Yamaha 115B Manuals

Yamaha 115B Manuals

Manuals and User Guides for Yamaha 115B. We have 6 Yamaha 115B manuals available for free PDF download: Service Manual, Owner's Manual

Yamaha 115B Service Manual

Yamaha 115B Service Manual (261 pages)

Brand: Yamaha | Category: Engine | Size: 16 MB

Table of Contents

Table of Contents

3
- Important Information
  2
- General Information
  5
  - How to Use this Manual
    6
    
    Manual Format
    6
    
    Symbol
    7
- Contents
  7
  - Safety While Working
    8
    
    Fire Prevention
    8
    
    Ventilation
    8
    
    Self-Protection
    8
    
    Parts, Lubricant, and Sealant
    8
    
    Good Working Practice
    9
    
    Disassembly and Assembly
    9
  - Identification
    10
    
    Applicable Model
    10
    
    Serial Number
    10
  - Special Service Tool
    11
  - Propeller Selection
    16
    
    Propeller Size
    16
    
    Selection
    16
  - Predelivery Check
    17
    
    Checking the Fuel System
    17
    
    Checking the Gear Oil
    17
    
    Checking the Outboard Motor Mounting Height
    17
    
    Checking the Remote Control Cable (Remote Control Model)
    18
    
    Checking the Steering System
    19
    
    Checking the Gear Shift and Throttle Operation
    19
    
    Checking the PTT System (ET)
    20
    
    Checking the Engine Start Switch and Engine Stop Lanyard Switch
    20
    
    Checking the Cooling Water Pilot Hole
    21
    
    Test Run
    21
    
    Break-In
    21
    
    After Test Run
    22
Spec Specification

23
- Specification
  23
- General Specification
  
  24
- Maintenance Specification
  
  28
  - Power Unit (E115A Models)
    28
  - Lower Unit (E115A Models)
    30
  - Electrical (E115A Models)
    30
  - Power Unit (115B, 140B Models)
    33
  - Lower Unit (115B, 140B Models)
    35
  - Dimension
    38
- Tightening Torque
  
  42
  - Specified Torque
    42
  - General Torque
    44
Chk Adj Periodic Check and Adjustment

45
- Periodic Check and Adjustment
  
  46
- Maintenance Interval Chart
  
  46
- Top Cowling
  
  47
  - Checking the Top Cowling
    47
  - Periodic Check and Adjustment
    48
- Fuel System
  
  47
  - Checking the Fuel Joint and Fuel Hose (Fuel Joint-To-Carburetor)
    47
  - Checking the Fuel Filter
    47
- Power Unit
  
  48
  - Checking the Spark Plug
    48
    
    Checking the Thermostat
    48
    
    Checking the Cooling Water Passage
    49
- Control System
  
  49
- Bracket
  
  55
  - Checking the PTT Operation (ET)
    55
  - Checking the PTT Fluid Level (ET)
    55
- Lower Unit
  
  56
  - Checking the Tilt Operation (MH, WH, E)
    56
    
    Checking the Gear Oil Level
    56
    
    Changing the Gear Oil
    57
    
    Checking the Lower Unit for Air Leakage
    58
    
    Checking the Propeller
    58
- General
  
  58
Fuel Fuel System

61
- Hose Routing
  
  62
  - Fuel Hose and Breather Hose
    62
- Fuel System
  
  62
- Fuel Line
  
  64
- Carburetor
  
  67
- Fuel Pump
  
  76
  - Checking the Fuel Pump
    77
  - Disassembling the Fuel Pump
    77
  - Assembling the Fuel Pump
    78
  - Checking the Fuel Joint
    78
Powr Power Unit

80
- Powr
  80
- Power Unit
  
  82
- Intake Manifold
  
  105
  - Removing the Intake Manifold
    105
  - Checking the Reed Valve
    105
- Exhaust Cover
  
  106
  - Removing the Exhaust Cover
    107
  - Checking the Exhaust Cover
    107
  - Checking the PCV
    107
  - Installing the PCV
    107
- Cylinder Head
  
  108
  - Removing the Cylinder Head
    110
  - Checking the Cylinder Head
    110
- Crankcase
  
  112
  - Removing the Crankcase
    115
  - Disassembling the Bearing Housing
    115
  - Disassembling the Oil Seal Housing
    116
  - Removing the Piston, Connecting Rod Assembly and Crankshaft Assembly
    116
  - Disassembling the Piston and Connecting Rod Assembly
    116
  - Checking the Bearing
    116
  - Disassembling the Crankshaft
    117
  - Checking the Piston Diameter
    117
  - Checking the Cylinder Bore
    118
  - Checking the Piston Clearance
    118
  - Checking the Piston Ring
    118
  - Checking the Internal Anode
    119
  - Checking the Piston Pin
    119
  - Checking the Piston Pin Boss Bore
    119
  - Checking the Piston Ring Side Clearance
    119
  - Checking the Connecting Rod Big End Side Clearance
    120
  - Checking the Connecting Rod Small End Axial Play
    120
  - Checking the Crankshaft
    120
  - Assembling the Crankshaft
    121
  - Assembling the Bearing Housing
    122
  - Assembling the Oil Seal Housing
    122
  - Assembling the Piston and Connecting Rod Assembly
    123
  - Assembling the Power Unit
    123
  - Installing the Power Unit
    130
  - Adjusting the Timing Plate
    133
  - Adjusting the Ignition Timing Stopper
    134
Lowr Lower Unit

137
- Lowr
  137
- Lower Unit
  
  138
- Propeller Shaft Housing
  
  143
- Drive Shaft and Lower Case
  
  149
  - Removing the Drive Shaft
    150
  - Disassembling the Drive Shaft Housing
    150
  - Disassembling the Forward Gear
    150
  - Disassembling the Lower Case
    151
  - Checking the Pinion and Forward Gear
    151
  - Checking the Bearing
    151
  - Checking the Drive Shaft
    151
  - Checking the Lower Case
    152
  - Assembling the Lower Case
    152
  - Assembling the Forward Gear
    152
  - Assembling the Drive Shaft Housing
    153
  - Installing the Drive Shaft
    153
  - Installing the Propeller Shaft Housing
    154
  - Installing the Water Pump and Shift Rod
    155
  - Installing the Lower Unit
    156
- Shimming
  
  159
  - Selecting the Pinion Shim
    160
  - Selecting the Forward Gear Shim
    161
  - Selecting the Reverse Gear Shim
    162
- Backlash
  
  163
  - Measuring the Forward and Reverse Gear Backlash
    163
Brkt Bracket Unit

166
- Brkt
  166
- Tiller Handle
  
  171
- Bottom Cowling
  
  172
- Upper Case, Steering Arm
  
  175
  - Disassembling the Upper Case
    179
  - Checking the Upper Case
    180
  - Assembling the Upper Case
    180
  - Removing the Steering Arm
    184
  - Removing the Oil Seal of Swivel Bracket (MH, WH, E)
    184
  - Installing the Oil Seal of Swivel Bracket (MH, WH, E)
    184
  - Installing the Steering Arm
    185
  - Installing the Upper Case
    186
- Clamp Bracket and Swivel Bracket
  
  187
- PTT Unit
  
  201
  - Checking the Hydraulic Pressure
    202
- PTT Motor
  
  206
  - Disassembling the PTT Motor
    206
  - Checking the PTT Motor
    207
  - Checking the Filter
    208
  - Assembling the PTT Motor
    208
- Gear Pump
  
  211
  - Disassembling the Gear Pump Housing
    211
  - Checking the Main Valve
    212
  - Checking the Gear Pump
    212
  - Checking the Gear Pump Housing
    212
  - Checking the Reservoir
    212
  - Checking the Relief Valve
    212
  - Assembling the Gear Pump Housing
    213
- Tilt Cylinder and Trim Cylinder
  
  217
- PTT Electrical System
  
  224
  - Checking the Fuse
    224
  - Checking the PTT Relay
    224
  - Checking the Trim Sensor
    224
Elec Electrical System

225
- Elec
  225
- Checking the Electrical Component
  
  226
  - Measuring the Peak Voltage
    226
- Electrical System
  
  226
- Electrical Component
  
  227
  - Port View
    227
  - Starboard View
    228
  - Top View
    230
- Ignition and Ignition Control System
  
  231
  - Checking the Ignition Spark Gap
    231
  - Checking the Spark Plug Cap
    231
  - Checking the Ignition Coil
    232
  - Checking the CDI Unit
    232
  - Checking the Pulser Coil
    233
  - Checking the Charge Coil
    233
  - Checking the Thermoswitch
    234
  - Checking the Fuse (WH, E, ET)
    234
    
    Checking the Engine Start Switch (WH, E, ET)
    235
    
    Checking the Engine Stop Lanyard Switch
    235
    
    Checking the Starter Relay (WH, E, ET)
    236
    
    Checking the Neutral Switch (WH)
    236
    
    Removing the Starter Motor Pinion
    239
    
    Checking the Starter Motor Pinion
    239
    
    Checking the Armature
    239
    
    Checking the Brush
    240
    
    Checking the Starter Motor Operation
    240
    
    Checking the Choke Solenoid
    240
- Starting System
  
  234
- Starter Motor (WH, E, ET)
  
  239
- Charging System
  
  241
  - Checking the Lighting Coil
    241
  - Checking the Rectifier Regulator
    241
  - Checking the Hour Meter
    242
  - Trbl Shtg
    243

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Table of Contents

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Brand: Yamaha | Category: Outboard Motor | Size: 2 MB

Table of Contents

Table of Contents

5
- General Information
  7
- Chapter 1 IDENTIFICATION NUMBERS RECORD
  8
- Key Number
  8
- Outboard Motor Serial Number
  8
- Labels
  9
  - EC Label
    9
  - EPA Label
    9
- Emission Control Information
  10
- Operation
  11
- Safety Information
  11
- Fueling Instructions
  13
  - Gasoline
    14
  - Engine Oil
    14
- Battery Requirement
  15
- Propeller Selection
  15
- Start-In-Gear Protection
  16
Basic Components

17
- Chapter 2
  18
- Main Components
  18
- Operations of Controls and Other Functions
  22
  - Fuel Tank
    22
  - Gear Shift Lever
    23
  - Engine Stop Lanyard Switch
    23
  - Choke Knob
    24
  - Manual Injection Knob
    24
  - Recoil Starter Handle
    24
  - Main Switch
    25
  - Tiller Handle
    25
  - Remote Control
    27
  - Steering Friction Adjusting Screw
    33
  - Trim Tab
    34
  - Trim Angle Adjusting Rod
    34
  - Tachometer
    35
  - Trim Meter
    35
  - Digital Hour Meter
    35
  - Tilt Lock Mechanism
    36
  - Tilt Support Lever
    37
  - Top Cowling Lock Levers
    37
- Warning System
  38
  - Overheat Warning
    38
Operation

39
- Chapter 3 INSTALLATION
  40
- Mounting the Outboard Motor
  41
- Breaking in (Running In) Engine
  44
- Pre-Operation Checks
  46
- Filling Fuel and Engine Oil
  47
  - Filling Fuel
    47
  - Gasoline (Petrol) and Oil Mixing
    48
- Starting Engine
  50
- Warming up Engine
  58
- Shifting
  59
  - Forward
    59
  - Reverse
    60
- Stopping Engine
  61
- Trimming Outboard Motor
  62
  - Adjusting Trim Angle
    63
- Tilting Up/Down
  66
- Cruising in Other Conditions
  70
  - Cruising in Salt Water
    70
  - Cruising in Turbid Water
    70
Maintenance

71
- Chapter 4
  72
- Specifications
  72
- Transporting and Storing Outboard Motor
  78
  - Trailering Outboard Motor
    78
  - Storing Outboard Motor
    78
- Periodic Maintenance
  82
  - Replacement Parts
    82
  - Maintenance Chart
    83
  - Greasing
    84
  - Cleaning and Adjusting Spark Plug
    85
  - Checking Fuel System
    87
  - Inspecting Fuel Filter
    88
  - Adjusting Idling Speed
    91
  - Replacing Fuse
    92
  - Checking Wiring and Connectors
    92
  - Exhaust Leakage
    92
  - Water Leakage
    92
  - Checking Power Trim and Tilt System
    93
  - Checking Propeller
    94
  - Changing Gear Oil
    96
  - Cleaning Fuel Tank
    97
  - Inspecting and Replacing Anode(S)
    98
  - Checking Battery
    99
  - Checking Bolts and Nuts
    102
  - Checking Top Cowling
    102
  - Motor Exterior
    102
  - Coating the Boat Bottom
    103
E -Memo-

105
- Trouble Recovery
  105
- Chapter 5
  106
- Troubleshooting
  106
- Temporary Action in Emergency
  110
  - Impact Damage
    110
  - Running Single Engine
    110
  - Power Trim/Tilt will Not Operate
    111
  - Starter will Not Operate
    112
  - Treatment of Submerged Motor
    116
- Index
  117

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