new exhaust makes it sound fantastic!!

[Fenlander]

Always good to get a motor running again. BTW attachments don't show this end.

[Spreu-boote]

Nice to see it is running! Cant wait to see a video!