Page 3 2001 Outboard Rigging Guide ©2000 by Yamaha Motor Corporation, 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.
Page 4 Outboard Rigging Guide - 2001 Intro- Introduction, General Rigging Information, and Quick Start ..Quick Start Standard Equipment, Rigging Kits, & Crate Contents ....Engine Dimensions, Mounting, &...
Page 5: Table Of Contents
Outboard Rigging Guide - 2001 SECTION 1 - STANDARD EQUIPMENT, RIGGING KITS, AND CRATE CONTENTS 2000 Model Standard Equipment ........1-1 Propeller, Controls, Fuel Tank, &...
Page 6 Outboard Rigging Guide - 2001 Rectifier - 6 ~ 25HP ..........3-34 Voltage Regulator .
Page 7 Outboard Rigging Guide - 2001 Fuel Management System Gauge/GPS Hook Up ......5-30 Fuel Management Gauge Components ........5-31 Fuel Management Gauge Installation .
Page 8 Outboard Rigging Guide - 2001 25/30HP Remote Control Attachment Kit - 3 Cyl......7-23 6/8HP Electric Starter Conversion Kit ........7-26 Steering Hooks .
Page 10 This introduction should usually rigging instructions. For information about rig- give the rigger information needed to deter- ging earlier Yamaha outboards, refer to the prop- mine which parts should be used. er Outboard Rigging Guide or Data edition for the particular year you are rigging.
Page 11 STANDARD ABBREVIATIONS AND SYMBOLS Color Codes The following color code chart would help you with the standard abbreviations. Listed is the Yamaha color codes and their purpose. Also included is the ABYC color code. Which is common to boat wiring systems.
Page 12 Outboard Rigging Guide - 2001 Standard Abbreviations and Symbols Color Codes (Cont’d.) YAMAHA COLOR ABYC COLOR ABBREVIATION ABBREVIATION YAMAHA USE ABYC USE G/R = Green/Red Red oil warning light ground through SW3 in main tank oil sensor to tachometer G/W = Green/White...
Page 13 Outboard Rigging Guide - 2001 Standard Abbreviations and Symbols Measurement Other Symbols In most cases, measurements are given in both The symbol “~” is used to indicate either one fig- metric and US Customary System (feet and inch- ure through another or “and following.” For es).
Page 14 Outboard Rigging Guide - 2001 MECHANIC’S METRIC CONVERTER CONVERSION FACTOR FORMULA LENGTH-DISTANCE 1mm = 0.0394 inch mm x 0.0394 = inches 1 inch = 25.4mm inches x 25.4 = mm 1km = 0.06214 miles km x 0.6214 = miles 1 mile = 1.6093 km mile x 1.6093 = km SPEED 1 km/hr = 0.6214 mph...
Page 15 Outboard Rigging Guide - 2001 1984 AND LATER OUTBOARD MODEL CODE LETTERS 1984 to 2001 The model code designator was standardized in 1991 to the following procedure for all models: 1 5 0 Special Model Variation Code (Used on Prop Shaft 25HP Model Description Horsepower...
Page 16 Located on starboard clamp bracket. PRIMARY I.D.: MODEL NAME YAMAHA S X 2 0 0 T L R Z 0 0 1 7 8 6 YAMAHA MOTOR CO., LTD MADE IN JAPAN PAYS D'ORIGINE JAPON MODEL PREFIX: 6G6 SHAFT LENGTH: L SERIAL NUMBER: 001786 NOTE: Primary ID consists of the model prefix, shaft length, and serial number.
Page 17 Outboard Rigging Guide - 2001 GENERAL RIGGING INFORMATION Fuel Line Routing and Installation ENGINE FLOW Fuel System Check 1. Ensure there is an anti-syphon valve or man- ual shut-off valve located on the fuel tank pickup tube. FUEL FLOW SENSOR LOCATION PRIMER BULB FILTER FLOW SENSOR...
Page 18 Outboard Rigging Guide - 2001 General Rigging Information 5. Run the fuel line to the engine via rigging V4 Rigging Tube Grommet 1 Throttle Cable tube and grommet. Make sure throughout the 2 Shift Cable route the fuel line is not crushed or pinched, 3 Main Harness which could...
Page 19 Control Cable Installation Remote Control Cables 1. Choose a mounting location for the control Yamaha remote control cables are available in lengths from 6 feet to 36 feet. The cables utilize head which will provide comfortable opera- 10-32 threaded ends.
Page 20 F9.9, 25, & 30 pull the throttle cable to open. NOTE: Twin engines using the 704 control box Yamaha outboards T8, 9.9, 15, 40~C40 and larg- must have the throttle cables synchronized. This er push the throttle cable to open. Shift cable con- is to ensure the engines are running the same trol is the same for all outboards.
Page 21 On twins only with the dual key switch panel, the alarms will self- check for three beeps. LEAD RESETTING IDENTIFICATION The Yamaha Digital Tachometer incorporates a double 2-way toggle dip-switch. REAR The left-hand switch is for the Trim Sender SWITCH SETTINGS Signal.
Page 22 2-Stroke Engines 1. Turn the key to the ON position and test the Premix Fuel: Yamaha recommends the use of oil warning system on the multifunction Yamalube. If it is not available, use a TCW 3 rated tachometer (see illustration following).
Page 23 2-stroke precision blend 4-Stroke Engines Filling Oil: NOTE: All 4-stroke engines are shipped with- out oil in the engine. Yamaha recommends the use of Yamalube™ 4M, 10W-30, 10W-40, SAE: SE, SF, SG, or SH. engines is a very important step. Consult service Perform the following steps when adding oil to manual or 1999 Marine Tech Guide page 3-27.
Page 24 2. Look for loose or damaged fasteners. NOTE: Yamaha recommends to prop the engine 3. Check the propeller for damage. to the high end of the RPM range for the cus- tomer’s normal load. In some cases, if a customer 4.
Page 25 Outboard Rigging Guide - 2001 General Rigging Information Fuel Pump/Fuel System Testing Results: When a fuel starvation problem is suspected (e.g., High Vacuum - Move the “T” fitting to the fuel engine hesitation or engine stopping), perform the filter outlet (2) and retest. Continue to the fuel fil- following fuel system test: ter inlet (3) and along the remaining fuel filter system until a large drop in vacuum locates the...
Page 26 Outboard Rigging Guide - 2001 General Rigging Information EFI FUEL RAIL GAUGE VACUUM GAUGE FUEL VACUUM TEST FUEL VACUUM FLOW xvii...
Page 27 NOTE: There is nothing more frustrating to a customer than to have problems with a new boat and engine. If the customer experiences problems on delivery, they feel they have received an inferior product. Also, the customer’s confidence level in Yamaha is greatly diminished. OUTBOARDSmmmmmmmmmm...
Page 28 Precision Blend mally. Use straight gasoline (petrol) in the fuel System. tank. For oil injected engines, Yamaha • Precision Blend Engines Only Precision Blend System provides proper lubri- After engine break-in, use gasoline (petrol) cation for normal operation.
Page 29 Yamaha outboards. The section is arranged by small engines, mid-sized engines, single engine V4 &...
Page 30 Hour Meter - digital 6Y5-83504-11-00 NOTE Only water temperature or water pressure on 90HP and smaller, not both. Both gauges can be used on V4, & V6. *Alarm sensor needed to activate water in gas signal when using Yamaha’s Multifunction Fuel Management Gauge.
Page 31 Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 2~30 ft. and in 2 ft. increments from 32~50 ft. ** This control box can be converted from push to open throttle to pull to open throttle.
Page 32 64D-82553-90-00 NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order additional length trim harnesses to connect to the standard harness (two trim harnesses will extend one 64D harness).
Page 33 6YR-W0035-C0-00 NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order additional length trim harnesses to connect to the standard harness (two trim harnesses will extend one 64D harness).
Page 34 6YR-W0035-C0-00 NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order two 6R3-82553-30-00 harnesses to extend 9.8 ft.
Page 36: Standard Equipment, Rigging Kits, And Crate Contents
Outboard Rigging Guide - 2001 SECTION 1 - STANDARD EQUIPMENT, RIGGING KITS, AND CRATE CONTENTS 2001 Model Standard Equipment ........1-1 Propeller, Controls, Fuel Tank, &...
Page 38 Below, is a list of the basic standard equip- help you get the right rigging equipment for your ment as of the publication date of this book. particular installations. The Yamaha Sales Additional standard equipment will depend upon Department is proud to continue the Kitting the kits you order.
Page 39: Propeller, Controls, Fuel Tank & Rigging Items Shipping Location
Outboard Rigging Guide - 2001 PROPELLER, CONTROLS, FUEL TANK & RIGGING ITEMS SHIPPING LOCATION MODEL STARTING RIGGING MODEL CODE PROPELLER CONTROL FUEL TANK ITEMS 2MSHZ 6A1S 193528 CRATE (7-1/4 x 4) 3MSHZ 6L5S 081842 CRATE (7-1/2 x 7) F4MLHZ 67DL 306528 CRATE (7-1/2 x 8) F4MSHZ...
Page 40 Outboard Rigging Guide - 2001 Propeller, Controls, Fuel Tank & Rigging Items Shipping Location Propeller, Controls, Fuel Tank & Rigging Items Shipping Location (Cont’d.) MODEL STARTING RIGGING MODEL CODE PROPELLER CONTROL FUEL TANK ITEMS F25MSHZ 65WS 151486 CRATE (9-7/8 x 10-1/2) SEPARATE T25TLRZ 65WL...
Page 41 L KIT Left Hand Rigging Kit. ORDER FROM PARTS Item is not standard equipment. Order from Yamaha Parts and Accessories. NOTE: All models that use a rigging kit still have some basic rigging items, such as mounting bolts and a steer-...
Page 42: Rigging Kits
Outboard Rigging Guide - 2001 RIGGING KITS For model year 2001, the rigging kits have not changed. 40hp~250hp 4-Stroke and 2-Stroke still use the same rigging kits. 2-Stroke 115hp and up have the option of a 2.8-gallon or 5.0-gallon remote oil tank. You need to specify which oil tank when ordering.
Page 43 Outboard Rigging Guide - 2001 Rigging Kits Dual Engine Counter Rotation Kit or Left Hand Engine Rigging Kit (6YR-W0035-67-00) For use with 2-Stroke/4-Stroke Engines Part Number Part Name Qty. 6Y5-83553-00-00 Gauge, Harness 1 Fuse 6Y5-82117-00-00 Wire, Lead 6R3-83621-00-00 Mark, 1 64D-82553-90-00 Trim/Oil, Harness 31.2 ft.
Page 44 Outboard Rigging Guide - 2001 Rigging Kits 5.0 Gallon Oil Tank (6YR-W0035-C0-00) 2-Stroke Oil Injected Engines Part Number Part Name Qty. 61A-21708-10-00 Oil Tank Sub Ass’y 61A-13437-40-00 Mark, Caution 90465-13M11-00 Clamp 6E5-2170A-01-00 Bracket, Sub. Complete 6Y2-24307-40-00 Fuel Pipe Complete 90450-10M07-00 Hose Clamp Ass’y TILLER HANDLE KITS Tiller Handle Kit for 40/C40/50/C50 (63D-W0086-Z0-4D)
Page 45 Outboard Rigging Guide - 2001 Rigging Kits Tiller Handle Kit for F30/F40 3 Cylinder (67C-W0086-Z1-4D) Steering Friction Ass’y. Part Number Part Name Qty. • 92990-06100-00 • Washer Tiller Kit Handle Ass’y. • 90109-06M88-00 • Bolt Tiller Handle Install. Manual • 67C-42527-00-00 • Plate, Friction 6F5-82540-00-00 Neutral Switch Ass’y.
Page 46 Outboard Rigging Guide - 2001 Rigging Kits Tiller Handle Kit for 60/C60/C70/70 (6H3-W0086-Z0-4D) Part Number Part Name Qty. • 92990-08600-00 • Plate Washer • 663-42528-00-00 • Piece, Friction Tiller Kit Handle Ass’y • 90175-06003-00 • Nut, Wing Tiller Handle Install. Manual •...
Page 47 Outboard Rigging Guide - 2001 Rigging Kits Tiller Handle Kit for F80/F100 (67G-W0086-Z1-4D) Part Number Part Name Qty. Steering Friction Ass’y • 6E5-42518-01-00 • Shaft, Friction Tiller Kit Handle Ass’y • 92990-08600-00 • Plate Washer Tiller Handle Install. Manual • 67G-42528-00-00 • Piece, Friction 6H2-82586-01-00 Wire Harness Extension •...
Page 48 Outboard Rigging Guide - 2001 2001 MODEL OUTBOARD MOTOR CRATE CONTENTS Because the factory does not include a packing list in outboard motor shipping cartons, the following lists are published. Listed are all items inside each crate or carton. 2MSHZ T8PLRZ/PXRZ Part Number Description...
Page 49 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents F9.9ELRZ T9.9ELRZ/EXRZ Part Number Description Part Number Description LIT-18626-04-26 Owner's Manual LIT-18626-04-26 Owner's Manual 90580-50M01-00 Emergency Starter Ass'y 90580-50M01-00 Emergency Starter Ass’y 6Y1-24306-51-00 Fuel Pipe Complete 6Y1-24306-51-00 Fuel Pipe Complete 91490-30025-00 Split Pin 91490-30025-00...
Page 50 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents 25MSHZ/MSHZ3/MLHZ F15PLRZ Part Number Description Part Number Description LIT-18626-04-27 Owner's Manual LIT-18626-04-13 Owner's Manual 6G8-15780-00-00 Emergency Starter Ass'y 6Ll5-2818N-30-00 Caution Tag 6R6-2818N-30-00 Caution Tag 6Y1-24306-53-00 Fuel Pipe Complete 6H3-48538-00-00 Cable Clamp 90580-50M01-00 Emergency Starter Ass'y...
Page 51 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents T25TLRZ F25TLRZ Part Number Description Part Number Description LIT-18626-04-28 Owner's Manual LIT-18626-04-28 Owner's Manual 677-15780-00-00 Emergency Starter Ass'y 90580-50M01-00 Emergency Starter Ass'y 6Y1-24306-53-00 Fuel Pipe Complete 6Y1-24306-51-00 Fuel Pipe Complete 663-48344-00-00 Cable End (Remote Control) 90201-10M20-00...
Page 52 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents 30ELRZ 40TLRZ Part Number Description Part Number Description LIT-18626-04/13 Owner's Manual LIT-18626-04-14 Owner's Manual 6G5-2818N-31-00 Caution Tag 6G5-2818N-31-00 Caution Tag 6Y1-24306-51-00 Fuel Pipe Complete 90580-50M01-00 Emergency Starter Ass'y 90101-10M58-00 Bolt 6Y1-24306-51-00 Fuel Pipe Complete...
Page 53 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents F40TLRZ 50TLRZ Part Number Description Part Number Description LIT-18626-04-29 Owner's Manual LIT-18626-04-14 Owner's Manual 90580-50M01-00 Emergency Starter Ass'y 677-15780-00-00 Emergency Starter Ass'y 6Y1-24306-51-00 Fuel Pipe Complete 6G5-2818N-31-00 Tag Caution 90101-12M65-00 Bolt 6Y1-24306-53-00...
Page 54 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents T50TLRZ 60TLRZ Part Number Description Part Number Description LIT-18626-04-30 Owner's Manual LIT-18626-04-14 Owner's Manual 64J-1819K-90-00 Set-Up Manual 677-15780-00-00 Emergency Starter Ass’y 64J-2819K-90-00 Splash Plate Install. Manual 6G5-2818N-31-00 Caution Tag 90580-50M01-00 Emergency Starter Ass'y 6Y1-24306-53-00...
Page 55 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents 90TLRZ C60TLRZ, C70TLRZ, C90TLRZ Part Number Description Part Number Description LIT-18626-04-34 Owner's Manual LIT-18626-04-34 Owner's Manual 6G5-2818N-31-00 Caution Tag 6R6-2818N-30-00 Caution Tag 90580-50M01-00 Emergency Starter Ass'y 689-2818N-30-00 Caution Tag 6Y1-24306-51-00 Fuel Pipe Complete 90580-50M01-00...
Page 56 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents 150TXRZ 115TLRZ/TXRZ, 130TLRZ/TXRZ Part Number Description Part Number Description LIT-18626-04-16 Owner's Manual LIT-18626-04-16 Owner's Manual 6G5-2818N-31-00 Caution Tag 6G5-2818N-31-00 Caution Tag 61A-28107-15-00 Rigging Instructions 61A-28107-15-00 Rigging Instructions 90580-50M01-00 Emergency Starter Ass'y 90580-50M01-00 Emergency Starter Ass'y 6E5-43145-01-00...
Page 57 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents DX150TLRZ SX150TLRZ/TXRZ Part Number Description Part Number Description LIT-18626-04-19 Owner's Manual LIT-18626-04-21 Owner's Manual 6G5-2818N-31-00 Caution Tag 6G5-2818N-31-00 Caution Tag 90580-50M01-00 Emergency Starter Ass'y 61A-28107-15-00 Rigging Instructions 61A-28107-15-00 Rigging Instructions 90580-50M01-00 Emergency Starter Ass'y 6E5-61351-01-00...
Page 58 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents V150TLRZ VX150TLRZ Part Number Description Part Number Description LIT-18626-04-16 Owner's Manual LIT-18626-04-17 Owner's Manual 6G5-2818N-31-00 Caution Tag 6G5-2818N-31-00 Caution Tag 61A-28107-15-00 Rigging Instructions 61A-28107-15-00 Rigging Instructions 90580-50M01-00 Emergency Starter Ass'y 90580-50M01-00 Emergency Starter Ass'y 6E5-43145-01-00...
Page 59 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents Z175TXRZ VX200TLRZ, VX225TLRZ Part Number Description Part Number Description LIT-18626-04-22 Owner's Manual LIT-18626-04-20 Owner's Manual 677-15780-00-00 Emergency Starter Ass’y 6Gl5-2818N-31-00 Caution Tag 61A-28107-15-00 Rigging Instructions 68F-42753-00-00 Fastener 90601-20022-00 Nylon Clip 90580-50M01-00 Emergency Starter Ass'y 90101-12M05-00...
Page 60 Outboard Rigging Guide - 2001 2001 Model Outboard Motor Crate Contents SX225TXRZ/TURZ SX250TXRZ/TURZ Part Number Description Part Number Description LIT-18626-04-23 Owner's Manual LIT-18626-04-23 Owner's Manual 6G5-2818N-31-00 Caution Tag 6G5-2818N-31-00 Caution Tag 90580-50M01-00 Emergency Starter Ass'y 61B-28107-15-00 Rigging Instructions 61B-28107-15-00 Rigging Instructions 90580-50M01-00 Emergency Starter Ass'y 90101-12M05-00...
Page 62 Outboard Rigging Guide - 2001 SECTION 2 - ENGINE DIMENSIONS, MOUNTING, & MOUNTING EQUIPMENT Engine Mounting Dimensions (Transom Only) ......2-1 Transom Mounting Patterns .
Page 64: Engine Mounting Dimensions (Transom Only)
Outboard Rigging Guide - 2001 Engine Mounting Dimensions ENGINE MOUNTING DIMENSIONS = Maximum rearward protrusion of power head from transom (TRANSOM ONLY) = Protrusion into boat (remote models) Proper mounting of the outboard will mean better = Maximum rearward protrusion of lower performance, maximum reliability, and maximum unit from transom (@ level trim) customer satisfaction.
Page 65 Outboard Rigging Guide - 2001 Engine Mounting Dimensions...
Page 66 Outboard Rigging Guide - 2001 Engine Mounting Dimensions Transom Dimensions MODEL 360° 73° 275mm 276mm 417mm 23~60mm 143.7mm 503mm 10.8in 16.4in 3.5in 0.9~2.4in 5.7in 16.8in 360° 76° 311mm S: 435mm (17.4in) 105mm 22~60mm 136mm S: 621mm (24.5in) 12.2in 4.1in 0.9~2.4in 5.4in 360°...
Page 67 Outboard Rigging Guide - 2001 Engine Mounting Dimensions...
Page 68 Outboard Rigging Guide - 2001 Engine Mounting Dimensions Transom Dimensions MODEL 614mm 302mm 397mm 331mm 276mm 122mm 164mm 100mm 24.2in 11.9in 15.6in 13.0in 10.9in 4.8in 6.5in 3.9in S:654mm (25.7in) 343mm 419mm 317mm 311mm 107mm 223mm 103mm 13.7in 16.5in 12.5in 12.2in 4.2in 8.8in 4.1in...
Page 69: Transom Mounting Patterns
Outboard Rigging Guide - 2001 Transom Mounting Patterns TRANSOM MOUNTING PATTERNS F9.9/T9.9 9.9HP & 15HP...
Page 70 Outboard Rigging Guide - 2001 Transom Mounting Patterns CENTERLINE TOP OF TRANSOM 18.5mm (.46 in) 254mm (10 in) 55.5mm (2.2 in) 125.9mm 125.9mm (4.54 in) (4.54 in)
Page 71 Outboard Rigging Guide - 2001 Transom Mounting Patterns 25HP (2-Cylinder)
Page 72 Outboard Rigging Guide - 2001 Transom Mounting Patterns 25X3 (3-Cyl.) 30HP, 40HP (Manual Tilt)
Page 73: Transom Drill Fixture
Outboard Rigging Guide - 2001 Transom Mounting Patterns T25~250 including 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.
Page 74: Four Stroke Splash Guards 40~F100 Splash Plates
Outboard Rigging Guide - 2001 Four Stroke Splash Guards 40~F100 Splash Plates FOUR STROKE SPLASH GUARDS F80/F100 Engine Spray Guard 40~50, F40~F100 Splash Plates (Spray Guards) Mounting (Optional on 40T, 50HP, F50, F80, & F100) The 1996 ~ newer T50 comes with an engine splash plate mounted on the lower motor mount.
Page 75: Jet Drive Model Identification And Serial Numbers
For easy reference, please record these Gross weights shown include the motor, hull, numbers on the inside front cover of your Yamaha fuel, passengers, and all gear. For a given horse- power, loading beyond the listed limits will obvi- ously give reduced performance.
Page 76: Jet Drive Engine Mounting, Maintenance, Shift Cable Instruction, Service Info
This height setting Mounting Height will never need to be changed, regardless of the load being carried. Your Yamaha Jet Drive must be mounted 6" to 7" higher on the transom than propeller- driven outboards; therefore, optimum mount- CAUTION: ing for 15"...
Page 77 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 3. Make two diagonal braces from 1/2" electri- cal conduit. Flatten each end in a vise, and ANTI-CAVITATION PLATES drill 1/4" holes in them. Determine the posi- tion and angle of the forward bend.
Page 78 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. Operating Instructions WARNING If you attempt a too tight of a turn at too high Shifting a speed, your boat could spin out or even roll over.
Page 79 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. obstacles or sharp rocks, you may damage the Mooring boat and motor. If you tie your boat up at a sandy beach, where the action of waves causes the boat to rise and fall, be If you do run aground, shut the motor off imme- sure to tip the motor up, out or the water.
Page 80 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. Maintenance, Lubrication, and Storage similar to that on a propeller drive. After replacing the key, draw the shaft nut up tight (17 ft-lb.) to General remove any play between the impeller and shaft.
Page 81 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. Location of Main Components JET DRIVE CASING 2-18...
Page 82 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 40 and 50 Models GREASE SPLINES GREASE LIGHTLY GREASE IMPELLER SLEEVE & KEY '95 & LATER '95 & LATER NOT USED ON PRE 95 40MJH NOT USED ON PRE 95 40MJH 81 82...
Page 83 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 40 and 50 Models (Cont’d.) NO. DESCRIPTION QTY. NO. DESCRIPTION QTY. Jet Drive Assembly Bearing and Seal Housing Main Housing Machine Screw, Housing 10-24 x 5/8" Reverse Gate Lock Washer #10 Pivot Pin, Reverse Gate...
Page 84 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 90, V4, and V6 Models GREASE SPLINES GREASE LIGHTLY GREASE IMPELLER SLEEVE & KEY 81 82 86 5 '97 AND LATER SERIAL NUMBER 59500 & UP *Grease all threads 2-21...
Page 85 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 90, V4 & V6 Models (Cont’d.) NO. DESCRIPTION QTY. NO. DESCRIPTION QTY. Jet Drive Assembly Locknut Main Housing Seal, Shaft Outer Reverse Gate Retaining Ring, Inner and Outer Seal Pivot Pin, Reverse Gate Seal, Shaft Inner Nylon Sleeve, Reverse Gate Pivot Pin...
Page 86 10. Lightly grease the rubber water pump NOTE: Using Yamaha Marine Grease or NLGI impeller and fit it on the shaft (note the No. 1-rated grease, grease all bolt threads, and use lockwashers on all bolts except where noted oth- impeller can be fitted only one way).
Page 87 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 19. Prior to main impeller installation, grease the 22. Install the intake assembly. Make sure the shaft threads, special key, and impeller bore. lowest part of the grille is positioned at the Place the split plastic sleeve inside the rear.
Page 88 Outboard Rigging Guide - 200128 Jet Drive Eng. Mtg., Maintenance, ‘95 and Later NO PART NO. DESCRIPTION QTY. 63D-J0001-38-20 Shift Cable Assembly A 63D-JD005-47-00 Cable 4 ft B 6H4-JD005-43-00 Clamp, Cable C 6H4-JD005-61-00 Bolt, Cable Clamp D 63D-JD005-58-02 Screw, Hex Head E 6H4-JD006-19-00 Nut, Fiberlock F 62D-JD005-53-02 Ball Rod End G 63D-JD006-21-01 Nut, Hex...
Page 89 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 40MJH ('95 and Later) DRILL TEMPLATE Shift Handle Installation and Adjustment The manual model no longer uses the con- trol rod. The shift handle on the tiller arm has a cable mounted to it to operate the shift gate.
Page 90 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. Adjustments CLEARANCE GAUGES-FULL SIZE Shift Cam Assembly CUT OUT AND USE TO SET ECCENTRIC FOR NEUTRAL POSITION. with Neutral Adjustment A shift mechanism has been incorporated that #1173 LARGE SERIES includes an adjustable shift cam.
Page 91 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. Trim dents. This will reduce drag and air entrap- ment. On some applications, your boat may tend to pull to starboard. This condition can easily be correct- 5.
Page 92 If you have trouble locating these impellers Overhaul Procedures on the market, contact your dealer. NOTE: It is recommended that these procedures be performed by only your authorized Yamaha Some calls have been received regarding dif- Outboard Motor Dealer. ficulty removing the impeller. The impeller doesn't corrode with the shaft because there is a delrin sleeve separating them.
Page 93 Press against Support the bearings and driveshaft, using the thrust ring, locking it in its groove. See Yamaha special tool #YB-06205-2. Heat the the illustrations on the next page. housing slightly again. It is important to slide the housing on squarely, and do not 5.
Page 94 Outboard Rigging Guide - 2001 Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info. 40MJH/EJR and 50EJR Models Liner Replacement NOTE: On pumps produced beginning in 1997, the liner is held in place by a 1/8"-thick flange instead of bolts. 1.
Page 95: Dual Engine Tie Bar Kit Installation
Outboard Rigging Guide - 2001 Dual Engine Tie Bar Kit Installation DUAL ENGINE TIE BAR KIT INSTALLATION Please read and understand these instructions completely before installation to avoid any possi- ble injury to yourself or damage to the outboard or the accessory.
Page 96 (preferably) wooden pads engine as shown in illustration. (to prevent damaging threads) as shown. 2. Lightly grease the bushing with Yamaha 6. Install the jam nut on the tie rod. Marine Grease. 7. Grease the threads on the end of the tie rod Be sure swivel clevis is pointing upward.
Page 97 19. Cut the tie bar at the marked length. Then, de- burr the threads of the rod with a die and thread file. Grease the threads with Yamaha Marine Grease. 20. Align the rod as before, and cut the black vinyl tube to the proper length to fit between the rod terminals.
Page 98 Outboard Rigging Guide - 2001 Dual Engine Tie Bar Kit Installation 22. Detach the port rod terminal and thread it on the tie rod to the proper toe-out position. NOTE: The end of the rod should be between the two holes on the rod terminal. Adjustments can be made to insure proper toe-out position.
Page 99: Dual Cable Steering Bracket Kit Installation
(rearmost) bolt hole and accessory. torque to specification. Be sure to use the Kit Includes: lock nut as shown in the Yamaha Rigging Steering Cable Mounting Bracket Specs. (See Illus. 2 below) (See pg 7-26~7- Steering Cable Support Tube 27 for assembly instructions.)
Page 100 Turn the steering Yamaha Marine Grease. Install steering cable wheel to extend cables to their full length, No. 1 into engine tilt tube and tighten the then back off 1/4 turn.
Page 101 Outboard Rigging Guide - 2001 Dual Cable Steering Bracket Kit 5. Carefully spread both cables to allow instal- Cable Adjustment lation of the cable connector but do not tight- en. (See Illus. 8) Center motor. 2. Loosen the support tube holding nuts (both ILLUSTRATION 8 STEERING LINK ROD ends) approximately 10 turns.
Page 102: Morse Universal Dual Cable Steering Bracket Kit Installation
Outboard Rigging Guide - 2001 Morse Universal Dual Cable Steering Bracket Kit Installation MORSE UNIVERSAL DUAL CABLE STEERING BRACKET KIT INSTALLATION (ABA-42110-00-00) Please completely read and understand these Steering Arm Installation installation instructions (prior to installation) to avoid damage to the outboard motor, boat or 1.
Page 103 100in-lbs. (See Illus. 5) 3. Slip the large support tube nut and locking tab washer over cable Number 2. Apply a coat of Yamaha Marine Grease to the cable end. Insert the cable through the mounting bracket holes without the support tube installed.
Page 104 Outboard Rigging Guide - 2001 Morse Universal Dual Cable Steering Bracket Kit Installation 5. Carefully spread both cables to allow instal- Cable Adjustment lation of the cable connector, but do not tight- en at this time. (See Illus. 8) 1. Center the motor. 2.
Page 105: V4 & V6 Rigging Tube Grommet
Gray Hose 100’ prior to installing the retainer, then tighten the 2 retaining screws and removed any excess For model year 2001, Yamaha has expanded the sealant. Note: Both the stainless angle model line-up that come standard with the rigging...
Page 106 Outboard Rigging Guide - 2001 V4 & V6 Rigging Tube Grommet 150~250, 3.1L, 2.6L, HPDI, OX66 V4 Rigging Tube Grommet 1 Throttle Cable Rigging Tube Grommet 2 Shift Cable 3 Main Harness 1 Shift Cable 4 Oil Warning Lead 2 Throttle Cable 5 Remote Oil Tank Lead 6 Trim Gauge Lead 3 10 Pin Main Harness...
Page 107: F9.9 Exhaust Well Kit Installation
Outboard Rigging Guide - 2001 F9.9 Exhaust Well Kit Installation F9.9 EXHAUST WELL KIT INSTALLATION NOTE: (6G8-W4537-00-00) Tighten the bolts completely. b. After mounting the outboard motor on the When mounting the F9.9 on a boat, the type of the boat, bolt the clamp bracket to the boat.
Page 108 7. Bring the idling exhaust gas exhaust pipe out of the boat. (Illus #7) ILLUSTRATION 5 ILLUSTRATION 7 YAMAHA 6. Bring the blow-by gas exhaust pipe out of the boat. (Illus. #6) NOTE: Secure the hose to the hull so it does not ILLUSTRATION 6 move.
Page 110 Outboard Rigging Guide - 2001 SECTION 3 - ELECTRICAL Wire Harnesses ........... . . 3-1 Switch Panel Assemblies .
Page 112: Wire Harnesses
Outboard Rigging Guide - 2001 WIRE HARNESSES F25T 2-Stroke F80/100 115~ F115 C40T L130 REF. F9.9 FT50 NO. DESCRIPTION PART NUMBER T9.9 F25E F40T C115 L250 Primary Engine Needed With Harness For Use Switch Panel With Switch Panel 7 pin 688-82586-50-00 2-1 10 Pin 5m 688-8258A-50-00...
Page 113 Outboard Rigging Guide - 2001 Wire Harnesses WIRE HARNESSES (Cont’d.) F25T 2-Stroke F80/100 115~ F115 C40T L130 REF. F9.9 FT50 NO. DESCRIPTION PART NUMBER T9.9 F25E F40T C115 L250 Control Box Adapters Aftermarket Harness 704-85721-00-00 To 704/705 Box Aftermarket Control 704-82541-10-00 To Main Harness Instrument Panel...
Page 114 Outboard Rigging Guide - 2001 Wire Harnesses Primary Engine Harness 3-2. Main Harness 10-Pin, 9.9M For Use W/Switch Panel 61B-8258A-00-00 (9.9M, 31.2ft) 1. 7-Pin Main Harness 688-82586-50-00 (5M, 16.4ft) 4. 7 to 10-Pin Adapter 703-8258A-00-00 2-1. Main Harness 10-Pin, 5M 688-8258A-50-00 (5M, 16.4ft) 2-2.
Page 115 Outboard Rigging Guide - 2001 Wire Harnesses Primary TANK HARNESSES Engine Harness Extensions 8-1. Oil Tank Lead, 3M 6. 7-Pin, 2M Extension (main harness) 6R3-85721-30-00 (3M, 9.8ft) 688-82586-11-00 (2M, 6.6ft) 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) 7-1.
Page 116 Outboard Rigging Guide - 2001 Wire Harnesses Special Harnesses 14. Oil Light Harness - F/T9.9M 6G8-82541-00-00 (2.5M, 8.2ft) 10. Tachometer Harness (no remote) 6Y5-83553-10-00 (5M, 16.4ft) 15. V6 Battery Cable 64D-82105-00-00 (3.2M, 10.6ft) 11. Rectifier to Battery - T9.9M 6G8-81949-00-00 (2.8M, 9.3ft) Control Box Adapters 12.
Page 117 Outboard Rigging Guide - 2001 Wire Harnesses Gauge Harness (one fuse) Extensions 6Y5-83553-00-00 (all except V4/V6) 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.
Page 118 Outboard Rigging Guide - 2001 Wire Harnesses PT & T Switch Lead Extension F.M. Meter to Tach. 6H5-82553-00-00 (2M, 6.6ft) 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. Fuel Management 24-1.
Page 119: Switch Panel Assemblies
40~90HP, LF115 or C40T~C90 models. The remote control except the 703 standard side overheat and low oil warning system on these mount control box. Yamaha makes available panels are not compatible with these models. single panels that vary in function and model application.
Page 120 Outboard Rigging Guide - 2001 Switch Panels SWITCH PANELS 2-Stroke LF115 40T~90 L130 F9.9 F25E T25~T50 Description Part Number T9.9 F25T~F115 L250 Switch Panel Needed With W/Push To Binnacle Or Flush Choke Control Single 704-82570-06-00 Twin 6K1-82570-05-00 Single No Horn 689-82570-18-00 Main Sw Only 64D-82570-02-00...
Page 121 Outboard Rigging Guide - 2001 Switch Panels Switch Panel Wiring Mounting Instructions For wiring information and diagrams, refer to the Boat Wiring Diagrams section of the Electrical Mounting Chapter elsewhere in this manual. 1. Select a mounting location so that the switch panel assembly is in easy reach from the helm.
Page 122 Outboard Rigging Guide - 2001 Switch Panels Single Switch Panel Assembly 689-82570-18-00 (1998~: 9.9E ~ 30HP) Single panel with push-to-choke ignition switch and lanyard. 704-82570-06-00 C40T~C60, 9.9~250HP Single panel with push-to-choke ignition switch, lanyard, and warning horn. NO PART NUMBER DESCRIPTION QTY.
Page 123 Outboard Rigging Guide - 2001 Switch Panels SINGLE SWITCH PANEL ASSEMBLY DRILL TEMPLATE (Actual Size) 8.5 mm (.33 in) 2x 51 mm (2.02 in) CUT OUT THE SHADED PORTION 22.5 mm 8.5 mm (.33 in) (1.01 in ) 51 mm (2.0 in) 68 mm (2.67 in) 3-12...
Page 124 Outboard Rigging Guide - 2001 Switch Panels 6K1-82570-05-00 (1998~: L130) Dual panel with push-to-choke ignition switches, common lanyard, and warning horn. NO PART NUMBER DESCRIPTION QTY. 6K1-82570-05-00 Panel Switch Ass’y 6K1-82571-01-00 • Panel, Switch 6K1-82510-04-00 • Main Switch Ass’y 6K1-82575-00-00 •...
Page 125 Outboard Rigging Guide - 2001 Switch Panels DUAL: SWITCH PANEL ASSEMBLY DRILL TEMPLATE (Actual Size) 128 mm (5.04 in) 40 mm 27 mm 27 mm (1.46 in) (1.06 in) (1.06 in) DRILL TEMPLATE 6x 54mm (2.12 in) 3-14...
Page 126 Outboard Rigging Guide - 2001 Switch Panels Switch Panel Assembly with Oil Light 6G8-82570-02-00 (T9.9) NO PART NUMBER DESCRIPTION QTY. 6G8-82570-02-00 Panel Switch Ass’y 6G8-82571-01-00 • Panel, Switch 68882-57501-00 • Engine Stop Switch Ass’y 68282-55600-00 • • Stopper 66382-58101-00 • Stay, Cord Clamp 6G8-83582-01-00 •...
Page 127 Outboard Rigging Guide - 2001 Switch Panels Four Stroke Switch Panel T9.9 (6G8-82570-02-00) DRILL TEMPLATE (Actual Size) CUT OUT SHADED PORTION 2-1/8 in. 27mm 2.12 in (54mm) 2.7 in (68mm) 3-16...
Page 128 Outboard Rigging Guide - 2001 Switch Panels Oil Lamp Panel Assembly (T9.9ELR) 6G8-83530-00-00 3-17...
Page 129 Outboard Rigging Guide - 2001 Switch Panels Oil Lamp DRILL TEMPLATE (Actual Size) 68 mm (2.67 in) 7.7 mm (.31 in) 52 mm (2.06 in) 7.7 mm (.31 in) 13.7 mm (.82 in) 56 mm (2.2 in) 14.3 mm (.56 in) 41 mm (1.58 in) 19 mm...
Page 130 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 3-19...
Page 131 Outboard Rigging Guide - 2001 Switch Panels Single Main Ignition Switch Panel (Option 9.9~250) 64D-82570-02-00 DRILL TEMPLATE (Actual Size) 3-20...
Page 132 Outboard Rigging Guide - 2001 Switch Panels Single Emergency Stop Lanyard Panel (Option 9.9~250) 64D-82570-10-00 DRILL TEMPLATE (Actual Size) 3-21...
Page 133: Battery Installations
Outboard Rigging Guide - 2001 BATTERY INSTALLATIONS 2.6L EFI Battery Cable Installation The battery cables are not mounted on the engine, but are in a separate box in the crate. This allows for the battery cable to be rigged to the boat along with the other rigging leads.
Page 134 Outboard Rigging Guide - 2001 Battery Installations F80/100/115/HPDI Battery Cable Installation The battery cables are not mounted on the engine, but are in a separate box in the crate. This allows for the battery cable to be rigged to the boat along with the other rigging leads.
Page 135 Gel cell batteries require special controlled charg- ing and may not be compatible with the Yamaha charging system. Marine, cranking types are most suitable. Consult the battery manufacturer for details.
Page 136 Outboard Rigging Guide - 2001 Battery Installations Battery Isolator Wiring For model year 2001, Yamaha has changed the battery isolator leads. The 3.1L Salt Water Series 225/250hp, carburetor 150/V150 and all HPDI engines will remain the same. The OX66 V-Max 200/225/250hp and OX66 2.6L engines have received a change as pointed out below.
Page 137 Outboard Rigging Guide - 2001 Battery Installations Dual Battery Installation (Recommended Battery Wiring 2. When using an accessory battery, a negative Without Accessory Battery Switch) connecting cable must be installed between the accessory battery and the main battery. WARNING This cable must be equivalent to the main battery cable.
Page 138 Outboard Rigging Guide - 2001 Battery Installations Dual Battery Installation (Recommended Battery Wiring with Accessory Battery, Selector Switch) WARNING Improper battery connections or wire size selection may result in a fire. 1. When one battery is used, connect the two red cables to the (+) terminal. If the smaller red cable is left unconnected, an accidental contact of the red cable with the (-) terminal of the bat- tery will form a short circuit and may cause a fire.
Page 139 Outboard Rigging Guide - 2001 Battery Installations (Recommended Battery Wiring with Accessory Battery Shut Off Switch) WARNING Improper battery connections or wire size selection may result in a fire. 1. When one battery is used, connect the two red cables to the (+) terminal. If the smaller red cable is left unconnected, an accidental contact of the red cable with the (-) terminal of the bat- tery will form a short circuit and may cause a fire.
Page 140 Outboard Rigging Guide - 2001 Battery Installations Twin Engine BATTERY SWITCH SELECTION MODE SWITCH #1 POSITION SWITCH #2 POSITION SYSTEM OFF NORMAL OPERATION BATTERY 1 BATTERY 2 BACK-UP CRANKING BATTERY 2 BATTERY 1 NOTE: 1. SWITCH POSITION “BOTH” SHOULD NOT BE USED FOR BACK-UP CRANKING. If Battery 1 is discharged and the “BOTH”...
Page 141 Outboard Rigging Guide - 2001 Battery Installations Typical 12/24 Volt Trolling Motor (3 pin plug) NOTE: If only two batteries are used, and one WARNING is being used for starting, do not use the bat- To reduce the risk of electrical short and fire: tery isolator.
Page 142 Outboard Rigging Guide - 2001 Battery Installations Typical 12/24 Volt Trolling Motor (4 pin plug) NOTE: If only two batteries are used, and one WARNING is being used for starting, do not use the bat- To reduce the risk of electrical short and fire: tery isolator.
Page 143 Outboard Rigging Guide - 2001 Battery Installations Typical 24 Volt Only Trolling Motor WARNING To reduce the risk of electrical short and fire: NOTE: If only two batteries are used, and one is being used for starting, do not use the bat- •...
Page 144: Electrical Connectors
This kit will allow you to make factory-like con- nections. Telephone 1-800-328-6657 Fax 1-800-578-7375 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...
Page 145: Rectifier - 6 ~ 25Hp
Yamaha offers the rectifier as optional 4. Locate the electrical wire connection cover equipment for the models listed below (it is stan- and remove it.
Page 146 Outboard Rigging Guide - 2001 Rectifier 6HP~25HP Wiring Connect the wiring as shown in the diagrams. Ref. No.. Description Battery Wire Connection Cover Fuse Holder Assembly Rectifier/Regulator Bracket Lighting Coil Additional Parts Required Part Number Description Remarks Model Qty. 6G8-81949-00-00 Lead Wire Connects fuse holder assembly to battery 6G8-82150-00-00...
Page 147: Voltage Regulator
663-81910-10-00 5HP~40HP (Manual) NOTE: The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage output from the rectifier to the battery. NOTE: On 4/5HP models, a lighting coil must be installed. All other applicable models have a stan- dard lighting coil.
Page 148: 5Hp Lighting Coil
Outboard Rigging Guide - 2001 5HP LIGHTING COIL The lighting coil will allow the motor to produce additional electrical current. With a voltage regu- lator, the lighting coil can be used to directly power lights or other accessories on a boat. Maximum output of the lighting coil is 60 watts.
Page 149 Outboard Rigging Guide - 2001 5HP Lighting Coil 6. In order to properly route the wiring for the 10. Make sure the O-ring in the groove of the lighting coil, remove the two bolts and pull magneto base is installed correctly. Slip the out the magneto base.
Page 150 5HP Lighting Coil 14. Reinstall the recoil starter onto the magneto NOTE: The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage base and tighten the bolts. input from the rectifier to the battery. NOTE: The rectifier can also be used with the...
Page 151 Outboard Rigging Guide - 2001 30HP 3 CYL. NEUTRAL SAFETY SWITCH 5. Connect the extension wire lead (P/N: 6H4- 688-82540-11-00 82553-00-00) to the leads of the neutral safe- ty switch. To avoid accidentally starting the motor while in 6. Route the extension leads around the front of gear, a neutral safety switch must be installed if the bottom cowling to the right side of the you are using a control box without start-in-gear...
Page 152 13mm (0.5in) in diameter as shown in the The Yamaha power trim/tilt switch can be mount- mounting diagram. ed on the instrument panel for easy access from 3. Secure the switch with the cap and plate.
Page 153: Remote Pt&T Switch - F/T25T, 40T~250Hp, C40T~C90
Outboard Rigging Guide - 2001 Remote PT&T Switch F/T25T, 40T~250HP, C40T~C90 Mounting For electric tiller model wiring, see the wiring diagrams in the Boat Wiring Diagrams Section. Think Instrument Panel Installation (over 2mm (0.08in) 1. Select a mounting location so the power trim/tilt switch is easy to reach from the helm.
Page 154 Outboard Rigging Guide - 2001 BOAT WIRING DIAGRAMS The following wiring diagrams cover most common remote control configurations. These include dia- grams using either the 703 control box with built-in electrics, or switch panel wiring required when either the 704 binnacle or 705 flush-mount control box is used. For details on harness part numbers, compo- nent dimensions, and mounting instructions, see the individual section covering the component in ques- tion.
Page 155: Boat Wiring Diagrams
Outboard Rigging Guide - 2001 Boat Wiring Diagrams T9.9 with 703 Control 3-44...
Page 156 Outboard Rigging Guide - 2001 T9.9 with Switch Panel 3-45...
Page 157 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 9.9 ~ 30HP, 30 ~ C40 ~ ‘98 with 703 Control, 10-pin and Analog Tachometer 3-46...
Page 158 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 9.9 ~ 30HP, 30 ~ C40 ~ ‘98 with 10-pin Switch Panel and Analog Tachometer 3-47...
Page 159 Outboard Rigging Guide - 2001 Boat Wiring Diagrams Wiring 9.9 ~ 30HP with 7 Pin Harness Switch Panel 3-48...
Page 160 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 40E, 50HP with 703 Control & Analog Tachometer (Except 40T or P50) 3-49...
Page 161 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 40E, 50HP with Switch Panel & Analog Tachometer (Except 40T or P50) 3-50...
Page 162 Outboard Rigging Guide - 2001 Boat Wiring Diagrams F40, F50, T50, F80/100, F115 with 703 Control Box and Analog Tachometer 3-51...
Page 163 Outboard Rigging Guide - 2001 Boat Wiring Diagrams F40, F50, T50, F80/100, F115 with Switch Panel and Analog Tachometer 3-52...
Page 164 Outboard Rigging Guide - 2001 Boat Wiring Diagrams C40 ~ C150 with 703 Control and Analog Tachometer 3-53...
Page 165 Outboard Rigging Guide - 2001 Boat Wiring Diagrams C40 ~ C150 with Switch Panel and Analog Tachometer 3-54...
Page 166 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 40T ~ 90HP with 703 Control and Multifunction Gauges C40~C115 3-55...
Page 167 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 40T ~ 90HP with Switch Panel and Multifunction Gauges C40~C115 3-56...
Page 168 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with 703 Control and Analog Gauges 3-57...
Page 169 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with Switch Panel and Analog Gauges 3-58...
Page 170 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with 703 Control and with Multifunction Gauges — 2-Stroke 3-59...
Page 171 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with Switch Panel and with Multifunction Gauges — 2-Stroke 3-60...
Page 172 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with 703 Control and Analog Tachometer — 2-Stroke 3-69 3-61...
Page 173 Outboard Rigging Guide - 2001 Boat Wiring Diagrams 115HP ~ 250HP Wiring with Switch Panel and Analog Tachometer — 2-Stroke 3-62...
Page 174 Outboard Rigging Guide - 2001 Boat Wiring 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. 3-63...
Page 175 Outboard Rigging Guide - 2001 Boat Wiring Diagrams Tiller Models with PT&T 40TLHW, 50TLHW, P60TLHW, P75TLHW, (F40~F100) 3-64...
Page 176 Outboard Rigging Guide - 2001 Boat Wiring Diagrams F40, F50TLH, T50, F80~F100 Tiller Model Analog Tachometer 3-65...
Page 177 Outboard Rigging Guide - 2001 After Market Dash Wiring 3-66...
Page 178 Outboard Rigging Guide - 2001 COMPLETE BOAT WIRING DIAGRAMS 70~90HP, F80~F115 3-67...
Page 179: Complete Boat Wiring Diagrams
Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V4/V6 Single Engine 3-68...
Page 180 Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V4/V6 Single Engine (Cont’d.) 3-69...
Page 181 Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V4/V6, F115 Dual Engine 3-70...
Page 182 Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V4/V6, F115 Dual Engine (Cont’d.) 3-71...
Page 183 Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V6 HPDI Single Engine 3-72...
Page 184 Outboard Rigging Guide - 2001 Complete Boat Wiring Diagrams V6 HPDI Dual Engine 3-73...
Page 186 Outboard Rigging Guide - 2001 SECTION 4 - REMOTE CONTROLS Control Boxes ............4-1 Control Box Illustrations .
Page 188 8, F9.9, T9.9, 25, & 30 use a pull to open throttle control with a 7 pin harness. T8~9.9, 15, and 40hp to 250hp use a push to open throttle control with a 10 pin harness. The 9.9 and 15 use a 7 pin to 10 pin adapter harness. The trim switch will not operate on models without power tilt or power trim.
Page 189 Outboard Rigging Guide - 2001 CONTROL BOX ILLUSTRATIONS 704 Dual Binnacle Kit Part Number 682-84380-00-00 704 Single Binnacle...
Page 190 Outboard Rigging Guide - 2001 CONTROL BOX APPLICATIONS F25T LF115 F40T F100 L130 F15E C40T~ F115 F9.9 F25E L250 Description Part Number T9.9 C115 V6** LX250 701 Pull - No Elec. 701-48101-51-00 701 Push - No Elec. 701-48130-02-00 703 Pull 703-48230-12-00 7 Pin/Choke 703-48240-12-00...
Page 191 Outboard Rigging Guide - 2001 701 REMOTE CONTROL ASSEMBLY 701 Remote Control & Pull/Manual Assembly (701-48101-51-00) NO PART NUMBER DESCRIPTION QTY. 701-48101-51-00 Remote Control Ass’y 701-48235-00-0 • Bushing 701-48197-10-00 • Washer, Wave 701-48252-00-00 • Roller, Cam 701-48234-00-00 • Bushing 1 701-48221-00-00 •...
Page 192 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 Yamaha Marine Grease to coat the hole in the end of each cable end. Preparation 1.
Page 193 Outboard Rigging Guide - 2001 701 Remote Control Ass’y. 4. Secure the cable end to the pin with the cir- Mounting clip. 1. Mount the 701 remote control as shown in the illustration. 5. Fit the anchor over the ridge and around the clamp.
Page 194 Outboard Rigging Guide - 2001 701 Remote Control Ass’y. 4. Adjust the throttle cable terminal (at the 2. Operate the hand lever several times to verify motor end) and line up with the hole or pin on proper operation. Make sure that the the throttle arm.
Page 195: Remote Controls
Outboard Rigging Guide - 2001 703 REMOTE CONTROL ASSEMBLIES 703 Remote Control (T9.9ER) [Pull 7-Pin] (703-48240-12-00) NO PART NUMBER DESCRIPTION QTY. Remote Control Assembly (7P) w/PT/T Sw 703-48261-01-00 • Arm, Throttle 703-48153-00-00 • Shaft, Free Accel. 703-48235-00-00 • Bushing 703-48268-00-00 •...
Page 196 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. 703 Remote Control (T9.9ER) [Pull 7-Pin] (703-48240-12-00) – Continued NO PART NUMBER DESCRIPTION QTY. 46 703-82531-00-00 • Wire, Lead 47 688-82575-01-00 • Engine Stop Switch Ass’y. 48 682-82556-00-00 • • Stopper 49 688-82586-21-00 •...
Page 197 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. 703 REMOTE CONTROL (T9.9ER) [PULL 10-PIN] (703-48207-15-00) NO PART NUMBER DESCRIPTION QTY. Remote Control Assembly (10P) w/PT/T Sw 703-48261-01-00 • Arm, Throttle 703-48153-00-00 • Shaft, Free Accel. 703-48235-00-00 • Bushing 703-48268-00-00 •...
Page 198 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. 703 REMOTE CONTROL (T9.9ER) [PULL 10-PIN] (703-48207-15-00) – Continued NO PART NUMBER DESCRIPTION QTY. 46 703-82531-00-00 • Wire, Lead 47 688-82575-01-00 • Engine Stop Switch Ass’y. 48 682-82556-00-00 • • Stopper 49 688-8258A-20-00 •...
Page 199 Measure from the control head to the shift and throttle connections on the motor. Allow an addition- al four feet cable length for the loop. Yamaha remote control cables are available in lengths from 6 feet to 36 feet.
Page 200 3. For installation of cable joints, see page 4-47. Tighten the lock nuts before installing the cable joints, apply Yamaha Marine Grease to the threaded holes in the cable joints. 7. Reinstall the lower back panel with the two screws and replace the wire cover.
Page 201 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. Reassembly for Port Side Application 3. Place a punch on the bolt head and tap it with (Optional) a hammer to remove the control lever from the control box. The 703 control can be used for left (port) side LOOSEN BOLT applications if it is reassembled as instructed in this section.
Page 202 NOTE: Use care so that the roller does not jump reassembled to operate properly. out due to spring force. CAUTION: 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.
Page 203 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. 4. Remove the throttle arm for the “push-to- Mounting open” throttle and install the type for the “pull-to-open” throttle, or vice versa, as 1. Mount the 703 remote control as shown in the shown in the illustration.
Page 204 Outboard Rigging Guide - 2001 703 Remote Control Ass’y. 2. Place the hand lever of the control in the neu- Shift Cable Connection tral detent. Proper adjustment of the shift cable will result in 3. Place the carburetor arm lightly against the a better operating control.
Page 205 Outboard Rigging Guide - 2001 704 BINNACLE MOUNT REMOTE CONTROL ASSEMBLIES 704 Single Binnacle Mount Remote Control Assembly (704-48205-13-00) NO PART NUMBER DESCRIPTION QTY. 704-48205-13-00 Remote Control Ass’y Single 98580-05016-00 • Screw, Pan Head EL8-48251-00-00 • Plate, Cam 704-48265-00-00 • Shaft, Friction 701-48246-00 •...
Page 206 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 704 Single Binnacle Mount Remote Control Assembly (704-48205-13-00) – Continued NO PART NUMBER DESCRIPTION QTY. 39 704-82594-00-00 • Clamp 40 704-48228-00-00 • Holder, Switch 41 704-82563-A0-00 • Trim & Tilt Switch Ass’y 42 704-48229-00-00 •...
Page 207 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 704 DUAL BINNACLE MOUNT REMOTE CONTROL ASSEMBLY (704-48205-31-00) NO PART NUMBER DESCRIPTION QTY. Remote Control Ass’y Dual 98580-05016-00 • Screw, Pan Head EL8-48251-00-00 • Plate, Cam 704-48265-00-00 • Shaft, Friction 701-48246-00-00 •...
Page 208 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 704 Dual Binnacle Mount Remote Control Assembly (704-48205-31-00) - Continued NO PART NUMBER DESCRIPTION QTY. 42 704-48229-00-00 • Grip, Control Lever 43 92990-05300-00 • Washer, Internal Tooth 44 95380-06600-00 •...
Page 209 Yamaha outboards. Features a thumb-operated tilt in a single synchronized thumb-operated trim-tilt switch on the handle, forward/reverse trim/tilt switch on the left lever - a Yamaha exclu- lever, neutral lock for fast idling (with touch but- sive. Additionally, separate trim/tilt switches for ton fast idle release), corrosion-resistant upper each engine are mounted on the control body.
Page 210 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. Preparation Choose a mounting location for the control head After determining the positions of remote control which will provide comfortable operation and box mounting holes, drill the holes. unobstructed movement of the hand lever and 1.
Page 211 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 704 Single 24.5 mm 24.5 mm 4-Dia. 6 mm (.24 in) (.96 in ) (.96 in ) 76.5 mm (3.01 in ) 59 mm (2.32 in ) CUT OUT THE SHADED PORTION 59 mm...
Page 212 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. PROJECTION HOLE 4-Dia. 6 mm (.24 in) 76.5 mm (3.01 in ) 69 mm (2.72 in ) CUT OUT THE SHADED 59 mm PORTION (2.32 in ) 59 mm (2.32 in ) 69 mm 4-Dia.
Page 213 Yamaha Marine Grease to the threaded holes in the cable joints. WARNING If the cable is not screwed in at least 8mm, the cable joint could break.
Page 214 704 Binnacle Mount Remote Control Ass’y. 6. Connect the remote control cable for the throttle to the throttle arm in the same man- ner. YAMAHA MARINE GREASE 4. Insert the outer sheave of the remote control cable for shifting into the housing clamp so that the groove on its end fits over the ridge in the clamp.
Page 215 After connecting the cables, secure the two remote control boxes with the three screws. CAUTION: When reinstalling parts, apply Yamaha Marine Grease to moving parts and contact surfaces of parts. 1. Remove the cover from the body.
Page 216 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 5. Remove the two screws and remove the throt- How To Change tle lever assembly. Position the throttle lever The Control Lever Position assembly so it faces downward and secure it with the two screws.
Page 217 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 3. Remove the brake arm assembly together 7. Loosen the locknuts, and reverse the right with the plain washer and circlip. and left stopper bolt positions. Secure the bolts with the two locknuts. 4.
Page 218 Outboard Rigging Guide - 2001 704 Binnacle Mount Remote Control Ass’y. 8. Install the brake arm assembly (with the plain Throttle Opening Adjustment washer and the circlip) on the throttle shaft. The remote control box is capable of adjusting the Install the bushing in the brake arm assembly, throttle opening in the following manner: then install the throttle arm assembly onto the...
Page 219 Outboard Rigging Guide - 2001 705 FLUSH SIDE MOUNT REMOTE CONTROL ASSEMBLY (PUSH TO-OPEN) NO PART NUMBER DESCRIPTION QTY. Remote Cotrol Ass’y (90°) 6X0-48252-00-00 • Plate, Cam 6X0-48138-00-00 • Cap, Lock Arm 93430-06024-00 • Circlip 92990-10600-00 • Washer EL8-48259-00-00 • Circlip 6X0-48265-00-00 •...
Page 220 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. 705 FLUSH SIDE MOUNT REMOTE CONTROL ASSEMBLY (Push-to-Open) (Cont’d.) NO PART NUMBER DESCRIPTION QTY. 47 703-48227-00-00 • Spring 48 98580-05008-00 • Screw, Pan Head 49 98580-04010-00 • Screw, Pan Head 50 6X0-82563-00-00 •...
Page 221 705 Flush Side Mount Remote Control Ass’y. 705 Flush Side Mount Remote Control (6X0-48206-11-00) Introduction Manufactured by Yamaha for precise control 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.
Page 222 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. Operation 1. Forward and reverse First pull up the neutral interlock trigger. To shift into forward and reverse, rotate the con- trol lever downward about 35° (detent posi- tion) to the: “F”...
Page 223 Outboard Rigging Guide - 200 705 Flush Side Mount Remote Control Ass’y. 3. Throttle Opening Adjustment 4. Control Lever Tension Adjustment The remote control box is capable of adjust- By turning in or out the throttle friction screw ing the throttle opening in the following man- at the rear of the remote control box, the stiff- ner: ness of the control lever can be adjusted.
Page 224 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. 6. Neutral Switch When selecting the control box position, The neutral switch keeps the engine from keep the following in mind: starting when gears are shifted. When the a.
Page 225 Sharp bends (less than 200mm [7.87 in] in Before installing the cable joints, radius) of the cables will obstruct a smooth apply Yamaha Marine Grease to the movement of the cables and shorten cable life. threaded holes in the cable joints.
Page 226 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. f. Hold the back plate firmly with the five b. Tightly bolt the base to the remote control screws. box. Tightening Torque: 30 ~ 45 cm-kg 1 Cover 3 Hole 5 Washer 2 Base...
Page 227 1 Cover 2 Neutral Lock Holder 3 Adjusting Screw Holes 4 Trim Switch Wire YAMAHA MARINE GREASE d. On the model with the trim switch, wind the trim switch wire two turns counter- clockwise around the boss at the lower end of the control lever.
Page 228 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. i. Place the plain washer around the boss of Connecting the Remote Control the control lever and fasten it with the Cable to the Engine and Fixing the screws and washers.
Page 229 CAUTION: position. Adjust the cables so the free accel- When reinstalling parts, apply the Yamaha erator button can reset automatically. Marine Grease to moving parts and contact NOTE: The cable joints (on the engine side) must surfaces of parts.
Page 230 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. 3. Remove the circlip, and remove the dwell 5. Turn the dwell plate 180° so the cam groove plate and cam plate. Then, shift the throttle is on the PULL side, and align the throttle arm assembly position slightly backward.
Page 231 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. Change in the 2. Remove the circlip and plain washer from the Control Lever Position throttle shaft, loosen the adjusting screw, and remove the throttle arm assembly and bush- ing.
Page 232 Outboard Rigging Guide - 2001 705 Flush Side Mount Remote Control Ass’y. 5. Loosen the hexagon head bolt, and install the CAUTION: shift arm assembly, while holding it in an Do not allow the stopper bolt to project 11mm inverted position. (0.4 in) or more from the nut surface.
Page 233 To ensure a longer life of the remote control box, be sure to take the following steps when storing 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.
Page 234 Outboard Rigging Guide - 2001 REMOTE CONTROL CABLES Cable Measuring Yamaha remote control cables are available in Use the following examples as a guide for mea- lengths from 6 feet to 36 feet. The cables utilize surement. Obviously, different boats will required 10-32 threaded ends.
Page 235: Control Box Adjustments
Yamaha outboards; 8, F9.9, T9.9, 20, 25, & 30 pull the throttle cable to open. Yamaha outboards T8, 9.9, 15, 40 ~ C40 and larger push the throttle cable to open. Shift cable control is the same for all outboards.
Page 237: Instrument & Gauge Installations
Outboard Rigging Guide - 2001 SECTION 5 - INSTRUMENT & GAUGE INSTALLATIONS Digital Instruments ..........5-1 Tachometer .
Page 238: Digital Instruments
Only dual engines with a dual key switch panel have the alarm self-check with three beeps LEAD RESETTING IDENTIFICATION The Yamaha Digital Tachometer incorporates a double 2-way toggle dip-switch. REAR The left-hand switch is for the Trim Sender SWITCH SETTINGS Signal.
Page 239: Tachometer
Yamaha has three types of tachometers; two Pro Series, one with oil lights, and one for the F40, F50, T50, F80, F100, F115 4-stroke; and a multi- function digital tachometer.
Page 240 Outboard Rigging Guide - 2001 Tachometer Mounting 1. Select a mounting location so the tachometer is easy to read from the operating position. Be sure there is sufficient clearance behind the panel for the meter. 2. Make a 3-3/8 inch diameter hole in the desired location.
Page 241 Outboard Rigging Guide - 2001 Tachometer Wiring Refer to the following illustrations for basic NOTE: A special relay, Part number 6Y5- wiring. For detailed wiring information, refer to 81950-02-00, is required when using the Pro the diagrams in the Boat Wiring Diagrams in the Series analog tachometer with oil lights.
Page 242 Outboard Rigging Guide - 2001 Tachometer Digital Multi-function Tachometer...
Page 243 Calibration For Number Of Poles The tachometer indicates the engine speed by receiving the pulses from the lighting coil. The flywheel magnetos used in Yamaha outboards vary in number of poles used: 4-pole, 6-pole, and 12-pole. It is necessary to change the calibration switch(es) on the back of the meter to correspond to the particular motor being used.
Page 244: Speedometer
This impact force will vary with Yamaha speedometers use the stock pitot tube on the density of the water and the speed of the the 30hp and larger motors. The optional impact.
Page 245 Outboard Rigging Guide - 2001 Speedometer Speedometer Installation Speedometer Mounting 1. Select a mounting location so the speedome- ter is easy to read from the helm. Be sure there is sufficient clearance behind the instru- ment panel for the meter. 2.
Page 246 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 Outboard Rigging Guide - 2001 Speedometer Speedometer Wiring Multi-Function Digital Speedometer For wiring information and diagrams, refer to the Analog Speedometer Boat Wiring Diagrams in the Electrical Section 3 of this manual. 1. Connect the wiring as shown. The same lead wire used for the tachometer can be used.
Page 248 Outboard Rigging Guide - 2001 Speedometer Speedometer Tube Installation Speedometer Tube Routing 40T ~ 250HP The speedometer tube must be routed carefully to NOTE: The speedometer tube comes installed as avoid crimping or damage. standard equipment, routed to the clamp bracket area.
Page 249 The typical marine speedometer, including all turning the ignition off for 5 seconds and then Yamaha marine speedometers, use the pressure of turning it on again. This will reset the gauge water impacting a pitot tube to indicate the speed to zero.
Page 250 • Plate, Fitting 14 688-83664-00-00 • Damper • Component parts For model year 2001, Yamaha has introduced a The multifunction tachometer factory settings new OEM standard 2-wire trim sender on all will be changed. The gauge has not changed. If power trim and tilt engines.
Page 251: Trim Meter
Outboard Rigging Guide - 2001 Trim Meter Trim Meter Installation Mounting 1. Select a mounting location so the meter is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter. 2. Make a 2-1/6 in. hole in the desired location. 3.
Page 252 Outboard Rigging Guide - 2001 Trim Meter Trim Meter Sender Adjustment Adjusting 1. For a down position adjustment, loosen the Checking trim sender screws and make an adjustment 1. When checking the trim sender, connect the so the needle aligns with the marking line lead wires of the trim sender and move the indicating “DOWN.”...
Page 253 While operating, the water pres- sure must not drop below 11 psi during full throt- tle operation. The Yamaha Water Pressure Gauge uses a sensor installed on the motor, which is connected to the gauge by a hose.
Page 254: Water Pressure Gauge
Outboard Rigging Guide - 2001 Water Pressure Gauge Installation Mounting NOTE: If the instrument panel has a thickness of Select a mounting location so the gauge is more than 13mm (0.5 in) and it is impossible to easy to read from the helm. Be sure there is secure the meter with the fitting plate, cut the fit- sufficient clearance behind the panel for the ting plate so the meter can be installed.
Page 255 Outboard Rigging Guide - 2001 Water Pressure Gauge Sender Installation 3. Connect the pressure sender to the water pressure meter by the tube. Clamp the tube to 1. Remove the screw plug from the cylinder the hull with clips and screws so it is not flat- head and install the pressure sender.
Page 256 Outboard Rigging Guide - 2001 WATER TEMPERATURE GAUGE NO PART NUMBER DESCRIPTION QTY. • Water Temperature Ass’y 11 6Y5-83518-00-00 • • Bulb, Meter 12 6Y5-83536-00-00 • • Socket, Meter 13 688-83664-00-00 • • Damper 14 6Y5-83544-00-00 • • Plate, Fitting 15 688-83591-00-00 •...
Page 257: Water Temperature Gauge
Outboard Rigging Guide - 2001 Water Temperature Gauge Installation NOTE: If the instrument panel has a thickness of Mounting more than 13mm (0.5 in) and it is impossible to secure the meter with the fitting plate, cut the fit- 1. Select a mounting location so the gauge is ting plate so the meter can be installed.
Page 258 Outboard Rigging Guide - 2001 Water Temperature Gauge Wiring 1. Connect the wiring as shown using the appro- priate lead wire. NOTE: If an instrument light switch is to be used, NOTE: When testing the thermosensor, set at connect it as shown. Otherwise, connect the yel- 900~1000Ω...
Page 259: Water Pressure/Temperature Sender Installation
Outboard Rigging Guide - 2001 Water Pressure/Temperature Sender Installation Water Pressure/Temperature Sender Installation 1. Remove the screw plug from the cylinder 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)
Page 260 Outboard Rigging Guide - 2001 Water Pressure/Temperature Sender Installation CAUTION: If installing a water temperature sender and a water pressure sender together on one engine: Be sure the water pressure sender is installed on the port side. If it is installed on the star- board side, the sensor tube could break or bend.
Page 261 Outboard Rigging Guide - 2001 VOLTMETER - (6Y5-83503-00-00) NO PART NUMBER DESCRIPTION QTY. Voltmeter Ass’y 36 6Y5-83544-00-00 • Plate 37 688-83664-00-00 • Damper 38 6Y5-83536-00-00 • Socket, Meter 39 6Y5-83518-00-00 • Bulb, Meter • Component parts The voltmeter provides information about the charging condition of the battery.
Page 262: Voltmeter
Outboard Rigging Guide - 2001 Voltmeter Mounting Wiring 1. Select a mounting location so the voltmeter is 1. Connect the wires as shown: easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter.
Page 263 Outboard Rigging Guide - 2001 HOUR METER KIT (6Y5-83504-11-00) 10000 Hr 1000 Hr 100 Hr For Model Year 2001, Yamaha has developed a new digital hour meter. It mounts in the same 2 10 Hr 1/16-diameter hole. The gauge sports the tradi- 1 Hr tional Yamaha styling.
Page 264: Hour Meter Kit
Outboard Rigging Guide - 2001 Hour Meter Kit Mounting Wiring Connect the wires as shown: 1. Select a mounting location so the hour meter is easy to read from the helm. Be sure there is • Counting time while engine is running. sufficient clearance behind the panel for the meter.
Page 265 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.
Page 266: Fuel Gauge
Outboard Rigging Guide - 2001 Fuel Gauge Mounting Wiring 1. Select a mounting location so the fuel gauge 1. Connect the wires as shown: is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the gauge.
Page 267 Outboard Rigging Guide - 2001 FUEL MANAGEMENT GAUGE Modification Procedure (Input for MPG from GPS or Multifunction Speedometer) 1. Cut off three prong connector. 2. Remove the black plug and install it on the The fuel management gauge can receive data speedometer to plug the hole in the back of from either a GPS or the multifunction speedome- the gauge.
Page 268 Outboard Rigging Guide - 2001 Fuel Management Gauge Fuel Management Gauge V4-V6 Only FUEL MANAGEMENT GAUGE ASSEMBLY SYSTEM Part Number Description Remarks 6Y5-W0088-53-00 Single F/M Kit Single Engine 6Y5-W0088-64-00 Dual F/M Kit Dual Engine Parts Identification Part Number Description Remarks 6Y5-83500-F2-00* Meter Assembly 6Y5-83553-F1-00...
Page 269 Outboard Rigging Guide - 2001 Fuel Management Gauge Installation For each gauge: 1. Cut a 3-3/8 inch diameter hole in the dash Gauge Location panel. A paper pattern is printed on this page. Pick a location in the dash for the fuel manage- 2.
Page 270 Outboard Rigging Guide - 2001 Fuel Management Gauge Sensor Placement & Installation 1. Locate the sensor after the filter and before the primer bulb (if equipped) or engine. FUEL FLOW SENSOR LOCATION PRIMER BULB FILTER FLOW SENSOR ON/OFF FUEL VALVE OR ANTI-SYPHON VALVE 3.
Page 271: Twin Engine Fuel Management Gauge
Outboard Rigging Guide - 2001 Fuel Management Gauge Twin Engine Fuel Management Gauge The fuel management gauge operates only on one engine of a twin engine installation. No wiring is connected to the second ignition source. The fuel management gauge and speedometer must be connected to one common power source.
Page 272 Outboard Rigging Guide - 2001 Fuel Management Gauge Wiring G/W = (Green/White) 1. The green and green/white wires on the fuel To the G (Green) wire from the PORT management gauge are for engine synchro- Multifunction Tachometer (on twin-engine nization and are connected to the tachome- installations) ter(s).
Page 273: 2001 Hpdi Water Detection Switch
Outboard Rigging Guide - 2001 Fuel Management Gauge 2001 HPDI Water Detection Switch The HPDI engines were introduced with a new warning feature. The engines come standard with water detection switch mounted on the engine. When water is present the switch will activate and the alarm will sound along with a reduction of engine rpm’s.
Page 274 Outboard Rigging Guide - 2001 Fuel Management Gauge The diagram below shows the recommended wiring for the water detection harness without using the optional water/fuel filter sensors. The diagram below shows the recommended wiring with the use of the optional water/fuel fil- ter sensors.
Page 275 Outboard Rigging Guide - 2001 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 sensor (Part Number: MAR-24560-00-00). 5-38...
Page 276: Digital Fuel Management Gauge
(winter or summer fuel and amount of addi- tives). 2. The Yamaha Digital Speedometer and Fuel Management Meter calculates speed, miles traveled, and fuel economy by water move- ment at the stern of the boat. This distance...
Page 277 Outboard Rigging Guide - 2001 Fuel Management Gauge Fuel Flow Meter NOTE: The fuel consumption is kept in memory by battery power. The stored data will be lost if the battery is disconnected. The meter displays fuel flow within one hour, at the rate of current engine operation.
Page 278 Outboard Rigging Guide - 2001 Fuel Management Gauge Twin-engine Speed Synchronization Water Separator Warning Indication Push and release the Mode button until the indi- NOTE: This indicator operates only when an cator on the face of the gauge points to “SYNC.” optional water separator with sensor has been installed.
Page 279 Outboard Rigging Guide - 2001 Fuel Management Gauge Remove the cap 1 to access the switches. The Fuel Management Meter fuel management switch 2 can be set to either 1. Remove the cap on the back of the gauge 1. gallons per hour (gph) or liters per hour (1/h).
Page 280 Outboard Rigging Guide - 2001 SECTION 6 - TILLER HANDLE KITS T9.9 Remote Tiller Rigging Kit ......... 6-1 F15 Tiller Handle Kit .
Page 281 Outboard Rigging Guide - 2001 T9.9 REMOTE TILLER RIGGING KIT (6G8-W4831-01-00) NO PART NUMBER DESCRIPTION QTY. Remote Tiller Rigging Kit 6G8-48311-11-00 • Cable 6G8-48321-10-00 • Cable 90445-20ME5-00 • Damper 6G8-82550-10-00 • Stop Switch Ass’y • Grommet • Component parts NOTE: This kit is intended to be used only with 2.
Page 282: T9.9 Remote Tiller Rigging Kit
Outboard Rigging Guide - 2001 T9.9 Remote Tiller Rigging Kit 4. To remove the bracket on the control panel 6. Remove the wave washer, the washer, and the that holds the control cables, remove the two steering handle assembly. To remove the screws (with washer), fitting plate, and then cables from the ring nut, route the cable ends the bracket.
Page 283 Outboard Rigging Guide - 2001 T9.9 Remote Tiller Rigging Kit 8. Remove the rubber steering grip. Remove the 10. Remove the bolt, washer, shift arm, wave screw in the end of the handle, and along with washer, cotter pin, washer, and the detent the plastic and steel washers, the compression roller as shown.
Page 284 Outboard Rigging Guide - 2001 T9.9 Remote Tiller Rigging Kit 2. Install the new throttle cable, being sure to fit 5. Reinstall the components of the steering han- the inner cable end in the groove and the dle grip. Reinstall the handle grip, the friction outer cable end into the hole as shown.
Page 285 Outboard Rigging Guide - 2001 T9.9 Remote Tiller Rigging Kit 8. Install the cable ends on the cables. Screw the Installing the Control Handle end of the cable into the cable joint a mini- mum of 8mm (0.3mm) and lock it with the 1.
Page 286: F15 Tiller Handle Kit
Outboard Rigging Guide - 2001 F15 Tiller Handle Kit F15 TILLER HANDLE KIT (66M-W0084-00-4D) NO PART NUMBER DESCRIPTION QTY. 66M-W0084-00-4D Handle Steering Ass’y 65W-42101-00-4D Handle, Steering 65W-42101-01-4D Handle, Steering 90109-06M86-00 • Bolt 65W-42138-00-00 Lever, Throttle 65W-42159-00-00 Stay 6G1-42126-00-00 Friction, Steering Handle Grip 65W-42125-00-00 Bolt, Friction Adjusting 91490-16010-00...
Page 287 Outboard Rigging Guide - 2001 F15 Tiller Handle Kit F15 Tiller Handle Kit – Additional Parts Required PART NUMBER DESCRIPTION QTY. 66M-42508-00-00 Steering Friction Ass’y. 93700-06M03-00 • Nipple, Grease 66M-42527-00-00 • Plate, Friction 90109-08M91-00 • Bolt 65W-42562-00-00 • Shaft, Steering Lock 66M-42561-00-00 •...
Page 288 Outboard Rigging Guide - 2001 F15 Tiller Handle Kit STEERING HANDLE ASS’Y (F15) EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART STEP PROCEDURE/PART NAME QTY. SERVICE POINTS Follow the “Step” order for removal. STEERING HANDLE ASS’Y REMOVAL Flywheel magneto cover (for EH models) Manual starter (for MH models) Throttle Cable N O T E :...
Page 289 Outboard Rigging Guide - 2001 F15 Tiller Handle Kit STEERING HANDLE ASS’Y (F15) EXPLODED DIAGRAM STEP PROCEDURE/PART NAME QTY. SERVICE POINTS STEERING HANDLE ASS’Y DISASSEMBLY Follow the “Step” order for disassembly. Steering Handle Ass’y. Manual starter (for MH models) Plastic Washer Metal Washer Wave Washer Metal Washer...
Page 290: F25 Tiller Handle Kit
Outboard Rigging Guide - 2001 F25 Tiller Handle Kit F25 TILLER HANDLE KIT (65W-W0084-01-4D) NO PART NUMBER DESCRIPTION QTY. 65W-W0084-01-4D Handle Steering Ass’y 65W-44111-00-00 Handle, Gear Shift 95895-06016-00 Bolt, Flane 90206-f12M00-00 Washer, Wave 90201-12M34-00 Washer, Plate 65W-42123-00-00 Bolt, Handle Joint 65W-44124-00-00 Link, Shift Rod 92990-06200-00 Washer...
Page 291 Outboard Rigging Guide - 2001 F25 Tiller Handle Kit F25 Tiller Handle Kit – Additional Parts Required PART NUMBER DESCRIPTION QTY. 65W-42508-00-00 Steering Friction Ass’y. 65W-42527-00-00 • Plate, Friction 90109-06M50-00 • Bolt 92990-06100-00 • Washer, Spring 65W-42561-00-00 • Knob, Steering Lock1 689-43633-00-00 •...
Page 292 Outboard Rigging Guide - 2001 F25 Tiller Handle Kit F25 ELECTRICAL (65W-85790-00-00) NO PART NUMBER DESCRIPTION QTY. 65W-85790-00-00 Thermosensor Ass’y 65W-85757-00-00 Retainer 97595-06512-00 Bolt 90465-11M10-00 Clamp 65W-82590-00-00 Wire Harness Ass’y 65W-82590-20-00 Wire Harness Ass’y 65W-82590-30-00 Wire Harness Ass’y 97595-06516-00 Bolt 90465-08M08-00 Camp 90465-08M51-00...
Page 293 Outboard Rigging Guide - 2001 F25 Tiller Handle Kit F25 STEERING HANDLE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART STEP PROCEDURE/PART NAME QTY. SERVICE POINTS STEERING HANDLE REMOVAL Follow the “Step” order for removal. Flywheel magneto cover ass’y. Refer to “FLYWHEEL MAGNETO” in Chapter 5.
Page 294 Outboard Rigging Guide - 2001 F25 Tiller Handle Kit F25 STEERING HANDLE EXPLODED DIAGRAM REMOVAL AND INSTALLATION CHART STEP PROCEDURE/PART NAME QTY. SERVICE POINTS Follow the “Step” order for removal. STEERING HANDLE DISASSEMBLY Shift Link Rod Shift Lever Cable Guide Bushing Plastic Washer Wave Washer...
Page 295 Outboard Rigging Guide - 2001 30HP Tiller Handle Kit 30HP TILLER HANDLE KIT (6L2-W0084-10-4D) NO PART NUMBER DESCRIPTION QTY. Handle Steering Ass’y 6G1-42111-11-4D • Handle, Steering 6E0-44191-11-00 • Indicator, Shift 90206-36M21-00 • Washer, Wave 90202-36M55-00 • Washer, Plate 90386-33M96-00 • Bush 90386-44M97-00 •...
Page 296: 30Hp Tiller Handle Kit
C atch any fuel that may drain from the hose ( or carburetors when removed) in a suitable The Yamaha tiller handle kit (optional for the container. D o not perform this operation near 30HP, 3-cylinder) lets you steer your boat from an open flame, heater, or while smoking.
Page 297 Outboard Rigging Guide - 2001 30HP Tiller Handle Kit 9. Route the throttle cables toward the throttle 15. Locate the new brown wire extension lead cam assembly. Disconnect the links for the (Part Number: 6H4-82553-00-00) and con- throttle and magneto controls. nect the two wires at either end of it to the neutral safety switch.
Page 298 Outboard Rigging Guide - 2001 30HP Tiller Handle Kit 20. Loosen the lock nut on the “push” throttle Do not tighten the bolts that retain the black ground wires until the next instruction. cable, adjust the cable adjuster until there is 3mm (0.12 in) slack in the inner cable (as 22.
Page 299 Outboard Rigging Guide - 2001 30HP Tiller Handle Kit 23. Hook up the starter switch by connecting its N O T E : The blue choke solenoid lead is no longer used and should be secured away from all moving brown lead to one of the brown leads from parts.
Page 300 Outboard Rigging Guide - 2001 Steer. Friction Kit – F30/F40 Tiller Handle STEERING FRICTION KIT – F30/F40 TILLER HANDLE (67C-W0084-00-4D) 6-20...
Page 301 Outboard Rigging Guide - 2001 Steer. Friction Kit – F30/F40 Tiller Handle STEERING FRICTION KIT – F30/F40 TILLER HANDLE (67C-W0084-00-4D) [Cont’d.] NO PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. 67C-W0084-4D-00 Handle Steering Ass’y 67C-26301-00-00 Throttle Cable Ass’y 67C-42121-00-04D Bracket 63D-48538-00-00 Clamp, Cable 1 90101-12M09-00...
Page 302 Outboard Rigging Guide - 2001 Steer. 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) 6-22...
Page 303 Outboard Rigging Guide - 2001 Steer. 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) [Cont’d.] NO PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. Handle Steering Ass’y 6G1-42177-00-00 •...
Page 304 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 5. Disconnect the oil level gauge coupler 6, the 40, 50 Tiller Handle trim sender coupler 7, and the power Installation Instructions Preparation for Remote Control Model trim/tilt switch lead coupler 8.
Page 305 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 3. Disconnect the brown lead terminals 4. 2. Install the grommet 1, engine stop switch lead 2, main switch lead 3, battery cable 4. Connect the neutral switch lead terminals 5. 4, extension wire harness 5, and the power trim/tilt switch leads 6.
Page 306 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 3. Install the fitting plate 1 and bolt 2. 5. Check the shift operation for unsmooth oper- T orque: B olt - 8N m ( 0.8m-kg, 5.8 ft-lb.) ation.
Page 307 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 7. Check the throttle for its fully open position. 10. For electric start models with instruments a. Turn the shift handle to the in-gear posi- (Illust.
Page 308 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle Completion Check Dynamic Check CAUTION: Static Check T he engine is going to be started for checking. 1. Check the shift operation. Make sure the shift M ake sure the engine has an adequate supply action is smooth for Forward, Neutral and of cooling water.
Page 309 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 6. Check the main switch. Steering Friction (63D-42508-00-00) a. Turn the main switch to “ON” from “OFF” then to “START.” The starting 1. Remove the cap 1. 2.
Page 310 Outboard Rigging Guide - 2001 Steer. Friction Kit – 40, C40, 50, C50 Tiller Handle 5. Adjust the friction force. 7. Install the fuel hose 1. a. Turn the friction lever 1 fully to the left WARNING b. Turn the nut 2 to adjust the steering fric- F it the fuel hose securely in the clamp.
Page 311 Outboard Rigging Guide - 2001 F40 4-Cyl, F/T50 Tiller Handle Kit F40 4-Cyl. F/T50 TILLER HANDLE KIT (62Y-W0086-Z0-4D) 6-31...
Page 312 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit F40 4-Cyl., F/T50 Tiller Handle Kit [Cont’d.] NO PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. 93430-04M03-00 • Circlip 62Y-W0086-20-4D Handle Steering Ass’y 63D-42121-00-4D • Bracket 63D-42131-10-00 • Cover, Handle Steering 63D-42111-00-4D •...
Page 313 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit 5. Disconnect the wire harness coupler 8. F50 Tiller Handle Installation Instructions Preparation for Remote Control Model 1. Remove the steering hook 1. 6. Disconnect the overheat, oil warning lead coupler 9, the trim sender lead coupler 10, 2.
Page 314 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit Neutral Switch – 3. Disconnect the brown lead terminal 4 and Remote Control Model the brown/blue lead terminal 5. 1. Install the neutral switch ass'y 1 and the slip plate 2.
Page 315 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit N O T E : Align the taped end (see illustration 2 5. Adjust the shift cable joint position. below) of the battery cable and the extension wire a. Turn the shift handle 1 to the neutral lead with the end of the grommet.
Page 316 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit Electric Start Model WARNING without Instruments (A) M ake sure the cable joint is screwed in more than 8mm ( 0.31in) . 9. Connect the main switch coupler 1 and the zip tie 2.
Page 317 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit N O T E : Fit the extension wire harness coupler 3. Install the following: into the zip tie, then zip tie the wire leads as 1 Collar 3 Washer shown.
Page 318 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit 6. Check the steering movement for smooth Completion Check operation. Static Check N O T E : With the friction lever turned fully to the right, check the tiller for smooth movement. 1.
Page 319 Outboard Rigging Guide - 2001 F40 4-Cyl., F/T50 Tiller Handle Kit Dynamic Check 6. Check the main switch. a. Turn the main switch to “ON” from “OFF” then to “START.” The starter CAUTION: motor turns over then the engine will start. T he engine is going to be started for checking.
Page 320 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit STEERING FRICTION KIT 60/C60/C70/70 TILLER HANDLE (6H3-W0086-Z0-4D) 6-40...
Page 321: 60, C60, C70, 70Hp Tiller Handle, Steering Friction Kit
Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit 60, C60/C70/70 Tiller Handle & Steering Friction Kit [Cont’d.] PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. 6H3-W0086-Z0-4D Handle Steering Ass’y 93430-04M03-00 Circlip 63D-42111-01-4D Handle, Steering 63D-42131-10-00 Cover, Handle Steering 664-42119-00-00 Grip, Steering Handle...
Page 322 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit Neutral Switch (for 70hp model) 4. Disconnect the power trim/tilt switch lead coupler 5. 1. Install the neutral switch assembly 1 and slip plate 2. 2. Install the neutral switch stay 3. Install the stay 3 with washer and the N O T E : bolt.
Page 323 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit Tiller Handle N O T E : a. Pass the wire harness and remote control 1. Remove (for 70hp model) the steering hook cables through the grommet, and refit the grommet.
Page 324 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit 5. Adjust the shift cable joint position. 7. Adjust the throttle cable joint position. a. Turn the shift handle 1 in neutral posi- a. Turn the throttle grip fully close. b.
Page 325 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit 9. Connect the following: Steering Friction 1 Main Switch Wire Lead Coupler 1. Remove the end cap 1. 2 Extension Wire Harness Coupler 3 Oil Level Gauge Lead Coupler 4 Trim Sender Lead Coupler 5 Power Trim/Tilt Switch Lead Coupler 6 Zip Tie...
Page 326 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit 4. Adjust the friction control nut 1 according Check tiller handle tilt up/down. Make sure to the following: the cables and wires are not stretched. Throttle Friction 1.
Page 327 Outboard Rigging Guide - 2001 60, C60/C70/70 Tiller Handle & Steering Friction Kit 7. Check the engine stop switch. a. Run the engine. b. Pull the lanyard off the lock plate. The running engine will stop. 5. Check start-in-gear protection. a.
Page 328 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit C90/90 TILLER HANDLE KIT (6H1-W0086-Z0-4D) & STEERING FRICTION 6-48...
Page 329 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit C90/90 Tiller Handle & Steering Friction Kit [Cont’d.] PART NUMBER DESCRIPTION QTY. PART NUMBER DESCRIPTION QTY. 6H1-W0086-Z0-4D Handle Steering Ass’y 63D-42131-10-00 Cover, Handle Steering 63D-42111-01-4D Handle, Steering 90480-14M14-00 Grommet 664-42119-00-00 Grip, SteeringHandle...
Page 330 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit INSTALLATION WARNING Neutral Switch S tart in gear protection will not operate with- 1. Install the neutral switch assembly 1 and out the neutral switch leads connected. slip plate 2. 5.
Page 331 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit 4. Install the cable clamp 1. Tiller Handle 1. Remove the steering hook 1. N O T E : The removed nut should be used for the handle installation, so keep it for the installation. 5.
Page 332 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit 6. Adjust the shift cable joint position. WARNING a. Turn the shift handle 1 to the neutral M ake sure the cable joint is screwed in more position. than 8mm ( 0.31in) .
Page 333 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit 11. Tie down with a zip tie 5. 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.
Page 334 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit Completion Check Dynamic Check CAUTION: Static Check T he engine is going to be started for checking. 1. Check the shift operation for smooth shifting T herefore the engine should be supplied cool- into Forward, Neutral and Reverse.
Page 335 Outboard Rigging Guide - 2001 C90/90 Tiller Handle & Steering Friction Kit 6. Check the main switch. 8. Check for steady engine speed. a. Turn the main switch to “ON” from a. Run the engine at idle. “OFF” then to “START.” The starter b.
Page 336 Outboard Rigging Guide - 2001 Outboards F30, F40 TILLER HANDLE, STEERING FRICTION INSTALLATION MANUAL 6A-1...
Page 337 Outboard Rigging Guide - 2001 TILLER HANDLE (For manual start model) Ref. No. Parts Name Qty. Remarks Tiller Handle Ass’y PREPARATION Remove: • Lock plate 1 Remove: • Fitting plate 2 6A-2...
Page 338 Outboard Rigging Guide - 2001 INSTALLATION Install: • Tiller handle ass’y 1 • Nuts 2 Nut: 38 Nm (3.8 m•kg, 27 ft•lb) Install: • Grommet 1 • Engine stop switch connectors 2 Install: • Cable stopper 1 • Rubber seal 2 •...
Page 339 Outboard Rigging Guide - 2001 Align the 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. •...
Page 340 Outboard Rigging Guide - 2001 OPTION - TILLER HANDLE AND STEERING FRICTIO KIT (For remote control model) Ref. No. Parts Name Qty. Remarks Tiller Handle Ass’y Neutral Switch Neutral Switch Stay Bolt Shift Control Lever Spring Pin Grommet Steering Friction Ass’y Bolt with Washer Extension, Wire Harness 10 pin - 12 pin...
Page 341 Outboard Rigging Guide - 2001 PREPARATION Remove: • Steering hook 1 Remove: • Fitting plate 2 Remove: • Grommet 3 • Cable stopper 4 • Rubber seal 5 Remove: • Shift cable joint 6 • Throttle cable joint 7 Disconnect: •...
Page 342 Outboard Rigging Guide - 2001 Remove: • Flywheel magnet cover 1 • Starter motor 2 Remove: • Shift rod lever ass’y 3 Remove: • Grease nipples 1 • Clamp 2 NEUTRAL SWITCH Install: • Shift control lever 1 • Spring pin 2 •...
Page 343 Outboard Rigging Guide - 2001 Disconnect: • Brown lead connector 1 Connect: • Neutral switch connectors 2 STEERING FRICTION Install: • Steering friction ass’y 1 • Clamp 2 • Bolt with washers (M5) 3 TILLER HANDLE Install: • Tiller handle ass’y 1 •...
Page 344 Outboard Rigging Guide - 2001 Install: • Fitting plate 1 • Bolts 2 Bolt: 10 Nm (1.0 m•kg, 7.2 ft•lb) Adjust: • Shift cable joint position Adjustment steps: Turn the shift handle 1 in neutral posi- • tion. Align the set pin 2 as shown. •...
Page 345 Outboard Rigging Guide - 2001 Check: • Fully open positionn Incorrect → Repair. 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. Connect: •...
Page 346 Outboard Rigging Guide - 2001 13. Install: • Starter motor 1 • Flywheel magnet cover 2 14 Check: • Friction force Turn the friction lever 1 to a or b. Incorrect → Retighten the nut 2. Friction is increased. Friction is decreased. Nut: 5 Nm (0.5 m•kg, 3.6 ft•lb) 15.
Page 347 Outboard Rigging Guide - 2001 Outboards F80, F100 TILLER HANDLE, STEERING FRICTION INSTALLATION MANUAL 67G-2819K-10 6B-1...
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. 6B-2...
Page 349 Outboard Rigging Guide - 2001 Ref. No. Parts Name Qty. Remarks Tiller handle assembly Zip tie Neutral switch Damper plate Switch stay Bolt Friction rod Steering friction set Link rod Bolt Washer Friction control Bolt Wing nut Extension, wire harness 10 pin —...
Page 350 Outboard Rigging Guide - 2001 TILLER HANDLE PREPARATION 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.
Page 351 Outboard Rigging Guide - 2001 6. Remove: • Bolt 1 • Grommet retaining plate 2 • Bolt 3 • Hose locating plate 4 • Grommet 5 • Bolt 6 • Cable clamp 7 7. Disconnect: • Overheat and oil warning lead coupler •...
Page 352 Outboard Rigging Guide - 2001 INSTALLATION 1. Install: • Tiller handle assembly 1 • Nut 2 Nut: 38 Nm (3.8 m•kg, 27 ft•lb) 2. Install: • Grommet 1 • Fuel Hose 2 • Battery wire harness 3 • Speedometer hose 4 •...
Page 353 Outboard Rigging Guide - 2001 5. Connect: • Trailer/PTT switch couplers 1 6. Install: • Intake silencer • Throttle control assembly • CDI unit cover • Junction box covers • Flywheel cover NOTE: Refer to “PREPARATION” section. 7. Install: • Shift control cable 1 •...
Page 354 Outboard Rigging Guide - 2001 • Loosen the locknut 1 and remove the clip 2. • Remove shift cable joint 3 from the set pin a. • Position the shift lever 4 in the neutral position. • Adjust the position of the shift cable joint until it aligns with the set pin.
Page 355 Outboard Rigging Guide - 2001 STEERING FRICTION 1. Install: • Bolt 1 • Wing nut 2 • Friction controller 3 • Link rod 4 • Bolt 5 • Washers 6 • Nut 7 NOTE: Tighten the nut so that the link rod can pivot, and so that it is not too loose.
Page 356 Outboard Rigging Guide - 2001 1. Check: • Start in gear protection Checking steps: • Shift in forward/reverse. • Turn the key to “START.” → The starting motor will not be turned. • Shift in neutral. • Turn the key to “START.” →...
Page 357 Outboard Rigging Guide - 2001 6. Check: • Throttle position sensor (TPS) output voltage (at idle speed) Out of specification → Refer to “SERVICE MANUAL.” Output voltage (P —O): 0.7 + 0.02V Checking steps: • Connect the test harness. • Connect the tester leads to the test harness (P —O).
Page 358 Outboard Rigging Guide - 2001 Outboards F80, F100 TILLER HANDLE, STEERING FRICTION OWNER’S MANUAL 6C-1...
Page 359 Outboard Rigging Guide - 2001 FEATURES 6C-2...
Page 360 Outboard Rigging Guide - 2001 STEERING FRICTION 1. Adjust: • Friction control nut 1 Steering friction to be; Increased Decreased THROTTLE FRICTION 1. Adjust: • Friction control nut 1 Throttle friction to be; Increased Decreased PTT SWITCH Operation steps: • Turn the main switch to “ON.” •...
Page 361 Outboard Rigging Guide - 2001 SECTION 7 - CONVERSION & STEERING KITS Remote Control Attachment Kits ........7-1 6/8HP Remote Control Attachment Kit .
Page 362: Remote Control Attachment Kits
Outboard Rigging Guide - 2001 REMOTE CONTROL ATTACHMENT KITS Model Mechanical Kit Electrical Kit/Part Notes 6 & 8hp 6G1-48501-50-00 Throttle & Shift 9.9/15 63V-48501-00-00 Throttle & Shift 63V-48511-01-00 Steering Hook 63V-61350-00-00 Steering Arm 63V-43131-10-00 Longer Steering Tilt Tube F9.9/T9.9 6G8-48501-03-00 Throttle &...
Page 363: 6/8Hp Remote Control Attachment Kit
N O T E : Be sure to grease all the washers, bush- ings and the shaft as shown. Use Yamaha Marine Grease. 2. Install the magneto control lever 3 onto the magneto control shaft as shown in the pre- ceding illustration.
Page 364 Outboard Rigging Guide - 2001 6/8HP Remote Control Attach. Kit 4. Adjust the accelerator link to properly fit 7. Fit the remote control cables to the bracket between the magneto control lever 1 and and secure them with the cable clamp. magneto control lever 3 as shown (distance 8.
Page 365 Outboard Rigging Guide - 2001 9.9/15 (2-STROKE) REMOTE CONTROL ATTACHMENT KIT (63V-48501-00-00) NO PART NUMBER DESCRIPTION QTY. 63V-48511-00 Hook, Steering 97395-08020-00 Bolt 92995-08600-00 Washer 63V-48501-00-00 Remote Control Attach. Ass’y 63V-48531-00-00 • Bracket, Remote Control 1 682-48538-50-00 • Clamp, Cable 1 91590-30012-00 •...
Page 366 Outboard Rigging Guide - 2001 9.9/15 (2-Stroke) Remote Control Attach. Kit Preparation Remote Control Attachment Assembly 1. Remove: 1. Install: • Grommet a • Bushing • Grommet b • Lever • Screw c • Rod • Plane Washer • Cotter Pin 2.
Page 367 Outboard Rigging Guide - 2001 9.9/15 (2-Stroke) Remote Control Attach. Kit 3. Install: Clamp Bracket Bolt • Bushing 1. Replace: • Shift Lever • Screw • Clamp Bracket Bolt Nut a a Tightening Torque: Screw Tightening Torque: 13 Nm (1.3 m•kg) 3.5 Nm (0.35 m•kg) 4.
Page 368 Outboard Rigging Guide - 2001 9.9/15 (2-Stroke) Remote Control Attach. Kit 3. Adjust: 4. Adjust: • Shift cable joint position • Throttle cable joint position A djustment S tep: • Place the remote control lever of the remote control box in Neutral Position. •...
Page 369 Outboard Rigging Guide - 2001 F9.9/T9.9 (4-Stroke) REMOTE CONTROL ATTACHMENT KIT (6G8-48501-03-00) NO PART NUMBER DESCRIPTION QTY. Remote Control Attach Assy 6G8-48531-51-00 • Remote Control Bracket 1 6G8-48532-50-00 • Remote Control Bracket 2 6G8-48538-50-00 • Cable Clamp 1 97395-06030-00 • Bolt 92990-06600-00 •...
Page 370 Outboard Rigging Guide - 2001 F9.9/T9.9 Remote Control Attach. Kit Removal 4. Remove the steering handle. Do this by first removing the white and black leads of the 1. Disconnect the cable joints from the engine. stop switch, behind the CDI unit cover. Loosen the locknut, and remove the cable joints and the locknuts from the control cables.
Page 371 Outboard Rigging Guide - 2001 F9.9/T9.9 Remote Control Attach. Kit 12. Remove the ring nut. 2. Pass the remote control cables through the bottom cowling. Installation 3. Install the remote control bracket onto the 1. Fit the grommet into fitting plate 1 and install bottom cowling, and tighten the nuts.
Page 372 Outboard Rigging Guide - 2001 F9.9/T9.9 Remote Control Attach. Kit 5. Install the collar on the shift handle pin and 7. Install the stop switch in the motor pan. clip the circlip. Connect the shift cable joint 8. Reconnect the white and black leads (see to the “R”...
Page 373: F15 Remote Control Attachment Kit
Outboard Rigging Guide - 2001 F15 REMOTE CONTROL ATTACHMENT KIT (66M-48501-00-00) NO PART NUMBER DESCRIPTION QTY. 65W-44142-00-00 Seal Joint 91690-30320-00 Pin, Spring 65W-44125-00-00 Lever, Shift Rod 90387-06M29-00 Collar 90201-06M31-00 Washer, Plate 97595-06525-00 Bolt, with Washer 66M-44192-00-00 Joint, Rod 1 90201-05M06-00 Washer, Plate 90468-18008-00 Clip...
Page 374 Outboard Rigging Guide - 2001 F15 Electrical Kit F15 ELECTRICAL KIT NO PART NUMBER DESCRIPTION QTY. 6G1-81941-10-00 Starter Relay Ass’y 6G1-81952-00-00 Holder, Relay 66M-82117-00-00 Wire, Lead 65W-8182B-00-00 Nut, Special 66M-82105-00-00 Wire Harness 95380-08700-00 92990-08600-00 Washer, Plate 65W-81870-00-00 Starting Switch Ass’y 8G1-42725-00-00 Grommet 6H3-82540-00-00...
Page 375: F25 Remote Control Attachment Kit
Outboard Rigging Guide - 2001 F15/F25 Remote Control Attach. Kit F25 REMOTE CONTROL ATTACHMENT KIT (65W-48501-00-00) NO PART NUMBER DESCRIPTION QTY. 91690-30320-00 Pin, Spring 65W-44142-00-00 Seal 91690-30320-00 Pin, Spring 90387-06M29-00 Collar 90201-06M31-00 Washer, Plate 1 97595-06525-00 Bolt, With Washer 65W-44192-00-00 Joint, Rod 1 90201-05M06-00 Washer, Plate...
Page 376 Outboard Rigging Guide - 2001 F15/F25 Remote Control Attach. Kit REMOVAL 7-15...
Page 377 Outboard Rigging Guide - 2001 F15/F25 Remote Control Attach. Kit INSTALLATION B.D. mm (0.31 in) 7-16...
Page 378: 25Hp Remote Control Attachment Kit - 2 Cyl
Outboard Rigging Guide - 2001 25HP REMOTE CONTROL ATTACHMENT KIT – 2 CYL. (6L2-48501-11-00) NO PART NUMBER DESCRIPTION QTY. Remote Control Attach. Kit 6L2-48544-01-00 Shift Control Lever 6L2-48534-01-00 Throttle Control Lever 90386-10009-00 Bushing 95780-08300-00 Flange Nut 6L2-42154-01-00 Control Joint 6L2-42191-01-00 Rod 1 6L2-42192-20-00 Rod 2...
Page 379 Outboard Rigging Guide - 2001 25HP Remote Control Attach. Kit 5. Install the bushing and throttle control lever 7. Install rod 1 on the shift rod link . Then, into the throttle joint control, and secure it loosen bolt to allow a small amount of gap with the nut flange.
Page 380 Outboard Rigging Guide - 2001 25HP Remote Control Attach. Kit 10. Screw a cable joint in each remote control General Torque cable. Then, align the opening of the cable Specifications joint with the control lever and secure the (Nut) (Bolt) m-kg ft-lb.
Page 381 Outboard Rigging Guide - 2001 25E REMOTE CONTROL CONVERSION KIT - 2-Cylinder NO PART NUMBER DESCRIPTION QTY. 6L2-42725-50 Grommet 6L2-86111-00 Coil, Solenoid 682-86117-00 Hook, Wire Pull 6L2-86115-00 Holder, Solenoid 98580-05008 Screw, Pan Head (7G3A) 92990-05600 Washer, Plain (646) 90480-10155 Grommet (664) 98580-04008 Screw, Pan Head (713) 92990-04200...
Page 382 Outboard Rigging Guide - 2001 25HP Remote Control Attach. Kit 4. Install the choke solenoid in the specified 6. Replace the grommet 3 . position, as shown below. Pass the wire harness and battery cord 1 Choke Solenoid Bracket through the grommet, and fit the grommet in 2 Bolt the bottom cowling.
Page 383 Outboard Rigging Guide - 2001 25HP Remote Control Attach. Kit 7. According to the wiring diagram, connect the wires correctly. Next, place the cover over the clamp. 9. Reinstall the silencer cover (which was 8. Retighten the four bolts (which were loos- removed in #2 on the previous page), and ened in #4 on the previous page) securing the retighten the four screws.
Page 384 N O T E : Apply Yamaha Marine Grease with re- installation. YA M A H A M A R I N E...
Page 385 YA M A H A M A R I N E G R E A S E 5. Apply Yamaha Marine Grease to the shift control lever (inner) and install it to the bot- 9. The parts shown below should be assembled tom cowling and the link rod.
Page 386 Outboard Rigging Guide - 2001 25HP Remote Control Attach. Kit 11. Screw in the cable joint (over the remote con- 12. Fit the new cover. trol cable) a minimum of 8mm (0.31 in). Align joint hole with the cable joint set pin, and lock it with the lock nut.
Page 387: 6/8Hp Electric Starter Conversion Kit
Outboard Rigging Guide - 2001 6/8HP ELECTRIC STARTER CONVERSION KIT (6G1-W0086-80-00) NO PART NUMBER DESCRIPTION QTY. Electric Starter Kit 682-81800-11-00 Electric Motor Ass'y 97313-08025-00 Bolt 92990-08600-00 Washer 682-81822-43-94 Electric Motor Bracket 97313-06025-00 Bolt 97313-06020-00 Bolt 97313-06030-00 Bolt 92903-06600-00 Washer 6G1-81941-10-00 Starter Relay Ass'y 6G1-81952-00-00 Starter Relay Holder...
Page 388 Outboard Rigging Guide - 2001 6/8HP Electric Starter Conversion Kit 2. Remove the three bolts holding the manual 6. Disconnect the carburetor linkage. Remove starter assembly and lift off the assembly. the two carburetor mounting bolts. Remove the carburetor and air box. 3.
Page 389 Outboard Rigging Guide - 2001 6/8HP Electric Starter Conversion Kit 9. Mount the starter motor on the bracket as 11. Install the grommet on the battery lead shown below. Install the lead wire (larger assembly and then route the lead through the end) on the connection on the bottom of the front panel as shown below.
Page 390 Outboard Rigging Guide - 2001 6/8HP Electric Starter Conversion Kit 13. Connect the color-coded leads of the wire 16. Reinstall the carburetor and reconnect the harness to the components of the bracket throttle and choke linkage. assembly. The wire harness end with the red 17.
Page 391 Outboard Rigging Guide - 2001 6/8HP Electric Starter Conversion Kit Wiring Be sure the wiring is connected as shown in the following diagram: 7-30...
Page 392: Steering Hooks
The steering hook is permanently A steering hook is necessary in order to guide any attached on 115hp models and larger. boat from the helm. Some Yamaha outboard motors come with a steering hook as standard equipment, or are designed to accommodate a hook for later adaptation to remote steering.
Page 393 Outboard Rigging Guide - 2001 Steering Hooks Installation T9.9 Mount the steering hook onto the steering bracket as shown below: 25HP and C40 9.9, 15, and F15 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.
Page 394: Steering Attachment Kits
There is a Yamaha Steering Attachment Kit made with readily available aftermarket product. for every outboard (from the 9.9hp model and up).
Page 395 Outboard Rigging Guide - 2001 Steering Attachment Kits Installation F/T9.9 1. Remove and discard the caps from both ends of the hollow steering/tilt tube. 2. Route the steering cable through the steering/tilt tube and attach the cable to the tube with the securing nut that is on the steer- ing cable.
Page 396 Outboard Rigging Guide - 2001 25HP (ER Model), 30HP ~ 90HP 115~250HP Including C Series 25HP~90HP/F80/F100/F115 F80/F100/F115 115~250HP 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.
Page 397 Outboard Rigging Guide - 2001 SECTION 8 - PROPELLERS Propellers ............8-1 Propeller Application Charts .
Page 398 Available blades provide superior mid-range fuel efficiency in aluminum for Yamaha 4hp & 5hp models, and and excellent anti-cavitation performance. For the stainless steel for 25hp & 30hp motors.
Page 399 Outboard Rigging Guide - 2001 Propellers Location of Letter Codes & Pitches The location of the letter code and pitch on the propeller varies. To find this information on alu- minum and stainless steel propellers, use the illus- tration and the corresponding table below. The circles numbered in the illustration indicate the location of the letter code and corresponds with the far left column in the table.
Page 400 Outboard Rigging Guide - 2001 PROPELLER APPLICATION CHARTS Small Engines MODEL DIA. PITCH DESCRIPTION PART NUMBER 7-1/4 Plastic, Std 6A1-45943-00-00 7-1/4 7-1/4 Aluminum, Std 6L5-45945-00-EL 7-1/4 8-1/4 Aluminum 6L5-45947-00-EL 4/F4/5 7-1/2 Aluminum, Std 6E0-45943-01-EL 7-1/2 Aluminum 6E0-45941-01-EL Aluminum, Dual Thrust 6G1-W4591-01-EL 8-1/2 6-1/2...
Page 401 Outboard Rigging Guide - 2001 Propeller Application Charts Propellers for the T25, F30, 40, C40, F40, C50, F50 DIAM. PITCH DESCRIPTION PART NUMBER 12-1/4 Aluminum 663-45956-01-EL 11-5/8 Aluminum 663-45947-02-EL 10-5/8 Aluminum 6H5-45952-00-EL 10-3/8 Aluminum 6H5-45945-00-EL 10-1/4 Aluminum 6H5-45958-00-EL 11-1/4 Aluminum 663-45958-01-EL Aluminum 6H5-45943-00-EL...
Page 402 Outboard Rigging Guide - 2001 Propeller Application Charts Propellers for the T50, 60, C60, C70, F80, 90, C90, F100, 115, F115, & 130 DIAM. PITCH DESCRIPTION PART NUMBER Aluminum 6E5-45954-00-EL 13-5/8 Aluminum 6E5-45949-00-EL 13-1/2 Aluminum 6E5-45947-00-EL 13-1/4 Aluminum 6E5-45945-01-EL Aluminum 6E5-45941-00-EL 12-5/8 Aluminum...
Page 403 Outboard Rigging Guide - 2001 Propeller Application Charts Propellers for the 150, SX150, V150, VX150, VZ150, Z150, V175, Z175, SX200, VX200, Z200, SX225, VX225, SX250 DIAM. PITCH DESCRIPTION PART NUMBER 15-1/4 Aluminum 6G5-45941-00-98 14-5/8 Aluminum 6G5-45952-00-98 14-1/2 Aluminum 6G5-45947-01-98 Aluminum 6G5-45945-01-98 Aluminum 6G5-45943-01-98...
Page 404 Outboard Rigging Guide - 2001 Propeller Application Charts Propellers for the D150, DX150 DIAM. PITCH DESCRIPTION PART NUMBER Front TRP MAR-TRP14-19-FR Rear TRP MAR-TRP13-19-RR Front TRP MAR-TRP14-21-F2 Rear TRP MAR-TRP13-21-R2 Front TRP 65N-45941-00-00 Rear TRP 65N-45943-00-00 Front TRP 65N-45945-00-00 Rear TRP 65N-45947-00-00...
Page 405 Outboard Rigging Guide - 2001 Propeller Application Charts Propellers for the LX150, LZ150, LX200, LZ200, LX225, LX250 DIAM. PITCH DESCRIPTION PART NUMBER 14-1/2 Aluminum 6K1-45947-00-98 Aluminum 6K1-45945-00-98 15-1/4 Stainless Steel 6K1-45970-01-98 13-3/4 Stainless Steel 6K1-45978-01-98 13-3/4 Stainless Steel 6K1-45974-01-98 13-3/4 Stainless Steel 6K1-45972-01-98 13-3/8...
Page 406 NOTES...
Page 407 NOTES...
Page 408 Outboard Rigging Guide - 2001 SECTION 9 - RIGGING COMPONENTS/KITS Portable Fuel Tank ..........9-1 Remote Oil Tank Mounting Instructions (2.8 Gal.
Page 409 Outboard Rigging Guide - 2001 PORTABLE FUEL TANK Yamaha offers two different types of portable fuel tanks. One series is galvanized metal and the other is the Scepter heavy-duty plastic. Provided here are their part numbers and also replacement part numbers.
Page 410 Outboard Rigging Guide - 2001 REMOTE OIL TANK MOUNTING INSTRUCTIONS (2.8 Gal. and 5.0 Gal.) Remote Oil Tank 2.8 Gallon (61A-21708-03-00) A remote oil tank bracket should be used to secure N O T E : When installing the oil tank and routing the oil tank at the desired mounting location.
Page 411 Outboard Rigging 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 Ref. Description Qty. sealant or other material from the boat deck. Filler Cap Ass'y: Deck plate with cap 6. Remove the original Yamaha Oil Tank Cap, Oil Tank Reducer Fitting w/Gasket (6E5-24478-01-00) and install the reducer fitting in its place. Be...
Page 413 Outboard Rigging Guide - 2001 VERTICAL STARTER The sailboat owner will appreciate the conve- Vertical Starter Installation nience of the optional vertical starter. Simply bolt it to the motor and it redirects the starter rope to 1. Remove the starter assembly. pull vertically.
Page 414 Outboard Rigging Guide - 2001 OUTBOARD DISPLAY STANDS Outboard display stands are useful sales tools. Potential owners are able to get an up-close look at the motor while it sits on these handsome stands. Part Number Applicable Models ABA-STAND-00-SM 2~8HP (small size) ABA-STAND-00-MD 9.9~30HP, C25~30 (medium size)
Page 415 Outboard Rigging Guide - 2001 Outboard Display Stands Display Stand Assembly 1. Install the skeg base plate as shown. 2. Take the display stand in hand and align the outboard's cavitation plates, (LH & RH) and N O T E : Be sure the upper cavitation plate support skeg with that of the cavitation plate supports slot faces inboard.
Page 416 Outboard Rigging Guide - 2001 Outboard Display Stands 3. Insert the upper support bolt through the 4. Insert the lower skeg support pinch bolt tubes located directly under the cavitation through the rear hole of the skeg plate. Place supports of the left and right-hand main sup- one hex nut onto the bolt and tighten.
Page 417 Outboard Rigging Guide - 2001 SECTION 10 - APPENDICES 6X1 Dual Station System - Installation Manual ......10A 6X1 Dual Station System - Service Guide .
Page 418 Outboards DUAL STATION SYSTEM INSTALLATION MANUAL YAMAHA MOTOR CO., LTD. 6X1-28199-Y2 10A-1...
Page 419 6X1 Dual Station System 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 NOTICE The 6X1 Dual Station System has been developed for use in boats with two helm stations, such as off-shore fishing boats with “tuna towers.” The Dual Station System allows control of throttle and shifting of the outboard motor(s) from either station. For the correct installation and checking of the 6X1 dual station system, please read this manual carefully and thoroughly.
Page 421 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 :...
Page 422 CONTENTS NOTICE ..............1 GENERAL INFORMATION .
Page 423: Notice
GENERAL INFORMATION WIRING AND COMPONENT PARTS Single engine system: Second station 10A-6...
Page 424: Twin Engine System
Twin engine system: Second station 10A-7...
Page 425: Control Functions
CONTROL FUNCTIONS DIGITAL TACHOMETER This meter is integrated with the tachometer, trim-meter and oil-level warning meter. 1 Tachometer 2 Trim-meter 3 Oil-level warning indicator Tachometer This meter indicates the engine speed. Readings are digitally displayed in hundreds (100) of rpm. Trim-meter The trim level is shown by segments;...
Page 426: Switch Panel
SWITCH PANEL 115~200-hp 1 Main switch 2 Choke switch 3 Engine start button 4 Engine stop button 5 Engine stop switch 115~200-hp First station (except Prime Start models): When the engines are cold and need the acti- vation of the choke switch, they must be start- 225~250-hp ed from the first station.
Page 427: Installing Instrument
INSTALLING INSTRUMENT For the single engine switch panel Second station SWITCH PANEL WARNING Disconnect battery leads before installing or disconnecting electrical com- ponents. CAUTION: 115~200-hp First station Install the switch panel on the dashboard in a position allowing easy access from the helmsman’s seat.
Page 428 DIGITAL TACHOMETER NOTE: Before installing the tachometer, make sure the terminal plate is set to the 12-pole position. If it is set on the other side, the tachometer will not show correct measurement. 1) Install the digital meter onto the dash- board.
Page 429: Preparation Before Rigging
To prevent excessive end play, these cable selection recommendations should be fol- lowed: Use quality cables To reduce the internal space and reduce the resulting end play to a minimum, always use YAMAHA CONTROL CABLES or cables of equivalent design and quality. 10A-12...
Page 430 ALL THREE THROTTLE CABLES . 50 FEET 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...
Page 431: Actuator Installation
ACTUATOR INSTALLATION WARNING Do not mount the actuator in a location which prevents operation of the emergency lever and emergency manual shift lever. This would prevent the operator of the boat from being able to override the shift acuta- tor manually if the system is not function- ing correctly.
Page 432: Attaching The Identification Labels
ATTACHING THE IDENTIFICATION LABELS 1) Attaching the labels to the cables (in case of a single engine installation, use only the Throttle and Shift labels.) Attach the labels to their corresponding cables. Two identical labels are provided for each identification. Attach them to both ends of the cable.
Page 433: Rigging
RIGGING CONNECTING THE CABLES-SUMMARY Connecting the cables in the following order: A: 704 remote control boxes B: Remote 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...
Page 434: Connecting The Cables To The Remote Control Boxes
A. CONNECTING THE CABLES TO THE REMOTE CONTROL BOXES NOTE: Additional rigging information on the 704 con- trol boxes is contained in the 704 Remote Control Box Operation Manual. 1) Install the upper and lower 704 shift and throttle cable ends 13mm on to the cables.
Page 435 3) Remove the upper clamps 4) Install both throttle cables into the junc- tion unit. When doing this, pull slightly on the cables and note the location of the holder slots to the grooves in the cables. If required, readjust the brass cable ends until both cables align the same.
Page 436 Installing the control box shift cables to the junction unit. 1) Install the dual station brass barrel ends on the shift cables from the 704 control boxes. When doing this, pull slightly on the cable to eliminate any backlash and then push slightly in order to find the center point.
Page 437: Connecting The Throttle Cable To The Dual Station Junction Unit
C. CONNECTING THE OUTBOARD THROTTLE CABLE TO THE JUNCTION UNIT 1) Install the outboard throttle cable ends 16mm on to the cable. Tighten jam nut, then install the cable ends on the junction unit. CAUTION: When changing the cable end piece posi- tion.
Page 438: Connecting The Cables To The Outboard Motor
5) Run the shift cable through the shift rack and fix the cable at the end with the rod clamp. 6) Bring the groove of the shift cable to that at the actuator side and install the cable. 7) Install the water prevention cap by referring the illustrations.
Page 439 Connecting the shift cable to the outboard motor. 1) Install the motor’s shift cables in the outboard motor. Again, when doing this, pull slightly on the cable to eliminate any backlash and then push slightly in order to find the center point. CAUTION: Make certain that the clamp groove fits in the C hub groove of the shift cable without...
Page 440: Connecting The Wire Harnesses
CONNECTING THE WIRE HARNESS CAUTION: Length of the extension wire harness should be 6m (20 ft.) or less. Use of longer harness may cause defective operation of the acutator. CONNECTING THE WIRE HARNESSES FOR THE UPPER STATIONS 1) Feed the wire harness between the first and second station.
Page 441: Testing
TESTING WARNING • Dual Station controls must be tested after rigging. Improperly installed or adjusted com- ponents could operate incorrectly, which would increase the chance for loss of control and an accident. • Test the operation with the boat properly supported on land. •...
Page 442: Checking Actuator Operation
CHECKING ACTUATOR OPERATION 1) Turn the main switch to ON and adjust the cable lengths at engine side according to the following specifications with the remote control lever at neutral, forward and reverse position. Shift Specification in mm (in.) V4/V6 : 198mm (7.80 in.) Neutral 250-hp : 189mm (7.40 in.)
Page 443: Shift Voltage Adjustment
3) Place the remote control lever in neutral and turn the main switch to start to check that the engine is started. In case the engine is not started, refer SHIFT VOLTAGE ADJUST- MENT. Page 21. SHIFT VOLTAGE ADJUSTMENT In case the engine is started at either forward or reverse shift through the cable lengths are within the specifications, check the shift volt- age by using the following procedure.
Page 444 3) Remove three screws securing the shift side cover. 4) Remove two tabs on junction unit shift side and pull out the cable clamps. 5) Move the remote control lever between forward and reverse positions at the first station several times and place the shift cam in the junction unit in neutral.
Page 445 10) Move the remote control lever between forward and reverse positions at the first station several times and place the shift rack in the junction unit in neutral. Check if the grooves on the rack and cable end are offset each other. Repeat the check at the second station.
Page 446: Shift Stroke Adjustment
SHIFT STROKE ADJUSTMENT If the engine shift cable is over 12 feet in length, it may be necessary to adjust the actu- ator shift stroke travel to compensate for exces- sive cable end play. Shift cable end play can be measured by holding one end of the cable while lightly pushing and pulling the opposite end.
Page 447 5) Remove shift cable from the actuator cam and turn main switch to ON. NOTE: The actuator should move the shift cam to neu- tral position automatically. 6) Confirm that the shift position at engine side is in neutral and then install the shift cable on the shift cam at actuator side.
Page 448: Testing Throttle Operation
TESTING THROTTLE OPERATION When testing the throttle operation, use two people. With the engine off, the main switch off and the lanyard removed, position one person at the engine with the cowling removed to observe throttle movement to verify correct operation. The second person should operate the controls. Operate the first station in the following sequence and observe operation: 1) Shift to forward and move the lever to full throttle.
Page 449: Installation
INSTALLATION OPTIONAL MOUNTING BRACKET MOUNTING BRACKET (p/n ABA-DSBKT-00-00) If only limited space is available to mount either the junction unit and or the actuator, an option- al mounting bracket 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...
Page 450: Fastening The Junction Unit And The Actuator To The Cabin Floor
FASTENING THE JUNCTION UNIT AND THE ACTUATOR TO THE CABIN FLOOR Fastening the units using bolts 1) Bore holes, each 8.5mm (0.335 in.) in diameter, in the cabin floor using a tem- plate. 2) Tighten the hexagon headed bolts. Screw: 1.5 Nm (0.15 m•kg, 1.1 ft•lb) 1-A Using an optional mounting bracket 1) Select a place for installation which is...
Page 451 After all the installation is completed, check that the cables are properly connected as shown below. 10A-34...
Page 452: Adapter
ADAPTER WARNING This adapter is required for older Yamaha outboards. Refer the “Applicable Models” section for details. Installation instructions: 1) Remove the top cowling and remove the cover from the CDI unit on the outboard motor. 2) Remove the white wire on the CDI from the main harness.
Page 453: Wiring Diagram
WIRING DIAGRAM FIRST STATION (Single engine) 10A-36...
Page 454: Second Station (Single Engine)
SECOND STATION (Single engine) 10A-37...
Page 455: First Station (Twin Engine)
10A-38...
Page 456: Second Station (Twin Engine)
10A-39...
Page 457 Outboards DUAL STATION SYSTEM SERVICE GUIDE 10B-1...
Page 458 6X1 Dual Station System 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 Specifications given in this manual may be subject to change without 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:...
Page 460 10B-4...
Page 461 CONTENTS EXTERNAL VIEW ............10B-6 OUTLINE OF FEATURES .
Page 462: External View
Outboard Rigging Guide - 2001 EXTERNAL VIEW OUTLINE OF FEATURES 10B-6...
Page 463: Features And Benefits
Outboard Rigging Guide - 2001 FEATURES AND BENEFITS ELECTRIC SHIFTING SYSTEM The dual station system uses an electric servo system to have the system perform the shifting oper- ation. The shifting motion of the remote control 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.
Page 464: Emergency Manual Shift System
Outboard Rigging Guide - 2001 EMERGENCY MANUAL SHIFT SYSTEM The emergency manual shift system is provided against failure in shifting with the remote control lever. 1 Emergency lever (red) 2 Shift rack 3 Emergency manual shift lever Lifting up the emergency lever 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.
Page 465: Shift Cut System
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. WARNING Without the adapter, use of the shift cut system on those models not listed in the SAFETY INFORMATION disable the system.
Page 466: Automatic Interlock System
Outboard Rigging Guide - 2001 AUTOMATIC INTERLOCK SYSTEM The dual station unit allows automatic switch- station, the settings cannot be altered at the ing of throttle and shift control between the first other station. In other words, the throttle and and second stations.
Page 467: Second Station Switch Panel
Outboard Rigging Guide - 2001 SECOND STATION SWITCH PANEL The switch panel of the second station has one trol and one emergency stop switch. An alarm start button (two start buttons on the twin buzzer on the rear of the switch panel sounds engine model), one stop button (two stop but- if the warning system is activated.
Page 468: Warning Functions
Outboard Rigging Guide - 2001 WARNING FUNCTIONS This dual station control system has a shift dis- engagement failure warning and a shift engagement failure warning functions. Buzzer on the remote control box or the switch panel warns of the failure. Shift disengagement failure warning.
Page 469 For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23. Run to the nearest port immediately and consult your YAMAHA dealer. WARNING Do not cruise if the emergency lever and emergency manual shift lever have to be used.
Page 470 Power failure or shift disengagement failure warning. In case of power failure or shift disengagement failure on either of the two outboards; • The buzzers for both of the outboards should sound. • Speeds of the two engines should be reduced to about 2000 rpm.
Page 471: Shift Engagement Failure Warning
For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23. Run to the nearest port immediately and consult your YAMAHA dealer. WARNING Do not cruise if the emergency lever and emergency manual shift lever have to be used.
Page 472 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 473 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: Warning System
Outboard Rigging Guide - 2001 WARNING SYSTEM A warning buzzer is provided for the second station. With the addition of the second station mode, the warning system functions as follows. 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.
Page 475: Engine Stop Switch
Outboard Rigging Guide - 2001 Engine stop switch ON (Lock plate OFF) • The warning ends when the engine is restarted with the lock plate ON or when the main switch is turned off. 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.
Page 476: Oil Level Warning
Outboard Rigging Guide - 2001 Oil level warning (Oil level sensor 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 oil level is low.
Page 477: Optional Parts Information
Outboard Rigging Guide - 2001 OPTIONAL PARTS 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: Technical Tips
TECHNICAL TIPS SHIFT MOTOR WILL NOT OPERATE Emergency manual shift system Emergency lever and emergency manual shift lever are provided against failure in shifting with the remote control lever. NOTE: • It is recommended to use a person specif- ically for operating these lever. The person operating these levers and the person operating the remote control lever for the adjusting the engine speed should...
Page 479 NOTE: The emergency manual shift lever 2 must be moved in the direction opposite to the remote control lever. Moving the emergency manual shift lever 2 in the same direction as the remote control lever causes the buzzer to sound. Operating procedure at shift disengagement failure NOTE:...
Page 480: Rigging Instructions
Outboard Rigging Guide - 2001 RIGGING INSTRUCTIONS ALL COMPONENTS IN ONE PACKAGE The 6X1 dual station includes a 704 remote and purchased separately in the past, are sup- control box, digital tachometer, switch panel, plied in a single package, thereby offering the wire harness, dual station unit and actuator.
Page 481: Preparation Of Installation
Outboard Rigging Guide - 2001 PREPARATION OF INSTALLATION Attaching 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: Arranging The Remote Control Cables, Wire Harnesses And Steering Cables
Outboard Rigging Guide - 2001 Arranging the remote control cables, wire harnesses and steering cables 10B-26...
Page 483: Precautions When Routing Cables
Outboard Rigging Guide - 2001 Precautions when routing cables When rigging the second station, pass each cable and wire harness up through the pipe as illustrated below. Wire harness: 1 Pass a rope through the pipe and tie it to the wire harness.
Page 484: Service Procedures
Outboard Rigging Guide - 2001 SERVICE PROCEDURES CHECKING ACTUATOR OPERATION 1) Turn the main switch to ON and adjust the cable lengths at engine side according to the following specifications with the remote control lever at neutral, forward and reverse position. Shift Specification in mm (in.) Neutral...
Page 485: Shift Voltage Adjustment
Outboard Rigging Guide - 2001 3) Place the remote control lever in neutral and turn the main switch to start to check that the engine is started. In case the engine is not started, refer to the SHIFT VOLTAGE ADJUSTMENT. Page 10B-29.
Page 486 Outboard Rigging Guide - 2001 3) Remove three screws securing the shift side cover. 4) Remove two tabs on junction unit shift side and pull out the cable clamps. 5) Move the remote control lever between for- ward and reverse positions at the first sta- tion several times and place the shift cam in the junction unit in neutral.
Page 487 Outboard Rigging Guide - 2001 10) Move the remote control lever between for- ward and reverse positions at the first sta- tion several times and place the shift rack in the junction unit in neutral. Check if the grooves on the rack and cable end are offset each other.
Page 488: Shift Stroke Adjustment
Outboard Rigging Guide - 2001 SHIFT STROKE ADJUSTMENT If the engine shift cable is over 12 feet in length, it may be necessary to adjust the actu- ator shift stroke travel to compensate for exces- sive cable end play. Shift cable end play can be measured by holding one end of the cable while lightly pushing and pulling the opposite end.
Page 489 Outboard Rigging Guide - 2001 5) Remove shift cable from the actuator cam and turn main switch to ON. NOTE: The actuator should move the shift cam to neu- tral position automatically. 6) Confirm that the shift position at engine side is in neutral and then install the shift cable on the shift cam at actuator side.
Page 490: Adapter
Outboard Rigging Guide - 2001 ADAPTER WARNING This adapter is required for older Yamaha out- boards. Refer to the “Applicable Models” sec- tion for details. Installation instructions: 1) Remove the top cowling and remove the cover from the CDI unit on the outboard motor.
Page 491: Special Service Tool
Outboard Rigging Guide - 2001 WARNING The adapter must be connected correctly. Be sure the main switch, engine stop 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.
Page 492: Specifications And Maintenance Data
Frequency of maintenance operations may be If replacement parts are necessary, use only adjusted according to the operating conditions, genuine Yamaha parts or equivalents of the but the following table gives general guidelines. same type and of equivalent strength and materials.
Page 493: Wiring Diagram
Outboard Rigging Guide - 2001 WIRING DIAGRAM FIRST STATION (Single engine) 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...
Page 494 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 10B-38...
Page 495 Outboard Rigging Guide - 2001 10B-39...
Page 496 Outboard Rigging Guide - 2001 10B-40...
Page 497 F A X C O R R E C T I O N S H E E T If an error is found in this book, please make copies of this page and FAX to Yamaha: DEALER NUMBER: _____________________ DATE: _________________________________...

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Yamaha T8 Rigging Manual

Section 1 -

Standard Equipment, Rigging Kits, and Crate Contents

Remote Controls

Section 5 - Instrument & Gauge Installations

Section 6 - Tiller Handle Kits

Tiller Handle Kits

Section 6

Section 7 - Conversion & Steering Kits

Conversion & Steering Kits

Section 7

Section 5

Notice

General Information

Control Functions

Installing Instrument

Preparation before Rigging

Rigging

Testing

Installation

Wiring Diagram

Section 6

External View

Features and Benefits

Optional Parts Information

Technical Tips

Rigging Instructions

Service Procedures

Special Service Tool

Specifications and Maintenance Data

Wiring Diagram

Quick Links

Chapters

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Summary of Contents for Yamaha T8

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Table of Contents