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  4. 115B
  5. Owner's Manual

Yamaha 115B Owner's Manual

Summary of 115B

  • Page 1

    60h-28199-e1 e115a 115b 140b 150a l150a 175a 200a l200a owner’s manual 60h-9-e1 hyoshi 4/9/02 1:09 pm page 1 (2,1).

  • Page 2

    67k-9-14-1 2/28/02 11:23 am page 2.

  • Page 3

    E emu01449 to the owner thank you for choosing a yamaha outboard motor. This owner’s manual contains infor- mation needed for proper operation, main- tenance and care. A thorough understand- ing of these simple instructions will help you obtain maximum enjoyment from your new yamaha. If you have any...

  • Page 4

    60h-9-e1-1 3/1/02 9:25 pm page 2.

  • Page 5: Contents

    General information basic components operation maintenance trouble recovery index 1 2 3 4 5 6 emu00003 contents e read this owner’s manual carefully before operating your outboard motor. 60h-9-e1-1 3/1/02 9:25 pm page 3.

  • Page 6

    60h-9-e1-1 3/1/02 9:25 pm page 4.

  • Page 7: Chapter 1

    Emu00004 chapter 1 general information identification numbers record ............................................... 1-1 outboard motor serial number ............ 1-1 key number ........................................ 1-1 labels ................................................ 1-2 ec label ...........

  • Page 8: Yamaha

    E 1-1 yamaha motor co., ltd. Made in japan pays d'origine japon 1 401012 000319 123 yamaha q emu00005 identification numbers record emu00007 outboard motor serial number the outboard motor serial number is stamped on the label attached to the port side of the clamp-bracket. Record your outboard moto...

  • Page 9

    1-2 e emu01532 labels emu01526 ec label engines affixed with this label conform to certain portions of the european parliament directive relating to machinery. Refer to the label and the ec declaration of conformity for more details. Emu01527 epa label engines affixed with this label conform to u.S....

  • Page 10

    E 1-3 emu01385 emission control information emu01390 u.S. Insular areas engines affixed with the label pictured below conform to u.S. Environmental protection agency (epa) regulations for marine si engines. See the label affixed to your engine for details. 1 emission control information label approv...

  • Page 11

    1-4 e emu00918 q safety information 8 before mounting or operating the out- board motor, read this entire manual. Reading it should give you an under- standing of the motor and its operation. 8 before operating the boat, read any owner’s or operator’s manuals supplied with it and all labels. Be sure...

  • Page 12

    E 1-5 8 this product emits exhaust gases which contain carbon monoxide, a colorless, odorless gas which may cause brain damage or death when inhaled. Symptoms include nausea, dizziness, and drowsiness. Keep cockpit and cabin areas well ventilated. Avoid blocking exhaust outlets. 8 check throttle, sh...

  • Page 13

    1-6 e emu00016 fueling instructions w gasoline and its vapors are high- ly flammable and explosive! 8 do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition. 8 stop engine before refueling. 8 refuel in a well-ventilated area. Refuel portable fuel tanks off the b...

  • Page 14

    E 1-7 emu01799 gasoline if knocking or pinging occurs, use a differ- ent brand of gasoline or premium unleaded fuel. If unleaded gasoline is not available, then premium gasoline can be used. Emu01356 engine oil if the recommended engine oil is not avail- able, another 2-stroke engine oil with a nmma...

  • Page 15

    1-8 e 901015 upper level lower level emu01775 battery requirement c c do not use a battery that does not meet the specified capacity. If a battery which does not meet specifications is used, the electric system could perform poorly or be overloaded, causing electric system damage. For electric start...

  • Page 16

    E 1-9 yamaha dealers stock a range of pro- pellers, and can advise you and install a propeller on your outboard that is best suit- ed to your application. Note: at full throttle and under a maximum boat load, the engine’s rpm should be within the upper half of the full throttle operating range, as l...

  • Page 17: Chapter 2

    Emu00037 chapter 2 basic components main components ........................... 2-1 operations of controls and other functions ............................ 2-5 fuel tank ............................................. 2-5 gear shift lever ................................... 2-6 engine stop lanyard swi...

  • Page 18

    E 2-1 emu01206 main components 1 top cowling 2 tilt support lever 3 tilt lock lever 4 trim angle adjusting rod 5 anti-cavitation plate 6 trim tab (anode) 7 propeller 8 cooling water inlet 9 anode 0 engine stop switch q main switch w tiller handle e manual injection knob r recoil starter handle * may...

  • Page 19

    2-2 e emu01206 main components 1 top cowling 2 tilt support lever 3 tilt lock lever 4 trim angle adjusting rod 5 anti-cavitation plate 6 trim tab (anode) 7 propeller 8 cooling water inlet 9 anode 0 cowling lock lever q choke knob * may not be exactly as shown; also may not be included as standard eq...

  • Page 20

    E 2-3 emu01206 main components 1 top cowling 2 cowling lock levers 3 anti-cavitation plate 4 trim tab(anode) 5 propeller 6 cooling water inlet 7 anode 8 clamp bracket 9 tilt support lever 0 power trim/tilt switch q fuel joint w choke knob * may not be exactly as shown; also may not be included as st...

  • Page 21

    2-4 e emu01206 main components 1 remote control box (side mount type) 2 remote control box (binnacle mount type) 3 switch panel (for use with 2 ) 4 tachometer 5 trim meter 6 digital hour meter 7 remote control cable 8 fuel tank * may not be exactly as shown; also may not be included as standard equi...

  • Page 22

    E 2-5 902016 e q r w emu00039 operations of controls and other functions emu01465 fuel tank if your model included a portable fuel tank, its parts and functions are as follows. 1 fuel hose joint 2 fuel meter (if equipped) 3 fuel tank cap 4 air vent screw (if equipped) emu00042 fuel hose joint this c...

  • Page 23

    2-6 e 507014 1 2 3 000974 q w emu00051 gear shift lever (for tiller control model) turning the gear-shift lever towards you engages the clutch with the forward gear so that the boat moves ahead. Turning the lever away from you engages the reverse gear so that the boat moves astern. 1 neutral 2 forwa...

  • Page 24

    E 2-7 note: the engine cannot be started with the lock- plate removed. 305034 001310 209015 emu00055 choke knob pulling out this knob (setting it to on) sup- plies a rich mixture required to start the engine. Note: the choke knob for remote control model has the same function as the choke switch on ...

  • Page 25

    2-8 e 000530 off on start 000952 q e w 000529 emu01292 main switch e115awh the main switch controls the ignition sys- tem; its operation is described below. 8 off electrical circuits switched off. (the key can be removed.) 8 on electrical circuits switched on. (the key cannot be removed.) 8 start st...

  • Page 26

    E 2-9 502025 emu01293 throttle friction adjusting screw/ knob a friction device in the tiller handle provide resistance to movement of the throttle grip. This is adjustable for operator preference. An adjusting screw/knob is located within the tiller handle. When constant speed is desired, tighten t...

  • Page 27

    2-10 e 000322 w q e t y u i q r u u 001276 i on start off on start off t y 001277 a b c emu01691 remote control both the shifter and the throttle are actuated by the remote control lever. Additionally, the remote control also has the electrical switches. å side mount remote control box ∫ binnacle mo...

  • Page 28

    E 2-11 r n f q w e r t y u u t r y 701031 702032 q w e r r t t y y u u 000323 up dn n 000324 q w emu00098 remote control lever moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral engages reverse. The engine will continue to run at idle until t...

  • Page 29

    2-12 e on start off 701021 on start off on start off 001242 701055 on start off 703031 emu00101 main switch the main switch controls the ignition sys- tem; its operation is described below. 8 off electrical circuits switched off. (the key can be removed.) 8 on electrical circuits switched on. (the k...

  • Page 30

    E 2-13 000569 q w on start off on start off q w 000715 emu00934 engine stop lanyard switch the lock-plate 1 must be attached to the engine stop lanyard switch for the engine to run. The lanyard 2 should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall...

  • Page 31

    2-14 e up dn 701034 up dn dn up 000921 emu01112 power trim/tilt switches the power trim/tilt adjusts the motor angle in relation to the transom. The power trim/tilt switch is located on the remote control lever grip. Individual-engine switches are also on the control cover. Pushing the switch “up” t...

  • Page 32

    E 2-15 001278 35° q e q emu00106 free accelerator to open the throttle without shifting into either forward or reverse, push the free accelerator button and turn the remote con- trol lever. Note: 8 the free accelerator button can be oper- ated only when the remote control lever is in the neutral pos...

  • Page 33

    2-16 e 701035 702035 000550 emu01155 throttle friction adjusting screw a friction device in the remote control box provides adjustable resistance to movement of the remote control lever, and can be set according to operator preference. An adjusting screw is located on the front of the remote control...

  • Page 34

    E 2-17 q w e 603014 a b 000625 001290 emu01552 trim tab the trim tab should be adjusted so that the steering control can be turned to either the right or left by applying the same amount of force. W an improperly adjusted trim tab may cause difficult steering. Always test run after the trim tab has ...

  • Page 35

    2-18 e 801023 yamaha x1000 r/min 7 6 5 4 3 1 2 801011 yamaha 001326 hour yamaha w q emu00124 tachometer this meter shows the engine speed. Emu00132 trim meter (for power trim/tilt model) this meter shows the trim angle of your out- board. Note: memorize the trim angles that work best for your boat u...

  • Page 36

    E 2-19 000130 001286 q emu01610 digital hour meter 200a, l200a located on the engine inside the top cowl- ing, this device measures the total number of hours the engine has been run since manufacture. When the main switch is turned on, initially all segments of the dis- play will light. The indicato...

  • Page 37

    2-20 e 001288 001375 q 001376 q emu00157 tilt support lever to keep the outboard motor in the tilted-up position, lock the tilt support lever to the clamp bracket. Emu00160 top cowling lock levers to remove the engine top cowling, turn the front lock lever and rear lock lever(s). Then lift off the c...

  • Page 38

    E 2-21 701054 703026 off start off start on on 605015 emu00169 warning system c c do not continue to operate the engine if the warning device has activated. Consult your yamaha dealer if the prob- lem cannot be located and corrected. Emu00171 overheat warning this engine has an overheat warning devi...

  • Page 39: Chapter 3

    Emu00174 chapter 3 operation installation .................................... 3-1 mounting the outboard motor .............. 3-2 breaking in (running in) engine ................................................. 3-5 running in the engine ......................... 3-5 pre-operation checks ..............

  • Page 40

    E 3-1 emu00175 installation c c incorrect engine height or obstructions to smooth water flow (such as the design or condition of the boat or acces- sories such as transom ladders/depth finder transducers) can create airborne water spray while the boat is cruising. Severe engine damage may result if ...

  • Page 41

    3-2 e emu01478 mounting the outboard motor w 8 overpowering a boat may cause severe instability. Do not install an outboard motor with more horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a capacity plate, consult the boat manufacturer. 8 the informati...

  • Page 42

    E 3-3 mount the outboard motor on the center line (keel line) of the boat, and ensure that the boat itself is well balanced. Otherwise, the boat will be hard to steer. For boats without a keel or which are asymmetrical, consult your dealer. 1 center line (keel line) q 104016 000371 q 0–25 mm (0–1 in...

  • Page 43

    3-4 e note: 8 the optimum mounting height of the out- board motor is affected by the boat/motor combination and the desired use. Test runs at different heights can help deter- mine the optimum mounting height. 8 refer to the section “trimming out- board motor” for instructions on set- ting the trim ...

  • Page 44

    E 3-5 emu01534 breaking in (running in) engine your new engine requires a period of break- in (running-in) to allow mating surfaces of moving parts to wear-in evenly. Correct break-in (running-in) will help ensure proper performance and longer engine life. C c failure to follow the break-in (running...

  • Page 45

    3-6 e 3) second hour: accelerate at full throttle onto plane, then reduce engine speed to three- quarter throttle (approximately 4,000 r/min). Vary engine speed occasionally. Run at full throttle for one minute, then allow about 10 minutes of operation at three-quarter throttle or less to let the en...

  • Page 46

    E 3-7 emu00204 pre-operation checks w if any item in the pre-operation check is not working properly, have it inspected and repaired before operating the out- board motor. Otherwise, an accident could occur. C c do not start the engine out of water. Overheating and serious engine damage can occur. E...

  • Page 47

    3-8 e 902021 emu00209 controls 8 check throttle, shift, and steering for proper operation before starting the engine. 8 the controls should work smoothly, with- out binding or unusual free play. 8 look for loose or damaged connections. 8 check operation of the starter and stop switches when the outb...

  • Page 48

    E 3-9 902031 q w emu01481 gasoline (petrol) and oil mixing pre-mix models 1) pour oil and gasoline into the fuel tank, in that order. 1 engine oil 2 gasoline (petrol) 2) mix the fuel thoroughly by shaking. 3) make sure the oil is mixed with the gasoline. C c 8 avoid using any oil other than the des-...

  • Page 49

    3-10 e note: if using a permanently installed tank, pour the oil gradually as the fuel is being added to the tank. Mixing ratio 25 : 1 gasoline (petrol) engine oil 1 l (0.26 us gal, 0.22 imp gal) 0.04 l (0.04 us qt, 0.04 imp qt) 12 l (3.2 us gal, 2.6 imp gal) 14 l (3.7 us gal, 3.1 imp gal) 24 l (6.3...

  • Page 50

    E 3-11 902043 001309 902023 902025 emu01461 starting engine w 8 before starting the engine, make sure that the boat is tightly moored and that you can steer clear of any obstruc- tions. Be sure there are no swimmers in the water near you. 8 when the air vent screw is loosened, gasoline (petrol) vapo...

  • Page 51

    3-12 e n 507022 000975 503022 emu01497 procedure for tiller control model 4) place the gear-shift lever in the neutral position. Note: the start-in-gear protection device prevents the engine from starting except when in neutral. 5) attach the engine stop switch lanyard to a secure place on your clot...

  • Page 52

    E 3-13 emu01707 manual start models 7) fully pull out the manual injection knob firmly once. Release the knob to allow it to automatically return to its home posi- tion. Note: 8 it is not necessary to use the manual injection knob when restarting a warm engine. 8 pull out the manual injection knob t...

  • Page 53

    3-14 e emu01706 electric start models e115awh 7) fully pull out the manual injection knob firmly once. Release the knob to allow it to automatically return to its home posi- tion. Note: 8 it is not necessary to use the manual injection knob when restarting a warm engine. 8 pull out the manual inject...

  • Page 54

    E 000560 3-15 9) immediately after the engine starts, release the main switch to return it to on. C c 8 do not turn the main switch to start when the engine is running. 8 do not keep the starter motor turning for more than 5 seconds. The battery will rapidly become exhausted and it will be impossibl...

  • Page 55

    3-16 e emu00248 procedure for remote control models 4) place the remote control lever in the neutral position. Note: the start-in-gear protection device permits the engine to be started only when it is in neutral. N 701015 n 702025 000293 on start off on start off 000714 5) attach the engine stop sw...

  • Page 56

    E 3-17 6) turn the main switch to “on”. Note: in case of dual-engine operation, when the main switch is turned on, the buzzer oper- ates for a few seconds and stops automati- cally. Should either of the dual engines stall, the buzzer operates. Emu00948 electric start models 7) open the throttle slig...

  • Page 57

    3-18 e 8) press in and hold the main switch to operate the remote choke system.(the remote choke switch returns to its home position when you release your hand. Therefore, keep the switch pressed in.) note: 8 it is not necessary to use the choke when the engine is warm. 8 set the choke knob to the h...

  • Page 58

    E 3-19 001318 emu01507 warming up engine 1) before beginning operation, allow the engine to warm up at idling speed for 3 minutes. (failure to do this will shorten engine life.) gradually return the choke knob to the home position as the engine warms up. 2) check for a steady flow of water from the ...

  • Page 59

    3-20 e 000560 n f 507015 701043 n f n f 702015 emu00261 shifting w before shifting, make sure there are no swimmers or obstacles in the water near you. C c to change the shifting position from for- ward to reverse or vice-versa, close the throttle first so that the engine idles (or runs at low speed...

  • Page 60

    E 3-21 emu01326 reverse w when operating in reverse, go slowly. Do not open the throttle more than half. Otherwise, the boat may become unsta- ble, which could result in loss of control and an accident. 1) place the throttle control grip in the fully closed position (for tiller control model). 2) ch...

  • Page 61

    3-22 e 000973 off on start off 701023 001312 902044 emu00273 stopping engine let it cool off for a few minutes at idle or low speed first. Stopping the engine immediate- ly after operating at high speed is not rec- ommended. Emu00277 1) push and hold the engine stop button or turn the main switch to...

  • Page 62

    E 3-23 000862 q emu01412 trimming outboard motor the trim angle of the outboard motor helps determine the position of the bow of the boat in the water. The correct trim angle will help improve performance and fuel econo- my while reducing strain on the engine. The correct trim angle depends upon the...

  • Page 63

    3-24 e adjusting trim angle emu00951 manual tilt model there are 4 or 5 holes provided in the clamp bracket to adjust the outboard motor trim angle. 1) stop the engine. 2) remove the trim angle adjusting rod 1 from the clamp bracket while tilting the motor up slightly. 3) reposition the rod in the d...

  • Page 64

    E 3-25 up dn 000350 up dn q dn up 000351 q emu01401 power trim/tilt model w 8 be sure all people are clear of the out- board motor when adjusting the trim/tilt angle, also be careful not to pinch any body parts between the drive unit and clamp bracket. 8 use caution when trying a trim posi- tion for...

  • Page 65

    3-26 e emu01558 bow up when the boat is on plane, a bow-up atti- tude results in less drag, greater stability and efficiency. This is generally when the keel line of the boat is up about 3 to 5 degrees. When trimmed out, the boat may have more tendency to steer to one side or the other. Compensate f...

  • Page 66

    E 3-27 000817 emu00285 tilting up/down if the engine will be stopped for some time, or if the boat is moored in shallows, the engine should be tilted up to protect the propeller and casing from damage by colli- sion with obstructions, and also to reduce salt corrosion. C c 8 before tilting the motor...

  • Page 67

    3-28 e 001312 001313 001314 emu00286 procedure for tilting up manual tilt model 1) remove the fuel-line connection from the motor. (if the fuel connector is pro- vided on the motor.) 2) place the tilt-lock lever in release. 3) hold the rear of the top cowling with one hand, tilt the engine up, and t...

  • Page 68

    E 3-29 001312 up dn 701034 up dn dn up 000921 001315 emu01575 procedure for tilting up power trim and tilt models 1) disconnect the fuel line or close the fuel cock. 3) turn the tilt support lever toward you to support the engine. W 8 after tilting the engine, be sure to sup- port it with the tilt s...

  • Page 69

    3-30 e 411043 411045 emu01576 4) once the engine is supported with the tilt support lever, push the power trim and tilt switch “dn” (down) to retract the trim rods. C c be sure to retract the trim rods com- pletely during mooring. This protects the rods from marine growths and corrosion which could ...

  • Page 70

    E 3-31 emu00316 cruising in other conditions cruising in salt water after operating in salt water, wash out the cooling-water passages with fresh water to prevent them from becoming clogged-up with salt deposits. Note: refer to cooling system flushing instructions in “transporting and storing out- b...

  • Page 71: Chapter 4

    Emu00317 chapter 4 maintenance specifications ................................ 4-1 transporting and storing out- board motor ................................... 4-7 trailering outboard motor ................... 4-7 storing outboard motor ....................... 4-8 periodic maintenance ................

  • Page 72

    E 4-1 emu01695* specifications spark plug n·m (kgf·m, lb·ft) propeller nut n·m (kgf·m, lb·ft) model item unit e115amh dimensions performance overall length mm (in.) overall width mm (in.) overall height l/y/x mm (in.) transom height l/y/x mm (in.) weight l/y/x kg (lb.) full throttle operating range ...

  • Page 73

    4-2 e 25 (2.5, 18) 55 (5.6, 40) e115awh e115ae e115aet 1,458 (57.4) 600 (23.6) 1,558 (61.3) / 1,611 (63.4) / 1,684 (66.3) 516 (20.3) / 569 (22.4) / 642 (25.3) 156 (344) / 158 (348) / 160 (353) 4,500–5,500 84.6 (115) @ 5,000 700–800 2-stroke, v4 1,730 (105.6) 90 × 68 (3.54 × 2.68) cdi system b8hs-10 ...

  • Page 74

    E 4-3 emu01695* specifications spark plug n·m (kgf·m, lb·ft) propeller nut n·m (kgf·m, lb·ft) model item unit 115be dimensions performance overall length mm (in.) overall width mm (in.) overall height l/y/x mm (in.) transom height l/y/x mm (in.) weight l/y/x kg (lb.) full throttle operating range r/...

  • Page 75

    4-4 e 25 (2.5, 18) 55 (5.6, 40) 115bet 140bet 150aet 828 (32.6) 600 (23.6) — / — / 1,561 (61.5) — / — / 642 (25.3) — / — / 160 (353) 4,500–5,500 84.6 (115) @ 5,000 700–800 2-stroke, v4 1,730 (105.6) 90 × 68 (3.54 × 2.68) cdi system b8hs-10 0.9–1.0 (0.035–0.039) remote control electric start 430 70 1...

  • Page 76

    E 4-5 emu01695* specifications spark plug n·m (kgf·m, lb·ft) propeller nut n·m (kgf·m, lb·ft) model item unit l150aet dimensions performance overall length mm (in.) overall width mm (in.) overall height l/y/x mm (in.) transom height l/y/x mm (in.) weight l/y/x kg (lb.) full throttle operating range ...

  • Page 77

    4-6 e 25 (2.5, 18) 55 (5.6, 40) 175aet 200aet l200aet 828 (32.6) 600 (23.6) 1,577 (62.1) / — / 1,703 (67.0) 516 (20.3) / — / 642 (25.3) 180 (397) / — / 184 (406) 4,500–5,500 128.7 (175) @ 5,000 675–725 2-stroke, v6 2,596 (158.4) 90 × 68 (3.54 × 2.68) cdi system b8hs-10 0.9–1.0 (0.035–0.039) remote c...

  • Page 78

    E 4-7 001329 emu01369 transporting and storing outboard motor w leaking fuel is a fire hazard. When trans- porting and storing the outboard motor, close the air vent screw and fuel cock to prevent fuel from leaking. Emu00326 trailering outboard motor the motor should be trailered and stored in the n...

  • Page 79

    4-8 e emu00329 storing outboard motor when storing your outboard motor for pro- longed periods of time (2 months or longer), several important procedures must be per- formed to prevent expensive damage. It is advisable to have your outboard ser- viced by an authorized yamaha dealer prior to storage....

  • Page 80

    E 4-9 7) pour a teaspoonful of clean engine oil into the cylinder(s). 8) crank several times manually. 9) replace the spark plug(s). Emu00336 fuel tank 1) drain the fuel from the tank for a long period of storage. 2) store the fuel tank in a dry, well-venti- lated place, not in direct sunlight. Emu0...

  • Page 81

    4-10 e emu01545 battery care w battery electrolyte is poisonous and dangerous, causing severe burns, etc. It contains sulfuric acid. Avoid contact with skin, eyes, or clothing. Antidote: external: flush with water. Internal: drink large quantities of water or milk. Follow with milk of magne- sia, be...

  • Page 82

    E 4-11 emu00356 replacement parts if replacement parts are necessary, use only genuine yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers. Ya...

  • Page 83

    4-12 e emu01708 maintenance chart frequency of maintenance operations may be adjusted according to the operating condi- tions, but the following table gives general guidelines. The mark ( ● ) indicates the check-ups which you may carry out yourself. The mark ( 1 ) indicates work to be carried out by...

  • Page 84

    E 4-13 103072 emu00909 greasing yamaha grease a (water resistant grease) yamaha grease d (corrosion resistant grease) *1 *1. For propeller shaft 60h-9-e1-4 3/1/02 9:39 pm page 14.

  • Page 85

    4-14 e 000655 emu01202 cleaning and adjusting spark plug w when removing or installing a spark plug, be careful not to damage the insu- lator. A damaged insulator could allow external sparks, which could lead to explosion or fire. The spark plug is an important engine com- ponent and is easy to insp...

  • Page 86

    E 4-15 000535 903022 q w when fitting the plug, always clean the gas- ket surface and use a new gasket. Wipe off any dirt from the threads and screw in the spark plug to the correct torque. Note: if a torque-wrench is not available when you are fitting a spark plug, a good estimate of the correct to...

  • Page 87

    4-16 e 001319 001320 v4 v6 emu01509 checking fuel system w gasoline (petrol) and its vapors are high- ly flammable and explosive. Keep away from sparks, cigarettes, flames or other sources of ignition. Check the fuel line for leaks, cracks, or mal- functions. If any problem is found, it should be re...

  • Page 88

    E 4-17 emu00370 inspecting fuel filter w gasoline (petrol) is highly flammable, and its vapors are flammable and explo- sive. 8 if you have any question about proper- ly doing this procedure, consult your yamaha dealer. 8 do not perform this procedure on a hot or running engine. Allow the engine to ...

  • Page 89

    4-18 e emu00978 115b, 140b 1) remove the nut holding the fuel filter assembly if equipped. 2) unscrew the filter cup 1 , catching any spilled fuel in a rag. 3) remove the filter element 2 , and wash it in solvent. Allow it to dry. Inspect the filter element and o-ring 3 to make sure they are in good...

  • Page 90

    E 4-19 emu01308 200a, l200a note: if any water is in the fuel, the float 7 will rise. If so, remove the cup and drain the water. 1) loosen and remove the locking tab bolt and tab 1 . Slightly loosen the filter cup ring nut 2 . 2) remove the filter cup 3 , catching any spilled fuel in a rag. 3) remov...

  • Page 91

    E 4-20 emu00991 adjusting idling speed w 8 do not touch or remove electrical parts when starting or during opera- tion. 8 keep hands, hair and clothes away from flywheel and other rotating parts while engine is running. C c this procedure must be performed while the outboard motor is in the water. A...

  • Page 92

    E 4-21 413016 emu00383 checking wiring and connectors 1) check that each grounding wire is properly secured. 2) check that each connector is engaged securely. Emu00384 exhaust leakage start the engine and check that no exhaust leaks from the joints between the exhaust cover, cylinder head and crank ...

  • Page 93

    E 4-22 411046 q w 411044 e 411045 emu01690 checking power trim and tilt system w 8 never get under the lower unit while it is tilted, even when the tilt-support lever is locked. Severe injury could occur if the outboard accidentally falls. 8 make sure no one is under the out- board before performing...

  • Page 94

    E 4-23 recommended fluid: yamaha power trim & tilt fluid or atf (dexron- ii ). Emu00388 checking propeller w you could be seriously injured if the engine accidentally starts while you are near the propeller. 8 before inspecting, removing or installing the propeller, remove the spark plug caps from t...

  • Page 95

    E 4-24 000357 q w e t y r 602053 emu00976 removing the propeller 1) straighten the cotter-pin 1 and pull it out using a pair of pliers. 2) remove the propeller nut 2 , washer 3 and spacer 4 . 3) remove the propeller 5 and thrust washer 6 . Emu01560 installing the propeller c c 8 be sure to install t...

  • Page 96

    E 4-25 001324 q w emu01460 changing gear oil w 8 be sure the outboard is securely fas- tened to the transom or a stable stand. You could be severely injured if the outboard falls on you. 8 never get under the lower unit while it is tilted, even when the tilt-support lever/knob is locked. Severe inju...

  • Page 97

    E 4-26 5) with the outboard motor in a vertical position, and using a flexible or pres- surized filling device, inject the gear oil into the oil drain plug hole. 6) when the oil begins to flow out of the oil level plug hole, insert and tighten the oil level plug. 7) insert and tighten the oil drain ...

  • Page 98

    E 4-27 000274 603024 405016 emu00402 cleaning the fuel filter 1) remove the screws holding the fuel hose joint assembly. Pull the assembly out of the tank. 2) clean the filter (located on the end of the suction pipe) in a suitable cleaning solvent. Allow the filter to dry. 3) replace the gasket with...

  • Page 99

    E 4-28 901015 upper level lower level emu00404 checking battery (for electric start models) w battery electrolytic fluid is dangerous; it contains sulfuric acid and therefore is poisonous and highly caustic. Always follow these preventive mea- sures: 8 avoid bodily contact with electrolytic fluid as...

  • Page 100

    E 4-29 upper level lower level 000639 c c 8 a poorly maintained battery will quick- ly deteriorate. 8 ordinary tap-water contains minerals harmful to a battery, and should not be used for topping-up. 1) check the electrolyte level at least once a month. Fill to the manufacturer’s rec- ommended level...

  • Page 101

    E 4-30 upper level lower level 901012 q w e emu01279 connecting the battery electric start models w mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged battery in the holder. C c 8 make sure the main switch (on applica- ble mode...

  • Page 102

    E 4-31 102024 emu00408 checking bolts and nuts 1) check that bolts securing the cylinder head and engine and the nut securing the flywheel are tightened with their specified tightening torque. 2) check the tightening torque of other bolts and nuts. Emu01635 checking top cowling check the fitting of ...

  • Page 103

    E 4-32 102025 emu00413 coating the boat bottom a clean hull improves boat performance. The boat bottom should be kept as clean of marine growths as possible. If necessary, the boat bottom can be coated with an anti- fouling paint approved for your area to inhibit marine growth. Do not use anti-fouli...

  • Page 104: -Memo-

    E -memo- 60h-9-e1-4 3/1/02 9:39 pm page 34.

  • Page 105: Chapter 5

    Emu00414 chapter 5 trouble recovery troubleshooting .......................... 5-1 temporary action in emergency ....................................... 5-5 impact damage ................................... 5-5 running single engine ........................ 5-5 power trim/tilt will not operate ........

  • Page 106

    E 5-1 emu01663¯ troubleshooting a problem in the fuel, compression, or ignition systems can cause poor starting, loss of power, or other problems. The troubleshooting chart describes basic checks and possible remedies. (this chart covers all yamaha outboard motors. Therefore, some items may not appl...

  • Page 107

    5-2 e c. Engine idles irregularly or stalls. Trouble possible cause remedy 8. Poor connections or damaged ignition wiring. 9. Specified engine oil not used. 10. Thermostat faulty or clogged. 11. Carburetor adjustments incorrect. 12. Fuel pump damaged. 13. Air vent screw on the fuel tank closed. 14. ...

  • Page 108

    E 5-3 trouble possible cause remedy 14. Failed ignition parts. 15. Specified engine oil not used. 16. Thermostat faulty or clogged. 17. Air vent screw closed. 18. Fuel pump damaged. 19. Fuel joint connection incorrect. 20. Heat range of spark plug incorrect. 14. Have serviced by a yamaha dealer. 15....

  • Page 109: -Memo-

    5-4 e -memo- 60h-9-e1-5 3/1/02 9:41 pm page 5.

  • Page 110

    E 5-5 607011 001422 emu00416 temporary action in emergency emu01492 impact damage w the outboard motor can be seriously damaged by a collision while operating or trailering. Damage could make the outboard motor unsafe to operate. If the outboard motor hits any object in the water, follow the procedu...

  • Page 111

    5-6 e 411025 q emu00419 power trim/tilt will not operate if the engine cannot be tilted up or down with the power trim and tilt because of a dis- charged battery or a failure with the power trim and tilt unit, the engine can be tilted manually. 1 manual valve screw emu00421 1) loosen the manual valv...

  • Page 112

    E 5-7 emu00423 starter will not operate if the starter mechanism does not operate (engine cannot be cranked with the starter), the engine can be started with an emer- gency starter rope. W 8 use this procedure only in an emer- gency and only to return to port for repairs. 8 when the emergency starte...

  • Page 113

    5-8 e emu01513 emergency starting engine 1) remove the top cowling. 2) remove the start-in-gear protection cable from the starter if equipped. 3) remove the starter/flywheel cover after removing the bolt(s). 4) prepare the engine for starting. Refer to “starting engine” for details. Be sure the engi...

  • Page 114

    E 5-9 6) insert the knotted end of the emer- gency starter rope into the notch in the flywheel rotor and wind the rope 1 or 2 turns clockwise. 7) give a strong pull straight out to crank and start the engine. Repeat if neces- sary. 208041 n 507022 214015 emu01705* starting engine after manual inject...

  • Page 115

    5-10 e 902025 001317 214016 4) squeeze the primer pump once to feed fuel to the engine. 5) pull the starter handle slowly until you feel resistance. Then give a strong pull straight out to crank and start the engine. Repeat if necessary. 6) return the emergency valve to off after the engine has star...

  • Page 116

    E 5-11 107012 107013 107014 emu01511 treatment of submerged motor if the outboard motor is submerged, imme- diately take it a yamaha dealer. Otherwise, some corrosion may begin almost immedi- ately. If you cannot immediately take the outboard motor to a yamaha dealer, follow the proce- dure below in...

  • Page 117: Chapter 6

    Emu00450 chapter 6 index index ......................................................6-1 e 1 2 3 4 5 6 60h-9-e1-6 3/1/02 9:42 pm page 1.

  • Page 118

    E 6-1 emu00451 index a adjusting idling speed .......................... 4-20 adjusting trim angle ............................. 3-24 air vent screw ........................................ 2-5 b battery care ......................................... 4-10 battery requirement ...........................

  • Page 119

    6-2 e mounting height ..................................... 3-3 mounting the outboard motor ................ 3-2 n neutral interlock trigger ....................... 2-11 neutral throttle lever ............................ 2-11 o oil ............................................................3-7 ope...

  • Page 120

    60h-9-e1-6 3/1/02 9:42 pm page 4.

  • Page 121

    60h-9-e1-6 3/1/02 9:42 pm page 5.

  • Page 122: Own

    Yamaha motor co., ltd. Printed in japan march 2002-0.1 × 1 ! 60h-28199-e1 (e115amh, e115awh, e115ae, e115aet, 115be, 115bet, 140bet, 150aet, l150aet, 175aet, 200aet, l200aet) (e) printed on recycled paper own 60h-9-e1 hyoshi 4/9/02 1:09 pm page 1 (1,1).