Yamaha E115A User manual

YAMAHA MOTOR CO., LTD.
Printed in Japan
Oct. 2005 – 1.2 ×1 !
(E_1) Printed on recycled paper
115B
SERVICE MANUAL
61U-28197-5H-11
140B
E115A
E115A, 115B, 140B
61U_A3Cover 06.6.9 18:50 Page 1

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
QThe Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E115A, 115B, 140B
SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st Edition, October 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
61U_A3Cover 05.10.13 11:29 AM Page 2

Specification
General information
Periodic check and adjustment
Fuel system
Power unit
Bracket unit
Electrical system
Troubleshooting
Index
Contents
Lower unit
9
8
7
6
2
1
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
3
4
5
61U5H11_01 05.10.7 3:50 PM Page 1

61U5H11_01 05.10.7 3:50 PM Page 2

61U5H11 1-
9
8
7
6
5
4
3
2
1
General information
How to use this manual ............................................................................... 1-1
Manual format .......................................................................................... 1-1
Symbol ..................................................................................................... 1-2
Safety while working ................................................................................... 1-3
Fire prevention ......................................................................................... 1-3
Ventilation ................................................................................................ 1-3
Self-protection ......................................................................................... 1-3
Parts, lubricant, and sealant .................................................................... 1-3
Good working practice ............................................................................. 1-4
Disassembly and assembly ..................................................................... 1-4
Identification ................................................................................................. 1-5
Applicable model ..................................................................................... 1-5
Serial number .......................................................................................... 1-5
Special service tool ..................................................................................... 1-6
Propeller selection ..................................................................................... 1-11
Propeller size ......................................................................................... 1-11
Selection ................................................................................................ 1-11
Predelivery check ....................................................................................... 1-12
Checking the fuel system ...................................................................... 1-12
Checking the gear oil ............................................................................. 1-12
Checking the outboard motor mounting height ..................................... 1-12
Checking the remote control cable (Remote control model) ...................1-13
Checking the steering system ............................................................... 1-14
Checking the gear shift and throttle operation.........................................1-14
Checking the PTT system (ET) ...............................................................1-15
Checking the engine start switch and engine stop lanyard switch ........ 1-15
Checking the cooling water pilot hole .................................................... 1-16
Test run .................................................................................................. 1-16
Break-in ................................................................................................. 1-16
After test run .......................................................................................... 1-17
GEN
INFO
61U5H11_01 05.10.7 3:50 PM Page 3

GEN
INFO
1- 61U5H11
General information
1-1
How to use this manual
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
9Parts are shown and detailed in an exploded diagram and are listed in the components list (see 1
in the figure below for an example page).
9The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2in the figure below).
9Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3in the figure below).
9Tightening torque specifications are provided in the exploded diagrams (see 4in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
9Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR Lower unit
6-5 62Y5A11
Lower unit
No. Part name Q ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2 Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR Lower unit
6-19 62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut , tighten it finger
tight, and then remove the drive shaft
bearing using a press.
CAUTION:
• Do not press the drive shaft threads
directly.
Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the for-
ward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Drive shaft holder 4 : 90890-06518
Pinion nut holder : 90890-06505
Socket adapter 2 : 90890-06507
Bearing inner race attachment :
90890-06639
S62Y6850K
Bearing separator : 90890-06534
Stopper guide plate : 90890-06501
Stopper guide stand :
90890-06538
Bearing puller : 90890-06535
Bearing puller claw 1 :
90890-06536
S62Y6740K
341
1
2
3
3
2
3
4
5
1
2
5
a
×
×
×
1
2
6F660190
1
2
3
61U5H11_01 05.10.7 3:51 PM Page 4

How to use this manual
61U5H11
9
8
7
6
5
4
3
2
1
1-2
GEN
INFO
Symbol
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
Specification Power unit Electrical system
Periodic check and adjustment Lower unit Troubleshooting
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to ein an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7Apply Yamaha 2-stroke outboard motor oil
8Apply gear oil
9Apply water resistant grease (Yamaha grease A)
0Apply molybdenum disulfide grease
qApply corrosion resistant grease
(Yamaha grease D)
wApply low temperature resistant grease
(Yamaha grease C)
eApply injector grease
Symbols rto oin an exploded diagram or illustration indicate the type of sealant or locking agent
and the application point.
rApply Gasket Maker
tApply ThreeBond 1104J
yApply LOCTITE 271 (red)
uApply LOCTITE 242 (blue)
iApply LOCTITE 572
oApply silicon sealant
FUEL BRKT
SPEC POWR ELEC
CHK
ADJ LOWR TRBL SHTG
123456
C
78 0qwe
rtyuio
9
61U5H11_01 05.10.7 3:51 PM Page 5

GEN
INFO
1- 61U5H11
General information
1-3
Safety while working
To prevent an accident or injury and to ensure
quality service, follow the safety procedures
provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricant, and sealant
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for exam-
ple, place a soiled rag in your pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
61U5H11_01 05.10.7 3:51 PM Page 6

Safety while working
1-4
61U5H11
9
8
7
6
5
4
3
2
1
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practice
Special service tool
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indicat-
ed in the installation procedure. In addi-
tion, be sure to lubricate the bearings lib-
erally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normal-
ly after assembly.
61U5H11_01 05.10.7 3:51 PM Page 7

1-5
GEN
INFO
61U5H11
General information
Identification
Applicable model
This manual covers the following model.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
6G410010
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
1
3
2
4
6B410020
Applicable model
E115AMH, E115AWH, E115AE, E115AET
115BE, 115BET, 140BET
Model name Approved Starting
model code serial No.
E115A 61U 1015056–
115B 6E5 1015056–
140B 6F3 1000671–
61U5H11_01 05.10.7 3:51 PM Page 8

61U5H11 1-6
9
8
7
6
5
4
3
2
1
Identification/Special service tool
Special service tool
Digital tachometer
90890-06760
Timing light
90890-03141
Leakage tester
90890-06840
Digital caliper
90890-06704
Vacuum/pressure pump gauge set
90890-06756
Compression gauge
90890-03160
Flywheel holder
90890-06522
Flywheel puller
90890-06521
Ball bearing attachment
90890-06663
Driver rod LS
90890-06606
61U5H11_01 05.10.7 3:51 PM Page 9

GEN
INFO
1- 61U5H11
General information
1-7
Driver rod L3
90890-06652
Needle bearing attachment
90890-06609, 90890-06610, 90890-06611,
90890-06612, 90890-06653, 90890-06654
Gear puller
90890-06540
Bearing separator
90890-06534
Support
90890-02394
Bearing outer race attachment
90890-06620, 90890-06624
Bearing inner race attachment
90890-06640, 90890-06662
Cylinder gauge
90890-06759
Ball bearing attachment
90890-06633, 90890-06636
90890-06637, 90890-06656
Small end bearing installer
90890-06528
61U5H11_01 05.10.7 3:51 PM Page 10

Special service tool
1-8
61U5H11
9
8
7
6
5
4
3
2
1
Piston slider
90890-06530
Dial gauge set
90890-01252
Shift rod push arm
90890-06052
Ring nut wrench 3
90890-06511
Stopper guide plate
90890-06501
Bearing housing puller claw L
90890-06502
Center bolt
90890-06504
Ring nut wrench extension
90890-06513
Bearing puller assembly
90890-06535
Stopper guide stand
90890-06538
61U5H11_01 05.10.7 3:51 PM Page 11

61U5H11
1-9
GEN
INFO General information
Backlash indicator
90890-06706
Driver rod SS
90890-06604
Bearing depth plate
90890-06603
Drive shaft holder 6
90890-06520
Pinion nut holder
90890-06715
Bearing outer race puller assembly
90890-06523
Driver rod SL
90890-06602
Pinion height gauge
90890-06710
Shimming plate
90890-06701
Driver rod LL
90890-06605
61U5H11_01 05.10.7 3:51 PM Page 12

61U5H11 1-10
9
8
7
6
5
4
3
2
1
Special service tool
Magnet base B
90890-06844
Digital circuit tester
90890-03174
Up relief fitting
90890-06773
Down relief fitting
90890-06774
Test harness (4 pins)
90890-06878
Trim and tilt wrench
90890-06587
Ignition tester
90890-06754
Magnet base plate
90890-07003
Hydraulic pressure gauge
90890-06776
Peak voltage adaptor B
90890-03172
Test harness (4 pins)
90890-06871
61U5H11_01 05.10.7 3:51 PM Page 13

GEN
INFO
1-11 61U5H11
General information
Selection
When the engine speed is at the full throttle
operating range (4,500–5,500 r/min), the
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption.
Propeller selection
The performance of a boat and outboard
motor will be critically affected by the size and
type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and could
also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size
The size of the propeller is indicated as
shown.
aPropeller diameter (in inches)
bPropeller pitch (in inches)
cPropeller type (propeller mark)
69D10020
×−
abc
6B410035
-
bc
Propeller size (in) Material
14 ×11 - K
13 5/8 ×13 - K
13 1/2 ×14 - K
12 1/2 ×15 - K
13 1/2 ×16 - K
13 ×17 - K Aluminum
13 1/4 ×17 - K
13 ×19 - K
12 5/8 ×21 - K
13 ×21 - K
13 ×23 - K
13 ×25 - K
14 ×20 - P
14 ×22 - P
14 ×24 - P Stainless steel
14 ×26 - P
14 ×28 - P
61U5H11_01 05.10.7 3:51 PM Page 14

61U5H11 1-12
9
8
7
6
5
4
3
2
1
Propeller selection
Predelivery check
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the fuel system
1. Check that the fuel hoses is securely
connected and that the fuel tank is filled
with fuel.
cC
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 50:1. For
break-in period, 25:1 mixture shall be
used.
Checking the gear oil
1. Check the gear oil level.
Checking the battery
(E, ET, WH)
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
2. Check that the positive and negative bat-
tery cable are securely connected.
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation will
occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to over-
heat. If the mounting height is too low,
water resistance will increase and reduce
engine efficiency.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights.
2. Check that the clamp brackets are
secured with the mounting bolts.
61U10080
69D10080
69D10055
Recommended battery capacity:
CCA/EN: 430 A
20HR/IEC: 70 Ah
Electrolyte specified gravity:
1.280 at 20°C (68°F)
61U5H11_01 05.10.7 3:51 PM Page 15

GEN
INFO
1-13 61U5H11
General information
Checking the remote control cable
(Remote control model)
1. Set the remote control lever to the neutral
position and fully close the throttle lever.
2. Check that the control lever 1is in its
fully closed position, and check the
adjusting screw 2is contact the stopper
3.
3. Fully open the throttle lever, and then
check that the control lever 1 is in its
fully opened position, and check the con-
trol lever contact the adjusting screw 4.
4. Check that the remote control lever is in
the neutral position, and check that the
center of the set pin 5is aligned with the
alignment mark aon the bottom cowling.
cC
The shift / throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
b.
5
a61U10065
1
2
3
61U10040
1
4
61U10050
6D430227
b
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61U5H11 1-14
9
8
7
6
5
4
3
2
1
Predelivery check
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the shift lever or remote
control lever is shifted from neutral to for-
ward or reverse.
2. Check that the throttle operates smoothly
when the throttle grip (tiller handle model)
is turned from the fully closed position to
the fully open position a.
Check that the throttle operates smoothly
when the remote control lever (remote
control model) is shifted from forward or
reverse to the fully open positions a.
Checking the steering system
1. Check the steering friction for proper
adjustment.
NOTE:
9To increase the friction, turn the friction
adjusting nut in direction a.
9To decrease the friction, turn the friction
adjusting nut in direction b.
2. Check that the steering operates smooth-
ly.
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
6F610120
F
N
R
a
a
61U10070
6S310030
61U10020
a
b
F
R
N
a
61U10030
61U5H11_01 05.10.7 3:51 PM Page 17

3. Check that the choke solenoid operates
when the engine start switch is pushed
in. (E, ET)
4. Check that the engine turns off when the
engine stop lanyard switch is pushed or
the engine stop lanyard is pulled from the
engine stop lanyard switch.
GEN
INFO
1-15 61U5H11
General information
Checking the PTT system
(ET)
1. Check that the outboard motor tilts up
and down smoothly when operating the
PTT unit.
2. Check that there is no abnormal noise
produced when the outboard motor is tilt-
ed up or down.
3. Check that there is no interference with
wires or hoses when the tilted up out-
board motor is steered.
4. Check that the trim meter points down
when the outboard motor is tilted all the
way down.
Checking the engine start switch,
engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
(E, ET, WH)
2. Check that the engine turns off when the
engine start switch is turned to OFF. (E,
ET, WH)
69D10200
OFF
ON
START
WH
69D10210
69D10215
6S310110
61U5H11_01 05.10.7 3:51 PM Page 18