Yamaha E115A 115B 140B Outboard Service Repair Manual 61U-28197-5H-11 PDF
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261-page Yamaha service manual for E115A, 115B and 140B outboard motors, covering specifications, periodic maintenance, fuel system, power unit, lower unit, bracket and PTT systems, electrical testing and troubleshooting. Document 61U-28197-5H-11, 1st Edition, October 2005.
Description
Yamaha E115A 115B 140B Outboard Service Repair Manual 61U-28197-5H-11 PDF
This Yamaha E115A 115B 140B Outboard Service Repair Manual 61U-28197-5H-11 PDF provides detailed maintenance, inspection, adjustment, disassembly, repair, assembly and troubleshooting information for the Yamaha E115A, 115B and 140B outboard families. The manual covers the applicable E115AMH, E115AWH, E115AE, E115AET, 115BE, 115BET and 140BET models and includes model-specific specifications where the E115A, 115B and 140B differ.
The manual is built around workshop procedures rather than basic operating instructions. It combines exploded component illustrations, service-tool references, measurement procedures, tightening torques, wear limits, electrical test values, maintenance data and diagnostic charts so that servicing can be carried out against the values and procedures specified for these outboards.
File Details
- Manual type: Service Manual
- Brand: Yamaha
- Models: E115A, 115B, 140B
- Applicable models: E115AMH, E115AWH, E115AE, E115AET, 115BE, 115BET, 140BET
- Language: English
- Pages: 261
- File format: PDF
- Document number: 61U-28197-5H-11
- Edition: 1st Edition
- Date: October 2005
Model Identification and Service Data
The Yamaha E115A 115B 140B service manual identifies the E115A with approved model code 61U from starting serial number 1015056–, the 115B with code 6E5 from 1015056–, and the 140B with code 6F3 from 1000671–. This identification information is especially useful before selecting specifications or carrying out model-dependent adjustment procedures.
General specification data describes a 2-stroke V-type, four-cylinder power unit with a total displacement of 1,730 cm3 (105.56 cu. in), 90.0 x 68.0 mm (3.54 x 2.68 in) bore and stroke, reed-valve intake, loop-charge scavenging, carburetor fuel system and CDI ignition. The manual specifies 84.6 kW (115 hp) at 5,000 r/min for the E115A and 115B, while the 140B is listed at 103 kW (140 hp) at 5,000 r/min. The full-throttle operating range is 4,500–5,500 r/min and specified engine idle speed is 700–800 r/min.
Service information also covers fuel and oil requirements, gear oil, propeller selection, battery specifications where applicable, dimensions, tightening torques, compression pressure, piston and cylinder measurements, crankshaft limits, carburetor settings, ignition timing, electrical resistance and peak-voltage checks, gear backlash, PTT hydraulic pressure and other workshop measurements.
Chapters Covered
- General information
- How to use this manual and service symbols
- Safety while working and good working practice
- Identification, applicable models and serial numbers
- Special service tools
- Propeller selection
- Predelivery checks, test run and break-in
- Specification
- General specifications
- Power unit, lower unit and electrical maintenance specifications
- Dimensions
- Specified and general tightening torques
- Periodic check and adjustment
- Maintenance interval chart
- Fuel system and fuel filter checks
- Spark plugs, thermostat and cooling-water passage
- Control links, carburetor synchronization and idle speed
- Throttle cable, gear shift and ignition timing
- PTT and tilt checks
- Gear oil, lower-unit leakage and propeller checks
- Anodes, battery and lubrication
- Fuel system
- Fuel and breather hose routing
- Fuel line
- Carburetor disassembly, checking and assembly
- Fuel pump checking, disassembly and assembly
- Fuel joint checking
- Power unit
- Compression pressure testing
- Manual starter servicing for applicable models
- Power unit and flywheel magnet removal
- Electrical component removal
- Intake manifold and reed valve inspection
- Exhaust cover and PCV servicing
- Cylinder head removal and inspection
- Crankcase, pistons, connecting rods and crankshaft
- Piston, cylinder bore and clearance measurements
- Power unit assembly and installation
- Timing plate and ignition timing stopper adjustment
- Lower unit
- Lower-unit removal and installation
- Water pump and shift rod
- Propeller shaft and propeller shaft housing
- Drive shaft, forward gear, pinion and lower case
- Bearing and shaft inspection
- Pinion, forward gear and reverse gear shimming
- Forward and reverse gear backlash measurement
- Bracket unit
- Tiller handle and bottom cowling
- Upper case and steering arm
- Clamp and swivel brackets
- PTT unit and hydraulic pressure checks
- PTT motor and gear pump
- Tilt and trim cylinders
- PTT bleeding procedures
- PTT electrical system and trim sensor
- Electrical system
- Peak-voltage measurement and component locations
- Ignition spark, spark plug cap and ignition coil checks
- CDI unit, pulser coil and charge coil testing
- Thermoswitch testing
- Starting system, fuse, switches and starter relay
- Starter motor inspection
- Choke solenoid
- Charging system and Rectifier Regulator
- Hour meter checking
- Troubleshooting
- Power unit troubleshooting
- PTT unit troubleshooting
- Lower unit troubleshooting
- Index
Across these chapters, the Yamaha E115A 115B 140B Outboard Service Repair Manual 61U-28197-5H-11 PDF moves from routine checks into complete mechanical service. Procedures include carburetor work, compression diagnosis, power-unit removal, cylinder-head and crankcase service, piston and crankshaft measurement, lower-unit rebuilding, water-pump work, gear shimming, PTT hydraulic servicing and electrical diagnosis. Exploded diagrams identify components and their assembly relationships, while related procedures provide the required tools, measurements and tightening values.
Maintenance, Repair and Diagnostic Coverage
The maintenance section provides an interval chart covering initial break-in service and recurring checks at the intervals shown in the manual. It includes cooling passages, fuel system, gear oil, lubrication points, idle speed, PTT, propeller, shift and throttle controls, thermostat, water pump and spark plugs. Gear oil procedures specify Hypoid gear oil meeting API GL-4, SAE 90, with a listed quantity of 760 cm3 (25.70 US oz, 26.81 Imp oz).
For engine work, the manual supplies inspection limits and dimensions for the cylinder head, cylinders, pistons, piston rings, piston pins, connecting rods and crankshaft. It also documents compression testing, reed-valve checks, carburetor adjustment, cooling-system inspection and ignition timing. Lower-unit servicing extends beyond basic oil changes to propeller-shaft disassembly, bearings, pinion and gear inspection, shimming calculations and backlash measurement.
Electrical diagnosis includes ignition-coil resistance, CDI output peak voltage, pulser and charge-coil testing, thermoswitch checks, starter and charging-system inspection, switch continuity and starter-relay testing. The troubleshooting chapter then links symptoms to possible causes and checking steps for conditions such as no-crank, failure to start, unstable idle, poor acceleration, restricted engine speed, PTT faults and lower-unit shifting problems.
Service Your Yamaha E115A, 115B or 140B with the Correct Procedures
The Yamaha E115A 115B 140B Outboard Service Repair Manual 61U-28197-5H-11 PDF supports routine servicing as well as substantial engine, fuel-system, lower-unit, bracket, PTT and electrical repair work. Having the specified measurements, wear limits, test values, assembly sequences and tightening torques available is important when diagnosing faults, checking whether components remain within service limits and rebuilding assemblies correctly.
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