2004-2005 Yamaha 115HP (F115C/LF115C) 2-Stroke Outboard OEM Service & Repair Manual

F115C LF115C SERVICE MANUAL 68V-28197-1F-11 LIT-18616-02-71 *LIT186160271*

E 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 succes- sive editions of this manual. F115C, LF115C SERVICE MANUAL ©2003 by Yamaha Motor Corporation, USA 1st Edition, October 2003 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-71

E HOW TO USE THIS MANUAL MANUAL FORMAT All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy refer- ence that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations. For instance, the condition of a faulty component will precede an arrow symbol and the course of action required will follow the symbol. • Bearings Pitting/scratches → Replace. To assist you in finding your way through this manual, the section title and major heading is given at the top of every page. MODEL INDICATION Multiple models are mentioned in this manual and their model indications are noted as fol- lows. ILLUSTRATIONS The illustrations within this service manual represent all of the designated models. CROSS REFERENCES The cross references have been kept to a minimum. Cross references will direct you to the appropriate section or chapter. Model name F115AET FL115AET USA and Canada name F115TR LF115TR Indication F115AET FL115AET

E IMPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING 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. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer.

E HOW TO USE THIS MANUAL 1 The main points regarding removing/installing and disassembling/assembling procedures are shown in the exploded views. 2 The numbers in the exploded views indicate the required sequence of the procedure and should be observed accordingly. 3 Symbols are used in the exploded views to indicate important aspects of the procedure. A list of meanings for these symbols is provided on the following page. 4 It is important to refer to the job instruction charts at the same time as the exploded views. These charts list the sequence that the procedures should be carried out in, as well as pro- viding explanations on part names, quantities, dimensions and important points relating to each relevant task. Example: O-ring size 39.5 × 2.5 mm: inside diameter (D) × ring diameter (d) 5 In addition to tightening torques, the dimensions of the bolts and screws are also mentioned. Example: Bolt and screw size : bolt and screw diameter (D) × length (L) 6 In addition to the exploded views and job instruction charts, this manual provides individ- ual illustrations when further explanations are required to explain the relevant procedure. d D 10 × 25 mm D L

E SYMBOLS Symbols 1 to 9 are designed as thumb- tabs to indicate the content of a chapter. 1 General information 2 Specifications 3 Periodic inspections and adjustments 4 Fuel system 5 Power unit 6 Lower unit 7 Bracket unit 8 Electrical systems 9 Trouble analysis Symbols 0 to E indicate specific data. 0 Special tool A Specified liquid B Specified engine speed C Specified torque D Specified measurement E Specified electrical value [Resistance (Ω), Voltage (V), Electric current (A)] Symbol F to H in an exploded diagram indicate the grade of lubricant and the location of the lubrication point. F Apply Yamaha 4-stroke outboard motor oil (TC-W3) G Apply water resistant grease (Yamaha grease A, Yamaha marine grease) H Apply molybdenum disulfide oil Symbols I to N in an exploded diagram indicate the grade of the sealing or locking agent and the location of the application point. I Apply Gasket Maker ® J Apply Yamabond #4 (Yamaha bond number 4) K Apply LOCTITE ® No. 271 (Red LOCTITE) L Apply LOCTITE ® No. 242 (Blue LOCTITE) M Apply LOCTITE ® No. 572 N Apply silicon sealant 1 2 3 4 5 6 7 8 9 0 A B C D E F G H I J K L M N GEN INFO SPEC INSP ADJ FUEL POWR LOWR BRKT – + ELEC TRBL ANLS T R . . E A M GM 4 271 LT 242 LT 572 LT SS

E CONTENTS GENERAL INFORMATION 1 SPECIFICATIONS 2 SPEC PERIODIC INSPECTIONS AND ADJUSTMENTS 3 FUEL SYSTEM 4 FUEL POWER UNIT 5 POWR LOWER UNIT 6 LOWR BRACKET UNIT 7 BRKT ELECTRICAL SYSTEMS 8 ELEC TROUBLE ANALYSIS 9 GEN INFO INSP ADJ – + TRBL ANLS

E 1 2 3 4 5 6 7 8 9 GEN INFO CHAPTER 1 GENERAL INFORMATION IDENTIFICATION ............................................................................................ 1-1 SERIAL NUMBER ..................................................................................... 1-1 STARTING SERIAL NUMBERS ............................................................... 1-1 SAFETY WHILE WORKING ............................................................................ 1-2 FIRE PREVENTION ................................................................................... 1-2 VENTILATION........................................................................................... 1-2 SELF-PROTECTION.................................................................................. 1-2 OILS, GREASES AND SEALING FLUIDS................................................ 1-2 GOOD WORKING PRACTICES ................................................................ 1-3 DISASSEMBLY AND ASSEMBLY ........................................................... 1-4 SPECIAL TOOLS ............................................................................................. 1-5 MEASURING ............................................................................................ 1-5 REMOVING AND INSTALLING ............................................................... 1-7

1-1 GEN INFO E IDENTIFICATION IDENTIFICATION 1 SERIAL NUMBER The outboard motor serial number is stamped on a label attached to the port clamp bracket. S68V1010 1 Model name 2 Approved model code 3 Transom height 4 Serial number 1020 STARTING SERIAL NUMBERS The starting serial number blocks are as fol- lows: Model name Approved model code Starting serial number F115TR 68V L: 1016859 - X: 1016859 - LF115TR 68W X: 1000743 -

1-2 GEN INFO E SAFETY WHILE WORKING SAFETY WHILE WORKING 1 The procedures given in this manual are those recommended by Yamaha to be fol- lowed by Yamaha dealers and their mechanics. FIRE PREVENTION Gasoline (petrol) is highly flammable. Petroleum vapor is explosive if ignited. Do not smoke while handling gasoline and keep it away from heat, sparks and open flames. 1030 VENTILATION Petroleum vapor is heavier than air and is deadly if inhaled in large quantities. Engine exhaust gases are harmful to breathe. When test-running an engine indoors, maintain good ventilation. 1040 SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when grinding or when doing any operation which may cause particles to fly off. Protect hands and feet by wearing safety gloves or protective shoes if appropriate to the work you are doing. 1050 OILS, GREASES AND SEALING FLUIDS Use only genuine Yamaha oils, greases and sealing fluids or those recommended by Yamaha. 1060

2004-2005 Yamaha 115HP (F115C/LF115C) 2-Stroke Outboard OEM Service & Repair Manual

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