Yamaha 115 C Service Manual

							EMK00010
Chapter 4
MAINTENANCE
SPECIFICATIONS.....................................4-1
TRANSPORTING AND STORING
OUTBOARD MOTOR...............................4-3
Trailering outboard motor...................4-3
Storing outboard motor ......................4-4
PERIODIC MAINTENANCE......................4-8
Replacement parts ...............................4-8
Maintenance chart................................4-9
Cleaning and adjusting spark plug ...4-10
Checking top cowling ........................4-11
Checking fuel system .........................4-12
Cleaning fuel filter ..............................4-13
Inspecting idling speed......................4-14
Checking water trap under engine 
oil tank .................................................4-15
Replacing fuse ....................................4-16
Checking wiring and connectors ......4-16
Exhaust leakage..................................4-16
Water leakage .....................................4-16
Greasing ..............................................4-17
Checking power trim and tilt 
system .................................................4-19
Checking propeller .............................4-20
Changing gear oil ...............................4-22
Inspecting and replacing anode(s) ...4-23
Checking battery.................................4-24
Checking bolts and nuts ....................4-28
Motor exterior .....................................4-28
Cleaning cooling-water passages.....4-28
Coating the boat bottom ...................4-29
E
1
2
3
4
5
6
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E
EMK10010SPECIFICATIONS
9Fuel
Fuel tank capacity L (US gal, Imp gal)
9Recommended engine oil
Lubrication 
Engine oil capacity (engine oil tank) L (US qt, Imp qt)
(remote oil tank)
9Recommended gearcase oil
Gear oil capacity cm
3(US oz, Imp oz)
9Spark plug N•m (kgf•m, lb•ft)
9Propeller nut N•m (kgf•m, lb•ft) TIGHTENING TORQUE
25 (2.5, 18)
55 (5.5, 40)
Model
Unit 115TRC
Item
DIMENSIONS
PERFORMANCE 9Overall Length mm (in.)
9Overall Height L/X mm (in.)
9Overall Width mm (in.)
9Transom height L/X mm (in.)
9Weight* L/X kg (lb.)808 (31.8)
1,472 (58.0)/1,599 (63.0)
582 (22.9)
516 (20.3)/642 (25.3)
163 (359)/167 (368)
9Full throttle operating range r/min
9Maximum output kW (HP)
9Idling speed (in neutral) r/min4,500 ~ 5,500
84.6 (115) at 5,000 r/min
700~800
ENGINE
9Engine type
Number of cylinder
Displacement cm
3(cu.in.)
Bore ×stroke mm (in.)
9Ignition system
9Spark plug NGK
Spark plug gap mm (in.)
9Control system
9Starting system
9Battery
Min. cold cranking amps (CCA/SAE) amps at -18°C (-0.4°F)
Min. marine cranking amps (MCA/ABYC)amps at 0°C (32°F)
Min. reserve capacity (RC/SAE) minutes
9Alternator output V-A (W)
9Starting carburation system2-stroke, 90°V
4
1,730 (105.6)
90.0 ×68.0 (3.54 ×2.68)
C.D.I system
BR8HS-10
0.9~1.0 (0.035~0.039)
Remote control
Electric start
380
502
124
12-20
Choke valve start system
DRIVE UNIT
9Gear positions
Gear ratio
9Trim/tilt system
9Propeller markForward-Neutral-Reverse
2.00 (26/13)
Power trim/tilt
K
FUEL AND OIL
Regular unleaded gasoline
(P.O.N.: minimum 86)
–
YAMALUBE 2 STROKE OUTBOARD OIL
or an equivalent TC-W3 certified outboard oil
oil injection system
0.9 (0.95, 0.79)
10.5 (11.1, 9.2)
Hypoid gear oil (SAE90)
760 (25.7, 26.8)
* Listed weight does not include propeller.
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808 (31.8)
1,472 (58.0)/1,599 (22.9)
582 (22.9)
516 (20.3)/642 (25.3)
163 (359)/167 (368)
5,000~6,000
95.6 (130) at 5,500 r/min
700~800
2-stroke, 90°V
4
1,730 (105.6)
90.0 ×68.0 (3.54 ×2.68)
C.D.I system
BR9HS-10
0.9~1.0 (0.035~0.039)
Remote control
Electric start
380
502
124
12-20
Choke valve start system
Regular unleaded gasoline (P.O.N.:
minimum 86)
–
YAMALUBE 2 STROKE OUTBOARD OIL oran equivalent TC-W3 certified outboard oiloil injection system
0.9 (0.95, 0.79)
10.5 (11.1, 9.2)
Hypoid gear oil (SAE90)
760 (25.7, 26.8) Forward-Neutral-Reverse
2.00 (26/13)
Power trim/tilt
K
25 (2.5, 18)
55 (5.5, 40)823 (32.4)
—/1,742 (68.6)
577 (22.7)
—/642 (25.3)
—/194 (428)
4,500 ~ 5,500
110.3 (150) at 5,000 r/min
675~725
2-stroke, 90°V
6
2,596 (158.4)
90.0 ×68.0 (3.54 ×2.68)
C.D.I system (Microcomputer)
BR7HS-10
0.9~1.0 (0.035~0.039)
Remote control
Electric start
380
502
124
12-25
Choke valve start system
Regular unleaded gasoline
(P.O.N.: minimum 86)
–
Yamalube 2-M outboard oil or another outboard
motor manufacture’s factory-brand oil with TC-W3
oil injection system
0.9 (0.95, 0.79)
10.5 (11.1, 9.2)/18.0 (19.1, 15.9)
Hypoid gear oil (SAE90)
980 (33.1, 34.5) Forward-Neutral-Reverse
1.86 (26/14)
Power trim/tilt
M
25 (2.5, 18)
55 (5.5, 40)823 (32.4)
1,637 (64.4)/—
577 (22.7)
516 (20.3)/—
190 (419)/—
4,500 ~ 5,500
110.3 (150) at 5,000 r/min
675~725
2-stroke, 90°V
6
2,596 (158.4)
90.0 ×68.0 (3.54 ×2.68)
C.D.I system (Microcomputer)
BR7HS-10
0.9~1.0 (0.035~0.039)
Remote control
Electric start
380
502
124
12-25
Choke valve start system
Regular unleaded gasoline (P.O.N.:
minimum 86)
–
Yamalube 2-M outboard oil or another outboard
motor manufacture’s factory-brand oil with TC-W3
oil injection system
0.9 (0.95, 0.79)
10.5 (11.1, 9.2)/18.0 (19.1, 15.9)
Hypoid gear oil (SAE90)
980 (33.1, 34.5) Forward-Neutral-Reverse
2.0 (28/14)
Power trim/tilt
M
25 (2.5, 18)
55 (5.5, 40) 130TRC 150TRC V150TRC
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4-3
EMU01369*
TRANSPORTING AND
STORING OUTBOARD MOTOR
w
Leaking fuel is a fire hazard. When trans-
porting and storing the outboard motor,
close the air vent screw and fuel cock to
prevent fuel from leaking.
TRAILERING OUTBOARD MOTOR
The motor should be trailered and stored in
the normal running position. If there is insuf-
ficient road clearance in this position, then
trailer the motor in the tilt position using a
motor support device such as a transom
saver bar.
cC
Do not use the tilt support lever/knob
when trailering the boat. The outboard
motor could shake loose from the tilt
support and fall. If the motor can not be
trailered in the down position, use an
additional support device to secure it in
the up position.
w
8Never get under the lower unit while it
is tilted, even if a motor support bar is
used. Severe injury could occur if the
outboard accidentally falls.
8USE CARE when transporting fuel
tank, whether in a boat or car.
DO NOT fill fuel container to maximum
capacity.
Gasoline will expand considerably as
it warms up and can build up pressure
in the fuel container. This can cause
fuel leakage and a potential fire haz-
ard.
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4-4
EMU01796*
STORING OUTBOARD MOTOR
When storing your Yamaha outboard
motor for prolonged periods of time (2
months or longer), several important pro-
cedures must be performed to prevent
excessive damage. This is especially
important for your oil injection-equipped
outboard motor due to the lean oil ratios
used at idle prior to shutting the engine
off for the season. It is advisable to have
your outboard motor serviced by an
authorized Yamaha dealer prior to stor-
age. However, the following procedures
can be performed by you, the owner, with
a minimum of tools.
Filling Fuel Tank
Fill the fuel tank with fresh fuel and add one
ounce of “Yamaha fuel conditioner and sta-
bilizer” (Part No. LUB-FUELC-12-00) to
each gallon of fuel.
NOTE:
The use of Yamaha Fuel Conditioner and
Stabilizer eliminates the need to drain the
fuel system. Consult your Yamaha dealer or
other qualified mechanic if the fuel system
is to be drained instead.
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4-5
Flushing Cooling System and Fogging
Engine
Cooling system flushing is essential to pre-
vent the cooling system from clogging up
with salt, sand, or dirt. In addition, fogging
of the engine is mandatory to prevent
expensive engine damage due to rust. Per-
form the flushing and fogging at the same
time.
1) Remove the top cowling and silencer
cover. Remove the propeller.
2) Install a flushing attachment to the lower
unit. (Flushing attachment available
from your Yamaha dealer).
cC
Avoid running the outboard at high rpm
while on the flushing attachment or
overheating could occur.
w
8Do not touch or remove electrical
parts when starting or during opera-
tion.
8Keep hands, hair and clothes away
from flywheel and other rotating parts
while engine is running.
3) Run the engine at a fast idle for 10~15
minutes.
4) Just prior to turning off the engine,
quickly spray “Yamaha Stor-Rite Engine
Fogging Oil (Part No. LUB-STRRT-12-
00) alternately into each carburetor.
When properly done, the engine will
smoke excessively and almost stall.
5) Remove the flushing attachment and
wipe off any excess water.
6) Install the silencer cover and top cowl-
ing. Install the propeller.
605014
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4-6
EMK26110*
Lubrication
1) Remove the spark plugs, and spray a 10
second  spray of Yamaha Stor-Rite
Engine Fogging Oil into each cylinder.
Grease the spark plug threads and rein-
stall the spark plugs and torque to prop-
er specification.
(Refer to the Periodic Cleaning and
Inspection section, “Cleanning and
adjusting spark plug.”).
2) Turn the engine over with the stop lan-
yard disconnected to work the fogging
oil into the piston rings.
3) Fill the oil tanks. This prevents the for-
mation of condensation. For models with
a remote tank, it may be necessary to
manually override the control unit to
completely fill the engine main tank. 
(Refer to the Troubleshooting section,
“Temporary action in emergency.”).
4) Change the lower unit oil. (Refer to the
Periodic Cleaning and Inpsection sec-
tion, “Changing gear oil.”). Inspect the
oil for the presence of water which indi-
cates a leaky seal. Seal replacement
should be performed by an authorized
Yamaha dealership prior to use.
5) Grease all grease fittings. (Refer to the
Periodic Cleaning and Inspection sec-
tion, “Greasing.”)
EMK27010*
Cleaning and Anti-corrosion Measure
1) Wash down the exterior of the outboard
with fresh water and dry off completely.
2) Spray the engine’s exterior with Yamaha
Silicone Protectant (Part No. LUB-SILC-
NE-13-00).
3) Wax the cowling with a non-abrasive
wax such as Yamaha Silicone Wax
(Part No. ACC-11000-15-02).
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4-7
EMK28010*
Battery Care
w
Battery electrolyte is poisonous and
dangerous, causing severe burns, etc. It
contains sulfuric acid. Avoid contact
with skin, eyes, or clothing.
Antidote:
EXTERNAL; Flush with water.
INTERNAL; Drink large quantities of
water or milk. Follow with milk of magne-
sia, beaten egg, or vegetable oil. Call
physician immediately.
EYES; Flush with water for 15 minutes
and get prompt medical attention.
Batteries produce explosive gases: Keep
sparks, flame, cigarettes, etc. away. Ven-
tilate when charging or using in a closed
space. Always wear eye protection when
working near batteries.
KEEP OUT OF REACH OF CHILDREN.
NOTE:
Batteries vary among manufacturers.
Therefore the following procedures may not
always apply. Consult your battery manu-
facturer’s instructions.
1) Disconnect and remove the battery from
the boat. Always disconnect the black
negative lead first to prevent the risk of
shorting.
2) Clean the battery casing and terminals.
Fill each cell to the upper level with dis-
tilled water.
3) Store the battery on a level surface in a
cool, dry, well-ventilated place out of
direct sunlight.
4) Once a month, check the specific gravity
of the electrolyte and recharge as
required to prolong battery life.
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4-8
EMU01569
PERIODIC MAINTENANCE
w
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. If the owner is not familiar with
machine servicing, this work should be
done by a Yamaha dealer or other quali-
fied mechanic.
Maintenance, replacement, or repair of
the emission control devices and systems
may be performed by any marine engine
repair establishment or individual. All
warranty repairs, however, including
those to the emission control system,
must be performed by an authorized
Yamaha marine dealership.
A service manual is available for purchase
through a Yamaha dealer for owners who
have the mechanical skills, tools, and
other equipment necessary to perform
maintenance not covered by this owner’s
manual.
EMK33011
REPLACEMENT PARTS
If replacement parts are necessary, use
only genuine Yamaha parts or equiva-
lents of the same type and of equivalent
strength and materials. Any part of inferi-
or quality may malfunction, and the
resulting loss of control could endanger
the operator and passengers.
Yamaha genuine parts and accessories
are available from a Yamaha dealer.
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4-9
EMU19470
MAINTENANCE CHART
Frequency of maintenance operations may be adjusted according to the operating con-
ditions, but the following table gives general guidelines. Refer to the sections in this
chapter for explanations of each owner-specific action.
The mark (
) indicates the check-ups which you may carry out yourself.
The mark (1) indicates work to be carried out by your Yamaha dealer.
NOTE:
When operating in salt water, turbid or muddy water, the engine should be flushed
with clean water after each use.
10 hours 50 hours 100 hours 200 hours(1 month) (3 months) (6 months) (1 year)
Spark plug(s)Cleaning / adjustment /
replacement
Greasing points GreasingGear oil ChangeFuel systemInspectionFuel filter (can be
disassembled)Inspection / cleaning
Fuel tank (Yamaha
portable tank)Inspection / cleaning
Idling speed (carburetor
models)Inspection / adjustment/1/1
Anode(s)  (external) Inspection / replacement/1/1Anode(s)  (internal) Inspection / replacement1Cooling water passages CleaningPropeller and cotter pin Inspection  /  replacementBatteryInspection / charging/1Throttle link / throttle cable
/ throttle pick-up timingInspection / adjustment1
Shift link / shift cable Inspection  /  adjustment1Oil tank water drain Inspection  /  cleaning/1/1/1Oil pump Inspection / adjustment1
ThermostatInspection1PCV (Pressure Control
Valve)Inspection1
Power trim and tilt unitInspection1Water pumpInspection1Cowling clampInspection
ActionsItemInitialEvery
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