2 vent plugs?

Teseal

Seaman
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Aug 2, 2018
Messages
74
Finishing up replacing drive shaft bearings on a Yamaha c40, about to fill the gear box and found what I think is an additional vent plug that is not labeled on the top of the gear box housing, the upper plug is labeled vent/fill. Are both to be open when refilling then closing the non labeled when the oil reaches it and then continuing until the top fills?
 

Teseal

Seaman
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Aug 2, 2018
Messages
74
Sorry the top plug is not labeled vent/fill, I was too lazy to back out to the shop and check for sure, it is labeled "Fill Level" so no doubt what it is for but still would like to make sure about the one that is not labeled and should it be used as a vent?
 

99yam40

Fleet Admiral
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A pic of what you are talking about would help.
sounds like you have a drain, vent, and fill level, and I never heard of this.
giving the motors complete model info might help look up what you are seeing
 

racerone

Supreme Mariner
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Remove both upper plugs.----Fill with oil from the bottom.----When oil reaches middle plug , intall it.----Then continue to fill until oil comes out the top , if indeed it does.----Perhap a plug for flushing ?
 

Jeff J

Petty Officer 1st Class
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Jun 23, 2021
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Suzuki has that arrangement on one of their motors. Their book says pull all 3 and fill to the middle one. Let sit 15(?) minutes and top off to the middle one and install the plugs. The Volvo SX-A drive isn’t much different. Fill to the vent plug, install plug and fill to the level marked on the dip stick.

This Yamaha is labeled with an oil level mark. It seems foolish to me to fill it beyond that mark. The top plug probably allows a cavity to vent so the oil level is even across the lower unit.
 

Teseal

Seaman
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Aug 2, 2018
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74
I missed some of that Jeff but the top plug is labeled Oil Level not the middle.
racerone, there is a plug higher up closer to the pump for flushing.

History: I changed the oil last year and didn't notice there were three plugs until the recent repair. I don't use the outboard much, I live on the lake and mostly use the boat for fishing so when I go out early I'm on the trolling motor. I don't remember exactly how many hours were on the motor after changing the oil but it wasn't much. When I could hear something was wrong I stopped using the outboard completely. During disassembly I found the top drive shaft seal, this unit doubles on both the drive and prop shaft, was completely distorted and thought at the time it was heat damaged. The top drive shaft roller bearing was the noise maker. Both top and bottom drive shaft bearings were replaced. When I found the top drive shaft roller bearing race mfg's part number did not match the roller assembly number I blamed the failure on that mismatch. There were some obvious signs this lower unit has been apart in the past. Researching the bearing part number mismatch I had learned that the bearing mfg suggests that bearing be used as a pair, (no clue why) same bearing assembly on each end of the shaft. Yamaha didn't engineer it that way instead it has this two different style bearings the top is the tapered roller and the bottom pin style roller. ANYWAY possibly when I replace the oil previously I may not have seen the top plug and removed the middle one to vent as I filled from the bottom. Gear box then may have only been half filled and that top bearing was damaged due to lack of oil. (??)

With all that said I'm inclined to refill as racerone suggest. Waiting for ordered oil now.

Many thx for your time guys, be safe.
 

99yam40

Fleet Admiral
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Sep 7, 2008
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9,186
Suzuki has that arrangement on one of their motors. Their book says pull all 3 and fill to the middle one. Let sit 15(?) minutes and top off to the middle one and install the plugs. The Volvo SX-A drive isn’t much different. Fill to the vent plug, install plug and fill to the level marked on the dip stick.

This Yamaha is labeled with an oil level mark. It seems foolish to me to fill it beyond that mark. The top plug probably allows a cavity to vent so the oil level is even across the lower unit.
if you read his #2 post, the top hole is labeled fill level.

I see OP posted while I was posting, and he covered what was said
 

Jeff J

Petty Officer 1st Class
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Jun 23, 2021
Messages
346
I looked at the picture wrong. I was thinking the plug above the cav plate is the top plug and missed the hole in the bottom so I am looking at 4 plugs instead of 3. What is the plug above the cav plate for?

I would find an owner’s manual or shop manual and see what the procedure is. A lot of owner’s manuals are available to download for free. It still reminds me of the Suzuki except the Suzuki doesn’t have “middle” plug.
 

Teseal

Seaman
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Aug 2, 2018
Messages
74
I'm not close to the outboard now but I think the top plug, the one above the plate was labeled "Wash". If I recall correctly it taps into the cavity for the water pump so it must be for flushing. I have a service manual but it is one that has every Yamaha built, hard to follow sometimes. Nowhere that I could find where it shows or mentions a model with 3 plugs when it refers to a 40hp range. Also I could not find a model that had 3 step wedge style shifter with a straight shift rod as this one does. There were only the ones with an offset in the rod or the twist style shift shaft.

Thx again.
 

Jeff J

Petty Officer 1st Class
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Jun 23, 2021
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I searched online and found what you are seeing in your manual. All diagrams and instructions for servicing show 2 plugs. I didn’t see a middle plug in the parts diagram I looked at either. I didn’t think to look for flushing instructions.

Could it be an aftermarket case?
 

Jeff J

Petty Officer 1st Class
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Jun 23, 2021
Messages
346
That’s not the diagram I found. I didn’t have the serial number to give to Yamaha so they were zero help.

It’s interesting that the middle plug is different.
 
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