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  4. 115B
  5. Service Manual

Yamaha 115B Service Manual

Summary of 115B

  • Page 1

    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.

  • Page 2

    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 conc...

  • Page 3: Specification

    Specification general information periodic check and adjustment fuel system power unit bracket unit electrical system troubleshooting index contents lower unit 9 8 7 6 2 1 gen info spec chk adj fuel powr lowr brkt elec trbl shtg 3 4 5 61u5h11_01 05.10.7 3:50 pm page 1.

  • Page 4

    61u5h11_01 05.10.7 3:50 pm page 2.

  • Page 5: General Information

    61u5h11 1- 9 8 7 6 5 4 3 2 1 general information how to use this manual ............................................................................... 1-1 manual format .......................................................................................... 1-1 symbol ...............................

  • Page 6

    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. 9 parts are shown and detailed in an explode...

  • Page 7

    How to use this manual 61u5h11 9 8 7 6 5 4 3 2 1 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 1 to 6 indicate specific ...

  • Page 8

    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...

  • Page 9

    Safety while working 1-4 61u5h11 9 8 7 6 5 4 3 2 1 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. Tighte...

  • Page 10

    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. 1 model name 2 approved model code 3 transom height 4 serial number 6g410010 yamah...

  • Page 11

    61u5h11 1-6 9 8 7 6 5 4 3 2 1 identification/special service tool special service tool digital tachometer 90890-06760 timing light 90890-03141 leakage tester 90890-06840 digital caliper 90890-06704 vacuum/pressure pump gauge set 90890-06756 compression gauge 90890-03160 flywheel holder 90890-06522 f...

  • Page 12

    Gen info 1- 61u5h11 general information 1-7 driver rod l3 90890-06652 needle bearing attachment 90890-06609, 90890-06610, 90890-06611, 90890-06612, 90890-06653, 90890-06654 gear puller 90890-06540 bearing separator 90890-06534 support 90890-02394 bearing outer race attachment 90890-06620, 90890-0662...

  • Page 13

    Special service tool 1-8 61u5h11 9 8 7 6 5 4 3 2 1 piston slider 90890-06530 dial gauge set 90890-01252 shift rod push arm 90890-06052 ring nut wrench 3 90890-06511 stopper guide plate 90890-06501 bearing housing puller claw l 90890-06502 center bolt 90890-06504 ring nut wrench extension 90890-06513...

  • Page 14

    61u5h11 1-9 gen info general information backlash indicator 90890-06706 driver rod ss 90890-06604 bearing depth plate 90890-06603 drive shaft holder 6 90890-06520 pinion nut holder 90890-06715 bearing outer race puller assembly 90890-06523 driver rod sl 90890-06602 pinion height gauge 90890-06710 sh...

  • Page 15

    61u5h11 1-10 9 8 7 6 5 4 3 2 1 special service tool magnet base b 90890-06844 digital circuit tester 90890-03174 up relief fitting 90890-06773 down relief fitting 90890-06774 test harness (4 pins) 90890-06878 trim and tilt wrench 90890-06587 ignition tester 90890-06754 magnet base plate 90890-07003 ...

  • Page 16

    Gen info 1-11 61u5h11 general information selection when the engine speed is at the full throttle operating range (4,500–5,500 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Propeller selection the performance of a ...

  • Page 17

    61u5h11 1-12 9 8 7 6 5 4 3 2 1 propeller selection predelivery check to make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses is securely connected and that the fuel tank is filled with fue...

  • Page 18

    Gen info 1-13 61u5h11 general information checking the remote control cable (remote control model) 1. Set the remote control lever to the neutral position and fully close the throttle lever. 2. Check that the control lever 1 is in its fully closed position, and check the adjusting screw 2 is contact...

  • Page 19

    61u5h11 1-14 9 8 7 6 5 4 3 2 1 predelivery check checking the gear shift and throttle operation 1. Check that the gear shift operates smoothly when the shift lever or remote control lever is shifted from neutral to for- ward or reverse. 2. Check that the throttle operates smoothly when the throttle ...

  • Page 20

    3. Check that the choke solenoid operates when the engine start switch is pushed in. (e, et) 4. Check that the engine turns off when the engine stop lanyard switch is pushed or the engine stop lanyard is pulled from the engine stop lanyard switch. Gen info 1-15 61u5h11 general information checking t...

  • Page 21

    61u5h11 1-16 9 8 7 6 5 4 3 2 1 predelivery check break-in during the test run, perform the break-in operation in the following 5 stages. 1. 10 minutes a at the lowest possible speed. A fast idle in neutral is best. 2. 50 minutes b at 1/2 throttle (approxi- mately 3,000 r/min) or less. Vary engine sp...

  • Page 22

    Gen info 1-17 61u5h11 general information after test run 1. Check for water in the gear oil. 2. Check for fuel leakage in the cowling. 3. Flush the cooling water passage with fresh water using the flushing kit 1 and with the engine running at idle. C c be sure to supply sufficient water when flushin...

  • Page 23: Specification

    61u5h11 9 8 7 6 5 4 3 2 1 spec specification general specification .....................................................................................2-1 maintenance specification ............................................................................2-5 power unit (e115a models) ...............

  • Page 24

    Spec 2-1 61u5h11 specification general specification item unit model e115amh e115awh e115ae e115aet dimension overall length mm (in) 1,458 (57.4) 828 (32.6) overall width mm (in) 600 (23.6) overall height (l) mm (in) 1,558 (61.3) 1,435 (56.5) (y) mm (in) 1,611 (63.4) — (x) mm (in) 1,684 (66.3) 1,561...

  • Page 25

    61u5h11 2-2 9 8 7 6 5 4 3 2 1 general specification (*1) meeting both api and sae requirements (*2) cca: cold cranking ampere en: european norm (european standard) iec: international electrotechnical commission item unit model e115amh e115awh e115ae e115aet cooling system water exhaust system propel...

  • Page 26

    Spec 2-3 61u5h11 item unit model 115be 115bet 140bet dimension overall length mm (in) 828 (32.6) overall width mm (in) 600 (23.6) overall height (l) mm (in) 1,435 (56.5) (x) mm (in) 1,561 (61.5) boat transom height (l) mm (in) 508 (20.0) (x) mm (in) 635 (25.0) weight (with aluminum propeller) (l) kg...

  • Page 27

    61u5h11 2-4 9 8 7 6 5 4 3 2 1 item unit model 115be 115bet 140bet cooling system water exhaust system propeller boss lubrication system pre-mixed fuel and oil fuel and oil fuel type regular unleaded gasoline engine oil 2-stroke outboard motor oil engine oil grade nmma-certified tc-w3 gear oil type h...

  • Page 28

    Spec 2-5 61u5h11 specification maintenance specification power unit (e115a models) (*1) measuring conditions: ambient temperature 20°c (68°f), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. Item unit model e115amh e115awh e115ae e115aet power uni...

  • Page 29

    Item unit model e115amh e115awh e115ae e115aet piston ring top ring dimension b mm (in) 1.970–1.990 (0.0776–0.0783) dimension t mm (in) 2.700–2.900 (0.1063–0.1142) end gap mm (in) 0.30–0.40 (0.0118–0.0157) side clearance mm (in) 0.02–0.06 (0.0008–0.0024) oversize outside diameter 1st mm (in) 90.25 (...

  • Page 30

    Spec 2-7 61u5h11 specification electrical (e115a models) item unit model e115amh e115awh e115ae e115aet ignition and ignition control system ignition timing (full retarded) degree atdc 4–6 ignition timing (full advanced) degree btdc 22–24 spark plug gap mm (in) 0.9–1.0 (0.035–0.039) ignition coil re...

  • Page 31

    61u5h11 2-8 9 8 7 6 5 4 3 2 1 maintenance specification item unit model e115amh e115awh e115ae e115aet charge coil output peak voltage (b/r–l: high-speed) at cranking (unloaded) v 45 at cranking (loaded) v 45 at 1,500 r/min (loaded) v 160 at 3,500 r/min (loaded) v 160 (r–br: low-speed) at cranking (...

  • Page 32

    Spec 2-9 61u5h11 specification item unit model e115amh e115awh e115ae e115aet ptt system trim sensor resistance Ω — 239–379 at 20°c (68°f) (p–b) fluid type — atf dexron 2 motor type — 64e00 output kw — 0.40 brushes standard length mm (in) — 9.8 (0.39) wear limit mm (in) — 4.8 (0.19) commutator stand...

  • Page 33

    61u5h11 2-10 9 8 7 6 5 4 3 2 1 maintenance specification power unit (115b, 140b models) (*1) measuring conditions: ambient temperature 20°c (68°f), wide open throttle, with spark plugs removed from all cylinders. The figures are for reference only. Item unit model 115be 115bet 140bet power unit mini...

  • Page 34

    Spec 2-11 61u5h11 item unit model 115be 115bet 140bet piston ring top ring dimension b mm (in) 1.970–1.990 (0.0776–0.0783) dimension t mm (in) 2.700–2.900 (0.1063–0.1142) end gap mm (in) 0.30–0.50 (0.0118–0.0197) side clearance mm (in) 0.02–0.06 (0.0008–0.0024) oversize outside diameter 1st mm (in) ...

  • Page 35

    61u5h11 2-12 9 8 7 6 5 4 3 2 1 electrical (115b, 140b models) item unit model 115be 115bet 140bet ignition and ignition control system ignition timing (full retarded) degree atdc 4–6 ignition timing (full advanced) degree btdc 24–26 btdc 21–23 spark plug gap mm (in) 0.9–1.0 (0.035–0.039) ignition co...

  • Page 36

    Spec 2-13 61u5h11 item unit model 115be 115bet 140bet charge coil output peak voltage (b/r–l: high-speed) at cranking (unloaded) v 45 at cranking (loaded) v 45 at 1,500 r/min (loaded) v 160 at 3,500 r/min (loaded) v 160 (r–br: low-speed) at cranking (unloaded) v 130 at cranking (loaded) v 140 at 1,5...

  • Page 37

    61u5h11 2-14 9 8 7 6 5 4 3 2 1 item unit model 115be 115bet 140bet ptt system trim sensor resistance Ω — 239–379 at 20°c (68°f) (p–b) fluid type — atf dexron 2 motor type — 64e00 output kw — 0.40 brushes standard length mm (in) — 9.8 (0.39) wear limit mm (in) — 4.8 (0.19) commutator standard diamete...

  • Page 38

    Spec 2-15 61u5h11 l: 515 (20.3) y: 568 (22.4) x: 642 (25.3) l: 929 (36.6) y: 982 (38.7) x: 1,056 (41.6) l: 1,005 (39.6) y: 1,055 (41.5) x: 1,120 (44.1) l: 735 (28.9) y: 765 (30.1) x: 810 (31.9) 570 (22.4) 780 (30.7) 631 (24.8) 155 (6.1) 539 (21.2) 705 (27.8) 210 (8.3) 424 (16.7) 300 (11.8) 616 (24.3...

  • Page 39

    61u5h11 2-16 9 8 7 6 5 4 3 2 1 214 (8.4) 64 (2.5) 616 (24.3) 4 l: 80 (3.1)* x: 85 (3.5) l: 735 (28.9) x: 810 (31.9) 70 ** 66 * 53 (2.1) 45 (1.8) 150 (5.9) 508 (20.0) l: 515 (20.3) x: 642 (25.3) 190 (7.5) 730 (28.7) l: 929 (36.6) x: 1,056 (41.6) 12 539 (21.2) 297 (11.7) 422 (16.6) 35 l: 1,005 (39.6) ...

  • Page 40

    Spec 2-17 61u5h11 182 (7.2) 182 (7.2) 163.5 (6.4) 163.5 (6.4) 125.4 (4.9) 125.4 (4.9) 13 (0.5) 18.5 (0.7) 50.8 (2.0) 350 (13.8) 13 (0.5) 62 (2.4) 55.5 (2.2) 254 (10.0) 6iu2003m clamp bracket mm (in) specification 61u5h11_02_1 06.2.10 5:15 pm page 18.

  • Page 41

    61u5h11 2-18 9 8 7 6 5 4 3 2 1 6g42003m 82 (3.2) 254 (10.0) 367 (14.5) 163.5 (6.4) 163.5 (6.4) 101.5 (4.0) 101.5 (4.0) 125.4 (4.9) 125.4 (4.9) 180 (7.1) 180 (7.1) 50.8 (2.0) 18.5 (0.7) 52 (2.0) 55.5 (2.2) 13 (0.5) 13 (0.5) mm (in) maintenance specification 61u5h11_02_1 06.2.10 5:15 pm page 19.

  • Page 42

    Spec 2- 61u5h11 2-19 specification tightening torque specified torque part to be tightened thread size tightening torques n·m kgf·m ft·lb fuel system intake silencer cover bolt m6 6 0.6 4.4 manual injection cable end bolt m5 4 0.4 3.0 screw (carburetor) — 2 0.2 1.5 plug (carburetor) — 6 0.6 4.4 plug...

  • Page 43

    61u5h11 2-20 9 8 7 6 5 4 3 2 1 tightening torque part to be tightened thread size tightening torques n·m kgf·m ft·lb lower unit check screw — 9 0.9 6.6 drain screw — 9 0.9 6.6 lower case mount bolt m10 39 3.9 28.8 lower case mount nut (e115a: y-transom) — 39 3.9 28.8 trim tab bolt m10 39 3.9 28.8 wa...

  • Page 44

    Spec 2-21 61u5h11 specification general torque this chart specifies tightening torques for standard fasteners with a standard iso thread pitch. Tightening torque specification for special components or assemblies are provided in applicable sections of this manu- al. To avoid warpage, tighten multi-f...

  • Page 45

    61u5h11 9 8 7 6 5 4 3 2 1 3 1 periodic check and adjustment maintenance interval chart .......................................................................... 3-1 top cowling .................................................................................................. 3-2 checking the top co...

  • Page 46

    Chk adj 61u5h11 3-1 maintenance interval chart use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Periodic check and adjustment chk adj initial every refer item actions 10 hours 50 hours 100 ho...

  • Page 47

    Top cowling checking the top cowling 1. Check the fitting by pushing the cowling with both hands. Adjust the fittings if nec- essary. 2. Loosen the bolts 1. 3. Move the hook 2 up or down slightly to adjust its position. Note: 9 to loosen the fitting, move the hook 2 in direction a. 9 to tighten the ...

  • Page 48

    Power unit checking the spark plug 1. Disconnect the spark plug caps, and then remove the spark plugs. 2. Clean the electrodes 1 with a spark plug cleaner or wire brush. Replace the spark plug if necessary. 3. Check the electrodes for erosion and excessive carbon or other deposits, and the gasket fo...

  • Page 49

    5. Install the new gaskets, thermostats and thermostat covers, and then tighten the cover bolts to specified torques. Checking the cooling water passage 1. Check the cooling water inlet cover 1, screw 2 and cooling water inlet for clog- ging. Clean the water inlet cover and cooling water inlet if ne...

  • Page 50

    Checking the control link and throt- tle link position 1. Remove the throttle cable. 2. Measure the length of control link rod 1. 3. Measure the length of throttle link rod 2. 4. Adjust the length of the link rod if out of specification. Synchronizing the carburetor 1. Remove the throttle cable and ...

  • Page 51

    61u5h11 3-6 9 8 7 6 5 4 3 2 1 3. Turn the throttle stop screw 3 in direc- tion a or b until the specified engine idle speed is obtained. Note: 9 to increase the idle speed, turn the throttle stop screw in direction a. 9 to decrease the idle speed, turn the throttle stop screw in direction b. 4. If t...

  • Page 52

    4. Connect the cable joint 3, install the nut 2, and then tighten the lock nut 1. 5. Check the throttle grip or remote control lever fully closed position and adjust the throttle cable length, if necessary, repeat the steps 1–4. Checking the gear shift operation 1. Check that the gear shift operates...

  • Page 53

    61u5h11 3-8 9 8 7 6 5 4 3 2 1 4. Make sure to align the center of the set pin a on the shift lever with the align- ment mark b on the bottom cowling. 5. Adjust the position of the shift cable joint 3 until its hole is aligned with the set pin 4. W the shift cable joint must be screwed in a minimum o...

  • Page 54

    5. Check that the scale c on the flywheel magnet is advances to specified position, when the throttle is fully opened. 6. If the ignition timing is out of specification, refer to “adjusting the timing plate” p5-52 and “adjusting the ignition timing stopper” p5-53. Checking the choke solenoid (e, et)...

  • Page 55

    61u5h11 3-10 9 8 7 6 5 4 3 2 1 checking the ptt fluid level (et) 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. W after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could sud- denly lower if the ptt...

  • Page 56

    Chk adj 3-11 61u5h11 periodic check and adjustment 3. If necessary, add sufficient fluid of the recommended type until it overflows out of the filler hole. 4. Install the new o-ring, reservoir cap 2, and then tighten it to the specified torque. Checking the tilt operation (mh, wh, e) 1. Set the tilt...

  • Page 57

    61u5h11 3-12 9 8 7 6 5 4 3 2 1 bracket/lower unit changing the gear oil 1. Tilt the outboard motor so that the gear oil drain screw at the lowest point possi- ble. 2. Place a drain pan under the drain screw 1, remove the drain screw, then the check screw 2 and let the oil drain com- pletely. 3. Chec...

  • Page 58

    Chk adj 3-13 61u5h11 periodic check and adjustment general checking the anode 1. Check the anode and trim tab. Clean if there are scales, grease, or oil. C c do not oil, grease, or paint the anodes or the trim tab, otherwise they will be ineffec- tive. Note: if it is necessary to disassemble the out...

  • Page 59

    61u5h11 3-14 9 8 7 6 5 4 3 2 1 lower unit/general checking the battery (wh, e, et) 1. Check the battery electrolyte level. If the level is at or below the minimum level mark a, add distilled water until the level is between the maximum and minimum level marks. 2. Check the specific gravity of the el...

  • Page 60

    Chk adj 3-15 61u5h11 periodic check and adjustment note: apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the area shown. 3. Apply corrosion resistant grease to the area shown. 6g430540 c 6b430300 d a 61u30170 a a 61u30180 a 61u30190 ...

  • Page 61: Fuel System

    61u5h11 9 8 7 6 5 4 3 2 1 fuel system hose routing ................................................................................................. 4-1 fuel hose and breather hose .................................................................. 4-1 fuel line .........................................

  • Page 62

    Fuel 4-1 61u5h11 fuel system hose routing fuel hose and breather hose 1 fuel hose (fuel joint-to-fuel filter) 2 fuel hose (fuel filter-to-manual injection : mh, wh) 3 fuel hose (fuel filter-to-fuel pump) 4 manual injection pump : mh, wh 5 fuel hose (manual injection-to-upper carburetor : mh, wh) 6 f...

  • Page 63

    61u5h11 4-2 9 8 7 6 5 4 3 2 1 hose routing 1 3 2 5 8 4 4 6 7 8 1 2 8 6 9 8 7 61u4001b port stbd mh, wh e, et 1 breather hose (manifold-to-cylinder body #2) 2 breather hose (manifold-to-cylinder body #4) 3 breather hose (breather hose-to-manual injection) 4 breather hose (manifold-to-manual injection...

  • Page 64

    Fuel 4-3 61u5h11 fuel system 61u4040e 4 n·m (0.4 kgf·m, 3.0 ft·lb) no. Part name q’ty remarks 1 bolt 2 m6 × 16 mm 2 fuel filter assembly 1 3lock tie 18 mh, wh lock tie 10 e, et 4 fuel hose 1 5 fuel hose 1 mh, wh 6 fuel hose 1 7 joint 1 mh, wh 8 hose 1 mh, wh 9 bypass valve 1 mh, wh 10 hose 1 mh, wh ...

  • Page 65

    61u5h11 4-4 9 8 7 6 5 4 3 2 1 fuel line 61u4040e 4 n·m (0.4 kgf·m, 3.0 ft·lb) no. Part name q’ty remarks 17 fuel pump assembly 1 18 gasket 1 19 fuel hose 1 20 joint 1 21 fuel hose 1 22 fuel hose 1 23bolt 1 m6 × 10 mm mh, wh 24 start-in-gear protection cable 1 mh, wh 25 bolt 1 m6 × 12 mm mh, wh 26 bo...

  • Page 66

    Fuel 4-5 61u5h11 fuel system 6g44040e no. Part name q’ty remarks 1 bolt 1 m6 × 16 mm 2 washer 1 3holder 1 4 bolt 1 m6 × 14 mm 5 bracket 1 6 fuel filter assembly 1 7 o-ring 1 8 fuel filter element 1 9 fuel filter cup 1 10 nut 1 not reusable 61u5h11_04_1 06.2.13 1:23 pm page 6.

  • Page 67

    61u5h11 4-6 9 8 7 6 5 4 3 2 1 fuel line/carburetor 6 n·m (0.6 kgf·m, 4.4 ft·lb) 61u4060e e, et no. Part name q’ty remarks 1 bolt 8 m6 × 20 mm 2 cover 1 3gasket 1 4 bolt 8 m6 × 20 mm 5 intake silencer 1 6 bolt 2 m6 × 20 mm 7 breather hose 1 8 gasket 1 9 upper carburetor assembly 1 10 lower carburetor...

  • Page 68

    Fuel 4-7 61u5h11 fuel system 6 n·m (0.6 kgf·m, 4.4 ft·lb) 61u4060e e, et no. Part name q’ty remarks 18 bolt 2 m6 × 16 mm 19 choke solenoid 1 20 intake silencer 1 21 grommet 2 61u5h11_04_1 06.2.13 1:23 pm page 8.

  • Page 69

    61u5h11 4-8 9 8 7 6 5 4 3 2 1 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 61u4070e no. Part name q’ty remarks 1 plug 4 2 gasket 4 3screw 2 4 plate 2 5 gasket 2 6 main air bleed 4 7 pilot screw 4 8 spring 4 9 screw 2 10 gasket 2 11 air bleed plug 4 12 pilot...

  • Page 70

    Fuel 4-9 61u5h11 fuel system 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 61u4070e no. Part name q’ty remarks 18 gasket 2 19 plug 4 20 gasket 4 21 main jet 4 22 drain plug 4 23gasket 4 24 float chamber 2 25 plug 4 26 gasket 4 27 pilot jet 4 28 screw 8 ø5 × ...

  • Page 71

    61u5h11 4-10 9 8 7 6 5 4 3 2 1 carburetor e, et 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 61u4065e no. Part name q’ty remarks 1 plug 4 2 gasket 4 3screw 2 4 plate 2 5 pilot screw 4 6 spring 4 7 screw 2 8 gasket 2 9 air bleed plug 4 10 pilot air jet 4 11 ...

  • Page 72

    Fuel 4-11 61u5h11 fuel system 6 n·m (0.6 kgf·m, 4.4 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 10 n·m (1.0 kgf·m, 7.4 ft·lb) 61u4065e no. Part name q’ty remarks 18 gasket 4 19 main jet 4 20 float chamber 2 21 plug 4 22 gasket 4 23pilot jet 4 24 screw 8 ø5 × 16 mm 25 throttle stop screw 1 26 spring 1 27 low...

  • Page 73

    61u5h11 4-12 9 8 7 6 5 4 3 2 1 carburetor disassembling the carburetor note: 9 before disassembling the carburetors, make sure to note the number of times the pilot screw is turned out from the seated position to its set position. 9 disassembled jets and other components should be sorted out and kep...

  • Page 74

    Fuel 4-13 61u5h11 fuel system å mh, wh ∫ e, et 4. Install the gaskets 0, plugs q, gaskets w and plugs e onto the float chamber r. 5. Install the float chamber r onto the car- buretor body and install the gasket t and screw y onto the carburetor body. 6. Install the pilot screw, and then turn in unti...

  • Page 75

    Note: when disassemble the carburetor, be sure to set the pilot screw by the specified times. 7. Install the carburetor assembly. 61u5h11 4-14 9 8 7 6 5 4 3 2 1 pilot screw turns out: e115a : 1–1 1/2 115b : 3/8–7/8 140b : 5/8–1 1/8 carburetor 61u5h11_04_1 06.2.13 1:23 pm page 15.

  • Page 76

    Fuel 4-15 61u5h11 fuel system fuel pump 3.5 n·m (0.35 kgf·m, 2.6 ft·lb) 6g44030e no. Part name q’ty remarks 1 base 1 2 gasket 1 3diaphragm 1 4 body assembly 1 5 nut 4 6 screw 4 ø5 × 28 mm 7 washer 4 8 check valve 4 9 body 1 10 gasket 1 11 diaphragm 1 12 collar 2 13o-ring 2 14 cover 1 15 plate 1 16 s...

  • Page 77

    61u5h11 4-16 9 8 7 6 5 4 3 2 1 fuel pump checking the fuel pump 1. Place a drain pan under the fuel hose connections, and then disconnect the fuel hoses from the fuel pump. 2. Connect the special service tool to the fuel pump inlet. 3. Cover the fuel pump outlet with a finger, and then apply the spe...

  • Page 78

    Fuel 4-17 61u5h11 fuel system note: make sure that the gaskets and diaphragms are kept in place through the assembly process. Checking the fuel joint 1. Visually check the fuel joint for cracks or damage. 2. Connect the special service tool at the outlet of fuel joint. 3. Apply the specified pressur...

  • Page 79: — Memo —

    61u5h11 4-18 9 8 7 6 5 4 3 2 1 — memo — 61u5h11_04_1 06.2.13 1:23 pm page 19.

  • Page 80: Power Unit

    Powr 61u5h11 power unit power unit ..................................................................................................... 5-1 checking the compression pressure ....................................................... 5-1 disassembling the manual starter (mh, wh) ..........................

  • Page 81

    61u5h11 9 8 7 6 5 4 3 2 1 checking the piston ring ........................................................................ 5-37 checking the piston ring side clearance ............................................... 5-38 checking the piston pin boss bore ...............................................

  • Page 82

    Powr 5-1 61u5h11 power unit power unit checking the compression pressure 1. Start the engine, warm it up for 5 min- utes, and then turn it off. 2. Remove the lock plate from the engine stop lanyard switch on the remote control box or tiller handle. 3. Remove the all spark plug caps and all spark plu...

  • Page 83

    61u5h11 9 8 7 6 5 4 3 2 1 5-2 power unit 25 n·m (2.5 kgf·m, 18.4 ft·lb) e,et 8 n·m (0.8 kgf·m, 5.9 ft·lb) 61u5010e no. Part name q’ty remarks 1 bolt 3 m8 × 35 mm mh, wh 2 grommet 6 mh, wh 3 manual starter assembly 1 mh, wh 4 collar 3 mh, wh 5 bolt 2 m6 × 20 mm mh, wh 6 power unit 1 7 dowel 2 8 gaske...

  • Page 84

    Powr 5-3 61u5h11 power unit 25 n·m (2.5 kgf·m, 18.4 ft·lb) e,et 8 n·m (0.8 kgf·m, 5.9 ft·lb) 61u5010e no. Part name q’ty remarks 18 bolt 6 m8 × 135 mm 19 apron 1 20 apron 1 21 bolt 2 m6 × 25 mm e, et 22 grommet 2 e, et 23 collar 2 e, et 24 grommet 2 e, et 25 flywheel cover 1 e, et 26 negative batter...

  • Page 85

    61u5h11 5-4 9 8 7 6 5 4 3 2 1 power unit 186 n·m (18.6 kgf·m, 137 ft·lb) 61u5020e 3 n·m (0.3 kgf·m, 2.2 ft·lb) no. Part name q’ty remarks 1 nut 1 2 washer 1 3 starter pulley 1 mh, wh 4 bolt 3 m8 × 25 mm mh, wh 5 flywheel magnet 1 6 bolt 3 m6 × 60 mm 7 stator assembly 1 8 pulser coil assembly 1 9 scr...

  • Page 86

    Powr 5-5 61u5h11 power unit 186 n·m (18.6 kgf·m, 137 ft·lb) 61u5020e 3 n·m (0.3 kgf·m, 2.2 ft·lb) no. Part name q’ty remarks 18 washer 2 19 rectifier regulator 1 20 bolt 1 m6 × 12 mm 21 main harness 1 22 control link 1 23 screw 2 if equipped ø5 × 20 mm 24 hour meter 1 if equipped 25 case 1 if equipp...

  • Page 87

    61u5h11 5-6 9 8 7 6 5 4 3 2 1 power unit 61u5030e no. Part name q’ty remarks 1 joint 2 2 lock nut 2 3 control link rod 1 4 throttle link rod 1 5 bolt 1 m6 × 25 mm 6 collar 1 7 wave washer 1 8 cam 1 9 cap 2 10 lock nut 2 11 screw 1 12 spring 1 13 screw 1 14 bolt 1 m8 × 45 mm 15 washer 1 16 collar 1 1...

  • Page 88

    Powr 5-7 61u5h11 power unit 61u5030e no. Part name q’ty remarks 18 bushing 1 19 spring 1 20 control lever 1 1 21 plastic washer 1 22 washer 1 23 bracket 1 24 bolt 2 m8 × 30 mm 25 bushing 1 26 control lever 2 1 61u5h11_05_1 06.2.10 17:22 page 10

  • Page 89

    61u5h11 5-8 9 8 7 6 5 4 3 2 1 power unit 6iu5060e no. Part name q’ty remarks 1 screw 4 ø6 × 16 mm 2 cover 1 3 screw 2 ø6 × 40 mm 4 cdi unit 1 5 charge coil coupler 1 6 bolt 1 m6 × 12 mm 7 spark plug cap 4 8 bolt 4 m6 × 20 mm 9 ignition coil 4 10 bolt 2 m6 × 12 mm 11 bolt 3 m6 × 28 mm 12 grommet 3 13...

  • Page 90

    Powr 5-9 61u5h11 power unit 29 n·m (2.9 kgf·m, 21.4 ft·lb) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 61u5050e et wh, e no. Part name q’ty remarks 1 bolt 2 m8 × 45 mm 2 starter motor 1 3 washer 1 4 bolt 1 m8 × 35 mm 5 positive battery lead 1 6 washer 2 7...

  • Page 91

    61u5h11 5-10 9 8 7 6 5 4 3 2 1 power unit 29 n·m (2.9 kgf·m, 21.4 ft·lb) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 61u5050e et wh, e no. Part name q’ty remarks 18 bolt 1 m6 × 12 mm 19 clamp 1 20 holder 1 21 ptt relay (up) 1 et 22 holder 1 et 23 ptt rela...

  • Page 92

    Powr 5-11 61u5h11 power unit 61u5040e mh, wh no. Part name q’ty remarks 1 manual starter case 1 2 plastic washer 2 3 spiral spring 1 4 collar 1 5 sheave drum 1 6 washer 1 7 clip 1 8 collar 1 9 drive pawl 1 10 spring 1 11 spring 1 12 drive plate 1 13 washer 1 14 bolt 1 m6 × 16 mm 15 bolt 1 m6 × 12 mm...

  • Page 93

    61u5h11 5-12 9 8 7 6 5 4 3 2 1 power unit 61u5040e mh, wh no. Part name q’ty remarks 18 rope guide 1 19 roller 1 20 bushing 1 21 bolt 4 m6 × 30 mm 22 grommet 4 23 collar 4 24 bolt 2 m6 × 20 mm 25 bracket 1 26 nut 4 27 damper 1 28 starter handle 1 29 cap 1 30 bracket 1 31 bolt 1 m6 × 12 mm 32 cotter ...

  • Page 94

    Powr 5-13 61u5h11 power unit 61u5040e mh, wh no. Part name q’ty remarks 35 spring 1 36 guide 1 37 bolt 1 38 stopper 1 39 spring 1 40 starter rope 1 61u5h11_05_1 06.2.10 17:22 page 16.

  • Page 95

    61u5h11 5-14 9 8 7 6 5 4 3 2 1 power unit disassembling the manual starter (mh, wh) w 9 the sheave drum can pop out. Hold the sheave drum with your hand, then pull it out. 9 the spiral spring can pop out. Wear suit- able protective gloves and cover the spi- ral spring with cloths, then pull out the ...

  • Page 96

    Powr 5-15 61u5h11 power unit assembling the manual starter (mh, wh) 1. Install the starter rope 1 into the sheave drum 2. 2. Install the manual starter handle 3. Note: 9 tie a knot at the end of the starter rope as shown in the illustration. 9 be sure to leave 5.0–10.0 mm (0.2–0.4 in) at the end a o...

  • Page 97

    6. Install the collar 8, washer 9, clip 0, drive pawl q, spring w, spring e, and drive plate r. 7. Turn the sheave drum 5 times in the direction of the arrow shown, and then remove the starter rope from the notch e. 8. Install the roller t and rope guide y. 61u5h11 5-16 9 8 7 6 5 4 3 2 1 power unit ...

  • Page 98

    Powr 5-17 61u5h11 power unit 1. Remove the cdi unit cover, start-in-gear protection cable 1, then remove the manual starter and starter pully (mh, wh). 2. Disconnect the negative battery cable 2, positive battery cable 3 and ptt motor lead 4. å ∫ å wh, e ∫ et 3 2 61u50350 9. Pull the manual starter ...

  • Page 99

    61u5h11 5-18 9 8 7 6 5 4 3 2 1 power unit 3. Disconnect the 10-pin main harness cou- pler 5. 4. Disconnect the fuel hose 6. 5. Set the shift lever or remote control lever in the neutral position, and then discon- nect the shift cable 7, throttle cable 8. 6. Remove the clip 9 and bushing 0 and then, ...

  • Page 100

    Powr 5-19 61u5h11 power unit 2. Remove the flywheel magnet. C c to prevent damage to the engine or tools, screw in the flywheel puller set bolts evenly and completely so that the fly- wheel puller is parallel to the flywheel magnet. Note: apply force to the crankshaft end until the fly- wheel magnet...

  • Page 101

    61u5h11 5-20 9 8 7 6 5 4 3 2 1 power unit removing the electrical component 1. Remove the cover 1 and disconnect the coupler. 2. Remove the hour meter 2. 3. Remove the stator assembly 3, retainer screw 4, retainer 5, pulser coil assem- bly 6, and rectifier regulator 7. 4. Remove the starter relay 8 ...

  • Page 102

    Powr 5-21 61u5h11 power unit 6. Disconnect the ignition coil leads, and then remove the cdi unit q and case w. 61u50600 w q 61u5h11_05_1 06.2.10 17:22 page 24.

  • Page 103

    61u5h11 5-22 9 8 7 6 5 4 3 2 1 power unit/intake manifold mh, wh 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) e, et 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 61u5070e no. Part name q’ty remarks 1 gasket 1 2 reed valve 4 3 gasket 4 4 clamp 1 5 bolt 9 m6 × 25 mm bolt 12 e,...

  • Page 104

    Powr 5-23 61u5h11 power unit mh, wh 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) e, et 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 61u5070e no. Part name q’ty remarks 15 cap 2 16 bracket 1 17 bracket 1 18 intake manifold 1 19 bracket 1 mh, wh 20 bolt 3 m6 × 45 mm mh, wh 21...

  • Page 105

    61u5h11 5-24 9 8 7 6 5 4 3 2 1 intake manifold removing the intake manifold 1. Remove the carburetor assemblies and the fuel hoses. 2. Disconnect the breather hoses 1. Note: mark the hoses connecting position, before disconnect. 3. Remove the intake manifold bolts in the sequence shown. Checking the...

  • Page 106

    Powr 5-25 61u5h11 power unit 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 61u5080e no. Part name q’ty remarks 1 bolt 7 m6 × 20 mm 2 cover 1 3 gasket 1 4 gasket 2 5 exhaust...

  • Page 107

    61u5h11 5-26 9 8 7 6 5 4 3 2 1 exhaust cover checking the pcv 1. Remove the pcv. 2. Check the pcv for wear or deformation. Replace the pcv if necessary. 3. Check the grommet for deformation. Replace the grommet if necessary. 4. Check the spring for fatigue or deforma- tion. Replace the spring if nec...

  • Page 108

    Powr 5-27 61u5h11 power unit cylinder head 15 n·m (1.5 kgf·m, 11.1 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 25 n·m (2.5 kgf·m, 18.4 ft·lb) e, et mh, wh 61u5090e no. Part name q’ty remarks...

  • Page 109

    61u5h11 5-28 9 8 7 6 5 4 3 2 1 cylinder head 15 n·m (1.5 kgf·m, 11.1 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 25 n·m (2.5 kgf·m, 18.4 ft·lb) e, et mh, wh 61u5090e no. Part name q’ty remar...

  • Page 110

    Powr 5-29 61u5h11 power unit 5. Remove the cylinder head bolts in the sequence shown. C c do not scratch or damage the mating sur- faces of the cylinder head and cylinder block. Note: insert a flat-head screw driver between the pry tabs to pry off the cylinder heads. Checking the cylinder head 1. El...

  • Page 111

    61u5h11 5-30 9 8 7 6 5 4 3 2 1 cylinder head 2. Check the cylinder head warpage using a straightedge 1 and thickness gauge 2 in 4 directions as shown. Replace the cylinder head if above specification. 61u50240 2 1 61u50250 cylinder head warpage limit: 0.10 mm (0.0039 in) 61u5h11_05_1 06.2.10 17:22 p...

  • Page 112

    Powr 5-31 61u5h11 power unit crankcase 10 n·m (1.0 kgf·m, 7.4 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 20 n·m (2.0 kgf·m, 14.8 ft·lb) 37 n·m (3.7 kgf·m, 27.3 ft·lb) 61u5100e 12 n·m (1.2 kgf·m, 8.9 ft·lb) no. Part name q’ty remarks 1 bolt 4 m6 × 25 mm 2 oil seal 1 3 bearing housing 1 4 o-ring 2 5 needle...

  • Page 113

    61u5h11 5-32 9 8 7 6 5 4 3 2 1 crankcase 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) * 19 n·m (1.9 kgf·m, 14.0 ft·lb) 36 n·m (3.6 kgf·m, 26.6 ft·lb) 23 n·m (2.3 kgf·m, 17.0 ft·lb) 61u5110e no. Part name q’ty remarks 1 bolt 8 m8 × 22 mm 2 piston and connecting rod assembly 4 3 rolle...

  • Page 114

    Powr 5-33 61u5h11 power unit 61u5120e no. Part name q’ty remarks 1 connecting rod 4 2 piston (starboard side) 2 3 washer 8 4 needle bearing 120 5 clip 8 6 piston pin 4 7 piston ring set 4 8 piston (port side) 2 not reusable 61u5h11_05_1 06.2.10 17:22 page 36.

  • Page 115

    61u5h11 5-34 9 8 7 6 5 4 3 2 1 crankcase note: insert a flat-head screw driver between the pry tabs to pry off the crankcase. Disassembling the bearing housing 1. Remove the oil seal 1 and o-rings 2. 2. Remove the needle bearing 3 using a press. Removing the crankcase 1. Remove the bearing housing b...

  • Page 116

    Powr 5-35 61u5h11 power unit disassembling the oil seal housing 1. Remove the oil seals and o-ring. Removing the piston, connecting rod assembly and crankshaft assembly 1. Remove the connecting rod bolts and the connecting rod caps, and then remove the piston with connecting rod. Note: 9 mark each p...

  • Page 117

    61u5h11 5-36 9 8 7 6 5 4 3 2 1 crankcase disassembling the crankshaft 1. Remove the seal rings 1. Note: to remove the seal rings 1, widen the seal ring end gap a, and then remove the ring from the groove and remove the crankpin b. 2. Remove the circlip 2, and then remove the ball bearing. C c do not...

  • Page 118

    Powr 5-37 61u5h11 power unit checking the cylinder bore 1. Measure the cylinder bore (d 1 –d 6 ) at measuring points a, b, and c, and in direction d (d 1 , d 3 , d 5 ), which is parallel to the crankshaft, and direction e (d 2 , d 4 , d 6 ), which is at a right angle to the crankshaft. A: 10.0 mm (0...

  • Page 119

    61u5h11 5-38 9 8 7 6 5 4 3 2 1 crankcase checking the piston ring side clear- ance 1. Measure the piston ring side clearance. Replace the piston and piston rings as a set if out of specification. Checking the piston pin boss bore 1. Measure the piston pin boss bore. Replace the piston if out of spec...

  • Page 120

    Powr 5-39 61u5h11 power unit checking the connecting rod small end axial play 1. Measure the connecting rod small end axial play. Replace the bearing and con- necting rod if above specification. Note: to measure the axial play, set the dial gauge at the connecting rod small end and parallel to the c...

  • Page 121

    61u5h11 5-40 9 8 7 6 5 4 3 2 1 crankcase 2. Measure the crankshaft runout. Replace the crankshaft if above specification. Assembling the crankshaft 1. Installing the ball bearing 1 into the crankshaft using a press, then the circlip. C c do not reuse the ball bearing, always replace it with a new on...

  • Page 122

    Powr 5-41 61u5h11 power unit assembling the bearing housing 1. Install the needle bearing. C c do not reuse the needle bearing, always replace it with a new one. 2. Apply grease to the new oil seal, new o- rings and then install it into the bearing housing. Needle bearing attachment 1: 90890-06654 d...

  • Page 123

    61u5h11 5-42 9 8 7 6 5 4 3 2 1 crankcase assembling the piston and connect- ing rod assembly 1. Assemble the pistons 1, connecting rods 2, needle bearings 3, washers 4, piston pins 5, and new piston pin clips 6. Note: 9 face the embossed “yamaha” mark a on the connecting rod in the same direction as...

  • Page 124

    Powr 5-43 61u5h11 power unit 2. Install the pistons into the cylinders with the “up” mark on the piston crown facing towards the flywheel magnet. Note: 9 apply engine oil to the pistons and piston rings before installation. 9 be sure to install the piston and connecting rod assemblies into the corre...

  • Page 125

    61u5h11 5-44 9 8 7 6 5 4 3 2 1 crankcase 4. Install the bearing housing onto the cylin- der block. Note: install the bearing housing with the arrow mark facing toward the cylinder block. 5. Install the oil seal housing onto the cylin- der block. Note: install the oil seal housing with the projec- ti...

  • Page 126

    Powr 5-45 61u5h11 power unit 10. Tighten the crankcase bolts to the speci- fied torques in 2 stages and in the sequence shown. Note: tighten crankcase bolts z–n to the speci- fied torques in 2 stages first, and then tighten crankcase bolts m–⁄4 to the specified torques in 2 stages. 11. Tighten the b...

  • Page 127

    61u5h11 5-46 9 8 7 6 5 4 3 2 1 crankcase note: apply engine oil to the cylinder head bolts before installation. 14. Install the thermoswitches q onto the cylinder head w. 61u50225 w q 9 0 61u50790 cylinder head bolt: 1st: 15 n·m (1.5 kgf·m, 11.1 ft·lb) 2nd: 30 n·m (3.0 kgf·m, 22.1 ft·lb) 61u50220 po...

  • Page 128

    Powr 5-47 61u5h11 power unit 19. Connect the hoses as shown below. å ∫ 17. Install the spark plugs temporary tight d, and then to the specified torque e with a spark plug wrench. 18. Install the new gasket t and the intake manifold assembly y, and then tighten the intake manifold bolts u to the spec...

  • Page 129

    22. Install the starter relay f, the ptt relay assembly g and rectifier regulator h onto the power unit. å mh, wh ∫ e, et 20. Install the starter motor i, pulser coil assembly o and stator assembly p onto the power unit. 21. Install the case s and the cdi unit d onto the power unit. 61u5h11 5-48 9 8...

  • Page 130

    23. Install the hour meter into the case, and then onto the power unit. 24. Install the new gaskets k, carburetor assemblies l and choke solenoid ; onto the power unit. Installing the power unit 1. Clean the power unit matching surface, and install the dowels 1 and a new gasket 2. 2. Install the pow...

  • Page 131

    61u5h11 5-50 9 8 7 6 5 4 3 2 1 crankcase 3. Install the apron 7, and then tighten the apron bolt 8 to specified torque. 4. Connect the cooling water pilot hose 9 and pcv hose 0. 5. Install the manual injection pump cable end, and start-in-gear protection cable end, and then install the bracket bolt ...

  • Page 132

    Powr 5-51 61u5h11 power unit 15. Connect the negative battery cable o, positive battery cable p, and ptt motor lead a. å ∫ å wh ∫ e, et 16. Install the all removed parts. P o 61u50355 starter motor positive terminal nut: 9 n·m (0.9 kgf·m, 6.6 ft·lb) p o a 61u50365 10. Install the woodruff key and fl...

  • Page 133

    61u5h11 5-52 9 8 7 6 5 4 3 2 1 crankcase adjusting the timing plate note: remove the all spark plugs and lock plate before adjusting the timing plate. 1. Remove the manual starter or flywheel cover. 2. Slowly turn the flywheel magnet clock- wise, align the piston of the #1 cylinder at the tdc. 3. In...

  • Page 134

    3. Check that the mark 3 on the flywheel magnet aligned with the pointer 4 on the pulser coil assembly. 4. If not align them, loosen the lock nut 5 and adjust the length of the adjusting screw 2. 5. Slowly turn the flywheel magnet clock- wise, and check that the timing plate a is aligned with the sc...

  • Page 135

    61u5h11 5-54 9 8 7 6 5 4 3 2 1 crankcase 6. Set the control lever 1 to the full retard position, and check that the adjusting screw 2 contact with the stopper. 7. Check that the mark 3 on the flywheel magnet aligned with the pointer 4 on the pulser coil assembly. 8. If not align them, adjust the len...

  • Page 136: — Memo —

    Powr 5-55 61u5h11 power unit — memo — 61u5h11_05_1 06.2.10 17:22 page 58.

  • Page 137: Lower Unit

    61u5h11 9 8 7 6 5 4 3 2 1 lower unit lower unit .......................................................................................................6-1 removing the lower unit ............................................................................6-4 removing the water pump and shift rod ......

  • Page 138

    Lowr 6-1 61u5h11 lower unit 54 n·m (5.4 kgf·m, 39.8 ft·lb) 39 n·m (3.9 kgf·m, 28.8 ft·lb) 39 n·m (3.9 kgf·m, 28.8 ft·lb) 39 n·m (3.9 kgf·m, 28.8 ft·lb) 61u6010e lower unit no. Part name q’ty remarks 1 lower unit 1 2 bolt 6 m10 × 45 mm 3 bolt 1 m10 × 70 mm 4 trim tab 1 5 spacer 1 6 propeller 1 7 wash...

  • Page 139

    61u5h11 6-2 9 8 7 6 5 4 3 2 1 lower unit 9 n·m (0.9 kgf·m, 6.6 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 61u6020e no. Part name q’ty remarks 1 shift rod 1 2 oil seal 1 3 cover 1 4 o-ring 1 5 spring 1 6 circlip 1 7 bolt 3 m6 × 20 mm 8 joint 1 9 woodruff key 1 10 bolt 4 m8 × 45 mm 11 cover 1 12 seal 1 13 ...

  • Page 140

    Lowr 6-3 61u5h11 lower unit 9 n·m (0.9 kgf·m, 6.6 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 61u6020e no. Part name q’ty remarks 18 spacer 1 19 washer 2 20 wave washer 1 21 impeller 1 22 outer plate cartridge 1 23 gasket 1 24 dowel 2 25 rubber seal 1 26 plate 1 27 check screw 1 28 gasket 2 29 drain screw...

  • Page 141

    61u5h11 6-4 9 8 7 6 5 4 3 2 1 lower unit 3. Mark the trim tab 1 at the area shown, and then remove it. 4. Loosen the bolts (nuts) and then remove the lower unit from the upper case. 5. Disconnect the speedometer hose 2. å e115a: y-transom 6. Remove the stud bolts. (e115a: y-transom) removing the low...

  • Page 142

    Lowr 6-5 61u5h11 lower unit removing the water pump and shift rod 1. Remove the water pump housing 1, col- lar 2, spacer 3, washer 4, wave wash- er 5, washer 6 and impeller 7. 2. Remove the woodruff key 8. 3. Remove the outer plate cartridge 9, gasket 0 and dowels q. 4. Set the gear shift to the neu...

  • Page 143

    61u5h11 6-6 9 8 7 6 5 4 3 2 1 propeller shaft housing propeller shaft housing 103 n·m (10.3 kgf·m, 76.0 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 61u6030e no. Part name q’ty remarks 1 shift rod joint 1 2 ball 2 3 shift slider 1 4 ball 2 5 ball 2 6 spring 1 7 dog clutch 1 8 crosspin 1 9 spring 1 10 propell...

  • Page 144

    Lowr 6-7 61u5h11 lower unit 103 n·m (10.3 kgf·m, 76.0 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 61u6030e no. Part name q’ty remarks 18 straight key 1 19 needle bearing 1 20 oil seal 2 21 claw washer 1 22 ring nut 1 23 cooling water inlet cover 2 24 nut 1 25 screw 1 ø5 × 45 mm not reusable 61u5h11_06_1 06....

  • Page 145

    61u5h11 6-8 9 8 7 6 5 4 3 2 1 propeller shaft housing removing the propeller shaft hous- ing assembly 1. Remove the ring nut from the lower case, use the special service tools. Note: 9 before removing the propeller shaft from the lower case, remove the shift rod. 9 straighten the one tab 1 of the cl...

  • Page 146

    Lowr 6-9 61u5h11 lower unit checking the propeller shaft 1. Check the propeller shaft. Replace if bent or worn. 2. Measure the propeller shaft runout. 3. Check the dog clutch, shift rod joint, and slider. Replace if cracked or worn. Assembling the propeller shaft assembly 1. Insert the large ball 1,...

  • Page 147

    61u5h11 6-10 9 8 7 6 5 4 3 2 1 propeller shaft housing 2. Install the dog clutch 5 onto the propeller shaft 6. Note: face the marking side to original direction, and then install the dog clutch 5. 3. Insert the smallest balls 7 into the shift slider 4, and then insert the shift slider into the prope...

  • Page 148

    2. Apply grease to new oil seals, and then install them into the propeller shaft hous- ing to the specified depth. Note: install an oil seal halfway into the propeller shaft housing, then the other oil seal. 3. Install the thrust washer 5 and new ball bearing 6 onto the reverse gear 7 using a press....

  • Page 149

    61u5h11 6-12 9 8 7 6 5 4 3 2 1 drive shaft and lower case drive shaft and lower case 93 n·m (9.3 kgf·m, 68.6 ft·lb) 61u6040e no. Part name q’ty remarks 1 drive shaft 1 2 sleeve 1 3 cover 1 4 oil seal 2 5 bolt 4 m8 × 25 mm 6 drive shaft housing 1 7 needle bearing 1 8 o-ring 1 9 pinion shim — 10 thrus...

  • Page 150

    Lowr 6-13 61u5h11 lower unit removing the drive shaft 1. Loosen the pinion nut. 2. Remove the pinion nut 3, pinion 4, drive shaft housing 5, thrust bearing 6, pinion shim(s) 7, drive shaft 8, sleeve 9 from lower case. 3. Pull out the forward gear. Disassembling the drive shaft housing 1. Remove the ...

  • Page 151

    61u5h11 6-14 9 8 7 6 5 4 3 2 1 drive shaft and lower case 2. Remove the needle bearing from the for- ward gear using a chisel. C c do not reuse the bearing, always replace it with a new one. Disassembling the lower case 1. Remove the needle bearing. 2. Remove the taper roller bearing outer race and ...

  • Page 152

    Lowr 6-15 61u5h11 lower unit assembling the forward gear 1. Install new needle bearing into the for- ward gear to the specified depth. 2. Install a new taper roller bearing into the forward gear using a press. Checking the lower case 1. Check the skeg and torpedo. Replace the lower case if cracked o...

  • Page 153

    61u5h11 6-16 9 8 7 6 5 4 3 2 1 drive shaft and lower case assembling the drive shaft housing 1. Install the new needle bearing into the drive shaft housing to the specified depth. Note: be careful not to let the stopper a get out of position when using the driver rod. 2. Apply grease to new oil seal...

  • Page 154

    Lowr 6-17 61u5h11 lower unit note: face the shift rod joint connect part to upward. 4. Install the original shim(s) 4 and pro- peller shaft housing assembly 5 into the lower case, and then install the straight key 6, claw washer 7, and ring nut 8. Note: 9 be sure to select the reverse gear shim(s) i...

  • Page 155

    61u5h11 6-18 9 8 7 6 5 4 3 2 1 drive shaft and lower case note: 9 to secure the ring nut, bend one tab q of the claw washer into a slot in the ring nut. 9 bend all other tabs toward the propeller shaft housing assembly. Installing the water pump and shift rod 1. Install the shift rod assembly 1. Not...

  • Page 156

    Lowr 6-19 61u5h11 lower unit 6. Install the new o-ring q and insert car- tridge w into the pump housing e. Note: align the insert cartridge projections b with the holes c in the pump housing. 7. Install the new o-ring r and pump hous- ing assembly t into the lower case, tighten the bolts y, and then...

  • Page 157

    61u5h11 6-20 9 8 7 6 5 4 3 2 1 drive shaft and lower case 2. Set the gear shift to the neutral position at the lower unit. Make sure that the shift rod is in the neutral position using a spe- cial service tool. 3. Install the 2 dowels 1 into the lower unit and extension 2 (e115a: y-transom). 4. Conn...

  • Page 158

    Lowr 6-21 61u5h11 lower unit 9. Insert a gear oil tube or gear oil pump into the drain hole and slowly fill the gear oil until oil flows out of the check hole and no air bubbles are visible. 10. Install the new gasket, check screw 9 and quickly install the drain screw, then tighten to specified torq...

  • Page 159

    61u5h11 6-22 9 8 7 6 5 4 3 2 1 shimming shimming 6g46090e t3 m3 m4 m1 m2 t1 t2 f r p 61u5h11_06_1 06.2.10 16:38 page 23.

  • Page 160

    Lowr 6-23 61u5h11 lower unit shimming note: 9 shimming is not required when assembling the original lower case and inner parts. 9 shimming is required when assembling the original inner parts and a new lower case. 9 shimming is required when replacing the inner part(s). Selecting the pinion shim 1. ...

  • Page 161

    61u5h11 6-24 9 8 7 6 5 4 3 2 1 shimming example: if “t3” is 0.70 mm, then the pinion shim is 0.68 mm. If “t3” is 0.74 mm, then the pinion shim is 0.72 mm. Selecting the forward gear shim 1. Turn the taper roller beaning outer race 1 2 or 3 times to seat the rollers, and then measure the bearing heig...

  • Page 162

    Lowr 6-25 61u5h11 lower unit example: if “t1” is 0.85 mm, then the forward gear shim is 0.82 mm. If “t1” is 0.80 mm, then the forward gear shim is 0.78 mm. Selecting the reverse gear shim 1. Install the ball bearing, thrust washer, and reverse gear onto the propeller shaft housing. 2. Measure the ge...

  • Page 163

    61u5h11 6-26 9 8 7 6 5 4 3 2 1 shimming/backlash note: 9 without the o-ring, when measuring the reverse gear height. 9 select the shim thickness (t2) by using the specified measurement(s) and the calcula- tion formula. 9 measure the reverse gear at 4 points to find the height average. 9 make of note...

  • Page 164

    Lowr 6-27 61u5h11 lower unit 5. Set the lower unit upside down. Note: install the dial gauge so that the plunger a contacts the mark b on the backlash indica- tor. 6. Slowly turn the drive shaft clockwise and counterclockwise, and measure the backlash when the drive shaft stops in each direction. 7....

  • Page 165

    61u5h11 6-28 9 8 7 6 5 4 3 2 1 backlash 8. Remove the special service tools from the propeller shaft. 9. Apply a load to the reverse gear by installing the propeller 8, the spacer 9 (without the washer 0), then the washer q as shown. Note: while turning the drive shaft clockwise 5–6 times to contact...

  • Page 166: Bracket Unit

    Brkt 61u5h11 bracket unit tiller handle ....................................................................................................7-1 checking the throttle cable and shift cable ...............................................7-4 assembling the tiller handle....................................

  • Page 167

    61u5h11 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder .....................................................................7-48 disassembling the tilt cylinder and trim cylinder .....................................7-50 checking the tilt cylinder and trim cylinder ..................................

  • Page 168

    Brkt 7-1 61u5h11 bracket unit wh mh 37 n·m (3.7 kgf·m, 27.3 ft·lb) 11 n·m (1.1 kgf·m, 8.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 37 n·m (3.7 kgf·m, 27.3 ft·lb) 61u7010e no. Part name q’ty remarks 1 throttle cable 1 2 bolt 2 m6 × 16 mm 3 grommet 1 4 nut 1 5 tiller handle 1 6...

  • Page 169

    61u5h11 7-2 9 8 7 6 5 4 3 2 1 tiller handle wh mh 37 n·m (3.7 kgf·m, 27.3 ft·lb) 11 n·m (1.1 kgf·m, 8.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 37 n·m (3.7 kgf·m, 27.3 ft·lb) 61u7010e no. Part name q’ty remarks 18 washer 1 19 bushing 2 20 collar 1 21 ball 1 22 spring 1 23 sh...

  • Page 170

    Brkt 7-3 61u5h11 bracket unit wh mh 37 n·m (3.7 kgf·m, 27.3 ft·lb) 11 n·m (1.1 kgf·m, 8.1 ft·lb) 4 n·m (0.4 kgf·m, 3.0 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 37 n·m (3.7 kgf·m, 27.3 ft·lb) 61u7010e no. Part name q’ty remarks 35 screw 4 ø6 × 8 mm 36 screw 1 ø5 × 12 mm 37 grease nipple 1 38 gasket 1 39 c...

  • Page 171

    61u5h11 7-4 9 8 7 6 5 4 3 2 1 tiller handle checking the throttle cable and shift cable 1. Check that the operation of the throttle cable and shift cable. 2. Check the inner wire, outer wire of the throttle cable and shift cable. Replace if the outer wire is bent or damaged and the rubber seals are ...

  • Page 172

    Brkt 7- 61u5h11 bracket unit 7-5 61u7030e 24 n·m (2.4 kgf·m, 17.7 ft·lb) no. Part name q’ty remarks 1 clip 3 2 shift rod 1 3 bushing 1 4 washer 1 5 shift lever 1 6 o-ring 1 7 washer 1 8 bushing 1 9 bracket 1 10 grease nipple 1 11 circlip 1 12 grommet 1 13 ball 1 14 spring 1 15 bolt 1 not reusable no...

  • Page 173

    61u5h11 7-6 9 8 7 6 5 4 3 2 1 bottom cowling 61u7040e no. Part name q’ty remarks 1 clamp 1 2 bolt 1 m6 × 20 mm 3 plate 1 4 bolt 1 m8 × 20 mm 5 bracket 1 6 holder 2 7 pin 2 8 holder 2 9 bolt 3 m6 × 12 mm 10 wave washer 3 11 clamp lever 3 12 bolt 1 m6 × 12 mm 13 collar 6 14 pilot hole 1 15 lock lever ...

  • Page 174

    Brkt 7- 61u5h11 bracket unit 7-7 61u7040e no. Part name q’ty remarks 18 bolt 1 m6 × 28 mm 19 grommet 1 20 bolt 3 m8 × 35 mm 21 ground lead 1 22 grommet 4 23 collar 4 24 washer 1 25 grommet 2 26 hose 1 27 screw 3 e, et 28 bracket 2 e, et 29 bracket 1 e, et 61u5h11_07_1 06.2.13 1:24 pm page 10

  • Page 175

    61u5h11 7-8 9 8 7 6 5 4 3 2 1 bottom cowling/upper case, steering arm 71 n·m (7.1 kgf·m, 52.4 ft·lb) 51 n·m (5.1 kgf·m, 37.6 ft·lb) 61u7060e upper case, steering arm no. Part name q’ty remarks 1 nut 2 2 grommet 1 3 upper mount 2 4 bracket 1 5 washer 2 6 rubber washer 2 7 washer 2 8 bolt 2 9 damper 2...

  • Page 176

    Brkt 7-9 61u5h11 bracket unit no. Part name q’ty remarks 18 washer 2 19 ground lead 1 20 bolt 2 m14 × 180 mm 21 upper case assembly 1 22 ground lead 1 23 hose 1 24 bolt 3 m10 × 45 mm 25 bolt 1 m6 × 10 mm 26 cover 2 27 screw 2 28 rubber seal 1 29 lock tie 1 not reusable 71 n·m (7.1 kgf·m, 52.4 ft·lb)...

  • Page 177

    61u5h11 7-10 9 8 7 6 5 4 3 2 1 upper case, steering arm 21 n·m (2.1 kgf·m, 15.5 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 61u7070e x no. Part name q’ty remarks 1 bolt 2 m8 × 45 mm 2 bolt 2 m8 × 30 mm 3 gasket 1 4 joint 1 5 upper exhaust guide...

  • Page 178

    Brkt 7-11 61u5h11 bracket unit 21 n·m (2.1 kgf·m, 15.5 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 61u7070e x no. Part name q’ty remarks 18 dowel 2 19 upper case 1 20 rubber seal 1 21 pipe 1 22 rubber seal 1 23 bushing 1 24 circlip 1 25 hose 1 ...

  • Page 179

    61u5h11 7-12 9 8 7 6 5 4 3 2 1 upper case, steering arm disassembling the upper case 1. Remove the bolts 1, 2, muffler assem- bly 3 and rubber seal 4 from the upper case 5. 2. Remove the bolts 6, muffler 7, cooling water pipe 8, rubber dampers 9 and gasket 0. Note: insert a flat-head screw driver be...

  • Page 180

    Brkt 7-13 61u5h11 bracket unit 5. Remove the circlip, and then remove drive shaft bushing. Checking the upper case 1. Check the rubber dampers. Replace if deteriorated or cracked. 2. Check the cooling water pipe. Replace if deformated or corrosion. 3. Check the exhaust guide, exhaust mani- fold, and...

  • Page 181

    61u5h11 7-14 9 8 7 6 5 4 3 2 1 4. Install the rubber damper 9 and clip 0 onto the muffler q. 5. Install the cooling water pipe w onto the muffler q. 6. Install the new gasket, muffler q onto the exhaust guide assembly e, and then tighten the bolts r to the specified torque. 7. Install the muffler as...

  • Page 182

    Brkt 7-15 61u5h11 bracket unit 10. Install the upper mounts a and bracket s into the upper case assembly, and then tighten it with the bolts d. Note: first tighten the center located, when tighten the bolts d. 11. Install the lower mounts f and bolts g as below shown. Note: install the lower mounts ...

  • Page 183

    61u5h11 7-16 9 8 7 6 5 4 3 2 1 upper case, steering arm mh, wh, e 61u7080e 36 n·m (3.6 kgf·m, 26.6 ft·lb) no. Part name q’ty remarks 1 steering arm 1 2 washer 1 3 bushing 2 4 bracket assembly 1 5 o-ring 1 6 bushing 1 7 washer 1 8 steering yoke 1 9 circlip 1 10 nut 2 11 trim stopper 2 12 damper 1 13 ...

  • Page 184

    Brkt 7-17 61u5h11 bracket unit removing the steering arm 1. Remove the circlip 1. 2. Remove the steering yoke 2 as shown. 3. Remove the steering arm from the swivel bracket by pulling the arm off the bracket. Removing the oil seal of swivel bracket (mh, wh, e) 1. Remove the oil seal by using the fla...

  • Page 185

    61u5h11 7-18 9 8 7 6 5 4 3 2 1 4. Install the steering yoke 9 to the steer- ing arm 3 by aligning the center a of the yoke with the center b of the steering arm. Note: hold the steering arm after tilt up the swivel bracket, and then strike the steering yoke until the circlip installing groove visibl...

  • Page 186

    Brkt 7-19 61u5h11 bracket unit installing the upper case 1. Install the upper and lower mount assem- bly into the bracket assembly 1 simulta- neously. 2. Install the upper mount nuts 2 and lower mount nuts 3, and then tighten them to the specified torques. Note: before tighten the uppercase, wiring ...

  • Page 187

    61u5h11 7-20 9 8 7 6 5 4 3 2 1 upper case, steering arm/clamp bracket and swivel bracket 61u7035e 15 n·m (1.5 kgf·m, 11.1 ft·lb) clamp bracket and swivel bracket no. Part name q’ty remarks 1 cap 2 2 self-locking nut 1 3 bolt 6 m10 × 45 mm 4 clamp bracket 1 5 grease nipple 3 6 ground lead 1 7 washer ...

  • Page 188

    Brkt 7-21 61u5h11 bracket unit 61u7035e 15 n·m (1.5 kgf·m, 11.1 ft·lb) no. Part name q’ty remarks 18 anode 1 19 bolt 4 m6 × 30 mm 20 tilt pin 1 21 pin 1 22 circlip 1 61u5h11_07_1 06.2.13 1:24 pm page 24.

  • Page 189

    61u5h11 7-22 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket 61u7140e no. Part name q’ty remarks 1 tilt stop lever 1 2 bushing 6 3 tilt lock lever 1 4 pin 3 5 spring 1 6 plate 1 7 bolt 1 m6 × 10 mm 8 distance collar 1 9 collar 1 10 cotter pin 1 11 lever 1 12 rod 1 13 pin 1 14 cotter pin 2 15 wash...

  • Page 190

    Brkt 7-23 61u5h11 bracket unit 61u7140e no. Part name q’ty remarks 18 bolt 2 m6 × 16 mm 19 spring 2 20 lever 1 21 pin 2 22 lever 1 23 washer 1 24 cotter pin 1 25 spring 1 26 washer 1 27 tilt lock lever 1 28 rod 1 29 tilt stop lever 1 61u5h11_07_1 06.2.13 1:24 pm page 26.

  • Page 191

    61u5h11 7-24 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket removing the clamp bracket (mh, wh, e) w 9 do not tamper or attempt to open the shock absorber. 9 do not subject the shock absorber to an open flame or any other source of high heat. High heat can cause an explosion due to excessive gas...

  • Page 192

    Brkt 7-25 61u5h11 bracket unit assembling the swivel bracket (mh, wh, e) 1. Install the rod 1 and rod 2 into the tilt lock lever 3, and then install the tilt lock lever to the swivel bracket 4. 2. Install the tilt stopper 5 into the swivel bracket 4 with the cotter pin 6 and pin 7. Note: pass the ti...

  • Page 193

    61u5h11 7-26 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket 6. Install the lever y to the swivel bracket 4 with the cotter pin u. 7. Install the lever i to the lever y with the 2 cotter pins o. 8. Install the 2 large springs p. 9. Install the small spring a. Note: after assembling the swivel bra...

  • Page 194

    Brkt 7-27 61u5h11 bracket unit 15 n·m (1.5 kgf·m, 11.1 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 61u7020e et no. Part name q’ty remarks 1 swivel bracket 1 2 clamp bracket 1 3 clamp bracket 1 4 self-locking nut 1 5 grease nipple 6 6 ground lead 3 7 screw 1 ø6 × 12 mm 8 washer 2 9 bushing 2 10 trim sensor 1...

  • Page 195

    61u5h11 7-28 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket 15 n·m (1.5 kgf·m, 11.1 ft·lb) 2 n·m (0.2 kgf·m, 1.5 ft·lb) 61u7020e et no. Part name q’ty remarks 18 through tube 1 19 bolt 1 m8 × 20 mm 20 tilt stop lever 1 21 bushing 4 22 collar 1 23 distance collar 1 24 spring pin 2 25 spring 1 26 ...

  • Page 196

    Brkt 7-29 61u5h11 bracket unit 61u7090e no. Part name q’ty remarks 1 ptt unit 1 2 ptt motor lead 1 3 pin 1 4 lock tie 3 5 circlip 1 6 bolt 2 m8 × 16 mm 7 washer 2 8 shaft 1 9 bushing 6 10 bolt 1 m6 × 10 mm 11 ground lead 1 12 trim sensor lead 1 13 cap 2 not reusable 61u5h11_07_1 06.2.13 1:24 pm page...

  • Page 197

    61u5h11 7-30 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket removing the ptt unit (et) 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. W 9 after tilting up the outboard motor, be sure to support it with the tilt stop lever. Otherwise, the outboard motor could...

  • Page 198

    Brkt 7-31 61u5h11 bracket unit 3. Assemble the clamp brackets, washers, swivel bracket, trim sensor, and then install the through tube. Note: 9 align the projection inside of the trim sensor cam with the through tube hole a, and then install it. 9 adjust the trim sensor cam after installing the ptt....

  • Page 199

    61u5h11 7-32 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket installing the ptt unit (et) 1. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. W 9 when installing the ptt unit without removing the power unit, be sure to sus- pend the outboard motor. Otherwise, the ...

  • Page 200

    Brkt 7-33 61u5h11 bracket unit adjusting the trim sensor cam (et) 1. Fully retract the ptt unit. 2. Connect the test harness to the trim sen- sor coupler. 3. Turn the engine start switch to on. 4. Measure the trim sensor voltage. 61u70580 o gy p b b p 1 dcv r g trim sensor voltage: pink (p)–black (b...

  • Page 201

    61u5h11 7-34 9 8 7 6 5 4 3 2 1 clamp bracket and swivel bracket/ptt unit 5 n·m (0.5 kgf·m, 3.7 ft·lb) 5 n·m (0.5 kgf·m, 3.7 ft·lb) 7 n·m (0.7 kgf·m, 5.2 ft·lb) 61u7100e no. Part name q’ty remarks 1 ptt motor 1 2 reservoir 1 3 reservoir cap 1 4 o-ring 1 5 o-ring 1 6 bolt 3 m6 × 13 mm 7 bolt 4 m6 × 34...

  • Page 202

    Brkt 7-35 61u5h11 bracket unit checking the hydraulic pressure 1. Fully extend the trim and tilt rams. 2. Remove the reservoir cap, and then check the fluid level in the reservoir. Note: if the fluid is at the correct level, the fluid should overflow out of the filler hole when the reservoir cap is ...

  • Page 203

    61u5h11 7-36 9 8 7 6 5 4 3 2 1 ptt unit 8. Reverse the ptt motor leads between the battery terminals to fully extend the trim and tilt rams, and then measure the hydraulic pressure. 9. Replace the up relief fitting with the down relief fitting 5. Note: quickly install the special service tools befor...

  • Page 204

    Brkt 7-37 61u5h11 bracket unit 13. Connect the ptt motor leads to the bat- tery terminals to fully retract the trim and tilt rams, and then measure the hydraulic pressure. If out of specification, overhaul the ptt unit. 14. Reverse the ptt motor leads between the battery terminals to fully extend th...

  • Page 205

    61u5h11 7-38 9 8 7 6 5 4 3 2 1 ptt unit/ptt motor 61u7110e no. Part name q’ty remarks 1 screw 1 ø4 × 15 mm 2 stator 1 3 armature 1 4 o-ring 1 5 screw 2 ø4 × 12 mm 6 brush holder 1 7 brush 1 1 8 brush 2 1 9 brush holder 1 10 brush spring 2 11 ptt motor base 1 12 oil seal 1 13 bearing 1 14 screw 2 ø4 ...

  • Page 206

    Brkt 7-39 61u5h11 bracket unit q w w a 6g470320 lg sb disassembling the ptt motor 1. Loosen the bolts 1, remove the ptt motor 2, o-ring 3, gear pump filter 4, and joint 5 from the gear pump housing. W 9 make sure that the trim and tilt rams are fully extended when removing the ptt motor, otherwise f...

  • Page 207

    61u5h11 7-40 9 8 7 6 5 4 3 2 1 ptt motor c c 9 do not pull the ptt motor leads out from the stator. 9 do not touch the bimetal a, otherwise the operation of the circuit breaker can be affected. Checking the ptt motor 1. Check the commutator. Clean with 600 – grit sandpaper and compressed air if dirt...

  • Page 208

    Assembling the ptt motor 1. Connect the ptt motor leads 1, and then tighten the screws 2. 2. Install the spring and push the brushes 3 into the brush holder, and then install the armature 4. 3. Install the stator 5 onto the base. Note: place a clean cloth over the end of the arma- ture shaft, hold i...

  • Page 209

    61u5h11 7-42 9 8 7 6 5 4 3 2 1 ptt motor/gear pump 6 n·m (0.6 kgf·m, 4.4 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 61u7120e no. Part name q’ty remarks 1 bolt 4 m5 × 16 mm 2 gear pump assembly 1 3 ball 2 4 shuttle piston 2 5 o-ring 2 6 main valve 2 ...

  • Page 210

    Brkt 7-43 61u5h11 bracket unit 6 n·m (0.6 kgf·m, 4.4 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 8 n·m (0.8 kgf·m, 5.9 ft·lb) 3 n·m (0.3 kgf·m, 2.2 ft·lb) 61u7120e no. Part name q’ty remarks 18 up-relief valve seat 1 19 o-ring 1 20 filter 2 21 o-ring 1 22 down-relief valve 1 23 valve pin 1 24 o-ring 5 25 va...

  • Page 211

    61u5h11 7-44 9 8 7 6 5 4 3 2 1 gear pump disassembling the gear pump hous- ing 1. Remove the bolts 1 and gear pump housing 2. Note: make sure that the o-rings 3, valve pin 4, and valve seat assembly 5 are removed. 2. Remove the filters 6, down-relief valve 7, and o-ring 8 from the gear pump housing....

  • Page 212

    Brkt 7-45 61u5h11 bracket unit 5. Cover the pump housing with a clean cloth, and then blow compressed air through holes a and b while holding the cloth down. 6. Remove the main valves y. W never look into the pump housing open- ing while removing the main valves because the main valves and ptt fluid...

  • Page 213

    61u5h11 7-46 9 8 7 6 5 4 3 2 1 gear pump assembling the gear pump housing 1. Install a new o-ring 1, up-relief valve seat 2, ball 3, absorber valve pin 4, and spring 5 into the gear pump hous- ing. 2. Install new o-rings 6 onto the main valves 7, and then install the main valves into the gear pump h...

  • Page 214

    Brkt 7-47 61u5h11 bracket unit 7. Install a new o-ring r onto the down- relief valve t. 8. Install the filter y, down-relief valve t, and filter u into the gear pump housing i. 9. Install a new o-ring o, p onto the man- ual valve a. 10. Install the manual valve a and circlip s into the gear pump hou...

  • Page 215

    61u5h11 7-48 9 8 7 6 5 4 3 2 1 gear pump/tilt cylinder and trim cylinder 96 n·m (9.6 kgf·m, 70.8 ft·lb) 132 n·m (13.2 kgf·m, 97.4 ft·lb) 127 n·m (12.7 kgf·m, 93.7 ft·lb) 61u7130e no. Part name q’ty remarks 1 tilt ram 1 2 trim ram 2 3 cylinder body 1 4 free piston 1 5 backup ring 1 6 o-ring 1 7 dust ...

  • Page 216

    Brkt 7-49 61u5h11 bracket unit 96 n·m (9.6 kgf·m, 70.8 ft·lb) 132 n·m (13.2 kgf·m, 97.4 ft·lb) 127 n·m (12.7 kgf·m, 93.7 ft·lb) 61u7130e no. Part name q’ty remarks 18 o-ring 1 19 o-ring 1 20 washer 1 21 nut 1 22 ball 4 23 valve 4 24 spring 4 not reusable not reusable 61u5h11_07_1 06.2.13 1:24 pm pag...

  • Page 217

    61u5h11 7-50 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder disassembling the tilt cylinder and trim cylinder 1. Hold the ptt body in a vise using alu- minum plates on the both sides. 2. Loosen the tilt cylinder end screw 1, and then remove the tilt piston assembly. C c make sure that the ram are...

  • Page 218

    Brkt 7-51 61u5h11 bracket unit checking the tilt cylinder and trim cylinder 1. Disassemble the tilt piston assembly. 2. Check the tilt piston 1 and free piston 2. Replace tilt piston and free piston if worn or deteriorated. 3. Blow the tilt piston absorber valve 3 with compressed air to remove any d...

  • Page 219

    61u5h11 7-52 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder 6. Install a new backup ring w and a new o-ring e onto the free piston r. 7. Install a new seal t, a new dust seal y, and a new o-ring u onto each trim cylin- der end screw. 8. Install the backup ring i and a new o- ring o onto each trim...

  • Page 220

    Brkt 7-53 61u5h11 bracket unit 4. Install the trim piston assemblies into the trim cylinders, and then tighten the trim cylinder end screws to the specified torque. C c 9 make sure that the trim rams are fully extended when installing them. 9 once installed, never push the trim rams down, otherwise ...

  • Page 221

    61u5h11 7-54 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder c c 9 make sure that the tilt ram is fully extended when installing it. 9 once installed, never push the tilt ram down, otherwise fluid can spurt out. 11. Install the joint 0 and gear pump filter q into the gear pump housing. 12. Fill th...

  • Page 222

    Brkt 7-55 61u5h11 bracket unit bleeding the ptt unit 1. Tighten the manual valve 1 clockwise. 2. Place the ptt unit in an upright position. 3. Remove the reservoir cap, and then check the fluid level in the reservoir. Note: if the fluid is at the correct level, the fluid should overflow out of the f...

  • Page 223

    61u5h11 7-56 9 8 7 6 5 4 3 2 1 tilt cylinder and trim cylinder 8. Check the fluid level when the tilt ram is fully extended. Add sufficient fluid if nec- essary. Bleeding the ptt unit (built-in) 1. Check the manual valve is fully tightened, and then connect the battery to the bat- tery leads. Note: ...

  • Page 224

    Brkt 7-57 61u5h11 bracket unit 7. Install the reservoir cap, and then tighten it to the specified torque. Note: repeat this procedure until the fluid is at the correct level. Ptt electrical system checking the fuse 1. Check the fuse for continuity. Replace if there is no continuity. Checking the ptt...

  • Page 225: Electrical System

    Electrical system checking the electrical component..............................................................8-1 measuring the peak voltage ......................................................................8-1 electrical component ................................................................

  • Page 226

    Elec 8-1 61u5h11 electrical system checking the electrical component measuring the peak voltage to check the electrical components or mea- sure the peak voltage, use the special service tools. A faulty electrical components can be easily checked by measuring the peak volt- age. The specified engine ...

  • Page 227

    61u5h11 8-2 9 8 7 6 5 4 3 2 1 checking the electrical component/electrical component electrical component port view 3 5 4 2 1 2 3 2 61u80040d et e 1 starter motor (wh, e, et) 2 starter relay (wh, e, et) 3 ptt relay (et) 4 ignition coil 5 fuse holder (20a: wh, e, et) 61u5h11_08 05.10.7 3:02 pm page 3.

  • Page 228

    61u80020b 2 1 ç ∫ ∫ å 3 3 2 elec 8-3 61u5h11 electrical system starboard view 1 choke solenoid (e, et) 2 rectifier regulator 3 hour meter (if equipped) å to pulser coil assembly. ∫ to cdi unit. ç to wire harness. 61u5h11_08 05.10.7 3:02 pm page 4.

  • Page 229

    61u5h11 8-4 9 8 7 6 5 4 3 2 1 electrical component aft view 8 2 4 7 1 5 6 3 9 ∫ ∫ å å 61u80030c top bottom 1 ignition coil #1 2 ignition coil #2 3 ignition coil #3 4 ignition coil #4 5 spark plug 6 spark plug cap 7 thermoswitch 8 cdi unit 9 pcv 61u5h11_08 05.10.7 3:02 pm page 5.

  • Page 230

    Elec 8-5 61u5h11 electrical system top view å å 1 1 7 9 8 5 2 6 2 4 3 61u80010a 1 spark plug 2 thermoswitch 3 ignition coil #1 4 ignition coil #2 5 rectifier regulator 6 starter motor (wh, e, et) 7 stator assembly 8 pulser coil assembly 9 neutral switch (wh) 61u5h11_08 05.10.7 3:02 pm page 6.

  • Page 231

    61u5h11 8-6 9 8 7 6 5 4 3 2 1 ignition and ignition control system ignition and ignition control system checking the ignition spark gap 1. Disconnect the spark plug caps from the spark plugs. 2. Connect a spark plug cap to the special service tool shown as below illustration. 3. Crank the engine and...

  • Page 232

    Elec 8-7 61u5h11 electrical system checking the cdi unit 1. Remove the cdi unit cover. 2. Connect the digital circuit tester with peak voltage adaptor b to the ignition coil lead and the ground. 3. Measure the cdi unit output peak volt- age. If less than specification, measure the charge coil output...

  • Page 233

    61u5h11 8-8 9 8 7 6 5 4 3 2 1 ignition and ignition control system checking the charge coil 1. Remove the cdi unit cover. 2. Connect the test harness to the charge coil. 3. Measure the charge coil output peak volt- age. Replace the stator assembly if less than specification. Checking the pulser coil...

  • Page 234

    ( ): manual start 4. Disconnect the charge coil coupler. 5. Connect the digital circuit tester to the charge coil coupler (charge coil side). 6. Measure the charge coil resistance. Replace the stator assembly if out of specification. Test harness 1: 90890-06871 elec 8-9 61u5h11 electrical system 6s3...

  • Page 235

    Checking the engine stop lanyard switch 1. Check the engine stop lanyard switch for continuity. Replace if there is no continu- ity. å wh ∫ mh ç e, et 61u5h11 8-10 9 8 7 6 5 4 3 2 1 ignition and ignition control system/starting system checking the engine start switch (wh, e, et) 1. Disconnect the 10...

  • Page 236

    Elec 8-11 61u5h11 electrical system checking the starter relay (wh, e, et) 1. Remove the starter relay 1. 2. Connect the digital circuit tester leads to the starter relay terminals. 3. Connect the positive battery terminal to the brown (br) lead 2, also connect the negative battery terminal to the b...

  • Page 237

    61u5h11 8-12 9 8 7 6 5 4 3 2 1 starting system/starter motor (wh, e, et) 9 n·m (0.9 kgf·m, 6.6 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 61u8010e no. Part name q’ty remarks 1 bolt 2 m8 × 25 mm 2 starter motor bracket 1 3 clip 2 4 pinion stopper 1 5 spring 1 6 pinion 1 7 fr...

  • Page 238

    Elec 8-13 61u5h11 electrical system 9 n·m (0.9 kgf·m, 6.6 ft·lb) 18 n·m (1.8 kgf·m, 13.3 ft·lb) 30 n·m (3.0 kgf·m, 22.1 ft·lb) 61u8010e no. Part name q’ty remarks 18 screw 2 19 bolt 2 m6 × 115 mm 61u5h11_08 05.10.7 3:02 pm page 14.

  • Page 239

    61u5h11 8-14 9 8 7 6 5 4 3 2 1 starter motor (wh, e, et) removing the starter motor pinion 1. Slide the pinion stopper 1 down using the box wrench, and then remove the clips 2. 2. Remove the starter motor pinion. Checking the starter motor pinion 1. Check the teeth of the pinion. Replace if cracked ...

  • Page 240

    Elec 8-15 61u5h11 electrical system 2. Check the brush holder assembly for continuity. Replace the brush holder if not shown as below chart. Checking the starter motor operation 1. Check the operation of the starter motor after installing it onto the power unit. Checking the choke solenoid 1. Discon...

  • Page 241

    61u5h11 8-16 9 8 7 6 5 4 3 2 1 starter motor (wh, e, et)/charging system checking the rectifier regulator 1. Disconnect the rectifier regulator (r) connector, then connect the digital circuit tester to rectifier regulator (r) connec- tor and ground 2. Measure the rectifier regulator output peak volt...

  • Page 242

    Elec 8-17 61u5h11 electrical system checking the hour meter 1. Disconnect the hour meter coupler from the wiring harness. 2. Connect the positive battery lead to the yellow (y) terminal a, also connect the negative battery lead to the black (b) ter- minal b, and then check that the hour meter displa...

  • Page 243: Troubleshooting

    61u5h11 9 8 7 6 5 4 3 2 1 trbl shtg trbl shtg troubleshooting troubleshooting the power unit ..................................................................9-1 troubleshooting the power unit..................................................................9-1 troubleshooting the ptt unit............

  • Page 244

    Trbl shtg 9-1 61u5h11 trbl shtg troubleshooting troubleshooting the power unit troubleshooting the power unit (trouble code not available) the trouble shooting when a trouble code is not available consists of the following 4 items. Symptom 1: specific trouble conditions. Symptom 2: trouble condition...

  • Page 245

    Refer symptom 2 cause 1 cause 2 checking step to page 61u5h11 9-2 9 8 7 6 5 4 3 2 1 troubleshooting the power unit refer symptom 2 cause 1 cause 2 checking step to page manual starter or starter motor operates, but the engine does not crank stuck piston — disassemble and check the power unit. 5-17 p...

  • Page 246

    Trbl shtg 9-3 61u5h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page 8-8 8-8 5-4 8-6 pulser coil malfunction measure the pulser coil resistance. Change the pulser coil and check the ignition spark. Pulser coil out- put peak volt- age less than specifications 5-4 8-6 charge coi...

  • Page 247

    61u5h11 9-4 9 8 7 6 5 4 3 2 1 trouble shooting the power unit refer symptom 2 cause 1 cause 2 checking step to page fuel not sup- plied properly carburetor malfunction disassemble and check the carburetor. 4-12 float height improperly spark plug malfunction spark plug sparks improperly *1 short, ope...

  • Page 248

    Trbl shtg 9-5 61u5h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page symptom 1: limited engine speed (below 2,000 r/min) clogged cooling water inlet check the cooling water inlet. 3-4 9buzzer comes on 9overheat warn- ing indicator comes on 9cooling water does not dis- charge f...

  • Page 249

    61u5h11 9-6 9 8 7 6 5 4 3 2 1 troubleshooting the power unit refer symptom 2 cause 1 cause 2 checking step to page troubleshooting the ptt unit symptom 1: ptt unit does not operate ptt relay does not operate short, open, or loose connection of the wiring harness check the wiring har- ness continuity...

  • Page 250

    Trbl shtg 9-7 61u5h11 troubleshooting refer symptom 2 cause 1 cause 2 checking step to page symptom 1: ptt unit does not hold the outboard motor up manual valve opened check the manual valve for open. — insufficient ptt fluid add sufficient fluid. 3-10 — manual valve malfunction — ptt fluid leakage ...

  • Page 251

    61u5h11 i-1 9 8 7 6 5 4 3 2 1 a. Adjusting the ignition timing stopper........5-53 adjusting the start-in-gear protection (mh, wh) .................................................3-4 adjusting the throttle cable ........................3-6 adjusting the timing plate ........................5-52 adj...

  • Page 252

    I-2 61u5h11 index checking the hydraulic pressure .............7-35 checking the ignition coil ...........................8-7 checking the ignition spark gap ................8-6 checking the ignition timing.......................3-8 checking the internal anode....................5-38 checking the li...

  • Page 253

    61u5h11 i-3 9 8 7 6 5 4 3 2 1 i. Identification...............................................1-5 ignition and ignition control system ...........8-6 installing the pcv ....................................5-26 installing the ptt unit (et)......................7-31 installing the clamp bracket (et) ....

  • Page 254

    Wiring diagram e115amh 1 thermoswitch 2 spark plug 3 ignition coil 4 cdi unit 5 charge coil 6 lighting coil 7 pulser coil 8 rectifier regulator 9 engine stop lanyard switch 0 over revolution color code b : black br : brown g : green gy : gray l : blue p : pink r : red w : white b/r : black/red b/w :...

  • Page 255

    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 conc...

  • Page 256: 115B

    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.

  • Page 257

    E115amh 2 2 1 2 3 4 1 2 3 4 1 2 3 4 4 4 1 1 3 3 g /w r b p p b b p b r r r gy b b b w b w w w g g/w g/w g g g g b b b b l b /r p b/w b/w b /w b /w b /w b /w b/w b/w b/w b/w b/w b/w w /r w /b w /y w /g w/r w/b w/y w/g w /r w /b w /y w /g r b br l b /r r br l b /r r br l b/r r br w b b b p b p b p p b...

  • Page 258

    Wiring diagram e115ae, e115awh, 115be 1 starter motor 2 starter relay 3 battery 4 fuse (20a) 5 thermoswitch 6 spark plug 7 ignition coil 8 cdi unit 9 charge coil 0 lighting coil q pulser coil w rectifier regulator e choke solenoid (e115ae, 115be) r over revolution å to remote control box/switch pane...

  • Page 259

    E115ae,e115awh,115be 2 2 1 2 3 4 1 2 3 4 1 2 3 4 20a 4 4 1 1 3 3 g /w r br b b b p p b p b b b b g sb lg r r br sb lg r br sb lg r r r r br gy b b b b b b b b b w r br b p sb lg w l b l l g g/w g/w g g g g b b b b b l b /r p b/w b/w b /w b /w b /w b /w b/w b/w b/w b/w b/w b/w w /r w /b w /y w /g w/r...

  • Page 260

    Wiring diagram e115aet, 115bet, 140bet 1 starter motor 2 starter relay 3 ptt relay (up) 4 ptt relay (down) 5 ptt motor 6 battery 7 fuse (20a) 8 thermoswitch 9 spark plug 0 ignition coil q cdi unit w charge coil e lighting coil r pulser coil t rectifier regulator y choke solenoid u hour meter (e115a)...

  • Page 261

    E115aet,115bet,140bet y 2 2 1 2 3 4 1 2 3 4 1 2 3 4 20a 4 4 1 1 3 3 1 2 3 4 1 2 3 g /w r br b b b p b p p b p b b b b b p g sb lg r r br sb lg r br sb lg r r r r br sb lg gy b b b b b b b b b b b b b b b b w r br b p sb lg w l b l l g g g/w g/w g g g g b b b b l l b /r p b/w b/w b /w b /w b /w b /w ...