Re: 1991 yamaha 40 rebuild
Two-stroke right? The procedures are the same as a new motor. Check your owner's manual for break-in, but the following generic procedure I found in my Evinrude manual can be used.
Enrich the fuel/Oil ration to 25:1 for the FIRST 12 gallons of fuel (after 12 gallons, use 50:1 ratio).
First 20 minutes: Operate the motor in the water, in gear with a load at fast idle
Next 40 minutes: operate below 1/2 throttle...changing throttle every 15 minutes. Use higher rpms only to get boat on a plane, then reduce below 1/2 throttle while maintaining planing speed.
Check/clean plugs
Next nine hours: operate below 3/4 throttle...with every 30 minutes operate at WOT for only ONE minute
Replace plugs
I hope this helps,
MAS