Yamaha 115b 115A

E115A, 115B, 140B
E115A
115B
140B
SERVICE MANUAL
61U-28197-5H-11
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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 concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information
Particularly important information is distinguished in this manual by the following notations:
Q The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
w
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
cC
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
E115A, 115B, 140B

SERVICE MANUAL
©2005 by Yamaha Motor Co., Ltd.
1st Edition, October 2005
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan

Contents
General information GEN
INFO
1
Specification SPEC 2
Periodic check and adjustment CHK
ADJ
3
Fuel system FUEL 4
Power unit POWR 5
Lower unit LOWR 6
Bracket unit BRKT 7
Electrical system ELEC 8
Troubleshooting TRBL
SHTG
9
Index

GEN
INFO
General information
How to use this manual ............................................................................... 1-1

Manual format .......................................................................................... 1-1
Symbol ..................................................................................................... 1-2 1
Safety while working ................................................................................... 1-3
2
Fire prevention ......................................................................................... 1-3
Ventilation ................................................................................................ 1-3
Self-protection ......................................................................................... 1-3
Parts, lubricant, and sealant .................................................................... 1-3
Good working practice ............................................................................. 1-4
Disassembly and assembly ..................................................................... 1-4
Identification ................................................................................................. 1-5

Applicable model ..................................................................................... 1-5
3
Serial number .......................................................................................... 1-5
Special service tool ..................................................................................... 1-6 4

Propeller selection ..................................................................................... 1-11
Propeller size ......................................................................................... 1-11
Selection ................................................................................................ 1-11
5
Predelivery check ....................................................................................... 1-12
6
Checking the fuel system ...................................................................... 1-12
Checking the gear oil ............................................................................. 1-12
Checking the outboard motor mounting height ..................................... 1-12
Checking the remote control cable (Remote control model) ...................1-13
Checking the steering system ............................................................... 1-14
7
Checking the gear shift and throttle operation.........................................1-14
Checking the PTT system (ET) ...............................................................1-15
Checking the engine start switch and engine stop lanyard switch ........ 1-15
Checking the cooling water pilot hole .................................................... 1-16
Test run .................................................................................................. 1-16
Break-in ................................................................................................. 1-16
After test run .......................................................................................... 1-17
8
9
61U5H11 1-

GEN
INFO General information
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 exploded diagram and are listed in the components list (see 1
in the figure below for an example page).
9 The component list consists of part names and quantities, as well as bolt and screw dimensions
(see 2 in the figure below).
9 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and
lubrication point (see 3 in the figure below).
9 Tightening torque specifications are provided in the exploded diagrams (see 4 in the figure below
for an example), and in the related detailed instructions. Some torque specifications are listed in
stages as torque figures or angles in degrees.
9 Separate procedures and illustrations are used to explain the details of removal, checking, and
installation where necessary (see 5 in the figure below for an example page).
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR
Lower unit
3 4 1
Lower unit
LOWR
Lower unit
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
S62Y6740K
2 CAUTION:
3
Do not reuse the bearing, always replace
6F660190
S62Y6850K it with a new one.
Drive shaft holder 4 1 : 90890-06518

No. Part name Q ty Remarks Pinion nut holder 2 : 90890-06505 Bearing separator 1 : 90890-06534
1 Lower unit 1 Socket adapter 2 3 : 90890-06507
2 Plastic tie 1 Not reusable
Disassembling the drive shaft 2. Remove the needle bearing from the for-
3 Hose 1 ward gear.
1. Install the pinion nut 1 , tighten it finger
4 Check screw 1
tight, and then remove the drive shaft
5 Gasket 2 Not reusable bearing 2 using a press.
6 Dowel pin 2
7 Bolt 4 M10 × 40 mm
8 Drain screw 1
9 Grommet 1
10 Bolt 1 M10 × 45 mm
11 Bolt 1 M8 × 60 mm
12 Thrust washer 1
13 Propeller 1 CAUTION:
14 Washer 1 Do not reuse the bearing, always replace
CAUTION: it with a new one.
15 Washer 1
16 Cotter pin 1 • Do not press the drive shaft threads a
Not reusable
directly. Stopper guide plate 2 : 90890-06501
17 Propeller nut 1
Do not reuse the bearing, always Stopper guide stand 3 :
18 Trim tab 1 replace it with a new one. 90890-06538
Bearing puller 4 : 90890-06535
Bearing puller claw 1 5 :
Bearing inner race attachment 3 :
6-5 62Y5A11 90890-06536
90890-06639
Disassembling the forward gear

1. Remove the taper roller bearing from the
forward gear using a press.
2
6-19 62Y5A11
1-1
1- 61U5H11

How to use this manual
Symbol
The symbols below indicate the content of a chapter.
General information Fuel system Bracket unit
GEN
INFO
FUEL BRKT 1
Specification Power unit Electrical system
SPEC
Periodic check and adjustment

POWR
Lower unit
ELEC
Troubleshooting
2
CHK
ADJ
LOWR
TRBL
SHTG
3
Symbols 1 to 6 indicate specific data.
1 2 3 4 5 6
4
1
2
3
4
Special tool
Specified oil or fluid
Specified engine speed
Specified tightening torque
5 Specified measurement
6 Specified electrical value
(resistance, voltage, electric current) 5
Symbols 7 to e in an exploded diagram or illustration indicate the grade of lubricant and the lubri-
cation point.
7 8 9 0 q w e
6
C
7
8
Apply Yamaha 2-stroke outboard motor oil
Apply gear oil
q Apply corrosion resistant grease
(Yamaha grease D)
7
9 Apply water resistant grease (Yamaha grease A) w Apply low temperature resistant grease
0 Apply molybdenum disulfide grease (Yamaha grease C)
e Apply injector grease
Symbols r to o in an exploded diagram or illustration indicate the type of sealant or locking agent
8
and the application point.
r t y u i o
9
r Apply Gasket Maker u Apply LOCTITE 242 (blue)
t Apply ThreeBond 1104J i Apply LOCTITE 572
y Apply LOCTITE 271 (red) o Apply silicon sealant
61U5H11 1-2

GEN
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.
Parts, lubricant, and sealant

Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade- Under normal conditions, the lubricants men-
quate ventilation can be maintained. tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and

industrial hygiene.
2. Change and wash clothing as soon as

possible if soiled with lubricants.
Self-protection 3. Avoid contact with skin. Do not, for exam-

Protect your eyes by wearing safety glasses ple, place a soiled rag in your pocket.
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air 4. Wash hands and any other part of the
compressor. body thoroughly with soap and hot water
Protect your hands and feet by wearing pro- after contact with a lubricant or lubricant
tective gloves and safety shoes when neces- soiled clothing has been made.
sary.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.
1-
1-3 61U5H11

Safety while working
6. Keep a supply of clean, lint-free cloths for Disassembly and assembly

wiping up spills, etc. 1. Use compressed air to remove dust and
dirt during disassembly.
1
Good working practice
Special service tool 2. Apply engine oil to the contact surfaces
Use the recommended special service tools of moving parts before assembly.
to protect parts from damage. Use the right
tool in the right manner–do not improvise.
2
3. Install bearings with the manufacture
3
identification mark in the direction indicat-
Tightening torque
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
ed in the installation procedure. In addi-
tion, be sure to lubricate the bearings lib-
erally.
4
large sizes first, and tighten fasteners starting 4. Apply a thin coat of water-resistant
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate normal-

5
assembling parts. ly after assembly.
6
7
8
9
61U5H11 1-4

GEN
Identification
Applicable model
This manual covers the following model.
Applicable model
E115AMH, E115AWH, E115AE, E115AET
115BE, 115BET, 140BET
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
6G410010
3 1
4
2
YAMAHA MOTOR CO., LTD.
MADE IN JAPAN
PAYS D'ORIGINE JAPON
6B410020
1 Model name
2 Approved model code
3 Transom height
4 Serial number
Approved Starting
Model name
model code serial No.
E115A 61U 1015056–
115B 6E5 1015056–
140B 6F3 1000671–
1-5 61U5H11

Identification/Special service tool
Special service tool
1
Digital tachometer
90890-06760
Compression gauge
90890-03160
2
3
Timing light Flywheel holder
90890-03141 90890-06522
4
5
Leakage tester Flywheel puller
6
90890-06840 90890-06521
Digital caliper Ball bearing attachment

7
90890-06704 90890-06663
8
Vacuum/pressure pump gauge set Driver rod LS
9
90890-06756 90890-06606
61U5H11 1-6

GEN
Needle bearing attachment

Gear puller 90890-06609, 90890-06610, 90890-06611,
90890-06540 90890-06612, 90890-06653, 90890-06654
Bearing separator Driver rod L3

90890-06534 90890-06652
Cylinder gauge Ball bearing attachment

90890-06759 90890-06633, 90890-06636
90890-06637, 90890-06656
Support Bearing outer race attachment

90890-02394 90890-06620, 90890-06624
Bearing inner race attachment Small end bearing installer

90890-06640, 90890-06662 90890-06528
1-
1-7 61U5H11

1
2
Piston slider Stopper guide plate
90890-06530 90890-06501
3
Dial gauge set Bearing housing puller claw L
4
90890-01252 90890-06502
Shift rod push arm Center bolt

5
90890-06052 90890-06504
6
Ring nut wrench 3 Stopper guide stand
7
90890-06511 90890-06538
8
Ring nut wrench extension Bearing puller assembly
90890-06535
9
90890-06513
61U5H11 1-8

GEN
Driver rod SS Bearing outer race puller assembly

90890-06604 90890-06523
Bearing depth plate Driver rod SL

90890-06603 90890-06602
Drive shaft holder 6 Pinion height gauge

90890-06520 90890-06710
Pinion nut holder Shimming plate

90890-06715 90890-06701
Driver rod LL Backlash indicator

90890-06605 90890-06706
1-9 61U5H11

1
Magnet base plate
90890-07003
Test harness (4 pins)
90890-06878
2
3
Magnet base B
90890-06844
Trim and tilt wrench
90890-06587 4
5
6
Digital circuit tester Ignition tester
90890-03174 90890-06754
7
Up relief fitting
90890-06773
8
Peak voltage adaptor B
Down relief fitting 90890-03172
90890-06774
9
Hydraulic pressure gauge Test harness (4 pins)
90890-06776 90890-06871
61U5H11 1-10

GEN
Propeller selection Selection

The performance of a boat and outboard When the engine speed is at the full throttle
motor will be critically affected by the size and operating range (4,500–5,500 r/min), the
type of propeller you choose. Propellers ideal propeller for the boat is one that pro-
greatly affect boat speed, acceleration, vides maximum performance in relation to
engine life, fuel economy, and even boating boat speed and fuel consumption.
and steering capabilities. An incorrect choice
could adversely affect performance and could
Propeller size (in) Material
also seriously damage the engine.
14 × 11 - K
Use the following information as a guide for
selecting a propeller that meets the operating 13 5/8 × 13 - K
conditions of the boat and the outboard 13 1/2 × 14 - K
motor. 12 1/2 × 15 - K
13 1/2 × 16 - K
Propeller size
13 × 17 - K
The size of the propeller is indicated as Aluminum
shown. 13 1/4 × 17 - K
13 × 19 - K
12 5/8 × 21 - K
13 × 21 - K
× −
13 × 23 - K
a b c 13 × 25 - K
14 × 20 - P
14 × 22 - P
69D10020 14 × 24 - P Stainless steel
14 × 26 - P
14 × 28 - P
-
b c
6B410035
a Propeller diameter (in inches)

b Propeller pitch (in inches)
c Propeller type (propeller mark)
1-11 61U5H11

Propeller selection
Predelivery check Checking the battery

To make the delivery process smooth and (E, ET, WH)
efficient, the predelivery checks should be 1. Check the capacity, electrolyte level, and
completed as explained below.
Checking the fuel system

1. Check that the fuel hoses is securely
specified gravity of the battery.
Recommended battery capacity:
CCA/EN: 430 A
1
20HR/IEC: 70 Ah
connected and that the fuel tank is filled
2
Electrolyte specified gravity:
with fuel.
1.280 at 20°C (68°F)
2. Check that the positive and negative bat-

tery cable are securely connected.
Checking the outboard motor

mounting height
3
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation will
occur and propulsion will be reduced.
Also, the engine speed will increase
4
abnormally and cause the engine to over-
5
heat. If the mounting height is too low,
water resistance will increase and reduce
engine efficiency.
61U10080
cC
Use pre-mixed fuel only.
Fuel and oil mixing ratio is 50:1. For
break-in period, 25:1 mixture shall be
6
used.
Checking the gear oil

1. Check the gear oil level.
69D10080 7
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
8
ent heights.
69D10055
2. Check that the clamp brackets are
secured with the mounting bolts. 9
61U5H11 1-12

GEN
Checking the remote control cable 4. Check that the remote control lever is in
(Remote control model) the neutral position, and check that the
1. Set the remote control lever to the neutral center of the set pin 5 is aligned with the
position and fully close the throttle lever. alignment mark a on the bottom cowling.
2. Check that the control lever 1 is in its

fully closed position, and check the
adjusting screw 2 is contact the stopper
3.
3 5
a 61U10065
61U10040
3. Fully open the throttle lever, and then

check that the control lever 1 is in its
fully opened position, and check the con- b 6D430227
trol lever contact the adjusting screw 4.
cC
4
The shift / throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
b.
61U10050
1-13 61U5H11

Predelivery check
Checking the steering system Checking the gear shift and throttle
1. Check the steering friction for proper operation
adjustment. 1. Check that the gear shift operates
b
smoothly when the shift lever or remote
control lever is shifted from neutral to for-
ward or reverse. 1
2. Check that the throttle operates smoothly
a
61U10020
when the throttle grip (tiller handle model)
is turned from the fully closed position to
the fully open position a.
Check that the throttle operates smoothly
2
when the remote control lever (remote
NOTE:
9 To increase the friction, turn the friction
adjusting nut in direction a.
control model) is shifted from forward or
reverse to the fully open positions a.
3
9 To decrease the friction, turn the friction
adjusting nut in direction b.
4
a
2. Check that the steering operates smooth-

ly.
R
N
F 61U10030
5
N
61U10070
F R
a
6
a
6F610120
7
6S310030
8
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
9
61U5H11 1-14

GEN
Checking the PTT system 3. Check that the choke solenoid operates
(ET) when the engine start switch is pushed
1. Check that the outboard motor tilts up in. (E, ET)
and down smoothly when operating the
PTT unit.
2. Check that there is no abnormal noise

produced when the outboard motor is tilt-
ed up or down.
3. Check that there is no interference with

wires or hoses when the tilted up out- 6S310110
board motor is steered.
4. Check that the engine turns off when the
4. Check that the trim meter points down engine stop lanyard switch is pushed or
when the outboard motor is tilted all the the engine stop lanyard is pulled from the
way down. engine stop lanyard switch.
Checking the engine start switch,

engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
(E, ET, WH)
2. Check that the engine turns off when the

engine start switch is turned to OFF. (E, 69D10210
ET, WH)
WH
ON
OFF START
69D10215
69D10200
1-15 61U5H11

Predelivery check
Checking the cooling water pilot hole Break-in

1. Start the engine, then check that the During the test run, perform the break-in
cooling water is discharged from the operation in the following 5 stages.
1
cooling water pilot hole. 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
speed occasionally. On an easy-planing
boat, accelerate at full throttle onto plane,
then immediately reduce the throttle to
3,000 r/min or less.
2
3
6G410070
3. 1 hour c at 3/4 throttle (approximately
Test run 4,000 r/min). Vary engine speed occa-
1. Start the engine, and then check that the sionally. Run at full throttle for 1 minute,
gear shift operates smoothly. then allow about 10 minutes of operation
at 3/4 throttle or less to let the engine
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.

cool.
4. 8 hours d at any speed, but avoid oper-

ating at full throttle for more than 5 min-
4
utes at a time. Let the engine cool
4. Run the outboard motor for 1 hour at
3,000 r/min or at half throttle, then for
another hour at 4,000 r/min or at 3/4
throttle.
between full-throttle runs. Vary engine
speed occasionally.
5. After the first 10 hours. Use standard pre-

5
mix ratio of fuel and oil. Refer to page 1-
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
12.
6
7
NOTE:
The test run is part of the break-in operation.
0 1 2 10
8
6F610180
å Hours
9
61U5H11 1-16

GEN
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.
6S310070
cC
Be sure to supply sufficient water when
flushing the cooling water passage, other-
wise the engine may overheat.
1-17 61U5H11

SPEC
Specification
General specification .....................................................................................2-1
Maintenance specification ............................................................................2-5

Power unit (E115A models) .......................................................................2-5
1
Lower unit (E115A models)........................................................................2-7
2
Electrical (E115A models)..........................................................................2-7
Power unit (115B, 140B models) .............................................................2-10
Lower unit (115B, 140B models) .............................................................2-12
Electrical (115B, 140B models) ...............................................................2-12
Dimension ................................................................................................2-15
Tightening torque.........................................................................................2-19
Specified torque.......................................................................................2-19
General torque.........................................................................................2-21
3
4
5
6
7
8
9
61U5H11

SPEC
Specification
General specification
Model
Item Unit
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 (61.5)
Boat transom height
(L) mm (in) 508 (20.0)
(Y) mm (in) 572 (22.5) —
(X) mm (in) 635 (25.0)
Weight
(with aluminum propeller)
(L) kg (lb) 151 (333) 154 (340) 147 (324) 154 (340)
(Y) kg (lb) 153 (337) 156 (344) — —
(X) kg (lb) 155 (342) 158 (348) 151 (333) 158 (348)
(with stainless propeller)
(L) kg (lb) 153 (337) 156 (344) 149 (328) 156 (344)
(Y) kg (lb) 153 (337) 156 (344) — —
(X) kg (lb) 157 (346) 160 (353) 153 (337) 160 (353)
Performance
Maximum output kW (hp) 84.6 (115) at 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L 47 (12.4, 10.3) 5,500 r/min
(US gal,
lmp gal)/hr
Engine idle speed r/min 700–800
Power unit
Engine type 2-stroke, V
Cylinder quantity 4
Total displacement cm3 (cu. in) 1,730 (105.56)
Bore x stroke mm (in) 90.0 × 68.0 (3.54 × 2.68)
Compression ratio 5.70 :1
Intake system Reed valve
Scavenging system Loop charge
Control system Tiller handle Remote control
Starting system Manual Manual and Electric
electric
Fuel system Carburetor
Ignition control system CDI
Maximum generator output V, A 12, 10
Starting enrichment Manual injection Choke valve
Spark plug (NGK) B8HS-10
— BR8HS-10
2-1 61U5H11

Model
Item Unit
Cooling system Water
Exhaust system
Lubrication system
Fuel and oil
Fuel type
Propeller boss
Pre-mixed fuel and oil
Regular unleaded gasoline

1
Engine oil 2-stroke outboard motor oil
Engine oil grade
Gear oil type
Gear oil grade (*1) API
SAE
NMMA-certified TC-W3
Hypoid gear oil
GL-4
90
2
Gear oil quantity cm3 (US oz, 760 (25.70, 26.81)
Bracket unit
Trim angle
lmp oz)
Degree -4.0 to 16.0

3
(at 12° boat transom)
Tilt-up angle Degree 66.0 70.0
Steering angle
Drive unit
Gear shift positions
Degree 35 + 35
F-N-R
4
Gear ratio 2.00 (26/13)
5
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller ID mark K
Electrical
Battery minimum capacity (*2)
CCA/EN
20HR/IEC
A
Ah
—
—
430
70
6
(*1) Meeting both API and SAE requirements
(*2) CCA: Cold Cranking Ampere
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
7
8
9
61U5H11 2-2

SPEC
Specification
Model
Item Unit
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 (lb) 146 (322) 154 (340)
(X) kg (lb) 158 (348)
(with stainless propeller)
(L) kg (lb) 148 (326) 156 (344)
(X) kg (lb) 160 (353)
Performance
Maximum output kW (hp) 84.6 (115) at 5,000 r/min 103 (140)
at 5,000 r/min
Full throttle operating range r/min 4,500–5,500
Maximum fuel consumption L 49 (12.9, 10.8) 5,500 r/min 56 (14.8, 12.3)
(US gal, 5,500 r/min
lmp gal)/hr
Engine idle speed r/min 700–800
Power unit
Engine type 2-stroke, V
Cylinder quantity 4
Total displacement cm3 (cu. in) 1,730 (105.56)
Bore x stroke mm (in) 90.0 × 68.0 (3.54 × 2.68)
Compression ratio 6.50 :1 6.80 :1
Intake system Reed valve
Scavenging system Loop charge
Control system Remote control
Starting system Electric
Fuel system Carburetor
Ignition control system CDI
Maximum generator output V, A 12, 10
Starting enrichment Choke valve
Spark plug (NGK) B8HS-10 B9HS-10
BR8HS-10 BR9HS-10
2-3 61U5H11

Model
Item Unit
115BE 115BET 140BET
Cooling system Water
Exhaust system
Lubrication system
Fuel and oil
Fuel type
Propeller boss
Pre-mixed fuel and oil
Regular unleaded gasoline

1
Engine oil 2-stroke outboard motor oil
Engine oil grade
Gear oil type
Gear oil grade (*1) API
SAE
NMMA-certified TC-W3
Hypoid gear oil
GL-4
90
2
Gear oil quantity cm3 (US oz, 760 (25.70, 26.81)
Bracket unit
Trim angle
lmp oz)
Degree -4.0 to 16.0

3
(at 12° boat transom)
Tilt-up angle Degree 66.0 70.0
Steering angle
Drive unit
Gear shift positions
Degree 35 + 35
F-N-R
4
Gear ratio 2.00 (26/13)
5
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller ID mark K
Electrical
Battery minimum capacity (*2)
CCA/EN
20HR/IEC
A
Ah
430
70
6
(*1) Meeting both API and SAE requirements
(*2) CCA: Cold Cranking Ampere
EN: European Norm (European standard)
IEC: International Electrotechnical Commission
7
8
9
61U5H11 2-4

SPEC
Specification
Maintenance specification
Power unit (E115A models)
Model
Item Unit
Power unit
Minimum compression
kPa — 450 (4.5, 64)
pressure (*1) at electric starter
(kgf/cm2, psi)
at manual starter 400 (4.0, 57) —
Cylinder head
Warpage limit mm (in) 0.10 (0.0039)
(lines indicate straightedge

position)
Cylinder
Bore size mm (in) 90.000–90.020 (3.5433–3.5441)
Piston
Piston diameter (D) mm (in) 89.920–89.935 (3.5402–3.5407)
Measuring point (H) mm (in) 10.0 (0.39)
Piston clearance mm (in) 0.080–0.085 (0.0032–0.0033)
Piston pin boss bore mm (in) 21.504–21.515 (0.8466–0.8470)
Oversize piston
1st mm (in) 0.25 (0.010)
2nd mm (in) 0.50 (0.020)
Oversize piston diameter
1st mm (in) 90.170–90.185 (3.5500–3.5506)
2nd mm (in) 90.420–90.435 (3.5598–3.5604)
Piston pin
Piston pin diameter mm (in) 21.495–21.500 (0.8463–0.8465)
(*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.
2-5 61U5H11

Model
Item Unit
Piston ring
Top ring
Dimension B
Dimension T
End gap
mm
mm
mm
(in)
(in)
(in)
1.970–1.990 (0.0776–0.0783)
2.700–2.900 (0.1063–0.1142)
0.30–0.40 (0.0118–0.0157)
1
Side clearance mm (in) 0.02–0.06 (0.0008–0.0024)
Oversize outside diameter
1st
2nd
mm (in)
mm (in)
90.25 (3.5531)
90.50 (3.5630)
2
2nd piston ring
3
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)
1st
2nd
Connecting rod
Small-end inside diameter
mm (in)
mm (in)
mm (in)
90.25 (3.5531)
90.50 (3.5630)
26.500–26.512 (1.0433–1.0438)
4
Connecting rod big-end mm (in) 0.120–0.260 (0.0047–0.0102)
side clearance
Small-end axial play limit
Crankshaft
mm (in) 2.0 (0.08) 5
Crankshaft journal diameter mm (in) 53.975–53.991 (2.1250–2.1256)
6
Crankpin diameter mm (in) 35.985–36.000 (1.4167–1.4173)
Runout limit mm (in) 0.02 (0.0008)
Thermostat
Opening temperature °C (°F) 48–52 (118.40–125.60)
Fully open temperature °C (°F) 60 (140)
7
Valve open lower limit mm (in) 3.0 (0.12)
Reed valve
Valve stopper height mm (in) 6.2–6.8 (0.24–0.26)
Valve bending limit mm (in) 0.2 (0.0079)
Carburetor
ID mark
Main jet (M.J.)
Main nozzle (M.N.)
Main air jet
#
mm (in)
#
61UM2
174
61U03
3.6 (0.14)
270
61U03/61U10
8
Pilot jet (P.J.) # 78
Pilot air jet (P.A.J.)
Pilot screw (P.S.)
Valve seat size
Float height
#
turns out
mm (in)
mm (in)
60
1–1 1/2
1.2 (0.05)
16 (0.63)
9
61U5H11 2-6

SPEC
Specification
Lower unit (E115A models)

Model
Item Unit
Gear backlash
Pinion-to-forward mm (in) 0.32–0.50 (0.0126–0.0197)
Pinion-to-reverse mm (in) 0.80–1.17 (0.0315–0.0461)
Pinion gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Electrical (E115A models)

Model
Item Unit
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 resistance
Primary coil (B/W–B) Ω 0.18–0.24
at 20°C (68°F)
Secondary coil
(B/W–spark plug wire) kΩ 3.26–4.88
at 20°C (68°F)
CDI unit output peak voltage
(B/W–B)
at Cranking (loaded) V 120
at 1,500 r/min (loaded) V 150
Pulser coil output peak voltage
(W/R–W/Y, W/B–W/G)
at Cranking (unloaded) V 4.8
at Cranking (loaded) V 3.8
at 1,500 r/min (loaded) V 8.8
Pulser coil resistance Ω 256–384
at 20°C (68°F)
Thermoswitch
ON temperature °C (°F) 84.0–90.0 (183–194)
OFF temperature °C (°F) 60.0–74.0 (140–165)
2-7 61U5H11

Model
Item Unit
Charge coil output peak
voltage
(B/R–L: High-speed)
at Cranking (unloaded)
at Cranking (loaded)
V
V
45
45
1
at 3,500 r/min (loaded)
(R–Br: Low-speed)
V
V
V
160
130
140
2
Charge coil resistance
at 20°C (68°F)
(B/R–L)
V
Ω
160
48–72
3
(R–Br) Ω 428–642
Starter motor
Type
Output kW
—
—
Bendix
1.10
4
Brushes
5
Standard length mm (in) — 17.0 (0.67)
Wear limit mm (in) — 10.0 (0.39)
Commutator
Standard diameter mm (in) — 33.0 (1.30)
Standard undercut
Wear limit
Choke solenoid resistance
Charging system
mm (in)
mm (in)
Ω
—
—
—
0.8 (0.03)
0.2 (0.01)
3.4–4.0 6
Fuse A — 20
Lighting coil output peak
voltage (G–G/W)
at 1,500 r/min (unloaded)
V
V
8.0
31.0
7
at 3,500 r/min (unloaded) V 72.0
Lighting coil resistance
at 20°C (68°F) (G–G/W)
Rectifier Regulator
output peak voltage (battery)
Ω 0.36–0.54
8
9
61U5H11 2-8

SPEC
Specification
Model
Item Unit
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)
Commutator
Standard undercut mm (in) — 1.35
(0.053)
Wear limit mm (in) — 0.85
(0.033)
Hydraulic pressure (down) MPa (kgf/cm2) — 6–9
(60–90)
Hydraulic pressure (up) MPa (kgf/cm2) — 10–12
(100–120)
2-9 61U5H11

Power unit (115B, 140B models)
Model
Item Unit
115BE 115BET 140BET
Power unit
Minimum compression
pressure (*1)
Cylinder head
kPa
(kgf/cm2, psi)
450 (4.5, 64)
1
Warpage limit mm (in) 0.10 (0.0039)
2
(lines indicate straightedge
position)
Cylinder
Bore size mm (in) 90.000–90.020 (3.5433–3.5441) 3
Piston
Piston diameter (D)
Measuring point (H)
Piston clearance
Piston pin boss bore
mm
mm
mm
mm
(in)
(in)
(in)
(in)
89.920–89.935 (3.5402–3.5407)
10.0 (0.39)
0.080–0.085 (0.0032–0.0033)
23.074–23.085 (0.9084–0.9089)
4
Oversize piston
1st
2nd
Oversize piston diameter
1st
mm (in)
mm (in)
mm (in)
0.25 (0.010)
0.50 (0.020)
90.170–90.185 (3.5500–3.5506)
5
2nd mm (in) 90.420–90.435 (3.5598–3.5604)
Piston pin
Piston pin diameter
(*1) Measuring conditions:
mm (in) 23.065–23.070 (0.9081–0.9083) 6
Ambient temperature 20°C (68°F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
7
8
9
61U5H11 2-10

SPEC
Specification
Model
Item Unit
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)
1st mm (in) 90.25 (3.5531)
2nd mm (in) 90.50 (3.5630)
2nd piston 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)
1st mm (in) 90.25 (3.5531)
2nd mm (in) 90.50 (3.5630)
Connecting rod
Small-end inside diameter mm (in) 28.070–28.082 (1.1051–1.1056)
Connecting rod big-end mm (in) 0.120–0.260 (0.0047–0.0102)
side clearance
Small-end axial play limit mm (in) 2.0 (0.08)
Crankshaft
Crankshaft journal diameter mm (in) 53.975–53.991 (2.1250–2.1256)
Crankpin diameter mm (in) 35.985–36.000 (1.4167–1.4173)
Runout limit mm (in) 0.02 (0.0008)
Thermostat
Opening temperature °C (°F) 48–52 (118.40–125.60)
Fully open temperature °C (°F) 60 (140)
Valve open lower limit mm (in) 3.0 (0.12)
Reed valve
Valve stopper height mm (in) 6.2–6.8 (0.24–0.26)
Valve bending limit mm (in) 0.2 (0.0079)
Carburetor
ID mark 6E517 6L105
Main jet (M.J.) # 176 180
Main nozzle (M.N.) mm (in) 3.6 (0.14)
Main air jet # 270 240
Pilot jet (P.J.) # 78 82
Pilot air jet (P.A.J.) # 60
Pilot screw (P.S.) turns out 3/8–7/8 5/8–1 1/8
Valve seat size mm (in) 1.2 (0.05)
Float height mm (in) 16 (0.63)
2-11 61U5H11

Lower unit (115B, 140B models)

Model
Item Unit
115BE 115BET 140BET
Gear backlash
Pinion-to-forward
Pinion-to-reverse
Pinion gear shims
mm (in)
mm (in)
mm
0.32–0.50 (0.0126–0.0197)
0.80–1.17 (0.0315–0.0461)
0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
1
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Reverse gear shims
Electrical (115B, 140B models)

mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
2
Model
Item
Ignition and ignition control
system
Unit
115BE 115BET 140BET
3
Ignition timing (full retarded) Degree ATDC 4–6
Ignition timing (full advanced)
Spark plug gap
Ignition coil resistance
Primary coil (B/W–B)
Degree
mm (in)
Ω
BTDC 24–26 BTDC 21–23
0.9–1.0 (0.035–0.039)
0.18–0.24
4
at 20°C (68°F)
Secondary coil
(B/W–spark plug wire)
at 20°C (68°F)
CDI unit output peak voltage
kΩ 3.26–4.88
5
(B/W–B)
Pulser coil output peak voltage
V
V
V
120
150
150
6
V
V
V
4.8
3.8
8.8
7
8
Pulser coil resistance Ω 256–384
at 20°C (68°F)
Thermoswitch
ON temperature °C (°F) 84.0–90.0 (183–194)
OFF temperature °C (°F) 60.0–74.0 (140–165)
9
61U5H11 2-12

SPEC
Specification
Model
Item Unit
115BE 115BET 140BET
Charge coil output peak
voltage
(B/R–L: High-speed)
at Cranking (unloaded) V 45
(R–Br: Low-speed)
at Cranking (unloaded) V 130
Charge coil resistance
at 20°C (68°F)
(B/R–L) Ω 48–72
(R–Br) Ω 428–642
Starter motor
Type Bendix
Output kW 1.10
Brushes
Standard length mm (in) 17.0 (0.67)
Wear limit mm (in) 10.0 (0.39)
Commutator
Standard diameter mm (in) 33.0 (1.30)
Standard undercut mm (in) 0.8 (0.03)
Choke solenoid resistance Ω 3.4–4.0
Charging system
Fuse A 20
Lighting coil output peak
voltage (G–G/W)
at Cranking (unloaded) V 8.0
Lighting coil resistance Ω 0.36–0.54
at 20°C (68°F) (G–G/W)
Rectifier Regulator
output peak voltage (battery)
2-13 61U5H11

Model
Item Unit
115BE 115BET 140BET
PTT system
Trim sensor resistance
at 20°C (68°F) (P–B)
Fluid type
Motor type
Ω —
—
—
239–379
ATF Dexron 2
64E00
1
Output kW — 0.40
Brushes
Standard length
Wear limit
Commutator
mm (in)
mm (in)
—
—
9.8 (0.39)
4.8 (0.19)
2
Wear limit
Standard undercut
Wear limit
Hydraulic pressure (down)
mm (in)
mm (in)
mm (in)
MPa (kgf/cm2)
—
—
—
—
21.0 (0.83)
1.35 (0.053)
0.85 (0.033)
6–9 (60–90)
3
Hydraulic pressure (up) MPa (kgf/cm2) — 10–12 (100–120)
4
5
6
7
8
9
61U5H11 2-14

SPEC
Specification
Dimension
Exterior
E115A
325 (12.8)
mm (in)
539 (21.2)
424 (16.7)
210 (8.3)
35
705 (27.8)
300 (11.8)
845 (33.3)
L: 1,005 (39.6)
Y: 1,055 (41.5)
570 (22.4) X: 1,120 (44.1)
270 (10.6)
64 (2.5)
780 (30.7)
695 (27.4)
631 (24.8)
150 (5.9)
45 (1.8)
Y: 568 (22.4)
X: 642 (25.3)
L: 515 (20.3)
155 (6.1)
X: 1,056 (41.6)
Y: 982 (38.7)
L: 929 (36.6)
Y: 765 (30.1)
X: 810 (31.9)
L: 735 (28.9)
190 (7.5)
66
12
MH, WH
616 (24.3)
61U2001M
2-15 61U5H11

E115A, 115B, 140B
mm (in)
1
539 (21.2)
422 (16.6)
35
2
3
297 (11.7)
482 (19.0)
214 (8.4)
L: 1,005 (39.6)
X: 1,120 (44.1)
4
64 (2.5)
5
730 (28.7)
6
150 (5.9)
508 (20.0)
7
45 (1.8)
53 (2.1)
190 (7.5) X: 642 (25.3)
L: 515 (20.3)
X: 1,056 (41.6)
L: 929 (36.6)
X: 810 (31.9)
L: 735 (28.9)
8
70 6 *
**
6
L: 80
(3
X: 85 .1)*
(3.5)
12
4 9
*E 616 (24.3)
** ET
6IU2002M
61U5H11 2-16

SPEC
Specification
Clamp bracket
mm (in)
182 (7.2) 182 (7.2)

163.5 (6.4) 163.5 (6.4)
50.8 (2.0)
62 (2.4)
254 (10.0)
18.5 (0.7)
13 (0.5)
350 (13.8)
(2.2)
55.5
13 (0.5)
125.4 (4.9) 125.4 (4.9)
6IU2003M
2-17 61U5H11

mm (in)
1
180 (7.1) 180 (7.1)
2
163.5 (6.4) 163.5 (6.4)
3
50.8 (2.0)
254 (10.0) 82 (3.2)

4
5
13 (0.5)
18.5 (0.7)
367 (14.5)
13 (0.5)
6
(2.2)
55.5
7
52 (2.0)
101.5 (4.0) 101.5 (4.0) 6G42003M
125.4 (4.9) 125.4 (4.9) 8

9
61U5H11 2-18

SPEC
Specification
Tightening torque
Specified torque
Tightening torques
Part to be tightened Thread size
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 (float chamber) — 10 1.0 7.4
Fuel pump screw — 3.5 0.35 2.6
Power unit
Power unit bolt M8 25 2.5 18.4
Apron bolt M6 8 0.8 5.9
Flywheel magnet nut — 186 18.6 137
Hour meter screw — 3 0.3 2.2
Relay terminal nut — 4 0.4 3.0
Starter motor mount bolt M8 29 2.9 21.4
Starter motor positive terminal nut — 9 0.9 6.6
1st 4 0.4 3.0
Intake manifold bolt M6
2nd 8 0.8 5.9
1st 4 0.4 3.0
Thermostat cover bolt M6
2nd 8 0.8 5.9
1st 4 0.4 3.0
Cover bolt M6
2nd 8 0.8 5.9
1st 4 0.4 3.0
PCV cover bolt M6
2nd 8 0.8 5.9
1st 4 0.4 3.0
Exhaust cover bolt M6
2nd 8 0.8 5.9
1st 4 0.4 3.0
Cylinder head cover bolt M6
2nd 8 0.8 5.9
1st 15 1.5 11.1
Cylinder head bolt M8
2nd 30 3.0 22.1
Spark plug M14 25 2.5 18.4
1st 20 2.0 14.8
M10
2nd 37 3.7 27.3
Crankcase bolt
1st 10 1.0 7.4
M8
2nd 18 1.8 13.3
1st 19 1.9 14.0
2nd 36 3.6 26.6
Connecting rod bolt 3rd M8 Loosen completely
4th 19 1.9 14.0
5th 36 3.6 26.6
Sensor plug — 23 2.3 17.0
Bearing housing bolt M6 12 1.2 8.9
2-
2-19 61U5H11

Tightening torque
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Lower unit
Check screw
Drain screw
Lower case mount bolt
Lower case mount nut (E115A: Y-transom)
—
—
M10
—
9
9
39
39
0.9
0.9
3.9
3.9
6.6
6.6
28.8
28.8
1
Trim tab bolt M10 39 3.9 28.8
Water pump housing bolt
Ring nut
Pinion nut
M8
—
—
18
103
93
1.8
10.3
9.3
13.3
76.0
68.6
2
Propeller nut — 54 5.4 39.8
3
Cooling water inlet cover screw — 4 0.4 3.0
Bracket unit
Lock nut — 11 1.1 8.1
Tiller handle mount nut (MH, WH) — 37 3.7 27.3
Tiller handle bracket nut (MH, WH) — 37 3.7 27.3
Engine stop lanyard switch nut
Engine start switch nut (WH)
Shift position bolt
—
—
—
3
4
24
0.3
0.4
2.4
2.2
3.0
17.7
4
Upper mount nut — 51 5.1 37.6
5
Lower mount nut — 71 7.1 52.4
Exhaust guide bolt M8 18 1.8 13.3
Exhaust manifold bolt M8 18 1.8 13.3
Muffler bolt M8 18 1.8 13.3
Upper case mount bolt M8 21 2.1 15.5
Self-locking nut
Trim stopper nut
Trim sensor cam screw
1.5
—
—
15
36
—
1.5
3.6
2
11.1
26.6
0.2
6
PTT unit
PTT motor mount bolt
Reservoir tank mount bolt
Reservoir cap
M6
M6
—
5
7
5 0.5
0.5
0.7
3.7
3.7
5.2
7
Manual valve — 3 0.3 2.2
Gear pump cover bolt
Gear pump housing bolt
Tilt cylinder end screw
Tilt piston nut
M5
M6
—
—
6
8
127
96
0.6
0.8
12.7
9.6
4.4
5.9
93.7
70.8
8
Trim cylinder end screw — 132 13.2 97.4
Erectrical
Starter motor bracket bolt M8 30 3.0 21.1 9
61U5H11 2-20

SPEC
Specification
General torque General torque
This chart specifies tightening torques for Nut (A) Bolt (B) specifications
standard fasteners with a standard ISO N·m kgf·m ft·lb
thread pitch. Tightening torque specification 8 mm M5 5 0.5 3.6
for special components or assemblies are 10 mm M6 8 0.8 5.8
provided in applicable sections of this manu- 12 mm M8 18 1.8 13
al. 14 mm M10 36 3.6 26
To avoid warpage, tighten multi-fastener 17 mm M12 43 4.3 31
assemblies in a crisscross fashion and pro-
gressive stages until the specified torque is
reached. Unless otherwise specified, torque
specification require clean, dry threads.
Components should be at room temperature.
2-21 61U5H11

CHK
ADJ
Periodic check and adjustment
Maintenance interval chart .......................................................................... 3-1
Top cowling .................................................................................................. 3-2

Checking the top cowling ......................................................................... 3-2
1
Fuel system .................................................................................................. 3-2
Checking the fuel joint and fuel hose (fuel joint-to-carburetor) ............... 3-2
Checking the fuel filter .............................................................................. 3-2
2
Power unit ..................................................................................................... 3-3
Checking the spark plug .......................................................................... 3-3
Checking the thermostat ......................................................................... 3-3
Checking the cooling water passage.........................................................3-4
3
Control system ............................................................................................. 3-4
Adjusting the start-in-gear protection (MH, WH) ..................................... 3-4
Checking the control link and throttle link position .................................. 3-5
Synchronizing the carburetor ................................................................... 3-5
4
Checking the engine idle speed .............................................................. 3-6
Adjusting the throttle cable ...................................................................... 3-6
Checking the gear shift operation ............................................................ 3-7
Checking the ignition timing .................................................................... 3-8
Checking the choke solenoid (E, ET) ....................................................... 3-9
5
Bracket ........................................................................................................ 3-10
Checking the PTT operation (ET)........................................................... 3-10
Checking the PTT fluid level (ET)............................................................3-10
6
Checking the tilt operation (MH, WH, E)..................................................3-11
Lower unit ...................................................................................................

Checking the gear oil level ....................................................................
Changing the gear oil ............................................................................
3-11
3-11
3-12
7
Checking the lower unit for air leakage ................................................. 3-13
Checking the propeller ...........................................................................
General ........................................................................................................
3-13
3-13
8
Checking the anode ............................................................................... 3-13
9
Checking the battery (WH, E, ET).......................................................... 3-14
Lubricating the outboard motor ............................................................. 3-14
61U5H11

CHK
ADJ Periodic check and adjustment
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.
Initial Every Refer
Item Actions 10 hours 50 hours 100 hours 200 hours to
(Break-in) (3 months) (6 months) (1 year) page
Anode (s) (external) Check / replace 1 1 3-13
Anode (s) (internal) Check / replace 1 3-13
Battery Check / charge 1 3-14
Cooling water passages Clean 1 1 3-4
Cowling clamp Check 1 3-2
Fuel filter (can be dis-
Check / clean 1 1 1 3-2
assembled)
Fuel system Check 1 1 1 3-2
Fuel tank (Yamaha por-
Check / clean 1 —
table tank)
Gear oil Change 1 1 3-12
Lubrication points Lubricate 1 3-14
Idle speed (carbure-
Check / adjust 1 1 3-6
tor model)
PCV Check 1 5-26
PTT unit Check / replace 1 1 3-10
Propeller and cotter pin Check / replace 1 1 3-13
Shift link / shift cable Check / adjust 1 3-7
Thermostat Check 1 3-3
Throttle link / throttle
3-5
cable / throttle pick-up Check / adjust 1
3-6
timing
Water pump Check 1 6-5
Spark plugs Clean / adjust / replace 1 1 1 3-3
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed with clean water
after each use.
3-1 61U5H11

Maintenance interval chart/Top cowling/Fuel system
Top cowling Fuel system

Checking the top cowling Checking the fuel joint and fuel
1. Check the fitting by pushing the cowling hose (fuel joint-to-carburetor)
with both hands. Adjust the fittings if nec-
essary.
1. Check the fuel hose connections and fuel
joint for leaks. Replace them if necessary.
Also, check the fuel filter 1, fuel pump
2, and carburetors 3 for leaks or deteri-
1
oration. Replace if necessary.
3
2
2. Loosen the bolts 1.
6G430010
1
3
3. Move the hook 2 up or down slightly to
adjust its position.
a
2
61U30200
4
2
1
Checking the fuel filter
1. Check the fuel filter element 1 for dirt
and residue and check the fuel filter cup
5
2 for foreign substances and cracks.
6
b Clean the cup with straight gasoline and
6G430020 replace the element if necessary.
NOTE:
9 To loosen the fitting, move the hook 2 in
direction a.
9 To tighten the fitting, move the hook 2 in
direction b.
1
2
7
4. Tighten the bolts 1.
5. Check the fitting again, and if necessary

repeat steps 2–4.
6G430045
8
NOTE:
9
Be sure not to spill any fuel when removing
the fuel filter cup.
61U5H11 3-2

CHK
Power unit 5. Install the spark plug temporary tight,

Checking the spark plug then to the specified torque with a spark
1. Disconnect the spark plug caps, and then plug wrench.
remove the spark plugs.
Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
2. Clean the electrodes 1 with a spark plug
cleaner or wire brush. Replace the spark Checking the thermostat
plug if necessary. 1. Remove the thermostat covers 1, gas-
kets 2, and thermostats 3.
1
2
3 1
6B430025
3. Check the electrodes for erosion and 61U30210
excessive carbon or other deposits, and

the gasket for damage. Replace the 2. Suspend the thermostats 3 in a con-
spark plug if necessary. tainer with water.
4. Check the spark plug gap a. Adjust if out 3. Place a thermometer in the water and
of specification. slowly heat the water.
a
6B430030
6B430060
Specified spark plug: 4. Check the thermostat valve opening at

E115AMH, E115AWH the specified water temperatures.
B8HS-10 (NGK) Replace if out of specification.
E115AE, E115AET
B8HS-10, BR8HS-10 (NGK)
115B
140B
Spark plug gap a:
0.9–1.0 mm (0.035–0.039 in)
6B430070
3-3 61U5H11

Power unit/Control system
3. Check for water flow at the cooling water

Water
Valve lift a pilot hole. If there is no water flow, check
temperature
the cooling water passage inside of the
48–52°C 0.05 mm (0.002 in)
1
outboard motor.
(118.4–125.6°F) (valve begins to tilt)
above more than
60°C (140°F) 3.0 mm (0.12 in)
5. Install the new gaskets, thermostats and

thermostat covers, and then tighten the
cover bolts to specified torques. 2
Thermostat cover bolt:
3
6G430070
1st : 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd : 8 N·m (0.8 kgf·m, 5.9 ft·lb)
Control system
Checking the cooling water passage Adjusting the start-in-gear protec-
tion (MH, WH)
4
1. Check the cooling water inlet cover 1,
screw 2 and cooling water inlet for clog- 1. Set the gear shift to the neutral position.
ging. Clean the water inlet cover and
cooling water inlet if necessary. 2. Loosen the bolt 1, and then adjust the
start-in-gear protection cable 2 until the
2
5
mark a, aligns with the mark b as
1 shown.
a
1
2 1
6G430055
b
6
2. Place the lower unit in water, and then
start the engine.
3. Tighten the bolt 1.
69D30070
7
8
9
61U5H11 3-4

CHK
Checking the control link and throt- NOTE:

tle link position Make a note that how many times you turn
1. Remove the throttle cable. out the throttle stop screw.
2. Measure the length of control link rod 1. 3. Loosen the throttle lever tightening
screws 3 and 4 clockwise.
a 3
61U30060
3. Measure the length of throttle link rod 2.
4
61U30030
NOTE:
b b
The screws 3 and 4 are left hand thread.
2 4. Make sure that the throttle valves are fully

closed position.
61U30070
5. Tighten the throttle lever tightening screw
4. Adjust the length of the link rod if out of 3 counterclockwise on the upper carbu-
specification. retor.
Length (reference): 6. Turn the throttle stop screw 1 until it con-

a : 60 mm (2.36 in) tacts the stopper. From this position,
b : 53 mm (2.09 in) tighten it another 1 1/8 turns further.
Synchronizing the carburetor 7. Make sure that the mark 5 on the accel-
1. Remove the throttle cable and intake erator cam align with the center of the
silencer cover. roller 6 on the lower carburetor.
2. Loosen the throttle stop screw 1 on the

lower carburetor to make a clearance 6
until the screw tip does not touch the
stopper 2.
5
1
2
4
61U30310
61U30020
3-5 61U5H11

Control system
8. Tighten the throttle lever tightening screw 3. Turn the throttle stop screw 3 in direc-
4 counterclockwise on the lower carbu- tion a or b until the specified engine idle
retor. speed is obtained.
NOTE:
The screw 4 is left hand thread.
9. Make sure the throttle valves are open 3

1
and close simultaneously. b a
10. Install the throttle cable and intake

silencer.
61U30220
2
NOTE:
3
After synchronizing the carburetor, start the
NOTE:
engine and check the engine idle speed to
9 To increase the idle speed, turn the throttle
adjust the throttle stop screw.
stop screw in direction a.
9 To decrease the idle speed, turn the throttle
stop screw in direction b.
Checking the engine idle speed
NOTE:
Before checking the engine idle speed, the
4. If the specified engine idle speed cannot
be obtained, adjust the pilot screws.
4
pilot screws should be properly adjusted.
NOTE:
1. Attach the special service tool 1 to the
spark plug wire #1 2.
When adjust the pilot screws, adjust it in the
all of cylinders.
Adjusting the throttle cable

5
Digital tachometer 1: 90890-06760
6
NOTE:
Before adjusting the throttle cable, the throt-
2. Start the engine and warm it up for 5 min- tle stop screw should be properly adjusted.
utes, and then check the engine idle
speed. Adjust if out of specification. 1. Loosen the locknut 1, remove the nut 2
2
1
and then remove the throttle cable joint
3.
7
3
8
61U30040
Engine idle speed:

700–800 r/min
2 1 61U30080
9
NOTE:
Verify the stability of the engine idle speed.
61U5H11 3-6

CHK
2. Set the throttle grip or remote control 4. Connect the cable joint 3, install the nut
lever to the fully closed position. 2, and then tighten the lock nut 1.
N 2
61U30095
3 61U30085
3. Adjust the position of the throttle cable 5. Check the throttle grip or remote control
joint 3 until its hole aligned with the set lever fully closed position and adjust the
pin 4 on control lever. throttle cable length, if necessary, repeat
the steps 1–4.
Checking the gear shift operation

4
1. Check that the gear shift operates
smoothly when shifting it from neutral to
forward or reverse. Adjust the shift cable
if necessary.
2. Set the gear shift to the neutral position.

3 61U30090
3. Loosen the locknut 1, remove the clip

2, and then remove the shift cable joint
3.
2
a 61U30320
w 3
1 61U30105
The throttle cable joint must be screwed in
a minimum of 8.0 mm (0.31 in) a.
NOTE:
Pull the throttle cable arrow direction shown
to remove any free play in the cable before
adjusting the position of the throttle cable
joint.
3-7 61U5H11

Control system
4. Make sure to align the center of the set 6. Install the shift cable joint 3, install the
pin a on the shift lever with the align- clip 2, and then tighten the locknut 1.
ment mark b on the bottom cowling.
1
2
3 1 61U30100
2
7. Check the gear shift for smooth operation
b 61U30230
and adjust the shift cable length, if nec-
essary, repeat the steps 3–6.
8. Check that the neutral switch 5 is push-

3
5. Adjust the position of the shift cable joint ing by the shift lever 6. (WH)
3 until its hole is aligned with the set pin
4.
4
6
5
F
3
5
R N 61U30240
4
61U30106
Checking the ignition timing
1. Start the engine and warm it up for 5 min-
utes.
6
NOTE:
Turn off the engine when warmed it up com-
pletely.
2. Attach the special service tool 1 to spark

7
plug wire #1 2.
w
c 6D430226
2
1
8
The shift cable joint must be screwed in a
minimum of 8.0 mm (0.31 in) c.
9
61U30040
Digital tachometer 1: 90890-06760
61U5H11 3-8

CHK
3. Attach the special service tool 3 to spark 5. Check that the scale c on the flywheel
plug wire #1 2, and then start the magnet is advances to specified position,
engine. Cheek the engine idle speed and when the throttle is fully opened.
ignition timing.
c
2
30 20
3
61U30270
61U30250
Engine speed (throttle fully opened):
Engine idle speed: 5,500 r/min
700–800 r/min
Timing plate position:
Timing light 3: 90890-03141 E115A:
BTDC 22–24°
4. Check that the ATDC 5° scale a on the 115B:
flywheel magnet is aligned with the point- BTDC 24–26°
er b on the timing plate, when the throt- 140B:
tle is fully closed. BTDC 21–23°
a 6. If the ignition timing is out of specification,

refer to “Adjusting the timing plate”
10 TDC
10 P5-52 and “Adjusting the ignition timing
stopper” P5-53.
b
Checking the choke solenoid
(E, ET)
1. Check that the choke solenoid face a is
between the line b on the plunger. Adjust
the position of the choke solenoid to
loosen the bolt 1 if necessary.
61U30260 1

ATDC 4–6° b
a
61U30120
3-9 61U5H11

Control system/Bracket
Bracket Checking the PTT fluid level

Checking the PTT operation (ET)
(ET) 1. Fully tilt the outboard motor up, and then
1. Fully tilt the outboard motor up and down
a few times and check the entire trim and
tilt range for smooth operation. Check the
PTT fluid level if necessary.
support it with the tilt stop lever 1.
1
1
2
3
61U30140
61U30280
w
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
4
NOTE: Otherwise, the outboard motor could sud-
Be sure to listen to the winding sound of the
PTT motor for smooth operation.
denly lower if the PTT unit should lose
fluid pressure.
2. Remove the reservoir cap 2, and then

5
2. Fully tilt the outboard motor up, and then check the fluid level in the reservoir.
support it with the tilt stop lever 1 to
check the lock mechanism of the lever.
6
1
2
7
6G430380
w
Make sure that the trim and tilt rams are
fully extended when removing the reser-
8
voir cap, otherwise fluid can spurt out
61U30140
from the unit due to internal pressure.
NOTE:
9
If the fluid is at the correct level, the fluid
should overflow out of the filler hole when the
reservoir cap 2 is removed.
61U5H11 3-10

CHK
3. If necessary, add sufficient fluid of the 3. Fully tilt the outboard motor up, then sup-
recommended type until it overflows out port it with the tilt stop lever 2 to check
of the filler hole. the lock mechanism of the lever.
Recommended PTT fluid:

ATF Dexron 2
4. Install the new O-ring, reservoir cap 2,

and then tighten it to the specified torque.
2
Reservoir cap 2:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
69D30135
Checking the tilt operation Lower unit

(MH, WH, E) Checking the gear oil level
1. Set the tilt lock lever 1 to tilt position. 1. Fully tilt the outboard motor down.
Check the outboard motor could tilting
up. Fully tilt the outboard motor up and 2. Remove the check screw 1, and then
down a few times and check the entire tilt check the gear oil level in the lower case.
range for smooth operation.
69D10055
NOTE:
1 should overflow out of the filler hole when the
check screw is removed.
61U30290
3. If necessary, add sufficient gear oil of the

2. Fully tilt the outboard motor down and set
recommended type until it overflows out
the tilt lock lever 1 to lock position.
of the check hole.
Check the outboard motor could not tilt-
ing up. Recommended gear oil:
Hypoid gear oil
API: GL-4
SAE: 90
4. Install the new gasket, check screw 1,

and then tighten it to the specified torque.
1 Check screw 1:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
61U30295
3-11 61U5H11

Bracket/Lower unit
Changing the gear oil

1. Tilt the outboard motor so that the gear
oil drain screw at the lowest point possi-
1
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.
2
6G430420
2
1
Recommended gear oil:
Hypoid gear oil
API: GL-4
3
SAE: 90
Gear oil quantity
760 cm3
(25.70 US oz, 26.81 Imp oz)
4
69D30140
5
5. Install the new gaskets, check screw and
quickly install the drain screw, and then
3. Check the oil for metal and discoloration,
tighten them to the specified torque.
and its viscosity. Check the internal parts
of the lower case if necessary. Check and drain screw:
4. 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
9 N·m (0.9 kgf·m, 6.6 ft·lb)
6
no air bubbles are visible.
7
8
69D10050
9
61U5H11 3-12

CHK
Checking the lower unit for air leak- General

age Checking the anode
cC 1. Check the anode and trim tab. Clean if
there are scales, grease, or oil.
Do not over pressurize the lower unit, oth-
erwise the oil seals may be damaged.
1. Remove the check screw 1, and then

install the special service tool.
61U50670
6G430430
Leakage tester: 90890-06840
2. Apply the specified pressure to check 61U30130
that the pressure is maintained in the

lower unit for at least 10 seconds.
NOTE:
Cover the check hole with a rag when remov-
ing the special service tool from the lower
unit.
Lower unit holding pressure:

70 kPa (0.7 kgf/cm2, 10 psi)
cC
3. If the pressure drops below specification, Do not oil, grease, or paint the anodes or
check the drive shaft, propeller shaft oil the trim tab, otherwise they will be ineffec-
seals, shift rod oil seal, and gasket of tive.
drain screw for damage.
NOTE:
Checking the propeller If it is necessary to disassemble the outboard
1. Check the propeller blades for cracks and motor to check an anode, refer to the applic-
splines for damage or wear. Replace if able disassembly procedure in this manual.
necessary.
2. Replace the anodes or trim tab if exces-
sively eroded. Also check the ground lead
together.
3-13 61U5H11

Lower unit/General
Checking the battery (WH, E, ET) NOTE:

1. Check the battery electrolyte level. If the 9 Batteries vary per manufacturer. The proce-
level is at or below the minimum level dures mentioned in this manual may not
1
mark a, add distilled water until the level always apply, therefore, consult the instruc-
is between the maximum and minimum tion manual of the battery.
level marks. 9 Disconnect the negative battery cable first,
then the positive battery cable.
a Electrolyte specific gravity:

1.280 at 20° C (68° F) 2
6F630240
2. Check the specific gravity of the elec-

Lubricating the outboard motor
1. Apply water resistant grease to the areas
shown.
3
trolyte. Fully charge the battery if below
w
specification.
4
Battery electrolyte is dangerous; it con-
tains sulfuric acid which is poisonous and
highly caustic.
9 Avoid bodily contact with electrolyte as
it can cause severe burns or permanent
A
61U30150 5
eye injury.
9 Wear protective eye gear when handling
or working near batteries.
Antidote (EXTERNAL):
9 SKIN – Wash with water.
6
9 EYES – Flush with water for 15 minutes
and get immediate medical attention.
Antidote (INTERNAL):
9 Drink large quantities of water or milk
followed with milk of magnesia, beaten
A
61U30300
7
egg, or vegetable oil. Get immediate
medical attention.
9 Charge batteries in a well-ventilated
area.
9 Keep batteries away from fire, sparks or
8
open flames (e.g., welding equipment,
lighted cigarettes).
9 DO NOT SMOKE when charging or han-
dling batteries.
A
61U30160
9
KEEP BATTERIES AND ELECTROLYTE
OUT OF REACH OF CHILDREN.
61U5H11 3-14

CHK
A
61U30170
A
a
6G430530
6G430500 NOTE:
Apply grease to the grease nipple until it flows
from the bushings a.
A
2. Apply low temperature resistant grease
to the area shown.
C
6G430510
a
6G430540
3. Apply corrosion resistant grease to the

area shown.
A
D
61U30180
A
6B430300
61U30190
3-15 61U5H11

FUEL
Fuel system
Hose routing ................................................................................................. 4-1

Fuel hose and breather hose .................................................................. 4-1
Fuel line ........................................................................................................ 4-3

1
Carburetor ..................................................................................................... 4-6
Disassembling the carburetor ................................................................ 4-12
Checking the carburetor ........................................................................ 4-12
Assembling the carburetor .................................................................... 4-13
2
Fuel pump ................................................................................................... 4-15
Checking the fuel pump ......................................................................... 4-16
Disassembling the fuel pump ................................................................ 4-16
3
Assembling the fuel pump ..................................................................... 4-17
4
Checking the fuel joint ........................................................................... 4-17
5
6
7
8
9
61U5H11

FUEL
Fuel system
Hose routing
Fuel hose and breather hose
5
1
4 3
61U4001A
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 Fuel hose (fuel pump-to-carburetor)
4-1 61U5H11

Hose routing
MH, WH
PORT STBD
1
2
4
3
1
4
3
7 6
4
8 7
5 8
2
E, ET
5
6
1
6
8
2
9
8
61U4001B
7
1 Breather hose (manifold-to-cylinder body #2)
8
3 Breather
4 Breather
5 Breather
6 Breather
hose
hose
hose
hose
(breather hose-to-manual injection)
(manifold-to-manual injection)
(breather hose-to-manual injection hose)
(manifold-to-cylinder body #1)
9
7 Breather hose (cylinder body #3-to-manual injection hose)
8 Breather hose (manifold-to-intake silencer)
61U5H11 4-2

FUEL
Fuel system
Fuel line
4 N·m (0.4 kgf·m, 3.0 ft·lb)
61U4040E
No. Part name Q’ty Remarks

1 Bolt 2 M6 × 16 mm
2 Fuel filter assembly 1
3 Lock tie 18 Not reusable MH, WH
Lock tie 10 Not reusable 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
11 Bolt 2 M6 × 20 mm MH, WH
12 Manual injection pump 1 MH, WH
13 Bolt 2 M8 × 30 mm
14 Bracket 1 MH, WH
15 Hose 1 MH, WH
16 Bolt 2 M6 × 50 mm
4-3 61U5H11

Fuel line
1
2
3
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5
6
61U4040E

17 Fuel pump assembly 1
7
18 Gasket 1 Not reusable
19 Fuel hose 1
20 Joint 1
21 Fuel hose 1
22 Fuel hose 1
23
24
25
26
Bolt
Start-in-gear protection cable
Bolt
Bolt
1
1
1
1
M6 × 10 mm MH, WH
MH, WH
M6 × 12 mm MH, WH
M5 × 10 mm MH, WH
8
27 Cable 1 MH, WH
28
29
30
Fuel joint
Bolt
Clamp
1
1
1
M8 × 28 mm
9
61U5H11 4-4

FUEL
Fuel system
6G44040E

1 Bolt 1 M6 × 16 mm
2 Washer 1
3 Holder 1
4 Bolt 1 M6 × 14 mm
5 Bracket 1
6 Fuel filter assembly 1
7 O-ring 1 Not reusable
8 Fuel filter element 1
9 Fuel filter cup 1
10 Nut 1
4-5 61U5H11

Fuel line/Carburetor
Carburetor
E, ET
1
2
3
4
5
No. Part name
6 N·m (0.6 kgf·m, 4.4 ft·lb)
Q’ty Remarks
61U4060E
6
1 Bolt 8 M6 × 20 mm
7
2 Cover 1
4 Bolt 8 M6 × 20 mm
5 Intake silencer 1
6 Bolt 2 M6 × 20 mm
7
8
9
10
Breather hose
Gasket
Upper carburetor assembly
Lower carburetor assembly
1
1
1
1
Not reusable
8
11 Link rod 1
12
13
14
15
Nut
Gasket
Rod
Joint
8
2
1
3
Not reusable
9
16 Choke knob 1
61U5H11 4-6

FUEL
Fuel system
E, ET
6 N·m (0.6 kgf·m, 4.4 ft·lb) 61U4060E

18 Bolt 2 M6 × 16 mm
19 Choke solenoid 1
20 Intake silencer 1
21 Grommet 2
4-7 61U5H11

Carburetor
MH, WH
6 N·m (0.6 kgf·m, 4.4 ft·lb)
1
2
2 N·m (0.2 kgf·m, 1.5 ft·lb)
3
10 N·m (1.0 kgf·m, 7.4 ft·lb)
4
5
61U4070E
6
1 Plug 4
7
2 Gasket 4
3 Screw 2
4 Plate 2
6 Main air bleed 4
7
8
9
10
Pilot screw
Spring
Screw
Gasket
4
4
2
2
8
11 Air bleed plug 4
12
13
14
15
Pilot air jet
Carburetor body
Needle valve
Clip
4
2
4
4
9
16 Float pin 4
17 Float 4
61U5H11 4-8

FUEL
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

19 Plug 4
20 Gasket 4
21 Main jet 4
22 Drain plug 4
23 Gasket 4
24 Float chamber 2
25 Plug 4
26 Gasket 4
27 Pilot jet 4
28 Screw 8 ø5 × 16 mm
29 Throttle stop screw 1
30 Spring 1
31 Lower carburetor assembly 1
4-9 61U5H11

Carburetor
E, ET
6 N·m (0.6 kgf·m, 4.4 ft·lb)
1
2
2 N·m (0.2 kgf·m, 1.5 ft·lb)
3
10 N·m (1.0 kgf·m, 7.4 ft·lb) 4
5
61U4065E
6
1 Plug 4
7
2 Gasket 4
3 Screw 2
4 Plate 2
5 Pilot screw 4
6 Spring 4
7
8
9
10
Screw
Gasket
Air bleed plug
Pilot air jet
2
2
4
4
8
11 Carburetor body 2
12
13
14
15
Needle valve
Clip
Float pin
Float
4
4
4
4
9
17 Plug 4
61U5H11 4-10

FUEL
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

18 Gasket 4
19 Main jet 4
20 Float chamber 2
21 Plug 4
22 Gasket 4
23 Pilot jet 4
24 Screw 8 ø5 × 16 mm
25 Throttle stop screw 1
26 Spring 1
27 Lower carburetor assembly 1
4-11 61U5H11

Carburetor
Disassembling the carburetor 4. Check the pilot screw and needle valve
for bends or wear. Replace the pilot
NOTE:
screw and needle valve if necessary.
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
1
should be sorted out and kept in order, so
that they can be re-assembled in their orig-
inal positions.
6B440040
2
Checking the carburetor
1. Check the air and fuel passages and jets,
for dirt and foreign matter. Clean the car-
buretor body with a petroleum based sol-
5. Check the float for deterioration. Replace
the float if necessary.
6. Measure the float height a. Replace the

3
vent if necessary. float and needle valve as a set, if out of
4
2. Blow compressed air into all passages specification.
and jets.
1
5
6
6D440025 6G440080
cC
9 Direct the compressed air downward,
otherwise cleaning solvent may be
7
blown into your eyes or small parts of
the carburetor may be blown off.
9 Do not use steel wire for cleaning the
jets, otherwise the jet diameters may be
enlarged, which may seriously affect
8
6G440090
performance.
NOTE:
When measure the float height, the float
3. Check the main jet, pilot jet, and main should not be compressing.
nozzle for dirt or residue. Clean if neces-
sary.
Digital caliper 1: 90890-06704
9
Float height a (without gasket):
16 mm (0.63 in)
61U5H11 4-12

FUEL
Fuel system
Assembling the carburetor ∫ 7

1. Install the gaskets 1, plugs 2, pilot air
6
jets 3, and air bleed plugs 4, main air
bleed 5 onto the carburetor body.
å 2
2 1
1 6
5
6G440110
3
å MH, WH
∫ E, ET
4
3 61U40100
4. Install the gaskets 0, plugs q, gaskets
∫ 2 w and plugs e onto the float chamber
2 r.
1 1
5. Install the float chamber r onto the car-
buretor body and install the gasket t
3 and screw y onto the carburetor body.
q 0 q
3 4 6G440100 0 e
w
å MH, WH w r
∫ E, ET e
2. Install a new gasket, and then install the t

needle valves, floats and float pins onto y
6G440130
the carburetor body. Check the float for
smooth operation, after install them.
6. Install the pilot screw, and then turn in
3. Install the main jets 6 and pilot jets 7, until it is lightly seated, and then turn out
gaskets 8, drain plugs 9 onto the float by the specified number of turns.
chamber.
å 8 9
7
6
8
9
6
61U40020
4-13 61U5H11

Carburetor
NOTE:
When disassemble the carburetor, be sure to
set the pilot screw by the specified times.
Pilot screw turns out:

E115A : 1–1 1/2
115B : 3/8–7/8
1
140B : 5/8–1 1/8
7. Install the carburetor assembly.

2
3
4
5
6
7
8
9
61U5H11 4-14

FUEL
Fuel system
Fuel pump
3.5 N·m (0.35 kgf·m, 2.6 ft·lb) 6G44030E

1 Base 1
3 Diaphragm 1
4 Body assembly 1
5 Nut 4
6 Screw 4 ø5 × 28 mm
7 Washer 4
8 Check valve 4
9 Body 1
11 Diaphragm 1
12 Collar 2
14 Cover 1
15 Plate 1
16 Spring 1
17 Screw 3 ø5 × 35 mm
4-15 61U5H11

Fuel pump
Checking the fuel pump 6. Apply the specified positive pressure and
1. Place a drain pan under the fuel hose check that there is no air leakage.
connections, and then disconnect the Disassemble the fuel pump if necessary.
1
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 specified positive
pressure. Check that there is no air leak-
age. 6G440030
2
Specified pressure:
50 kPa (0.5 kgf/cm2, 7.3 psi)
Disassembling the fuel pump

3
6G440010
1. Disconnect the inlet and outlet hose from
the fuel pump.
2. Remove the 2 bolts 1 securing the
pumps to the crankcase.
4
Vacuum/pressure pump gauge set:
90890-06756
Specified pressure:
5
50 kPa (0.5 kgf/cm2, 7.3 psi)
4. Apply the specified negative pressure

and check that there is no air leakage.
1
1
61U40030
6
7
3. Remove the 3 screws securing the pump
together. Refer to exploded diagram
P4-15.
NOTE:
Take care not to let the spring fly out or lose
Specified pressure:
6G440020
the plate.
4. Check the diaphragm for tears or deteri-

oration. Replace the diaphragm if neces-
8
30 kPa (0.3 kgf/cm2, 4.4 psi) sary.
5. Connect the special service tool to the

fuel pump outlet.
5. Check the valves for bends or damage.
Replace the valve if necessary. Also,
check the fuel pump body and spring for
damage. Replace the fuel pump body
9
and spring if necessary.
6. Clean the fuel pump body.
61U5H11 4-16

FUEL
Fuel system
Assembling the fuel pump NOTE:

Make sure that the gaskets and diaphragms
NOTE:
are kept in place through the assembly
Clean the parts and soak the valves and the
process.
diaphragms in gasoline before assembly to
obtain prompt operation of the fuel pump
when starting the engine.
Checking the fuel joint
1. Visually check the fuel joint for cracks or
damage.
1. Install the check valves 1 onto the fuel
pump body.
2. Connect the special service tool at the
outlet of fuel joint.
1
3. Apply the specified pressure to check
1 that the positive pressure is maintained
1 1
for 10 seconds. Replace the fuel joint if
necessary.
1
6G440040
2. Install the spring 2 and plate 3.

3
2
6G440070
Vacuum/pressure pump gauge set:

90890-06756
6G440050
Specified pressure:
3. Install the new gaskets 4, diaphragms 50 kPa (0.5 kgf/cm2, 7.3 psi)
5, collars 6, O-rings 7, base 8, cover
9 on to the fuel pump body, and then
tighten the screws 0 to specified torque.
8
4
5
4
5
67
9 0 6G440060
Fuel pump screw 0:

3.5 N·m (0.35 kgf·m, 2.6 ft·lb)
4-17 61U5H11

— MEMO —
1
2
3
4
5
6
7
8
9
61U5H11 4-18

POWR
Power unit
Power unit ..................................................................................................... 5-1

Checking the compression pressure ....................................................... 5-1
Disassembling the manual starter (MH, WH) ........................................ 5-14
Checking the spiral spring (MH, WH) .................................................... 5-15
Checking the drive pawl (MH, WH) ....................................................... 5-15
Checking the starter rope (MH, WH) ..................................................... 5-15
Assembling the manual starter (MH, WH) ............................................. 5-15
Removing the power unit ....................................................................... 5-17
Removing the flywheel magnet ............................................................. 5-19
Removing the electrical component ........................................................5-20
Intake manifold ........................................................................................... 5-22

Removing the intake manifold ............................................................... 5-24
Checking the reed valve ........................................................................ 5-24
Exhaust cover ............................................................................................ 5-25

Removing the exhaust cover ................................................................. 5-26
Checking the exhaust cover .................................................................. 5-26
Checking the PCV ................................................................................. 5-26
Installing the PCV ....................................................................................5-26
Cylinder head ............................................................................................. 5-27

Removing the cylinder head .................................................................. 5-29
Checking the cylinder head ................................................................... 5-29
Crankcase ................................................................................................... 5-31

Removing the crankcase ....................................................................... 5-34
Disassembling the bearing housing.........................................................5-34
Disassembling the oil seal housing ....................................................... 5-35
Removing the piston, connecting rod assembly and crankshaft
assembly .............................................................................................. 5-35
Disassembling the piston and connecting rod assembly ...................... 5-35
Checking the bearing ............................................................................ 5-35
Disassembling the crankshaft ............................................................... 5-36
Checking the piston diameter ................................................................ 5-36
Checking the cylinder bore .................................................................... 5-37
Checking the piston clearance .............................................................. 5-37
61U5H11

Checking the piston ring ........................................................................ 5-37
Checking the piston ring side clearance ............................................... 5-38
Checking the piston pin boss bore ........................................................ 5-38
1
Checking the piston pin ......................................................................... 5-38
Checking the internal anode .................................................................. 5-38
Checking the connecting rod small end axial play ................................ 5-39
Checking the connecting rod big end side clearance ........................... 5-39
Checking the crankshaft ........................................................................ 5-39
Assembling the crankshaft .................................................................... 5-40
Assembling the bearing housing ........................................................... 5-41
Assembling the oil seal housing ............................................................ 5-41
Assembling the piston and connecting rod assembly ........................... 5-42
2
Assembling the power unit .................................................................... 5-42
Installing the power unit ......................................................................... 5-49
Adjusting the timing plate ...................................................................... 5-52
Adjusting the ignition timing stopper ..................................................... 5-53 3
4
5
6
7
8
9
61U5H11

POWR Power unit
Power unit 5. If the compression pressure is below

Checking the compression pressure specification and the compression pres-
1. Start the engine, warm it up for 5 min- sure for each cylinder is unbalanced, add
utes, and then turn it off. a small amount of engine oil to the cylin-
ders, and then check the compression
2. Remove the lock plate from the engine pressure again.
stop lanyard switch on the remote control NOTE:
box or tiller handle. 9 If the compression pressure increases,
check the pistons and piston rings for worn.
3. Remove the all spark plug caps and all Replace if necessary.
spark plugs, and then install the special 9 If the compression pressure does not
service tools into a spark plug hole. increase, check the cylinder head gasket,
and cylinder head. Replace if necessary.
61U50010
cC
Before removing the spark plugs, blow
compressed air in the spark plug well to
clear out any dirt or dust that may fall into
the cylinder.
Compression gauge:
90890-03160
4. Fully open the throttle, and then crank the

engine until the reading on the compres-
sion gauge stabilizes.
NOTE:
9 Do not pull the choke knob when checking
the compression pressure.
9 Disconnect the choke solenoid blue lead
from the wireharness.
Minimum compression pressure

(reference data):
Electric start
450 kPa (4.5 kgf/cm2, 64 psi)
Manual start
400 kPa (4.0 kgf/cm2, 57 psi)
5-1 61U5H11

Power unit
E,ET
1
2
3
4
5
25 N·m (2.5 kgf·m, 18.4 ft·lb)
No. Part name Q’ty

8 N·m (0.8 kgf·m, 5.9 ft·lb)
Remarks
61U5010E
6
7
2 Grommet 6 MH, WH
3 Manual starter assembly 1 MH, WH
4 Collar 3 MH, WH
6 Power unit 1
8
7 Dowel 2
9 Bolt 2 M6 × 20 mm
10 Ground lead 1
11 Bolt 2 M6 × 16 mm
12
13
14
15
Retaining plate
Grommet
Washer
Nut
1
1
2
2
9
16 Bolt 4 M8 × 30 mm
17 Bolt 4 M6 × 20 mm
61U5H11 5-2

POWR Power unit
E,ET
25 N·m (2.5 kgf·m, 18.4 ft·lb)
8 N·m (0.8 kgf·m, 5.9 ft·lb) 61U5010E

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 battery cable 1 WH, E, ET
27 Positive battery cable 1 WH, E, ET
28 Positive lead 1 WH, E, ET
29 PTT motor lead (up) 1 ET
30 PTT motor lead (down) 1 ET
31 Neutral switch 1 WH
32 Bolt 2 M6 × 16 mm WH
Bolt 1 MH, E, ET
33 Clamp 1
5-3 61U5H11

Power unit
186 N·m (18.6 kgf·m, 137 ft·lb)
1
2
3
4
5
6
3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U5020E

1 Nut 1
7
2 Washer 1
3 Starter pulley 1 MH, WH
5 Flywheel magnet 1
6 Bolt 3 M6 × 60 mm
7
8
9
10
Stator assembly
Pulser coil assembly
Screw
Plate
1
1
4
4
ø5 × 18 mm 8
11 Retainer 1
12
13
14
15
Woodruff key
Screw
Timing plate
Bolt
1
1
1
2
ø6 × 10 mm
M6 × 45 mm
9
16 Collar 2
17 Case 1
61U5H11 5-4

POWR Power unit
186 N·m (18.6 kgf·m, 137 ft·lb)
3 N·m (0.3 kgf·m, 2.2 ft·lb) 61U5020E

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 equipped
26 Bolt 2 If equipped M6 × 30 mm
27 Collar 2 If equipped
28 Grommet 2 If equipped
29 Bolt 2 If equipped M6 × 20 mm
30 Washer 2 If equipped
5-5 61U5H11

Power unit
1
2
3
4
5
61U5030E
6
1 Joint 2
7
2 Lock nut 2
3 Control link rod 1
4 Throttle link rod 1
5 Bolt 1 M6 × 25 mm
6 Collar 1
7
8
9
10
Wave washer
Cam
Cap
Lock nut
1
1
2
2
8
11 Screw 1
12
13
14
15
Spring
Screw
Bolt
Washer
1
1
1
1
M8 × 45 mm
9
16 Collar 1
17 Bushing 1
61U5H11 5-6

POWR Power unit
61U5030E

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
5-7 61U5H11

Power unit
1
2
3
4
5
6IU5060E
6
7
2 Cover 1
4 CDI unit 1
5 Charge coil coupler 1
6 Bolt 1 M6 × 12 mm
7
8
9
10
Spark plug cap
Bolt
Ignition coil
Bolt
4
4
4
2
M6 × 20 mm
M6 × 12 mm
8
11 Bolt 3 M6 × 28 mm
12
13
14
15
Grommet
Case
Collar
Pulser coil coupler
3
1
3
1
9
16 Main harness coupler 1
17 Start-in-gear protection cable 1 MH, WH
61U5H11 5-8

POWR Power unit
WH, E ET
30 N·m (3.0 kgf·m, 22.1 ft·lb)
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)
61U5050E

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 Nut 1
8 Bolt 1 M8 × 16 mm
9 Negative battery cable 1
10 Wireharness 1
11 Fuse holder 1
12 Fuse 1 20A
13 Spring washer 2
14 Nut 2
15 Starter relay 1
16 Holder 1
17 Positive battery cable 1
5-9 61U5H11

Power unit
WH, E ET
30 N·m (3.0 kgf·m, 22.1 ft·lb) 1

29 N·m (2.9 kgf·m, 21.4 ft·lb)
2
3
4
9 N·m (0.9 kgf·m, 6.6 ft·lb)
5
4 N·m (0.4 kgf·m, 3.0 ft·lb)

61U5050E
6
18 Bolt 1 M6 × 12 mm
7
19 Clamp 1
20 Holder 1
21 PTT relay (up) 1 ET
22 Holder 1 ET
23 PTT relay (down) 1 ET
24
25
26
27
PTT relay lead
Connector
Spring washer
Nut
1
1
4
4
ET
ET
ET
ET
8
28 Lock tie 1 ET
29
30
31
32
Tube
Starter motor bracket
Bolt
Cap
1
1
2
2
ET
M8 × 25 mm
ET
9
61U5H11 5-10

POWR Power unit
MH, WH
61U5040E

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
16 Washer 1
17 Bolt 1 M6 × 25 mm
5-11 61U5H11

Power unit
MH, WH
1
2
3
4
5
61U5040E
6
18 Rope guide 1
7
19 Roller 1
20 Bushing 1
21 Bolt 4 M6 × 30 mm
22 Grommet 4
23 Collar 4
24
25
26
27
Bolt
Bracket
Nut
Damper
2
1
4
1
M6 × 20 mm
8
28 Starter handle 1
29
30
31
32
Cap
Bracket
Bolt
Cotter pin
1
1
1
1
M6 × 12 mm
9
33 Washer 1
34 Start-in-gear protection cable 1
61U5H11 5-12

POWR Power unit
MH, WH
61U5040E

35 Spring 1
36 Guide 1
37 Bolt 1
38 Stopper 1
39 Spring 1
40 Starter rope 1
5-13 61U5H11

Power unit
Disassembling the manual starter 3. Remove the bolt, drive plate 6, spring
(MH, WH) 7, drive pawl 8, spring 9, clip 0, wash-
er q and collar w.
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-
7
6
1
able protective gloves and cover the spi-
ral spring with cloths, then pull out the
sheave drum.
9
8
2
1. Remove the bolts 1, rope guide 2 and 61U50490
roller 3.
1 q
0
3
w
4
1 61U50500
3 2
5
61U50300
4. Insert a flat-head screwdriver into the
2. Turn the sheave drum 4 clockwise until hole b in the sheave drum and push
the spiral spring is free. down on the spiral spring so that it
release from the sheave drum.
5 a
5. Remove the sheave drum 4 from the
manual starter case e. 6
b
4 61U50020 7
NOTE:
8
9 Turn the sheave drum to hook the starter 4
rope with the notch on the sheave drum e 61U50030
easily.
9 Pass the starter rope 5 through the notch
a.
9
61U5H11 5-14

POWR Power unit
6. Remove the plastic washers r, spiral Assembling the manual starter

spring t from the manual starter case. (MH, WH)
1. Install the starter rope 1 into the sheave
drum 2.
2. Install the manual starter handle 3.
r
3
2
t
r 61U50040
7. Remove the starter rope y and collar u. 1
a
u
61U50050
61U50510
Checking the spiral spring (MH, WH) NOTE:

1. Check the spiral spring. Replace if 9 Tie a knot at the end of the starter rope as
cracked, bent or damaged. shown in the illustration.
9 Be sure to leave 5.0–10.0 mm (0.2–0.4 in)
Checking the drive pawl (MH, WH) at the end a of the starter rope.
1. Check the drive pawl. Replace if worn or
damaged. 3. Wind the starter rope 1 1/2 around the
sheave drum in the direction of the arrow
Checking the starter rope (MH, WH) shown in the illustration.
1. Measure the starter rope length. Replace
if the starter rope is worn or damaged.
Starter rope length:

(Reference data)
2,300 mm (90.6 in) b
69D50090
NOTE:
After winding the starter rope around the
sheave drum, install the starter rope in the
notch b.
5-15 61U5H11

Power unit
4. Install the plastic washer 4 and spiral 6. Install the collar 8, washer 9, clip 0,
spring 5 into the manual starter case 6. drive pawl q, spring w, spring e, and
drive plate r.
d
9
0
1
c
5
4
8
2
6 61U50060 61U50520
NOTE:
Install the outer end c of the spiral spring
e
r
3
onto the pin d of the starter case.
5. Install the collar 7, plastic washer 4

and the sheave drum 2 into the manual
starter case 6.
w
q
4
61U50530
2
4
7
7. Turn the sheave drum 5 times in the
direction of the arrow shown, and then
remove the starter rope from the notch
e.
5
6 61U50070
e
6
NOTE:
Install the sheave drum in the direction of
arrow shown, and then set the spiral spring
by turning the sheave drum.
61U50540
7
8
8. Install the roller t and rope guide y.
9
t y 61U50550
61U5H11 5-16

POWR Power unit
9. Pull the manual starter handle several 1. Remove the CDI unit cover, start-in-gear
times in the direction of the arrow to protection cable 1, then remove the
check that the sheave drum turns manual starter and starter pully (MH,
smoothly and to check the starter rope for WH).
slack. Repeat steps 3–8 if necessary.
1
f
69D50160
61U50080 2. Disconnect the negative battery cable 2,

positive battery cable 3 and PTT motor
NOTE: lead 4.
Align the mark f on the stopper with guide, å
and then turn the sheave drum.
10. Pull the manual starter handle complete-

ly, then measure the starter rope length.
If the starter rope length is out of specifi-
cation, refer to the step 7 and adjust the 2
starter rope by rewind times.
g 3
61U50350
∫
61U50090
2
4
Starter rope length g:
(Reference data)
1,700–1,900 mm (66.9–74.8 in)
Removing the power unit

NOTE:
It is recommended to loosen the flywheel
magnet nut before removing the power unit to 3
improve working efficiency.
61U50360
å WH, E
∫ ET
5-17 61U5H11

Power unit
3. Disconnect the 10-pin main harness cou- 8. Remove the bracket bolt w manual
pler 5. injection pump cable end e and start-in-
gear protection cable end r.
1
e
5
61U50470
w 61U50460
2
4. Disconnect the fuel hose 6.
r 3
6
4
61U50560 61U50461
5. Set the shift lever or remote control lever

in the neutral position, and then discon-
nect the shift cable 7, throttle cable 8.
9. Disconnect the cooling water pilot hose
t and PCV hose y. 5
8
6
7 61U50570
y
10. Remove the apron u.

t
61U50330
7
6. Remove the clip 9 and bushing 0 and
then, push the shift lever q down.
9
0
8
q
9
6G450910
u
7. Disconnect the choke link rod. 61U50580
61U5H11 5-18

POWR Power unit
11. Remove the power unit by removing the 2. Remove the flywheel magnet.
bolts i, bolts o and nuts p.
i
p
o 61U50590
6B450090
Removing the flywheel magnet

1. Loosen the flywheel magnet nut. cC
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-
6F650200 wheel magnet comes off the tapered portion
of the crankshaft.
cC
Apply force in the direction of the arrows
Flywheel puller: 90890-06521
shown. While working, do not allow the
flywheel holder to slip off the flywheel.
3. Remove the Woodruff key.
Flywheel holder: 90890-06522
5-19 61U5H11

Power unit
Removing the electrical component

1. Remove the cover 1 and disconnect the
coupler.
1
1
7
2
61U50630
61U50610
61U50600
4. Remove the starter relay 8 and the PTT
relay assembly 9. 3
2. Remove the hour meter 2.
9
4
2 8
5
61U50615
61U50650
6
5. Remove the starter motor 0.
3. Remove the stator assembly 3, retainer

screw 4, retainer 5, pulser coil assem-
bly 6, and Rectifier Regulator 7.
7
3
0
8
6
5
4
61U50640
9
61U50620
61U5H11 5-20

POWR Power unit
6. Disconnect the ignition coil leads, and

then remove the CDI unit q and case w.
61U50600
5-21 61U5H11

Power unit/Intake manifold
Intake manifold
4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb)
1
MH, WH
2
E, ET 3
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5
8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
61U5070E

7
2 Reed valve 4
4 Clamp 1
5 Bolt 9 M6 × 25 mm
Bolt 12 E, ET
8
7 Hose 3
Hose 1 E, ET
8 Hose 2 MH, WH
Hose 1 E, ET
9
10
11
12
Hose
Hose
Clip
Joint
2
2
11
2
MH, WH
MH, WH
9
13 Hose 4
14 Bolt 4 M6 × 20 mm
61U5H11 5-22

POWR Power unit
4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb)
MH, WH
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

15 Cap 2
16 Bracket 1
17 Bracket 1
18 Intake manifold 1
19 Bracket 1 MH, WH
21 Hose 1 E, ET
22 Bolt 1 M6 × 12 mm
5-23 61U5H11

Intake manifold
Removing the intake manifold Checking the reed valve

1. Remove the carburetor assemblies and 1. Check the reed valves for bends a.
the fuel hoses. Replace the reed valves if above specifi-
1
cation.
2. Disconnect the breather hoses 1.
a
2
3
6G450180
1
61U50370
Valve bending limit a:

0.2 mm (0.0079 in)
2. Measure the reed valve stopper height

b. Replace the reed valve stopper if out
of specification.
4
b
1
NOTE:
61U50380
b 5
Mark the hoses connecting position, before
6
disconnect.
3. Remove the intake manifold bolts in the 6G450200

sequence shown.
Valve stopper height b:
6.2–6.8 mm (0.24–0.26 in)
7
8
61U50140
9
61U5H11 5-24

POWR Power unit
Exhaust cover
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

1 Bolt 7 M6 × 20 mm
2 Cover 1
5 Exhaust inner cover 1
6 Exhaust outer cover 1
7 Bolt 23 M6 × 35 mm
9 PCV cover 1
10 Bolt 2 M6 × 20 mm
11 Grommet 1
12 PCV 1
13 Spring 1
14 Clamp 1
15 Bolt 1 M6 × 12 mm
16 Clamp 1
5-25 61U5H11

Exhaust cover
Removing the exhaust cover Checking the PCV

1. Remove the exhaust cover bolts in the 1. Remove the PCV.
sequence shown.
1
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 necessary. 2
Installing the PCV
61U50100
1. Install a new gasket 1 and the PCV 2
with the its rounded side facing towards
the exhaust cover, and then tighten the
bolts 3 to the specified torque.
3
4
61U50120 3
1 2
61U50390
5
PCV cover bolts 3:
1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
6
61U50130
7
8
NOTE:
Insert a flat-head screw driver between the
pry tabs to pry off the exhaust cover.
Checking the exhaust cover

1. Check the exhaust cover for distortion or
corrosion. Replace the exhaust cover if
necessary.
9
61U5H11 5-26

POWR Power unit
Cylinder head
MH, WH 25 N·m (2.5 kgf·m, 18.4 ft·lb)
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)

15 N·m (1.5 kgf·m, 11.1 ft·lb) 8 N·m (0.8 kgf·m, 5.9 ft·lb)
30 N·m (3.0 kgf·m, 22.1 ft·lb) 61U5090E

1 Anode 4
2 Screw 4
4 Cylinder head 2
5 Thermoswitch 2
7 Cylinder head cover 2
9 Thermostat 2
10 Thermostat cover 2
11 Bolt 8 M6 × 40 mm
12 Spark plug 4
13 Bolt 24 M6 × 30 mm
14 Clamp 2
15 Bolt 20 M8 × 60 mm
16 Bolt 2 M6 × 12 mm
17 Ground lead 2
5-27 61U5H11

Cylinder head
MH, WH 25 N·m (2.5 kgf·m, 18.4 ft·lb)
4 N·m (0.4 kgf·m, 3.0 ft·lb)

8 N·m (0.8 kgf·m, 5.9 ft·lb) 1
2
3
E, ET
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5
No. Part name

30 N·m (3.0 kgf·m, 22.1 ft·lb)
Q’ty Remarks
61U5090E
6
18 Bolt 2 M8 × 20 mm
7
19 Engine hanger 1
8
9
61U5H11 5-28

POWR Power unit
Removing the cylinder head 5. Remove the cylinder head bolts in the
1. Remove the spark plugs. sequence shown.
2. Remove the thermostat cover bolts in the PORT STBD

sequence as shown, and then remove
the thermostat.
61U50170 61U50210
3. Remove the cylinder head cover bolts in

the sequence shown.
PORT STBD
61U50230
cC
Do not scratch or damage the mating sur-
faces of the cylinder head and cylinder block.
61U50180 NOTE:
pry tabs to pry off the cylinder heads.
Checking the cylinder head

1. Eliminate carbon deposits from the com-
bustion chambers and check for deterio-
ration.
61U50200
4. Remove the thermoswitch.
5-29 61U5H11

Cylinder head
2. Check the cylinder head warpage using a

straightedge 1 and thickness gauge 2
in 4 directions as shown. Replace the
1
cylinder head if above specification.
2
2
61U50240
3
4
5
61U50250
Cylinder head warpage limit:

0.10 mm (0.0039 in)
6
7
8
9
61U5H11 5-30

POWR Power unit
Crankcase
12 N·m (1.2 kgf·m, 8.9 ft·lb)
20 N·m (2.0 kgf·m, 14.8 ft·lb)

37 N·m (3.7 kgf·m, 27.3 ft·lb)
10 N·m (1.0 kgf·m, 7.4 ft·lb)

18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U5100E

1 Bolt 4 M6 × 25 mm
2 Oil seal 1 Not reusable
3 Bearing housing 1
5 Needle bearing 1
6 Crankcase 1
7 Dowel 2
8 Bolt 6 M10 × 60 mm
9 Bolt 8 M8 × 30 mm
10 Bolt 4 M6 × 20 mm
11 Oil seal housing 1
15 Cover 1
16 Bolt 2 M6 × 16 mm
5-31 61U5H11

Crankcase
1
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)
*
19 N·m (1.9 kgf·m, 14.0 ft·lb)
36 N·m (3.6 kgf·m, 26.6 ft·lb)
2
3
4
5
61U5110E
6
1 Bolt 8 M8 × 22 mm
7
2 Piston and connecting rod assembly 4
3 Roller bearing 4 set
4 Crankshaft 1
5 Circlip 1
6 Main bearing 1 set
7
8
9
10
Cylinder block
Plug
Gasket
Circlip
1
2
2
1
Not reusable 8
11 Ball bearing 1
12 Seal ring
*: Loosen completely
6
9
61U5H11 5-32

POWR Power unit
61U5120E

1 Connecting rod 4
2 Piston (starboard side) 2
3 Washer 8
4 Needle bearing 120
5 Clip 8 Not reusable
6 Piston pin 4
7 Piston ring set 4
8 Piston (port side) 2
5-33 61U5H11

Crankcase
Removing the crankcase

1. Remove the bearing housing bolts.
1
6G450270
2
61U50280
2. Remove the oil seal housing bolts.
NOTE:
pry tabs to pry off the crankcase.
3
Disassembling the bearing housing
1. Remove the oil seal 1 and O-rings 2.
1
4
5
6G450280
3. Remove the crankcase bolts in the

sequence shown.
6G450330
2. Remove the needle bearing 3 using a

6
press.
7
4 5
61U50260 2
3
8
6G450330
Ball bearing attachment 4:

90890-06663
9
Driver rod LS 5: 90890-06606
61U5H11 5-34

POWR Power unit
Disassembling the oil seal housing NOTE:

1. Remove the oil seals and O-ring. 9 Mark each piston with the identification
number a of the corresponding cylinder.
Also, mark each connecting rod and con-
necting rod cap with an identification num-
ber b as shown.
9 Be sure to keep the bearings in the order as
they were removed.
9 Do not mix the connecting rods and caps.
Keep them organized in their each groups.
6G450320 2. Remove the crankshaft assembly.
61U50930
Removing the piston, connecting 61U50410

rod assembly and crankshaft
assembly Disassembling the piston and con-
1. Remove the connecting rod bolts and the necting rod assembly
connecting rod caps, and then remove 1. Remove the piston pin clips 1 with pli-
the piston with connecting rod. ers, and then remove the piston pin 2,
needle bearings 3 and washers 4.
2. Remove the top ring 5 and 2nd piston

ring 6.
a
1
4
2
3
61U50660 6
5
61U50420
61U50400
Checking the bearing
1. Check the needle bearings, main bearing
and ball bearing for pitting or rumbling.
5-35 61U5H11

Crankcase
Disassembling the crankshaft Checking the piston diameter

1. Remove the seal rings 1. 1. Measure the piston outside diameter at
the specified measuring point. Replace
1
a the piston and piston rings as a set if out
of specification.
1
a
b
b
61U50290
2
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.
Piston diameter a:
6G450410
3
89.920–89.935 mm
2. Remove the circlip 2, and then remove
the ball bearing.
(3.5402–3.5407 in)
Measuring point b:
10.0 mm (0.39 in)
Oversize piston diameter a:
4
1st:
5
2 90.170–90.185 mm
(3.5500–3.5506 in)
2nd:
90.420–90.435 mm
(3.5598–3.5604 in)
6G450390
6
4
3
7
6G450400
8
cC
9
Do not reuse the ball bearing, always
replace it with a new one.
Gear puller 3: 90890-06540

Bearing separator 4:
90890-06534
61U5H11 5-36

POWR Power unit
Checking the cylinder bore Checking the piston ring

1. Measure the cylinder bore (D1–D6) at 1. Check the piston ring dimensions of B
measuring points a, b, and c, and in and T. Replace the piston and piston
direction d (D1, D3, D5), which is parallel rings as a set if out of specification.
to the crankshaft, and direction e (D2,
D4, D6), which is at a right angle to the
crankshaft.
B
1
T
a
b
69D50410
c
Piston ring dimension
d Top ring and 2nd piston ring:
e 6F650370 B: 1.970–1.990 mm
(0.0776–0.0783 in)
T: 2.700–2.900 mm
a: 10.0 mm (0.39 in) from the cylinder head top
surface
(0.1063–0.1142 in)
b: 5.0 mm (0.20 in) above the exhaust port
upper edge 2. Level the piston ring 1 in a cylinder with
c: 5.0 mm (0.20 in) below the scavenging port a piston crown.
lower edge
3. Check the piston ring end gap a at the
Cylinder bore (D1–D6): specified measuring point b. Replace
90.000–90.020 mm the piston ring set if out of specification.
(3.5433–3.5441 in)
Cylinder gauge 1:
90890-06759 b
Checking the piston clearance 1

1. Calculate the piston clearance using the
piston outside diameter and the cylinder 1
bore specifications. Replace the piston
and piston rings as a set or the cylinder
block or all parts, or rebore the cylinder if a
out of specification.
6F650430
NOTE:
Be sure to rebore the cylinder for matching Piston ring end gap a:
the replacement oversize pistons, when E115A:
using the specified oversize pistons. 0.30–0.40 mm (0.0118–0.0157 in)
115B, 140B:
Piston clearance: Top:
0.080–0.085 mm 0.30–0.50 mm (0.0118–0.0197 in)
(0.0032–0.0033 in) 2nd:
0.30–0.40 mm (0.0118–0.0157 in)
Measuring point b: 10 mm (0.39 in)
5-37 61U5H11

Crankcase
Checking the piston ring side clear- Checking the piston pin
ance 1. Measure the piston pin outside diameter.
1. Measure the piston ring side clearance. Replace the piston pin if out of specifica-
1
Replace the piston and piston rings as a tion.
set if out of specification.
2
3
6S350110
6G450420
Piston pin diameter:

Piston ring side clearance: E115A:
Top ring and 2nd piston ring: 21.495–21.500 mm
4
0.02–0.06 mm (0.8463–0.8465 in)
(0.0008–0.0024 in) 115B, 140B:
23.065–23.070 mm
(0.9081–0.9083 in)
Checking the piston pin boss bore
1. Measure the piston pin boss bore.
Replace the piston if out of specification. Checking the internal anode
1. Check the anodes on the cylinder block.
Clean the anode’s surface and replace if
it has been eroded into half size or small-
5
er.
6
Piston pin boss bore:
E115A:
6G450430
7
21.504–21.515 mm 61U50670
(0.8466–0.8470 in)
115B, 140B:
23.074–23.085 mm
(0.9084–0.9089 in)
cC
Do not oil or grease the anodes, otherwise
8
they will not be able to prevent galvanic
corrosion effectively.
9
61U5H11 5-38

POWR Power unit
Checking the connecting rod small Checking the crankshaft

end axial play 1. Measure the crankshaft journal diameter
1. Measure the connecting rod small end a and crankpin diameter b. Replace the
axial play. Replace the bearing and con- crankshaft if out of specification.
necting rod if above specification.
a
61U50680
6G450550
NOTE:
To measure the axial play, set the dial gauge
at the connecting rod small end and parallel
to the crankshaft.
b
Connecting rod small end 61U50690
axial play limit:

2.0 mm (0.08 in)
Crankshaft journal diameter a:
53.975–53.991 mm
Checking the connecting rod big (2.1250–2.1256 in)
end side clearance Crankpin diameter b:
1. Measure the connecting rod big end side 35.985–36.000 mm
clearance a. Replace the connecting rod (1.4167–1.4173 in)
or crankshaft or both if out of specifica-
tion.
6G450560
Connecting rod big end side

clearance a:
0.120–0.260 mm
(0.0047–0.0102 in)
5-39 61U5H11

Crankcase
2. Measure the crankshaft runout. Replace 2. Install the seal rings 4.

the crankshaft if above specification.
b
c c
4
a 1
E 61U50700 2
NOTE:
61U50430
First pass the seal ring 4 over the crankpin
a, and then widen the seal ring end gap b
to install the ring into the crankshaft groove.
3
Crankshaft runout limit c:
3. Install the main bearings onto the crank-
0.02 mm (0.0008 in)
Assembling the crankshaft

1. Installing the ball bearing 1 into the
shaft.
4
crankshaft using a press, then the circlip.
5
3
6
E
61U50710
7
E
6G450590
cC
Do not reuse the ball bearing, always
8
Support 2:
90890-02394
Bearing inner race attachment 3:
9
90890-06662
61U5H11 5-40

POWR Power unit
Assembling the bearing housing Assembling the oil seal housing

1. Install the needle bearing. 1. Apply grease to the new oil seals, new O-
ring and then install them into the oil seal
housing.
2
1
6G450620
6G450640
cC
Do not reuse the needle bearing, always
2
Needle bearing attachment:

90890-06654 3
2. Apply grease to the new oil seal, new O-

rings and then install it into the bearing 6G450650
housing.
2 90890-06637
Driver rod LS 2: 90890-06606
Bearing outer race attachment 3:
90890-06624
1
6G450630
Needle bearing attachment 1:

90890-06654
Driver rod L3 2: 90890-06652
5-41 61U5H11

Crankcase
Assembling the piston and connect- cC

ing rod assembly
Do not scratch the pistons or break the
1. Assemble the pistons 1, connecting
piston rings.
1
rods 2, needle bearings 3, washers 4,
piston pins 5, and new piston pin clips
6. NOTE:
3 Install the piston rings with the recess for the
locating pin facing up toward the piston
2
crown.
c 6
b Assembling the power unit

7
6 1. Set the crankshaft in the cylinder block.
4
2
3
5
a 2
3
a
4
1
6
1
4
61U50720
NOTE:
9 Face the embossed “YAMAHA” mark a on
5
the connecting rod in the same direction as
the “UP” mark b on the piston.
9 Use the small end bearing installer 7 to
install the needle bearings.
9 Always use new piston pin clips.
61U50440
6
9 Be sure to align the piston pin clip end with
the piston pin slot c.
Small end bearing installer 7:
90890-06528
NOTE:
9 Fit dowels 1 on the cylinder block into the
dowel holes 2 in the main bearings.
9 Align the seal ring end gaps a with the
7
crankcase center line.
2. Install the 2nd piston ring 8 and top ring
9 onto the pistons.
9
8
8
9
6G450670
61U5H11 5-42

POWR Power unit
2. Install the pistons into the cylinders with Piston slider 3:

the “UP” mark on the piston crown facing 90890-06530
towards the flywheel magnet.
3. Install the connecting rod bearings and
connecting rod caps onto the connecting
rods, and then tighten the connecting rod
bolts 4 to the specified torques in 5
stages.
4
6G450690
c
61U50755
b
NOTE:
9 Align the identification numbers c on the
connecting rod caps and connecting rods,
which you made during disassembly.
61U50730
9 Apply engine oil to the connecting rod bear-
ings, connecting rod caps, and connecting
rod bolts before installation.
Connecting rod bolt 4:

1st: 19 N·m (1.9 kgf·m, 14.0 ft·lb)
3 2nd: 36 N·m (3.6 kgf·m, 26.6 ft·lb)
3rd: Loosen completely
4th: 19 N·m (1.9 kgf·m, 14.0 ft·lb)
5th: 36 N·m (3.6 kgf·m, 26.6 ft·lb)
61U50740
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 corresponding
cylinders according to the marks b made
during disassembly. Also, be sure to install
the assemblies with an “S” mark on the
starboard side, and the assemblies with a
“P” mark on the port side.
5-43 61U5H11

Crankcase
4. Install the bearing housing onto the cylin- NOTE:

der block. Do not get any sealant on the journals.
7. Install the dowels, crankcase onto the

cylinder block, and then temporarily tight-
en the crankcase bolts. 1
61U50760
2
NOTE:
Install the bearing housing with the arrow
mark facing toward the cylinder block. 3
4
5. Install the oil seal housing onto the cylin-
61U50455
der block.
NOTE:
Apply engine oil to the crankcase bolts before
installation.
8. Install the bearing housing bolts tempo-

rary tight.
5
NOTE:
61U50770
Install the oil seal housing with the projec-

6
tions facing toward the cylinder block.
6. Apply sealant to the mating surface of the 6G450275

7
crankcase.
9. Install the oil seal housing bolts tempo-
rary tight.
8
61U50450
9
6G450285
61U5H11 5-44

POWR Power unit
10. Tighten the crankcase bolts to the speci- 12. Install the new gasket 5, exhaust inner
fied torques in 2 stages and in the cover 6, new gasket 7, exhaust outer
sequence shown. cover 8, and then tighten the exhaust
cover bolts to the specified torques in 2
stages and in the sequence shown.
5
6
7
8
61U50270
NOTE: 61U50780
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.
z–n: Crankcase bolt (M10):

1st: 20 N·m (2.0 kgf·m, 14.8 ft·lb)
2nd: 37 N·m (3.7 kgf·m, 27.3 ft·lb)
m–⁄4: Crankcase bolt (M8):
1st: 10 N·m (1.0 kgf·m, 7.4 ft·lb)
2nd: 18 N·m (1.8 kgf·m, 13.3 ft·lb)
11. Tighten the bearing housing bolts and oil

61U50110
seal housing bolts.
NOTE:
Bearing housing bolt: Apply LOCTITE 572 to the exhaust cover
12 N·m (1.2 kgf·m, 8.9 ft·lb) bolts before installation.
Exhaust cover bolt:

1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
5-45 61U5H11

Crankcase
13. Install the new gaskets 9 and the cylin- 15. Install the new gaskets e and the cylin-
der head 0, and then tighten the cylinder der head covers r, and then tighten the
head bolts to the specified torques in 2 cylinder head cover bolts to the specified
1
stages and in the sequence shown. torques in 2 stages and in the sequence
shown.
2
9
e
3
0 61U50790
4
r
61U50800
PORT STBD
PORT STBD
5
61U50220
6
NOTE:
7
61U50190
Apply engine oil to the cylinder head bolts
before installation.
NOTE:
Apply LOCTITE 572 to the cylinder head
Cylinder head bolt:
cover bolts before installation.
1st: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
14. Install the thermoswitches q onto the
cylinder head w.
Cylinder head cover bolt:
1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
8
w
9
q
61U50225
61U5H11 5-46

POWR Power unit
16. Install the new gaskets, thermostats and

the thermostat covers, and then tighten
the thermostat cover bolts to the speci- MH, WH
fied torques in 2 stages and in the
sequence shown.
u t
y
61U50810
61U50160
Intake manifold bolt u:

NOTE: 1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
Apply LOCTITE 572 to the thermostat cover 2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
bolts before installation.
19. Connect the hoses as shown below.
å
Thermostat cover bolt:
1st: 4 N·m (0.4 kgf·m, 3.0 ft·lb)
2nd: 8 N·m (0.8 kgf·m, 5.9 ft·lb)
17. Install the spark plugs temporary tight d,

and then to the specified torque e with a
spark plug wrench.
61U50820
Spark plug: 61U50830
25 N·m (2.5 kgf·m, 18.4 ft·lb) ∫
18. Install the new gasket t and the intake

manifold assembly y, and then tighten
the intake manifold bolts u to the speci-
fied torques in 2 stages and in the
sequence shown.
61U50825
5-47 61U5H11

Crankcase
1
d
2
61U50835
å MH, WH
∫ E, ET
61U50605
20. Install the starter motor i, pulser coil
assembly o and stator assembly p onto
the power unit.
22. Install the starter relay f, the PTT relay
assembly g and Rectifier Regulator h
onto the power unit.
3
4
i g
a
5
a f
61U50645
61U50655 6
p
o
7
h
8
61U50625
Starter motor mount bolt a :

29 N·m (2.9 kgf·m, 21.4 ft·lb)
61U50635
9
21. Install the case s and the CDI unit d
61U5H11 5-48

POWR Power unit
23. Install the hour meter into the case, and Installing the power unit
then onto the power unit. 1. Clean the power unit matching surface, and
install the dowels 1 and a new gasket 2.
j
1 1
2
61U50850
2. Install the power unit 3, and then tighten

61U50636
the power unit bolts 4, bolts 5 and nut
6 to the specified torque.
Hour meter screw j:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
24. Install the new gaskets k, carburetor 3

assemblies l and choke solenoid ;
k 4
l
4
6
5 61U50595
;
61U50840
Power unit bolt 4,5, nut 6:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
5-49 61U5H11

Crankcase
3. Install the apron 7, and then tighten the 6. Install the bushing w and clip e.
apron bolt 8 to specified torque.
e
8 8
w
1
7. Connect the choke link rod.
6G450905
2
7
3
8. Connect the 10-pin main harness coupler
r.
8 7 8 61U50585
Apron bolt 8:
8 N·m (0.8 kgf·m, 5.9 ft·lb)
4. Connect the cooling water pilot hose 9

and PCV hose 0.
4
r
61U50475
9. Connect the shift cable t and throttle

5
cable y, and then adjust their lengths.
0 9
61U50335
For adjustment procedures, see P3-6,
“Adjusting the throttle cable,” and P3-7
“Checking the gear shift operation”.
6
5. Install the manual injection pump cable
end, and start-in-gear protection cable
end, and then install the bracket bolt q.
y 7
t 61U50575
8
q 61U50465
9
61U5H11 5-50

POWR Power unit
10. Install the Woodruff key and flywheel 15. Connect the negative battery cable o,
magnet. positive battery cable p, and PTT motor
lead a.
11. Tighten the flywheel magnet nut to the å
specified torque.
cC
61U50355
Apply force in the direction of the arrows
shown, to prevent the flywheel holder
from slipping off easily. ∫
NOTE: o
a
Apply engine oil to the flywheel magnet nut
thread before installation.
Flywheel holder: 90890-06522
Flywheel magnet nut:

186 N·m (18.6 kgf·m, 137 ft·lb) p
12. Install the starter pulley.
61U50365
13. Tighten the cable holder plate u and
retaining plate i. å WH
∫ E, ET
i
Starter motor positive terminal nut:
9 N·m (0.9 kgf·m, 6.6 ft·lb)
16. Install the all removed parts.

u
61U50480
14. Install the manual starter, start-in-gear

protection cable, and then adjust it. For
adjustment procedures, refer to
“Adjusting the start-in-gear protection”
P3-4.
5-51 61U5H11

Crankcase
Adjusting the timing plate Cylinder #1 piston position (BTDC):

NOTE: E115A, 115B:
Remove the all spark plugs and lock plate 3.33 mm (0.1311 in)
before adjusting the timing plate.
1. Remove the manual starter or flywheel

cover.
140B:
3.91 mm (0.1539 in)
5. Align the timing plate with the flywheel at

1
specified position and install the timing
2. Slowly turn the flywheel magnet clock-
wise, align the piston of the #1 cylinder at
the TDC.
plate 2.
NOTE:
When finish the adjusting of timing plate, fly-
wheel must be turn clockwise twice.
2
3. Install the dial gauge 1 into the #1cylin-
der.
1
E115A:
BTDC 23°
3
115B:
BTDC 25°
140B:
BTDC 22° 4
5
61U50860
6. Start the engine, and then check the igni-
tion timing once more.
NOTE:
Set the dial gauge to “zero” position which is 7. If the ignition timing out of specification.
more than 4 mm from TDC. Replace the CDI unit.
Dial gauge set 1 : 90890-01252 6

4. As look at the dial gauge, slightly turn the
flywheel counterclockwise to the speci-
fied position.
7
8
30 20 10
TDC
9
2
61U50870
61U5H11 5-52

POWR Power unit
Adjusting the ignition timing stop- 3. Check that the mark 3 on the flywheel
per magnet aligned with the pointer 4 on the
pulser coil assembly.
NOTE:
For adjust the timing plate, refer to “Adjusting
the timing plate”.
3
4
1. Slowly turn the flywheel magnet clock-
wise, and check that the timing plate a is
aligned with the scale b on the flywheel
magnet in the specified position.
61U50890
4. If not align them, loosen the lock nut 5

and adjust the length of the adjusting
screw 2.
C
TD
5
30 20 10
2
a b
61U50905
c
61U50910

E115A: Specified length c :
BTDC 23° (Reference data)
115B: E115A, 115B:
BTDC 25° 24.5 mm (0.96 in)
140B: 140B:
BTDC 22° 22.0 mm (0.87 in)
2. Set the control lever 1 to the full 5. Slowly turn the flywheel magnet clock-
advanced position, and then check that wise, and check that the timing plate a is
the adjusting screw 2 contact with the aligned with the scale b on the flywheel
stopper. magnet in the specified position.
1 TDC
10 TDC
10
a b
61U50900
61U10055
5-53 61U5H11

Crankcase

ATDC 5°
1
6. Set the control lever 1 to the full retard
position, and check that the adjusting
screw 2 contact with the stopper.
1
2
2
3
7. Check that the mark 3 on the flywheel
magnet aligned with the pointer 4 on the
61U10045
4
pulser coil assembly.
3 5
4
6
61U50880
8. If not align them, adjust the length of the

adjusting screw 2. 7
8
2
61U50920
9
Specified length d :
(Reference data)
23.5 mm (0.92 in)
61U5H11 5-54

POWR Power unit
— MEMO —
5-55 61U5H11

LOWR
Lower unit
Lower unit .......................................................................................................6-1

Removing the lower unit ............................................................................6-4
Removing the water pump and shift rod ...................................................6-5
Checking the water pump and shift rod.....................................................6-5
1
Propeller shaft housing .................................................................................6-6
Removing the propeller shaft housing assembly.......................................6-8
Disassembling the propeller shaft assembly .............................................6-8
Disassembling the propeller shaft housing................................................6-8
2
Checking the propeller shaft housing ........................................................6-9
3
Checking the propeller shaft......................................................................6-9
Assembling the propeller shaft assembly ..................................................6-9
Assembling the propeller shaft housing ..................................................6-10
Drive shaft and lower case..........................................................................6-12

Removing the drive shaft.........................................................................6-13
Disassembling the drive shaft housing ....................................................6-13
Disassembling the forward gear ..............................................................6-13
Disassembling the lower case .................................................................6-14
4
Checking the pinion and forward gear.....................................................6-14
Checking the bearing...............................................................................6-14
Checking the drive shaft ..........................................................................6-14
Checking the lower case .........................................................................6-15
Assembling the lower case......................................................................6-15
5
Assembling the forward gear...................................................................6-15
Assembling the drive shaft housing.........................................................6-16
Installing the drive shaft...........................................................................6-16
Installing the propeller shaft housing .......................................................6-17
6
Installing the water pump and shift rod ...................................................6-18
Installing the lower unit ............................................................................6-19
Shimming ......................................................................................................6-22
Shimming .................................................................................................6-23
7
Selecting the pinion shim.........................................................................6-23
Selecting the forward gear shim ..............................................................6-24
Selecting the reverse gear shim ..............................................................6-25
Backlash........................................................................................................6-26
8
Measuring the forward and reverse gear backlash .................................6-26
9
61U5H11

LOWR Lower unit
Lower unit
39 N·m (3.9 kgf·m, 28.8 ft·lb)
39 N·m (3.9 kgf·m, 28.8 ft·lb)
54 N·m (5.4 kgf·m, 39.8 ft·lb)
39 N·m (3.9 kgf·m, 28.8 ft·lb)

61U6010E

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 Washer 1
8 Washer 1
9 Cotter pin 1 Not reusable
10 Nut 1
11 Dowel 2 E115A: Y-transom
12 Bolt 1 M10 × 45 mm
13 Grommet 1
14 Nut 6 E115A: Y-transom
15 Spring washer 6 E115A: Y-transom
16 Washer 6 E115A: Y-transom
17 Extension 1 E115A: Y-transom
6-1 61U5H11

Lower unit
18 N·m (1.8 kgf·m, 13.3 ft·lb)
1
2
3
4
5
No.
9 N·m (0.9 kgf·m, 6.6 ft·lb)
Part name Q’ty Remarks

61U6020E
6
1 Shift rod 1
7
3 Cover 1
5 Spring 1
6 Circlip 1
7
8
9
10
Bolt
Joint
Woodruff key
Bolt
3
1
1
4
M6 × 20 mm
M8 × 45 mm
8
11 Cover 1
12
13
14
15
Seal
Water pump housing
O-ring
Insert cartridge
1
1
1
1
Not reusable
9
17 Collar 1
61U5H11 6-2

LOWR Lower unit
18 N·m (1.8 kgf·m, 13.3 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb) 61U6020E

18 Spacer 1
19 Washer 2
20 Wave washer 1
21 Impeller 1
22 Outer plate cartridge 1
24 Dowel 2
25 Rubber seal 1
26 Plate 1
27 Check screw 1
29 Drain screw 1
30 Dowel 2
31 Lock tie 1 Not reusable
6-3 61U5H11

Lower unit
Removing the lower unit 3. Mark the trim tab 1 at the area shown,
1. Drain the gear oil. For draining proce- and then remove it.
dures, see Chapter 3, “Changing the
1
gear oil.” 4. Loosen the bolts (nuts) and then remove
the lower unit from the upper case.
2. Set the gear shift to the neutral position,
and place a block of wood between the 5. Disconnect the speedometer hose 2.
anti-cavitation plate and propeller to pre-
å
2
vent the propeller from turning, and then
remove the propeller nut and propeller.
3
4
å E115A: Y-transom
1
61U60040
5
6. Remove the stud bolts.
(E115A: Y-transom)
6
7
61U60010
w
9 Do not hold the propeller with your
hands when loosening or tightening it.
9 Be sure to disconnect the battery cables
from the battery and the lock plate from
the engine stop lanyard switch.
9 Put a block of wood between the anti-
8
cavitation plate and propeller to prevent 61U60020
the propeller from turning.

9 When removing the lower unit without
removing the power unit, be sure to sus-
pend the outboard motor. Otherwise, the
9
outboard motor could suddenly fall and
result in injury.
61U5H11 6-4

LOWR Lower unit
Removing the water pump and shift Checking the water pump and shift
rod rod
1. Remove the water pump housing 1, col- 1. Check the water pump housing. Replace
lar 2, spacer 3, washer 4, wave wash- if there is deformation.
er 5, washer 6 and impeller 7.
2. Check the impeller and insert cartridge.
2. Remove the Woodruff key 8. Replace if cracked or worn.
3. Remove the outer plate cartridge 9, 3. Check the Woodruff key 1 and the
gasket 0 and dowels q. groove a on the drive shaft. Replace if
worn.
4. Set the gear shift to the neutral position
at the lower unit. Make sure that the shift a
rod is in the neutral position using a spe- 1
cial service tool.
6S360027
4. Check the shift rod. Replace if cracked or

worn.
69D60036
Shift rod push arm:

90890-06052
5. Remove the shift rod assembly w.
4
5
6
1
7
9
0 2
q 3
w 8
61U60050
6-5 61U5H11

Propeller shaft housing
103 N·m (10.3 kgf·m, 76.0 ft·lb)
1
2
3
4 N·m (0.4 kgf·m, 3.0 ft·lb)
4
5
61U6030E
6
1 Shift rod joint 1
7
2 Ball 2
3 Shift slider 1
4 Ball 2
5 Ball 2
6 Spring 1
7
8
9
10
Dog clutch
Crosspin
Spring
Propeller shaft
1
1
1
1
8
11 Reverse gear shim —
12
13
14
15
Washer
Reverse gear
Thrust washer
Ball bearing
1
1
1
1
9
17 Propeller shaft housing 1
61U5H11 6-6

LOWR 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

18 Straight key 1
19 Needle bearing 1
21 Claw washer 1
22 Ring nut 1
23 Cooling water inlet cover 2
24 Nut 1
25 Screw 1 ø5 × 45 mm
6-7 61U5H11

Removing the propeller shaft hous- Stopper guide plate 4:

ing assembly 90890-06501
1. Remove the ring nut from the lower case,
Bearing housing puller claw L 5:
use the special service tools.
90890-06502
Center bolt 6: 90890-06504
Disassembling the propeller shaft

1
assembly
1
1. Remove the spring 1, then remove the
cross pin 2, dog clutch 3, balls 4,
spring 5, shift slider 6, and shift rod
joint 7.
2
6F600060
2
1
2
3
3 6 5
7 4 3
6G460030
4
6F660070
NOTE:
9 Before removing the propeller shaft from
the lower case, remove the shift rod.
NOTE:
Mark the front side of the dog clutch 3.
Disassembling the propeller shaft

5
9 Straighten the one tab 1 of the claw wash- housing
6
er, then turn the ring nut. 1. Remove the reverse gear and ball bear-
9 Turn the ring nut toward to “OFF”. ing.
Ring nut wrench 3 2:

90890-06511
2
7
Ring nut wrench extension 3:
90890-06513
3
4
2. Remove the propeller shaft housing use
the special service tools.
1
5 6
8
4
Bearing separator 1: 90890-06534
Stopper guide plate 2:
90890-06501
9
Stopper guide stand 3:
90890-06538
Bearing puller assembly 4:
6B460580 90890-06535
61U5H11 6-8

LOWR Lower unit
2. Remove the ball bearing. Checking the propeller shaft

1. Check the propeller shaft. Replace if bent
or worn.
2
2. Measure the propeller shaft runout.
3
cC
S6P26200
it with a new one.
Stopper guide plate 2: Runout limit: 0.02 mm (0.0008 in)

90890-06501
Stopper guide stand 3:
90890-06538 3. Check the dog clutch, shift rod joint, and
Bearing puller assembly 4: slider. Replace if cracked or worn.
90890-06535
Assembling the propeller shaft
3. Remove the oil seals and needle bearing.
assembly
1. Insert the large ball 1, spring 2, and
6
other large ball 3 into the shift slider 4.
3
2
1
5
61U60060
Needle bearing attachment 5: 4

61U60140
90890-06653
Driver rod L3 6: 90890-06652
Checking the propeller shaft hous-

ing
1. Clean the propeller shaft housing using a
soft brush and cleaning solvent, and then
check it. Replace if cracked or damaged.
2. Check the teeth and dogs of the reverse

gear. Replace if cracked or worn.
3. Check the bearings. Replace if pitted or if

there is rumbling.
6-9 61U5H11

2. Install the dog clutch 5 onto the propeller 6. The hole in the dog clutch align with the
shaft 6. 2 holes (propeller shaft and shift slider).
NOTE:
1
7. Install the cross pin 0 and spring q.
Face the marking side to original direction,
and then install the dog clutch 5.
q
0
5
6
2
3
61U60160
61U60170
Assembling the propeller shaft
3. Insert the smallest balls 7 into the shift housing
slider 4, and then insert the shift slider 1. Install the new needle bearing into the
into the propeller shaft 6.
4. Insert the medium balls 8 into the shift

propeller shaft housing to the specified
depth.
1
4
slider, and then continue to insert the shift
c
5
slider into the propeller shaft.
3
b a
b
2
7
8
6
NOTE:
61U60070
6
7
4 8 9 Install the needle bearing with the manufac-
7
61U60180
ture identification mark a facing toward the
5. Hook the shift rod joint 9 onto the knob propeller side.
on the end of the shift slider. 9 Be careful not to let the stopper c get out
of position when using the driver rod SS 1.
Driver rod SS 1: 90890-06604

90890-06610
8
Bearing depth plate 3:
9
9
90890-06603
61U60190 Depth b:
24.75–25.25 mm (0.974–0.994 in)
61U5H11 6-10

LOWR Lower unit
2. Apply grease to new oil seals, and then 4. Install the reverse gear assembly into the
install them into the propeller shaft hous- propeller shaft housing using a press.
ing to the specified depth.
d
4
61U60080
NOTE:
Install an oil seal halfway into the propeller
shaft housing, then the other oil seal.
Bearing inner race attachment 4:

90890-06640 NOTE:
After installing the reverse gear, check that
Depth d: the reverse gear rotates smoothly.
4.75–5.25 mm (0.187–0.207 in)
3. Install the thrust washer 5 and new ball 90890-06654
bearing 6 onto the reverse gear 7 using
a press.
NOTE:
Install the ball bearing with the manufacture
identification mark e facing toward the pro-
peller side.

90890-06656
6-11 61U5H11

Drive shaft and lower case
1
2
3
4
5
6
93 N·m (9.3 kgf·m, 68.6 ft·lb)
61U6040E

1 Drive shaft 1
7
2 Sleeve 1
3 Cover 1
5 Bolt 4 M8 × 25 mm
6 Drive shaft housing 1
7
8
9
10
Needle bearing
O-ring
Pinion shim
Thrust bearing
—
1
1
1
Not reusable
8
11 Lower case 1
12
13
14
15
Needle bearing
Pinion
Forward gear shim
Taper roller bearing
—
1
1
1
9
16 Needle bearing 1
17 Forward gear 1
61U5H11 6-12

LOWR Lower unit
Removing the drive shaft Disassembling the drive shaft

1. Loosen the pinion nut. housing
1. Remove the cover, oil seals, and needle
1 bearing.
6F660190
1
S6P26070E
Drive shaft holder 6 1:
90890-06520 Needle bearing attachment 1:
Pinion nut holder 2: 90890-06610
90890-06715 Driver rod L3 2: 90890-06652
2. Remove the pinion nut 3, pinion 4, Disassembling the forward gear

drive shaft housing 5, thrust bearing 6, 1. Remove the taper roller beaning from the
pinion shim(s) 7, drive shaft 8, sleeve forward gear using a press.
9 from lower case.
1
5
8
7
6
9 6F660210
cC
it with a new one.
4
Bearing separator 1:
3
90890-06534
61U60090
3. Pull out the forward gear.
6-13 61U5H11

2. Remove the needle bearing from the for- 2. Remove the taper roller bearing outer
ward gear using a chisel. race and shim(s).
1
3
2
a
6G460100 61U60030
Bearing outer race puller

cC
it with a new one. NOTE:
assembly 3: 90890-06523
3
Install the claws a as shown.
Disassembling the lower case
1. Remove the needle bearing.
2
Checking the pinion and forward
gear
1. Check the teeth of the pinion, and the
4
teeth and dogs of the forward gear.
2
1
1
Replace if cracked or worn.
Checking the bearing

1. Check the bearing. Replace if pitted or if
5
there is rumbling.
S6P26090E
Checking the drive shaft
1. Check the drive shaft. Replace if bent or
worn.
6
90890-06636
Driver rod LL 2: 90890-06605
2. Measure the drive shaft runout.
7
8
S6P26210
Runout limit: 0.2 mm (0.008 in)

9
61U5H11 6-14

LOWR Lower unit
Checking the lower case Needle bearing attachment 3:

1. Check the skeg and torpedo. Replace the 90890-06609
lower case if cracked or damaged. Driver rod SL 4:
90890-06602
Assembling the lower case Bearing depth plate 5:
1. Install the original shim(s) and taper roller 90890-06603
bearing outer race.
Depth b: 182 mm (7.16 in)

2
Assembling the forward gear

1. Install new needle bearing into the for-
ward gear to the specified depth.
1 2
6B460350
1
NOTE:
9 Be sure to select the forward gear shim(s) if a
replacing the lower case or taper roller
bearing.
9 To select the shim(s), see “Shimming.” 61U60110
Bearing outer race attachment 1: Needle bearing attachment 1:

90890-06620 90890-06612
Driver rod LL 2: 90890-06605 Driver rod SS 2: 90890-06604
Depth a:
2. Install the new needle bearing into the
2.5–3.5 mm (0.098–0.137 in)
lower case.
2. Install a new taper roller bearing into the

forward gear using a press.
4 a
5
61U60100
NOTE:
9 Apply gear oil to the needle bearing before
installation. Needle bearing attachment 3:
9 Be careful not to let the stopper a get out 90890-06654
of position when using the driver rod.
6-15 61U5H11

Assembling the drive shaft housing Installing the drive shaft

1. Install the new needle bearing into the 1. Install the forward gear into the lower
drive shaft housing to the specified case.
1
depth.
2. Install the thrust bearing 1 and original
shim(s) 2 onto the drive shaft 3.
3
1
2
2
NOTE:
Be careful not to let the stopper a get out of
position when using the driver rod. NOTE:
6G460160 3
9 Be sure to select the pinion shim(s) if
90890-06610
Driver rod SS 2: 90890-06604
Bearing depth plate 3:
replacing the thrust bearing, drive shaft
housing, drive shaft or lower case.
9 To select the shim(s), see “Shimming.”
4
90890-06603
3. Install the sleeve 4 drive shaft 3 into the
Depth b:
5.75–6.25 mm (0.226–0.246 in)
2. Apply grease to new oil seals, new O-
lower case. Install the pinion 5, pinion
nut 6, and then tighten the pinion nut to
the specified torque.
5
ring, and then install oil seals into the
drive shaft housing to the specified
depth.
3
6
7
5
4
4
NOTE:
6G460150
5
6
8
Install an oil seal halfway into the drive shaft
housing, then the other oil seal.
9
61U60120

90890-06633 NOTE:
Driver rod LS 5: 90890-06606 Install the drive shaft by lifting it up slightly,
then aligning it with the pinion and the spline
Depth c: of the drive shaft.
0.25–0.75 mm (0.01–0.03 in)
61U5H11 6-16

LOWR Lower unit
7 1
2
8
6F660310
1 61U60130
NOTE:
Drive shaft holder 6 7:
Face the shift rod joint connect part to
90890-06520
upward.
Pinion nut holder 8:
90890-06715
4. Install the original shim(s) 4 and pro-
peller shaft housing assembly 5 into the
Pinion nut:
lower case, and then install the straight
93 N·m (9.3 kgf·m, 68.6 ft·lb)
key 6, claw washer 7, and ring nut 8.
4. Install the drive shaft housing 9, and 8

then tighten the drive shaft housing bolt 7
0.
0
9
4 5 6
6S360106
6G460190
NOTE:
NOTE:
Apply LOCTITE 572 to the drive shaft hous-
9 Be sure to select the reverse gear shim(s) if
ing bolts before installation.
replacing the propeller shaft housing, lower
case, or ball bearing.
9 To select the shim(s), see “Shimming”.
Installing the propeller shaft
housing 5. Tighten the ring nut to the specified
1. Set the shift rod joint and dog clutch 1 to torque.
the neutral position as shown.
2. Apply grease to a new O-rings, and then 9

install it onto the propeller shaft housing.
0
3. Install the washer 2 and propeller shaft
assembly 3 into the propeller shaft
housing assembly.
6F660075
6-17 61U5H11

2. Install a new gasket 2, the outer plate

cartridge 3, and dowels 4.
q 4
2
4
1
NOTE:
9 To secure the ring nut, bend one tab q of
6F600065
the claw washer into a slot in the ring nut.

2
9 Bend all other tabs toward the propeller
shaft housing assembly.
Ring nut wrench 3 9:

3
90890-06511
Ring nut wrench extension 0:
90890-06513
Ring nut 8:
6G460210
3. Install the Woodruff key 5 into the drive

shaft.
4. Align the groove in the impeller 6 with
4
103 N·m (10.3 kgf·m, 76.0 ft·lb) the Woodruff key 5, and then install the
Installing the water pump and shift

rod
impeller onto the drive shaft.
6
5
1. Install the shift rod assembly 1.
5 6
7
1 69D60235
5. Install the washers 7, wave washer 8,

spacer 9, and collar 0 onto the drive
shaft.
6G460200
8
9
NOTE:
9 Check the gear shift to the neutral position,
when installing the shift rod.
9 After assembling the lower unit, check that NOTE:
the shift rod operates smoothly, and check 9 The collar and spacer should fit together
firmly.
that the drive shaft and propeller shaft
9 While pulling the drive shaft up, install the
rotates smoothly. collar with an appropriate tool a that fits
over the drive shaft as shown.
61U5H11 6-18

LOWR Lower unit
6. Install the new O-ring q and insert car- NOTE:

tridge w into the pump housing e. 9 When installing the pump housing, apply
q A
grease to the inside of the housing, and
e then turn the drive shaft clockwise while
pushing down the pump housing.
9 Align the cover projection d with the hole
b w e in the pump housing.
b
c
c Installing the lower unit

6G460240 w
NOTE: When installing the lower unit without
Align the insert cartridge projections b with removing the power unit, be sure to sus-
the holes c in the pump housing. pend the outboard motor. Otherwise, the
7. Install the new O-ring r and pump hous- result in injury.
ing assembly t into the lower case,
tighten the bolts y, and then install the
seal u and cover i.
A
i
y d
u
e
A t
r
61U60200
1. Align the center of the set pin a with the

alignment mark b on the bottom cowl-
ing.
6G460250
Water pump housing bolt y:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
cC a
Do not turn the drive shaft counterclock-
wise, otherwise the water pump impeller
may be damaged.
b 61U30230
6-19 61U5H11

2. Set the gear shift to the neutral position 7. Install the grommet 7.
at the lower unit. Make sure that the shift
rod is in the neutral position using a spe- 8. Install the propeller and propeller nut 8,
cial service tool.
1
and then temporarily tighten the nut.
Place a block of wood between the anti-
cavitation plate and propeller to prevent
the propeller from turning, and then tight-
en the nut to the specified torque.
69D60036
2
Shift rod push arm:
90890-06052
3. Install the 2 dowels 1 into the lower unit
and extension 2 (E115A: Y-transom).
8
3
4. Connect the speedometer hose 3.
5. Install the lower unit into the upper case,

and then tighten the lower case mount
4
bolts 4 or nuts to the specified torque.
6. Install the trim tab 5 to its original posi-

tion, and then tighten the trim tab bolt 6
to the specified torque.
5
7
6
6 å 1
1
1 6F660420
3 w
2
1
1
4
9 Do not hold the propeller with your
hands when loosening or tightening it.
9 Be sure to disconnect the battery cables
from the battery and remove the lock
7
1 plate from the engine stop lanyard
5
switch.
9 Put a block of wood between the anti-
cavitation plate and propeller to prevent
the propeller from turning.
8
4
å E115A: Y-transom
4 6G460270
NOTE:
If the grooves in the propeller nut 8 do not
align with the propeller shaft hole, tighten the
9
Lower case mount bolt (nut) 4: nut until they are aligned.
39 N·m (3.9 kgf·m, 28.8 ft·lb)
Trim tab bolt 6: Propeller nut 8:
61U5H11 6-20

LOWR 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.
69D10050
Recommended gear oil:

Hypoid gear oil
API: GL-4
SAE: 90
Gear oil quantity:
760 cm3
(25.70 US oz, 26.81 Imp oz)
10. Install the new gasket, check screw 9

and quickly install the drain screw, then
tighten to specified torque.
Check screw 9 and drain screw:

9 N·m (0.9 kgf·m, 6.6 ft·lb)
6-21 61U5H11

Shimming
Shimming
F
P
R
1
2
3
M3 T3
4
5
M4
6
7
M1
T1
M2
T2
8
6G46090E
9
61U5H11 6-22

LOWR Lower unit
Shimming 2. Install the pinion and pinion nut, and then

NOTE: tighten the nut to the specified torque.
9 Shimming is not required when assembling Pinion nut:
the original lower case and inner parts. 93 N·m (9.3 kgf·m, 68.6 ft·lb)
9 Shimming is required when assembling the
original inner parts and a new lower case. 3. Measure the distance (M4) between the
9 Shimming is required when replacing the special service tool and the pinion as
inner part(s). shown.
Selecting the pinion shim

1. Install the special service tools onto the
drive shaft 1.
M4
4
T3 6S360170
NOTE:
9 Measure the pinion at 4 points to find the
distance average.
6S360150 9 Make of note the each measurement
numerical.

2
4. Turn the thrust bearing 5 2 or 3 times to
3
seat the drive shaft housing 6, and then
measure the housing height (M3) as
shown.
1
6S360160 5
M3
NOTE:
6
9 Select the shim thickness (T3) by using the
specified measurement(s) and the calcula- S60V6640
tion formula.
9 Install the special service tools onto the
drive shaft so that the shaft is at the center NOTE:
of the hole. 9 Measure the thrust bearing at 4 points to
9 Tighten the wing nuts another 1/4 of a turn find the height average.
after they contact the fixing plate 2. 9 Make of note the each measurement
numerical.
Pinion height gauge 3:
90890-06710
6-23 61U5H11

Shimming
5. Calculate the pinion shim thickness (T3) Example:

as shown in the examples below. If “T3” is 0.70 mm, then the pinion shim is
0.68 mm.
1
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 height (M1) as
shown. 2
NOTE:
“P” is the deviation of the lower case dimen-
sion from standard. The “P” mark a is
stamped on the trim tab mounting surface of
3
the lower case in 0.01 mm units. If the “P”
mark is unreadable, assume that “P” is zero
and check the backlash when the unit is
assembled.
M1
4
Calculation formula:
Pinion shim thickness (T3) =
62.5 + P/100 – M3 – M4
6B460550
5
Example:
6
If “M3” is 46.65 mm and “M4” is 15.15 mm
and “P” is (+ 2), then
T3 = 62.5 + (+ 2)/100 – 46.65 – 15.15 mm
= 62.5 + 0.02 – 46.65 – 15.15 mm
= 0.72 mm
6. Select the pinion shim(s) (T3) as follows.
Calculated numeral
Rounded numeral NOTE:
7
at 1/100th place 9 Select the shim thickness (T1) by using the
1, 2
3, 4, 5
6, 7, 8
9, 10
0
2
5
8
specified measurement(s) and the calcula-
tion formula.
9 Measure the bearing outer race at 4 points
to find the height average.
8
9 Make of note the each measurement
Available shim thicknesses:
0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and
0.50 mm
numerical.
Shimming plate 2: 90890-06701

9
61U5H11 6-24

LOWR Lower unit
2. Calculate the forward gear shim thick- Available shim thicknesses:

ness (T1) as shown in the examples 0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and
below. 0.50 mm
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
NOTE: housing.
“F” is the deviation of the lower case dimen- 2. Measure the gear height (M2) from the
sion from standard. The “F” mark a is thrust washer on the propeller shaft
stamped on the trim tab mounting surface of housing.
the lower case in 0.01 mm units. If the “F”
mark is unreadable, assume that “F” is zero
and check the backlash when the unit is
assembled.
2
Forward gear shim thickness (T1) =
M2
24.6 + F/100 – M1
1
Example:
If “M1” is 23.80 mm and “F” is (+5), then
T1 = 24.6 + (+5)/100 – 23.80 mm 6F660520
= 24.6 + 0.05 – 23.80 mm
= 0.85 mm
If “M1” is 23.80 mm and “F” is (0), then

T1 = 24.6 + (0)/100 – 23.80 mm
= 24.6 + 0 – 23.80 mm
= 0.80 mm
3. Select the forward gear shim(s) (T1) as

follows.
Calculated numeral
Rounded numeral
at 1/100th place
1, 2 0
3, 4, 5 2
6, 7, 8 5
9, 10 8
6-25 61U5H11

Shimming/Backlash
NOTE: 4. Select the reverse gear shim(s) (T2) as

9 Without the O-ring, when measuring the follows.
reverse gear height.
9 Select the shim thickness (T2) by using the Calculated numeral
specified measurement(s) and the calcula-
tion formula.
9 Measure the reverse gear at 4 points to find
at 1/100th place
1, 2
3, 4, 5
6, 7, 8
Rounded numeral
2
5
8
1
the height average.
9, 10 10
2
9 Make of note the each measurement
numerical.
0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and
Shimming plate 1: 90890-06701
0.50 mm
3. Calculate the reverse gear shim thick-

ness (T2) as shown in the examples
Example:
If “T2” is 1.30 mm, then the reverse gear shim
is 1.30 mm.
3
below. If “T2” is 1.36 mm, then the reverse gear shim
is 1.38 mm.
Backlash
4
Measuring the forward and reverse
gear backlash
1. Remove the water pump assembly. 5
2. Set the gear shift to the neutral position
NOTE:
“R” is the deviation of the lower case dimen-
sion from standard. The “R” mark a is
at the lower unit.
6
stamped on the trim tab mounting surface of
7
the lower case in 0.01 mm units. If the “R”
mark a is unreadable, assume that “R” is
zero and check the backlash when the unit is
assembled.
69D60035
Reverse gear shim thickness (T2) =
M2 – 27.4 – R/100 Shift rod push arm:
90890-06052
8
Example:
If “M2” is 28.25 mm and “R” is (– 1), then
T2 = 28.25 – 27.4 – (– 1)/100 mm
= 28.25 – 27.4 + 0.01 mm
= 1.36 mm
9
61U5H11 6-26

LOWR Lower unit
3. Install the special service tools so that it 5. Set the lower unit upside down.
pushes against the propeller shaft.
1
3 2 6S360190
NOTE:
NOTE: Install the dial gauge so that the plunger a
While turning the drive shaft clockwise 5–6 contacts the mark b on the backlash indica-
times to contact the gear evenly it tightens tor.
center bolt 3 to specified torque.
Backlash indicator 4: 90890-06706
Center bolt 3: Magnet base plate 5: 90890-07003
5 N·m (0.5 kgf·m, 3.7 ft·lb) Dial gauge set 6: 90890-01252
Magnet base B 7: 90890-06844
Bearing housing puller claw L 1:
90890-06502 6. Slowly turn the drive shaft clockwise and
Stopper guide plate 2: counterclockwise, and measure the
90890-06501 backlash when the drive shaft stops in
Center bolt 3: 90890-06504 each direction.
Forward gear backlash:

4. Install the backlash indicator onto the
0.32–0.50 mm
drive shaft (22.4 mm [0.88 in] in diame-
(0.0126–0.0197 in)
ter), then the dial gauge onto the lower
unit.
7. Add or remove shim(s) if out of specifica-
tion.
Forward gear
Shim thickness
backlash
Less than To be decreased by
0.32 mm (0.0126 in) (0.41 – M) × 0.63
More than To be increased by
0.50 mm (0.0197 in) (M – 0.41) × 0.63
M: Measurement

0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and
0.50 mm
6-27 61U5H11

Backlash
8. Remove the special service tools from 10. Slowly turn the drive shaft clockwise and
the propeller shaft. counterclockwise, and measure the
backlash when the drive shaft stops in
1
9. Apply a load to the reverse gear by each direction.
installing the propeller 8, the spacer 9
(without the washer 0), then the washer
q as shown.
2
3
Reverse gear backlash:
0.80–1.17 mm
(0.0315–0.0461 in)
4
11. Add or remove shim(s) if out of specifica-
tion.
Reverse gear
Shim thickness
5
backlash
Less than
0.80 mm (0.0315 in)
More than
1.17 mm (0.0461 in)
To be increased by
(0.98 – M) × 0.63
To be decreased by
(M – 0.98) × 0.63
6
M: Measurement
NOTE:
6S360200
While turning the drive shaft clockwise 5–6

0.10, 0.12, 0.15, 0.18, 0.30, 0.40 and
0.50 mm
7
times to contact the gear evenly it tightens
propeller nut w to specified torque.
Propeller nut w:
12. Remove the special service tools, and
then install the water pump assembly. 8
5 N·m (0.5 kgf·m, 3.7 ft·lb)
9
61U5H11 6-28

BRKT
Bracket unit
Tiller handle ....................................................................................................7-1

Checking the throttle cable and shift cable ...............................................7-4
Assembling the tiller handle.......................................................................7-4
Lubricating the throttle gear.......................................................................7-4
Bottom cowling ..............................................................................................7-5
Upper case, steering arm ..............................................................................7-8

Disassembling the upper case ................................................................7-12
Checking the upper case.........................................................................7-13
Assembling the upper case .....................................................................7-13
Removing the steering arm .....................................................................7-17
Removing the oil seal of swivel bracket (MH, WH, E).............................7-17
Installing the oil seal of swivel bracket (MH, WH, E)...............................7-17
Installing the steering arm .......................................................................7-18
Installing the upper case..........................................................................7-19
Clamp bracket and swivel bracket .............................................................7-20

Removing the clamp bracket (MH, WH, E) .............................................7-24
Disassembling the swivel bracket (MH, WH, E) ......................................7-25
Assembling the swivel bracket (MH, WH, E)...........................................7-25
Assembling the clamp bracket (MH, WH, E)..........................................7-26
Removing the PTT unit (ET)....................................................................7-30
Removing the clamp bracket (ET) ...........................................................7-30
Installing the clamp bracket (ET) .............................................................7-31
Installing the PTT unit (ET)......................................................................7-32
Adjusting the trim sensor cam (ET) .........................................................7-33
PTT unit .........................................................................................................7-34

Checking the hydraulic pressure .............................................................7-35
PTT motor .....................................................................................................7-38

Disassembling the PTT motor .................................................................7-39
Checking the PTT motor..........................................................................7-40
Checking the filter ....................................................................................7-41
Assembling the PTT motor ......................................................................7-41
Gear pump ....................................................................................................7-42

Disassembling the gear pump housing ...................................................7-44
Checking the main valve .........................................................................7-45
Checking the gear pump .........................................................................7-45
Checking the gear pump housing............................................................7-45
Checking the reservoir.............................................................................7-45
Checking the relief valve .........................................................................7-45
Assembling the gear pump housing ........................................................7-46
61U5H11

Tilt cylinder and trim cylinder.....................................................................7-48
Disassembling the tilt cylinder and trim cylinder .....................................7-50
Checking the tilt cylinder and trim cylinder ..............................................7-51
1
Assembling the tilt piston and trim piston ................................................7-51
Assembling the PTT unit .........................................................................7-52
Bleeding the PTT unit ..............................................................................7-55
Bleeding the PTT unit (built-in) ................................................................7-56
PTT electrical system ..................................................................................7-57

Checking the fuse ....................................................................................7-57
Checking the PTT relay ...........................................................................7-57
Checking the trim sensor.........................................................................7-57
2
3
4
5
6
7
8
9
61U5H11

BRKT
Bracket unit
Tiller handle
MH
11 N·m (1.1 kgf·m, 8.1 ft·lb)
37 N·m (3.7 kgf·m, 27.3 ft·lb)
WH
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

1 Throttle cable 1
2 Bolt 2 M6 × 16 mm
3 Grommet 1
4 Nut 1
5 Tiller handle 1
6 Plastic washer 2
7 Metal washer 2
8 Wave washer 1
9 Bolt 1 M8 × 70 mm
10 Bushing 1
11 Engine stop lanyard switch 1
12 Bolt 2 M6 × 16 mm
13 Bracket 1
14 Cotter pin 1
15 Washer 1
16 Shift cable 1
17 Nut 1
7-1 61U5H11

Tiller handle
MH
11 N·m (1.1 kgf·m, 8.1 ft·lb)
37 N·m (3.7 kgf·m, 27.3 ft·lb) 1

2
WH
3
4
4 N·m (0.4 kgf·m, 3.0 ft·lb)
5
3 N·m (0.3 kgf·m, 2.2 ft·lb)
No. Part name Q’ty

37 N·m (3.7 kgf·m, 27.3 ft·lb)
Remarks
61U7010E
6
18 Washer 1
7
19 Bushing 2
20 Collar 1
21 Ball 1
22 Spring 1
23 Shift lever 1
24
25
26
27
Bolt
Screw
Bolt
Switch holder
1
1
1
2
M6 × 20 mm
ø6 × 26 mm
M6 × 30 mm 8
28 Engine start switch 1
29
30
31
32
Nut
Screw
Throttle grip
Washer
1
1
1
1
9
33 Spring 1
34 Bushing 1
61U5H11 7-2

BRKT
Bracket unit
MH
11 N·m (1.1 kgf·m, 8.1 ft·lb)
37 N·m (3.7 kgf·m, 27.3 ft·lb)
WH
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

36 Screw 1 ø5 × 12 mm
37 Grease nipple 1
39 Cover 1
40 Plate 1
41 Throttle shaft 1
42 Housing 1
43 Bolt 1 M6 × 25 mm
44 Friction piece 1
45 Nut 2
46 Bracket 1
47 Bolt 1 M6 × 25 mm
48 Washer 1
49 Screw 1
50 Shift link rod 1
51 Nut 1
7-3 61U5H11

Tiller handle
Checking the throttle cable and shift

cable 4
5
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
6
1
the outer wire is bent or damaged and
the rubber seals are damaged.
Assembling the tiller handle

1. Install the throttle shaft 1 into the tiller
Lock nut 6:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
61U70480
2
handle 2 so that the pin 3 of the throttle
shaft 1 aligned with the mating surface
of the tiller handle 2 in horizontal posi-
tion.
5. Install the bushing 7, spring 8, throttle
grip 9 and cover 0 into the tiller handle
2. 3
2
A
2
4
7
5
1 3
8 0
9
A A
3
2
61U70490
6
Lubricating the throttle gear
7
1. Inject grease into the grease nipple until
61U70470 grease comes out from the screw hole
a.
2. Insert the throttle cable 4 into the gear
5 until the inner cable is engaged with
the gear.
3. Turn the throttle shaft 1 clockwise to

wind the inner cable around the gear 5.
8
4. Tighten the nut 6. A
a 69D70170
9
61U5H11 7-4

BRKT
Bracket unit
Bottom cowling
24 N·m (2.4 kgf·m, 17.7 ft·lb)
61U7030E

1 Clip 3
2 Shift rod 1
3 Bushing 1
4 Washer 1
5 Shift lever 1
7 Washer 1
8 Bushing 1
9 Bracket 1
10 Grease nipple 1
11 Circlip 1 Not reusable
12 Grommet 1
13 Ball 1
14 Spring 1
15 Bolt 1
7-
7-5 61U5H11

Bottom cowling
1
2
3
4
5
61U7040E
6
1 Clamp 1
M6 × 20 mm
7
2 Bolt 1
3 Plate 1
4 Bolt 1 M8 × 20 mm
5 Bracket 1
6 Holder 2
7
8
9
10
Pin
Holder
Bolt
Wave washer
2
2
3
3
M6 × 12 mm 8
11 Clamp lever 3
12
13
14
15
Bolt
Collar
Pilot hole
Lock lever
1
6
1
3
M6 × 12 mm
9
16 Bolt 1 M8 × 35 mm
17 Clamp 1
61U5H11 7-6

BRKT
Bracket unit
61U7040E

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
7-
7-7 61U5H11

Bottom cowling/Upper case, steering arm
Upper case, steering arm
1
2
51 N·m (5.1 kgf·m, 37.6 ft·lb)
3
4
5
71 N·m (7.1 kgf·m, 52.4 ft·lb)

61U7060E
6
1 Nut 2
7
2 Grommet 1
3 Upper mount 2
4 Bracket 1
5 Washer 2
6 Rubber washer 2
7
8
9
10
Washer
Bolt
Damper
Nut
2
2
2
2
8
11 Washer 2
12
13
14
15
Bolt
Mount housing
Spring
Washer
4
2
4
2
M10 × 45 mm
9
16 Lower mount 2
17 Rubber washer 2
61U5H11 7-8

BRKT
Bracket unit
51 N·m (5.1 kgf·m, 37.6 ft·lb)
71 N·m (7.1 kgf·m, 52.4 ft·lb)

61U7060E

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
7-9 61U5H11

21 N·m (2.1 kgf·m, 15.5 ft·lb)
1
18 N·m (1.8 kgf·m, 13.3 ft·lb)
2
3
4
5
X
18 N·m (1.8 kgf·m, 13.3 ft·lb)

18 N·m (1.8 kgf·m, 13.3 ft·lb)

61U7070E
6
1 Bolt 2 M8 × 45 mm
M8 × 30 mm
7
2 Bolt 2
4 Joint 1
5 Upper exhaust guide 1
7
8
9
10
Lower exhaust guide
Bolt
Gasket
Exhaust manifold
1
4
1
1
M8 × 30 mm
Not reusable 8
11 Bolt 4 M8 × 45 mm
12
13
14
15
Gasket
Muffler
Bolt
Rubber damper
1
1
5
2
Not reusable
M8 × 45 mm
9
16 Clip 2
17 Rubber seal 1 Not reusable
61U5H11 7-10

BRKT
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

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
27 Grommet 1
7-11 61U5H11

Disassembling the upper case 3. Remove the bolts q, exhaust manifold

1. Remove the bolts 1, 2, muffler assem- w and gasket e.
bly 3 and rubber seal 4 from the upper
w
1
case 5. q
1
2
q
3
e
2
4
5
61U70040
4. Remove the bolts r, lower exhaust

3
guide t and gasket y from the upper
61U70010
exhaust guide u.
r
4
2. Remove the bolts 6, muffler 7, cooling r
5
water pipe 8, rubber dampers 9 and
gasket 0. t
y
6
9
6
7
8 6
61U70050
0 7
61U70020
8
61U70060
NOTE:
pry tabs to pry off the exhaust guide.
9
61U70030
NOTE:
pry tabs to pry off the muffler.
61U5H11 7-12

BRKT
Bracket unit
5. Remove the circlip, and then remove 2. Install a new gasket 3, the lower exhaust
drive shaft bushing. guide 4, and bolts 5, and then tighten
the bolts to the specified torque.
5
o
p
4
o
i 3
61U70220
Bearing puller assembly i:

90890-06535
Stopper guide stand o:
90890-06538
61U70070
Stopper guide plate p:
90890-06501 Exhaust guide bolt 5:
18 N·m (1.8 kgf·m, 13.3 ft·lb)
Checking the upper case
1. Check the rubber dampers. Replace if 3. Install a new gasket 6, the exhaust man-
deteriorated or cracked. ifold 7, and bolts 8, and then tighten the
bolts to the specified torque.
2. Check the cooling water pipe. Replace if
deformated or corrosion.
7
3. Check the exhaust guide, exhaust mani- 8
fold, and muffler. Replace if deformated
8
or corrosion.
Assembling the upper case 6
1. Install the drive shaft bushing into the
upper case, and then install the circlip.
1
61U70080
Exhaust manifold bolt 8:

18 N·m (1.8 kgf·m, 13.3 ft·lb)
61U70230
NOTE:
After installing the drive shaft bushing, apply
grease to the inside of the bushing.

90890-06653
Driver rod L3 2: 90890-06652
7-13 61U5H11

4. Install the rubber damper 9 and clip 0

onto the muffler q. y u
1
5. Install the cooling water pipe w onto the
muffler q.
t
6. Install the new gasket, muffler q onto the
exhaust guide assembly e, and then
tighten the bolts r to the specified
torque.
0
2
e 9
q
a w
61U70100
3
r
w Upper case mount bolt y and u:

21 N·m (2.1 kgf·m, 15.5 ft·lb) 4
9. Install the upper mounts i and bolts o
5
61U70090
as below shown.
i o
p
6
7
6S370016
61U70360
Muffler bolt r: NOTE:

18 N·m (1.8 kgf·m, 13.3 ft·lb) Install the upper mounts i so that the mark
p of the upper mounts toward the forward
7. Install the muffler assembly t during

inserting the tip of the cooling water pipe
w into the joint hole a of the upper case.
side.
8
8. Tighten the muffler assembly bolts y and
u to the specified torque.
9
61U5H11 7-14

BRKT
Bracket unit
10. Install the upper mounts a and bracket 12. Install the lower mounts f and mount
s into the upper case assembly, and housings j and tighten the bolts k.
then tighten it with the bolts d.
d
s
j k 61U70240
S60V7230
NOTE:
First tighten the center located, when tighten
the bolts d.
11. Install the lower mounts f and bolts g

as below shown.
f h
g
61U70017
NOTE:
Install the lower mounts f so that the mark
h of the lower mounts toward the reverse
side.
7-15 61U5H11

1
MH, WH, E
2
36 N·m (3.6 kgf·m, 26.6 ft·lb)
3
4
5
61U7080E
6
1 Steering arm 1
7
2 Washer 1
3 Bushing 2
4 Bracket assembly 1
6 Bushing 1
7
8
9
10
Washer
Steering yoke
Circlip
Nut
1
1
1
2
8
11 Trim stopper 2
12
13
Damper
Oil seal
1
1 Not reusable
9
61U5H11 7-16

BRKT
Bracket unit
Removing the steering arm Installing the oil seal of swivel

1. Remove the circlip 1. bracket (MH, WH, E)
1. Install the bushing 1 and oil seal 2.
1
2
1
3
S69J7075
4 61U70250
2. Remove the steering yoke 2 as shown. Needle bearing attachment 3:

90890-06654
2 Driver rod L3 4: 90890-06652
4
61U70120

90890-06611
Gear puller 4: 90890-06540
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 flat
head driver.
61U70130
7-17 61U5H11

Installing the steering arm 4. Install the steering yoke 9 to the steer-
1. Install the washer 1 and bushing 2 onto ing arm 3 by aligning the center a of the
the steering arm 3. yoke with the center b of the steering
2. Place the swivel bracket 4 in an upright

position, and then install the steering arm
3 onto the bracket assembly.
arm.
NOTE:
Hold the steering arm after tilt up the swivel
bracket, and then strike the steering yoke
1
until the circlip installing groove visible.
5. Install the circlip 0. 2

3
9
b
3
3. Install the bushing 5, new O-ring 6,
4
0 a
bushing 7, and washer 8 onto the
bracket assembly. 6S370020
6. Inject grease into the grease nipple until

5
grease comes out from both the upper
5
and lower bushings c.
6
6
7
8
7
6G470150
8
9
61U5H11 7-18

BRKT
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.
6S370025
NOTE:
Before tighten the uppercase, wiring the
ground lead.
Upper mount nut 2:

51 N·m (5.1 kgf·m, 37.6 ft·lb)
Lower mount nut 3:
71 N·m (7.1 kgf·m, 52.4 ft·lb)
3. Install the covers.
6S370026
7-19 61U5H11

Upper case, steering arm/Clamp bracket and swivel bracket
Clamp bracket and swivel bracket

15 N·m (1.5 kgf·m, 11.1 ft·lb)
1
2
3
4
5
61U7035E
6
1 Cap 2
7
2 Self-locking nut 1
3 Bolt 6 M10 × 45 mm
4 Clamp bracket 1
5 Grease nipple 3
6 Ground lead 1
7
8
9
10
Washer
Bushing
Swivel bracket
Bushing
2
2
1
2
8
11 Shock absorber 1
12
13
14
15
Bushing
Bracket
Bolt
Pin
2
1
1
1
M6 × 14 mm
9
16 Through tube 1
17 Clamp bracket 1
61U5H11 7-20

BRKT
Bracket unit
15 N·m (1.5 kgf·m, 11.1 ft·lb)
61U7035E

18 Anode 1
19 Bolt 4 M6 × 30 mm
20 Tilt pin 1
21 Pin 1
22 Circlip 1
7-21 61U5H11

1
2
3
4
5
61U7140E
6
1 Tilt stop lever 1
7
2 Bushing 6
3 Tilt lock lever 1
4 Pin 3
5 Spring 1
6 Plate 1
7
8
9
10
Bolt
Distance collar
Collar
Cotter pin
1
1
1
1
M6 × 10 mm
8
11 Lever 1
12
13
14
15
Rod
Pin
Cotter pin
Washer
1
1
2
2
9
16 Arm 1
17 Bracket 1
61U5H11 7-22

BRKT
Bracket unit
61U7140E

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
7-23 61U5H11

Removing the clamp bracket

(MH, WH, E) 7
w
9 Do not tamper or attempt to open the
shock absorber.
9 Do not subject the shock absorber to an 6 5
1
open flame or any other source of high
2
heat. High heat can cause an explosion
due to excessive gas pressure.
9 Do not deform or damage the shock
absorber. If the shock absorber is dam-
61U70430
aged, damping performance will suffer.
1. Fully tilt the outboard motor up, and then

support it with the tilt stop lever 1. 4. Remove the circlip 8, pin 9, and then
shock absorber 0.
3
8
1
9
4
0
61U70450 5
5. Remove the starboard clamp bracket q
2. Remove the tilt pin 2, anode 3, and

61U70410
in the direction arrow.
6. Remove the washer w.

6
clamp bracket bolt 4. 7. Remove the swivel bracket e.
e w 7
4
8
2 3
61U070420
3. Remove the caps 5, self-locking nut 6

and then ground lead 7.
q
61U70460
9
61U5H11 7-24

BRKT
Bracket unit
Disassembling the swivel bracket Assembling the swivel bracket

(MH, WH, E) (MH, WH, E)
1. Remove the 2 large springs 1 and 2 cot- 1. Install the rod 1 and rod 2 into the tilt
ter pins 2. lock lever 3, and then install the tilt lock
lever to the swivel bracket 4.
2. Remove the cotter pin 3 and lever 4.
2. Install the tilt stopper 5 into the swivel
bracket 4 with the cotter pin 6 and pin
4 7.
1
1
NOTE:
3 Pass the tilt stopper 5 into the bushing 8.
2
2 3. Install the tilt stopper 9 with the pin 0.
61U70540
4. Install the plate q and spring w and
then hook the spring w to the distance
collar e.
3. Remove the pin 5 and tilt lock lever 6.
5. Install the tilt lock lever r with pin t.
4. Remove the 2 pins 7 and cotter pin 8
and then remove the both tilt stopper 9, 6
0. 8
0 e 7
5. Remove the tilt lock lever q.
5
8 1
7
9
w
0 q 3
2
4
9
q r t
61U70570
6 5
61U70550
7-25 61U5H11

6. Install the lever y to the swivel bracket

4 with the cotter pin u. 4 5
1
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.
4
2
6
2
61U70510
a
p
y
p
4. Tighten the self-locking nut 7 in tempo-
rary tight.
3
5. Install the shock absorber 8 into the
4
o
u swivel bracket 4.
6. Install the pin 9 with the circlip 0.

i o
61U70560 0
NOTE:
After assembling the swivel bracket, check
the tilt stop lever for proper operation.
4
9 5
7
Assembling the clamp bracket
(MH, WH, E)
1. Pass the through tube 1 into the clamp
bracket 2 and washer 3.
8
61U70520
6
7. Tighten the self-locking nut 7 in the
specified torque.
3
Self-locking nut 7:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
7
8. Install the clamp bracket bolt q, anode
8
w and tilt pin e.
1
2
61U70500
2. Install the swivel bracket 4 to the clamp

bracket 2.
3. Install the washer 5 and starboard

q 9
clamp bracket 6.
e w
61U070530
9. Install the ground lead and caps.
61U5H11 7-26

BRKT
Bracket unit
15 N·m (1.5 kgf·m, 11.1 ft·lb) ET
2 N·m (0.2 kgf·m, 1.5 ft·lb)
61U7020E

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
8 Washer 2
9 Bushing 2
10 Trim sensor 1
11 Screw 2 ø6 × 15 mm
12 Trim sensor cam 1
13 Screw 1 ø6 × 25 mm
14 Clamp 1
15 Bolt 4 M6 × 30 mm
16 Bracket 2
17 Anode 1
7-27 61U5H11

15 N·m (1.5 kgf·m, 11.1 ft·lb) ET
1
2
3
2 N·m (0.2 kgf·m, 1.5 ft·lb)
4
5
61U7020E
6
18 Through tube 1
M8 × 20 mm
7
19 Bolt 1
21 Bushing 4
22 Collar 1
23 Distance collar 1
24
25
26
27
Spring pin
Spring
Spring hook
Bolt
2
1
1
1 M6 × 10 mm
8
9
61U5H11 7-28

BRKT
Bracket unit
61U7090E

1 PTT unit 1
2 PTT motor lead 1
3 Pin 1
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
7-29 61U5H11

Removing the PTT unit (ET) w

1. Fully tilt the outboard motor up, and then Do not remove the tilt stop lever 1 from
support it with the tilt stop lever 1. the clamp brackets.
1 5. Remove the lock ties 6, and then pull

out the PTT motor lead 7.
1
6. Remove the circlip 8, and then remove
the pin 9.
7. Remove the PTT unit 0.

1
2
6G470190
3
5
9
8
7
6 4
w
9 After tilting up the outboard motor, be 4
3
0 5
sure to support it with the tilt stop lever. 61U70260
Otherwise, the outboard motor could
suddenly lower if the PTT unit should
lose fluid pressure.
9 When removing the PTT unit without
Removing the clamp bracket (ET)
1. Remove the PTT unit. For removal pro-
cedures, see “Removing the PTT unit.”
6
result in injury.
2. Remove the screw 1 and grease nipples
2, and then disconnect the ground leads
3.
7
8
NOTE:
If the PTT does not operate, turn the manual
valve 2 counterclockwise and tilt the out-
board motor up manually.
2. Disconnect the ground lead 3 at the bot-

tom of the PTT unit.
3. Remove the anode 4.

9
4. Loosen the self-locking nut 5, and then
move the clamp brackets slightly in the
direction of the arrows.
61U5H11 7-30

BRKT
Bracket unit
5 3. Assemble the clamp brackets, washers,

swivel bracket, trim sensor, and then
3
install the through tube.
1
9 w
2
8
4 0
q a
6G470765
8
6 NOTE:
7 9 Align the projection inside of the trim sensor
cam with the through tube hole a, and then
61U70360
install it.
9 Adjust the trim sensor cam after installing
3. Remove the trim sensor cam screw 4.
the PTT.
4. Remove the self-locking nut 5 and bolt

4. Install the bolts on the through tube.
6.
5. Install the ground lead between the
5. Remove the through tube 7, then disas-
clamp brackets and the swivel bracket.
semble the clamp brackets 8 and then
remove the swivel bracket 9.
6. Remove the trim sensor 0.
7. Remove the pins q and tilt stop levers

w.
Installing the clamp bracket (ET)

1. Install the tilt stop levers onto the swivel
bracket assembly.
2. Install the trim sensor 1 and bushings 2

onto the swivel bracket assembly.
2 1
6G470760
7-31 61U5H11

Installing the PTT unit (ET) 7. Fasten the PTT motor lead and trim sen-
1. Fully tilt the outboard motor up, and then sor lead with the lock ties 9.
support it with the tilt stop lever 1.
1
1
4
5
6
1
8
9
2
6G470720
2
3
3
7
w 3
9 When installing the PTT unit without
61U70280
8. Inject grease into all grease nipples until

4
outboard motor could suddenly fall and grease comes out from the bushings a.
result in injury.
9 After tilting the outboard motor up, be
sure to support it with the tilt stop lever. 5
2. Lift the PTT unit up, install the lower
mounting shaft 2 and then tighten the
bolts 3.
3. Install the tilt ram upper end into the swiv-

6
el bracket with the pin 4 and circlip 5.
4. Tighten the self-locking nut 6 to the

specified torque.
a
7
Self-locking nut 6:
15 N·m (1.5 kgf·m, 11.1 ft·lb)
5. Install the anode 7. 6G470770

8
6. Pass the PTT motor lead 8 through the
hole of the port clamp bracket.
9
61U5H11 7-32

BRKT
Bracket unit
Adjusting the trim sensor cam (ET) 5. If the trim sensor voltage is out of specifi-
1. Fully retract the PTT unit. cation, adjust the trim sensor cam 2 until
the specified trim sensor setting voltage
2. Connect the test harness to the trim sen- is obtained.
sor coupler.
B O B
P Gy P
2
61U70590
DCV
G 61U70580
Test harness 1:
90890-06878
Digital circuit tester:
90890-03174
3. Turn the engine start switch to ON.
4. Measure the trim sensor voltage.
Trim sensor voltage:

Pink (P)–Black (B)
0.03–0.11 V
7-33 61U5H11

Clamp bracket and swivel bracket/PTT unit
PTT unit
7 N·m (0.7 kgf·m, 5.2 ft·lb)

1
2
5 N·m (0.5 kgf·m, 3.7 ft·lb)
3
5 N·m (0.5 kgf·m, 3.7 ft·lb)
4
5
61U7100E
6
1 PTT motor 1
7
2 Reservoir 1
3 Reservoir cap 1
6 Bolt 3 M6 × 13 mm
7
8
9
10
Bolt
O-ring
Filter
Joint
4
1
1
1
M6 × 34 mm
Not reusable
8
9
61U5H11 7-34

BRKT
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. 2
1
4
6G470240
3
NOTE:
6G470250
should overflow out of the filler hole when the NOTE:
reservoir cap is removed. Quickly install the special service tools before
any fluid flows out of the hole.
3. If necessary, add sufficient fluid of the
recommended type until it overflows out Up relief fitting 3: 90890-06773
of the filler hole. Hydraulic pressure gauge 4:
90890-06776
ATF Dexron 2
7. Connect the PTT motor leads to the bat-
tery terminals to fully retract the trim and
4. Install the reservoir cap, and then tighten tilt rams.
it to the specified torque.
Reservoir cap: Sb Lg
7 N·m (0.7 kgf·m, 5.2 ft·lb)
5. Remove the circlip 1, then remove the

manual valve 2.
6G470260
6. Install the up relief fitting 3 and hydraulic
pressure gauge 4.
Battery
Rams PTT motor lead
terminal
Light green (Lg) +
Down
Sky blue (Sb) -
7-35 61U5H11

PTT unit
8. Reverse the PTT motor leads between 10. Remove the reservoir cap, and then
the battery terminals to fully extend the check the fluid level.
trim and tilt rams, and then measure the
1
hydraulic pressure.
Lg Sb
6G470240
2
6G470270 NOTE:
Rams PTT motor lead

Battery
terminal
reservoir cap is removed.
3
Sky blue (Sb) +
4
Up
Light green (Lg) - 11. If necessary, add sufficient fluid of the
Hydraulic pressure (up): of the filler hole.
10–12 MPa (100–120 kgf/cm2)
5
12. Install the reservoir cap, and then tighten
9. Replace the up relief fitting with the down
relief fitting 5. Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
6
5
6G470280 7
NOTE:
Quickly install the special service tools before
any fluid flows out of the hole.
Down relief fitting 5: 90890-06774

8
Hydraulic pressure gauge:
90890-06776
9
61U5H11 7-36

BRKT
Bracket unit
13. Connect the PTT motor leads to the bat- 15. Remove the special service tools, and
tery terminals to fully retract the trim and then install the manual valve and circlip.
tilt rams, and then measure the hydraulic
NOTE:
pressure. If out of specification, overhaul
Quickly install the manual valve before any
the PTT unit.
fluid flows out of the hole.
Manual valve:
Sb Lg
3 N·m (0.3 kgf·m, 2.2 ft·lb)
6G470260
Battery
Rams PTT motor lead
terminal
Light green (Lg) +
Down
Sky blue (Sb) -
Hydraulic pressure (down):

6–9 MPa (60–90 kgf/cm2)
14. Reverse the PTT motor leads between

the battery terminals to fully extend the
trim and tilt rams.
Lg Sb
6G470270
Battery
Rams PTT motor lead
terminal
Sky blue (Sb) +
Up
Light green (Lg) -
7-37 61U5H11

PTT unit/PTT motor
PTT motor
1
2
3
4
5
6
61U7110E

7
2 Stator 1
3 Armature 1
6 Brush holder 1
8
7 Brush 1 1
8 Brush 2 1
9 Brush holder 1
10 Brush spring 2
11 PTT motor base 1
12
13
14
Oil seal
Bearing
Screw
1
1
2
Not reusable
ø4 × 15 mm
9
61U5H11 7-38

BRKT
Bracket unit
Disassembling the PTT motor 4. Remove the armature from the PTT
1. Loosen the bolts 1, remove the PTT motor base.
motor 2, O-ring 3, gear pump filter 4,
and joint 5 from the gear pump housing. cC
2 Do not allow grease or oil to contact the
commutator.
1
5. Disconnect the PTT motor lead 0.
3
Lg
4
5 Sb
0
61U70140
w 6G470310
9 Make sure that the trim and tilt rams are NOTE:
fully extended when removing the PTT Hold the brush with a screwdriver as shown,
motor, otherwise fluid can spurt out and then disconnect the PTT motor lead 0.
from the unit due to internal pressure.
9 Do not push the trim and tilt rams down
while the PTT motor is removed from the 6. Remove the screw, disconnect the PTT
PTT unit, otherwise fluid can spurt out. motor lead q, and then remove the
brushes w.
2. Remove the lead holder 6 and rubber
spacers 7 from the stator, and then slide Lg
q
them away from the stator.
3. Remove the screws 8 and the stator 9.
67 Sb
9
w
w
8 6G470300
a
NOTE:
Place a clean cloth over the end of the arma-
6G470320
ture shaft, hold it with a pair of pliers, and
then carefully slide the stator off of the arma-
ture.
7-39 61U5H11

PTT motor
cC 3. Measure the commutator undercut b.

Replace the armature if below specifica-
9 Do not pull the PTT motor leads out from
tion limit.
the stator.
9 Do not touch the bimetal a, otherwise
the operation of the circuit breaker can
be affected.
b 1
Checking the PTT motor
1. Check the commutator. Clean with 600 –
grit sandpaper and compressed air if
dirty.
2
6F680180
Commutator standard
undercut b:
1.35 mm (0.053 in)
3
Wear limit: 0.85 mm (0.033 in)
6G480220
4. Check the armature for continuity.
Replace if not shown as below chart.
4
5
2. Measure the commutator diameter.
tion limit.
c d
6
a
6S370140
7
Commutator standard Armature continuity
diameter a:
22.0 mm (0.87 in)
Wear limit:
21.0 mm (0.83 in)
Commutator segments c
Segment c –
Armature core d
Continuity
No continuity
8
Segment c –
Armature shaft e
No continuity
9
61U5H11 7-40

BRKT
Bracket unit
5. Measure the brush length. Replace if Assembling the PTT motor

below specification limit. 1. Connect the PTT motor leads 1, and
then tighten the screws 2.
1 Lg
f Sb
2
6S370150
6G470370
Brush standard length:

9.8 mm (0.39 in) 2. Install the spring and push the brushes 3
Wear limit f: into the brush holder, and then install the
4.8 mm (0.19 in) armature 4.
6. Check the base. Replace if cracked or

damaged.
7. Check the bearing and oil seal. Replace

if damaged or worn.
Checking the filter

1. Check gear pump filter 1. Clean if there
is dirt or residue.
3. Install the stator 5 onto the base.

1
5
61U70210
6G470390
NOTE:
Place a clean cloth over the end of the arma-
ture shaft, hold it with a pair of pliers, and
then carefully slide the stator over the arma-
ture.
7-41 61U5H11

PTT motor/Gear pump
Gear pump
6 N·m (0.6 kgf·m, 4.4 ft·lb)
1
2
3
8 N·m (0.8 kgf·m, 5.9 ft·lb)
4
8 N·m (0.8 kgf·m, 5.9 ft·lb)
5
6
3 N·m (0.3 kgf·m, 2.2 ft·lb)
61U7120E

1 Bolt 4 M5 × 16 mm
7
2 Gear pump assembly 1
3 Ball 2
4 Shuttle piston 2
6 Main valve 2
7
8
9
10
Ball
Bolt
Bolt
Circlip
2
1
2
1
8
11 Manual valve 1
12
13
14
15
O-ring
O-ring
Backup ring
Spring
1
1
1
1
Not reusable
Not reusable
9
16 Absorber valve pin 1
17 Ball 1
61U5H11 7-42

BRKT
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

18 Up-relief valve seat 1
20 Filter 2
22 Down-relief valve 1
23 Valve pin 1
25 Valve seat 1
26 Pin 1
27 Ball 1
28 Drive gear 1
29 Driven gear 1
7-43 61U5H11

Gear pump
Disassembling the gear pump hous- 3. Remove the bolts 9, gear pump cover
ing 0, drive gear q and driven gear w.
1. Remove the bolts 1 and gear pump 9
housing 2.
0
1
5
w
r
e
q
2
3
3
4
1
2
1
3
1 61U70170
NOTE:
Make sure that the O-rings 3, valve pin 4,
and valve seat assembly 5 are removed.
NOTE:
61U70180
Make sure that the shuttle pistons e and

4
balls r are removed, so that they tend to
2. Remove the filters 6, down-relief valve
7, and O-ring 8 from the gear pump
housing.
stick to the gear pump cover.
4. Remove the up-relief valve assembly t

5
67 and balls.
8
6
t
6
7
6
NOTE:
61U70370
Use compressed air to remove the filter deep

61U70380 8
inside of the gear pump housing, and be
careful not to blow the filter out abruptly.
9
61U5H11 7-44

BRKT
Bracket unit
5. Cover the pump housing with a clean Checking the main valve
cloth, and then blow compressed air 1. Check the main valve 1. Clean if there is
through holes a and b while holding the dirt or residue.
cloth down.
6. Remove the main valves y.

1
y 61U70290
Checking the gear pump

1. Check the drive gear and driven gear.
Replace the gear pump assembly if there
are damage or wear.
a
b 6G470430
Checking the gear pump housing
1. Check the inside of the gear pump hous-
w ing. Replace if scratched or worn.
Never look into the pump housing open-
ing while removing the main valves Checking the reservoir
because the main valves and PTT fluid 1. Check the reservoir and O-ring. Replace
can be forcefully expelled out. if deteriorated and cracked.
Checking the relief valve

7. Remove the circlip u and then remove 1. Check the up-relief valve 1 and down-
the manual valve i. relief valve 2. Clean if there is dirt or
residue.
i
u 61U70300
2. Check the valve seat. Clean if there is

dirt. Replace if damaged or worn.
6G470440
7-45 61U5H11

Gear pump
Assembling the gear pump housing 4. Install the balls 0, shuttle pistons q, and
1. Install a new O-ring 1, up-relief valve balls w into the gear pump cover.
seat 2, ball 3, absorber valve pin 4,
1
and spring 5 into the gear pump hous-
ing.
q
5
0
4
1
3
2
w
2
2. Install new O-rings 6 onto the main
valves 7, and then install the main
6G470450
6G470480 3
NOTE:
valves into the gear pump housing. Apply fluid to the balls w and shuttle pistons
q to prevent them from falling out of the gear
pump cover. 4
5
5. Install the gear pump cover e into the
gear pump housing, and then tighten the
bolts.
3. Install the drive gear 8 and driven gear

9 into the gear pump housing as shown.
6
e
9 7
8
6G470470
61U70200
6. Check that the gear pump turns smooth-

8
ly, and then tighten the gear pump cover
bolts to the specified torque.
Gear pump cover bolt:

6 N·m (0.6 kgf·m, 4.4 ft·lb)
9
61U5H11 7-46

BRKT
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.
u
t i
r
y
6G470500
9. Install a new O-ring o, p onto the man-

ual valve a.
p
o
a
61U70390
10. Install the manual valve a and circlip s

into the gear pump housing i.
a
s
61U70400
Manual valve a:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
7-47 61U5H11

Gear pump/Tilt cylinder and trim cylinder
Tilt cylinder and trim cylinder
1
127 N·m (12.7 kgf·m, 93.7 ft·lb)
2
3
132 N·m (13.2 kgf·m, 97.4 ft·lb)
4
96 N·m (9.6 kgf·m, 70.8 ft·lb)
5
61U7130E
6
1 Tilt ram 1
7
2 Trim ram 2
3 Cylinder body 1
4 Free piston 1
5 Backup ring 1
7 Dust seal 2
8
Not reusable
8 Seal 2 Not reusable
9 Trim cylinder end screw 2
11 Backup ring 2
12
13
14
15
O-ring
Dust seal
Tilt cylinder end screw
O-ring
2
1
1
1
Not reusable
Not reusable
Not reusable
9
17 Tilt piston 1
61U5H11 7-48

BRKT
Bracket unit
127 N·m (12.7 kgf·m, 93.7 ft·lb)
132 N·m (13.2 kgf·m, 97.4 ft·lb)
96 N·m (9.6 kgf·m, 70.8 ft·lb)
61U7130E

20 Washer 1
21 Nut 1
22 Ball 4
23 Valve 4
24 Spring 4
7-49 61U5H11

Disassembling the tilt cylinder and 5. Drain the fluid.

trim cylinder
1. Hold the PTT body in a vise using alu- 6. Install the trim piston assemblies, and
1
minum plates on the both sides. then temporarily tighten the trim cylinder
end screws.
2. Loosen the tilt cylinder end screw 1, and
then remove the tilt piston assembly. 7. Cover the tilt cylinder opening with a
clean cloth 4, and then blow com-
1
pressed air through the hole a to remove
the free piston 5.
2
6G470510
3
cC
Make sure that the ram are fully extended
before removing the end screw. 4
Trim and tilt wrench 2:
90890-06587
3. Drain the fluid.

5
4. Loosen the trim cylinder end screws 3,
and then remove the trim piston assem-
blies.
w
Never look into the tilt cylinder opening
6
while removing the free piston because
the free piston and PTT fluid can be force-
fully expelled out.
7
8. Loosen the trim cylinder end screws, and
2
3 6G470520
then remove the trim piston assemblies.
8
90890-06587
9
61U5H11 7-50

BRKT
Bracket unit
Checking the tilt cylinder and trim Assembling the tilt piston and trim
cylinder piston
1. Disassemble the tilt piston assembly. 1. Install the new dust seal 1 and new O-
rings 2 and 3 onto the tilt cylinder end
screw.
4
1
1
2 3
1
2
3
2
3
6G470550
6G470540
2. Install the tilt cylinder end screw onto the
tilt ram.
2. Check the tilt piston 1 and free piston 2.
Replace tilt piston and free piston if worn 3. Install the new O-rings 4 and 5 onto the
or deteriorated. tilt piston 6.
3. Blow the tilt piston absorber valve 3 with 4. Install the ball 7, valve 8, and spring 9,
compressed air to remove any dust. in this order.
Check the valve and spring. Replace if
worn or deteriorated. 5. Install the tilt piston assembly and wash-
er 0 onto the tilt ram, and then tighten
4. Check the tilt ram 4 and trim rams for the tilt piston nut q to the specified
bends or excessive corrosion. Polish with torque.
400–600 grit sandpaper if there is light
rust or replace if necessary.
4
5. Check the trim pistons. Replace if 5
scratched.
0 98
q
6. Check the inner walls of the trim and tilt
cylinders. Replace if scratched.
4 6
7 5 6G470560
Tilt piston nut q:

96 N·m (9.6 kgf·m, 70.8 ft·lb)
7-51 61U5H11

6. Install a new backup ring w and a new Recommended PTT fluid:

O-ring e onto the free piston r. ATF Dexron II
Fluid quantity:
30 cm3 (1.0 US oz, 1.1 Imp oz)
2. Push the free piston 1 into the tilt cylin-

der until it bottoms out.
1
2
7. Install a new seal t, a new dust seal y,
and a new O-ring u onto each trim cylin-
der end screw. 3
8. Install the backup ring i and a new O-
ring o onto each trim piston.
y
t
3. Fill the trim cylinders with the recom-
mended fluid to the correct level through
holes b and c, and d as shown.
4
y
u
u
i
o
5
t
i
o
6G470580 b c
6
Assembling the PTT unit
1. Fill the tilt cylinder with the specified
amount of the recommended fluid
7
through the hole a to bleed the fluid pas- d
sage.
6G470610
8
a
9
6G470590
61U5H11 7-52

BRKT
Bracket unit
4. Install the trim piston assemblies into the Gear pump housing mounting bolt 8:
trim cylinders, and then tighten the trim 8 N·m (0.8 kgf·m, 5.9 ft·lb)
cylinder end screws to the specified
torque. 7. Install the O-ring into the reservoir cap.
8. Install the reservoir and new O-ring onto

the gear pump housing.
Reservoir tank mounting bolt:

5 N·m (0.5 kgf·m, 3.7 ft·lb)
2 9. Fill the tilt cylinder with the recommended

3 6G470525 fluid to the correct level through the hole
e as shown.
cC
9 Make sure that the trim rams are fully
extended when installing them.
e
9 Once installed, never push the trim rams
down, otherwise fluid can spurt out.

90890-06587
6G470630
Trim cylinder end screw 3:

10. Install the tilt piston assembly into the tilt
132 N·m (13.2 kgf·m, 97.4 ft·lb)
cylinder, and then tighten the tilt cylinder
end screw 9 to the specified torque.
5. Install the new O-rings 4, valve pin 5,
and valve seat assembly 6 onto the tilt
cylinder.
NOTE:
Refer to the illustration for valve pin and valve
seat assembly installation.
6. Install the gear pump housing 7 with the

bolts 8.
6G470640
4
7
4 8
5
8
8 61U70600
7-53 61U5H11

13. Remove all of the air bubble using a

2
syringe or suitable tool.
9 NOTE:
Turn the joint with a screwdriver to bleed the
gear pump.
14. Install a new O-ring w and the PTT motor

1
e, and then tighten the bolts r to the
2
6G470650
specified torque.
cC r
9 Make sure that the tilt ram is fully
extended when installing it. e
9 Once installed, never push the tilt ram
down, otherwise fluid can spurt out. w 3
90890-06587
Tilt cylinder end screw 9:

NOTE:
6G470680
Align the armature shaft with the recess in the

4
127 N·m (12.7 kgf·m, 93.7 ft·lb)
joint.
11. Install the joint 0 and gear pump filter q

into the gear pump housing. PTT motor mount bolt r:
5 N·m (0.5 kgf·m, 3.7 ft·lb)
5
q
0
check the fluid level in the reservoir.
NOTE:
6
7
6G470660

12. Fill the gear pump housing with the rec- recommended type until it overflows out
ommended fluid to the correct level as
shown.
of the filler hole.

8
Reservoir cap:
7 N·m (0.7 kgf·m, 5.2 ft·lb)
18. Bleed the PTT unit.

9
19. Check the hydraulic pressure of the PTT
6G470670 unit.
61U5H11 7-54

BRKT
Bracket unit
Bleeding the PTT unit 6. Connect the PTT motor leads to the bat-
1. Tighten the manual valve 1 clockwise. tery terminals to fully retract the trim and
tilt rams.
Sb Lg
6G470830
Battery
Rams PTT motor lead
terminal
2. Place the PTT unit in an upright position. Light green (Lg) +
Down
Sky blue (Sb) -
check the fluid level in the reservoir. 7. Reverse the PTT motor leads between
the battery terminals to fully extend the
NOTE:
trim and tilt rams.
Lg Sb
of the filler hole.

ATF Dexron II
6G470840

Battery
it to the specified torque. Rams PTT motor lead
terminal
Reservoir cap: Sky blue (Sb) +
7 N·m (0.7 kgf·m, 5.2 ft·lb) Up
Light green (Lg) -
NOTE:
9 Repeat this procedure so that the rams go
up and down 4 or 5 times (be sure to wait a
few seconds before switching the leads).
9 If the rams do not move up and down easi-
ly, push and pull on the rams to assist oper-
ation.
7-55 61U5H11

8. Check the fluid level when the tilt ram is 3. Support the outboard motor with the tilt
fully extended. Add sufficient fluid if nec- stop lever 1.
essary.
Bleeding the PTT unit (built-in)

1. Check the manual valve is fully tightened,
and then connect the battery to the bat-
1
1
tery leads.
6G470190
2
w
After tilting up the outboard motor, be
sure to support it with the tilt stop lever.
3
6G470740 Otherwise, the outboard motor could sud-
4
denly lower if the PTT unit should lose
NOTE: fluid pressure.
If the manual valve is loosened, be sure to
tighten it to the specified torque before tilting 4. Let the fluid settle for 5 minutes.
the outboard motor up.
Manual valve:
3 N·m (0.3 kgf·m, 2.2 ft·lb)
5. Remove the reservoir cap 2, and then
check the fluid level in the reservoir.
5
2. Operate the PTT switch of the remote
control box to fully tilt the outboard motor
up and fully tilt it down. Repeat this pro-
cedure 4 or 5 times.
6
7
2
6G470750
NOTE:
8

recommended type to the correct level.

9
ATF Dexron II
61U5H11 7-56

BRKT
Bracket unit
7. Install the reservoir cap, and then tighten 3. Connect the sky blue (Sb) lead or the
it to the specified torque. light green (Lg) lead to the positive bat-
tery terminal and the black (B) lead to the
NOTE:
negative battery terminal as shown.
Repeat this procedure until the fluid is at the
correct level. 1
Reservoir cap:
Sb (Lg)
7 N·m (0.7 kgf·m, 5.2 ft·lb)
3
2
PTT electrical system
B
Checking the fuse
61U70320
1. Check the fuse for continuity. Replace if
there is no continuity.
4. Check for continuity between terminals.
Replace the PTT relay if not shown as
Checking the PTT relay below chart.
1. Check the PTT relay for continuity.
Replace the PTT relay if not shown as PTT relay continuity
below chart. (battery connected)
Terminal 1 – Terminal 2 Continuity
a 1 Terminal 2 – Terminal 3 No continuity
3
Sb (Lg) Checking the trim sensor
2 1. Measure the trim sensor resistance.
Replace sensor if out of specification.
B
NOTE:
61U70330 Turn the lever 1 and measure the resistance
as it gradually changes.
NOTE:
Be sure to set the measurement range a
shown in the illustration when checking for
continuity.
PTT relay continuity
Sky blue (Sb) – Black (B)

Continuity
Light green (Lg) – Black (B)
Terminal 1 – Terminal 2 No continuity
Terminal 2 – Terminal 3 Continuity
Trim sensor resistance:
Pink (P)–Black (B)
2. Connect the digital circuit tester between
239–379 Ω at 20°C (68°F) a
PTT relay terminals 1 and 2.
9–11 Ω at 20°C (68°F) b
7-57 61U5H11

ELEC
Electrical system
Checking the electrical component..............................................................8-1

Measuring the peak voltage ......................................................................8-1
Electrical component .....................................................................................8-2

1
Port view ....................................................................................................8-2
Starboard view...........................................................................................8-3
Aft view ......................................................................................................8-4
Top view .....................................................................................................8-5 2
Ignition and ignition control system ............................................................8-6
Checking the ignition spark gap ................................................................8-6
Checking the spark plug cap .....................................................................8-6
Checking the ignition coil...........................................................................8-7
Checking the CDI unit................................................................................8-7
3
Checking the pulser coil ............................................................................8-8
Checking the charge coil ...........................................................................8-8
Checking the thermoswitch........................................................................8-9
4
Starting system .............................................................................................8-9
Checking the fuse (WH, E, ET) .................................................................8-9
Checking the
Checking the
Checking the
engine start switch (WH, E, ET) ........................................8-10
engine stop lanyard switch ................................................8-10
starter relay (WH, E, ET) ...................................................8-11
5
Checking the neutral switch (WH) ...........................................................8-11
Starter motor (WH, E, ET) ............................................................................8-12

Removing the starter motor pinion ..........................................................8-14
Checking the starter motor pinion ...........................................................8-14
6
Checking the armature ............................................................................8-14
Checking the brush..................................................................................8-15
Checking the starter motor operation ................................................................8-15
Checking the choke solenoid...................................................................8-15
7
8
Charging system ..........................................................................................8-16
Checking the lighting coil.........................................................................8-16
Checking the Rectifier Regulator.............................................................8-16
Checking the hour meter .........................................................................8-17
9
61U5H11

ELEC Electrical system
Checking the electrical NOTE:

component 9 Before measuring the peak voltage, check
all wiring for proper connection and corro-
Measuring the peak voltage
sion, and check that the battery is fully
To check the electrical components or mea-
charged.
sure the peak voltage, use the special service
9 Use the peak voltage adapter with the rec-
tools. A faulty electrical components can be
ommended digital circuit tester.
easily checked by measuring the peak volt-
9 Connect the positive pin of the peak voltage
age. The specified engine speed when mea-
adapter to the positive terminal of the digital
suring the peak voltage is effected by many
tester, and the negative pin to the negative
factors such as fouled spark plugs or a weak
terminal.
battery. If one of these factors is present, the
9 When measuring the peak voltage, set the
peak voltage cannot be measured properly.
selector on the digital circuit tester to the
DC voltage mode.
Digital circuit tester: 90890-03174

Peak voltage adaptor B:
90890-03172
6B480015
w
When checking the peak voltage, do not
touch any of the connections of the digital
circuit tester leads.
cC
When measuring the voltage of an electri-
cal component with the digital circuit
tester, make sure that the tester leads do
not contact each other. Otherwise, the
electrical component could be damaged.
8-1 61U5H11

Checking the electrical component/Electrical component
Electrical component
Port view
1
ET E
2
3
2
2
1
3
3
4
5
2
4
6
7
5
61U80040D
8
1 Starter motor (WH, E, ET)
2
3
4
5
Starter relay (WH, E, ET)
PTT relay (ET)
Ignition coil
Fuse holder (20A: WH, E, ET)
9
61U5H11 8-2

Starboard view
3 3
2
ç
∫
∫
2 1
61U80020B
1 Choke solenoid (E, ET) å To pulser coil assembly.

2 Rectifier Regulator ∫ To CDI unit.
3 Hour meter (if equipped) ç To wire harness.
8-3 61U5H11

Electrical component
Aft view
TOP
1
7 2 8 1 5
6 2
3
4
5
4
å
9 3
∫ 6
å ∫
BOTTOM 7
61U80030C
8
1 Ignition coil #1
2
3
4
5
Ignition coil #2
Ignition coil #3
Ignition coil #4
Spark plug
9
6 Spark plug cap
7 Thermoswitch
8 CDI unit
9 PCV
61U5H11 8-4

Top view
3 4
1 2
1
2
å
5
6
9
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)
8-5 61U5H11

Ignition and ignition control system
Ignition and ignition control Checking the spark plug cap

system 1. Check the spark plug caps. Replace if
cracked or damaged.
Checking the ignition spark gap
1. Disconnect the spark plug caps from the
spark plugs.
2. Connect a spark plug cap to the special

1
service tool shown as below illustration.
6G480095
2
1
2. Remove the spark plug cap 1 from the
spark plug wire 2. 3
61U80010 1
2
Ignition tester 1: 90890-06754 4

5
3. Crank the engine and observe the spark
through the discharge window of the igni-
tion tester. Check that the ignition system 61U80190
if the spark is weak.

3. Check the spark plug wire. Replace if
cracked or damaged.
OK
6
61U80070
7
w 61U80180
9 Do not touch any of the connections of

the ignition tester leads.
9 Keep flammable gas or liquids away,
8
since this test can produce sparks.
9
61U5H11 8-6

Checking the ignition coil Checking the CDI unit

1. Remove the spark plug cap from the 1. Remove the CDI unit cover.
spark plug.
2. Connect the digital circuit tester with
2. Disconnect the ignition coil connectors. peak voltage adaptor B to the ignition coil
lead and the ground.
3. Measure the ignition coil resistance.
Replace the ignition coil if out of specifi- 3. Measure the CDI unit output peak volt-
cation. age. If less than specification, measure
the charge coil output peak voltage.
Replace the CDI unit if the output peak
voltage of the charge coil is more than
specification.
DCV
61U80020
CDI unit output peak voltage:

6G480105
Black/white (B/W) – Ground (B)
Loaded
r/min
Cranking 1,500 3,500
Ignition coil resistance: DC V 120 150 150
å Primary coil:
Black/white (B/W) – Black (B)
0.18–0.24 Ω at 20°C (68°F) NOTE:
∫ Secondary coil: Remove the all spark plug caps to prevent the
Black/white (B/W) – Spark plug wire engine ignite, when measure the CDI unit
3.26–4.88 kΩ at 20°C (68°F) peak voltage at engine cranking.
8-7 61U5H11

Ignition and ignition control system
Checking the pulser coil

1. Remove the CDI unit cover.
2. Connect the test harness to the pulser

coil.
3. Measure the pulser coil output peak volt-

1
age. Replace the pulser coil if less than
2
specification. 61U80120
Pulser coil resistance

(reference data):
White/red (W/R) 2 –
White/yellow (W/Y) 4
White/black (W/B) 1 –
White/green (W/G) 3
3
256–384 Ω at 20°C (68°F)
Checking the charge coil

1. Remove the CDI unit cover.
4
W/B W/R W/B
1 W/G W/Y W/G
61U80110
2. Connect the test harness to the charge
coil.
3. Measure the charge coil output peak volt-

5
age. Replace the stator assembly if less
Test harness 1: 90890-06871 than specification.
1
6
Pulser coil output peak voltage:
7
White/red (W/R) – White/yellow (W/Y)
White/black (W/B) – White/green (W/G)
Unloaded Loaded
r/min
4.8 3.8
8
DC V 8.8 14.2
(2.7) (2.2)
( ): Manual start
4. Disconnect the pulser coil coupler.
5. Connect the digital circuit tester to the

pulser coil coupler (pulser coil side).
Br
R
L
B/R
Br
R
9
6. Measure the pulser coil resistance. 61U80100
Replace the pulser coil resistance if out

of specification.
61U5H11 8-8

Checking the thermoswitch

Test harness 1: 90890-06871 1. Place the thermoswitches in a container
of water and slowly heat the water.
Charge coil output peak voltage:
(low-speed)
Red (R) – Brown (Br)
Unloaded Loaded
r/min
DC V 130 140 160 160
(100) (80)
Charge coil output peak voltage: S6P28750
(high-speed)
Black/red (B/R) – Blue (L)
2. Check the switches for continuity at the
Unloaded Loaded specified temperatures. Replace the ther-
r/min
Cranking 1,500 3,500 moswitches if out of specification.
DC V 45 45 160 160
(30) (30)
( ): Manual start
4. Disconnect the charge coil coupler.

charge coil coupler (charge coil side).
6. Measure the charge coil resistance.

Replace the stator assembly if out of a Temperature
b Time
specification. c No continuity
d Continuity
Thermoswitch continuity
temperature:
Pink (P) – Black (B)
e: 84.0–90.0 °C (183–194°F)
f: 60.0–74.0 °C (140–165°F)
6S380145
Starting system
Checking the fuse (WH, E, ET)
Charge coil resistance 1. Check the fuse (20A) for continuity.
(reference data): Replace the fuse if there is no continuity.
Brown (Br) 1 – Red (R) 3
428–642 Ω at 20°C (68°F)
Blue (L) 2 – Black/red (B/R) 4
48–72 Ω at 20°C (68°F)
8-9 61U5H11

Ignition and ignition control system/Starting system
Checking the engine start switch Checking the engine stop lanyard
(WH, E, ET) switch
1. Disconnect the 10-pin main harness cou- 1. Check the engine stop lanyard switch for
1
pler. continuity. Replace if there is no continu-
ity.
2. Check the engine start switch for continu-
å a b c
ity at the 10-pin main harness coupler
(engine start switch side). Check the
å
wiring harness or replace the engine start
switch if there is no continuity.
2
∫
1
2 3
1
4
3 2 61U80140
4
1 ç
2 5
5
61U80130
∫
1
Switch
2
Lead color
61U80150
position White (W) 1 Black (B) 2

6
Lock plate
7
3
4 removed a
1 Lock plate
inserted b
2 5 69D80206 Engine stop
Lead color
lanyard switch
pushed c
å WH
8
Switch White (W) Black (B) Red (R) Yellow (Y) Brown (Br) ∫ MH
position 1 2 3 4 5
OFF
ON
START
ç E, ET
9
å WH
∫ E, ET
61U5H11 8-10

Checking the starter relay Checking the neutral switch (WH)

(WH, E, ET) 1. Check the neutral switch for continuity.
1. Remove the starter relay 1. Replace if there is no continuity.
1
a b
Br
61U80030
Br 6F680140
2. Connect the digital circuit tester leads to Switch Lead color

the starter relay terminals. position Brown (Br) Brown (Br)
Free a
3. Connect the positive battery terminal to
the brown (Br) lead 2, also connect the Push b
negative battery terminal to the black (B)
lead 3, and then check for continuity
between the starter relay terminals.
Replace the starter relay if there is no
continuity.
2
6G480196
4. Check that there is no continuity between

the starter relay terminals after discon-
necting a battery terminal from the brown
2 or black lead 3. Replace the starter
relay if there is continuity.
8-11 61U5H11

Starting system/Starter motor (WH, E, ET)
Starter motor (WH, E, ET)
30 N·m (3.0 kgf·m, 22.1 ft·lb)
1
2
3
4
9 N·m (0.9 kgf·m, 6.6 ft·lb)
5
No. Part name
18 N·m (1.8 kgf·m, 13.3 ft·lb)
Q’ty Remarks
61U8010E
6
1 Bolt 2 M8 × 25 mm
7
2 Starter motor bracket 1
3 Clip 2
4 Pinion stopper 1
5 Spring 1
6 Pinion 1
8
7 Front bracket 1
8 Washer —
9 Armature 1
10 Stator 1
11 Brush holder 1
12
13
14
15
Brush
Washer
Washer
Nut
1
1
1
1
9
16 Washer 2
17 Rear bracket 1
61U5H11 8-12

30 N·m (3.0 kgf·m, 22.1 ft·lb)
9 N·m (0.9 kgf·m, 6.6 ft·lb)
18 N·m (1.8 kgf·m, 13.3 ft·lb) 61U8010E

18 Screw 2
19 Bolt 2 M6 × 115 mm
8-13 61U5H11

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.
1
2
1
6G480220
2. Measure the commutator diameter a.

2
tion limit.
6S380195
3
2. Remove the starter motor pinion.
Checking the starter motor pinion

1. Check the teeth of the pinion. Replace if a
4
cracked or worn.
2. Check the pinion for smooth operation.

Replace pinion if necessary.
Standard diameter a:
33.0 mm (1.30 in)
Wear limit:
5
32.0 mm (1.26 in)
3. Measure the commutator undercut b.

6
tion limit.
b 7
NOTE:
Turn the pinion counterclockwise to check
that it operates smoothly and turn it clockwise
to check that it locks in place.
6F680180
8
Checking the armature
1. Check the commutator for dirt. Clean with
600 – grit sandpaper and compressed air
Standard undercut b:
0.8 mm (0.03 in)
Wear limit :
9
0.2 mm (0.01 in)
if necessary.
61U5H11 8-14

4. Check the armature for continuity. 2. Check the brush holder assembly for
Replace the armature if not shown as continuity. Replace the brush holder if not
below chart. shown as below chart.
2
1
e
c d
6G480270
Brush continuity:
6G480256
Brush 1 – Brush 2 No continuity
Armature continuity Checking the starter motor operation

1. Check the operation of the starter motor
Commutator segments c Continuity after installing it onto the power unit.
Segment – Armature core d No continuity
Segment – Armature shaft e No continuity Checking the choke solenoid
1. Disconnect the choke solenoid leads.
Checking the brush 2. Connect the digital circuit tester to the

1. Measure the brush length a. Replace choke solenoid leads.
the brush assembly if below specification
limit. 3. Measure the resistance of the choke
solenoid. Replace the choke solenoid if
out of specification.
6G480280
Standard length:
17.0 mm (0.67 in)
Wear limit a: Choke solenoid resistance:
10.0 mm (0.39 in) 3.4–4.0 Ω
8-15 61U5H11

Starter motor (WH, E, ET)/Charging system
Charging system Checking the Rectifier Regulator

Checking the lighting coil 1. Disconnect the Rectifier Regulator (R)
1. Disconnect the lighting coil connector. connector, then connect the digital circuit
tester to Rectifier Regulator (R) connec-
2. Connect the probe to the lighting coil.
3. Measure the lighting coil output peak

tor and ground
2. Measure the Rectifier Regulator output

1
voltage. Replace the stator assembly if peak voltage. If less than specification,
2
less than specification. measure the lighting coil output peak
voltage. Replace the Rectifier Regulator if
the output peak voltage of the lighting coil
is more than specification.
R
DCV 3
4
61U80050
Lighting coil output peak voltage:

61U80040
Green (G) – Green/white (G/W)
Unloaded NOTE:
r/min
DC V
Cranking
8.0
1,500
31.0
3,500
72.0

Do not use the peak voltage adaptor when
measuring the output peak voltage of the
Rectifier Regulator.
5
lighting coil connector.
r/min
Rectifier Regulator output peak voltage:
Red (R) – Ground (B)
Unloaded
6
1,500 3,500
7
DC V 13 13
8
61U80170
5. Measure the lighting coil resistance.

Replace the stator assembly if out of
specification.
9
Lighting coil resistance
(reference data):
Green(G) – Green/white (G/W)
0.36–0.54 Ω at 20°C (68°F)
61U5H11 8-16

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 displayed the all segments which
has been illuminated for 2 seconds.
Replace the hour meter if there is no illu-
minated.
a
b
61U80160
8-17 61U5H11

TRBL
SHTG
Troubleshooting
Troubleshooting the power unit ..................................................................9-1

Troubleshooting the power unit..................................................................9-1
Troubleshooting the PTT unit.....................................................................9-6
Troubleshooting the lower unit ...................................................................9-7
1
2
3
4
5
6
7
8
9
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 conditions of an area or individual part.
Cause 1: The content considered as the trouble factors of symptom 2.
Cause 2: The content considered as the trouble causes of cause 1 (described if necessary).
Symptom 1: Engine does not crank
Refer
Symptom 2 Cause 1 Cause 2 Checking step to
page
Gear shift not in the Shift the gear shift lever
— 3-7
neutral position to neutral.
Manual starter — Disassemble and
does not Broken spiral spring 5-14
check the spiral spring.
operate
— Check and adjust or
Start-in-gear protection
replace the start-in- 3-4
system malfunction
gear protection cable.
Gear shift not in the Shift the remote control
— 3-7
neutral position lever to neutral.
Check the battery for
Discharged battery — electrolyte level, gravity 3-14
and voltage.
Loose connection of Check the battery
— —
battery terminal terminal connection.
Starter motor Blown fuse (20A) — Check the fuse (20A). 8-9
does not Starter relay
— Check the starter relay. 8-11
operate malfunction
Engine start switch Check the engine start
— 8-10
malfunction switch.
Short, open, or loose
Check the wiring har-
connection in starter — *1
ness continuity.
motor circuit
Starter motor Disassemble and
— 8-14
malfunction check the starter motor.
*1 See the wiring diagram
9-1 61U5H11

Refer
page
Manual starter
or starter motor
Stuck piston
Piston lock due to —

Disassemble and
check the power unit.
5-17
1
operates, but water or oil in the com-
bustion chamber
the engine does
not crank Salt buildup on the
drive shaft and bushing
—
Disassemble and
check the upper case.
7-13 2
Symptom 1: Engine will not start (engine cranks)
Symptom 2 Cause 1 Cause 2 Checking step

Refer
to
3
page
—
Deterioration or dirty
fuel
—
Fuel filter
Replace the new fuel.
Check the fuel filter for

—
3-2
4
malfunction clog.
Fuel not
supplied
Fuel supplied to the
carburetor improperly
Fuel joint
malfunction
Fuel pump
malfunction
Check the fuel joint
pressure.
Check the fuel pump.

4-17
4-16
5
6
Adjust and check the
Carburetor malfunction — 4-12
carburetor.
Engine stop lanyard
— Check for continuity. 8-10
switch malfunction
Spark plug gap Check the spark plug
7
Spark plug malfunction 3-3
improperly gap and condition.
Short, open or loose
connection in ignition Check the wiring har-
— *1
coil circuit and ground ness continuity.
circuit
Spark plug does
not spark
Ignition coil malfunction
Ignition coil
resistance out
of specifications
Change the ignition coil
and check the ignition
spark.
5-8
8-6
8
Measure the charge
9
CDI unit output coil output peak voltage 8-8
peak voltage and resistance.
CDI unit malfunction
less than speci- Change the CDI unit
5-8
fications and check the ignition
8-6
spark.
61U5H11 9-2

TRBL
Refer
page
Measure the pulser coil

Pulser coil out- 8-8
resistance.
put peak volt-
Pulser coil malfunction
age less than Change the pulser coil
5-4
specifications and check the ignition
8-6
Spark plug does spark.
not spark
Measure the charge
Charge coil out- 8-8
coil resistance.
put peak volt-
Charge coil malfunction
age less than Change the stator
5-4
specifications assembly and check
8-6
the ignition spark.
Cylinder head gasket — Check the compression
5-1
malfunction pressure.
Reed valves Disassemble and
— 5-24
Low compres- malfunction check the reed valves.
sion pressure Scratched piston or Check the compression
wear the piston rings pressure and disas- 5-1
—
sembling the power 5-35
Scratched cylinder wall unit.
Symptom 1: Unstable engine idle speed, poor acceleration, poor performance

Refer
page
Throttle cable adjusting Check and adjust the
— 3-6
improperly throttle cable.
—
Throttle link length Check and adjust the
— 3-5
improperly throttle link length.
Fuel filter Check the fuel filter for
3-2
malfunction clog.
Fuel supplied to the Fuel joint Check the fuel joint
4-17
carburetor improperly malfunction pressure.
Fuel pump
Check the fuel pump. 4-16
malfunction
Fuel not sup- Pilot screw set- Check and adjust the
4-13
plied properly tings improperly pilot screw settings.
Throttle valve
Carburetor malfunction stuck or
damage Disassemble and
4-12
Jet or nozzle check the carburetor.
clogged and or
float damaged
9-3 61U5H11

Trouble shooting the power unit
Refer
page
Fuel not sup-
plied properly
Carburetor malfunction
Spark plug malfunction

Float height
improperly
Spark plug gap
improperly
Disassemble and
check the carburetor.
Check the spark plug
gap and condition.
4-12
3-3
1
2
Short, open or loose
connection in ignition Check the wiring har-
— *1
coil circuit and ground ness continuity.
circuit
Spark plug Ignition coil Change the ignition coil
3
5-8
sparks Ignition coil malfunction resistance out and check the ignition
improperly 8-6
of specifications spark.
Measure the charge
CDI unit output coil output peak voltage 8-8
CDI unit malfunction
peak voltage
less than speci-
fications
and resistance.
Change the CDI unit
and check the ignition
spark.
5-8
8-6
4
Cylinder head gasket Check the compression
5
— 5-1
malfunction pressure.
Reed valves Disassemble and
— 5-24
Low compres- malfunction check the reed valves.
sion pressure Scratched piston or Check the compression
wear the piston rings
Scratched cylinder wall

—
pressure and disas-
sembling the power
unit.
5-1
5-35
6
7
8
9
61U5H11 9-4

TRBL
Symptom 1: Limited engine speed (below 2,000 r/min)

Refer
page
Clogged cooling water Check the cooling
— 3-4
inlet water inlet.
Water pump Check the impeller. 6-5

impeller
malfunction Check the Woodruff
9Buzzer comes 6-5
key.
on
Water pump Check the water pump
9Overheat warn- 6-5
malfunction housing.
ing indicator
Water leakage
comes on Check the insert car-
from water 6-5
9Cooling water tridge.
pump housing
does not dis- Check the outer plate
charge from the 6-5
cartridge.
cooling water
pilot hole Check the cooling
Clogged cooling water water passage
— 7-13
passage (exhaust guide, upper
case and water tube).
Thermostat
— Check the thermostat. 3-3
malfunction
9-5 61U5H11

Troubleshooting the PTT unit

Symptom 1: PTT unit does not operate
Refer
Symptom 2 Cause 1

Cause 2 Checking step
Check the wiring har-

to
page 1
connection of the — *1
PTT relay does ness continuity.
not operate
wiring harness
PTT relay malfunction — Check the PTT relay. 7-57 2

Discharge battery — Check the battery. 3-14
PTT motor does

Loose connection of
the battery terminal
Blown fuse (20A)
—
—
Check the battery ter-
minal.
Check the fuse (20A).
—
7-57
3
not operate
connection of the PTT
motor lead
—
Check the PTT motor
lead.
Disassemble and
*1
4
PTT motor malfunction — 7-39
check the PTT motor.
Manual valve opened
Insufficient PTT fluid

Manual valve
malfunction
—
Check the manual
valve for open.
Add sufficient fluid.
—
3-10
5
Oil pressure
6
Check the PTT unit for
does not PTT fluid leakage — 7-35
leakage.
increase
Clogged filter
Disassemble and 7-44
—
check the PTT unit. 7-50
Clogged fluid passage
*1 See the wiring diagram 7

8
9
61U5H11 9-6

TRBL
Symptom 1: PTT unit does not hold the outboard motor up

Refer
page
Manual valve Check the manual
Manual valve opened —
malfunction valve for open.
Insufficient PTT fluid — Add sufficient fluid. 3-10
— Check the PTT unit for
PTT fluid leakage — 7-35
leakage.
Main valves
Disassemble and
Clogged fluid passage does not oper- 7-44
check the PTT unit.
ate
Troubleshooting the lower unit

Symptom 1: Shift mechanism of the forward gear and reverse gear does not
operate properly
Refer
page
Remote control box Check the remote con-
— —
malfunction trol box.
Check the shift cable
3-7
Shift cable and shift and shift cable end.
—
cable end malfunction
Adjust the shift cable. 3-7
—
Disassemble the lower
— case and check the 6-5
Shift rod operation shift rod joint.
malfunction Shift rod
Check the shift rod
connection 6-5
connection.
malfunction
9-7 61U5H11

A. Checking the PTT fluid level (ET) ............3-10
Adjusting the ignition timing stopper........5-53 Checking the PTT motor..........................7-40
Adjusting the start-in-gear protection Checking the PTT operation (ET)............3-10
Checking the PTT relay ...........................7-57
1
(MH, WH) .................................................3-4
Adjusting the throttle cable ........................3-6 Checking the PTT system (ET) ...............1-15
Adjusting the timing plate ........................5-52 Checking the Rectifier Regulator .............8-16
Adjusting the trim sensor cam (ET) .........7-33 Checking the anode.................................3-13
Aft view ......................................................8-4 Checking the armature ............................8-14
After test run ............................................1-17 Checking the battery (WH, E, ET) ...........3-14
Applicable model........................................1-5
Assembling the PTT motor ......................7-41
Assembling the PTT unit..........................7-52
Assembling the bearing housing .............5-41
Checking the bearing .....................5-35, 6-14
Checking the brush..................................8-15
Checking the carburetor ..........................4-12
Checking the charge coil ...........................8-8
2
Assembling the carburetor .......................4-13 Checking the choke solenoid...................8-15
Assembling the clamp bracket
(MH, WH, E) ..........................................7-26
Assembling the crankshaft.......................5-40
Assembling the drive shaft housing.........6-16
Checking the choke solenoid (E, ET) ........3-9
Checking the compression pressure .........5-1
Checking the connecting rod big end
side clearance........................................5-39
3
Assembling the forward gear ...................6-15 Checking the connecting rod small end
4
Assembling the fuel pump .......................4-17 axial play ................................................5-39
Assembling the gear pump housing ........7-46 Checking the control link and throttle link
Assembling the lower case ......................6-15 position.....................................................3-5
Assembling the manual starter Checking the cooling water passage .........3-4
(MH, WH) ...............................................5-15 Checking the cooling water pilot hole ......1-16
Checking the crankshaft ..........................5-39
5
Assembling the oil seal housing ..............5-41
Assembling the piston and connecting Checking the cylinder bore ......................5-37
rod assembly .........................................5-42 Checking the cylinder head .....................5-29
Assembling the power unit.......................5-42 Checking the drive pawl (MH, WH)..........5-15
Assembling the propeller shaft Checking the drive shaft ..........................6-14
assembly..................................................6-9 Checking the electrical component............8-1
Assembling the propeller shaft housing...6-10
Assembling the swivel bracket
(MH, WH, E) ..........................................7-25
Assembling the tiller handle.......................7-4
Checking the engine idle speed ................3-6
Checking the engine start switch
(WH, E, ET) ...........................................8-10
Checking the engine start switch and
6
Assembling the tilt piston and trim engine stop lanyard switch ....................1-15
B.
piston .....................................................7-51
Assembling the upper case .....................7-13
Checking the engine stop lanyard
switch .....................................................8-10
Checking the exhaust cover.....................5-26
Checking the filter ....................................7-41
7
Checking the fuel filter ...............................3-2
Backlash ..................................................6-26
8
Checking the fuel joint .............................4-17
Bleeding the PTT unit ..............................7-55
Checking the fuel joint and fuel hose
Bleeding the PTT unit (built-in) ................7-56
(fuel joint-to-carburetor) ...........................3-2
Bottom cowling ..........................................7-5
Checking the fuel pump ...........................4-16
Bracket .....................................................3-10
Checking the fuel system.........................1-12
Break-in....................................................1-16
Checking the fuse ....................................7-57
C.
Carburetor..................................................4-6
Changing the gear oil ..............................3-12
Checking the fuse (WH, E, ET) .................8-9
Checking the gear oil ...............................1-12
Checking the gear oil level.......................3-11
Checking the gear pump housing............7-45
9
Charging system......................................8-16 Checking the gear shift and throttle
Checking relief valve................................7-45 operation ................................................1-14
Checking the CDI unit................................8-7 Checking the gear shift operation..............3-7
Checking the PCV ...................................5-26 Checking the hour meter .........................8-17
61U5H11 i-1

Index
Checking the hydraulic pressure .............7-35 D.

Checking the ignition coil ...........................8-7 Dimension ................................................2-15
Checking the ignition spark gap ................8-6 Disassembling the PTT motor .................7-39
Checking the ignition timing.......................3-8 Disassembling the bearing housing.........5-34
Checking the internal anode....................5-38 Disassembling the carburetor ..................4-12
Checking the lighting coil .........................8-16 Disassembling the crankshaft..................5-36
Checking the lower case..........................6-15 Disassembling the drive shaft housing ....6-13
Checking the lower unit for air Disassembling the forward gear ..............6-13
leakage ..................................................3-13 Disassembling the fuel pump...................4-16
Checking the main valve..........................7-45 Disassembling the gear pump housing ...7-44
Checking the neutral switch (WH) ...........8-11 Disassembling the lower case .................6-14
Checking the outboard motor mounting Disassembling the manual starter
height .....................................................1-12 (MH, WH) ...............................................5-14
Checking the pinion and forward gear .....6-14 Disassembling the oil seal housing .........5-35
Checking the piston clearance.................5-37 Disassembling the piston and connecting
Checking the piston diameter ..................5-36 rod assembly .........................................5-35
Checking the piston pin ...........................5-38 Disassembling the propeller shaft
Checking the piston pin boss bore ..........5-38 assembly..................................................6-8
Checking the piston ring ..........................5-37 Disassembling the propeller shaft
Checking the piston ring side housing ....................................................6-8
clearance ...............................................5-38 Disassembling the swivel bracket
Checking the propeller.............................3-13 (MH, WH, E) ..........................................7-25
Checking the propeller shaft ......................6-9 Disassembling the tilt cylinder and trim
Checking the propeller shaft housing ........6-9 cylinder...................................................7-50
Checking the pulser coil.............................8-8 Disassembling the upper case.................7-12
Checking the reed valve ..........................5-24 Disassembly and assembly .......................1-4
Checking the remote control cable Drive shaft and lower case ......................6-12
(Remote control model) .........................1-13
Checking the reservoir.............................7-45
Checking the spark plug ............................3-3
E.
Electrical (115B, 140B models) ...............2-12
Checking the spark plug cap .....................8-6
Electrical (E115A models) .........................2-7
Checking the spiral spring (MH, WH) ......5-15
Electrical component .................................8-2
Checking the starter motor operation ......8-15
Exhaust cover ..........................................5-25
Checking the starter motor pinion ...........8-14
Checking the starter relay (WH, E, ET) ...8-11
Checking the starter rope (MH, WH) .......5-15 F.
Checking the steering system .................1-14 Fire prevention ...........................................1-3
Checking the thermostat............................3-3 Fuel hose and breather hose.....................4-1
Checking the thermoswitch........................8-9 Fuel line .....................................................4-3
Checking the throttle cable and shift Fuel pump................................................4-15
cable ........................................................7-4 Fuel system ...............................................3-2
Checking the tilt cylinder and trim
cylinder...................................................7-51
Checking the tilt operation
G.
Gear pump...............................................7-42
(MH, WH, E) ..........................................3-11
General ....................................................3-13
Checking the top cowling...........................3-2
General specification .................................2-1
Checking the trim sensor .........................7-57
General torque .........................................2-21
Checking the upper case .........................7-13
Good working practice ...............................1-4
Checking the water pump and shift rod .....6-5
Clamp bracket and swivel bracket ...........7-20
Control system...........................................3-4 H.
Crankcase................................................5-31 Hose routing ..............................................4-1
Cylinder head...........................................5-27 How to use this manual .............................1-1
i-2 61U5H11

I. Removing the electrical component ........5-20
Identification...............................................1-5 Removing the exhaust cover ...................5-26
Ignition and ignition control system ...........8-6 Removing the flywheel magnet ...............5-19
Removing the intake manifold .................5-24
1
Installing the PCV ....................................5-26
Installing the PTT unit (ET)......................7-31 Removing the lower unit ............................6-4
Installing the clamp bracket (ET) .............7-31 Removing the piston, connecting rod
Installing the drive shaft ...........................6-16 assembly and crankshaft assembly.......5-35
Installing the lower unit ............................6-19 Removing the power unit .........................5-17
Installing the power unit ...........................5-49 Removing the propeller shaft housing
Installing the propeller shaft housing .......6-17
Installing the steering arm .......................7-18
Installing the upper case..........................7-19
Installing the water pump and shift rod....6-18
assembly..................................................6-8
Removing the starter motor pinion ..........8-14
Removing the steering arm .....................7-17
Removing the water pump and shift rod....6-5
2
Intake manifold.........................................5-22
L.
Lower unit .........................................3-11, 6-1
Lower unit (115B, 140B models) .............2-12
S.
Safety while working ..................................1-3
Selecting the forward gear shim ..............6-24
Selecting the pinion shim.........................6-23
3
Lower unit (E115A models) .......................2-7 Selecting the reverse gear shim ..............6-25
Lubricating the outboard motor................3-14
Lubricating the throttle gear.......................7-4
Selection ..................................................1-11
Self-protection............................................1-3
Serial number ............................................1-5
Shimming........................................6-22, 6-23
4
M. Special service tool....................................1-6
Maintenance interval chart ........................3-1
Maintenance specification .........................2-5
Manual format ............................................1-1
Measuring the forward and reverse gear
backlash.................................................6-26
Specified torque.......................................2-19
Starboard view ...........................................8-3
Starter motor (WH, E, ET) .......................8-12
Starting system ..........................................8-9
5
Symbol .......................................................1-2
Measuring the peak voltage ......................8-1
6
Synchronizing the carburetor.....................3-5
P. T.
PTT electrical system ..............................7-57
Test run ....................................................1-16
PTT motor................................................7-38
Tightening torque.....................................2-19
PTT unit ...................................................7-34
Parts, lubricant, and sealant ......................1-3
Port view ....................................................8-2
Power unit...........................................3-3, 5-1
Power unit (115B, 140B models) .............2-10
Tiller handle ...............................................7-1
Tilt cylinder and trim cylinder ...................7-48
Top cowling ................................................3-2
Top view .....................................................8-5
7
Troubleshooting the PTT unit.....................9-6
Power unit (E115A models) .......................2-5
8
Troubleshooting the lower unit ...................9-7
Predelivery check ....................................1-12
Troubleshooting the power unit..................9-1
Propeller selection ...................................1-11
Propeller shaft housing ..............................6-6
Propeller size ...........................................1-11 U.
Upper case, steering arm ..........................7-8
R.
Removing the PTT unit (ET)....................7-30
Removing the clamp bracket (ET) ...........7-30
Removing the clamp bracket
V.
Ventilation ..................................................1-3
9
(MH, WH, E) ..........................................7-24
Removing the crankcase .........................5-34
Removing the cylinder head ....................5-29
Removing the drive shaft .........................6-13
61U5H11 i-3

WIRING DIAGRAM
E115AMH
Color code
1 Thermoswitch B : Black
2 Spark plug Br : Brown
3 Ignition coil G : Green
4 CDI unit Gy : Gray
5 Charge coil L : Blue
6 Lighting coil P : Pink
7 Pulser coil R : Red
8 Rectifier Regulator W : White
9 Engine stop lanyard switch B/R : Black/red
0 Over revolution B/W : Black/white
G/W : Green/white
W/B : White/black
W/G : White/green
W/L : White/blue
W/R : White/red
W/Y : White/yellow

E115A, 115B, 140B
YAMAHA MOTOR CO., LTD.
Printed in Japan
Oct. 2005 – 1.2 × 1 !
(E_1) Printed on recycled paper

E115AMH
Br
L
R
B/R
B/R
Br
R
L
P
P P P 1 2 3 4 P
B B B B
B/R
Br
R
L
B/W
B/W
B/W
B/W 2 B/W 1 B/W
B
P
B
B/W
B/W
B/W
B/W
B/R
Br
B
L
2 1
W/G
W/R
W/Y
W/B
G
B/W 4 3 B/W
P
B
G
4 3 G/W
G/W
G
1 2 3 4 1 2 3 4
G
R R
W/G
W/R
W/B
W/Y
Gy
G/W
W
P
G
R
B
B
B
B
B B B
B
W/G
W/Y
W/R
W/B
B
P R B
W W W W

WIRING DIAGRAM
E115AE, E115AWH, 115BE
Color code
1 Starter motor B : Black
2 Starter relay Br : Brown
3 Battery G : Green
4 Fuse (20A) Gy : Gray
5 Thermoswitch L : Blue
6 Spark plug Lg : Light green
7 Ignition coil P : Pink
8 CDI unit R : Red
9 Charge coil Sb : Sky blue
0 Lighting coil W : White
q Pulser coil B/R : Black/red
w Rectifier Regulator B/W : Black/white
e Choke solenoid (E115AE, 115BE) Gy/B : Gray/black
r Over revolution G/W : Green/white
W/B : White/black
å To remote control box/switch panel W/G : White/green
W/L : White/blue
W/R : White/red
W/Y : White/yellow

E115AE,E115AWH,115BE
Br
L
R
B/R
B B P Gy/B Gy/B
B B B
B/R
Br
R
L
R R
P 1 2 3 4 P
B B
20A
B B
B/R
Br
R
L
Br Br B/W
R
B/W
B
B/W
B/W 2 B/W 1 B/W
B
P
B/W
B/W
B/W
B/W
B/R
Br
B
L
2 1
W/G
W/R
G/W
W/Y
W/B
G
Sb
B/W 4 3 B/W
Gy/B
Gy/B
B
B
Lg G
4 3 G/W
B
G/W
G
1 2 3 4 1 2 3 4
G G
R
Gy/B
Gy/B
R
B
R
B
W/G
W/R
W/B
W/Y
Gy/B
Gy
G/W
W
P
G
R
B
B
B
L
B
B B B
B
B
L
Sb
Lg
Br
R
W/G
W/Y
W/R
W/B R Sb
G
L Lg
Gy/B G W
B B
P P
B B W W
R R
Br L
Br Br
Sb Sb P B
Lg Lg

WIRING DIAGRAM
E115AET, 115BET, 140BET
Color code
1 Starter motor B : Black
2 Starter relay Br : Brown
3 PTT relay (up) G : Green
4 PTT relay (down) Gy : Gray
5 PTT motor L : Blue
6 Battery Lg : Light green
7 Fuse (20A) P : Pink
8 Thermoswitch R : Red
9 Spark plug Sb : Sky blue
0 Ignition coil W : White
q CDI unit Y :Yellow
w Charge coil B/R : Black/red
e Lighting coil B/W : Black/white
r Pulser coil Gy/B : Gray/black
t Rectifier Regulator G/W : Green/white
y Choke solenoid W/B : White/black
u Hour meter (E115A) W/G : White/green
i Trim sender W/L : White/blue
o Over revolution W/R : White/red
W/Y : White/yellow
å To remote control box/switch panel
∫ To trim meters

E115AET,115BET,140BET
Br
L
R
B/R
B B P Gy/B Gy/B
B B B
B/R
Br
R
L
R R
P 1 2 3 4 P
B B
20A
B B
B/R
Br
R
L
Br Br B/W
R
B/W
B/W
B/W 2 B/W 1 B/W
B
B
P
B/W
B/W
B/W
B/W
B/R
Br
B
L
L
2 1
W/G
W/R
G/W
W/Y
W/B
G
Sb Sb
B
B
B
B/W 4 3 B/W
B
Gy/B
Gy/B
B
B
Lg Lg G
4 3 G/W
B
G/W
Gy/B
G/W
G
B
Y
1 2 3 4 1 2 3 4
G G 1 2 3
R
Gy/B
Gy/B
R
B
R
G
B
Y
B
W/G
W/R
W/B
W/Y
Gy/B
B
Gy
G/W
W
P
G
R
B
L
B
B
B
B
B B B
L
Sb
Lg
Br
R
W/G
W/Y
W/R
W/B R Sb
G Y
L Lg
Gy/B G W
B B
P P
B B W W
Y
R R
Br L
Br Br
Sb Sb P B
Lg Lg
P
B
1
B 2
Gy/B Gy 3
P 4

Yamaha 115b 115A

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Yamaha 115b 115A

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Copyright:

Available Formats

Yamaha 115b 115A

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Available Formats

E115A, 115B, 140B

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E115A, 115B, 140B

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How to use this manual ............................................................................... 1-1

Identification ................................................................................................. 1-5

Special service tool ..................................................................................... 1-6 4

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How to use this manual

Drive shaft holder 4 1 : 90890-06518

Disassembling the forward gear

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Periodic check and adjustment

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Safety while working

Parts, lubricant, and sealant

1. Maintain good standards of personal and

2. Change and wash clothing as soon as

Self-protection 3. Avoid contact with skin. Do not, for exam-

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6. Keep a supply of clean, lint-free cloths for Disassembly and assembly

5. Check that moving parts operate normal-

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Special service tool

Digital caliper Ball bearing attachment

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Needle bearing attachment

Bearing separator Driver rod L3

Cylinder gauge Ball bearing attachment

Support Bearing outer race attachment

Bearing inner race attachment Small end bearing installer

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Shift rod push arm Center bolt

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Driver rod SS Bearing outer race puller assembly

Bearing depth plate Driver rod SL

Drive shaft holder 6 Pinion height gauge

Pinion nut holder Shimming plate

Driver rod LL Backlash indicator

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Propeller selection Selection

a Propeller diameter (in inches)

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Predelivery check Checking the battery

Checking the fuel system

2. Check that the positive and negative bat-

Checking the outboard motor

Checking the gear oil

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2. Check that the control lever 1 is in its

3. Fully open the throttle lever, and then

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2. Check that the steering operates smooth-

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2. Check that there is no abnormal noise

3. Check that there is no interference with

Checking the engine start switch,