Yamaha E115A Bedienungsanleitung

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!

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.

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

1st Edition, October 2005

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

GEN

INFO

SPEC

CHK

ADJ

FUEL

POWR

LOWR

BRKT

ELEC

TRBL

SHTG

61U5H11_01 05.10.7 3:50 PM Page 1

61U5H11_01 05.10.7 3:50 PM Page 2

61U5H11 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

6F660190

61U5H11_01 05.10.7 3:51 PM Page 4

How to use this manual

61U5H11

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

78 0qwe

rtyuio

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

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

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

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