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3-40

Outboard Rigging Guide - 2001

30HP 3 CYL. NEUTRAL SAFETY SWITCH
688-82540-11-00

To avoid accidentally starting the motor while in
gear, a neutral safety switch must be installed if
you are using a control box without start-in-gear
protection like the 701.

Additional Parts Required

Installation

1.

Remove the upper cowling, flywheel cover,
and carburetor air box from the motor.

2.

It will be necessary to remove the three car-
buretor assemblies to install the neutral safe-
ty switch. Shut off the fuel supply, and dis-
connect the choke rod from the lower part of
the carburetor assembly. Detach the oil pump
link, and disconnect the fuel line at the fuel
filter.

3.

Remove the six bolts holding the carburetors
to the intake manifold, and carefully remove
the carburetors. The choke solenoid shaft will
pull out of the choke solenoid as the carbure-
tors are removed.

4.

Install the neutral safety switch in its bracket
so, when the assembly is mounted, the button
on the switch faces toward the rear. Install the
switch and bracket on the bottom cowling
with the two 6mm bolts provided. Remove
the control cable cover from the front right
corner of the bottom cowling. Confirm the
proper location of the switch by operating the
shift lever. The switch button should be
pressed by the cam on the end of the shift
lever when the lever is moved to neutral.

5. Connect the extension wire lead (P/N: 6H4-

82553-00-00) to the leads of the neutral safe-
ty switch.

6. Route the extension leads around the front of

the bottom cowling to the right side of the
motor, opposite the CDI unit. Secure the
wires with cable ties to keep them clear of
moving parts in the throttle and shift link-
ages.

7. Remove the terminal cover (spare fuse is

attached). At the connector, disconnect the
brown wire coming from the starter solenoid
relay. Connect each of the two wires to the
appropriate leads from the neutral safety
switch.

8. Reinstall the carburetors, being careful not to

pinch any oil lines. Also, make sure the car-
buretor flange o-rings are properly seated.
Connect the oil pump link, choke solenoid
shaft, and the fuel line. Tighten the six
mounting bolts and install the air box.

9. Verify that all wires are properly and secure-

ly connected and reinstall the terminal cover.

10. Reinstall the control cable and flywheel cov-

ers and the upper cowling.

11. Test the operation of the neutral safety

switch. The unit should start only when in
neutral.

Part Number

Applicable Models

688-82540-11-00

30HP when 704 switch
panel is used

Part Number

Applicable Models

Qty

6J8-82554-00-00

Stay

1

97095-06012-00

6mm Bolt

2

6H4-82553-00-00

Extension Wire Lead

1

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Summary of Contents for C-50

Page 1: ...2 0 0 1 O u t b o a r d R i g g i n g G u i d e 2000 YAMAHA MOTOR CORPORATION U S A Printed in U S A LIT 18865 00 01 ...

Page 2: ......

Page 3: ...n U S A October 2000 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation U S A is expressly prohibited Printed in U S A Specifications features and options are subject to change without notice 00 149 ...

Page 4: ...ts Crate Contents Engine Dimensions Mounting Mounting Equipment Electrical Remote Controls Instruments Gauge Installations Tiller Handle Kits Remote Control Conversion Kits Steering Kits Propellers Fuel Tanks Accessories Remote Oil Tank Remote Oil Fill Engine Stands Appendices Intro Quick Start 1 2 4 5 6 7 8 9 3 10 ...

Page 5: ...rns 2 6 Transom Drill Fixture 2 10 Four Stroke Splash Guards 40 F100 Splash Plates 2 11 Jet Drive Model Identification and Serial Numbers 2 12 Jet Drive Engine Mounting Maintenance Shift Cable Instruction Service Info 2 13 Dual Engine Tie Bar Kit Installation 2 32 Dual Cable Steering Bracket Kit Installation 2 36 Morse Universal Dual Cable Steering Bracket Kit Installation 2 39 V4 V6 Rigging Tube ...

Page 6: ...lications 4 3 701 Remote Control Assembly 4 4 703 Control Assemblies 4 8 704 Binnacle Mount Remote Control Assemblies 4 18 705 Flush Side Mount Remote Control Assembly 4 32 Remote Control Cables Remote Conversion Kits 701 703 4 47 Control Box Adjustments 4 48 SECTION 5 INSTRUMENT GAUGE INSTALLATIONS Digital Instruments 5 1 Tachometer 5 2 Speedometer 5 7 Trim Meter 5 13 Water Pressure Gauge 5 16 Wa...

Page 7: ...r Handle Kit 6 15 F30 F40 3 Cylinder Tiller Handle Steering Friction Kit 6 20 40 C40 50 C50 Tiller Handle Steering Friction Kit 6 22 F40 4 Cylinder F T50 Tiller Handle Steering Friction Kit 6 31 C60 C70 70HP Tiller Handle Steering Friction Kit 6 40 C90 90HP Tiller Handle Steering Friction Kit 6 48 SECTION 7 CONVERSION STEERING KITS Remote Control Attachment Kits 7 1 6 8HP Remote Control Attachment...

Page 8: ...table Fuel Tank 9 1 Remote Oil Tank Mounting Instructions 2 8 Gal and 5 0 Gal 9 2 Oil Deck Filler Plate Mounting Instructions 9 4 Vertical Starter 9 5 Outboard Display Stands 9 6 SECTION 10 APPENDICES 6X1 Dual Station System Installation Manual 10A 6X1 Dual Station System Service Guide 10B F30 F40 Tiller Handle Steering Friction Installation Guide 10C F80 F100 Tiller Handle Steering Friction Insta...

Page 9: ......

Page 10: ...r or other components Be aware that warnings alone do not eliminate dangers or are they a substitute for safe boat handling and proper accident prevention measures 1 Introduction This will include a brief description model application illustrations of components and additional parts if any needed to install the component This introduction should usually give the rigger information needed to deter ...

Page 11: ... ORG Orange Trim position sender Accessory feed P or Pnk Pink P or Pk Pink Oil overheat signal ground Fuel gauge sender Trim signal W or WHT White W or WHT White Ignition stop circuit SW1 oil transfer off position V4 Br Brown Br Brown Start circuit Generator Armature Low speed charge coil Alternator charge light Positive potential to oil transfer pump SW2 transfer on position V4 Gr Gray Gr Gray Wa...

Page 12: ...oil level sensor SW2 oil transfer circuit L R Blue Red Main tank oil level sensor SW3 No oil warning circuit L W Blue White Main tank oil level sensor SW1 Oil transfer OFF circuit L Y Blue Yellow Shift cut switch Pu R Purple Red OX66 1 injector Pu B Purple Black OX66 2 injector Pu Y Purple Yellow OX66 3 injector Pu G Purple Green OX66 4 injector Pu L Purple Blue OX66 5 injector Pu W Purple White O...

Page 13: ...onversion following in parenthesis 1 0 m 3 3 ft Other Symbols The symbol is used to indicate either one fig ure through another or and following For example 2 15HP would mean the 2 3 5 8 9 9 and 15 HP motors are included A notation like 70HP means that the 70HP and all larger motors are included Pro Series SaltWater Series and counter rotation models are included in the previ ous explanation unles...

Page 14: ...4536 kg 1 gram 0 0353 oz gram x 0 0353 oz 1 oz 28 3286 oz x 28 3286 gram TEMPERATURE C 9 5 32 F C x 1 8 32 F 9 5 F 32 C F 32 x 5 9 C 5 9 is approx 0 555 Note 40 C 40 F 0 C 32 F 100 C 212 F PRESSURE 1kg cm2 14 223 psi psi kpa divided by 7 03 1 psi 0 07031 kg cm2 psi x 0 0731 kg cm2 TORQUE 1m kg 7 233 ft lb m kg x 7 233 ft lb 1ft lb 0 1383 m kg ft lb x 0 1383 m kg VOLUME 1 liter L 1 057 qt L x 1 057...

Page 15: ...w Electric Start L 20 H Tiller Handle K 1985 1997 D Twin Rotating Propellers 9 9 P Power Tilt w Electric Start X 25 J 1986 DX Twin Rotating 200 E Manual Tilt w Electric Start U 30 H 1987 3 3 Cyl Propeller 0X66 EFI 250 M Manual Tilt w Manual Start J Jet Drive G 1988 E Enduro Series Model Unit F 1989 F Four Stroke Engine Model D 1990 LF Left Hand Four Stroke P 1991 L Left Hand Engine Model Q 1992 LX...

Page 16: ...ication It is located on the port side of the lower cowling Explanation of the engine family code 6G6 S X 2 0 0 T L R Z L 0 0 1 7 8 6 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON YAMAHA PRIMARY I D MODEL NAME MODEL PREFIX 6G6 SHAFT LENGTH L SERIAL NUMBER 001786 Z YMXM 3130 2 1 B Model Year Manufacturer Displacement Application Technology Manufacturer Z 2001 YMX Yamaha Cubic Centimeters 1...

Page 17: ...system contamination 3 OPTIONAL Run fuel line from the outlet side of the water fuel separator to the fuel management sender inlet side The fuel flow is indicated by the arrows in the following illustration Install the fuel sender with the side arrow pointing up NOTE An optional feature for the fuel manage ment system is a water detection sender for the water fuel separator This provides a visual ...

Page 18: ...ging Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Oil Warning Lead 5 Remote Oil Tank Lead 6 Trim Gauge Lead 7 Battery Leads w Isolator Lead 8 Oil Hose 9 Fuel Hose Speedometer Hose F80 F100 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Trim Gauge Oil Warning Lead 5 Battery Leads 6 Fuel Hose 7 Speedometer Hose 8 Water Temperature Water Pressure Sensor F115 Tube Grommet...

Page 19: ...y next whole foot Add 3 feet for loop see illustration below Remote Control Cables Yamaha remote control cables are available in lengths from 6 feet to 36 feet The cables utilize 10 32 threaded ends TYPICAL CABLE ROUTING PART NUMBER LENGTH ABA CABLE 06 GY 6 FEET ABA CABLE 07 GY 7 FEET ABA CABLE 08 GY 8 FEET ABA CABLE 09 GY 9 FEET ABA CABLE 10 GY 10 FEET ABA CABLE 11 GY 11 FEET ABA CABLE 12 GY 12 F...

Page 20: ...onent Rigging as efficiently as possible means setting up the control box just once without having to open the box again to readjust the cable ends after hookup to the motor Refer to the following dia grams for proper cable end adjustments at the control box Using these settings at the control box will insure the cable ends at the motor will adjust properly Adjust the throttle friction so the hand...

Page 21: ... 3 LEAD 6 POLE 12 POLE 4 STROKE 2 STROKE OFF NUMBER OFLEADWIRES ONTRIM SENSOR 1 2 3 FACTORYSETTINGS ON km h mph mile h knot nautical mile 5 105Ω U S A 30 230Ω EUROPE 180 0Ω 6Y5 83570 S4 00 YAMAHA INDICATION GPH GALLON SPEEDOMETER GPS GPH 3 2 1 0 1 2 3 4 h 6Y5 83500 F2 00 PRESS BOTH BUTTONS TOGETHER Set mode TOTALFUELCONSUMPTION FUELMANAGEMENT TTC ECON SYNC l h sph km l mpg TRIPMETER CLOCK PRESS BO...

Page 22: ... system either by the primer bulb or electric primer pump This ensures against any fuel leaks Repair them immediately if found It is especially impor tant for EFI and HPDI engines to help avoid dam age to the VST pump NOTE Leaking fuel fittings could result in severe injury or fire Precision Blend On 90hp engines and below before filling the oil tank perform the following steps 1 Turn the key swit...

Page 23: ...E SE SF SG or SH Perform the following steps when adding oil to the engine 1 Remove the oil filler cap Place 3 4 of the rec ommended amount of oil per the service manual 2 Ensure the engine is level before removing the dip stick to check the oil level Fill oil to the appropriate level if necessary 3 Start the engine and let it run for a couple minutes then4 3 turn it off trim the engine until it i...

Page 24: ...se an accident could occur Fuel Oil 1 Make sure there is plenty of fuel oil for the scheduled trip 2 Make sure there are no fuel or oil leaks nor gas fumes 3 Be sure the fuel oil hoses are not being flat tened or kinked by objects in the boat and no sharp objects are near the fuel oil hoses Controls 1 Check throttle shift and steering for proper operation before starting the engine 2 The controls ...

Page 25: ...ceed 6 0 inches for engines greater than 200hp and all 3 1L 0X66 engines including the V200 3 1L EFI An anti siphon valve required if the fuel system drops below the top of the fuel tank will cause a 1 5 to 2 5 inches increase in vacuum Results High Vacuum Move the T fitting to the fuel filter outlet 2 and retest Continue to the fuel fil ter inlet 3 and along the remaining fuel filter system until...

Page 26: ...xvii Outboard Rigging Guide 2001 General Rigging Information FUEL VACUUM FLOW FUEL VACUUM TEST EFI FUEL RAIL GAUGE VACUUM GAUGE ...

Page 27: ... Tilt Operation Instrument Operation Power Trim Tilt Fluid Level Trim Tab Adjustment retorque after operation Power Trim Tilt Operation control pan switch Idle RPM Single P _____ S _____ Gear Oil Level In Gear Idle RPM Single P _______ S ______ Overheat Warning System ground sensor lead Factory recommended W O T RPM Range ___________ Visual Inspection of Engine W O T RPM Single P _______ S _______...

Page 28: ...gs could become oil fouled and affect engine performance Make sure to mix gasoline petrol and oil com pletely otherwise the engine may be damaged Procedure 1 First 10 minutes run the engine at idle or fast idle speed only 2 Next 50 minutes Do not exceed half throttle approximately 3 000 rpm Vary engine speed occasionally If you have an easy planing boat accelerate at full throttle onto plane then ...

Page 29: ...quired The Commonly Used Rigging Accessories chart lists many frequently used components like gauges fuel filters riggings hoses and optional control box spacers with their Yamaha part num bers The Quick Start Details section is a more com prehensive listing of rigging components for the most commonly rigged models and is aimed more at the technician who is new to rigging Yamaha outboards The sect...

Page 30: ...t Gray ABB RIGHS GY 25 Cut to length Rigging Hose 25 Ft Blue ABB RIGHS BE 25 Cut to length Rigging Hose 100 Ft Black ABB RIGHS BK 50 2 50 ft hoses in box Rigging Hose 100 Ft Gray ABB RIGHS GY 50 2 50 ft hoses in box Rigging Grommet MAR GROMM ET 02 Use with rigging hose Rigging Transom Flange MAR THRUT RA SM Use with rigging hose 704 Single Binnacle Control Box Spacer 704 48293 00 00 3 4 Thick w ha...

Page 31: ... Harness 10 Pin Main Harness 6 6 ft OPT 688 82586 11 00 Use as needed 9 9 ft OPT 688 8258A 30 00 Installing Engine with 704 Single Binnacle or 705 Flush Mount Control Control Cables1 2 req ABA CABLE XX GY Single Binnacle T9 9E F15 30 OPT 704 48230 12 00 Pull to Open Throttle No PT T Switch Single Binnacle T8 F25 OPT 704 48205 13 00 Push to Open Throttle PT T Switch or Flush Mount Control T9 9E F15...

Page 32: ... 00 Engine to Tach Harness2 Non Oil Injected Engines No Four Stroke Engines OPT 1 Req 9 8 ft OPT 6R3 82553 30 00 16 4 ft OPT 6R3 82553 50 00 22 9 ft OPT 6R3 82553 70 00 26 2 ft OPT 6R3 82553 80 00 31 2 ft OPT 6R3 82553 90 00 Engine to Tach Harness Trim Oil Harness2 Models with Oil Injection and Low Oil Warnings on Four Stroke Engines 9 8 ft OPT 64D 82553 30 00 16 4 ft OPT 64D 82553 50 00 Single Ga...

Page 33: ...9 ft OPT 6R3 82553 70 00 26 2 ft OPT 6R3 82553 80 00 31 2 ft OPT 6R3 82553 90 00 Engine to Tach Trim Oil Harness2 1 Req STD Rigging Kit 9 8 ft OPT 64D 82553 30 00 16 4 ft OPT 64D 82553 50 00 Single Gauge Rigging Kit 23 ft STD 64D 82553 70 00 26 2 ft OPT 64D 82553 80 00 Dual Gauge Rigging Kit 31 2 ft STD 64D 82553 90 00 Engine to Oil Tank Harness2 1 Req STD Engine Oil Tank all Precision Blend model...

Page 34: ... 30 00 16 4 ft OPT 64D 82553 50 00 Single Gauge Kit 23 ft STD 64D 82553 70 00 Dual Gauge Kit 26 2 ft STD 64D 82553 80 00 L H Rigging Kit 31 2 ft STD 64D 82553 90 00 Engine to Oil Tank Harness2 1 Req STD With Oil Tank All Precision Blend models 9 8 ft OPT 6R3 85721 30 00 16 4 ft OPT 6R3 85721 50 00 Oil Tank Rigging Kit 26 2 ft STD 6R3 85721 80 00 Dual Engine Tie Bar 1 Req Shipped in L H Engine Crat...

Page 35: ......

Page 36: ...01 SECTION 1 STANDARD EQUIPMENT RIGGING KITS AND CRATE CONTENTS 2001 Model Standard Equipment 1 1 Propeller Controls Fuel Tank Rigging Items Shipping Location 1 2 Rigging Kits 1 5 2001 Model Outboard Motor Crate Contents 1 11 1 ...

Page 37: ......

Page 38: ...is book Additional standard equipment will depend upon the kits you order Contact your Marketing Representative for full details about the Kitting Program Basic Standard Equipment 8 to 40 Fuel Tank in Crate F6 F25 F30M F40M Fuel Pipe in Crate F50 F30T F115 Fuel Pipe Steering Link in Crate 70 90 Fuel Pipe Steering Link 115 to 250 Battery Cable Mounting Bolts Steering Linkarm 115 2 6L Only 2 Stroke ...

Page 39: ...F9 9MLHZ 6G9L 309197 CRATE 9 1 4 x 9 N A SEPARATE N A F9 9MSHZ 6G9S 012208 CRATE 9 1 4 x 9 N A SEPARATE N A T9 9ELHZ 6G8L 474408 CRATE 11 3 4 x 9 1 4 N A SEPARATE N A T9 9ELRZ 6G8L 416517 CRATE 11 3 4 x 9 1 4 SEPARATE SEPARATE CRATE T9 9EXHZ 6G8X 790075 CRATE 11 3 4 x 9 1 4 N A SEPARATE CRATE T9 9EXRZ 6G8X 763983 CRATE 11 3 4 x 9 1 4 SEPARATE SEPARATE CRATE 15MSHZ 684CS 427330 CRATE 9 1 4 x 9 N A ...

Page 40: ...17 ORDER FROM PARTS SEPARATE N A 50TLRZ 6H5L 446404 ORDER FROM PARTS SEPARATE N A C50TLRZ 6H5L 904076 ORDER FROM PARTS SEPARATE N A F50TJRZ 62Y N A SEPARATE N A F50TLRZ 62YL 421732 ORDER FROM PARTS SEPARATE N A T50TLRZ 64JL 406850 ORDER FROM PARTS SEPARATE N A 60TLRZ 6H2L 474493 ORDER FROM PARTS SEPARATE N A C60TLRZ 6H2L 363147 ORDER FROM PARTS SEPARATE N A 70TLRZ 6H3L 495999 ORDER FROM PARTS SEPA...

Page 41: ...ROM PARTS L KIT N A L KIT SX200TXRZ 6G6X 004647 ORDER FROM PARTS SEPARATE N A VX200TLRZ 66XL 002839 ORDER FROM PARTS SEPARATE N A VZ200TLRZ ORDER FROM PARTS SEPARATE N A LX225TXRZ 62KX 101976 ORDER FROM PARTS SEPARATE N A SX225TURZ 62JU 200762 ORDER FROM PARTS SEPARATE N A LX225TXRZ 62KX 101976 ORDER FROM PARTS L KIT N A L KIT VX225TLRZ 66KL 302579 ORDER FROM PARTS SEPARATE N A VX MAX Single Gauge...

Page 42: ...5 00 For use on 2 Stroke and 4 Stroke Engines Multi Function LCD Tachometer Speedometer Kit or 2 Gauge Kit 6YR W0035 47 00 For use on 2 Stroke and 4 Stroke Engines Part Number Part Name Qty 6R3 83621 00 00 Mark 1 1 64D 82553 70 00 Trim Oil Harness 23 ft 1 6Y5 83500 T2 00 Meter Ass y 1 6Y5 83553 00 00 Gauge Harness 1 Fuse 1 Part Number Part Name Qty 6Y5 83553 M0 00 Gauge Harness 2 Fuse 1 6Y5 82117 ...

Page 43: ...6K1 82570 05 00 Panel Switch Ass y 1 6K1 8258A 40 00 Main Harness 26 ft 1 90465 13M18 00 Clamp 10 61B 28107 14 00 Rigging Manual l 61B 8258A 01 00 Main Harness 31 2 ft 1 90149 05M05 00 Screw 4 95380 05600 00 Nut 4 92990 05600 00 Washer 4 92990 05100 00 Washer 4 6Y5 83500 F2 00 Fuel Management Gauge 1 6Y5 83553 F1 00 Fuel Management Harness 1 6Y5 85752 01 00 Fuel Management Sender 2 90160 06M00 00 ...

Page 44: ...4 00 00 Grommet 1 688 82540 11 00 Neutral Switch Ass y 1 63D 82554 00 00 Stay Neutral Switch Ass y 1 663 82555 01 00 Damper Main Switch 1 63D 42546 00 00 Nut 2 63D 42541 00 00 Pipe 2 90201 08M01 00 Plate Washer 2 63D 42508 00 00 Steering Friction Ass y 1 63D 42527 00 00 Plate Friction 3 1 63D 42526 00 00 Plate Friction 2 1 63D 42528 00 00 Piece Friction 2 63D 42562 00 00 Shaft Steering Lock 1 63D ...

Page 45: ...62Y 82555 00 00 Damper Main Switch 1 90201 08M01 00 Plate Washer 2 63D 42508 00 00 Steering Friction Ass y 1 63D 42527 00 00 Plate Friction 3 1 63D 42526 00 00 Plate Friction 2 1 63D 42528 00 00 Piece Friction 2 63D 42562 00 00 Shaft Steering Lock 1 63D 42561 00 00 Knob Steering Lock 1 682 43318 01 00 Cover 1 90185 10M01 00 Nut Lock 1 97595 08550 00 Bolt 2 97595 06416 00 Bolt 2 97013 05010 00 Bolt...

Page 46: ...t Lock 1 97013 05010 00 Bolt 2 90185 10051 00 Nylon Lock Nut 2 92990 05100 00 Spring Washer 2 95380 05600 00 Nut 2 63D 83728 00 00 Connector Ass y 1 90464 15M11 00 Clamp 3 Part Number Part Name Qty Tiller Kit Handle Ass y 1 Tiller Handle Install Manual 1 6H2 82586 01 00 Wire Harness Extension 1 6H5 83553 11 00 Read Wire 1 90465 13M36 00 Clamp 1 688 83383 11 00 Buzzer 1 6H5 83386 00 00 Buzzer Stay ...

Page 47: ... 06035 00 Bolt 1 6E5 42515 00 00 Rod 1 90185 08057 00 Nut Lock 2 97595 06514 00 Bolt 2 63D 83720 00 00 Connector Ass y 1 Part Number Part Name Qty Tiller Kit Handle Ass y 1 Tiller Handle Install Manual 1 63D 83728 00 00 Connector Ass y 1 688 82540 11 00 Neutral Switch Ass y 1 67G 82554 01 00 Stay Neutral Switch 1 62Y 82555 00 00 Damper Main Switch 1 97595 06514 00 Bolt 1 97595 08530 00 Mark 1 67G ...

Page 48: ...HZ MLHZ Part Number Description Qty LIT 18626 04 25 Owner s Manual 1 6G8 15780 00 00 Emergency Starter Ass y 1 68T 2814F 00 00 Spark Plug Box 1 6Y1 24306 53 00 Fuel Pipe Complete 1 T8PLHZ PXHZ Part Number Description Qty LIT 18626 04 35 Owner s Manual 1 6G8 15780 00 00 Emergency Starter Ass y 1 6Y1 24306 53 00 Fuel Pipe Complete 1 90185 08057 00 Nylon Locking Nut 2 90201 08MA4 00 Plate Washer 2 92...

Page 49: ...8 90185 08057 00 Nylon Lock Nut 14 6Y1 24306 51 00 Fuel Pipe Complete 1 T9 9ELRZ EXRZ Part Number Description Qty LIT 18626 04 26 Owner s Manual 1 90580 50M01 00 Emergency Starter Ass y 1 6Y1 24306 51 00 Fuel Pipe Complete 1 91490 30025 00 Split Pin 2 6G8 48532 50 00 Remote Control Bracket 2 1 6G8 48538 50 00 Cable Clamp 1 1 97595 06530 00 Bolt 1 97595 06512 00 Bolt 2 6G8 48565 50 00 Grommet 1 6G8...

Page 50: ...e 1 6H3 48538 00 00 Cable Clamp 1 63V 48511 01 00 Steering Hook 1 663 48344 00 00 Cable End Remote Control 2 90185 08057 00 Nylon Locking Nut 1 90468 18008 00 Clip 2 97575 08535 00 Bolt w Washer 1 6E5 43145 01 00 Clamp Bracket Cap 1 90185 09M01 00 Nylon Nut 2 90201 10M20 00 Plate Washer 2 93210 16275 00 O Ring 1 90387 10M42 00 Collar 1 6E5 61355 00 00 Bolt 1 63V 61351 00 00 Steering Link Rod 1 901...

Page 51: ...13 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 6Y1 24306 51 00 Fuel Pipe Complete 1 90101 10M58 00 Bolt 4 92995 10600 00 Washer 8 90201 12426 00 Plate Washer 4 95380 10600 00 Nut 8 30MSHZ MLHZ Part Number Description Qty LIT 18626 04 13 Owner s Manual 1 6Ll5 2818N 31 00 Caution Tag 1 90580 50M01 00 Emergency Starter Ass y 1 6Y1 24306 51 00 Fuel Pipe Complete 1 T25TLRZ Part Number Description Qt...

Page 52: ... 95380 12600 00 Nut 8 90185 09M01 00 Nylon Nut 2 90201 10M20 00 Plate Washer 2 93210 16275 00 O Ring 1 6E5 43145 01 00 Clamp Bracket Cap 1 90101 09M01 00 Bolt 1 90170 09M03 00 Nut 1 90201 10M63 00 Plate Washer 1 90387 10M42 00 Collar 1 65W 61351 00 00 Steering Link Rod 1 40TLRZ Part Number Description Qty LIT 18626 04 14 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 90580 50M01 00 Emergency Start...

Page 53: ...01 00 Clamp Bracket Cap 1 90185 09M01 00 Nylon Lock Nut 2 90201 10M20 00 Plate Washer 2 93210 16275 00 O Ring 1 F50TLRZ Part Number Description Qty LIT 18626 04 30 Owner s Manual 1 90580 50M01 00 Emergency Starter Ass y 1 6Y1 24306 51 00 Fuel Pipe Complete 1 6G8 26363 00 00 Wire End 1 2 62Y 42727 00 00 Grommet 1 6E5 43145 01 00 Clamp Bracket Cap 1 6G5 43145 00 00 Clamp Bracket Cap 1 62Y 48538 00 0...

Page 54: ...0 Lead Wire 1 6Y5 83670 11 00 Trim Meter Ass y 1 60TLRZ Part Number Description Qty LIT 18626 04 14 Owner s Manual 1 677 15780 00 00 Emergency Starter Ass y 1 6G5 2818N 31 00 Caution Tag 1 6Y1 24306 53 00 Fuel Pipe Complete 1 90101 12M65 00 Bolt 4 92995 12200 00 Washer 8 90201 12426 00 Plate Washer 4 95380 12600 00 Nut 8 90201 10M20 00 Plate Washer 2 90185 09M01 00 Nylon Nut 2 6E5 43145 00 00 Clam...

Page 55: ... 00 Plate Washer 2 90201 10M63 00 Plate Washer 1 90387 10M42 00 Collar 1 92995 12200 00 Plate Washer 8 93210 16275 00 O Ring 1 95380 12600 00 Nut 8 F80TLRZ F100TLRZ Part Number Description Qty LIT 18626 04 31 Owner s Manual 1 90580 50M01 00 Emergency Starter Ass y 1 6Y2 24307 40 00 Fuel Pipe Complete 1 67F 82105 00 00 Battery Cable 1 67F 61351 00 00 Steering Link Rod 1 90170 09M03 00 Nut 1 90387 1...

Page 56: ... 1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 90201 12M05 00 Bolt 4 90101 12M77 00 Bolt 2 90201 12M05 00 Plate Washer 4 90201 13M01 00 Plate Washer 8 95380 12600 00 Nut 8 ABA DUALT IE BR Tie Bar 1 150TXRZ Part Number Description Qty LIT 18626 04 16 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Sta...

Page 57: ... Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 61B 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 67H 82105 00 00 Battery Cable 1 90101 12M05 00 Bolt 4 90201 12M05 00 Plate Washer 4 90201 13M01 00 Plate Washer 8 90465 13M18 00 Clamp 10 92990 06100 00 Spring Washer 1 95380 06700 00 Nut 1 97595 08516 00 Bolt 1 90101 12M77 00 Bolt 2 95380 12600 00 Nut 8 ABA DUALT IE BR T...

Page 58: ... 1 93210 16275 00 O Ring 1 95380 06700 00 Nut 1 95380 08700 00 Nut 1 95380 12600 00 Nut 8 1 21 Outboard Rigging Guide 2001 2001 Model Outboard Motor Crate Contents VX150TLRZ Part Number Description Qty LIT 18626 04 17 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 6E5 43145 01 00 Clamp Bracket Cap 1 6E5 61351 01 00 Ste...

Page 59: ...umber Description Qty LIT 18626 04 20 Owner s Manual 1 6Gl5 2818N 31 00 Caution Tag 1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 6E5 43145 01 00 Clamp Bracket Cap 1 6E5 61351 01 00 Steering Link Rod 1 6E5 61355 00 00 Bolt 1 90101 12M05 00 Bolt 4 90185 09M01 00 Nylon Lock Nut 2 90201 10M20 00 Plate Washer 2 90201 12M05 00 Plate Washer 4 90201 13M01 00 Plate Wash...

Page 60: ...late Washer 8 90465 13M18 00 Clamp 10 90465 13M30 00 Clamp 1 95380 12600 00 Nut 8 90465 11M10 00 Clamp 2 90101 12M77 00 Bolt 2 ABA DUALT IE BR Tie Bar 1 SX250TXRZ TURZ Part Number Description Qty LIT 18626 04 23 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 61B 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 90101 12M05 00 Bolt 4 90201 12M05 00 Plate Washer 4 90201 13M...

Page 61: ......

Page 62: ...sh Guards 40 F100 Splash Plates 2 11 Jet Drive Model Identification and Serial Numbers 2 12 Jet Drive Engine Mounting Maintenance Shift Cable Instruction Service Info 2 13 Dual Engine Tie Bar Kit Installation 2 32 Dual Cable Steering Bracket Kit Installation 2 36 Morse Universal Dual Cable Steering Bracket Kit Installation 2 39 V4 V6 Rigging Tube Grommet 2 42 F9 9 Exhaust Well Kit Installation 2 4...

Page 63: ......

Page 64: ...lation specifications Transom Dimensions A Steering Rotation each way from cen terline B Maximum tilt angle including 12 tran som angle C Protrusion into boat at maximum tilt D Cavitation plate distance from top of transom E Steering clearance each way from cen terline F Powerhead clearance at rear of motor each way from centerline G Transom thickness minimum maxi mum H Transom bracket height I Ch...

Page 65: ...2 2 Outboard Rigging Guide 2001 Engine Mounting Dimensions ...

Page 66: ... 21 5in 6 0in 12 2in 1 2 2 6in 9 6in L 648mm 25 5in 40M T 40 M 66 M 433mm 17 0in L 537mm 21 1in 175mm 340mm M 30 66mm M 245mm 9 6in M 579mm 22 8in C40T T 69 T 387mm 15 2in 6 9in 13 4in 1 2 2 6in T 355 14 0in T 709mm 27 9in T 69mm 2 7in F30T 3 40 62 353mm S 410 1mm 16 2in 189mm 313mm 69mm 338mm S 599 8mm 23 6in F40 E T 3 13 9in L 533mm 21 0in 7 4in 12 3in 2 7in 13 3in L 665 7mm 26 2in F40 M 3 40 63...

Page 67: ...2 4 Outboard Rigging Guide 2001 Engine Mounting Dimensions ...

Page 68: ... 4in 40M T S 751mm 29 6in M 472mm 18 6in M 683mm 26 9in M 490mm 19 3in M 493mm 19 4in 175mm 600mm C40T L 878mm 34 6in T 439mm 17 3in T 688mm 27 1in T 527mm 20 7in T 529mm 20 8in 6 9in 23 6in F30T 3 S 753 1mm 29 7in 464mm 708mm 763mm 569mm 132mm 521mm 175mm 600mm F40 E T 3 L 876mm 34 5in 18 3in 27 9in 30 1in 22 4in 5 2in 20 5in 6 9in 23 6in F40 M 3 L 876mm 34 5in 493mm 727mm 763mm 569mm 175mm 521mm...

Page 69: ...2 6 Outboard Rigging Guide 2001 Transom Mounting Patterns TRANSOM MOUNTING PATTERNS F9 9 T9 9 9 9HP 15HP ...

Page 70: ...2 7 Outboard Rigging Guide 2001 Transom Mounting Patterns F15 F25 CENTERLINE TOP OF TRANSOM 18 5mm 46 in 254mm 10 in 55 5mm 2 2 in 125 9mm 4 54 in 125 9mm 4 54 in ...

Page 71: ...2 8 Outboard Rigging Guide 2001 Transom Mounting Patterns 25HP 2 Cylinder ...

Page 72: ...2 9 Outboard Rigging Guide 2001 Transom Mounting Patterns 25X3 3 Cyl 30HP 40HP Manual Tilt ...

Page 73: ...F30 F40 F50 T50 F80 F100 F115 35hp and up jet drive transom bracket shape may vary from model to model however mounting hole pattern is the same on all models Not present on V 4 V 6 TRANSOM DRILL FIXTURE YB 34465 Available from Kent Moore Phone 1 800 328 6657 Fax 1 800 578 7375 ...

Page 74: ...he nuts to 43Nm 4 3 m kg 31 ft lb F80 F100 Engine Spray Guard Boat Spray Guard The boat spray guard splash plate can reduce spray when the engine is mounted on a catamaran or pontoon type boat 1 Install the plate between the boat transom and the clamp bracket see illustration below 2 Make sure the edge of the boat splash guard is between the engine splash plate 2b and the engine cavitation plate c...

Page 75: ... drive should be at least 48 and centerline length at least 13 NOTE Transom height is especially critical for jetdrive outboards which are usually mounted 6 to 7 higher than propeller driven outboards therefore it is advisable to use a full transom with your jet drive Motor Selection Motor Sizing A boat operating at slow speed requires consider ably more depth than one that is planing on the surfa...

Page 76: ...ting it is time to test run the boat If ventilation occurs air enters the pump which causes loss of thrust and motor overrevving then you must lower the engine 1 4 at a time until smooth operation is obtained If smooth operation is obtained with the initial setting raise the motor in 1 4 steps until ventila tion does occur Then lower the motor 1 4 and mark and lock that location This height settin...

Page 77: ...ustration An alternate mounting position for the plate with the plate attached to a keel or wedge for use in white water is shown in the second and third parts of the illustration The third part shows the width of the plate as well as the width of the drop bottom wedge that positions the intake in more solid water This installation however reduces shallow water capabilities and should be used only...

Page 78: ...r ing control If you attempt a too tight of a turn at too high a speed your boat could spin out or even roll over Running upstream is easier Running upstream the river speed is subtracted from the boat speed and the shore doesn t go by as fast You can throt tle back and maneuver your way through tight areas with good control At narrow and potential ly rough or dangerous passages you should stop an...

Page 79: ... howev er rocks have been jammed between the grille bars with the motor off they must be removed by prying them out with a suitable tool Mooring If you tie your boat up at a sandy beach where the action of waves causes the boat to rise and fall be sure to tip the motor up out or the water Failure to do this will result in the buildup of sand inside the intake housing around the impeller It is advi...

Page 80: ... the key sleeve and shaft threads any time it becomes nec essary to remove the impeller NOTE Your jet drive is equipped with a shear key to protect it in the event of a rock jam This can be located by removing the water intake hous ing and the drive shaft nut The key holds the jet drive impeller on the driveshaft This operation is similar to that on a propeller drive After replacing the key draw t...

Page 81: ...2 18 Outboard Rigging Guide 2001 Jet Drive Eng Mtg Maintenance Shift Cable Instruction Service Info Location of Main Components JET DRIVE CASING ...

Page 82: ...4 6 9 75 7 76 66 65 2 10 19 20 23 21 22 24 4 5 5 18 8 GREASE SPLINES GREASE IMPELLER SLEEVE KEY 10 6 84 80 79 78 11 77 81 82 17 6 16 95 LATER 95 LATER NOT USED ON PRE 95 40MJH NOT USED ON PRE 95 40MJH GREASE LIGHTLY 36 34 35 37 38 39 40 41 42 31 33 32 55 43 45 54 52 51 44 53 50 49 88 87 46 88 48 47 44 45 44 43 27 56 64 65 66 63 62 61 60 59 58 29 56 25 57 26 27 30 28 66 67 15 1 ...

Page 83: ...Shaft Bearing 1 37 Nylon Sleeve Impeller Bore 1 38 Special Key Impeller 1 39 Impeller 1 40 Shim Impeller Adjustment 9 41 Tab Lock 1 42 Locknut 1 43 Seal Shaft Outer 2 44 Retaining Ring Inner and Outer Seal 4 45 Seal Shaft Inner 2 REF NO DESCRIPTION QTY 46 Bearing and Seal Housing 1 47 Machine Screw Housing 10 24 x 5 8 2 48 Lock Washer 10 5 49 Bearing 1 50 Thrust Washer 1 51 Collar 1 52 Backup Wash...

Page 84: ...9 40 41 42 31 33 32 55 43 45 54 44 53 50 49 87 46 48 47 44 44 45 43 64 65 66 63 62 GREASE LIGHTLY 61 60 59 58 29 56 57 25 26 27 30 28 15 12 14 13 11 15 16 69 68 71 85 78 79 4 77 16 6 17 81 82 80 30 88 19 23 22 24 20 2 18 10 21 6 74 72 83 4 84 10 7 9 6 75 76 30 52 51 67 5 86 5 97 AND LATER SERIAL NUMBER 59500 UP GREASE SPLINES GREASE IMPELLER SLEEVE KEY 3 8 ...

Page 85: ... later 6 33b Nut 5 16 18 Nylock stainless steel 97 and later 6 34 Driveshaft 1 35 Woodruff Key Driveshaft 1 36 Thrust Ring Shaft Bearing 1 37 Nylon Sleeve Impeller Bore 1 38 Special Key Impeller 1 39 Impeller 1 40 Shim Impeller Adjustment 9 41 Tab Lock 1 REF NO DESCRIPTION QTY 42 Locknut 1 43 Seal Shaft Outer 2 44 Retaining Ring Inner and Outer Seal 4 45 Seal Shaft Inner 2 46 Bearing and Seal Hous...

Page 86: ...sealer place the gasket that has two curved slots and one round hole on top of the aluminum housing note the position of the dowel holes 8 Place the steel plate tangs down on top of the gasket 9 Tap the special key into place in the drive shaft 10 Lightly grease the rubber water pump impeller and fit it on the shaft note the impeller can be fitted only one way 11 Fit the other gasket over the dowe...

Page 87: ...Always install all shims on the bottom of a new impeller Installing shims on top of a new impeller may result in insufficient impeller to liner clearance This may cause scoring and impeller or liner damage 22 Install the intake assembly Make sure the lowest part of the grille is positioned at the rear 40 50 models Use six 1 4 20 by 3 4 bolts no lock washers The tightening torque is 8 ft lb 90 V4 V...

Page 88: ...1 38 20 Shift Cable Assembly 1 A 63D JD005 47 00 Cable 4 ft 1 B 6H4 JD005 43 00 Clamp Cable 1 C 6H4 JD005 61 00 Bolt Cable Clamp 2 D 63D JD005 58 02 Screw Hex Head 1 E 6H4 JD006 19 00 Nut Fiberlock 2 F 62D JD005 53 02 Ball Rod End 1 G 63D JD006 21 01 Nut Hex 1 H 6H4 J0006 37 00 Lock Washer Toothed M5 1 F H G C B A E D ...

Page 89: ...aded as far onto the cable as it will tighten Loosen the two cable support bracket bolts on the pump main housing and torque the mounting bolts to 8 ft lbs with the cable support bracket posi tioned as far forward as possible d Attach the upper cable clamp to the tiller arm using the two 10 24 x 5 8 bolts and fiberlock nuts e Shift to forward The roller should be at the end of the cam slot with th...

Page 90: ...e roller should be at the end of the slot in the cam so the gate cannot be forcibly rotated toward reverse Pull on the gate by hand to verify this If the forward lock condition is not met read just the cable positions giving less impor tance to the roller position in neutral e If the neutral position is too far out of adjust ment the tendency of the gate to move toward reverse under water pressure...

Page 91: ... that air is allowed to enter the pump This is likely in choppy water particularly when run ning with the wind Less than 48 inches on the other hand can make it difficult to reach planing with a heavy load 6 A slight vee in the boat bottom gives better steering and helps to keep solid water in the pump A 3 inch drop at centerline on a 60 inch bottom is enough Beyond that shallow draft is sacrifice...

Page 92: ...ust go around To correct the problem remove the grates and grind down this lip to make a smooth path for the water Overhaul Procedures NOTE It is recommended that these procedures be performed by only your authorized Yamaha Outboard Motor Dealer Disassembly Refer to Assembly and Installation page 2 23 and reverse the procedures outlined here Bearing Housing 1 Remove the large beveled circlip from ...

Page 93: ...ess only against the outer race of the bearing Only a light press is needed if everything is lined up properly FOR 90 AND V4 V6 MODELS ONLY Slip the bearing housing over the shaft Support the bearings and driveshaft using Yamaha special tool YB 06205 2 Heat the housing slightly again It is important to slide the housing on squarely and do not use a hammer or in any way apply impact loads to the ba...

Page 94: ... of bolts 1 Mark the liner bolts for reassembly in the same locations and remove the bolts 2 Loosen the liner by tapping on the liner edge with a long drift through the intake grille Lift out the liner 3 Drop the new liner into position Line up one of the liner bolts and lightly thread it in It may be necessary to tap or press the liner into the intake housing to locate the liner for installation ...

Page 95: ...or the accessory Dual Engine Tie Bar Kit ABA DUALT IE BR The tie bar is used to connect dual outboard motors in order to achieve synchronized steering and better engine performance Tie Bar Kit Application Chart o Optional Sc Standard in crate NOTE The LF115 cannot use this tie bar if a Teleflex Center Mount Hydraulic Cylinder 5354 is used MODEL 25HP 100HP PART NUMBER ALL MODELS 115 250HP2 423 LF11...

Page 96: ...threaded tie rod in vise using aluminum or preferably wooden pads to prevent damaging threads as shown 6 Install the jam nut on the tie rod 7 Grease the threads on the end of the tie rod that you installed on the jam nut 8 Install one tie rod terminal threading it onto tie rod until Hole A is covered REF NO DESCRIPTION QTY 1 ROD 9 16 18 UNF 2A 1 2 9 16 I D X 11 16 O D Black Vinyl Tubing 1 3 Tie Ro...

Page 97: ...e port swivel clevis install bolt and nut but do not tighten them 16 Set the engines so the toe out position is less than 1 inch See the illustration below NOTE For best results your toe out distance should be set so the twin engines wake meets approximately 25 50 ft past the stern of the boat 17 Swing the tie rod up and align it parallel with the tie rod terminal on the port swivel clevis 18 Plac...

Page 98: ...minal Adjustments can be made to insure proper toe out position 23 Re attach the rod terminal to the port engine swivel clevis and tighten nut to 12 ft lb Recheck all nuts and bolts to assure proper installation and torque After 2 hours of operation recheck all bolts and nuts to assure proper installation and torque At the end of every 50 hours of operation re lube inspect all parts for wear prope...

Page 99: ... be installed so both steering cables will be routed together on the same side of the boat and will push pull together See Illus 1 NOTE This procedure is best done prior to bolt ing motor to the transom Steering Arm Installation 1 Install the steering arm to the motor tiller arm using the inner rearmost bolt hole and torque to specification Be sure to use the lock nut as shown in the Yamaha Riggin...

Page 100: ...ble through the mounting bracket holes without the support tube installed Turn the steering wheel to extend cables to their full length then back off 1 4 turn See Illus 6 4 Install the support tube onto the extended portion of cable 2 and through only one hole in the mounting bracket Slide the second large nut and the lockwasher over end of the cable and onto the support tube a few turns Slide the...

Page 101: ...lus 8 9 Insert the nylon sleeve into the steering tube and slide the rod seal cap onto the end of the support tube 10 Install the motor to the boat using all proce dures prescribed Cable Adjustment 1 Center motor 2 Loosen the support tube holding nuts both ends approximately 10 turns 3 Take up any play in the cables by the pushing motor slightly in the direction of a turn to starboard 4 Tighten th...

Page 102: ... Both gear racks or rotary steering heads must be installed so both steering cables will be routed together on the same side of the boat and will push pull together See Illus 1 Steering Arm Installation 1 Install the steering arm to the motor tiller arm using the inner rearmost bolt hole and torque to specification Be sure to use the lock nut as shown in the rigging specifica tions See Illus 2 2 A...

Page 103: ...end Insert the cable through the mounting bracket holes without the support tube installed Turn the steering wheel to extend the cables to their full length then back off 1 4 turn See Illus 6 4 Install the support tube onto the extended portion of cable Number 2 and through only one hole in the mounting bracket Slide the second large nut and the locking tab washer over the end of the cable and ont...

Page 104: ...rquing to 120in lbs Then back nuts off 1 4 turn See Illus 8 9 Insert the nylon sleeve into the steering tube and slide the rod seal onto the end of the sup port tube See Illus 7 Cable Adjustment 1 Center the motor 2 Loosen the support tube holding nuts both ends approximately 10 turns 3 Take up any play in the cables by pushing the motor slightly in the direction of a turn to starboard 4 Tighten t...

Page 105: ...eading on the hose do a final check of all hose and cable routing If you are using a threaded transom plate thread the rig ging tube into it first 8 On the engine grommet side apply a small bead of silicone sealant to the first few threads of the hose and install Remember the thread is left hand so you will rotate the hose to the left facing the front of the engine Thread the rigging tube into the...

Page 106: ...Lead 5 Remote Oil Tank Lead 6 Trim Gauge Lead 7 Battery Leads w Isolator Lead 8 Oil Hose 9 Fuel Hose 10 Speedometer Hose F80 F100 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Trim Gauge Oil Warning Lead 5 Battery Leads 6 Fuel Hose 7 Speedometer Hose 8 Water Temperature Water Pressure Sensor F115 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Trim Gauge Oil Warning Lea...

Page 107: ...ing the outboard motor on the boat bolt the clamp bracket to the boat Mounting On a Well type Boat 1 When the boat is a well type the engine should be mounted in the following manner Mount the engine on the boat and secure it with clamp bolts Illus 1 NOTE a Tighten the bolts completely b After mounting the outboard motor on the boat bolt the clamp bracket to the boat c Apply a sealing compound to ...

Page 108: ...low by gas exhaust pipe out of the boat Illus 6 NOTE a Clamp the hose to the hull so it does not move b Route the hose so it inclines downward 7 Bring the idling exhaust gas exhaust pipe out of the boat Illus 7 NOTE a Secure the hose to the hull so it does not move ILLUSTRATION 5 ILLUSTRATION 6 YAMAHA ILLUSTRATION 7 ...

Page 109: ......

Page 110: ... Assemblies 3 8 Battery Installations 3 22 Electrical Connectors 3 33 Rectifier 6 25HP 3 34 Voltage Regulator 3 36 5HP Lighting Coil 3 37 Neutral Safety Switch 30E 3 40 Remote PT T Switch F T25T 40T 250HP C40T C90 3 41 Boat Wiring Diagrams 3 43 Complete Boat Wiring Diagrams 3 67 3 ...

Page 111: ......

Page 112: ... O O O 7 2 10 Pin 3m 688 8258A 30 00 O O O O O O O O Oil Harness 8 1 Oil Tank Lead 3m 6R3 85721 30 00 O O 8 2 Oil Tank Lead 5m 6R3 85721 50 00 O O 8 3 Oil Tank Lead 8m 6R3 85721 80 00 O O Instrument Panel Extensions 9 1 Blue Lead 6Y5 82149 00 00 O O O O O O 9 2 Black Lead 6Y5 82117 00 00 O O O O O O 9 3 Yellow Lead 6Y5 82521 00 00 O O O O O O Special Harnesses 10 Tachometer Harness 6Y5 83553 10 00...

Page 113: ...O O 22 2 Oil Gauge Lead 7m 6R3 82521 70 00 O O O 22 3 Oil Gauge Lead 8m 6R3 82521 80 00 O O O 22 4 Oil Gauge Lead 9 5m 6R3 82521 90 00 O O O 23 PT T Switch Lead Extension 2m 6H5 82553 00 00 O Fuel Management 24 1 F M Meter to Sender 5m 6Y5 83553 F0 00 O Ss 24 2 F M Meter to Sender 8m 6Y5 83553 F1 00 O Ss 25 Sender Extension 3m 6X1 82531 00 00 O O 26 F M Meter to Tach 703 82531 00 00 Ss WIRE HARNES...

Page 114: ...n Harness 688 82586 50 00 5M 16 4ft 2 1 Main Harness 10 Pin 5M 688 8258A 50 00 5M 16 4ft 2 2 Main Harness 10 Pin 8M 6K1 8258A 40 00 8M 26ft 3 2 Main Harness 10 Pin 9 9M 61B 8258A 00 00 9 9M 31 2ft 4 7 to 10 Pin Adapter 703 8258A 00 00 5 12 Pin Main Harness for Tiller Models 2 5M 6H5 83553 11 00 2 5M 8 2ft ...

Page 115: ...6ft 7 2 10 Pin 3M Extension main harness 688 8258A 30 00 3M 9 8ft TANK HARNESSES 8 1 Oil Tank Lead 3M 6R3 85721 30 00 3M 9 8ft 8 2 Oil Tank Lead 5M 6R3 85721 50 00 5M 16 4ft 8 3 Oil Tank Lead 8M 6R3 85721 80 00 8M 26 2ft Instrument Panel Harnesses 9 1 Accessory Blue Lead 6Y5 82149 00 00 12V lights 9 2 Accessory Black Lead 6Y5 82117 00 00 Ground 9 3 Accessory Yellow Lead 6Y5 82521 00 00 12v key ON ...

Page 116: ...2 8M 9 3ft 12 Rectifier to Battery w Connector 682 84338 00 00 6 05M 19 8ft 13 Remote Conversion Harness T9 9 6G8 82590 00 00 7 6M 24 9ft 14 Oil Light Harness F T9 9M 6G8 82541 00 00 2 5M 8 2ft 15 V6 Battery Cable 64D 82105 00 00 3 2M 10 6ft Control Box Adapters 16 Aftermarket Harness to 704 705 box 704 85721 00 00 17 Aftermarket Control to Main Harness 704 82541 10 00 ...

Page 117: ... Trim Oil Lead 9 5M 64D 82553 90 00 9 5M 31 2ft Extensions 21 1 Trim Gauge Lead 3M 6R3 82553 30 00 3M 9 8ft 21 2 Trim Gauge Lead 5M 6R3 82553 50 00 5M 16 4ft 21 3 Trim Gauge Lead 7M 6R3 82553 70 00 7M 23ft 21 4 Trim Gauge Lead 8M 6R3 82553 80 00 8M 26 3ft 21 5 Trim Gauge Lead 9M 6R3 82553 90 00 9 5M 31 2ft 22 1 Oil Gauge Lead 5M 6R3 82521 50 00 5M 16 4ft 22 2 Oil Gauge Lead 7M 6R3 82521 70 00 7M 2...

Page 118: ...24 1 F M Meter to Sender 5M 6Y5 83533 F0 00 5M 16 4ft 24 2 F M Meter to Sender 8M 6Y5 83533 F1 00 8M 26 2ft 25 Sender Extension 6X1 82531 00 00 3M 9 8ft 26 F M Meter to Tach 703 82531 00 00 F M l Meter to Sender Harness included with fuel management kit is F1 8m long For replace ment F0 5m must be used with extensions ...

Page 119: ...fied emergency stop lanyard two ignition switches and a warning buzzer NOTE Do not use a dual switch panel with the 40 90HP LF115 or C40T C90 models The overheat and low oil warning system on these panels are not compatible with these models Accessory Panels Yamaha offers three accessory panels Oil warning light panel for the T9 9ELR Single ignition key switch with push for choke activation Emerge...

Page 120: ...t Number T9 9 F15 30 40E F25T F115 C90 V6 L250 Switch Panel Needed With W Push To Binnacle Or Flush Choke Control Single 704 82570 06 00 O O O O O O Twin 6K1 82570 05 00 O Sk Single No Horn 689 82570 18 00 O O Main Sw Only 64D 82570 02 00 O O O O O O Stop Sw Only 64D 82570 10 00 O O O O O O Switch Panel W Oil Light Single W Oil Light 6G8 82570 02 00 O Oil Light Only 6G8 83530 00 00 O ...

Page 121: ...ated 3 Connect the wire harness to the switch panel assembly as shown in the correct wiring dia gram in the Boat Wiring Diagrams Section of this manual and pass the harness back through the hole 4 Secure the switch panel assembly to the instrument panel with screws washers and nuts or wood screws as required SAMPLE ONLY Actual pattern may vary with panel selected Wiring For wiring information and ...

Page 122: ...arning horn REF NO PART NUMBER DESCRIPTION QTY 10 704 82570 06 00 Panel Switch Ass y 1 11 704 82510 06 00 Main Switch Ass y 1 12 688 82575 01 00 Engine Stop Switch Ass y 1 13 682 82556 00 00 Stopper 1 14 640 82581 00 00 Stay Cord Clamp 1 15 97303 05012 00 Bolt 1 16 92903 05100 00 Washer Spring 1 17 95303 05700 00 Nut 1 18 658 83383 11 00 Buzzer 1 19 90149 05M05 00 Screw 4 20 95380 05600 00 Nut 4 2...

Page 123: ...ch Panels 22 5 mm 1 01 in 22 5 mm 1 01 in 110 mm 4 33 in 51 mm 2 0 in 8 5 mm 33 in 68 mm 2 67 in 93 mm 3 66 in 44 5 mm 1 75 in 8 5 mm 33 in 2x 51 mm 2 02 in CUT OUT THE SHADED PORTION SINGLE SWITCH PANEL ASSEMBLY DRILL TEMPLATE Actual Size ...

Page 124: ...n Switch Ass y 2 4 6K1 82575 00 00 Engine Stop Switch Ass y 1 5 682 82556 00 00 Stopper 1 6 6K1 83614 01 00 Stay 1 7 688 83383 11 00 Buzzer 2 8 6K1 85830 01 00 Control Unit Ass y 1 9 98580 06020 00 Screw Pan Head 2 10 92995 06100 00 Washer Spring 2 11 95380 06600 00 Nut 2 12 98580 05010 00 Screw Pan Head 2 13 92990 05100 00 Washer Spring 2 14 95380 05600 00 Nut 2 15 90149 05M05 00 Screw 4 16 95380...

Page 125: ...Rigging Guide 2001 Switch Panels 93 mm 3 66 in 128 mm 5 04 in 27 mm 1 06 in 27 mm 1 06 in 27 mm 1 06 in 27 mm 1 06 in 40 mm 1 46 in 6x 54mm 2 12 in DRILL TEMPLATE DUAL SWITCH PANEL ASSEMBLY DRILL TEMPLATE Actual Size ...

Page 126: ...h Ass y 1 3 6G8 82571 01 00 Panel Switch 1 4 68882 57501 00 Engine Stop Switch Ass y 1 5 68282 55600 00 Stopper 1 6 66382 58101 00 Stay Cord Clamp 1 7 6G8 83582 01 00 Pilot Light Ass y 1 8 6G8 82510 00 00 Main Switch Ass y 1 9 98903 04008 00 Screw Bind 1 10 92903 04100 00 Washer Spring 1 11 90149 05M05 00 Screw 4 12 95380 05600 00 Nut 4 13 92990 05100 00 Washer Spring 4 14 92990 05600 00 Washer Pl...

Page 127: ...utboard Rigging Guide 2001 Switch Panels 27mm 2 12 in 54mm 2 7 in 68mm 2 1 8 in 5 in 130mm 4 5 in 116mm 1 in CUT OUT THE SHADED PORTION Four Stroke Switch Panel T9 9 6G8 82570 02 00 DRILL TEMPLATE Actual Size ...

Page 128: ...3 17 Outboard Rigging Guide 2001 Switch Panels Oil Lamp Panel Assembly T9 9ELR 6G8 83530 00 00 ...

Page 129: ...igging Guide 2001 Switch Panels 30 mm 1 17 in 7 7 mm 31 in 7 7 mm 31 in 19 mm 75 in 56 mm 2 2 in 41 mm 1 58 in 68 mm 2 67 in 52 mm 2 06 in 13 7 mm 82 in 14 3 mm 56 in 4x 5 1 mm 2 in Oil Lamp DRILL TEMPLATE Actual Size ...

Page 130: ...3 19 Outboard Rigging Guide 2001 Switch Panels Single Main Ignition Switch Panel Option 9 9 250 64D 82570 02 00 Single Emergency Stop Lanyard Panel Option 9 9 250 64D 82570 10 00 ...

Page 131: ...3 20 Outboard Rigging Guide 2001 Switch Panels Single Main Ignition Switch Panel Option 9 9 250 64D 82570 02 00 DRILL TEMPLATE Actual Size ...

Page 132: ...3 21 Outboard Rigging Guide 2001 Switch Panels Single Emergency Stop Lanyard Panel Option 9 9 250 64D 82570 10 00 DRILL TEMPLATE Actual Size ...

Page 133: ...t route the battery cables through the engine rigging grommet which is on the starboard side of the lower pan Locate the battery cable in the proper position in the engine rig ging grommet 3 Run the battery cable to the starter motor The negative battery cable will be connected to the post on the starter housing up top and to the rear The positive battery cable end will be connected to the termina...

Page 134: ...he lower pan Ensure the cable is in its proper position in the grommet 3 Run the battery cable to the starboard side of the engine pan just in front of the air box 4 Remove the fuse box cover 5 Bring the battery cables from the lower pan up to the starter motor The positive terminal on the battery cable will be installed on relay 2 which is located on front side of the starter motor The negative b...

Page 135: ... are most suitable Consult the battery manufacturer for details NOTE The specifications above are minimum requirements It is always good practice to exceed the minimum specifications If mini mum specifications are not met the engine could experience electrical component issues Engine Size Minimum Battery Specification HP Class Amp Hour Cold Cranking Reserve 50 Smaller 40AH 210 Amps 59 Minutes T9 9...

Page 136: ...d Required Not Required Requires Part 68F 81949 00 00 Type of Installation Refer To 1 Motor 2 Batteries No Battery Switch Page 3 26 2 Motors 3 Batteries No Battery Switch Page 3 26 1 Motor 2 Batteries On Off Battery Switch Page 3 27 2 Motors 3 Batteries On Off Battery Switch Page 3 28 2 Motors 3 Batteries 1 Both 2 Battery Switch Page 3 29 Bass Boat 12 24 Volt Trolling Motor 3 pin plug Page 3 30 Ba...

Page 137: ...one battery is used connect the two red cables to the terminal If the smaller red cables is left unconnected an accidental con tact of the red cable with the terminal of the battery will form a short circuit and may cause a fire 2 When using an accessory battery a negative connecting cable must be installed between the accessory battery and the main battery This cable must be equivalent to the mai...

Page 138: ...tween the accessory battery and the main battery This cable must be made from wire equivalent to the main battery cable Use of a smaller wire could lead to a fire BATTERY SWITCH SELECTION NOTE 1 SWITCH POSITION BOTH SHOULD NOT BE USED FOR BACK UP CRANKING If Battery 1 is discharged and the BOTH position is selected then Battery 2 will discharge into Battery 1 2 Switch 2 is not required the battery...

Page 139: ...tarting battery shut off switch single battery high current type 2 Optional auxiliary battery shut off switch minimum capacity 80 amps 3 Accessory shut off switch capacity determined by current requirements of accessories and wire size used 4 Optional twin engines with three batteries the isolator leads from both engines could be wired to the accessory battery for electronics NOTE Switch 2 is not ...

Page 140: ...he battery isolator on the motor will prevent current from flowing to the electrical components on the engine even if the small wire remains connected to the battery However the Switch 4 can be installed to shut off electrical power to the accessories 3 Optional Isolator lead 3 from both engines could be hooked to the accessory battery MODE SWITCH 1 POSITION SWITCH 2 POSITION SYSTEM OFF OFF OFF NO...

Page 141: ... to the engine s electrical system could occur To reduce the risk of electrical short and fire The positive isolation lead must be at least 12 gauge wire The negative lead between batteries must be the same size as the battery cable if the second battery will be used for starting The negative lead between batteries must be at least 12 gauge if the second battery will be used to power a trolling mo...

Page 142: ...e to the engines electrical system could occur To reduce the risk of electrical short and fire The positive isolation lead must be at least 12 gauge wire The negative lead between batteries must be the same size as the battery cable if the second battery will be used for starting The negative lead between batteries must be at least 12 gauge if the second battery will be used to power a trolling mo...

Page 143: ...will be used for starting The negative lead between batteries must be at least 12 gauge if the second battery will be used to power a trolling motor NOTE The battery isolator cannot be used on a 24 36 volt trolling motor system A short could result causing a fire Consult the trolling motor manufacturer for wiring recommenda tions NOTE If only two batteries are used and one is being used for starti...

Page 144: ...low you to make factory like con nections Lead Wires Yamaha lead wires allow quicker and easier rig ging by providing two additional female recepta cles These wire leads are available in yellow black and blue Description Part Number Yellow Lead Wire 6Y5 82521 00 00 Black Lead Wire 6Y5 82117 00 00 Blue Lead Wire 6Y5 82149 00 00 Telephone 1 800 328 6657 Fax 1 800 578 7375 ...

Page 145: ...nnection cover and remove it 5 Dislodge the three green wire connectors originating from the lighting coil from the retainer under the connection cover Connect the two primary green wires with the green wire leads from the rectifier NOTE The extra green wire connector from the lighting coil will remain unused 6 Pass the red and black battery lead wires through the slits in the rubber grommet at th...

Page 146: ...l 1 6G8 82150 00 00 Fuse Holder Ass y Connects rectifier and lead wire All 1 6G8 81948 00 00 Bracket Mounts rectifier and regulator assembly F9 9 1 97095 06016 00 Bolt For mounting bracket F9 9 3 92990 06600 00 Washer For mounting bracket F9 9 3 6G1 81975 00 00 Plate Rectifier Fitting Mounts rectifier 6 8 1 98580 05525 00 Screw Panhead Mounts rectifier 6 8 9 9 15 25 1 92990 05600 00 Washer Use wit...

Page 147: ...odels a lighting coil must be installed All other applicable models have a stan dard lighting coil Installation Mounting 1 Select a suitable location near the motor and secure the voltage regulator to the boat NOTE The inside of the transom may be a good location for the voltage regulator provided it is not in an area subjected to a lot of water splash Wiring 1 Connect the yellow leads to the lead...

Page 148: ...e starter assembly 2 Loosen the flywheel nut using the flywheel holder and a socket wrench The main thrust must be made in the direction of the arrow If not the flywheel holder can slip off 3 Using the flywheel puller remove the fly wheel The flywheel puller bolts should be inserted into the hole marked P Loosen the flywheel nut out only to the end of the crankshaft until the flywheel has broken l...

Page 149: ... the grom met into the magneto base 9 Secure the wire leads with the stay The ground lead should be secured with the stay screw 10 Make sure the O ring in the groove of the magneto base is installed correctly Slip the magneto base over the boss located between the cylinder and crankcase 11 Align the bolt holes in the cylinder block with the holes in the magneto base then rein stall and tighten the...

Page 150: ...1 Connect the wire leads as shown in the dia grams NOTE The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage input from the rectifier to the battery NOTE The rectifier can also be used with the Yamaha Voltage Regulator 663 81910 10 00 to ensure proper voltage input from the rectifier to the battery ...

Page 151: ...operating the shift lever The switch button should be pressed by the cam on the end of the shift lever when the lever is moved to neutral 5 Connect the extension wire lead P N 6H4 82553 00 00 to the leads of the neutral safe ty switch 6 Route the extension leads around the front of the bottom cowling to the right side of the motor opposite the CDI unit Secure the wires with cable ties to keep them...

Page 152: ... the trim tilt switch can be mounted anywhere on the boat This would allow for example a fisherman to trim the motor while casting off the front of the boat The power trim tilt switch connects to the main instrument harness with wire leads that are included Thin Instrument Panel Installation maximum 2mm 0 08in 1 Select a mounting location so the power trim tilt switch is easy to reach from the hel...

Page 153: ...m Be sure there is sufficient clearance behind the instrument panel for the switch 2 When installing the power trim tilt switch into a thick instrument panel make a hole 40mm 1 57in high and 13mm 0 5in wide as shown in the mounting diagram 3 Secure the switch with the wood screws as shown For electric tiller model wiring see the wiring diagrams in the Boat Wiring Diagrams Section 40 mm 1 57 in 13 ...

Page 154: ...F50 T50 F80 100 F115 with Switch Panel 3 52 10 C40 C150 with 703 Control and Analog Tachometer 3 53 11 C40 C150 with Switch Panel and Analog Tachometer 3 54 12 40T 90HP C40 C115 with 703 Control and Multifunction Gauges 3 55 13 40T 90HP C40 C115 with Switch Panel and Multifunction Gauges 3 56 14 115 250HP with 703 Control and Analog Gauges 3 57 15 115 250HP with Switch Panel and Analog Gauges 3 58...

Page 155: ...3 44 Outboard Rigging Guide 2001 Boat Wiring Diagrams T9 9 with 703 Control ...

Page 156: ...3 45 Outboard Rigging Guide 2001 T9 9 with Switch Panel ...

Page 157: ...3 46 Outboard Rigging Guide 2001 Boat Wiring Diagrams 9 9 30HP 30 C40 98 with 703 Control 10 pin and Analog Tachometer ...

Page 158: ...3 47 Outboard Rigging Guide 2001 Boat Wiring Diagrams 9 9 30HP 30 C40 98 with 10 pin Switch Panel and Analog Tachometer ...

Page 159: ...3 48 Outboard Rigging Guide 2001 Boat Wiring Diagrams Wiring 9 9 30HP with 7 Pin Harness Switch Panel ...

Page 160: ...3 49 Outboard Rigging Guide 2001 Boat Wiring Diagrams 40E 50HP with 703 Control Analog Tachometer Except 40T or P50 ...

Page 161: ...3 50 Outboard Rigging Guide 2001 Boat Wiring Diagrams 40E 50HP with Switch Panel Analog Tachometer Except 40T or P50 ...

Page 162: ...3 51 Outboard Rigging Guide 2001 Boat Wiring Diagrams F40 F50 T50 F80 100 F115 with 703 Control Box and Analog Tachometer ...

Page 163: ...3 52 Outboard Rigging Guide 2001 Boat Wiring Diagrams F40 F50 T50 F80 100 F115 with Switch Panel and Analog Tachometer ...

Page 164: ...3 53 Outboard Rigging Guide 2001 Boat Wiring Diagrams C40 C150 with 703 Control and Analog Tachometer ...

Page 165: ...3 54 Outboard Rigging Guide 2001 Boat Wiring Diagrams C40 C150 with Switch Panel and Analog Tachometer ...

Page 166: ...Boat Wiring Diagrams 40T 90HP with 703 Control and Multifunction Gauges C40 C115 OPTIONAL ON C40 C90 May connect Gray wire to GRN WHT wire and set dip switch 3 for 4 stroke operation This will allow gauge not to flash a yellow warning ...

Page 167: ...Boat Wiring Diagrams 40T 90HP with Switch Panel and Multifunction Gauges C40 C115 OPTIONAL ON C40 C90 May connect Gray wire to GRN WHT wire and set dip switch 3 for 4 stroke operation This will allow gauge not to flash a yellow warning ...

Page 168: ...3 57 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with 703 Control and Analog Gauges ...

Page 169: ...3 58 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with Switch Panel and Analog Gauges ...

Page 170: ...3 59 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with 703 Control and with Multifunction Gauges 2 Stroke ...

Page 171: ...3 60 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with Switch Panel and with Multifunction Gauges 2 Stroke ...

Page 172: ...3 61 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with 703 Control and Analog Tachometer 2 Stroke 3 69 ...

Page 173: ...3 62 Outboard Rigging Guide 2001 Boat Wiring Diagrams 115HP 250HP Wiring with Switch Panel and Analog Tachometer 2 Stroke ...

Page 174: ...iring Diagrams Dual Control Boxes 704 Dual Control with Dual Switch Panel All Twin Engines Wiring same if panel with or without separate choke switch is used NOTE All other wiring tachometer speedometer etc is the same as individual engines ...

Page 175: ...3 64 Outboard Rigging Guide 2001 Boat Wiring Diagrams Tiller Models with PT T 40TLHW 50TLHW P60TLHW P75TLHW F40 F100 UNUSED ...

Page 176: ...3 65 Outboard Rigging Guide 2001 Boat Wiring Diagrams F40 F50TLH T50 F80 F100 Tiller Model Analog Tachometer UNUSED ...

Page 177: ...3 66 Outboard Rigging Guide 2001 After Market Dash Wiring ...

Page 178: ...3 67 Outboard Rigging Guide 2001 COMPLETE BOAT WIRING DIAGRAMS 70 90HP F80 F115 ...

Page 179: ...3 68 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V4 V6 Single Engine ...

Page 180: ...3 69 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V4 V6 Single Engine Cont d ...

Page 181: ...3 70 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V4 V6 F115 Dual Engine ...

Page 182: ...3 71 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V4 V6 F115 Dual Engine Cont d ...

Page 183: ...3 72 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V6 HPDI Single Engine ...

Page 184: ...3 73 Outboard Rigging Guide 2001 Complete Boat Wiring Diagrams V6 HPDI Dual Engine ...

Page 185: ......

Page 186: ...strations 4 2 Control Box Applications 4 3 701 Remote Control Assembly 4 4 703 Control Assemblies 4 8 704 Binnacle Mount Remote Control Assemblies 4 18 705 Flush Side Mount Remote Control Assembly 4 32 Remote Control Cables Remote Conversion Kits 701 703 4 47 Control Box Adjustments 4 48 4 ...

Page 187: ......

Page 188: ... trim and tilt switch Can be converted to pull to open throttle SNG BINN PUSH PT T 704 Dual Binnacle Control Box 704 48207 31 00 Push to open throttle with power trim and tilt switch Can be converted to pull to open throttle DUAL BINN PUSH PT T 705 Flush Mount Control Box 6X0 48206 11 00 Push to open throttle with power trim and tilt switch Note 90 quick throw handle movement FLUSH PUSH PT T 90 NO...

Page 189: ...4 2 Outboard Rigging Guide 2001 CONTROL BOX ILLUSTRATIONS 701 703 704 Single Binnacle 704 Dual Binnacle 705 Kit Part Number 682 84380 00 00 ...

Page 190: ...F25T F80 LF115 F40T F100 L130 F15E 40T C40T F115 To F9 9 9 9 25 F25E To To V4 L250 Description Part Number T9 9 15 30 40E 90 C115 V6 LX250 701 Pull No Elec 701 48101 51 00 O O 701 Push No Elec 701 48130 02 00 O 703 Pull 703 48230 12 00 Or Or 7 Pin Choke 703 48240 12 00 Or 703 Push 703 48207 15 00 U U Sk Sk Sk Sk 10 Pin Main Sw Except Except Choke F25 F25 Single Binnacle 704 48205 13 00 Sk Sk Sk Sk...

Page 191: ... 00 Bolt 2 23 702 48288 00 00 Washer Plain 1 24 701 48246 00 00 Spacer 2 25 92990 06300 00 Washer Internal Tooth 1 26 701 48229 00 00 Grip Control Lever 1 27 701 48222 00 00 Grip Control Lever 1 28 98580 05555 00 Screw Pan Head 2 29 701 48266 00 00 Spacer 1 30 701 48232 00 00 Gear 1 31 701 48189 11 00 Retainer 1 32 98580 05010 00 Screw Pan Head 2 33 701 48153 12 00 Shaft Free Accel 1 34 701 48271 ...

Page 192: ...with no sharp bends Measure from the control head to the shift and throttle con nections on the motor Yamaha remote con trol cables are available in lengths from 6 feet to 36 feet Installation of Remote Control Cables 1 Loosen the four screws and remove the back plate 2 Screw in the cable end about 11mm 0 43in over the threaded end of each remote control cable and secure it with the locknut Use Ya...

Page 193: ...be no bends of less than a 4 inch radius The cables should be supported with cable hangers or for long runs by running them through conduit Throttle Connection Proper adjustment of the throttle cable s will help ensure long component life Proper adjust ment is achieved when the engine speed remains at idle during shifting and will only increase when the hand lever is moved beyond the shift detent ...

Page 194: ...nnection Proper adjustment of the shift cable will result in a better operating control 1 Attach the control cable to the shift arm in the motor 2 Operate the hand lever several times to verify proper operation Make sure that the Forward Neutral and Reverse posi tions on the hand lever correspond to the same position of the motor shift arm Over jamming the shift stop at either end of the lever tra...

Page 195: ...58 00 00 Anchor Cable 1 21 703 48244 00 00 Spring Free Accel 1 22 703 48238 00 00 Spring Detent 5 23 703 48246 00 00 Spacer 1 24 703 48227 00 00 Spring Neutral Lock 1 25 703 82594 00 00 Clamp 1 26 703 48226 00 00 Plate Stopper 1 27 703 48222 00 00 Grip Control Lever Single 1 28 703 48223 00 00 Lock Neutral 1 29 703 48225 00 00 Cover 1 30 703 48219 00 00 Cover Lead 1 31 703 48281 00 00 Screw 2 32 7...

Page 196: ...A0 00 Buzzer 1 52 703 48284 00 00 Grommet 1 53 90464 13080 00 Clamp 2 54 703 82592 00 00 Band 1 55 703 82563 01 00 Trim Tilt Switch Ass y 1 56 703 48221 00 00 Lever Control 1 57 703 48152 00 00 Knob Free Accel 1 58 703 48212 00 00 Back Plate 1 1 59 703 48213 00 00 Back Plate 2 1 60 703 48271 00 00 Arm Shift 1 61 703 48211 01 00 Housing 1 62 703 48232 00 00 Gear 1 63 93430 06024 00 Circlip 2 64 703...

Page 197: ...03 48345 01 00 Cable End Rem Control 2 2 20 703 48358 00 00 Anchor Cable 1 21 703 48244 00 00 Spring Free Accel 1 22 703 48238 00 00 Spring Detent 5 23 703 48246 00 00 Spacer 1 24 703 48227 00 00 Spring Neutral Lock 1 25 703 82594 00 00 Clamp 1 26 703 48226 00 00 Plate Stopper 1 27 703 48222 00 00 Grip Control Lever Single 1 28 703 48223 00 00 Lock Neutral 1 29 703 48225 00 00 Cover 1 30 703 48219...

Page 198: ...A0 00 Buzzer 1 52 703 48284 00 00 Grommet 1 53 90464 13080 00 Clamp 2 54 703 82592 00 00 Band 1 55 703 82563 01 00 Trim Tilt Switch Ass y 1 56 703 48221 00 00 Lever Control 1 57 703 48152 00 00 Knob Free Accel 1 58 703 48212 00 00 Back Plate 1 1 59 703 48213 00 00 Back Plate 2 1 60 703 48271 00 00 Arm Shift 1 61 703 48211 01 00 Housing 1 62 703 48232 00 00 Gear 1 63 93430 06024 00 Circlip 2 64 703...

Page 199: ...wer trim tilt switch warning buzzer and a push to choke Preparation 1 Select a mounting location for the remote control which offers ease of use from the helm and allows full movement of the con trol lever 2 Choose an unobstructed path for the cables that will allow them to be routed as straight as possible with no sharp bends Measure from the control head to the shift and throttle connections on ...

Page 200: ...rease to the threaded holes in the cable joints 4 Insert the remote control cable for shifting into the housing clamp so that the groove on its end fits over the ridge in the clamp Fit the cable joint over the pin on the end of the shift arm and lock it with a circlip 5 Fit the grommet in the clamp groove as shown in the previous illustration 6 Connect the remote control cable for the throttle to ...

Page 201: ...move the control lever from the control box 4 Loosen the two screws as shown and remove the neutral lock holder 5 Invert the remote control box and reinstall the neutral lock holder 180 degrees from its pre vious position Tightening Torque 0 12 0 15m kg 0 87 1 1 ft lb 6 Reinstall the control lever on the opposite back side Secure it by retightening the bolt making sure that the washer is properly ...

Page 202: ... reassembled to operate properly When reinstalling parts apply Yamaha Marine Grease to moving parts and contact surfaces 1 Pinch the wire cover with your fingers and pull it off 2 Remove the screws as shown and then remove both upper and lower back panels 3 Remove the two screws holding the neutral throttle lever and remove the throttle drum Rotate the drum 180 degrees and reinstall it using the s...

Page 203: ...le as straight as possible from the control to the motor along the path previ ously chosen There should be no bends of less than a 4 inch radius The cables should be supported with cable hangers or for long runs by running them through conduit Throttle Connection Proper adjustment of the throttle cable s will help ensure long component life Proper adjust ment is achieved when the engine speed rema...

Page 204: ...t tle could damage the cable control or motor Shift Cable Connection Proper adjustment of the shift cable will result in a better operating control 1 Attach the control cable to the shift arm in the motor 2 Operate the hand lever several times to verify proper operation Make sure that the Forward Neutral and Reverse posi tions on the hand lever correspond to the same position of the motor shift ar...

Page 205: ... 00 00 Screw 1 17 98580 05525 00 Screw Pan Head 2 18 704 48261 00 00 Arm Throttle 1 19 EL8 48191 00 00 Washer 1 1 20 98580 05540 00 Screw Pan Head 4 21 97395 06018 00 Bolt 3 22 703 48345 01 00 Cable End Remote Control 2 2 23 704 48287 00 00 Washer 4 24 95380 05600 00 Nut 4 25 EL8 48271 00 00 Arm Shift 1 26 EL8 48127 00 00 Screw 1 9 27 703 48358 00 00 Anchor Cable 1 28 EL8 48231 00 00 Housing Gear ...

Page 206: ... 48164 00 00 Pin 2 1 49 704 48242 00 00 Shift Drive 1 50 704 48225 00 00 Cover 1 51 704 48192 00 00 Washer 2 1 52 97890 06018 00 Screw Pan Head 2 53 92990 06300 00 Washer Internal Tooth 2 54 702 48263 00 00 Bushing 1 55 EL8 48279 00 00 Circlip 2 1 56 704 48193 00 00 Washer 3 1 57 EL8 48234 00 00 Bushing 1 1 58 704 48219 00 00 Cover Lead 1 59 704 48144 00 00 Plate Stopper 2 2 60 704 48176 00 Gromme...

Page 207: ...81 00 00 Screw 2 17 98580 05525 00 Screw Pan Head 4 18 704 48261 00 00 Arm Throttle 2 19 EL8 48191 00 00 Washer 1 2 20 98580 05540 00 Screw Pan Head 4 21 97080 06018 00 Bolt 6 22 703 48345 01 00 Cable End Remote Control 2 4 23 704 48287 00 00 Washer 4 24 95380 05600 00 Nut 4 25 EL8 48271 00 00 Arm Shift 2 26 EL8 48127 00 00 Screw 1 16 27 703 48358 00 00 Anchor Cable 2 28 EL8 48231 00 00 Housing Ge...

Page 208: ...58 704 48219 00 00 Cover Lead 2 59 704 48144 00 00 Plate Stopper 2 2 60 704 48176 10 00 Grommet 1 61 703 48192 00 00 Washer 2 2 62 EL8 48233 00 00 Gear 2 2 63 703 48235 00 00 Bushing 2 64 704 48282 00 00 Screw 4 65 EL8 48153 10 00 Shaft Free Accel 2 66 704 48166 00 00 Plug 2 67 704 48284 00 00 Grommet 4 68 704 81950 00 00 Relay Ass y 1 69 704 82590 00 00 Wire Harness Ass y 1 704 82590 10 00 Wire H...

Page 209: ...t idling with touch but ton fast idle release corrosion resistant upper casing and a fully enclosed lower casing Wired for fast and convenient installation 704 Dual A revolutionary design puts dual engine trim and tilt in a single synchronized thumb operated trim tilt switch on the left lever a Yamaha exclu sive Additionally separate trim tilt switches for each engine are mounted on the control bo...

Page 210: ...the template to cut appropriate single or twin mounting holes as shown on pages 4 24 and 4 25 NOTE The remote control box should be installed on the right side of the steering wheel After determining the positions of remote control box mounting holes drill the holes 1 Make five 20mm 0 79 in diameter holes in the positions shown 2 Circumscribe the four holes other than one hole projecting to the le...

Page 211: ...innacle Mount Remote Control Ass y 28 5 mm 1 1 in 4 Dia 6 mm 24 in CUT OUT THE SHADED PORTION 28 5 mm 1 1 in 24 5 mm 96 in 76 5 mm 3 01 in 76 5 mm 3 01 in 59 mm 2 32 in 59 mm 2 32 in 24 5 mm 96 in 24 5 mm 0 96 in 24 5 mm 0 96 in 704 Single ...

Page 212: ... Remote Control Ass y 54 6 mm 2 15 in CUT OUT THE SHADED PORTION 4 Dia 6 mm 0 24 in 54 6 mm 2 15 in 76 5 mm 3 01 in 69 mm 2 72 in 69 mm 2 72 in 76 5 mm 3 01 in 59 mm 2 32 in 59 mm 2 32 in 44 mm 1 73 in 44 mm 1 73 in 4 Dia 6 mm 24 in DUAL PROJECTION HOLE ...

Page 213: ...les can be routed without being bent sharply The radius of a cable bend should be more than 101mm 4 0 in Sharp bends less than 101mm 4 0in radius of the cables will obstruct the smooth move ment of the cables and shorten cable life Installing the Remote Control Cables Cable connection should be started first from the remote control box side If started from the engine side cable adjustment will be ...

Page 214: ... end of the shift arm and lock it with the circlip 5 Fit the grommet accessory in the clamp groove 6 Connect the remote control cable for the throttle to the throttle arm in the same man ner 7 Secure the back plate and mounting flange firmly with the five screws and fit the pack ing in place 8 After installing the remote control cables temporarily secure the remote control box to the predetermined...

Page 215: ... and secure it to the boat hull so that the holes in the packing align with the remote control box mounting screw holes in the hull How To Change From The Push To Open Throttle Type To The Pull To Open Type The remote control box permits the change from the push to open throttle to the pull to open by performing the following procedure When reinstalling parts apply Yamaha Marine Grease to moving p...

Page 216: ...mounting flange back plate and packing with the five screws NOTE When installing the back plate use care so the wire harness is not pinched 9 Install the cover on the body How To Change The Control Lever Position When using a right hand remote control box for a left handed one without changing the arrangement of the inner parts do not forget that the control levers have to be moved in opposite dir...

Page 217: ...verted position Tightening Torque 0 5 0 8m kg 3 6 5 8ft lb 6 Install the throttle shaft on the opposite side to the original position with the two hexagon head bolts Tightening Torque 0 5 0 8m kg 3 6 5 8 ft lb 7 Loosen the locknuts and reverse the right and left stopper bolt positions Secure the bolts with the two locknuts Tightening Torque 0 5 0 8m kg 3 6 5 8ft lb Do not allow the stopper bolt to...

Page 218: ...in place 11 Install the dwell plate retainer mounting flange back plate packing and cover according to steps 7 9 Throttle Opening Adjustment The remote control box is capable of adjusting the throttle opening in the following manner 1 Loosen the four screws securing the cover and remove it from the body 2 Loosen the locknut and adjust the throttle opening by turning the stopper bolt NOTE Turning t...

Page 219: ...191 00 00 Washer 1 19 97380 06018 00 Bolt 3 20 703 48345 01 00 Cable End Rem Control 2 21 EL8 48271 00 00 Arm Shift 1 22 EL8 48127 00 00 Screw 9 23 703 48358 00 00 Anchor Cable 1 24 EL8 48231 00 00 Housing Gear 1 25 6X0 48241 00 00 Arm Drive 1 26 EL8 48254 00 00 Stopper 1 27 92780 06020 00 Screw 2 28 EL8 48158 00 00 Spring 1 1 29 98580 04005 00 Screw 1 30 EL8 48244 00 00 Spring Free Accel 1 31 EL8...

Page 220: ...53 6X0 48223 00 00 Lock Neutral 1 54 6X0 48221 00 00 Lever Control 1 55 6X0 48245 00 00 Plate Lock 1 56 704 48225 00 00 Cover 1 57 6X0 48155 00 00 Plunger 1 58 92990 05300 00 Washer 6 59 6X0 48281 00 00 Screw 6 60 6X0 48193 00 00 Washer 1 61 97890 06035 00 Screw Pan Head 3 6X0 48128 00 00 Screw 2 3 62 6X0 48156 00 00 Nut 1 3 63 701 48287 00 00 Washer 1 3 64 6X0 48129 00 00 Screw 3 4 65 6X0 48215 0...

Page 221: ...trol of Yamaha outboards Features a thumb operated trim tilt switch on the handle forward reverse lever neutral lock for fast idling with touch but ton fast idle release corrosion resistant upper casing and a fully enclosed lower casing Wired for fast and convenient installation NOTE Depending on the specification some models are not equipped with the power trim and tilt switch ...

Page 222: ...can be opened without shifting into any gear NOTE The control lever must be rotated more than 35 from neutral otherwise the throttle can not be opened It is impossible to operate the free accelerator button unless the control lever is in neutral After operating the free accelerator button set the control lever to neutral N and the free accelerator button will move automatically to its set position...

Page 223: ...ng Torque 5 8 Nm 0 5 0 8m kg 3 6 5 8ft lb 1 Locknut 2 Stopper Bolt 4 Control Lever Tension Adjustment By turning in or out the throttle friction screw at the rear of the remote control box the stiff ness of the control lever can be adjusted Turning the screw to the right makes the con trol lever stiff to turn and turning it to the left makes the lever easier to turn 5 Power Trim and Tilt Switch Th...

Page 224: ...s through it When selecting the control box position keep the following in mind a The remote control box should be set in a position in which it does not obstruct the operations of the control lever and switch es Make sure there is not obstruction on the path of the remote control cables b Allow a space for the remote control box so it does not contact any parts relat ed to the steering system c P...

Page 225: ... Back Plate b Screw in the cable joint accessories See page 4 47 Tighten the locknuts Before installing the cable joints apply Yamaha Marine Grease to the threaded holes in the cable joints 1 Remote Control Cable 2 Cable Joint 3 Lock Nut NOTE Screw the cable joint into the shaded area at least 8mm c Insert the remote control outer cable for shifting into the housing clamp so the groove on its end ...

Page 226: ...ightly bolt the base to the remote control box Tightening Torque 30 45 cm kg 1 Cover 3 Hole 5 Washer 2 Base 4 Screw c Install the remote control box to the mounting plate hull with screws and nuts When the mounting plate thickness is less than 20mm use the screws nuts and washers When 20mm or more use the wooden screws Tightening Torque 50 80 cm kg NOTE When the mounting plate hull is more than 30...

Page 227: ...ped portion of the trim switch wire to the hole in the neutral lock holder and insert the neutral lock holder into the base g Install the cover on the base NOTE Align the adjusting screw holes in the cover and the base and install the cover 1 Cover 2 Neutral Lock Holder 3 Adjusting Screw Holes 4 Trim Switch Wire h Install the control lever on the remote con trol box NOTE When installing the contro...

Page 228: ...tructions given in the respective owner s manuals of outboard motors connect the remote control cables both for shifting and throttle and wire harness to the engine When connecting set the con trol lever to Neutral 2 Operate the control lever a few times and check to see that the lever is turned to Forward or Reverse until it stops the gear shift once about 35 When the lever is turned further from...

Page 229: ... for good operation of the engine and remote control box Next firmly secure the remote control box which is tem porarily held with the screws to the hull Check that the cables are not sharply bent less than 200mm 7 87 in in radius or unnecessar ily bent The number of bends should be min imized Also check that no portions of the cables are clamped so hard as to deform the cable outers Change from t...

Page 230: ...m kg 3 6 5 8 ft lb 1 Screw 2 Throttle Lever Assembly 5 Turn the dwell plate 180 so the cam groove is on the PULL side and align the throttle lever roller with the specified position then secure the throttle arm assembly and dowel plate with the circlip 1Dwell Plate 3Groove for Push to Open 2Cam Plate 4Groove for Pull to Open NOTE Make sure the circlip is correctly fitted in place 6 Secure the dwel...

Page 231: ... from the right side to the left side or vice versa 1 Remove the cover packing mounting flange back plate dwell plate and cam plate out of the remote control box according to steps 1 2 3 and 5 page 4 42 4 43 2 Remove the circlip and plain washer from the throttle shaft loosen the adjusting screw and remove the throttle arm assembly and bush ing 3 Remove the brake disk and brake shoe assembly 1 Cir...

Page 232: ...s 1 Stopper Bolt Tightening Torque 5 8 Nm 0 5 0 8m kg 3 6 5 8 ft lb Do not allow the stopper bolt to project 11mm 0 4 in or more from the nut surface Otherwise the stopper contacts the cover 8 Set the brake disk and brake shoe assembly on the throttle arm assembly and install the throttle shaft NOTE Push in the brake shoe hook until it fits into the hole in the throttle shaft 1 Throttle Shaft 4 Br...

Page 233: ...ring it for a long period of time 1 Remove the cable joints and apply Yamaha Marine Grease to the threaded portion of the inner cable 1 Remote Control Cable 2 Cable Joint 2 Also apply Yamaha Marine Grease to inner parts of the remote control box particularly to contact surfaces of moving parts If any rust is found remove it and apply the grease YAMAHA MARINE GREASE YAMAHA MARINE GREASE ...

Page 234: ...T ABA CABLE 07 GY 7 FEET ABA CABLE 08 GY 8 FEET ABA CABLE 09 GY 9 FEET ABA CABLE 10 GY 10 FEET ABA CABLE 11 GY 11 FEET ABA CABLE 12 GY 12 FEET ABA CABLE 13 GY 13 FEET ABA CABLE 14 GY 14 FEET ABA CABLE 15 GY 15 FEET ABA CABLE 16 GY 16 FEET ABA CABLE 17 GY 17 FEET ABA CABLE 18 GY 18 FEET ABA CABLE 19 GY 19 FEET ABA CABLE 20 GY 20 FEET ABA CABLE 22 GY 22 FEET ABA CABLE 24 GY 24 FEET ABA CABLE 26 GY 2...

Page 235: ...ble control is the same for all outboards Yamaha 704 705 control boxes can be setup as push to open or pull to open by changing one internal component Rigging as efficiently as possible means setting up the control box just once without having to open up the box again to readjust the cable ends after hookup to the motor Refer to the following diagrams for proper cable end adjustments at the contro...

Page 236: ......

Page 237: ...emperature Sender Installation 5 22 Voltmeter 5 24 Hour Meter Kit 5 26 Fuel Gauge 5 28 Fuel Management System Gauge GPS Hook Up 5 30 Fuel Management Gauge Components 5 31 Fuel Management Gauge Installation 5 32 Twin Engine Fuel Management Gauge 5 34 2001 HPDI Water Detection Switch 5 36 Digital Fuel Management Gauge 5 39 Fuel Management Gauge Operation Instructions 5 39 Fuel Management Gauge Calib...

Page 238: ...2 STROKE OFF NUMBER OFLEADWIRES ONTRIM SENSOR 1 2 3 FACTORYSETTINGS ON km h mph mile h knot nautical mile 5 105Ω U S A 30 230Ω EUROPE 180 0Ω 6Y5 83570 S4 00 YAMAHA INDICATION GPH GALLON SPEEDOMETER GPS GPH 3 2 1 0 1 2 3 4 h 6Y5 83500 F2 00 PRESS BOTH BUTTONS TOGETHER Set mode TOTALFUELCONSUMPTION FUELMANAGEMENT TTC ECON SYNC l h sph km l mpg TRIPMETER CLOCK PRESS BOTH BUTTONS TOGETHER 2 MINUTES 3 ...

Page 239: ... night Included in this gauge is an easy to read trim indicator which blacks out if the engine is over trimmed and prominently dis played oil warnings NOTE The multi function digital gauge will not properly work on the 6 30HP engines The tachometer will not function properly and the oil lights and trim gauge will not work 4 POLE 6 POLE 12 POLE C40 C70 30 50T F T25 90 6hp to 25 F T9 9 25W3 to F30 t...

Page 240: ...nly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the dashboard has a thickness of more than 13mm 0 50 in and it is impossible to secure the meter with the fitting plate cut the fitting plate so the meter may be installed Pro Series Tachometer 1 2 3 4 7 7 6 5 9 8 REF NO PART NUMBER DESCRIPTION QTY 1 Tachometer Assembly 1 2 6Y5 83517 00 00 Bulb 12V 1 7W T10 1 3 ...

Page 241: ...llustrations for basic wiring For detailed wiring information refer to the diagrams in the Boat Wiring Diagrams in the Electrical Section 3 of this manual NOTE A special relay Part number 6Y5 81950 02 00 is required when using the Pro Series analog tachometer with oil lights ...

Page 242: ...5 5 Outboard Rigging Guide 2001 Tachometer Digital Multi function Tachometer ...

Page 243: ...ng used remove the rubber grommet from the back of the meter and set the calibration switch es The analog tachometer has a rotating switch that can be turned with a slotted head screwdriver as illustrated The digital meter uses toggle dip switches After setting the tachometer to the prop er pole value reinstall the grommet The pole set tings for each engine is given on the chart at the beginning o...

Page 244: ... installing and using boat speedometers it is important to remember that they indicate an approximate speed of the boat through the water by measuring the impact force of the water with a pressure gauge This impact force will vary with the density of the water and the speed of the impact The density can vary by the purity of the water salt fresh algae and the temperature of the water The speed of ...

Page 245: ... and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the meter with the fitting plate cut the fit ting plate so the meter can be installed Speedometer Tube Routing Be sure to route the speedometer tube carefully to avoid crimping or damage 29 23 29 26 27 28 31...

Page 246: ...5 9 Outboard Rigging Guide 2001 Speedometer Speedometer Installation 3 3 8 Inch Analog Speedometer Multi Function Speedometer NOTE For additional information refer to multi function tachometer wiring ...

Page 247: ... and blue leads together The instru ment light will then come on when the main switch is in the ON position 2 After installation connect the power and check the operation of the instrument light Multi Function Digital Speedometer For wiring information and diagrams refer to the Boat Wiring Diagrams in the Electrical Section 3 of this manual Speedometer Calibration Calibrate the multi function spee...

Page 248: ...nipple to open it Connect the speedometer tube to the nipple and tighten with the quick tie provided 3 Route the tube to the speedometer and secure it NOTE Before securing the tube be sure to tilt the engine up and down to make sure the tube is not stretched or pinched by other parts 40T 250HP NOTE The speedometer tube comes installed as standard equipment routed to the clamp bracket area Cut off ...

Page 249: ...eds below 30 mph because of the low pressures produced A dig ital speedometer like the Yamaha Multifunction Speedometer can more accu rately indicate these speeds 2 The pressure required to indicate speeds of less than 9 mph is less than 1 psi For the Yamaha Multifunction Speedometer to indi cate 5 mph only 1 2 psi is required This is also the pressure produced by a tube filled with water to a hei...

Page 250: ...hanged The gauge has not changed If you have 2000 rigging kits in stock you will only need to change the dip switch settings according ly When adjusting the trim sender and the gauge is very erratic verify the dip switch settings If you have the wrong setting for either 2 or 3 wire senders the trim bars will not operate normally REF NO PART NUMBER DESCRIPTION QTY 10 6Y5 83670 12 00 Trim Meter Ass ...

Page 251: ...in the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install over the mounting studs 4 Place the washers over the studs and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the meter with the fitting plate cut the f...

Page 252: ... to 80 Also avoid placing any strong magnet or magne tized object near the trim sender Adjusting 1 For a down position adjustment loosen the trim sender screws and make an adjustment so the needle aligns with the marking line indicating DOWN NOTE To adjust the trim sender bracket posi tion loosen the bolts and turn the bracket on pivot J and tighten the bolts The bolt positions will be changed fro...

Page 253: ...e to use both gauges with one engine NOTE There is now available an aftermarket water pressure gauge fitting P N MAR WPRES AD TR NOTE The operating water pressure of the P60 C60 70hp is lower than other applica ble models Therefore the water pressure gauge should not be used on this model Additional Parts Required NOTE The nut with a ferrule for the water pressure hose is 663 83668 00 00 Part Numb...

Page 254: ...in the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install the fitting plate over the mounting studs 4 Place the washers over the studs and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the meter with the fitti...

Page 255: ... pressure sender be sure to check for water leakage On V4 and V6 models also make sure the hose does not interfere with the flywheel 2 Bring out the sender tube through the bottom cowling grommet 3 Connect the pressure sender to the water pressure meter by the tube Clamp the tube to the hull with clips and screws so it is not flat tened or kinked Wiring 1 Connect the wires as shown NOTE If an afte...

Page 256: ...s with one engine NOTE The 30hp requires drilling and tapping the cylinder head for sensor installation If the needle rises above the shaded area the engine is in danger of overheating Slow down the engine to the specified trolling speed Additional Parts Required REF NO PART NUMBER DESCRIPTION QTY 10 Water Temperature Ass y 1 11 6Y5 83518 00 00 Bulb Meter 1 12 6Y5 83536 00 00 Socket Meter 1 13 688...

Page 257: ...n the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install the fitting plate over the mounting studs 4 Place the washers over the studs then even ly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the meter with the fitting p...

Page 258: ...he yel low and blue leads together The instrument light will then come on when the main switch is in the ON position 2 After installation connect the power and check the operation of the instrument light If the needle rises above the shaded area the engine is in danger of overheating Slow down the engine to the specified trolling speed NOTE When testing the thermosensor set at 900 1000Ω at room te...

Page 259: ...linder head and install the temperature sender on water pressure sender Be sure not to over tighten the sender The location of the plug for each model is shown below NOTE Aftermarket water pressure gauge adapter P N MAR WPRES AD TR NOTE To install the sender on the 30hp cylinder head cover drill a 11 5mm 0 453 in hole and cut threads of 14mm x 1 5mm C60 C70 70HP ...

Page 260: ...d on the star board side the sensor tube could break or bend After installing the temperature sender be sure to check for water leakage 2 Bring out the temperature sender lead wire through the bottom cowling grommet CAUTION CAUTION V4 V6 2 6L F25 INSTALL SENSOR HERE F40 F50 T50 FOR WATER PRESSURE SENSOR Outboard Rigging Guide 2001 Water Pressure Temperature Sender Installation ...

Page 261: ... voltage readings higher than 16 volts The voltage regulator on 75hp 225 L hp is set for fast battery charging with repeated engine starting Extended continuous engine opera tion may show voltage readings around 16 volts This is not a problem with properly maintained marine batteries Installation REF NO PART NUMBER DESCRIPTION QTY 35 Voltmeter Ass y 1 36 6Y5 83544 00 00 Plate 1 37 688 83664 00 00 ...

Page 262: ...lace the washers over the studs then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the gauge with the fitting place cut the fit ting plate so the meter can be installed Wiring 1 Connect the wires as shown NOTE If an aftermarket instrument light switch is to be us...

Page 263: ...e meter allows the operator to keep track of the number of hours the motor was used on one day and even how much time is required to reach a given destination The Yamaha Hour Meter has been designed for use with electric start motors and is easy to install Installation REF NO PART NUMBER DESCRIPTION QTY 16 6Y5 83504 10 00 Hour Meter Ass y 1 17 688 83664 00 00 Damper 1 18 6Y5 83577 00 00 Plate Fitt...

Page 264: ... meter fit the meter into the panel and install over the mounting studs 4 Place the washers over the studs then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the meter with the fitting plate cut the fit ting plate so the meter can be installed Wiring Connect the ...

Page 265: ...Component parts The fuel gauge indicates the amount of fuel remaining in the fuel tank This information will help the boater estimate the amount of cruising time available before refueling The Yamaha Fuel Gauge can be used from the helm by installing an aftermarket fuel tank sensor and making connection to the battery or by using the existing A B Y C sender with a resistance of 30 240 found in mos...

Page 266: ...s 4 Place the washers over the studs then evenly tighten the mounting nuts until the gauge can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the gauge with the fitting plate cut the fit ting plate so the meter can be installed Wiring 1 Connect the wires as shown NOTE If an instrument light switch is to be used conn...

Page 267: ... below Modification Procedure 1 Cut off three prong connector 2 Remove the black plug and install it on the speedometer to plug the hole in the back of the gauge 3 The white wire is the signal lead which needs to be connected to the NMEA 0183 output lead of the GPS unit NOTE All GPS units utilize different harnesses terminals and color codes on the output signal Always connect the white wire to wh...

Page 268: ... M Kit Single Engine 6Y5 W0088 64 00 Dual F M Kit Dual Engine Part Number Description Remarks 6Y5 83500 F2 00 Meter Assembly 1 6Y5 83553 F1 00 Extension Wire Lead 1 6Y5 85752 01 00 Fuel Sender 2 1 in Single Kit 703 82531 00 00 Extension Wire Lead 1 90465 13H39 00 Clamp 4 2 in Single Kit 95480 06363 00 Screw 4 2 in Single Kit Part Number Description 6X1 82531 00 00 Extension Wire Lead fuel flow sen...

Page 269: ...r source The maximum reach of these connector harnesses combined is 10 inches when speedo is used No extensions should be used or the gauge can malfunction because of electronic interference from radios or other devices Gauge Installation Install the instruments in the dashboard If no dashboard is available install them in a place protected from water spray Disconnect the battery leads before inst...

Page 270: ...r between the engine and the fuel filter refer to the illustration B On twin engine installations make sure the multifunction speedometer fuel man agement gauge and GPS are connected to the same key on power source C If a fuel primer is used install it between the fuel sensor and the engine All connec tions should be tight and all lines free of air Any air leakage in the fuel tank pickup or sensor...

Page 271: ...ine installation No wiring is connected to the second ignition source The fuel management gauge and speedometer must be connected to one common power source The power source must be supplied by one ignition switch NOTE The following part numbers are shown on page 3 39 in the 1999 Outboard Rigging Guide They can be ordered from Kent Moore at 1 800 345 2233 ...

Page 272: ...SITIVE Battery source G Green To the G Green wire from the Multifunction STBD Tachometer G W Green White To the G Green wire from the PORT Multifunction Tachometer on twin engine installations B Black Connect both black wires to a good ground L Blue Connect to the Blue wire from the multi function speedometer light circuit Y Yellow Connect this wire and the Yellow wire to the multifunction speedom...

Page 273: ...t water in fuel symbol present on that gauge This harness comes standard in the engine crate on all left hand rotation HPDI engines The wire diagrams are as follows This harness will work on either a single engine application or twins The harness will plug into the white red wire that is located on the starboard side of the engine harness Remove the cap and plug in the black connector from the har...

Page 274: ...fuel filter sensors The diagram below shows the recommended wiring with the use of the optional water fuel fil ter sensors NOTE If the boat is wired as above and the boat water fuel separating filter detects water only the visual warning will activate on the Fuel Management gauge Only the water detection switch on the engine will activate the alarm and rpm reduction ...

Page 275: ...001 Fuel Management Gauge NOTE Make sure all gauges are connected to the same KEY ON power source Use these connectors only on twin engine installations Optional fuel water separator w filter and sensor Part Number MAR 24560 00 00 ...

Page 276: ...r currents sea swells and the condition of the water speed sensor partially plugged or damaged 3 Individual engines may vary slightly in their fuel consumption because of manu facturing variations These variations can be even greater if the engines are of differ ent year models In addition variations in propellers even of the same basic dimen sions of the same design can cause a slight variation i...

Page 277: ... measurement by setting the selector switch on the back of the meter dur ing installation The fuel consumption meter and fuel economy meter will display the same unit of measurement Fuel Consumption Meter Push and release the Mode button until the indi cator on the face of the meter points to total TTL The meter will display the total amount of fuel consumed after the meter was last reset To reset...

Page 278: ...3 Engine speed is synchronized evenly between Port and Starboard engines 4 Starboard engine speed is slightly higher 5 Starboard engine speed is higher NOTE If the two engine speeds are not synchro nized while cruising they can be synchronized by adjusting the trim angle or throttle position Water Separator Warning Indication NOTE This indicator operates only when an optional water separator with ...

Page 279: ...ches 4 for fuel flow calibra tion If the amount of fuel consumed differs from that indicated on the meter it can be calibrat ed to the correct amount If the amount of fuel used differs from what is indicated on the meter calibrate it to the correct amount by 1 Fill the tank and operate the boat Use about 75 of the fuel in the tank 2 Refill the tank and record the amount used 3 Compare the actual a...

Page 280: ...on Kit 6 20 40 C40 50 C50 Tiller Handle Steering Friction Kit 6 22 F40 4 Cylinder F T50 Tiller Handle Steering Friction Kit 6 31 60 C60 C70 70HP Tiller Handle Steering Friction Kit 6 40 C90 90HP Tiller Handle Steering Friction Kit 6 48 F30 F40 Tiller Handle Steering Friction Installation Manual 6A F80 F100 Tiller Handle Steering Friction Installation Manual 6B F80 F100 Tiller Handle Steering Frict...

Page 281: ...o be used only with the 2m 6 6 ft cables provided The steering handle on the T9 9 models can be removed from the motor and used as a remote control unit for the throttle shifter and the stop switch The remote tiller rigging kit provides the neces sary cables hose cable sheath and stop switch assembly to relocate the steering handle Removal 1 Remove the screw holding the CDI cover then remove the C...

Page 282: ... handle backwards and fit a slotted head screwdriver into the slit in the ring nut Using the steering bracket as a fulcrum turn the steering handle forward to loosen the ring nut NOTE This procedure may need to be repeated several times for the ring nut to come off 6 Remove the wave washer the washer and the steering handle assembly To remove the cables from the ring nut route the cable ends throu...

Page 283: ...steering grip NOTE To remove the steering grip turn it to the left and pull it out of the steering handle 9 Remove the two screws holding the two halves of the steering handle together 10 Remove the bolt washer shift arm wave washer cotter pin washer and the detent roller as shown Disconnect the shift cable throttle cable and stop switch Installation 1 Install the new stop switch in the steering h...

Page 284: ...inner and outer cables of both the throttle and shift control cables are prop erly in place Verify proper movement of the shift lever once the handle has been reassem bled 5 Reinstall the components of the steering han dle grip Reinstall the handle grip the friction piece the compression spring the steel wash er the plastic washer and the screw Reinstall the rubber steering handle grip 6 Pass the ...

Page 285: ...elerator arm 10 Reconnect the white and black stop switch leads see Removal step 2 and reinstall the CDI cover Installing the Control Handle 1 Select a location near the steering wheel or tiller handle for the control handle Be sure there will be easy access to the stop switch and shift lever and that the throttle operation will not be hindered 2 Install the control handle using a strong bracket w...

Page 286: ...sion 1 16 90386 08032 00 Bush 1 17 66M 26311 00 00 Cable Throttle 1 2 18 90446 10M87 00 Hose 2 19 90386 40MA0 00 Bush 1 20 90201 43M00 00 Washer Plate 2 21 90206 43M22 00 Washer Wave 2 22 90202 43M57 00 Washer Plate 1 23 90386 40M99 00 Bush 1 24 66M 42131 00 00 Cover Handle Steering 1 66M 42131 01 00 Cover Handle Steering 1 25 90185 08057 00 Nut Self locking 1 95780 10300 00 Nut Flange 1 26 95380 ...

Page 287: ...3 00 Nipple Grease 1 3 66M 42527 00 00 Plate Friction 1 4 90109 08M91 00 Bolt 2 5 65W 42562 00 00 Shaft Steering Lock 1 6 66M 42561 00 00 Knob Steering Lock 1 7 689 43633 00 00 cover Tilt Lever 1 8 90202 10M56 00 Washer Plate 1 9 65W 42528 00 00 Plate Friction 2 10 90209 10M26 00 Washer 1 11 90185 10M14 00 Nut Self locking 1 12 90387 05M11 00 Collar 1 13 90109 05M89 00 Bolt 1 Component parts ...

Page 288: ...nual starter for MH models 1 Throttle Cable 2 N O T E When adjusting the Throttle Cables make sure the throttle control cam stopper touches the bracket stopper throttle fully opened and then tighten the locknuts 2 Engine Stop Switch Lead for MH EH models 1 3 Grommet 4 Locknut 1 5 Nut 1 N O T E 6 Plate 1 Tighten the nut to the specified torque Then while still holding this nut tighten the locknut t...

Page 289: ...ring Handle Ass y Manual starter for MH models 1 Plastic Washer 1 2 Metal Washer 1 3 Wave Washer 2 4 Metal Washer 2 5 Bushing 1 6 Steering Handle Bracket 1 7 Friction Adjusting Screw 1 8 Screw 1 9 Steering Grip 1 Washer 1 Spring 1 Bushing 1 Bolt 2 Self tapping bolt M8 Plate 1 Throttle Shaft 1 Friction Piece 1 Throttle Cable 2 Engine Stop Switch 1 Reverse the disassembly steps for assembly 10 11 12...

Page 290: ...1 16 65W 42125 00 00 Bolt Friction Adjusting 1 17 91490 16010 00 Pin Cotter 1 18 6F6 42177 A0 00 Rubber Handle 1 19 664 42119 00 00 Grip Steering Handle 1 20 6H2 42137 00 00 Indicator Throttle 1 6J0 42137 00 00 Indicator Throttle 1 21 90269 02M09 00 Rivet 1 22 90149 05M13 00 Screw 1 23 92903 10600 00 Washer Plate 1 24 90501 23215 00 Spring Compression 1 25 90386 08032 00 Bush 1 26 65W 26311 00 00 ...

Page 291: ...3 90109 06M50 00 Bolt 2 4 92990 06100 00 Washer Spring 2 5 65W 42561 00 00 Knob Steering Lock1 1 6 689 43633 00 00 Cover Tilt Lever 1 7 97595 05516 00 Bolt With Washer 1 8 90387 05M11 00 Collar 1 9 90185 10M14 00 Nut Self locking 1 10 65W 42562 00 00 Shaft Steering Lock 1 11 90202 10M56 00 Washer Plate 1 12 65W 42528 00 00 Plate Friction 2 13 90209 10M26 00 Washer 1 14 93700 06M03 00 Nipple Grease...

Page 292: ...7595 05516 00 Bolt With Washer 1 12 65W 82105 00 00 Wire Harness 1 13 6G8 82150 00 00 Fuse Holder Ass y 1 14 663 82151 00 00 Fuse 12V 20A 1 15 6G5 82152 00 00 Holder Fuse 1 16 6H1 82563 10 00 Trim Tilt Switch Ass y 1 17 6E5 82587 00 00 Gasket 1 18 62Y 83614 00 00 Bracket 1 19 90109 06M86 00 Bolt 2 20 61A 81950 00 00 Relay Assembly 1 21 97575 06520 00 Bolt With Washer 2 22 65W 81948 00 00 Bracket 1...

Page 293: ...er for removal Flywheel magneto cover ass y Refer to FLYWHEEL MAGNETO in Chapter 5 1 Throttle Cable 2 N O T E When adjusting the Throttle Cables make sure the throttle control cam stopper a touches the bracket stopper b when the throttle is fully opened and then tighten 2 Engine Stop Switch Lead 1 the locknuts 3 Shift Link Rod 4 Steering Handle Ass y 1 5 Grommet 1 1 Reverse the removal steps for i...

Page 294: ...low the Step order for removal 1 Shift Link Rod 1 2 Shift Lever 1 3 Cable Guide 1 4 Bushing 1 5 Plastic Washer 1 6 Wave Washer 2 7 Metal Washer 1 8 Bushing 1 9 Tiller Handle Bracket 1 10 Steering Bracket 1 11 Friction Piece 1 12 Steering Grip 1 13 Spring 1 14 Bushing 1 15 Throttle Shaft 1 16 Friction Piece 1 17 Throttle Cable 2 18 Engine Stop Switch 1 Reverse the disassembly steps for installation...

Page 295: ...3 00 Screw 1 20 90386 08032 00 Bush 1 21 6G1 42138 01 00 Lever Throttle 1 22 6E0 42159 02 00 Stay 1 23 97885 05012 00 Screw Pan Head 2 24 6J8 26301 00 00 Throttle Cable Ass y 2 25 6J8 44111 01 4D Handle Gear Shift 1 26 6J8 44125 00 00 Lever Shift Rod 1 27 682 44132 00 00 Bushing 2 28 91690 30318 00 Pin Spring 1 29 90386 06M12 00 Bush 1 30 6J8 44124 00 00 Link Shift Rod 1 31 92990 06200 00 Washer 1...

Page 296: ...refully remove the carburetors The choke solenoid shaft will pull out of the choke solenoid as the carbure tors are removed If desired the choke sole noid and shaft may both be removed as they will be no longer used 4 Install the neutral safety switch in its bracket so when the assembly is mounted the button on the switch faces towards the rear Install the switch and bracket on the bottom cowling ...

Page 297: ... grommet and install it through the new grommet from the kit Move the old grommet and wire harness aside and install the new grommet bracket clamp flat washer and 6mm nuts 15 Locate the new brown wire extension lead Part Number 6H4 82553 00 00 and con nect the two wires at either end of it to the neutral safety switch 16 Route all wires from the left side near the panel around the front of the bot...

Page 298: ...nd connect one end of its pink lead to the connector that goes to the pink thermoswitch wire at the back of the motor There is a pink T lead remain ing to be connected near the CDI box Connect the pink wire leading from the CDI box and the pink lead that goes to the oil level gauge tank switch and oil warning light to the pink T leads Connect the sin gle black ground male butt connector lead to th...

Page 299: ...re from the CDI box Make sure all ground black wires are beneath the appropriate bolt under the termi nal cover and tighten the bolt The same color wire lead in the harness you removed in step 21 was disconnected at this point N O T E The blue choke solenoid lead is no longer used and should be secured away from all moving parts In addition a replacement for the green wire from the lighting coil t...

Page 300: ...6 20 Outboard Rigging Guide 2001 Steer Friction Kit F30 F40 Tiller Handle STEERING FRICTION KIT 67C W0084 00 4D F30 F40 TILLER HANDLE ...

Page 301: ... 1 61 90501 23215 00 Spring Compression 1 62 92903 10600 00 Washer Plate 1 63 90149 05M13 00 Screw 1 REF NO PART NUMBER DESCRIPTION QTY 1 67C W0084 4D 00 Handle Steering Ass y 1 2 67C 42121 00 04D Bracket 1 3 90101 12M09 00 Bolt 1 4 92990 12200 00 Washer Plain 2 5 90206 12M22 00 Washer Wave 1 6 90387 12M02 00 Collar 1 7 90386 12M93 00 Bush 2 8 92990 12600 00 Washer Plate 1 9 90185 12M12 00 Nut Sel...

Page 302: ...6 22 Outboard Rigging Guide 2001Steer Friction Kit 40 C40 50 C50 Tiller Handle STEERING FRICTION KIT 63D 42508 00 00 40 C40 50 C50 TILLER HANDLE 63D W0086 Z0 4D ...

Page 303: ...6100 00 Washer Spring 2 105 90464 15M11 00 Zip Tie 1 106 688 83383 11 00 Buzzer 1 107 6H5 83386 00 00 Buzzer Stay 1 108 97013 05010 00 Bolt 2 109 90990 05100 00 Spring Washer 2 110 90185 10051 00 Nut 2 REF NO PART NUMBER DESCRIPTION QTY Handle Steering Ass y 1 2 63D 42121 00 4D Bracket 1 3 63D 42111 01 4D Handle Steering 1 4 6H2 42137 00 00 Indicator Throttle 1 6K5 42137 00 00 Indicator Throttle 1...

Page 304: ... on the side of the swivel bracket 1 Remove the steering hook 1 2 Remove the fitting plate 1 and grommet 2 3 Remove the shift cable joint 3 and throttle cable joint 4 4 Disconnect the wire harness coupler 5 5 Disconnect the oil level gauge coupler 6 the trim sender coupler 7 and the power trim tilt switch lead coupler 8 Neutral Switch Remote Control Model 1 Install neutral switch assembly 1 and sl...

Page 305: ...1 and nut 2 T orque N ut 38N m 3 8 m kg 2 7 ft lb 2 Install the grommet 1 engine stop switch lead 2 main switch lead 3 battery cable 4 extension wire harness 5 and the power trim tilt switch leads 6 N O T E Pass the engine stop switch lead through the grommet then install them to the bottom cowling Align the taped end a of the battery cable and the extension wire lead with the end of the grommet A...

Page 306: ...he clip 3 and tighten the lock nut 4 T he cable joint should be screwed in more than 8mm 0 31 in N O T E Put the UP mark upward Manual starter model only 5 Check the shift operation for unsmooth oper ation Diagnose and repair the problem if the operation is not smooth 6 Adjust the throttle cable joint position a Turn the throttle grip fully closed b Turn the magneto control lever 1 so its adjustin...

Page 307: ...d white 3 9 On electric start models without instruments See Illust B connect the main switch cou pler 1 and zip tie 2 N O T E Fit the main switch lead in the clamp and clamp the wire leads as shown 10 For electric start models with instruments Illust C connect the extension wire harness coupler 1 main switch wire lead coupler 2 trim sender lead coupler 3 oil level gauge coupler 4 power trim tilt ...

Page 308: ...h and hold the switch to UP the motor will tilt up c Push and hold the switch to DN the motor will tilt down d Release the switch the motor will stop at its current position Dynamic Check T he engine is going to be started for checking M ake sure the engine has an adequate supply of cooling water B efore checking make sure the following conditions are met L ock plate is installed to the engine sto...

Page 309: ...he engine stop switch a Run the engine b Pull the lanyard off the lock plate The running engine will stop 8 Check for steady engine speed a Run the engine at idle b Steer the tiller handle c Tilt the tiller handle up down d Make sure the engine speed remains steady under the above conditions Steering Friction 63D 42508 00 00 1 Remove the cap 1 2 Install the nut 2 T orque N ut 2 0N m 2 0m kg 14 ft ...

Page 310: ...check that the tiller becomes free from friction d If not repeat the above steps 6 Check steering movement for smooth opera tion N O T E With the friction lever turned fully to the right check the tiller for smooth movement 7 Install the fuel hose 1 F it the fuel hose securely in the clamp 8 Install the battery lead 1 extension wire har ness 2 under the shift cable 3 and throttle cable b N O T E S...

Page 311: ...6 31 Outboard Rigging Guide 2001 F40 4 Cyl F T50 Tiller Handle Kit F40 4 Cyl F T50 TILLER HANDLE KIT 62Y W0086 Z0 4D ...

Page 312: ...tay 1 114 97013 05010 00 Bolt 2 115 90990 05100 00 Spring Washer 2 116 90185 10051 00 Nut 2 REF NO PART NUMBER DESCRIPTION QTY 1 62Y W0086 20 4D Handle Steering Ass y 1 2 63D 42121 00 4D Bracket 1 3 63D 42111 00 4D Handle Steering 1 4 6H2 42137 00 00 Indicator Throttle 1 5 90269 02M09 00 Rivet 1 6 63D 44100 10 00 Shift Link Ass y 1 7 63D 44104 00 00 Plate Comp 1 8 63D 48261 00 00 Arm Throttle 1 9 ...

Page 313: ...Remove the steering hook 1 2 Remove the fitting plate 2 3 Remove the grommet 3 cable stopper 4 and rubber seal 5 4 Remove the shift cable joint 6 and throttle cable joint 7 5 Disconnect the wire harness coupler 8 6 Disconnect the overheat oil warning lead coupler 9 the trim sender lead coupler 10 and the power trim tilt switch leads coupler 11 10 11 ...

Page 314: ... bolt 3 Disconnect the brown lead terminal 4 and the brown blue lead terminal 5 4 Connect the neutral switch lead terminals 6 S tart in gear protection will not operate with out the neutral switch leads connected Installation 1 Install the tiller handle assembly 1 and nut 2 T orque N ut 38N m 3 8m kg 2 7 ft lb 2 Install the following 1 Grommet 2 Main Switch Leads 3 Battery Cable 4 Power Trim Tilt ...

Page 315: ...position b Align the center of the set pin 2 with the mark a on the bracket c Adjust the position of the cable joint until its hole aligns with the set pin d Install the clip 2 and tighten the lock nut 4 M ake sure the cable joint is screwed in more than 8mm 0 31 in 6 Check the shift control for smooth operation 7 Adjust the throttle cable joint position a Turn the throttle grip fully closed b Ali...

Page 316: ... throttle valve lever so it contacts the full opening stopper Electric Start Model without Instruments A 9 Connect the main switch coupler 1 and the zip tie 2 N O T E Fit the main switch coupler to the clamp then clamp the wire leads as shown Electric Start Model with Instruments B 10 Connect the following 1 Extension Wire Harness Coupler 2 Main Switch Wire Lead Couplers 3 Trim Sender Lead Coupler...

Page 317: ... N ut 2 0N m 2 0m kg 14ft lb 3 Install the following 1 Collar 3 Washer 2 Friction plate 4 Bolt M8 4 Install the bolt M6 1 5 Adjust the friction force a Turn the friction lever 1 fully to the left a b Turn the nut 2 in or out to adjust the steering friction force to the user s prefer ence according to the following 6 29 c Turn the friction lever fully to the right b and check that the tiller become...

Page 318: ... b 9 Install the screw 4 Completion Check Static Check 1 Check the shift operation Make sure the shift action is smooth for Forward Neutral and Reverse 2 Check the throttle operation for smoothness from fully closed to fully open N O T E Shift forward and then check the throttle operation 3 Check steering friction to make sure proper friction is obtained Move the tiller handle tilt up down and che...

Page 319: ...ar protection a Shift into forward reverse b Turn the key to START The starter motor should not turn over c Shift into neutral d Turn the key to START The starter motor will turn over 6 Check the main switch a Turn the main switch to ON from OFF then to START The starter motor turns over then the engine will start b Turn the main switch to OFF from ON The running engine should stop 7 Check the eng...

Page 320: ...6 40 STEERING FRICTION KIT 60 C60 C70 70 TILLER HANDLE 6H3 W0086 Z0 4D Outboard Rigging Guide 2001 60 C60 C70 70 Tiller Handle Steering Friction Kit ...

Page 321: ...00 00 Washer 1 46 6H3 48321 01 00 Cable 1 47 90386 29M95 00 Bush 1 48 90202 24M53 00 Washer Plate 1 49 63D 48531 00 00 Bracket Remote Control 1 1 50 63D 48538 00 00 Clamp Cable 1 2 51 97095 06016 00 Bolt 2 52 92995 06600 00 Washer 2 53 90387 12M02 00 Collar 1 54 92990 12600 00 Washer Plate 1 55 63D 42126 00 00 Friction Steering Handle Grip 1 56 63D 48154 00 00 Knob Throttle 1 57 95380 06600 00 Nut...

Page 322: ...mbly 1 and slip plate 2 2 Install the neutral switch stay 3 N O T E Install the stay 3 with washer and the bolt 3 Disconnect the brown lead terminals 4 4 Disconnect the power trim tilt switch lead coupler 5 5 Connect the neutral switch lead terminals 6 S tart in gear protection will not operate with out the neutral switch leads connected WARNING ...

Page 323: ...le 3 Shift Cable 4 Extension Wire Harness 5 Main Switch Wire Leads 6 Battery Leads 7 Power Trim Tilt Switch Leads N O T E a Pass the wire harness and remote control cables through the grommet and refit the grommet b Fit the cable clamp 7 to the outer remote control cables c Align the taped end a of the battery lead and the extension wire harness with the end of the grommet 4 Install the fitting pl...

Page 324: ...for smooth operation 7 Adjust the throttle cable joint position a Turn the throttle grip fully close b Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a c Adjust the position of the cable joint until its hole aligns with the set pin d Install the clip 2 and tighten the lock nut 3 T he cable joint should be screwed in more than 8mm 0 31in 8 Check the thr...

Page 325: ...oupler 5 Power Trim Tilt Switch Lead Coupler 6 Zip Tie 7 Clamp I llus D N O T E a Fit the extension wire harness and main switch wire leads b Clamp the wire leads as shown Steering Friction 1 Remove the end cap 1 2 Install the bolt 1 and wing nut 2 3 Install the friction controller 3 link rod 4 washer 5 and the nylon nut 6 N O T E The steering friction can be installed on the port side or starboar...

Page 326: ... to make sure proper friction is obtained Check tiller handle tilt up down Make sure the cables and wires are not stretched 4 Check the power trim tilt switch a Connect the battery b Push and hold the switch to UP the motor will tilt up c Push and hold the switch to DN the motor will tilt down d Release the switch the motor will stop at its current position Dynamic Check T he engine is going to be...

Page 327: ... motor should turn over 6 Check the main switch a Turn the main switch to ON from OFF then to START The starter motor starts the engine b Turn the main switch to OFF from ON The running engine will stop 7 Check the engine stop switch a Run the engine b Pull the lanyard off the lock plate The running engine will stop 8 Check for steady engine speed a Run the engine at idle b Steer the tiller handle...

Page 328: ...6 48 C90 90 TILLER HANDLE KIT 6H1 W0086 Z0 4D STEERING FRICTION Outboard Rigging Guide 2001 C90 90 Tiller Handle Steering Friction Kit ...

Page 329: ... 1 47 90386 29M95 00 Bush 1 48 90202 24M53 00 Washer Plate 1 49 63D 48531 00 00 Bracket Remote Control 1 1 50 63D 48538 00 00 Clamp Cable 1 2 51 97095 06016 00 Bolt 2 52 92990 06600 00 Washer Plate 2 53 90387 12M02 00 Collar 1 54 92990 12600 00 Washer Plate 1 55 63D 42126 00 00 Friction SteeringHandle Grip 1 56 63D 48154 00 00 Knob Throttle 1 57 95380 06600 00 Nut 1 58 91490 20010 00 Pin Cotter 1 ...

Page 330: ...tall the neutral switch stay 3 N O T E Remove the washer and bolt from the shifter bracket then install the stay with the removed washer and bolt 3 Disconnect the brown lead terminals 4 4 Connect neutral switch lead 5 S tart in gear protection will not operate with out the neutral switch leads connected 5 Disconnect the power trim tilt switch lead coupler 6 WARNING ...

Page 331: ...3 Install the following 1 Grommet 2 Shift Cable 3 Throttle Cable 4 Battery Cable 5 Extension Wire Harness 6 Main Switch Harness 7 Power Trim Tilt Switch Leads N O T E Align the taped end a of the battery cable and the extension wire harness with the end of the grommet 4 Install the cable clamp 1 5 Install the fitting plate 1 and bolt 2 N O T E After securing the fitting plate lift the tiller handl...

Page 332: ... throttle cable joint position a Turn the throttle grip fully close b Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a c Adjust the position of the cable joint until its hole aligns with the set pin d Install the clip 2 and tighten the lock nut 3 M ake sure the cable joint is screwed in more than 8mm 0 31in 9 Check the throttle for its fully open posit...

Page 333: ...ion control nut 1 according to the following diagram Steering Friction 1 Remove the end cap 1 2 Install the bolt 1 and wing nut 3 3 Install the friction controller 3 link rod 4 washer 5 and nylon nut 6 N O T E The steering friction can be installed on port side or starboard side 4 Adjust the steering friction control nut 1 according to the following diagram 1 4 ...

Page 334: ...nd hold the switch to UP the motor will tilt up c Push and hold the switch to DN the motor will tilt down d Release the switch the motor will stop at its current position Dynamic Check T he engine is going to be started for checking T herefore the engine should be supplied cool ing water Before performing the dynamic check make sure the following conditions are met Lock plate is installed to the e...

Page 335: ...ns over then the engine will start b Turn the main switch to OFF from ON The running engine should stop 7 Check the engine stop switch a Run the engine b Pull the lanyard off the lock plate The running engine will stop 8 Check for steady engine speed a Run the engine at idle b Steer the tiller handle c Tilt up down the tiller handle Make sure a steady engine speed is kept ...

Page 336: ...6A 1 Outboard Rigging Guide 2001 Outboards F30 F40 TILLER HANDLE STEERING FRICTION INSTALLATION MANUAL ...

Page 337: ...6A 2 Outboard Rigging Guide 2001 PREPARATION 1 Remove Lock plate 1 2 Remove Fitting plate 2 Ref No Parts Name Qty Remarks 1 Tiller Handle Ass y 1 TILLER HANDLE For manual start model ...

Page 338: ... Grommet 1 Engine stop switch connectors 2 3 Install Cable stopper 1 Rubber seal 2 Remote control cables 3 4 Install Fitting plate 1 Bolts 2 5 Adjust Shift cable joint position Adjustment steps Turn the shift handle 1 in neutral pos tion Nut 38 Nm 3 8 m kg 27 ft lb Bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 339: ...djustment steps Turn the throttle grip fully close Align the throttle lever 1 as shown Adjust the position of the cable joint 2 until its hole aligns with the set pin Install the clip 3 and tighten the lock nut 4 The cable joint should be screwed in more than 8 0mm 0 31 in 8 Check Fully open position Incorrect Repair 9 Connect Engine stop switch connectors 1 WARNING WARNING Checking steps Turn the...

Page 340: ... 1 4 Bolt 2 M6 5 Shift Control Lever 1 6 Spring Pin 1 7 Grommet 1 8 Steering Friction Ass y 1 9 Bolt with Washer 2 M5 10 Extension Wire Harness 1 10 pin 12 pin 11 Wire Harness 1 A To buzzer B To trim meter C To tachometer D To PTT switch 12 Connector ass y 1 OPTION TILLER HANDLE AND STEERING FRICTIO KIT For remote control model ...

Page 341: ...Grommet 3 Cable stopper 4 Rubber seal 5 4 Remove Shift cable joint 6 Throttle cable joint 7 5 Disconnect Wire harness coupler 8 6 Disconnect Overheat and oil warning lamp coupler 9 Trim sensor coupler 10 for PTT model NOTE The bottom cowling overhet and oil warn ing lights will not be able to be operated ...

Page 342: ...ver 1 Starter motor 2 8 Remove Shift rod lever ass y 3 9 Remove Grease nipples 1 Clamp 2 NEUTRAL SWITCH 1 Install Shift control lever 1 Spring pin 2 Shift rod lever ass y 3 2 Install Neutral switch 1 Neutral switch stay 2 Bolts M6 3 Bolt 10 Nm 1 0 m kg 7 2 ft lb ...

Page 343: ...M5 3 TILLER HANDLE 1 Install Tiller handle ass y 1 Nuts 2 Bolt with washers M5 3 2 Install Grommet 1 Main switch leads 2 Battery cable 3 PTT switch lead for PTT model 4 Extension wire harness 5 NOTE Align the taped end a of the battery cable and the extension wire lead with the end of the grommet 3 Install Cable stopper 1 Rubber seal 2 Remote control cables 3 Nut 38 Nm 3 8 m kg 27 ft lb ...

Page 344: ...set pin 2 as shown Adjust the position of the cable joint 3 until its hole aligns with the set pin Install the clip 4 and tighten the lock nut 5 The cable joint should be screwed in more than 8 0mm 0 31 in WARNING Adjustment steps Turn the throttle grip fully close Align the throttle lever 1 as shown Adjust the position of the cable joint 2 until its hole aligns with the set pin Install the clip 3...

Page 345: ...ion wire harness coupler 1 11 Connect Overheat and oil warning lamp coupler 1 Trim sensor coupler 2 for PTT model 12 Connect Trailer PTT switch couplers 1 for PTT model Checking steps Turn the shift handle in gear position Turn the throttle grip fully open Check the throttle valve lever so that it contacts the fully opening stopper ...

Page 346: ...Friction force Turn the friction lever 1 to a or b Incorrect Retighten the nut 2 15 Check Steering movement 1 Unsmooth Repair NOTE With the friction lver turned fully to the left check the tiller for smooth movement a a Friction is increased a a Friction is decreased Nut 5 Nm 0 5 m kg 3 6 ft lb ...

Page 347: ...6B 1 Outboard Rigging Guide 2001 Outboards F80 F100 TILLER HANDLE STEERING FRICTION INSTALLATION MANUAL 67G 2819K 10 ...

Page 348: ...Outboard Rigging Guide 2001 NOTE This manual is for use by Yamaha dealers and the Owner s Manual which is located inside is for use by the customer Remove the Owner s Manual and distribute it to the customer ...

Page 349: ...1 5 Switch stay 1 6 Bolt 2 7 Friction rod 1 Steering friction set 8 Link rod 1 9 Bolt 1 10 Washer 3 11 Nut 2 12 Friction control 1 13 Bolt 1 14 Wing nut 1 15 Extension wire harness 1 10 pin 12 pin 16 Wire harness 1 12 pin for buzzer tachometer and trim meter 17 Connector assembly 1 18 Grommet 1 19 Zip tie 1 20 Buzzer 1 21 Buzzer stay 1 ...

Page 350: ...PARATION 1 Remove Nut 1 Steering hook 2 2 Remove Bolt 1 Flywheel cover 2 Junction box cover 3 3 Remove Screw 1 CDI unit cover 2 4 Remove Bolt 1 Throttle control assembly 2 5 Remove Plastic locking tie 1 Hose 2 Bolt 3 Bolt 4 Intake silencer 5 O ring 6 E ...

Page 351: ...ead coupler 1 Trailer switch coupler 2 NEUTRAL SWITCH 1 Install Neutral switch assembly 1 Damper plate 2 Neutral switch stay 3 Bolt 4 NOTE Move the shift lever to the forward position for operation 2 Disconnect Brown lead connector 1 3 Connect Neutral switch lead connectors 1 Start in gear protection will not be obtained without the neutral switch leads connection E WARNING ...

Page 352: ...T switch lead 6 Extension wire harness 7 Shift control cable 8 Throttle control cable 9 3 Connect Main switch lead connectors 1 Zip tie 2 Zip tie 3 NOTE Pass the shift control cable 4 and throttle control cable 5 under the tiller handle assembly 4 Connect Extension wire harness coupler 1 Overheat and oil warning lead coupler 2 Trim sensor lead coupler 3 Nut 38 Nm 3 8 m kg 27 ft lb E ...

Page 353: ...ontrol cable 1 Throttle control cable 2 Cable clamp 3 Bolt 4 Clips 5 Hose locating plate 6 Bolt 7 Grommet retaining plate 8 Bolt 9 8 Check Shift operation Incorrect Adjust 9 Adjust Shift cable joint position E Adjustment steps Align the center of the set pin a with the mark b on the bracket c Cable clamp bolt 8 Nm 0 8 m kg 5 8 ft lb Hose retaining plate 8 Nm 0 8 m kg 5 8 ft lb Grommet retaining pl...

Page 354: ...d reverse positions and make sure it shifts smoothly and correctly If the shifting operation is unsmooth or incorrect repeat the above procedure WARNING Checking steps Fully close the throttle Check that the throttle control lever 1 touches the fully closed stopper 2 Adjustment steps Contact the throttle control lever 1 with the fully closed stopper 2 Loosen the locknut 3 and remove the clip 4 Rem...

Page 355: ...close to fully open NOTE Shift in forward and then check the throttle operation 3 Check Steering friction Proper friction is obtained Proper friction is obtained and that there is no interference with the hull Tiller handle tilt up down Cables and wires are not stretched DYNAMIC CHECK The engine is going to be started for checking Therefore the engine should be supplied cooling water E CAUTION Sta...

Page 356: ... OFF then to START The starting motor is turned then the engine will be started Turn the main switch to OFF from ON The running engine will be stopped Checking steps Run the engine Pull the lanyard and off the lock plate The running engine will be stopped Checking steps Run the engine in idling Steer the tiller handle Tilt up down the tiller handle Steady engine speed is kept Checking steps Turn t...

Page 357: ...efer to SERVICE MANUAL NOTE Set the ditital tester to the manual range In the auto range the voltage changes cannot be accurately measured Output voltage P O 0 7 0 02V Checking steps Connect the test harness Connect the tester leads to the test harness P O Start the engine and measure the volt age at engine idling speed E ...

Page 358: ...6C 1 Outboard Rigging Guide 2001 Outboards F80 F100 TILLER HANDLE STEERING FRICTION OWNER S MANUAL ...

Page 359: ...6C 2 Outboard Rigging Guide 2001 E FEATURES ...

Page 360: ...djust Friction control nut 1 Throttle friction to be PTT SWITCH ENGINE START Increased Decreased Increased Decreased Operation steps Turn the main switch to ON Push and hold the switch UP Tilt up DN Tilt down Operation steps Install the lanyard lock plate 1 to engine stop switch 2 Turn the main switch to ON from OFF then to START ...

Page 361: ...ent Kit 7 4 F9 9 T9 9 4 Stroke Remote Control Attachment Kit 7 8 F15 Remote Control Attachment Kit 7 12 F25 Remote Control Attachment Kit 7 14 25HP Remote Control Attachment Kit 2 Cyl 7 17 25E Remote Control Electrical Conversion 7 20 25 30HP Remote Control Attachment Kit 3 Cyl 7 23 6 8HP Electric Starter Conversion Kit 7 26 Steering Hooks 7 31 Steering Attachment Kits 7 33 7 ...

Page 362: ...ions 6L2 86112 00 00 1 req later in this section 97013 06012 00 2 req 92990 06100 00 2 req 93210 03261 00 1 req 97013 06012 00 1 req 92990 06100 00 1 req 6L2 82590 00 00 1 req 6K3 83557 00 00 1 req F25 65W 48501 00 00 Throttle Shift 65W 48511 00 00 Steering Hook 65W 61350 00 00 Steering Arm 65W 48501 00 00 Remote Attachment ER 65W 82590 20 00 Engine Harness ER TR 65W 82590 30 00 Engine Harness TR ...

Page 363: ...tter Pin 1 20 97780 50520 00 Screw 1 21 682 48340 50 00 Throttle Cable End Assembly 1 22 682 48344 50 00 Remote Control Cable End 1 1 23 617 48361 90 00 Cable Hook 1 24 90501 10264 00 Spring 1 25 92990 08600 00 Washer 1 26 91690 30012 00 Spring Pin 1 27 682 48330 50 00 Shift Cable End Assembly 1 28 682 48346 50 00 Remote Control Cable End 1 29 617 48331 91 00 Cable Hook 1 30 90501 10071 00 Spring ...

Page 364: ...decrease the amount the cable is screwed in on the remote control box side Be sure to tighten the locknut for each cable joint I f the cable is not screwed in at least 8mm the cable joint could break T his could cause loss of control and an accident 7 Fit the remote control cables to the bracket and secure them with the cable clamp 8 Install the throttle cable joint and the shift cable joint to th...

Page 365: ...91590 30012 00 Pin Spring 2 8 97095 06016 00 Bolt 2 9 92990 06600 00 Washer Plate 2 10 95380 06600 00 Nut 2 11 663 48344 00 Cable End Remote Control 2 12 90468 18008 00 Clip 2 13 90201 08M12 00 Washer Plate 2 14 63V 42154 00 Lever Throttle Control 1 15 90386 10025 00 Bush 2 16 90206 10M04 00 Washer Wave 1 17 90201 10M02 00 Washer Plate 1 18 63V 42192 00 Rod 2 1 19 90201 04M06 00 Washer Plate 2 20 ...

Page 366: ...mote Control Attachment Assembly 1 Install Bushing Lever Rod Plane Washer Cotter Pin 2 Install Throttle Lever Plane Washer Wave Washer Flange Nut B end the cotter pin ends securely a b c 33 2 1 33 12 11 15 16 17 18 14 13 19 17 WARNING Bolt 2 2 Tightening Torque 18 Nm 1 8 m kg Flange Nut Tightening Torque 8 Nm 0 8 m kg 19 15 11 12 16 17 16 17 2 1 4 2 2 2 0 5 3 7 18 6 14 13 12 19 242 ...

Page 367: ... Bracket Bolt 1 Replace Clamp Bracket Bolt Remote Control Cable 1 Install Cable End 8 2 Connect Shift Cable a Throttle Cable b Cable End 8 Plane Washer Clip 9 Screw Tightening Torque 3 5 Nm 0 35 m kg 15 11 12 16 17 16 17 2 1 4 2 2 2 0 5 3 7 18 6 14 13 12 19 242 22 20 21 21 Bolt 6 6 Tightening Torque 8 Nm 0 8 m kg 23 Nut a a Tightening Torque 13 Nm 1 3 m kg a 2 3 8 18 10 9 8 9 8 2 0 3 b 10 ...

Page 368: ... the upside of the set pin T he cable end 8 8 should be screwed in more than 8mm 0 31 in T he clip 9 9 should be installed from the up side as shown in the illustration WARNING 20 20 A djustment S tep Place the remote control lever of the remote control box in Neutral Position Install the throttle cable 6 to the remote control bracket 3 Place the throttle control grip to the fully closed position ...

Page 369: ... End 1 13 6G8 26364 00 00 Cable End 2 1 14 6G8 48511 00 00 Steering Hook 1 15 97395 06016 00 Bolt 2 16 92990 06600 00 Plate Washer 2 17 6G8 48511 10 00 Steering Hook 1 18 97395 06106 00 Bolt 2 19 92990 06600 00 Plate Washer 2 Component parts Additional Parts Required Component Parts Rope Type Electric Model Only Ball Post Type REF NO PART NUMBER DESCRIPTION QTY 1 6G8 82570 02 00 Switch Panel Assem...

Page 370: ...d the CDI unit cover N O T E After removing the stop switch from the engine use the emergency stop switch on the bot tom cowling to stop the engine 5 Turn the steering handle backward 6 Fit a slotted head screwdriver into the slit in the ring nut 7 Set the screwdriver using the steering brack et as a fulcrum 8 Turn the steering handle forward and loosen the ring nut 9 Repeat this operation until t...

Page 371: ...m decrease the amount of the cable to screw it in on the remote control box side Be sure to tighten the locknut for each cable joint I f the cable is not screwed in at least 8mm the cable joint could break T his could cause loss of control and an accident Fit fitting plate 1 and 2 into the grooves around the cable 2 Pass the remote control cables through the bottom cowling 3 Install the remote con...

Page 372: ...clip Connect the shift cable joint to the R mark side of the shift lever and lock it with the lock plate 6 Connect the throttle cable joint to the R mark on the throttle lever and lock it with the lock plate 7 Install the stop switch in the motor pan 8 Reconnect the white and black leads see Removal step 4 Reinstall the CDI cover ...

Page 373: ...next page illustration B Make sure the remote control cable end is screwed in more than 8mm 0 31in C Connect the throttle 1 when the throttle is fully closed and connect the shift cable 2 when the outboard is in neutral Reusable Parts F15 Additional Parts Required The following information would allow the engine to be started and stopped from a 703 con trol box Component parts PART NUMBER DESCRIPT...

Page 374: ...0 Washer Plate 1 8 65W 81870 00 00 Starting Switch Ass y 1 8G1 42725 00 00 Grommet 1 9 6H3 82540 00 00 Neutral Switch Ass y 1 10 90109 06M86 00 Bolt 2 11 6J8 82564 00 00 Stay Neutral Switch 1 12 66M 86111 00 00 Coil Solenoid 1 13 66M 6116 00 00 Wire Pull 1 14 66M 86112 00 00 Stay Solenoid 1 15 97980 05208 00 Screw with Washer 2 16 97505 06518 00 Bolt with Washer 2 17 90480 10M13 00 Grommet 1 18 66...

Page 375: ...p 1 11 663 48344 00 00 Cable End Remote Control 2 12 90468 18008 00 Clip 2 13 6H3 48538 00 00 Clamp Cable 1 1 14 65W 42725 10 00 Grommet 1 15 65W 26326 00 00 Grommet 1 16 6H1 42726 10 00 Grommet 1 17 6G1 42725 00 00 Grommet 1 18 65W 42726 00 00 Grommet 1 19 65W 82590 00 00 Wire Harness Assembly 1 Installation Refer to illustration on page 7 10 A Install the remote control as shown in the next page...

Page 376: ...7 15 Outboard Rigging Guide 2001 F15 F25 Remote Control Attach Kit REMOVAL ...

Page 377: ...7 16 Outboard Rigging Guide 2001 F15 F25 Remote Control Attach Kit 1 2 7 8 4 3 5 6 8 2 1 12 10 12 B B C A 11 B D mm 0 31 in 13 19 18 20 16 14 17 16 9 INSTALLATION ...

Page 378: ... 06M23 00 Washer Based Bolt 2 15 6G8 26363 00 00 Cable End 2 16 6G8 26364 00 00 Lock Plate 2 Component parts Installation 1 Remove the grommet and plugs from the bot tom cowling A Grommet B Plug 2 Install remote control bracket 1 to the place where the plugs have been removed 1 Remote Control Bracket 2 Washer based bolt 3 Remove the oil tank mounting bolts and the fuel filter nut By using adhesive...

Page 379: ... Lever Shift Control 4 Bushing 5 Nut Flange 6 Joint Control 7 Rod 1 7 Install rod 1 on the shift rod link E Then loosen bolt F to allow a small amount of gap between shift rod link and crankcase and insert rod 1 7 Rod 1 N O T E For this operation shift into Reverse and fully open the throttle 8 Slip the plate washers 9 respectively over rods 1 and 2 and lock each rod with the cot ter pin Retighten...

Page 380: ...e to secure the cable joint I Cable Joint J Lock Plate S crew in the cable joint so its flat end is at least 8mm away from the end of the cable 11 Operate the shift and throttle cables to check that they are not caught and move smoothly After confirmation reinstall the oil tank and fuel filter CAUTION General Torque A B Specifications Nut Bolt Nm m kg ft lb 8mm M5 5 0 0 5 3 6 10mm M6 8 0 0 8 5 8 1...

Page 381: ...n 4 11 6L2 86112 00 Stay Solenoid 1 12 97013 06012 Bolt 661 2 13 92990 06100 YBS67 6 Washer Spring 2 14 93210 03261 O ring 663 1 15 97013 06012 Bolt 9661 1 16 92990 06100 YBS67 6 Washer Spring 1 17 6L2 82590 00 Wire Harness Assy 1 18 6K3 83557 00 Tube 1 Component parts Installation 1 Install the following parts on the choke sole noid assembly 1 Screw 2 Plain Washer 3 Bracket 4 Grommet 5 Extension ...

Page 382: ...g wire to the starter mount bracket and install the ten sion bolt on the carburetor choke rod 1 Bracket 2 Choke Solenoid Assembly 3 Screw and Plain Washer 4 Grounding Wire black 5 Extension bolt 6 O ring N O T E Fit the O ring 6 in the groove in the choke rod so the extension bolt will not come off 6 Replace the grommet 3 Pass the wire harness and battery cord through the grommet and fit the gromm...

Page 383: ...e wiring diagram connect the wires correctly Next place the cover over the clamp 8 Retighten the four bolts which were loos ened in 4 on the previous page securing the carburetor 9 Reinstall the silencer cover which was removed in 2 on the previous page and retighten the four screws ...

Page 384: ...R DESCRIPTION QTY 1 Remote Control Attach Ass y 1 2 92990 08100 00 Washer Spring 1 3 6J8 48534 00 00 Control Throttle Lever 1 4 6J8 48544 01 00 Shift Control Lever 1 5 6J8 44177 00 00 Washer 1 6 91690 30016 00 Spring Pin 1 7 6J8 44173 02 00 Shift Control Lever 1 8 6J8 48531 00 00 Joint 1 9 6J8 48531 00 00 Remote Control Bracket 1 1 10 6J8 48532 00 00 Remote Control Bracket 2 1 11 682 48538 50 00 C...

Page 385: ...ol lever inner 7 Align the spring pin holes and drive the spring pin into the hole by using a pin punch and a hammer 8 Install the rubber grommet in the bottom cowling Route the wire harness through the grommet if it is necessary 9 The parts shown below should be assembled separately as a sub assembly and installed to the bottom cowling 10 Connect the remote control cables to the remote control br...

Page 386: ...the cable joint set pin and lock it with the lock nut Lock the cable joint to the cable joint set pin with this lock plate I f the cable is not screwed in at least 8mm the cable joint could break T his could cause loss of control and an accident 12 Fit the new cover Additional Parts Required WARNING Part Number Description 6J8 48511 51 4D Steering Hook Manual Model Only ...

Page 387: ...s Ass y 1 15 6G1 82105 00 00 Wire Lead Ass y 1 16 6G1 82117 00 00 Lead Wire 1 17 682 42724 00 00 Grommet 1 18 6G1 82362 00 00 Clamp 1 19 90105 06M23 00 Bolt 1 20 6G1 81970 61 00 Rectifier Ass y 1 21 98503 05025 00 Panhead Screw 1 22 92990 05600 00 Washer 1 23 6F5 82540 00 00 Neutral Switch Ass y 1 24 6G1 82554 00 00 Neutral Switch Stay 1 25 90105 06M23 00 Bolt 1 26 6G1 44125 00 00 Shift Rod 2 Leve...

Page 388: ... the three screws holding the front panel Pull the panel out to gain access to the carburetor mounting screws 6 Disconnect the carburetor linkage Remove the two carburetor mounting bolts Remove the carburetor and air box 7 Remove the two bolts and the screw which hold the shift shaft lever to the bottom cowl ing Install the shift rod lever 2 with the cot ter pin on the port side Reinstall the two ...

Page 389: ...e as shown N O T E The mounting bolts are of different lengths The two shortest bolts should be mount ed in the upper and lower holes on the left side The one longest bolt should be installed in the upper right hole after the battery cable is installed see next step The remaining bolt is installed in the lower right hole 11 Install the grommet on the battery lead assembly and then route the lead t...

Page 390: ... sheath and plug them in to the green leads from the har ness Route the harness through the sheath 15 Remove the grommet and install the starting switch on the front panel and connect the wiring as shown in the wiring diagram Also connect the leads for the neutral switch 16 Reinstall the carburetor and reconnect the throttle and choke linkage 17 Replace the front panel with the three screws and re...

Page 391: ...7 30 Outboard Rigging Guide 2001 6 8HP Electric Starter Conversion Kit Wiring Be sure the wiring is connected as shown in the following diagram ...

Page 392: ...lt These items must be ordered for 25hp and 30 40 applications on the 1 92990 10600 00 Washer steering hook 1 90185 10 51 00 Nut 1 90185 10051 00 Nut These items must be ordered for 30hp 90hp and C75 applications on 2 90116 10175 00 Stud the steering hook 2 N O T E The steering hook is permanently attached on 115hp models and larger STEERING HOOKS A steering hook is necessary in order to guide any...

Page 393: ...d C40 N O T E When a steering hook is standard equip ment on any particular model it should already be attached to that motor when you receive it in the crate On the 25hp and 40hp manual the steering hook not standard will need to be installed as shown above 30HP 40HP 90HP including C Series and F80 F100 F115 T9 9 9 9 15 and F15 F25 ...

Page 394: ...ing hook to the steering cable Application Chart Standard on Remote Models N O T E Some steering system components such as wheels and steering cables are not offered by Yamaha Parts and Accessories However Yamaha outboard motors are made to industry specifica tions to facilitate completing your steering system with readily available aftermarket product F25 C40 50 40 F80 9 9 15 F30 C50 F40 4 70HP 9...

Page 395: ...lt tube and attach the cable to the tube with the securing nut that is on the steer ing cable 3 Fit the O ring and cap nut on the other end of the steering tilt tube N O T E The O ring and cap mentioned above serve to keep inside the hollow steering tilt tube and water outside the tube Attach the steering link rod assembly to the steer ing hook and steering cable as shown 9 9 15 F15 F T9 9 F25 C40...

Page 396: ...01 25HP ER Model 30HP 90HP Including C Series F80 F100 F115 N O T E There are two holes in the steering hook For best results in steering use the inner hole to attach the steering link rod 115 250HP 25HP 90HP F80 F100 F115 115 250HP ...

Page 397: ...Outboard Rigging Guide 2001 SECTION 8 PROPELLERS Propellers 8 1 Propeller Application Charts 8 3 8 ...

Page 398: ...e for enhanced acceleration and low speed operation The 4 blade is designed to improve performance and handling on a variety of boats The 4 blade prop will improve hole shot performance while maintain ing nearly the same top speed as a comparable 3 blade propeller GYT props fit all 60 250hp Yamaha Outboards Counter rotation models are also available T he 4 blade V 6 performance propellers use an e...

Page 399: ...cate the location of the letter code and corresponds with the far left column in the table Location of Letter Codes on Aluminum and Some Selected Stainless Steel Propellers 1994 T25 F30 C60 C90 F40 3 T50 130 F4 F8 T8 9 9 F15 F25 C40 55 F80 100 225X DX150 L150 L225 HP 2 3 4 5 6 8 T9 9 F9 9 15 25 30 40 50 115 V6 250 L130 D150 L200 L250 Type A BS BA N R J F G K M T KL MF MR ML TL Mat l AL AL AL AL AL...

Page 400: ...947 00 EL 11 3 4 11 Plastic Dual Thrust 6G8 45941 00 00 11 3 4 12 1 4 Plastic Dual Thrust 6G8 45945 00 00 F9 9 9 9 15 F15 9 3 4 6 1 2 Aluminum Dual Thrust 683 W4592 02 EL 9 3 4 8 Aluminum Dual Thrust 683 W4591 02 EL 9 1 4 8 Aluminum 683 45947 00 EL 9 1 4 9 Aluminum Std 683 45952 00 EL 9 3 4 9 3 4 Aluminum 683 45952 00 EL 9 1 4 10 1 2 Aluminum 683 45943 00 EL DIAM PITCH DESCRIPTION PART NUMBER 10 5...

Page 401: ...3 8 13 Aluminum 6H5 45945 00 EL 10 1 4 14 Aluminum 6H5 45958 00 EL 11 1 4 14 Aluminum 663 45958 01 EL 10 15 Aluminum 6H5 45943 00 EL 10 3 4 16 Aluminum 663 45949 01 EL 10 3 4 17 Aluminum 663 45941 01 EL 12 11 Stainless Steel 663 45972 60 98 11 3 4 12 Stainless Steel 663 45970 60 98 11 1 2 13 Stainless Steel 663 45974 60 98 10 1 4 14 Stainless Steel 663 45930 00 98 10 1 4 15 Stainless Steel 663 459...

Page 402: ... 60 98 13 17 Stainless Steel 688 45930 01 98 13 19 Stainless Steel 688 45970 03 98 13 21 Stainless Steel 688 45972 02 98 13 23 Stainless Steel 688 45974 02 98 13 25 Stainless Steel 688 45976 01 98 13 1 4 18 GYT 3 Blade MAR GYT3B V4 18 13 1 4 20 GYT 3 Blade MAR GYT3B V4 20 13 1 4 22 GYT 3 Blade MAR GYT3B V4 22 13 1 4 24 GYT 3 Blade MAR GYT3B V4 24 13 1 2 19 Pro Series 62A 45974 00 00 13 1 2 21 Pro ...

Page 403: ...e Polished Stainless MAR GYT3B V6 24 14 1 4 26 GYT 3 Blade Polished Stainless MAR GYT3B V6 26 14 1 4 28 GYT 3 Blade Polished Stainless MAR GYT3B V6 28 14 1 2 21 Pro Series Polished Stainless 6J9 45976 B0 00 14 1 2 23 Pro Series Polished Stainless 6J9 45972 B0 00 14 1 2 25 HD Hub Pro Series Polished Stainless 66K 45972 B0 00 14 1 2 27 HD Hub Pro Series Polished Stainless 66K 45970 B0 00 13 3 4 18 G...

Page 404: ...50 DIAM PITCH DESCRIPTION PART NUMBER 14 19 Front TRP MAR TRP14 19 FR 13 19 Rear TRP MAR TRP13 19 RR 14 21 Front TRP MAR TRP14 21 F2 13 21 Rear TRP MAR TRP13 21 R2 14 25 Front TRP 65N 45941 00 00 13 25 Rear TRP 65N 45943 00 00 14 27 Front TRP 65N 45945 00 00 13 27 Rear TRP 65N 45947 00 00 ...

Page 405: ...tainless Steel 6K1 45972 01 98 13 3 8 23 Stainless Steel 6K1 45976 00 98 14 1 4 18 GYT 3 Blade MAR GYT3B L6 18 14 1 4 20 GYT 3 Blade MAR GYT3B L6 20 14 1 4 22 GYT 3 Blade MAR GYT3B L6 22 14 1 2 15 Saltwater Series 6R1 45976 A0 00 15 1 4 17 Saltwater Series 6R1 45978 A0 00 15 1 4 19 Saltwater Series 6R1 45970 A0 00 14 7 8 21 Saltwater Series 6R1 45972 A0 00 14 7 8 23 Saltwater Series 6R1 45974 A0 0...

Page 406: ...NOTES ...

Page 407: ...NOTES ...

Page 408: ... 2001 SECTION 9 RIGGING COMPONENTS KITS Portable Fuel Tank 9 1 Remote Oil Tank Mounting Instructions 2 8 Gal and 5 0 Gal 9 2 Oil Deck Filler Plate Mounting Instructions 9 4 Vertical Starter 9 5 Outboard Display Stands 9 6 9 ...

Page 409: ...uel Gauge 97760 10000 00 97760 00000 00 Fuel Meter Gasket 6Y1 24268 00 00 6Y1 24268 00 00 Seal 6Y1 24329 00 00 6Y1 24329 00 00 Pan Head Screw 98586 05016 00 98586 05016 00 Fuel Connector ABA FCONN CT OR ABA FCONN CT OR GALVANIZED FUEL TANK 3 7 Gallon 6 3 Gallon Tank Ass y 6Y4 W2420 42 24 6Y1 W2420 42 24 Fuel Cap 6Y1 24210 00 00 6Y1 24210 00 00 Fuel Meters 6Y4 24260 02 00 6Y1 24260 02 00 Seal 6Y1 2...

Page 410: ...ket should be used to secure the oil tank at the desired mounting location Sub Oil Tank Holder 6E5 21734 01 33 Used for 2 8 Gal and 5 0 Gal Tanks B e careful not to overtighten the bracket bolt N O T E When installing the oil tank and routing the oil lines between the engine and the remote oil tank be sure to keep the lines from being pinched off CAUTION ...

Page 411: ...gging Guide 2001 Remote Oil Tank Mounting Instr 5 0 Gallon Oil Tank Assembly 6YR W0035 C0 00 N O T E 5 Gallon oil tank components and pump in same bracket as 2 8 gallon tank Tank extends an additional 3 5 to each side ...

Page 412: ...ot blocked by sealant or other material from the boat deck 6 Remove the original Yamaha Oil Tank Cap and install the reducer fitting in its place Be sure the fitting is tight on the oil tank to pre vent leakage 7 Use oil resistant 1 1 2 I D hose between the filler cap assembly and the oil tank fitting a Be sure the 1 16 in vent hole in the filler cap neck is not obstructed when hose is attached b ...

Page 413: ...rter spring is free 5 Remove the original wire guide from the starter case 6 Install the vertical starter onto the starter case 7 Insert the rope through the vertical starter and starter handle holes respectively Knot the ends and install the cover into the starter han dle 8 Pass the starter rope through the cut 9 Wind the spring up two turns counterclock wise with the starter rope 10 Slowly relea...

Page 414: ...8HP small size ABA STAND 00 MD 9 9 30HP C25 30 medium size ABA STAND 00 LG 40 250 C40 C150 E48 E75 T9 9 large size Part Name Description Qty L H Main Support 1 R H Main Support 1 Skeg Base Plate 1 Upper Support Bolt 5 16 18 UNC Hex Head 1 Upper Support Hex Nut 5 16 18 UNC 1 Skeg Base Plate Pinch Bolt 1 4 20 UNC x 1 1 4 Large Hex Head 1 Skeg Base Plate Pinch Hex Nut 1 4 20 UNC 1 Skeg Base Plate Aco...

Page 415: ...o a hydraulic lift with the motor in a vertical upright position allowing an approximate clearance between the tip of the skeg and the floor of one foot B efore proceeding to the next step be certain the outboard is secure on the lift to prevent possible bodily injury to yourself and or dam age to the outboard motor or accessory 2 Take the display stand in hand and align the outboard s cavitation ...

Page 416: ...ld be damaged 4 Insert the lower skeg support pinch bolt through the rear hole of the skeg plate Place one hex nut onto the bolt and tighten D o not over tighten T he outboard or stand could be damaged A n outboard motor on a display stand can be bumped over causing injury or damage L ag bolt the display stand to the floor through the two pre drilled holed in the stand base D o not modify the disp...

Page 417: ...Outboard Rigging Guide 2001 SECTION 10 APPENDICES 6X1 Dual Station System Installation Manual 10A 6X1 Dual Station System Service Guide 10B 10 ...

Page 418: ...Outboards 6X1 DUAL STATION SYSTEM INSTALLATION MANUAL YAMAHA MOTOR CO LTD 6X1 28199 Y2 10A 1 ...

Page 419: ...INSTALLATION MANUAL 1991 by Yamaha Motor CO LTD 1st Edition July 1991 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 10A 2 ...

Page 420: ... carefully and thoroughly Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Failure to follow WARNING instructions could result in severe injury or death to the machine operator a bystander or a person installing inspecting or repairing the dual station control system or boat A ...

Page 421: ...RO V 150LD 350101 L250ETXD 700101 175ETLD 402800 L250TURQ 800101 175ETXD 753500 An additional adapter Part Number 6X1 81950 90 must be used with the 6X1 Dual Station System if it will be used on YAMAHA Outboard Motors earlier than those listed The adapter enables the shift cut system of the actuator to control the CDI unit to reduce engine rpm during shifting For installation details refer to page...

Page 422: ...it 12 C Connecting the Throttle Cable to the Dual Station Junction Unit 15 D Connecting the Shift Cable to the Actuator 15 E Connecting the Cables to the Outboard Motor 16 CONNECTING THE WIRE HARNESSES 18 CONNECTING THE TEN POLE CONNECTOR THE SWITCH PANEL AND THE ENGINE AND ACTUATOR 18 CONNECTING THE THREE POLE CONNECTOR BETWEEN THE JUNCTION UNIT AND THE ACTUATOR 18 TESTING 19 TESTING SHIFTING OPE...

Page 423: ...10A 6 GENERAL INFORMATION WIRING AND COMPONENT PARTS Single engine system Second station ...

Page 424: ...10A 7 Twin engine system Second station ...

Page 425: ...UNCTION UNIT This unit allows changeover of control between the first and second stations Whenever the controls lever at one remote control box is placed in either forward or reverse the control lever at the other remote control box is locked at the neutral position When free acceleration is used the control levers of both remote control boxes are locked ACTUATOR The actuator uses an electric serv...

Page 426: ...hey must be start ed from the first station 115 200 hp Second station except Prime Start models When the main switches are turned on and the engines are sufficiently warm they can be started from the second station too Prime Start models The engines can be started from either station but the main switches must be turned on in the first station before the main switches in the second station will wo...

Page 427: ... mounting diagram Using a correct inch hole saw make holes and then cut out the center portion as shown 2 Connect the wiring harness to the switch panel assembly and pass it back through the hole 3 Secure the switch panel assembly to the instrument panel with the screws washers and nuts provided 4 Connect the wiring harness to the cou pling lining up the arrow and triangle and lock the connection ...

Page 428: ...er will not show correct measurement 1 Install the digital meter onto the dash board If no dashboard is available use a wooden board having a thickness of 2 11mm in place of the dashboard 2 Select a place for installation which is free from splashes 3 Evenly tighten the mounting nuts on both right and left sides 4 For wiring refer to the WIRING section 10A 11 ...

Page 429: ...gle of the bend s in the cable the number of bends and the quality of the cable which control the amount of space between the inner cable and the tube Too much end play can prevent controls from work ing properly so cables must be installed care fully The Dual Station junction unit will not work properly if the control cables have exces sive end play Improper operation of the junction unit can cau...

Page 430: ...NE 26 FEET MAXIMUM LENGTH JUNCTION UNIT TO UPPER STATION 22 FEET MAXIMUM LENGTH JUNCTION UNIT TO LOWER STATION 22 FEET MAXIMUM LENGTH ACTUATOR TO ENGINE 26 FEET TOTAL LENGTH OF ALL THREE THROTTLE CABLES 50 FEET 3 Avoid excessive bends in cables The following recommendations are for quality YAMAHA cables MAXIMUM BENDS IN ONE CABLE 1 1 2 TURNS or 6 90 TURNS or 540 MINIMUM BEND RADIUS 8 INCHES 10A 13...

Page 431: ...ting on a ver tical surface RECOMMENDED JUNCTION UNIT AND ACTUATOR LOCATION The mounting location for the junction unit and actuator should be selected with the following recommendations in mind 1 The shortest possible cables should go to the motors with the least number of bends Since the cables for the lower sta tion are usually the shortest these cables can be lengthened or bent if necessary to...

Page 432: ... Two identical labels are provided for each identification Attach them to both ends of the cable 2 Attach the labels to the JUNCTION UNIT AND ACTUATOR In case of a single engine installation the JUNCTION UNIT AND ACTUATOR need not be identified by labels Attach the label to the JUNCTION UNIT AND ACTUATOR at a convenient place for easy reference Remove the junction cover to attach the labels 10A 15...

Page 433: ...emote control box cables to junction unit C Throttle cable to junction unit D Shift cable to actuator E Outboard motor cable ends NOTE Before connecting the cables set the remote control box and the outboard to the neutral position for the shift cable and to the fully closed position for the throttle cable 10A 16 ...

Page 434: ...JUNCTION UNIT 1 Removing the cover 1 Remove the cover and the three rubber plugs 2 Connecting the control box throttle cables to the junction unit 1 Install the dual station brass barrel cables ends on the throttle cables from the 704 control boxes When setting the 135mm length specified pull slightly on the cable to eliminate any backlash This will ensure that the throttle returns correctly to id...

Page 435: ... that the cable end piece should be screwed in at least 8mm Install the clamp so that the side of the clamp identified by the arrow mark directs the center of the junction unit 5 Securing the cables 1 Pass the cable through the opening in the rack 2 Fit the cable end groove in the rack groove 3 Position the rod clamp in place 4 Pull the cable with force and place the C hub in the clamp 5 Position ...

Page 436: ...tion If grooves are offset use the following steps to eliminate the offset 3 Remove cable clamp and pull out the shift cable 4 Loosen the rod nut on the cable and move the cable end so that the offset is eliminated 5 Install the shift cables into the junction box in the same manner as the installa tion of the throttle cable Install the clamp so that the side indicated by the arrow mark directs the...

Page 437: ...CTUATOR 1 Determine installation location of the actuator Fix the actuator by referring the instructions in ACTUATOR INSTAL LATION page 8 2 Remove four screws securing the cover of the actuator and then the cover 3 Screw cable end on the shift cable so that the edge of the cable end is in between 7 and 8mm 0 28 0 31 in from the end of the shift cable and tighten the rod nut NOTE Check shift cable ...

Page 438: ...eliminate any backlash when installing This will ensure that the throttle returns correctly idle In stall the throttle cable while pulling it in the direction of F2 with the throttle arm pressed by finger in the direction of F1 This is done to ensure the proper fully closed position of the throttle lever of the outboard At this time check that the cable groove fits in the cable C hub groove When c...

Page 439: ...n the C hub groove of the shift cable without applying any force to the cable and shift arm If a proper fit is not achieved change the position of the cable end piece After making any adjustment always check to make sure the cable end is screwed in at least 8mm 2 Secure the cable NOTE The cable ends at the motor may require fine adjustments later after rigging and testing 3 Adjust the shift cable ...

Page 440: ...ors or improper opera tion may result 2 Connect the matching connectors for the second station control switch panel and instruments 2 CONNECTING THE WIRING FOR THE LOWER STATION 1 Connect the matching connectors for the first station control switch panel and instruments 2 Connect the matching connectors between the dual station harness and the engine wire harnesses 3 CONNECT THE SHIFT ACTUATOR AND...

Page 441: ...not engage the forward or reverse gear perfectly The warning buzzer will sound after about four sec onds if the gear has not been engaged 1 Turn the main switch to ON and remove the engine stop switch lockplate from the stop switch 2 Operate the first station in the following sequence and observe operation 1 Shift 2 Shift to neutral 3 Shift to reverse 4 Shift to neutral 3 If incorrect operation is...

Page 442: ...er may turn if the cable length is out of the above specifications 2 Place the remote control lever on for ward and turn the main switch to start to check that the engine is not started Repeat the same check at reverse posi tion In case the engine is started check the neutral switch is the remote control box Do not use the outboard in case the engine is started at either the forward or reverse shi...

Page 443: ...t volt age by using the following procedure 1 Connect the throttle sensor adjusting lead special tool No YB 06443 in between the two sensors on the junc tion unit and the actuator 2 Turn the main switch to ON and check the voltage between the sensors according to the following specifications with the remote control lever at neutral forward and reverse positions If any of the voltage is out of spec...

Page 444: ...he second station 6 If the grooves are not offset either of the sensors may be defective Adjust the sensor position or replace the sensor if unadjustable If grooves are offset use the following steps to eliminate the offset 7 Remove cable clamp and pull out the shift cable 8 Loosen the rod nut on the cable and move the cable end so that the offset is eliminated NOTE At neutral the distance from th...

Page 445: ... and cable end are offset each other Repeat the check at the second station 11 If still offset repeat the above steps 4 to 10 until the offset is eliminated 12 Install the cable clamp move the remote control lever between forward and reverse positions at the first station several times and check that the volt age is within the specification 13 Install the clamp covers and the side cover 10A 28 ...

Page 446: ...e four screws securing the actuator cover and remove the cover 2 Move the emergency lever red fully in the direction indicated by the arrow 3 Move the adjusting pin and spacer of the shift sensor lever from hole M the standard location to hole L for longer travel Do not use the pin location S short travel This will result in travel less than standard and may result in improper or incomplete shifti...

Page 447: ...r side 7 Move the remote control lever from neutral to estimated forward and reverse positions to check that the out board shifts securely 8 In case the outboard will not shift with the adjusting pin and hole L the cable may be defective or the cable end play is excessive Replace the cable if it is defective 9 After confirming that the outboard shifts turn the main switch to OFF Install water prev...

Page 448: ... is observed make adjustments in the motor throttle cable end at the outboard motor 3 Operate the second station in the following sequence and observe operation 1 Shift to forward and move the lever to full throttle 2 Shift to neutral and check to see that the throttle returns to the idle position at the engine 3 Shift to reverse and open throttle part way 4 Shift to neutral and check to see that ...

Page 449: ... is available This bracket is not supplied with mounting hardware Use either the extra hardware supplied with the dual station system kit or contact a local sup plier for appropriate hardware for your specific installation Choose hardware that will hold the bracket securely to the boat without the chance of breaking loose Otherwise the junction unit or actuator could be damaged CAUTION 10A 32 ...

Page 450: ...3mm 0 118 in in diameter in the cabin floor referring illustration 3 Secure the mounting bracket to the cabin floor with screws 4 Secure the junction unit and actuator to the mounting bracket with hexagon headed bolts 2 Fastening the units using wood screws 1 Bore holes each 3mm 0 0118 in in diameter in the cabin floor using a tem plate 2 Tighten the wood screws 2 INSTALLING THE COVER Junction uni...

Page 451: ...After all the installation is completed check that the cables are properly connected as shown below 10A 34 ...

Page 452: ... a male bullet con nector 4 Connect the adapter wires as follows White wire to the white wire with the new buller connector White black wire to the CDI terminal that the white wire was removed from Red wire to the red wire terminal of the rectifier regulator Black wire to the black wire terminal of the CDI 5 Change the grommet for the black wire from a 1 hole to a 2 hole type 6 Clamp the adapter t...

Page 453: ...WIRING DIAGRAM FIRST STATION Single engine 10A 36 ...

Page 454: ...SECOND STATION Single engine 10A 37 ...

Page 455: ...10A 38 ...

Page 456: ...10A 39 ...

Page 457: ...Outboards 6X1 DUAL STATION SYSTEM SERVICE GUIDE 10B 1 ...

Page 458: ...m SERVICE GUIDE 1991 by Yamaha Motor CO LTD 1st Edition October 1991 All rights reserved Any reprinting or unauthorized use without the written permission of Yamaha Motor Co Ltd is expressly prohibited Printed in Japan 10B 2 ...

Page 459: ...ithout notice APPLICABLE MODELS The 6X1 Dual Station System is designed to be used with 1990 and later YAMAHA outboard motors with the following serial numbers and higher Engine Serial Numbers 115ETLD 385950 200ETLD 403500 115ETXD 721100 200ETXD 757400 130ETLD 302500 P200TLRP 300101 130ETXD 701450 L200ETXD 702750 L130ETXD 700550 225ETLD 350101 150ETLD 406000 225ETXD 750101 150ETXD 755500 250ETXD 7...

Page 460: ...10B 4 ...

Page 461: ...RTS INFORMATION 10B 21 EXTENSION WIRE HARNESS 10B 21 ADAPTER 10B 21 MOUNTING BRACKET 10B 21 TECHNICAL TIPS 10B 22 SHIFT MOTOR WILL NOT OPERATE 10B 22 1 Emergency manual shift system 10B 22 RIGGING INSTRUCTIONS 10B 24 ALL COMPONENTS IN ONE PACKAGE 10B 24 PREPARATION OF INSTALLATION 10B 25 1 Attaching the cable identification marks 10B 25 2 Arranging the remote control cables wire harnesses and stee...

Page 462: ...10B 6 Outboard Rigging Guide 2001 EXTERNAL VIEW OUTLINE OF FEATURES ...

Page 463: ...ontrol lever is transmitted to the junction unit mechanically through cable and then electrically to the servomotor which controls the shifting mechanism according to the lever movements The change of shift angle is converted to a voltage by the sensor in the junction unit Then the ser vomotor is actuated according to the voltage differences between the voltage and a voltage detect ed by the senso...

Page 464: ...er 1 moves the shaft of the rack 2 to disengage the rack from the motor side pinion and engage the rack with the pinion on the emergency manual shift lever 3 Then the outboard can be shifted by using the emergency manual shift lever 3 Turning the emergency lever 1 clockwise counterclockwise by approximately 5 12 shifts the out board motor forward revers NOTE The emergency manual shift lever 3 must...

Page 465: ...ETY INFORMA TION When installing the system in the outboard models not shown in the list the specific adapter must be used The adapter is available with extra charge For the installation of the shift cut system on the outboard not listed in the SAFETY INFORMATION and controlled with the 6X1 DUAL STATION SYSTEM INSTALLATION MANUAL consult your YAMAHA dealer Without the adapter use of the shift cut ...

Page 466: ... designed to min imize operating loads Due to the automatic interlock system if the throttle and shift control have been set at one station the settings cannot be altered at the other station In other words the throttle and shift control can be set at one station only if the throttle and shift levers at the other station are in neutral AUTOMATIC INTERLOCK SYSTEM ...

Page 467: ... start button two start buttons on the twin engine model one stop button two stop but tons on the twin engine model for engine con trol and one emergency stop switch An alarm buzzer on the rear of the switch panel sounds if the warning system is activated SECOND STATION SWITCH PANEL ...

Page 468: ...s can be moved NOTE No visual warning is provided The following are possible causes of the shift ing failure A wire disconnection in the power source of the actuator or the reduction of the actu ator operating voltage Failure of sensors on the actuator or in the junction unit or wire disconnection in those components Failure of actuator or its related compo nents NOTE As long as the battery is abl...

Page 469: ...hift yet use emergency lever and emergency manual shift lever to shift the outboard into neutral and then start the engine For operations of the emergency lever and emergency manual shift lever refer to page 10B 22 23 7 Run to the nearest port immediately and consult your YAMAHA dealer Do not cruise if the emergency lever and emergency manual shift lever have to be used The emergency means are des...

Page 470: ... the power failure or shift disengage ment failure has occurred on either of the two outboards perform the following steps 1 Turn the main switch for each outboard to OFF 2 Check battery terminal for looseness and disconnection on the warning outboard If the fuse has been burned out replace it referring to your outboard motor owner s manual 3 Check sensor wire terminal for looseness and disconnect...

Page 471: ...vice available port immediately The following are the possible causes of the shifting failure A wire disconnection in the power source of the actuator or reduction to the actuator operating voltage Failure of sensors on the actuator or in the junction unit or wire disconnection in those components Failure of actuator or its related compo nents 2 Shift engagement failure warning In case the outboar...

Page 472: ... lever have to be used The emergency means are designed exclusively for running to a service avail able port immediately Normally the shift motor is able to shift from neutral to forward or reverse with in 0 3 seconds from its actuation moment If the shift operation is performed while the engine is not running the dog clutch may not engage the forward or reverse gear perfectly causing the warning ...

Page 473: ...position and retry the shifting If the outboard shifts the cruising can be contin ued 2 In case it will not shift yet use emergency lever and emergency manual shift lever to shift the outboard run to the nearest port immediately and consult your YAMAHA dealer For operations of the emergency lever and emergency manual shift lever refer to page 10B 22 23 ...

Page 474: ... mode the warning system functions as follows 1 Monitoring of starting period Main switch ON NOTE If there is a problem the indicator corresponding to the problem does not light up and the buzzer does not sound 2 Stalled engine warning This warning is issued if an engine stalls or fails to start The warning ends once the engine is restarted ...

Page 475: ...ed off 4 Overheat warning Thermo switch ON NOTE In the case of a twin engine system the buzzers for both the starboard and port side engines sound when the shift lever is in either forward or reverse When the shift lever is placed in neutral the only buzzer that sounds is for the engine whose thermo switch is turned on The warning ends once the engine is sufficiently cooled ...

Page 476: ...e whose oil level is low The warning ends when engine oil is replenished Always turn off the main switch when replenishing engine oil 6 Stopping the engine at the second station Stop switch ON NOTE When stopping the engine from the second station press the stop switch for at least 1 second to completely stop the rotation of the engine If the stop switch is pressed only momentarily the stalled engi...

Page 477: ... INFORMATION EXTENSION WIRE HARNESS 1 3P Harness 2 10P Harness ADAPTER For installation of the adapter refer to page 10B 34 MOUNTING BRACKET P NO ABA DSBKT 00 00 For installation of the mounting bracket refer to DUAL STATION SYSTEM INSTALLATION MANUAL ...

Page 478: ...ne is running Do not attempt emergency manual shift override if you cannot perform shifting and steering operations well enough to react to hazards in your way An acci dent may result Do not cruise if the emergency lever and emergency manual shift lever have to be used The emergency means are designed exclusively for running to a service available port immediately 1 Emergency lever red 2 Emergency...

Page 479: ... Operating procedure at shift disengagement failure NOTE The engine is running and the outboard is in forward or reverse 1 Move the emergency lever 1 fully as indi cated by an arrow 2 Move the emergency manual shift lever 2 to neutral The outboard should shift into neutral 3 The emergency lever 1 fully against the arrow 4 When shifting forward or reverse again follow the steps in the operating pro...

Page 480: ...al station includes a 704 remote control box digital tachometer switch panel wire harness dual station unit and actuator These components which have been selected and purchased separately in the past are sup plied in a single package thereby offering the customer and the dealer greater convenience ...

Page 481: ...ON OF INSTALLATION 1 Attaching the cable identification marks Connect the cables in the following sequence as illustrated below NOTE Before connecting the cable be sure to move the shift levers on the remote control box and the engine to neutral ...

Page 482: ...10B 26 Outboard Rigging Guide 2001 2 Arranging the remote control cables wire harnesses and steering cables ...

Page 483: ... tape to keep it from being caught in the pipe 3 Pull the rope gently so that the wire har ness will not catch inside the pipe 4 Connect the bullet terminals as they were originally Remote control cable 1 Attach a cable end piece to the end of the cable NOTE The end piece should be screwed in at least 8mm 2 Pull the cable gently just as you did with the wire harness NOTE The cable should be bent a...

Page 484: ...are around the out board Propeller may turn if the cable length is out of the above specifications 2 Place the remote control lever on forward and turn the main switch to start to check that the engine is not started Repeat the same check at reverse posi tion In case the engine is started check the neutral switch is the neutral control box Do not use the outboard in case the engine is started at e...

Page 485: ...tions check the shift volt age by using the following procedure 1 Connect the throttle sensor adjusting lead special tool No YB 06443 in between the two sensors on the junction unit and the actuator 2 Turn the main switch to ON and check the voltage between the sensors according to the following specifications with the remote control lever at neutral forward and reverse positions If any of the vol...

Page 486: ... Repeat the check at the second station 6 If the grooves are not offset either of the sensors may be defective Adjust the sensor position or replace the sensor if unadjustable If grooves are offset use the following steps to eliminate the offset 7 Remove cable clamp and pull out the shift cable 8 Loosen the rod nut on the cable and move the cable end so that the offset is eliminat ed NOTE At neutr...

Page 487: ...n neutral Check if the grooves on the rack and cable end are offset each other 11 If still offset repeat the above steps 4 to 10 until the offset is eliminated 12 Install the cable clamp move the remote control lever between forward and reverse positions at the first station several times and check that the voltage is within the specification 13 Install the clamp covers and the side cover ...

Page 488: ... the actu ator cover and remove the cover 2 Move the emergency lever red fully in the direction indicated by the arrow 3 Move the adjusting pin and spacer of the shift sensor lever from the hole M the standard location to hole L for longer travel Do not use the pin location S short travel This will result in travel less than standard and may result in improper or incomplete shifting NOTE Shift str...

Page 489: ... shift cam at actuator side 7 Move the remote control lever from neutral to estimated forward and reverse positions to check that the outboard shifts securely 8 In case the outboard will not shift with the adjusting pin and hole L the cable may be defective or the cable end play is exces sive Replace the cable if it is defective 9 After confirming that the outboard shifts turn the main switch to O...

Page 490: ...ift cut system will not function if this wire is used 3 Cut the eye terminal from the end of the white and green wires and install two male bullet connectors 4 Connect the adapter wire as follows White wire to the white wire with the new bullet connector Green wire to the green wire the new bullet connector White black wire to the CDI terminal that the white wire was removed from Red wire to the r...

Page 491: ...op switch and the engine stop switch lanyard to stop the engine properly Ensure that all electrical connections are tight and will not vibrate loose during normal operation Otherwise the engine may not stop which could result in an accident SPECIAL SERVICE TOOL THROTTLE SENSOR ADJUSTING LEAD YB 06443 WARNING ...

Page 492: ... Yamaha dealer There is an automatic interlock which pre vents one control from being used while the other is in use The engine can be started from either sta tion as long as the key is on at the lower station There is no choke control on the upper station however if the engine requires manual choke control The engine can be stopped from either station by pushing the stop switch or by pulling the ...

Page 493: ... 1 Switch panel 6 Neutral switch Wire harness Sensor 2 Engine stop switch 7 P T T switch Digital tachometer Junction unit 3 Main switch 8 Buzzer Digital speedometer 4 Choke switch 9 Fuel sender Actuator 5 Remote control box Lamp switch option Control unit 10 11 12 13 14 15 16 17 ...

Page 494: ...8 Outboard Rigging Guide 2001 SECOND STATION Single engine 1 Switch panel 6 P T T switch 2 Stop switch 7 Neutral switch 3 Start switch 8 Buzzer 4 Engine stop switch 9 Digital tachometer 5 Remote control box ...

Page 495: ...10B 39 Outboard Rigging Guide 2001 ...

Page 496: ...10B 40 Outboard Rigging Guide 2001 ...

Page 497: ..._____________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ __________________________...

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