HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.
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IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING 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.
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HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page.
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Symbol F to H in an exploded diagram indicate the grade of lubricant and the loca- tion of the lubrication point. F Apply Yamaha 2-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease)
CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEMS TROUBLE ANALYSIS...
INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION .................... 1-1 SERIAL NUMBER ..................1-1 STARTING SERIAL NUMBERS ............... 1-1 SAFETY WHILE WORKING ................1-2 FIRE PREVENTION ................... 1-2 VENTILATION................... 1-2 SELF-PROTECTION.................. 1-2 OILS, GREASES AND SEALING FLUIDS..........1-2 GOOD WORKING PRACTICES ..............1-3 DISASSEMBLY AND ASSEMBLY ............
IDENTIFICATION INFO IDENTIFICATION SERIAL NUMBER The outboard motor’s serial number is stamped on a label which is attached to the port clamp bracket. NOTE: As an antitheft measure, a special label on which the outboard motor’s serial number S6E51010 is stamped is bonded to the port clamp bracket.
SAFETY WHILE WORKING INFO SAFETY WHILE WORKING The procedures given in this manual are those recommended by Yamaha to be fol- lowed Yamaha dealers their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames.
SAFETY WHILE WORKING INFO Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized. A summary of the most important precau- tions is as follows: 1.
SAFETY WHILE WORKING INFO 3. Non-reusable items Always use new gaskets, packings, O- rings, split-pins, circlips, etc., on reas- sembly. 1080 DISASSEMBLY AND ASSEMBLY 1. Clean parts with compressed air when disassembling. 2. Oil the contact surfaces of moving parts before assembly.
SPECIAL TOOLS INFO SPECIAL TOOLS Using the correct special tools recom- mended by Yamaha, will aid the work and enable accurate assembly and tune-up. Improvising and using improper tools can damage the equipment. NOTE: • For U.S.A. and Canada, use part numbers that start with “J-”, “YB-”, “YM-”, “YU-”...
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SPECIAL TOOLS INFO B Digital tester P/N. J-39299 90890-06752 C Peak voltage adapter P/N. YU-39991 ........ a 90890-03169 ......b D Spark gap tester P/N. YM-34487 ....... a 90890-06754 ......b E Shimming gauge P/N. YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7 F Shimming gauge P/N.
SPECIAL TOOLS INFO REMOVING AND INSTALLING 1 Flywheel magnet assembly holder P/N. YB-06139 ........ a 90890-06522 ......b 2 Universal puller P/N. YB-06117 ........ a 90890-06521 ......b 3 Bearing/oil seal attachment P/N. YB-06196 ........ a 90890-06610, 90890-06637 ..b 4 Driver rod P/N.
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SPECIAL TOOLS INFO A Bearing puller P/N. 90890-06535 B Bearing/oil seal attachment P/N. 90890-06661, 90890-06662 C Ring nut wrench P/N. YB-34447 90890-06511 D Ring nut wrench extension P/N. 90890-06513 E Propeller shaft housing puller P/N. YB-06207 ........ a YB-06502 ........ b 90890-06502 F Center bolt P/N.
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SPECIAL TOOLS INFO P Slide hammer attachment P/N. YB-06335 90890-06514 Q Bearing/oil seal attachment P/N. YB-06337 R End screw wrench P/N. YB-06548 90890-06548 S End screw wrench P/N. YB-06175-1A...
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SPEC CHAPTER 2 SPECIFICATIONS GENERAL SPECIFICATIONS................2-1 MAINTENANCE SPECIFICATIONS..............2-7 POWER UNIT.................... 2-7 LOWER UNIT..................2-11 ELECTRICAL ................... 2-12 DIMENSIONS ..................2-15 TIGHTENING TORQUES ................2-17 SPECIFIED TORQUES ................2-17 GENERAL TORQUES ................2-19...
SPEC GENERAL SPECIFICATIONS Model Worldwide 100AETO E115AMH E115AWH E115AE E115AET Item Unit — — — — — Canada 100TR — — — — Induction system Loop charge Exhaust system Through prop boss Lubrication system Oil injection Pre-mixed Cooling system Water Ignition system Starting system Electric...
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SPEC GENERAL SPECIFICATIONS Model Worldwide 115BE 115BET 115BETO 115CETO — Item Unit — C115TR — 115TR S115TR B115TR Canada — C115TR — 115TR S115TR — DIMENSION Overall length mm (in) 828 (32.6) 808 (31.8) (33.9) Overall width mm (in) 600 (23.6) 582 (22.9) Overall height mm (in)
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SPEC GENERAL SPECIFICATIONS Model Worldwide 115BE 115BET 115BETO 115CETO — Item Unit — C115TR — 115TR S115TR B115TR Canada — C115TR — 115TR S115TR — Number of carburetors Enrichment system Choke valve Intake system Reed valve Induction system Loop charge Exhaust system Through prop boss Lubrication system...
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SPEC GENERAL SPECIFICATIONS Model Worldwide 130BETO L130BETO 140BET Item Unit 130TR S130TR L130TR — Canada 130TR S130TR — — DIMENSION Overall length mm (in) 808 (31.8) 828 (32.6) Overall width mm (in) 582 (22.9) 600 (23.6) Overall height mm (in) 1,472 (58.0) —...
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SPEC GENERAL SPECIFICATIONS Model Worldwide 130BETO L130BETO 140BET Item Unit 130TR S130TR L130TR — Canada 130TR S130TR — — Ignition system Starting system Electric Advance type Mechanical FUEL AND OIL Fuel type Unleaded regular gasoline Fuel rating *PON Engine oil type 2-stroke outboard engine oil Engine oil grade TC-W3...
SPEC MAINTENANCE SPECIFICATIONS MAINTENANCE SPECIFICATIONS POWER UNIT Model Item Unit 100 hp 115 hp 130 hp 140 hp CYLINDER HEADS Warpage limit mm (in) 0.10 (0.004) (lines indicate straightedge position) CYLINDERS Bore size mm (in) 90.00 - 90.02 (3.543 - 3.544) Wear limit mm (in) 90.1 (3.55)
SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 100AETO E115AMH E115AWH E115AE E115AET Item Unit — — — — — Canada 100TR — — — — CARBURETORS ID mark 61U01 61UM0 61U01 Main jet Main air jet Main nozzle (inside diameter) mm (in) 3.6 (0.14) Pilot jet Pilot air jet...
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SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 115BE 115BET 115BETO 115CETO — Item Unit — C115TR — 115TR S115TR B115TR Canada — C115TR — 115TR S115TR — CARBURETORS ID mark 6E515 Main jet Main air jet Main nozzle (inside diameter) mm (in) 3.6 (0.14) Pilot jet Pilot air jet...
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SPEC MAINTENANCE SPECIFICATIONS Model Worldwide 130BETO L130BETO 140BET Item Unit 130TR S130TR L130TR — Canada 130TR S130TR — — CARBURETORS ID mark 6L103 Main jet Main air jet Main nozzle (inside diameter) mm (in) 3.6 (0.14) Pilot jet Pilot air jet 7/8 ±...
SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Oil injection Pre-mixed (except for 115BETO) (and 115BETO) IGNITION CONTROL SYSTEM Thermo switch (P – B) OFF → ON ˚C (˚F) 84 - 90 (183 - 194) ON → OFF ˚C (˚F) 60 - 74 (140 - 165) Oil level sensor (engine oil tank) Float position a...
SPEC MAINTENANCE SPECIFICATIONS Model Item Unit Oil injection Pre-mixed (except for 115BETO) (and 115BETO) POWER TRIM AND TILT SYSTEM Trim sensor Ω Resistance (P – B) 582 - 873 Ω Resistance (O – B) 800 - 1,200 POWER TRIM AND TILT MOTOR Fluid type ATF Dexron II...
SPEC TIGHTENING TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb LOWER UNIT Propeller Trim tab Lower unit Ring nut — 14.5 Pinion nut Gear oil drain screw — Gear oil level check screw — BRACKET UNIT Steering friction rod —...
SPEC TIGHTENING TORQUES GENERAL TORQUES General torque This chart specifies tightening torques for specifications Nut (A) Bolt (B) standard fasteners with a standard ISO m•kgf ft•lb thread pitch. Tightening torque specifica- 8 mm tions for special components or assemblies 10 mm are provided in applicable sections of this 12 mm manual.
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INSP CHAPTER 3 PERIODIC INSPECTIONS AND ADJUSTMENTS MAINTENANCE INTERVAL CHART .............. 3-1 TOP COWLING ....................3-2 INSPECTING THE LOCK RELEASE (OIL INJECTION MODELS) ... 3-2 INSPECTING THE TOP COWLING FIT ............ 3-2 FUEL SYSTEM ....................3-3 INSPECTING THE FUEL LINE..............3-3 INSPECTING THE FUEL FILTER ..............
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INSP POWER TRIM AND TILT SYSTEM .............. 3-18 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL ....3-18 LOWER UNIT ....................3-19 INSPECTING THE GEAR OIL LEVEL ............. 3-19 CHANGING AND INSPECTING THE GEAR OIL ........3-19 INSPECTING THE LOWER UNIT (FOR AIR LEAKS)......3-20 GENERAL ......................
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INSP MAINTENANCE INTERVAL CHART MAINTENANCE INTERVAL CHART Use the following chart as a guide to general maintenance intervals. Dependant on operating conditions, adjust the maintenance intervals accordingly. Initial Every Refer Item Remarks 10 hours 50 hours 100 hours 200 hours to page (Break-in) (3 months)
INSP TOP COWLING/FUEL SYSTEM (4) Check the top cowling fitting and repeat the adjustment if necessary. NOTE: • Moving the latch towards the seal will loosen the top cowling. • Moving the latch away from the seal will tighten the top cowling. FUEL SYSTEM INSPECTING THE FUEL LINE 1.
NOTE: Turn the flywheel magnet assembly clock- wise to locate BTDC. Piston position 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: 3.05 mm (0.12 in) E115A: 3.33 mm (0.13 in) 115B, 115C, S115C/...
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(8) Secure the timing plate. (9) Adjust the length a of the full advance adjusting screw 3 to specification. Full advance adjusting screw length a 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: 29.0 mm (1.14 in) E115A: 24.5 mm (0.96 in) 115B/C115TR: 22.0 mm (0.87 in)
INSP CONTROL SYSTEM 4. Adjust: • Ignition timing (full retard) Adjustment steps (1) Turn the flywheel magnet assembly clockwise and align the timing plate and the specified mark. Flywheel magnet assembly position ATDC 5˚ (2) Turn the magneto control lever 1 to the full retard position.
INSP CONTROL SYSTEM 2. Adjust: • Carburetor synchronization Adjustment steps (1) Loosen the throttle stop screw 1 until it does not touch the throttle arm stop- per 2. (2) Loosen the upper carburetor’s throttle lever securing screw 3 by turning them clockwise.
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(1) Turn in the pilot screw 1 until it is lightly seated. (2) Turn out the pilot screw 1 the speci- fied number of turns. 3071 Pilot screw (turns out) 100A, E115A/100TR: 1-1/4 ± 1/4 115B, 115C, S115C/ C115TR, 115TR, S115TR, 5/8 ± 1/4 B115TR: 130B, S130B, L130B, 140B/130TR, S130TR, 7/8 ±...
INSP CONTROL SYSTEM (4) Start the engine and allow it to warm up for a few minutes. (5) Install the tachometer onto the spark plug lead of cylinder #1. Tachometer YU-08036-A / 90890-06760 (6) Turn the magneto control lever 3 so that the full retard adjusting screw 4 contacts the crankcase 5.
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INSP CONTROL SYSTEM Inspecting steps (1) Turn the magneto control lever so that the full retard adjusting screw contacts the crankcase. (2) Check that the mark a on the throttle cam aligns with the center of the throt- tle roller 1. 3080 2.
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INSP CONTROL SYSTEM ADJUSTING THE REMOTE CONTROL SHIFT CABLE 1. Inspect: • Shift operation Incorrect → Adjust. 2. Adjust: • Remote control shift cable length Adjustment steps (1) Loosen the locknut 1. (2) Remove the clip 2. (3) Disconnect the shift cable joint 3. (4) Set the remote control lever to the neutral position.
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INSP CONTROL SYSTEM 2. Adjust: • Remote control throttle cable length Adjustment steps (1) Loosen the locknut 1. (2) Remove the clip 2. (3) Disconnect the cable joint at the mag- neto control lever 3. (4) Close the throttle grip fully. (5) Turn the magneto control lever so that the full retard adjusting screw 4 con- tacts the crankcase.
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INSP COOLING SYSTEM/OIL INJECTION SYSTEM COOLING SYSTEM INSPECTING THE COOLING WATER DISCHARGE Inspect: • Cooling water discharge No discharge → Clean and inspect the cooling water passage. 3140 Inspecting steps (1) Place the lower unit in water. (2) Start the engine. (3) Check that water flows from the cool- ing water outlet.
INSP OIL INJECTION SYSTEM AIR BLEEDING THE OIL INJECTION SYSTEM Bleed: • Air bubbles (from the oil injection system) Bleeding steps (1) Fill the fuel tank with the fuel/oil mix- ture (50:1). Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil...
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INSP OIL INJECTION SYSTEM MEASURING THE OIL PUMP DISCHARGE Measure: • Oil pump discharge Out of specification → Check all of the oil pump components and replace any defective parts. Engine oil discharge (3 minutes/1 cylinder) 100hp, 115hp: 3.20 ± 0.70 cm (0.108 ±...
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INSP OIL INJECTION SYSTEM Measuring steps (1) Fill the fuel tank with the fuel/oil mix- ture (50:1) and fill the oil tank with engine oil. Recommended fuel Fuel type Unleaded regular gasoline Fuel rating PON: 86 RON: 91 Recommended engine oil Engine oil type 2-stroke outboard engine oil Engine oil grade...
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INSP POWER TRIM AND TILT SYSTEM POWER TRIM AND TILT SYSTEM3 INSPECTING THE POWER TRIM AND TILT FLUID LEVEL Inspect: • Power trim and tilt fluid level Level is low → Add power trim and tilt fluid to the proper level. Recommended power trim and tilt fluid ATF Dexron II...
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