Care & Maintenance Job Card (D Class)

Operation / Model: / Engine Pre-use checks, Start up & Stopping
(Yamaha 40 2-Stroke Engine) / Ref: JCD-01
Source Document: / 40V, 50H Owner’s Manual 1st Edition, February 2008 / Frequency:
Each Use
Date Issued: 7 August 13 : Revision No.: Original
D:\BMT\IRCG Boat Ops Manual\FDs\Section 2 - Final Draft\S2 - C1 - CGB Layout and equipment - Final Draft.doc

This Document is UNCONTROLLED if printed or downloaded. Printed on 21/08/2013 09:21. The Controlled version is stored on IRCG M-Drive Extranet

SHEET 1 of 5

NB. Prior to using this job card, confirm that the make, model and source document described above match that of the equipment being worked on at the CGU

Job Specific Risks, Hazards & Control Measures

Risk / Hazard / Control Measures
Personal Injury
/ ▪ In gear start protector.
▪ Tilting the engine.
▪ Working with hazardous materials.
▪ Improper use of equipment. / ü Follow the job tasks & safety measures described.
ü Safety Management by person in charge.
Damage to / Failure of Equipment
/ ▪ Improper use of equipment.
▪ Lack of care and maintenance. / ü Follow the job tasks & safety measures described within.

NB. This Job Card is written for starting the engine whilst the CGB is in the Water. Refer to JCD -03 for additional instructions in relation to the supply of water for shoreside starting.

Job Steps and Job Tasks

Ø Pre-Use Checks:

JS (1): Fuel & Oil

Remain vigilant for signs of petrol leakage including vapours

ü Check the amount of fuel in the tanks

ü Visually inspect the fuel lines, connections & filter

ü Prime the connected fuel line, squeezing the bulb until it becomes firm

ü Check the amount of oil in the oil tank

ü Ensure all fuel and oil caps are secure


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Ø Pre-Use Checks // Cont.:

JS (2): Engine Cowling

ü Check to be sure the rubber seal fits correctly all the way around the engine.

ü Ensure the top cowling turn lever is in the locked position.

ü Check the fitting of the top cowling by pushing it with both hands.

JS (3): Controls

ü Turn the tiller handle fully to the left and right to make sure operation is smooth.

ü Operate the throttle lever several times to make sure there is no hesitation in its travel. Operation should be smooth over the complete range of motion and the lever should return completely to the idle position.

ü Make sure the gear shift is in neutral.

JS (4): Engine Kill Cord

ü Inspect the kill cord for damage, such as cuts, breaks, and wear.

ü Attach the kill cord to a secure fitting on your personal flotation device. Refer to SOP-03 Essential Safety for instruction on Kill Cord positioning.


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Ø Engine Start Up:

JS (5): Starting Procedure

ü Place the throttle grip in the start position.

ü Pull out / turn the choke knob fully. After the engine starts, replace / return the knob to the home position.

ü Make sure the gear shift is in neutral.

ü Pull the manual starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the engine. Slowly return the manual starter handle to its original position before releasing it.

NB. If unable to pull the manual starter check the gear shift is in neutral:

▪ If the engine does not start on the first try, repeat the procedure.

▪ If the engine fails to start after 4 or 5 tries, open the throttle a small amount

(between 1/8 and 1/4) and try again.

JS (6): Immediately On Start

ü Slowly return the throttle grip to the fully closed position.

ü Check for a steady flow of water from the cooling water pilot hole: A continuous flow of water from the pilot hole shows that the water pump is pumping water through the cooling passages.

NB. If water is not flowing out of the pilot hole at all times while the engine is running, overheating and serious damage could occur:

▪ Stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked.

▪ If the problem cannot be located and corrected, inform the OIC

so that an appointed service agent can be consulted.


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Ø Post Start:

JS (7): Post Start

ü After starting the engine, allow it to idle for 3 minutes** to warm up: Failure to do so will shorten engine life.

▪ Gradually return the choke knob to its home position as the engine warms up.

**Unless immediate response is required

JS (8): Control Checks

ü Without applying throttle, confirm that the engine shifts smoothly into forward and reverse, and back to neutral.

ü Turn the main switch to “off”, or press the engine stop button and make sure the engine stops.

ü Confirm that removing the clip from the engine shut-off switch stops the engine.

ü Confirm that the engine cannot be started with the clip removed from the engine shutoff switch.

Ø Stopping the Engine:

üBefore stopping the engine, first let it cool off for a few minutes at idle or low speed: Stopping the engine immediately after operating at high speed is not recommended.

Ø Tilting the Engine:

▪ For further guidance as to tilting the engine for road transport refer to Section 2 - Chapter 1 – CGB Layout and Equipment.

40Hp 2-Stroke: Engine Start Up Summary

Allow engine to warm up for 3 minutes (unless immediate response is required).

Engine maintenance graphics are reproduced with kind permission from Yamaha Motor Co. Ltd., Japan and Yamaha Motor in Ireland (Danfay Ltd.). Images/graphics are copyright of Yamaha Motor Co. Ltd.