Yamaha 100A Service Manual
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Yamaha 100A Service Manual

Yamaha 100A Service Manual

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WORLDWIDE
100A, E115A, 115B,
115C, 115F, 130B,
L130B, 140B
USA, CANADA
C115X, 115X,
S115X, B115X,
130X, S130X, L130X
SERVICE MANUAL
E
VERKSTADSHANDBOK
S
HUOLTO-OHJE
SF
MANUALE DI MANUTENZIONE
I
290360
6E5-28197-Z9-L1

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  • Page 1 WORLDWIDE 100A, E115A, 115B, 115C, 115F, 130B, L130B, 140B USA, CANADA C115X, 115X, S115X, B115X, 130X, S130X, L130X SERVICE MANUAL VERKSTADSHANDBOK HUOLTO-OHJE MANUALE DI MANUTENZIONE 290360 6E5-28197-Z9-L1...

  • Page 2: How To Use This Manual

    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.
  • Page 3 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.
  • Page 4 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.
  • Page 5 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)

  • Page 6: Specifications

    CONTENTS GENERAL INFORMATION SPECIFICATIONS PERIODIC INSPECTIONS AND ADJUSTMENTS FUEL SYSTEM POWER UNIT LOWER UNIT BRACKET UNIT ELECTRICAL SYSTEMS TROUBLE ANALYSIS...

  • Page 7: Table Of Contents

    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 ............

  • Page 8: Identification

    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.

  • Page 9: Safety While Working

    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.

  • Page 10: Good Working Practices

    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.

  • Page 11: Disassembly And Assembly

    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.

  • Page 12: Special Tools

    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-”...
  • Page 13 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.

  • Page 14: Removing And Installing

    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.
  • Page 15 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.
  • Page 16 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...
  • Page 17 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...

  • Page 18: General Specifications

    SPEC GENERAL SPECIFICATIONS GENERAL SPECIFICATIONS Model Worldwide 100AETO E115AMH E115AWH E115AE E115AET Item Unit — — — — — Canada 100TR — — — — DIMENSION Overall length mm (in) 808 (31.8) 1,458 (57.4) 828 (32.6) Overall width mm (in) 582 (22.9) 600 (23.6) Overall height...

  • Page 19: Fuel And Oil

    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...
  • Page 20 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)
  • Page 21 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...
  • Page 22 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) —...
  • Page 23 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...

  • Page 24: Maintenance Specifications

    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)

  • Page 25: Oil Injection Pump

    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...
  • Page 26 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...
  • Page 27 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 ±...

  • Page 28: Lower Unit

    SPEC MAINTENANCE SPECIFICATIONS LOWER UNIT Model Worldwide 100AETO E115AMH E115AWH E115AE E115AET Item Unit — — — — — Canada 100TR — — — — GEAR BACKLASH Pinion - forward gear mm (in) 0.32 - 0.50 (0.013 - 0.020) Pinion - reverse gear mm (in) 0.80 - 1.17 (0.031 - 0.046) Pinion shims...

  • Page 29: Electrical

    (E115A) BTDC 25 (115B, 115C, S115C/C115TR, 115TR, S115TR, B115TR) Piston position mm (in) 3.05 (0.12) (100A, 130B, S130B, L130B, 140B/ 100TR, 130TR, S130TR, L130TR) 3.33 (0.13) (E115A) 3.91 (0.15) (115B, 115C, S115C/C115TR, 115TR, S115TR, B115TR) CDI unit Output peak voltage lower limit (B/W –...

  • Page 30: Ignition Control System

    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...

  • Page 31: Power Trim And Tilt System

    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...

  • Page 32: Dimensions

    SPEC MAINTENANCE SPECIFICATIONS DIMENSIONS Symbol Models 100AETO, 115BE, 115BET, E115AMH, Worldwide (S)115CETO, E115AE, E115AET 115BETO, — E115AWH (S)130BETO L130BETO, 140BET Unit (S)115TR, (S)130TR — — C115TR, L130TR B115TR 100TR, (S)115TR, Canada — — C115TR — (S)130TR mm (in) 554 (21.8) 539 (21.2) 554 (21.8) mm (in)
  • Page 33 SPEC MAINTENANCE SPECIFICATIONS Symbol Models 100AETO, 115BE, 115BET, E115AMH, Worldwide (S)115CETO, E115AE, E115AET 115BETO, — E115AWH (S)130BETO L130BETO, 140BET Unit (S)115TR, (S)130TR — — C115TR, L130TR B115TR 100TR, (S)115TR, Canada — — C115TR — (S)130TR mm (in) 125.4 (4.9) 127 (5.0) 125.4 (4.9) mm (in) 254 (10.0)

  • Page 34: Tightening Torques

    SPEC TIGHTENING TORQUES TIGHTENING TORQUES SPECIFIED TORQUES Tightening torques Part to be tightened Thread size m•kgf ft•lb POWER UNIT Manual injection pump cable Fuel pump Intake silencer Carburetor drain plug — Pilot jet plug — Oil pump Recoil starter drive plate Flywheel magnet assembly Negative battery lead Power unit mount...

  • Page 35: Bracket Unit

    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 —...

  • Page 36: General Torques

    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.
  • Page 37 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 ..............
  • Page 38 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 ......................
  • Page 39 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)

  • Page 40: Top Cowling

    INSP TOP COWLING TOP COWLING INSPECTING THE LOCK RELEASE (OIL INJECTION MODELS) 1. Inspect: • Lock release Dull release → Adjust the release wire. 3001 2. Adjust: • Release wire length Adjustment steps (1) Push each locking plate down until it locks.

  • Page 41: Top Cowling/Fuel System

    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.

  • Page 42: Adjusting The Ignition Timing

    3050 (2) Turn the flywheel magnet assembly 1 clockwise and align the timing plate 2 with the specified mark. Flywheel magnet assembly position 100A, 130B, S130B, L130B, 140B/100TR, 130TR, S130TR, L130TR: BTDC 22˚ E115A: BTDC 23˚ 115B, 115C, S115C/...

  • Page 43: Control System

    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/...
  • Page 44 (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)

  • Page 45: Synchronizing The Carburetor

    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.

  • Page 46: Adjusting The Engine Idling Speed

    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.
  • Page 47 (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 ±...

  • Page 48: Adjusting The Carburetor Pickup Timing

    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.
  • Page 49 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.
  • Page 50 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.
  • Page 51 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.
  • Page 52 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.

  • Page 53: Oil Injection System

    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...
  • Page 54 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 ±...
  • Page 55 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...
  • Page 56 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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