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2-29

Outboard Rigging Guide - 2001

Jet Drive Eng. Mtg., Maintenance,

Shift Cable Instruction, Service Info.

If you have trouble locating these impellers
on the market, contact your dealer.

Some calls have been received regarding dif-
ficulty removing the impeller. The impeller
doesn't corrode with the shaft because there is
a delrin sleeve separating them. What can
happen, however, is that the driving torque
causes the flat on the shaft to "cam" or wedge
the key in the impeller.

To relieve this wedging, rotate the impeller
on the shaft until the keyway in the impeller
is perpendicular to the flat on the shaft. This
can be done with a soft hammer on a block of
wood, or by using a C-clamp on one blade
and bumping the clamp.

The impeller is now free to pull it. If neces-
sary, use two wood levers, about 3/4" x
1-1/2" x 12", wedged under the blades against
the housing flanges to assist with removing
the impeller.

9.

Some larger displacement jet drives have
experienced a performance problem above
4500rpm up to 5500rpm. On affected units,
there may be little or no change in boat speed,
only more noise. What may be happening is
impeller cavitation. This can happen if the
impeller liner is pushed too far into the foot.

Look up into the jet from the bottom of the
foot. If the liner is pushed too far in, there is
a lip that the water must go around. To correct
the problem, remove the grates and grind
down this lip to make a smooth path for the
water.

Overhaul Procedures

NOTE: It is recommended that these procedures
be performed by only your authorized Yamaha
Outboard Motor Dealer.

Disassembly

Refer to “Assembly and Installation” (page 2-23),
and reverse the procedures outlined here.

Bearing Housing

1.

Remove the large beveled circlip from the
bearing housing. Gently warm the housing
with a torch until it is just too hot to comfort-
ably touch.

Do not apply too much heat because the seals
may be damaged.

2.

Holding the driveshaft vertically, bump the
impeller end of the shaft against a wooden
block until the housing slides down off the
bearings.

3.

Note the direction of thrust faces of the bear-
ing(s), and press the bearing(s) off the drive-
shaft. Leave the round thrust ring on the shaft
unless it is damaged. Remove the seals from
the bearing housing and upper seal housing.
Clean all parts thoroughly and remove all
burrs.

NOTE: The inner seals are located on both sides
by spiral seal-retaining rings that must be
removed prior to extraction of the inner seals.

4.

FOR 40 AND 50 MODELS ONLY:
Before pressing on the collar, first, install the
coated thrust washer with the gray Teflon
coating facing the bearing. Note the direction
of the thrust face, and press the new bearing
onto the shaft, pressing against the inner race
only. Press against the thrust ring, locking it
in its groove.

FOR 90 AND V4/V6 MODELS ONLY:
Using Yamaha special tool #YB-06075, note

CAUTION:

«
...
90
91
92
93
94
...
»

Summary of Contents for T8

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

Page 2: ......

Page 3: ...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 feat...

Page 4: ...s Crate Contents Engine Dimensions Mounting Mounting Equipment Electrical Remote Controls Instruments Gauge Installations Tiller Handle Kits Remote Control Conversion Kits Steering Kits Propellers Fue...

Page 5: ...ns 2 6 Transom Drill Fixture 2 10 Four Stroke Splash Guards 40 F100 Splash Plates 2 11 Jet Drive Model Identification and Serial Numbers 2 12 Jet Drive Engine Mounting Maintenance Shift Cable Instruct...

Page 6: ...ications 4 3 701 Remote Control Assembly 4 4 703 Control Assemblies 4 8 704 Binnacle Mount Remote Control Assemblies 4 18 705 Flush Side Mount Remote Control Assembly 4 32 Remote Control Cables Remote...

Page 7: ...Handle Kit 6 15 F30 F40 3 Cylinder Tiller Handle Steering Friction Kit 6 20 40 C40 50 C50 Tiller Handle Steering Friction Kit 6 22 F40 4 Cylinder F T50 Tiller Handle Steering Friction Kit 6 31 C60 C7...

Page 8: ...able Fuel Tank 9 1 Remote Oil Tank Mounting Instructions 2 8 Gal and 5 0 Gal 9 2 Oil Deck Filler Plate Mounting Instructions 9 4 Vertical Starter 9 5 Outboard Display Stands 9 6 SECTION 10 APPENDICES...

Page 9: ......

Page 10: ...or other components Be aware that warnings alone do not eliminate dangers or are they a substitute for safe boat handling and proper accident prevention measures 1 Introduction This will include a br...

Page 11: ...ORG Orange Trim position sender Accessory feed P or Pnk Pink P or Pk Pink Oil overheat signal ground Fuel gauge sender Trim signal W or WHT White W or WHT White Ignition stop circuit SW1 oil transfer...

Page 12: ...il level sensor SW2 oil transfer circuit L R Blue Red Main tank oil level sensor SW3 No oil warning circuit L W Blue White Main tank oil level sensor SW1 Oil transfer OFF circuit L Y Blue Yellow Shift...

Page 13: ...nversion following in parenthesis 1 0 m 3 3 ft Other Symbols The symbol is used to indicate either one fig ure through another or and following For example 2 15HP would mean the 2 3 5 8 9 9 and 15 HP...

Page 14: ...536 kg 1 gram 0 0353 oz gram x 0 0353 oz 1 oz 28 3286 oz x 28 3286 gram TEMPERATURE C 9 5 32 F C x 1 8 32 F 9 5 F 32 C F 32 x 5 9 C 5 9 is approx 0 555 Note 40 C 40 F 0 C 32 F 100 C 212 F PRESSURE 1kg...

Page 15: ...Electric Start L 20 H Tiller Handle K 1985 1997 D Twin Rotating Propellers 9 9 P Power Tilt w Electric Start X 25 J 1986 DX Twin Rotating 200 E Manual Tilt w Electric Start U 30 H 1987 3 3 Cyl Propel...

Page 16: ...cation It is located on the port side of the lower cowling Explanation of the engine family code 6G6 S X 2 0 0 T L R Z L 0 0 1 7 8 6 YAMAHA MOTOR CO LTD MADE IN JAPAN PAYS D ORIGINE JAPON YAMAHA PRIMA...

Page 17: ...ystem contamination 3 OPTIONAL Run fuel line from the outlet side of the water fuel separator to the fuel management sender inlet side The fuel flow is indicated by the arrows in the following illustr...

Page 18: ...ing Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Oil Warning Lead 5 Remote Oil Tank Lead 6 Trim Gauge Lead 7 Battery Leads w Isolator Lead 8 Oil Hose 9 Fuel Hose Speedometer Hose F80 F...

Page 19: ...next whole foot Add 3 feet for loop see illustration below Remote Control Cables Yamaha remote control cables are available in lengths from 6 feet to 36 feet The cables utilize 10 32 threaded ends TY...

Page 20: ...nent Rigging as efficiently as possible means setting up the control box just once without having to open the box again to readjust the cable ends after hookup to the motor Refer to the following dia...

Page 21: ...3 LEAD 6 POLE 12 POLE 4 STROKE 2 STROKE OFF NUMBER OFLEADWIRES ONTRIM SENSOR 1 2 3 FACTORYSETTINGS ON km h mph mile h knot nautical mile 5 105 U S A 30 230 EUROPE 180 0 6Y5 83570 S4 00 YAMAHA INDICAT...

Page 22: ...system either by the primer bulb or electric primer pump This ensures against any fuel leaks Repair them immediately if found It is especially impor tant for EFI and HPDI engines to help avoid dam age...

Page 23: ...SE SF SG or SH Perform the following steps when adding oil to the engine 1 Remove the oil filler cap Place 3 4 of the rec ommended amount of oil per the service manual 2 Ensure the engine is level be...

Page 24: ...e an accident could occur Fuel Oil 1 Make sure there is plenty of fuel oil for the scheduled trip 2 Make sure there are no fuel or oil leaks nor gas fumes 3 Be sure the fuel oil hoses are not being fl...

Page 25: ...eed 6 0 inches for engines greater than 200hp and all 3 1L 0X66 engines including the V200 3 1L EFI An anti siphon valve required if the fuel system drops below the top of the fuel tank will cause a 1...

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

Page 27: ...Tilt Operation Instrument Operation Power Trim Tilt Fluid Level Trim Tab Adjustment retorque after operation Power Trim Tilt Operation control pan switch Idle RPM Single P _____ S _____ Gear Oil Level...

Page 28: ...s could become oil fouled and affect engine performance Make sure to mix gasoline petrol and oil com pletely otherwise the engine may be damaged Procedure 1 First 10 minutes run the engine at idle or...

Page 29: ...uired The Commonly Used Rigging Accessories chart lists many frequently used components like gauges fuel filters riggings hoses and optional control box spacers with their Yamaha part num bers The Qui...

Page 30: ...Gray ABB RIGHS GY 25 Cut to length Rigging Hose 25 Ft Blue ABB RIGHS BE 25 Cut to length Rigging Hose 100 Ft Black ABB RIGHS BK 50 2 50 ft hoses in box Rigging Hose 100 Ft Gray ABB RIGHS GY 50 2 50 f...

Page 31: ...Harness 10 Pin Main Harness 6 6 ft OPT 688 82586 11 00 Use as needed 9 9 ft OPT 688 8258A 30 00 Installing Engine with 704 Single Binnacle or 705 Flush Mount Control Control Cables1 2 req ABA CABLE XX...

Page 32: ...00 Engine to Tach Harness2 Non Oil Injected Engines No Four Stroke Engines OPT 1 Req 9 8 ft OPT 6R3 82553 30 00 16 4 ft OPT 6R3 82553 50 00 22 9 ft OPT 6R3 82553 70 00 26 2 ft OPT 6R3 82553 80 00 31 2...

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

Page 34: ...30 00 16 4 ft OPT 64D 82553 50 00 Single Gauge Kit 23 ft STD 64D 82553 70 00 Dual Gauge Kit 26 2 ft STD 64D 82553 80 00 L H Rigging Kit 31 2 ft STD 64D 82553 90 00 Engine to Oil Tank Harness2 1 Req ST...

Page 35: ......

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

Page 37: ......

Page 38: ...s book Additional standard equipment will depend upon the kits you order Contact your Marketing Representative for full details about the Kitting Program Basic Standard Equipment 8 to 40 Fuel Tank in...

Page 39: ...9 9MLHZ 6G9L 309197 CRATE 9 1 4 x 9 N A SEPARATE N A F9 9MSHZ 6G9S 012208 CRATE 9 1 4 x 9 N A SEPARATE N A T9 9ELHZ 6G8L 474408 CRATE 11 3 4 x 9 1 4 N A SEPARATE N A T9 9ELRZ 6G8L 416517 CRATE 11 3 4...

Page 40: ...7 ORDER FROM PARTS SEPARATE N A 50TLRZ 6H5L 446404 ORDER FROM PARTS SEPARATE N A C50TLRZ 6H5L 904076 ORDER FROM PARTS SEPARATE N A F50TJRZ 62Y N A SEPARATE N A F50TLRZ 62YL 421732 ORDER FROM PARTS SEP...

Page 41: ...OM PARTS L KIT N A L KIT SX200TXRZ 6G6X 004647 ORDER FROM PARTS SEPARATE N A VX200TLRZ 66XL 002839 ORDER FROM PARTS SEPARATE N A VZ200TLRZ ORDER FROM PARTS SEPARATE N A LX225TXRZ 62KX 101976 ORDER FRO...

Page 42: ...00 For use on 2 Stroke and 4 Stroke Engines Multi Function LCD Tachometer Speedometer Kit or 2 Gauge Kit 6YR W0035 47 00 For use on 2 Stroke and 4 Stroke Engines Part Number Part Name Qty 6R3 83621 0...

Page 43: ...K1 82570 05 00 Panel Switch Ass y 1 6K1 8258A 40 00 Main Harness 26 ft 1 90465 13M18 00 Clamp 10 61B 28107 14 00 Rigging Manual l 61B 8258A 01 00 Main Harness 31 2 ft 1 90149 05M05 00 Screw 4 95380 05...

Page 44: ...00 00 Grommet 1 688 82540 11 00 Neutral Switch Ass y 1 63D 82554 00 00 Stay Neutral Switch Ass y 1 663 82555 01 00 Damper Main Switch 1 63D 42546 00 00 Nut 2 63D 42541 00 00 Pipe 2 90201 08M01 00 Pla...

Page 45: ...2Y 82555 00 00 Damper Main Switch 1 90201 08M01 00 Plate Washer 2 63D 42508 00 00 Steering Friction Ass y 1 63D 42527 00 00 Plate Friction 3 1 63D 42526 00 00 Plate Friction 2 1 63D 42528 00 00 Piece...

Page 46: ...Lock 1 97013 05010 00 Bolt 2 90185 10051 00 Nylon Lock Nut 2 92990 05100 00 Spring Washer 2 95380 05600 00 Nut 2 63D 83728 00 00 Connector Ass y 1 90464 15M11 00 Clamp 3 Part Number Part Name Qty Til...

Page 47: ...06035 00 Bolt 1 6E5 42515 00 00 Rod 1 90185 08057 00 Nut Lock 2 97595 06514 00 Bolt 2 63D 83720 00 00 Connector Ass y 1 Part Number Part Name Qty Tiller Kit Handle Ass y 1 Tiller Handle Install Manual...

Page 48: ...Z MLHZ Part Number Description Qty LIT 18626 04 25 Owner s Manual 1 6G8 15780 00 00 Emergency Starter Ass y 1 68T 2814F 00 00 Spark Plug Box 1 6Y1 24306 53 00 Fuel Pipe Complete 1 T8PLHZ PXHZ Part Num...

Page 49: ...90185 08057 00 Nylon Lock Nut 14 6Y1 24306 51 00 Fuel Pipe Complete 1 T9 9ELRZ EXRZ Part Number Description Qty LIT 18626 04 26 Owner s Manual 1 90580 50M01 00 Emergency Starter Ass y 1 6Y1 24306 51...

Page 50: ...1 6H3 48538 00 00 Cable Clamp 1 63V 48511 01 00 Steering Hook 1 663 48344 00 00 Cable End Remote Control 2 90185 08057 00 Nylon Locking Nut 1 90468 18008 00 Clip 2 97575 08535 00 Bolt w Washer 1 6E5...

Page 51: ...3 Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 6Y1 24306 51 00 Fuel Pipe Complete 1 90101 10M58 00 Bolt 4 92995 10600 00 Washer 8 90201 12426 00 Plate Washer 4 95380 10600 00 Nut 8 30MSHZ MLHZ Part...

Page 52: ...95380 12600 00 Nut 8 90185 09M01 00 Nylon Nut 2 90201 10M20 00 Plate Washer 2 93210 16275 00 O Ring 1 6E5 43145 01 00 Clamp Bracket Cap 1 90101 09M01 00 Bolt 1 90170 09M03 00 Nut 1 90201 10M63 00 Plat...

Page 53: ...1 00 Clamp Bracket Cap 1 90185 09M01 00 Nylon Lock Nut 2 90201 10M20 00 Plate Washer 2 93210 16275 00 O Ring 1 F50TLRZ Part Number Description Qty LIT 18626 04 30 Owner s Manual 1 90580 50M01 00 Emerg...

Page 54: ...Lead Wire 1 6Y5 83670 11 00 Trim Meter Ass y 1 60TLRZ Part Number Description Qty LIT 18626 04 14 Owner s Manual 1 677 15780 00 00 Emergency Starter Ass y 1 6G5 2818N 31 00 Caution Tag 1 6Y1 24306 53...

Page 55: ...00 Plate Washer 2 90201 10M63 00 Plate Washer 1 90387 10M42 00 Collar 1 92995 12200 00 Plate Washer 8 93210 16275 00 O Ring 1 95380 12600 00 Nut 8 F80TLRZ F100TLRZ Part Number Description Qty LIT 1862...

Page 56: ...1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 90201 12M05 00 Bolt 4 90101 12M77 00 Bolt 2 90201 12M05 00 Plate Washer 4 90201 13M01 00 Plate Washer 8 95380 12600 00...

Page 57: ...Owner s Manual 1 6G5 2818N 31 00 Caution Tag 1 61B 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 67H 82105 00 00 Battery Cable 1 90101 12M05 00 Bolt 4 90201 12M05 00 Plat...

Page 58: ...1 93210 16275 00 O Ring 1 95380 06700 00 Nut 1 95380 08700 00 Nut 1 95380 12600 00 Nut 8 1 21 Outboard Rigging Guide 2001 2001 Model Outboard Motor Crate Contents VX150TLRZ Part Number Description Qty...

Page 59: ...mber Description Qty LIT 18626 04 20 Owner s Manual 1 6Gl5 2818N 31 00 Caution Tag 1 61A 28107 15 00 Rigging Instructions 1 90580 50M01 00 Emergency Starter Ass y 1 6E5 43145 01 00 Clamp Bracket Cap 1...

Page 60: ...ate Washer 8 90465 13M18 00 Clamp 10 90465 13M30 00 Clamp 1 95380 12600 00 Nut 8 90465 11M10 00 Clamp 2 90101 12M77 00 Bolt 2 ABA DUALT IE BR Tie Bar 1 SX250TXRZ TURZ Part Number Description Qty LIT 1...

Page 61: ......

Page 62: ...h Guards 40 F100 Splash Plates 2 11 Jet Drive Model Identification and Serial Numbers 2 12 Jet Drive Engine Mounting Maintenance Shift Cable Instruction Service Info 2 13 Dual Engine Tie Bar Kit Insta...

Page 63: ......

Page 64: ...ation specifications Transom Dimensions A Steering Rotation each way from cen terline B Maximum tilt angle including 12 tran som angle C Protrusion into boat at maximum tilt D Cavitation plate distanc...

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

Page 66: ...21 5in 6 0in 12 2in 1 2 2 6in 9 6in L 648mm 25 5in 40M T 40 M 66 M 433mm 17 0in L 537mm 21 1in 175mm 340mm M 30 66mm M 245mm 9 6in M 579mm 22 8in C40T T 69 T 387mm 15 2in 6 9in 13 4in 1 2 2 6in T 355...

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

Page 68: ...4in 40M T S 751mm 29 6in M 472mm 18 6in M 683mm 26 9in M 490mm 19 3in M 493mm 19 4in 175mm 600mm C40T L 878mm 34 6in T 439mm 17 3in T 688mm 27 1in T 527mm 20 7in T 529mm 20 8in 6 9in 23 6in F30T 3 S 7...

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

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

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

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

Page 73: ...30 F40 F50 T50 F80 F100 F115 35hp and up jet drive transom bracket shape may vary from model to model however mounting hole pattern is the same on all models Not present on V 4 V 6 TRANSOM DRILL FIXTU...

Page 74: ...e nuts to 43Nm 4 3 m kg 31 ft lb F80 F100 Engine Spray Guard Boat Spray Guard The boat spray guard splash plate can reduce spray when the engine is mounted on a catamaran or pontoon type boat 1 Instal...

Page 75: ...drive should be at least 48 and centerline length at least 13 NOTE Transom height is especially critical for jetdrive outboards which are usually mounted 6 to 7 higher than propeller driven outboards...

Page 76: ...ing it is time to test run the boat If ventilation occurs air enters the pump which causes loss of thrust and motor overrevving then you must lower the engine 1 4 at a time until smooth operation is o...

Page 77: ...stration An alternate mounting position for the plate with the plate attached to a keel or wedge for use in white water is shown in the second and third parts of the illustration The third part shows...

Page 78: ...ing control If you attempt a too tight of a turn at too high a speed your boat could spin out or even roll over Running upstream is easier Running upstream the river speed is subtracted from the boat...

Page 79: ...howev er rocks have been jammed between the grille bars with the motor off they must be removed by prying them out with a suitable tool Mooring If you tie your boat up at a sandy beach where the actio...

Page 80: ...the key sleeve and shaft threads any time it becomes nec essary to remove the impeller NOTE Your jet drive is equipped with a shear key to protect it in the event of a rock jam This can be located by...

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

Page 82: ...6 9 75 7 76 66 65 2 10 19 20 23 21 22 24 4 5 5 18 8 GREASE SPLINES GREASE IMPELLER SLEEVE KEY 10 6 84 80 79 78 11 77 81 82 17 6 16 95 LATER 95 LATER NOT USED ON PRE 95 40MJH NOT USED ON PRE 95 40MJH...

Page 83: ...haft Bearing 1 37 Nylon Sleeve Impeller Bore 1 38 Special Key Impeller 1 39 Impeller 1 40 Shim Impeller Adjustment 9 41 Tab Lock 1 42 Locknut 1 43 Seal Shaft Outer 2 44 Retaining Ring Inner and Outer...

Page 84: ...40 41 42 31 33 32 55 43 45 54 44 53 50 49 87 46 48 47 44 44 45 43 64 65 66 63 62 GREASE LIGHTLY 61 60 59 58 29 56 57 25 26 27 30 28 15 12 14 13 11 15 16 69 68 71 85 78 79 4 77 16 6 17 81 82 80 30 88...

Page 85: ...later 6 33b Nut 5 16 18 Nylock stainless steel 97 and later 6 34 Driveshaft 1 35 Woodruff Key Driveshaft 1 36 Thrust Ring Shaft Bearing 1 37 Nylon Sleeve Impeller Bore 1 38 Special Key Impeller 1 39 I...

Page 86: ...ealer place the gasket that has two curved slots and one round hole on top of the aluminum housing note the position of the dowel holes 8 Place the steel plate tangs down on top of the gasket 9 Tap th...

Page 87: ...lways install all shims on the bottom of a new impeller Installing shims on top of a new impeller may result in insufficient impeller to liner clearance This may cause scoring and impeller or liner da...

Page 88: ...38 20 Shift Cable Assembly 1 A 63D JD005 47 00 Cable 4 ft 1 B 6H4 JD005 43 00 Clamp Cable 1 C 6H4 JD005 61 00 Bolt Cable Clamp 2 D 63D JD005 58 02 Screw Hex Head 1 E 6H4 JD006 19 00 Nut Fiberlock 2 F...

Page 89: ...ded as far onto the cable as it will tighten Loosen the two cable support bracket bolts on the pump main housing and torque the mounting bolts to 8 ft lbs with the cable support bracket posi tioned as...

Page 90: ...roller should be at the end of the slot in the cam so the gate cannot be forcibly rotated toward reverse Pull on the gate by hand to verify this If the forward lock condition is not met read just the...

Page 91: ...that air is allowed to enter the pump This is likely in choppy water particularly when run ning with the wind Less than 48 inches on the other hand can make it difficult to reach planing with a heavy...

Page 92: ...st go around To correct the problem remove the grates and grind down this lip to make a smooth path for the water Overhaul Procedures NOTE It is recommended that these procedures be performed by only...

Page 93: ...ss only against the outer race of the bearing Only a light press is needed if everything is lined up properly FOR 90 AND V4 V6 MODELS ONLY Slip the bearing housing over the shaft Support the bearings...

Page 94: ...of bolts 1 Mark the liner bolts for reassembly in the same locations and remove the bolts 2 Loosen the liner by tapping on the liner edge with a long drift through the intake grille Lift out the liner...

Page 95: ...r the accessory Dual Engine Tie Bar Kit ABA DUALT IE BR The tie bar is used to connect dual outboard motors in order to achieve synchronized steering and better engine performance Tie Bar Kit Applicat...

Page 96: ...hreaded tie rod in vise using aluminum or preferably wooden pads to prevent damaging threads as shown 6 Install the jam nut on the tie rod 7 Grease the threads on the end of the tie rod that you insta...

Page 97: ...port swivel clevis install bolt and nut but do not tighten them 16 Set the engines so the toe out position is less than 1 inch See the illustration below NOTE For best results your toe out distance s...

Page 98: ...inal Adjustments can be made to insure proper toe out position 23 Re attach the rod terminal to the port engine swivel clevis and tighten nut to 12 ft lb Recheck all nuts and bolts to assure proper in...

Page 99: ...be installed so both steering cables will be routed together on the same side of the boat and will push pull together See Illus 1 NOTE This procedure is best done prior to bolt ing motor to the transo...

Page 100: ...le through the mounting bracket holes without the support tube installed Turn the steering wheel to extend cables to their full length then back off 1 4 turn See Illus 6 4 Install the support tube ont...

Page 101: ...us 8 9 Insert the nylon sleeve into the steering tube and slide the rod seal cap onto the end of the support tube 10 Install the motor to the boat using all proce dures prescribed Cable Adjustment 1 C...

Page 102: ...Both gear racks or rotary steering heads must be installed so both steering cables will be routed together on the same side of the boat and will push pull together See Illus 1 Steering Arm Installatio...

Page 103: ...nd Insert the cable through the mounting bracket holes without the support tube installed Turn the steering wheel to extend the cables to their full length then back off 1 4 turn See Illus 6 4 Install...

Page 104: ...quing to 120in lbs Then back nuts off 1 4 turn See Illus 8 9 Insert the nylon sleeve into the steering tube and slide the rod seal onto the end of the sup port tube See Illus 7 Cable Adjustment 1 Cent...

Page 105: ...ading on the hose do a final check of all hose and cable routing If you are using a threaded transom plate thread the rig ging tube into it first 8 On the engine grommet side apply a small bead of sil...

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

Page 107: ...ng the outboard motor on the boat bolt the clamp bracket to the boat Mounting On a Well type Boat 1 When the boat is a well type the engine should be mounted in the following manner Mount the engine o...

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

Page 109: ......

Page 110: ...Assemblies 3 8 Battery Installations 3 22 Electrical Connectors 3 33 Rectifier 6 25HP 3 34 Voltage Regulator 3 36 5HP Lighting Coil 3 37 Neutral Safety Switch 30E 3 40 Remote PT T Switch F T25T 40T 25...

Page 111: ......

Page 112: ...O O O 7 2 10 Pin 3m 688 8258A 30 00 O O O O O O O O Oil Harness 8 1 Oil Tank Lead 3m 6R3 85721 30 00 O O 8 2 Oil Tank Lead 5m 6R3 85721 50 00 O O 8 3 Oil Tank Lead 8m 6R3 85721 80 00 O O Instrument Pa...

Page 113: ...O 22 2 Oil Gauge Lead 7m 6R3 82521 70 00 O O O 22 3 Oil Gauge Lead 8m 6R3 82521 80 00 O O O 22 4 Oil Gauge Lead 9 5m 6R3 82521 90 00 O O O 23 PT T Switch Lead Extension 2m 6H5 82553 00 00 O Fuel Mana...

Page 114: ...Harness 688 82586 50 00 5M 16 4ft 2 1 Main Harness 10 Pin 5M 688 8258A 50 00 5M 16 4ft 2 2 Main Harness 10 Pin 8M 6K1 8258A 40 00 8M 26ft 3 2 Main Harness 10 Pin 9 9M 61B 8258A 00 00 9 9M 31 2ft 4 7...

Page 115: ...ft 7 2 10 Pin 3M Extension main harness 688 8258A 30 00 3M 9 8ft TANK HARNESSES 8 1 Oil Tank Lead 3M 6R3 85721 30 00 3M 9 8ft 8 2 Oil Tank Lead 5M 6R3 85721 50 00 5M 16 4ft 8 3 Oil Tank Lead 8M 6R3 85...

Page 116: ...8M 9 3ft 12 Rectifier to Battery w Connector 682 84338 00 00 6 05M 19 8ft 13 Remote Conversion Harness T9 9 6G8 82590 00 00 7 6M 24 9ft 14 Oil Light Harness F T9 9M 6G8 82541 00 00 2 5M 8 2ft 15 V6 B...

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

Page 118: ...4 1 F M Meter to Sender 5M 6Y5 83533 F0 00 5M 16 4ft 24 2 F M Meter to Sender 8M 6Y5 83533 F1 00 8M 26 2ft 25 Sender Extension 6X1 82531 00 00 3M 9 8ft 26 F M Meter to Tach 703 82531 00 00 F M l Meter...

Page 119: ...ied emergency stop lanyard two ignition switches and a warning buzzer NOTE Do not use a dual switch panel with the 40 90HP LF115 or C40T C90 models The overheat and low oil warning system on these pan...

Page 120: ...Number T9 9 F15 30 40E F25T F115 C90 V6 L250 Switch Panel Needed With W Push To Binnacle Or Flush Choke Control Single 704 82570 06 00 O O O O O O Twin 6K1 82570 05 00 O Sk Single No Horn 689 82570 1...

Page 121: ...ted 3 Connect the wire harness to the switch panel assembly as shown in the correct wiring dia gram in the Boat Wiring Diagrams Section of this manual and pass the harness back through the hole 4 Secu...

Page 122: ...rning horn REF NO PART NUMBER DESCRIPTION QTY 10 704 82570 06 00 Panel Switch Ass y 1 11 704 82510 06 00 Main Switch Ass y 1 12 688 82575 01 00 Engine Stop Switch Ass y 1 13 682 82556 00 00 Stopper 1...

Page 123: ...h Panels 22 5 mm 1 01 in 22 5 mm 1 01 in 110 mm 4 33 in 51 mm 2 0 in 8 5 mm 33 in 68 mm 2 67 in 93 mm 3 66 in 44 5 mm 1 75 in 8 5 mm 33 in 2x 51 mm 2 02 in CUT OUT THE SHADED PORTION SINGLE SWITCH PAN...

Page 124: ...Switch Ass y 2 4 6K1 82575 00 00 Engine Stop Switch Ass y 1 5 682 82556 00 00 Stopper 1 6 6K1 83614 01 00 Stay 1 7 688 83383 11 00 Buzzer 2 8 6K1 85830 01 00 Control Unit Ass y 1 9 98580 06020 00 Scr...

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

Page 126: ...Ass y 1 3 6G8 82571 01 00 Panel Switch 1 4 68882 57501 00 Engine Stop Switch Ass y 1 5 68282 55600 00 Stopper 1 6 66382 58101 00 Stay Cord Clamp 1 7 6G8 83582 01 00 Pilot Light Ass y 1 8 6G8 82510 00...

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

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

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

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

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

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

Page 133: ...route the battery cables through the engine rigging grommet which is on the starboard side of the lower pan Locate the battery cable in the proper position in the engine rig ging grommet 3 Run the ba...

Page 134: ...e lower pan Ensure the cable is in its proper position in the grommet 3 Run the battery cable to the starboard side of the engine pan just in front of the air box 4 Remove the fuse box cover 5 Bring t...

Page 135: ...are most suitable Consult the battery manufacturer for details NOTE The specifications above are minimum requirements It is always good practice to exceed the minimum specifications If mini mum specif...

Page 136: ...Required Not Required Requires Part 68F 81949 00 00 Type of Installation Refer To 1 Motor 2 Batteries No Battery Switch Page 3 26 2 Motors 3 Batteries No Battery Switch Page 3 26 1 Motor 2 Batteries...

Page 137: ...ne battery is used connect the two red cables to the terminal If the smaller red cables is left unconnected an accidental con tact of the red cable with the terminal of the battery will form a short c...

Page 138: ...ween the accessory battery and the main battery This cable must be made from wire equivalent to the main battery cable Use of a smaller wire could lead to a fire BATTERY SWITCH SELECTION NOTE 1 SWITCH...

Page 139: ...arting battery shut off switch single battery high current type 2 Optional auxiliary battery shut off switch minimum capacity 80 amps 3 Accessory shut off switch capacity determined by current require...

Page 140: ...e battery isolator on the motor will prevent current from flowing to the electrical components on the engine even if the small wire remains connected to the battery However the Switch 4 can be install...

Page 141: ...to the engine s electrical system could occur To reduce the risk of electrical short and fire The positive isolation lead must be at least 12 gauge wire The negative lead between batteries must be the...

Page 142: ...to the engines electrical system could occur To reduce the risk of electrical short and fire The positive isolation lead must be at least 12 gauge wire The negative lead between batteries must be the...

Page 143: ...ill be used for starting The negative lead between batteries must be at least 12 gauge if the second battery will be used to power a trolling motor NOTE The battery isolator cannot be used on a 24 36...

Page 144: ...ow you to make factory like con nections Lead Wires Yamaha lead wires allow quicker and easier rig ging by providing two additional female recepta cles These wire leads are available in yellow black a...

Page 145: ...nection cover and remove it 5 Dislodge the three green wire connectors originating from the lighting coil from the retainer under the connection cover Connect the two primary green wires with the gree...

Page 146: ...1 6G8 82150 00 00 Fuse Holder Ass y Connects rectifier and lead wire All 1 6G8 81948 00 00 Bracket Mounts rectifier and regulator assembly F9 9 1 97095 06016 00 Bolt For mounting bracket F9 9 3 92990...

Page 147: ...dels a lighting coil must be installed All other applicable models have a stan dard lighting coil Installation Mounting 1 Select a suitable location near the motor and secure the voltage regulator to...

Page 148: ...starter assembly 2 Loosen the flywheel nut using the flywheel holder and a socket wrench The main thrust must be made in the direction of the arrow If not the flywheel holder can slip off 3 Using the...

Page 149: ...the grom met into the magneto base 9 Secure the wire leads with the stay The ground lead should be secured with the stay screw 10 Make sure the O ring in the groove of the magneto base is installed co...

Page 150: ...Connect the wire leads as shown in the dia grams NOTE The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage input from the rectifier to the battery NOTE The rectif...

Page 151: ...perating the shift lever The switch button should be pressed by the cam on the end of the shift lever when the lever is moved to neutral 5 Connect the extension wire lead P N 6H4 82553 00 00 to the le...

Page 152: ...the trim tilt switch can be mounted anywhere on the boat This would allow for example a fisherman to trim the motor while casting off the front of the boat The power trim tilt switch connects to the m...

Page 153: ...Be sure there is sufficient clearance behind the instrument panel for the switch 2 When installing the power trim tilt switch into a thick instrument panel make a hole 40mm 1 57in high and 13mm 0 5in...

Page 154: ...50 T50 F80 100 F115 with Switch Panel 3 52 10 C40 C150 with 703 Control and Analog Tachometer 3 53 11 C40 C150 with Switch Panel and Analog Tachometer 3 54 12 40T 90HP C40 C115 with 703 Control and Mu...

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

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

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

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

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

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

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

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

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

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

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

Page 166: ...oat Wiring Diagrams 40T 90HP with 703 Control and Multifunction Gauges C40 C115 OPTIONAL ON C40 C90 May connect Gray wire to GRN WHT wire and set dip switch 3 for 4 stroke operation This will allow ga...

Page 167: ...oat Wiring Diagrams 40T 90HP with Switch Panel and Multifunction Gauges C40 C115 OPTIONAL ON C40 C90 May connect Gray wire to GRN WHT wire and set dip switch 3 for 4 stroke operation This will allow g...

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

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

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

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

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

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

Page 174: ...ring 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 speedomete...

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

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

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

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

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

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

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

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

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

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

Page 185: ......

Page 186: ...trations 4 2 Control Box Applications 4 3 701 Remote Control Assembly 4 4 703 Control Assemblies 4 8 704 Binnacle Mount Remote Control Assemblies 4 18 705 Flush Side Mount Remote Control Assembly 4 32...

Page 187: ......

Page 188: ...trim and tilt switch Can be converted to pull to open throttle SNG BINN PUSH PT T 704 Dual Binnacle Control Box 704 48207 31 00 Push to open throttle with power trim and tilt switch Can be converted t...

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

Page 190: ...25T F80 LF115 F40T F100 L130 F15E 40T C40T F115 To F9 9 9 9 25 F25E To To V4 L250 Description Part Number T9 9 15 30 40E 90 C115 V6 LX250 701 Pull No Elec 701 48101 51 00 O O 701 Push No Elec 701 4813...

Page 191: ...00 Bolt 2 23 702 48288 00 00 Washer Plain 1 24 701 48246 00 00 Spacer 2 25 92990 06300 00 Washer Internal Tooth 1 26 701 48229 00 00 Grip Control Lever 1 27 701 48222 00 00 Grip Control Lever 1 28 985...

Page 192: ...ith no sharp bends Measure from the control head to the shift and throttle con nections on the motor Yamaha remote con trol cables are available in lengths from 6 feet to 36 feet Installation of Remot...

Page 193: ...e no bends of less than a 4 inch radius The cables should be supported with cable hangers or for long runs by running them through conduit Throttle Connection Proper adjustment of the throttle cable s...

Page 194: ...nection Proper adjustment of the shift cable will result in a better operating control 1 Attach the control cable to the shift arm in the motor 2 Operate the hand lever several times to verify proper...

Page 195: ...8 00 00 Anchor Cable 1 21 703 48244 00 00 Spring Free Accel 1 22 703 48238 00 00 Spring Detent 5 23 703 48246 00 00 Spacer 1 24 703 48227 00 00 Spring Neutral Lock 1 25 703 82594 00 00 Clamp 1 26 703...

Page 196: ...0 00 Buzzer 1 52 703 48284 00 00 Grommet 1 53 90464 13080 00 Clamp 2 54 703 82592 00 00 Band 1 55 703 82563 01 00 Trim Tilt Switch Ass y 1 56 703 48221 00 00 Lever Control 1 57 703 48152 00 00 Knob Fr...

Page 197: ...3 48345 01 00 Cable End Rem Control 2 2 20 703 48358 00 00 Anchor Cable 1 21 703 48244 00 00 Spring Free Accel 1 22 703 48238 00 00 Spring Detent 5 23 703 48246 00 00 Spacer 1 24 703 48227 00 00 Sprin...

Page 198: ...0 00 Buzzer 1 52 703 48284 00 00 Grommet 1 53 90464 13080 00 Clamp 2 54 703 82592 00 00 Band 1 55 703 82563 01 00 Trim Tilt Switch Ass y 1 56 703 48221 00 00 Lever Control 1 57 703 48152 00 00 Knob Fr...

Page 199: ...er trim tilt switch warning buzzer and a push to choke Preparation 1 Select a mounting location for the remote control which offers ease of use from the helm and allows full movement of the con trol l...

Page 200: ...ease to the threaded holes in the cable joints 4 Insert the remote control cable for shifting into the housing clamp so that the groove on its end fits over the ridge in the clamp Fit the cable joint...

Page 201: ...ove the control lever from the control box 4 Loosen the two screws as shown and remove the neutral lock holder 5 Invert the remote control box and reinstall the neutral lock holder 180 degrees from it...

Page 202: ...reassembled to operate properly When reinstalling parts apply Yamaha Marine Grease to moving parts and contact surfaces 1 Pinch the wire cover with your fingers and pull it off 2 Remove the screws as...

Page 203: ...e as straight as possible from the control to the motor along the path previ ously chosen There should be no bends of less than a 4 inch radius The cables should be supported with cable hangers or for...

Page 204: ...tle could damage the cable control or motor Shift Cable Connection Proper adjustment of the shift cable will result in a better operating control 1 Attach the control cable to the shift arm in the mo...

Page 205: ...00 00 Screw 1 17 98580 05525 00 Screw Pan Head 2 18 704 48261 00 00 Arm Throttle 1 19 EL8 48191 00 00 Washer 1 1 20 98580 05540 00 Screw Pan Head 4 21 97395 06018 00 Bolt 3 22 703 48345 01 00 Cable En...

Page 206: ...48164 00 00 Pin 2 1 49 704 48242 00 00 Shift Drive 1 50 704 48225 00 00 Cover 1 51 704 48192 00 00 Washer 2 1 52 97890 06018 00 Screw Pan Head 2 53 92990 06300 00 Washer Internal Tooth 2 54 702 48263...

Page 207: ...1 00 00 Screw 2 17 98580 05525 00 Screw Pan Head 4 18 704 48261 00 00 Arm Throttle 2 19 EL8 48191 00 00 Washer 1 2 20 98580 05540 00 Screw Pan Head 4 21 97080 06018 00 Bolt 6 22 703 48345 01 00 Cable...

Page 208: ...8 704 48219 00 00 Cover Lead 2 59 704 48144 00 00 Plate Stopper 2 2 60 704 48176 10 00 Grommet 1 61 703 48192 00 00 Washer 2 2 62 EL8 48233 00 00 Gear 2 2 63 703 48235 00 00 Bushing 2 64 704 48282 00...

Page 209: ...idling with touch but ton fast idle release corrosion resistant upper casing and a fully enclosed lower casing Wired for fast and convenient installation 704 Dual A revolutionary design puts dual eng...

Page 210: ...he template to cut appropriate single or twin mounting holes as shown on pages 4 24 and 4 25 NOTE The remote control box should be installed on the right side of the steering wheel After determining t...

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

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

Page 213: ...es can be routed without being bent sharply The radius of a cable bend should be more than 101mm 4 0 in Sharp bends less than 101mm 4 0in radius of the cables will obstruct the smooth move ment of the...

Page 214: ...end of the shift arm and lock it with the circlip 5 Fit the grommet accessory in the clamp groove 6 Connect the remote control cable for the throttle to the throttle arm in the same man ner 7 Secure t...

Page 215: ...and secure it to the boat hull so that the holes in the packing align with the remote control box mounting screw holes in the hull How To Change From The Push To Open Throttle Type To The Pull To Open...

Page 216: ...ounting flange back plate and packing with the five screws NOTE When installing the back plate use care so the wire harness is not pinched 9 Install the cover on the body How To Change The Control Lev...

Page 217: ...erted position Tightening Torque 0 5 0 8m kg 3 6 5 8ft lb 6 Install the throttle shaft on the opposite side to the original position with the two hexagon head bolts Tightening Torque 0 5 0 8m kg 3 6 5...

Page 218: ...n place 11 Install the dwell plate retainer mounting flange back plate packing and cover according to steps 7 9 Throttle Opening Adjustment The remote control box is capable of adjusting the throttle...

Page 219: ...91 00 00 Washer 1 19 97380 06018 00 Bolt 3 20 703 48345 01 00 Cable End Rem Control 2 21 EL8 48271 00 00 Arm Shift 1 22 EL8 48127 00 00 Screw 9 23 703 48358 00 00 Anchor Cable 1 24 EL8 48231 00 00 Hou...

Page 220: ...3 6X0 48223 00 00 Lock Neutral 1 54 6X0 48221 00 00 Lever Control 1 55 6X0 48245 00 00 Plate Lock 1 56 704 48225 00 00 Cover 1 57 6X0 48155 00 00 Plunger 1 58 92990 05300 00 Washer 6 59 6X0 48281 00 0...

Page 221: ...rol 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 casin...

Page 222: ...an be opened without shifting into any gear NOTE The control lever must be rotated more than 35 from neutral otherwise the throttle can not be opened It is impossible to operate the free accelerator b...

Page 223: ...g Torque 5 8 Nm 0 5 0 8m kg 3 6 5 8ft lb 1 Locknut 2 Stopper Bolt 4 Control Lever Tension Adjustment By turning in or out the throttle friction screw at the rear of the remote control box the stiff ne...

Page 224: ...through it When selecting the control box position keep the following in mind a The remote control box should be set in a position in which it does not obstruct the operations of the control lever an...

Page 225: ...Back Plate b Screw in the cable joint accessories See page 4 47 Tighten the locknuts Before installing the cable joints apply Yamaha Marine Grease to the threaded holes in the cable joints 1 Remote Co...

Page 226: ...ghtly bolt the base to the remote control box Tightening Torque 30 45 cm kg 1 Cover 3 Hole 5 Washer 2 Base 4 Screw c Install the remote control box to the mounting plate hull with screws and nuts When...

Page 227: ...ed portion of the trim switch wire to the hole in the neutral lock holder and insert the neutral lock holder into the base g Install the cover on the base NOTE Align the adjusting screw holes in the c...

Page 228: ...ructions given in the respective owner s manuals of outboard motors connect the remote control cables both for shifting and throttle and wire harness to the engine When connecting set the con trol lev...

Page 229: ...for good operation of the engine and remote control box Next firmly secure the remote control box which is tem porarily held with the screws to the hull Check that the cables are not sharply bent less...

Page 230: ...kg 3 6 5 8 ft lb 1 Screw 2 Throttle Lever Assembly 5 Turn the dwell plate 180 so the cam groove is on the PULL side and align the throttle lever roller with the specified position then secure the thr...

Page 231: ...from the right side to the left side or vice versa 1 Remove the cover packing mounting flange back plate dwell plate and cam plate out of the remote control box according to steps 1 2 3 and 5 page 4 4...

Page 232: ...1 Stopper Bolt Tightening Torque 5 8 Nm 0 5 0 8m kg 3 6 5 8 ft lb Do not allow the stopper bolt to project 11mm 0 4 in or more from the nut surface Otherwise the stopper contacts the cover 8 Set the...

Page 233: ...ing it for a long period of time 1 Remove the cable joints and apply Yamaha Marine Grease to the threaded portion of the inner cable 1 Remote Control Cable 2 Cable Joint 2 Also apply Yamaha Marine Gre...

Page 234: ...ABA CABLE 07 GY 7 FEET ABA CABLE 08 GY 8 FEET ABA CABLE 09 GY 9 FEET ABA CABLE 10 GY 10 FEET ABA CABLE 11 GY 11 FEET ABA CABLE 12 GY 12 FEET ABA CABLE 13 GY 13 FEET ABA CABLE 14 GY 14 FEET ABA CABLE...

Page 235: ...le control is the same for all outboards Yamaha 704 705 control boxes can be setup as push to open or pull to open by changing one internal component Rigging as efficiently as possible means setting u...

Page 236: ......

Page 237: ...mperature Sender Installation 5 22 Voltmeter 5 24 Hour Meter Kit 5 26 Fuel Gauge 5 28 Fuel Management System Gauge GPS Hook Up 5 30 Fuel Management Gauge Components 5 31 Fuel Management Gauge Installa...

Page 238: ...2 STROKE OFF NUMBER OFLEADWIRES ONTRIM SENSOR 1 2 3 FACTORYSETTINGS ON km h mph mile h knot nautical mile 5 105 U S A 30 230 EUROPE 180 0 6Y5 83570 S4 00 YAMAHA INDICATION GPH GALLON SPEEDOMETER GPS...

Page 239: ...night Included in this gauge is an easy to read trim indicator which blacks out if the engine is over trimmed and prominently dis played oil warnings NOTE The multi function digital gauge will not pro...

Page 240: ...ly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the dashboard has a thickness of more than 13mm 0 50 in and it is impossible to secure the meter with the fitting...

Page 241: ...lustrations for basic wiring For detailed wiring information refer to the diagrams in the Boat Wiring Diagrams in the Electrical Section 3 of this manual NOTE A special relay Part number 6Y5 81950 02...

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

Page 243: ...g used remove the rubber grommet from the back of the meter and set the calibration switch es The analog tachometer has a rotating switch that can be turned with a slotted head screwdriver as illustra...

Page 244: ...installing and using boat speedometers it is important to remember that they indicate an approximate speed of the boat through the water by measuring the impact force of the water with a pressure gaug...

Page 245: ...and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is impossible to secure the mete...

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

Page 247: ...and blue leads together The instru ment light will then come on when the main switch is in the ON position 2 After installation connect the power and check the operation of the instrument light Multi...

Page 248: ...ipple to open it Connect the speedometer tube to the nipple and tighten with the quick tie provided 3 Route the tube to the speedometer and secure it NOTE Before securing the tube be sure to tilt the...

Page 249: ...ds below 30 mph because of the low pressures produced A dig ital speedometer like the Yamaha Multifunction Speedometer can more accu rately indicate these speeds 2 The pressure required to indicate sp...

Page 250: ...anged The gauge has not changed If you have 2000 rigging kits in stock you will only need to change the dip switch settings according ly When adjusting the trim sender and the gauge is very erratic ve...

Page 251: ...n the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install over the mounting studs 4 Place the washers over the studs and then evenly tighten the mountin...

Page 252: ...to 80 Also avoid placing any strong magnet or magne tized object near the trim sender Adjusting 1 For a down position adjustment loosen the trim sender screws and make an adjustment so the needle alig...

Page 253: ...to use both gauges with one engine NOTE There is now available an aftermarket water pressure gauge fitting P N MAR WPRES AD TR NOTE The operating water pressure of the P60 C60 70hp is lower than othe...

Page 254: ...n the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install the fitting plate over the mounting studs 4 Place the washers over the studs and then evenly t...

Page 255: ...pressure sender be sure to check for water leakage On V4 and V6 models also make sure the hose does not interfere with the flywheel 2 Bring out the sender tube through the bottom cowling grommet 3 Con...

Page 256: ...with one engine NOTE The 30hp requires drilling and tapping the cylinder head for sensor installation If the needle rises above the shaded area the engine is in danger of overheating Slow down the en...

Page 257: ...the desired location 3 Remove the fitting plate from the meter fit the meter into the panel and install the fitting plate over the mounting studs 4 Place the washers over the studs then even ly tight...

Page 258: ...e yel low and blue leads together The instrument light will then come on when the main switch is in the ON position 2 After installation connect the power and check the operation of the instrument lig...

Page 259: ...inder 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 gau...

Page 260: ...on the star board side the sensor tube could break or bend After installing the temperature sender be sure to check for water leakage 2 Bring out the temperature sender lead wire through the bottom c...

Page 261: ...voltage readings higher than 16 volts The voltage regulator on 75hp 225 L hp is set for fast battery charging with repeated engine starting Extended continuous engine opera tion may show voltage readi...

Page 262: ...ace the washers over the studs then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it is im...

Page 263: ...meter allows the operator to keep track of the number of hours the motor was used on one day and even how much time is required to reach a given destination The Yamaha Hour Meter has been designed fo...

Page 264: ...meter fit the meter into the panel and install over the mounting studs 4 Place the washers over the studs then evenly tighten the mounting nuts until the meter can no longer be rotated by hand NOTE If...

Page 265: ...omponent parts The fuel gauge indicates the amount of fuel remaining in the fuel tank This information will help the boater estimate the amount of cruising time available before refueling The Yamaha F...

Page 266: ...4 Place the washers over the studs then evenly tighten the mounting nuts until the gauge can no longer be rotated by hand NOTE If the instrument panel has a thickness of more than 13mm 0 5 in and it...

Page 267: ...below Modification Procedure 1 Cut off three prong connector 2 Remove the black plug and install it on the speedometer to plug the hole in the back of the gauge 3 The white wire is the signal lead whi...

Page 268: ...M Kit Single Engine 6Y5 W0088 64 00 Dual F M Kit Dual Engine Part Number Description Remarks 6Y5 83500 F2 00 Meter Assembly 1 6Y5 83553 F1 00 Extension Wire Lead 1 6Y5 85752 01 00 Fuel Sender 2 1 in S...

Page 269: ...source The maximum reach of these connector harnesses combined is 10 inches when speedo is used No extensions should be used or the gauge can malfunction because of electronic interference from radio...

Page 270: ...between the engine and the fuel filter refer to the illustration B On twin engine installations make sure the multifunction speedometer fuel man agement gauge and GPS are connected to the same key on...

Page 271: ...ne installation No wiring is connected to the second ignition source The fuel management gauge and speedometer must be connected to one common power source The power source must be supplied by one ign...

Page 272: ...ITIVE Battery source G Green To the G Green wire from the Multifunction STBD Tachometer G W Green White To the G Green wire from the PORT Multifunction Tachometer on twin engine installations B Black...

Page 273: ...water in fuel symbol present on that gauge This harness comes standard in the engine crate on all left hand rotation HPDI engines The wire diagrams are as follows This harness will work on either a s...

Page 274: ...uel filter sensors The diagram below shows the recommended wiring with the use of the optional water fuel fil ter sensors NOTE If the boat is wired as above and the boat water fuel separating filter d...

Page 275: ...01 Fuel Management Gauge NOTE Make sure all gauges are connected to the same KEY ON power source Use these connectors only on twin engine installations Optional fuel water separator w filter and senso...

Page 276: ...currents sea swells and the condition of the water speed sensor partially plugged or damaged 3 Individual engines may vary slightly in their fuel consumption because of manu facturing variations Thes...

Page 277: ...measurement by setting the selector switch on the back of the meter dur ing installation The fuel consumption meter and fuel economy meter will display the same unit of measurement Fuel Consumption Me...

Page 278: ...Engine speed is synchronized evenly between Port and Starboard engines 4 Starboard engine speed is slightly higher 5 Starboard engine speed is higher NOTE If the two engine speeds are not synchro niz...

Page 279: ...hes 4 for fuel flow calibra tion If the amount of fuel consumed differs from that indicated on the meter it can be calibrat ed to the correct amount If the amount of fuel used differs from what is ind...

Page 280: ...n Kit 6 20 40 C40 50 C50 Tiller Handle Steering Friction Kit 6 22 F40 4 Cylinder F T50 Tiller Handle Steering Friction Kit 6 31 60 C60 C70 70HP Tiller Handle Steering Friction Kit 6 40 C90 90HP Tiller...

Page 281: ...be used only with the 2m 6 6 ft cables provided The steering handle on the T9 9 models can be removed from the motor and used as a remote control unit for the throttle shifter and the stop switch The...

Page 282: ...handle backwards and fit a slotted head screwdriver into the slit in the ring nut Using the steering bracket as a fulcrum turn the steering handle forward to loosen the ring nut NOTE This procedure ma...

Page 283: ...teering grip NOTE To remove the steering grip turn it to the left and pull it out of the steering handle 9 Remove the two screws holding the two halves of the steering handle together 10 Remove the bo...

Page 284: ...nner and outer cables of both the throttle and shift control cables are prop erly in place Verify proper movement of the shift lever once the handle has been reassem bled 5 Reinstall the components of...

Page 285: ...lerator arm 10 Reconnect the white and black stop switch leads see Removal step 2 and reinstall the CDI cover Installing the Control Handle 1 Select a location near the steering wheel or tiller handle...

Page 286: ...ion 1 16 90386 08032 00 Bush 1 17 66M 26311 00 00 Cable Throttle 1 2 18 90446 10M87 00 Hose 2 19 90386 40MA0 00 Bush 1 20 90201 43M00 00 Washer Plate 2 21 90206 43M22 00 Washer Wave 2 22 90202 43M57 0...

Page 287: ...00 Nipple Grease 1 3 66M 42527 00 00 Plate Friction 1 4 90109 08M91 00 Bolt 2 5 65W 42562 00 00 Shaft Steering Lock 1 6 66M 42561 00 00 Knob Steering Lock 1 7 689 43633 00 00 cover Tilt Lever 1 8 902...

Page 288: ...ual starter for MH models 1 Throttle Cable 2 N O T E When adjusting the Throttle Cables make sure the throttle control cam stopper touches the bracket stopper throttle fully opened and then tighten th...

Page 289: ...ing Handle Ass y Manual starter for MH models 1 Plastic Washer 1 2 Metal Washer 1 3 Wave Washer 2 4 Metal Washer 2 5 Bushing 1 6 Steering Handle Bracket 1 7 Friction Adjusting Screw 1 8 Screw 1 9 Stee...

Page 290: ...16 65W 42125 00 00 Bolt Friction Adjusting 1 17 91490 16010 00 Pin Cotter 1 18 6F6 42177 A0 00 Rubber Handle 1 19 664 42119 00 00 Grip Steering Handle 1 20 6H2 42137 00 00 Indicator Throttle 1 6J0 42...

Page 291: ...90109 06M50 00 Bolt 2 4 92990 06100 00 Washer Spring 2 5 65W 42561 00 00 Knob Steering Lock1 1 6 689 43633 00 00 Cover Tilt Lever 1 7 97595 05516 00 Bolt With Washer 1 8 90387 05M11 00 Collar 1 9 901...

Page 292: ...595 05516 00 Bolt With Washer 1 12 65W 82105 00 00 Wire Harness 1 13 6G8 82150 00 00 Fuse Holder Ass y 1 14 663 82151 00 00 Fuse 12V 20A 1 15 6G5 82152 00 00 Holder Fuse 1 16 6H1 82563 10 00 Trim Tilt...

Page 293: ...r for removal Flywheel magneto cover ass y Refer to FLYWHEEL MAGNETO in Chapter 5 1 Throttle Cable 2 N O T E When adjusting the Throttle Cables make sure the throttle control cam stopper a touches the...

Page 294: ...ow the Step order for removal 1 Shift Link Rod 1 2 Shift Lever 1 3 Cable Guide 1 4 Bushing 1 5 Plastic Washer 1 6 Wave Washer 2 7 Metal Washer 1 8 Bushing 1 9 Tiller Handle Bracket 1 10 Steering Brack...

Page 295: ...00 Screw 1 20 90386 08032 00 Bush 1 21 6G1 42138 01 00 Lever Throttle 1 22 6E0 42159 02 00 Stay 1 23 97885 05012 00 Screw Pan Head 2 24 6J8 26301 00 00 Throttle Cable Ass y 2 25 6J8 44111 01 4D Handl...

Page 296: ...efully remove the carburetors The choke solenoid shaft will pull out of the choke solenoid as the carbure tors are removed If desired the choke sole noid and shaft may both be removed as they will be...

Page 297: ...grommet and install it through the new grommet from the kit Move the old grommet and wire harness aside and install the new grommet bracket clamp flat washer and 6mm nuts 15 Locate the new brown wire...

Page 298: ...d connect one end of its pink lead to the connector that goes to the pink thermoswitch wire at the back of the motor There is a pink T lead remain ing to be connected near the CDI box Connect the pink...

Page 299: ...e from the CDI box Make sure all ground black wires are beneath the appropriate bolt under the termi nal cover and tighten the bolt The same color wire lead in the harness you removed in step 21 was d...

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

Page 301: ...1 61 90501 23215 00 Spring Compression 1 62 92903 10600 00 Washer Plate 1 63 90149 05M13 00 Screw 1 REF NO PART NUMBER DESCRIPTION QTY 1 67C W0084 4D 00 Handle Steering Ass y 1 2 67C 42121 00 04D Brac...

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

Page 303: ...100 00 Washer Spring 2 105 90464 15M11 00 Zip Tie 1 106 688 83383 11 00 Buzzer 1 107 6H5 83386 00 00 Buzzer Stay 1 108 97013 05010 00 Bolt 2 109 90990 05100 00 Spring Washer 2 110 90185 10051 00 Nut 2...

Page 304: ...on the side of the swivel bracket 1 Remove the steering hook 1 2 Remove the fitting plate 1 and grommet 2 3 Remove the shift cable joint 3 and throttle cable joint 4 4 Disconnect the wire harness coup...

Page 305: ...and nut 2 T orque N ut 38N m 3 8 m kg 2 7 ft lb 2 Install the grommet 1 engine stop switch lead 2 main switch lead 3 battery cable 4 extension wire harness 5 and the power trim tilt switch leads 6 N...

Page 306: ...e clip 3 and tighten the lock nut 4 T he cable joint should be screwed in more than 8mm 0 31 in N O T E Put the UP mark upward Manual starter model only 5 Check the shift operation for unsmooth oper a...

Page 307: ...white 3 9 On electric start models without instruments See Illust B connect the main switch cou pler 1 and zip tie 2 N O T E Fit the main switch lead in the clamp and clamp the wire leads as shown 10...

Page 308: ...and hold the switch to UP the motor will tilt up c Push and hold the switch to DN the motor will tilt down d Release the switch the motor will stop at its current position Dynamic Check T he engine i...

Page 309: ...e engine stop switch a Run the engine b Pull the lanyard off the lock plate The running engine will stop 8 Check for steady engine speed a Run the engine at idle b Steer the tiller handle c Tilt the t...

Page 310: ...heck that the tiller becomes free from friction d If not repeat the above steps 6 Check steering movement for smooth opera tion N O T E With the friction lever turned fully to the right check the till...

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

Page 312: ...ay 1 114 97013 05010 00 Bolt 2 115 90990 05100 00 Spring Washer 2 116 90185 10051 00 Nut 2 REF NO PART NUMBER DESCRIPTION QTY 1 62Y W0086 20 4D Handle Steering Ass y 1 2 63D 42121 00 4D Bracket 1 3 63...

Page 313: ...emove the steering hook 1 2 Remove the fitting plate 2 3 Remove the grommet 3 cable stopper 4 and rubber seal 5 4 Remove the shift cable joint 6 and throttle cable joint 7 5 Disconnect the wire harnes...

Page 314: ...bolt 3 Disconnect the brown lead terminal 4 and the brown blue lead terminal 5 4 Connect the neutral switch lead terminals 6 S tart in gear protection will not operate with out the neutral switch lead...

Page 315: ...osition b Align the center of the set pin 2 with the mark a on the bracket c Adjust the position of the cable joint until its hole aligns with the set pin d Install the clip 2 and tighten the lock nut...

Page 316: ...throttle valve lever so it contacts the full opening stopper Electric Start Model without Instruments A 9 Connect the main switch coupler 1 and the zip tie 2 N O T E Fit the main switch coupler to the...

Page 317: ...N ut 2 0N m 2 0m kg 14ft lb 3 Install the following 1 Collar 3 Washer 2 Friction plate 4 Bolt M8 4 Install the bolt M6 1 5 Adjust the friction force a Turn the friction lever 1 fully to the left a b T...

Page 318: ...b 9 Install the screw 4 Completion Check Static Check 1 Check the shift operation Make sure the shift action is smooth for Forward Neutral and Reverse 2 Check the throttle operation for smoothness fro...

Page 319: ...r protection a Shift into forward reverse b Turn the key to START The starter motor should not turn over c Shift into neutral d Turn the key to START The starter motor will turn over 6 Check the main...

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

Page 321: ...0 00 Washer 1 46 6H3 48321 01 00 Cable 1 47 90386 29M95 00 Bush 1 48 90202 24M53 00 Washer Plate 1 49 63D 48531 00 00 Bracket Remote Control 1 1 50 63D 48538 00 00 Clamp Cable 1 2 51 97095 06016 00 Bo...

Page 322: ...bly 1 and slip plate 2 2 Install the neutral switch stay 3 N O T E Install the stay 3 with washer and the bolt 3 Disconnect the brown lead terminals 4 4 Disconnect the power trim tilt switch lead coup...

Page 323: ...e 3 Shift Cable 4 Extension Wire Harness 5 Main Switch Wire Leads 6 Battery Leads 7 Power Trim Tilt Switch Leads N O T E a Pass the wire harness and remote control cables through the grommet and refit...

Page 324: ...or smooth operation 7 Adjust the throttle cable joint position a Turn the throttle grip fully close b Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a c A...

Page 325: ...upler 5 Power Trim Tilt Switch Lead Coupler 6 Zip Tie 7 Clamp I llus D N O T E a Fit the extension wire harness and main switch wire leads b Clamp the wire leads as shown Steering Friction 1 Remove th...

Page 326: ...to make sure proper friction is obtained Check tiller handle tilt up down Make sure the cables and wires are not stretched 4 Check the power trim tilt switch a Connect the battery b Push and hold the...

Page 327: ...motor should turn over 6 Check the main switch a Turn the main switch to ON from OFF then to START The starter motor starts the engine b Turn the main switch to OFF from ON The running engine will sto...

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

Page 329: ...1 47 90386 29M95 00 Bush 1 48 90202 24M53 00 Washer Plate 1 49 63D 48531 00 00 Bracket Remote Control 1 1 50 63D 48538 00 00 Clamp Cable 1 2 51 97095 06016 00 Bolt 2 52 92990 06600 00 Washer Plate 2 5...

Page 330: ...all the neutral switch stay 3 N O T E Remove the washer and bolt from the shifter bracket then install the stay with the removed washer and bolt 3 Disconnect the brown lead terminals 4 4 Connect neutr...

Page 331: ...Install the following 1 Grommet 2 Shift Cable 3 Throttle Cable 4 Battery Cable 5 Extension Wire Harness 6 Main Switch Harness 7 Power Trim Tilt Switch Leads N O T E Align the taped end a of the batte...

Page 332: ...throttle cable joint position a Turn the throttle grip fully close b Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a c Adjust the position of the cable j...

Page 333: ...on control nut 1 according to the following diagram Steering Friction 1 Remove the end cap 1 2 Install the bolt 1 and wing nut 3 3 Install the friction controller 3 link rod 4 washer 5 and nylon nut 6...

Page 334: ...d hold the switch to UP the motor will tilt up c Push and hold the switch to DN the motor will tilt down d Release the switch the motor will stop at its current position Dynamic Check T he engine is g...

Page 335: ...s over then the engine will start b Turn the main switch to OFF from ON The running engine should stop 7 Check the engine stop switch a Run the engine b Pull the lanyard off the lock plate The running...

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

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

Page 338: ...Grommet 1 Engine stop switch connectors 2 3 Install Cable stopper 1 Rubber seal 2 Remote control cables 3 4 Install Fitting plate 1 Bolts 2 5 Adjust Shift cable joint position Adjustment steps Turn th...

Page 339: ...justment steps Turn the throttle grip fully close Align the throttle lever 1 as shown Adjust the position of the cable joint 2 until its hole aligns with the set pin Install the clip 3 and tighten the...

Page 340: ...1 4 Bolt 2 M6 5 Shift Control Lever 1 6 Spring Pin 1 7 Grommet 1 8 Steering Friction Ass y 1 9 Bolt with Washer 2 M5 10 Extension Wire Harness 1 10 pin 12 pin 11 Wire Harness 1 A To buzzer B To trim m...

Page 341: ...rommet 3 Cable stopper 4 Rubber seal 5 4 Remove Shift cable joint 6 Throttle cable joint 7 5 Disconnect Wire harness coupler 8 6 Disconnect Overheat and oil warning lamp coupler 9 Trim sensor coupler...

Page 342: ...er 1 Starter motor 2 8 Remove Shift rod lever ass y 3 9 Remove Grease nipples 1 Clamp 2 NEUTRAL SWITCH 1 Install Shift control lever 1 Spring pin 2 Shift rod lever ass y 3 2 Install Neutral switch 1 N...

Page 343: ...5 3 TILLER HANDLE 1 Install Tiller handle ass y 1 Nuts 2 Bolt with washers M5 3 2 Install Grommet 1 Main switch leads 2 Battery cable 3 PTT switch lead for PTT model 4 Extension wire harness 5 NOTE Al...

Page 344: ...et pin 2 as shown Adjust the position of the cable joint 3 until its hole aligns with the set pin Install the clip 4 and tighten the lock nut 5 The cable joint should be screwed in more than 8 0mm 0 3...

Page 345: ...on wire harness coupler 1 11 Connect Overheat and oil warning lamp coupler 1 Trim sensor coupler 2 for PTT model 12 Connect Trailer PTT switch couplers 1 for PTT model Checking steps Turn the shift ha...

Page 346: ...riction force Turn the friction lever 1 to a or b Incorrect Retighten the nut 2 15 Check Steering movement 1 Unsmooth Repair NOTE With the friction lver turned fully to the left check the tiller for s...

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

Page 348: ...utboard 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 cu...

Page 349: ...5 Switch stay 1 6 Bolt 2 7 Friction rod 1 Steering friction set 8 Link rod 1 9 Bolt 1 10 Washer 3 11 Nut 2 12 Friction control 1 13 Bolt 1 14 Wing nut 1 15 Extension wire harness 1 10 pin 12 pin 16 W...

Page 350: ...ARATION 1 Remove Nut 1 Steering hook 2 2 Remove Bolt 1 Flywheel cover 2 Junction box cover 3 3 Remove Screw 1 CDI unit cover 2 4 Remove Bolt 1 Throttle control assembly 2 5 Remove Plastic locking tie...

Page 351: ...ad coupler 1 Trailer switch coupler 2 NEUTRAL SWITCH 1 Install Neutral switch assembly 1 Damper plate 2 Neutral switch stay 3 Bolt 4 NOTE Move the shift lever to the forward position for operation 2 D...

Page 352: ...switch lead 6 Extension wire harness 7 Shift control cable 8 Throttle control cable 9 3 Connect Main switch lead connectors 1 Zip tie 2 Zip tie 3 NOTE Pass the shift control cable 4 and throttle cont...

Page 353: ...ntrol cable 1 Throttle control cable 2 Cable clamp 3 Bolt 4 Clips 5 Hose locating plate 6 Bolt 7 Grommet retaining plate 8 Bolt 9 8 Check Shift operation Incorrect Adjust 9 Adjust Shift cable joint po...

Page 354: ...reverse positions and make sure it shifts smoothly and correctly If the shifting operation is unsmooth or incorrect repeat the above procedure WARNING Checking steps Fully close the throttle Check th...

Page 355: ...lose to fully open NOTE Shift in forward and then check the throttle operation 3 Check Steering friction Proper friction is obtained Proper friction is obtained and that there is no interference with...

Page 356: ...OFF then to START The starting motor is turned then the engine will be started Turn the main switch to OFF from ON The running engine will be stopped Checking steps Run the engine Pull the lanyard and...

Page 357: ...fer to SERVICE MANUAL NOTE Set the ditital tester to the manual range In the auto range the voltage changes cannot be accurately measured Output voltage P O 0 7 0 02V Checking steps Connect the test h...

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

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

Page 360: ...just Friction control nut 1 Throttle friction to be PTT SWITCH ENGINE START Increased Decreased Increased Decreased Operation steps Turn the main switch to ON Push and hold the switch UP Tilt up DN Ti...

Page 361: ...nt Kit 7 4 F9 9 T9 9 4 Stroke Remote Control Attachment Kit 7 8 F15 Remote Control Attachment Kit 7 12 F25 Remote Control Attachment Kit 7 14 25HP Remote Control Attachment Kit 2 Cyl 7 17 25E Remote C...

Page 362: ...ons 6L2 86112 00 00 1 req later in this section 97013 06012 00 2 req 92990 06100 00 2 req 93210 03261 00 1 req 97013 06012 00 1 req 92990 06100 00 1 req 6L2 82590 00 00 1 req 6K3 83557 00 00 1 req F25...

Page 363: ...ter Pin 1 20 97780 50520 00 Screw 1 21 682 48340 50 00 Throttle Cable End Assembly 1 22 682 48344 50 00 Remote Control Cable End 1 1 23 617 48361 90 00 Cable Hook 1 24 90501 10264 00 Spring 1 25 92990...

Page 364: ...ecrease the amount the cable is screwed in on the remote control box side Be sure to tighten the locknut for each cable joint I f the cable is not screwed in at least 8mm the cable joint could break T...

Page 365: ...1590 30012 00 Pin Spring 2 8 97095 06016 00 Bolt 2 9 92990 06600 00 Washer Plate 2 10 95380 06600 00 Nut 2 11 663 48344 00 Cable End Remote Control 2 12 90468 18008 00 Clip 2 13 90201 08M12 00 Washer...

Page 366: ...ote Control Attachment Assembly 1 Install Bushing Lever Rod Plane Washer Cotter Pin 2 Install Throttle Lever Plane Washer Wave Washer Flange Nut B end the cotter pin ends securely a b c 33 2 1 33 12 1...

Page 367: ...Bracket Bolt 1 Replace Clamp Bracket Bolt Remote Control Cable 1 Install Cable End 8 2 Connect Shift Cable a Throttle Cable b Cable End 8 Plane Washer Clip 9 Screw Tightening Torque 3 5 Nm 0 35 m kg 1...

Page 368: ...the upside of the set pin T he cable end 8 8 should be screwed in more than 8mm 0 31 in T he clip 9 9 should be installed from the up side as shown in the illustration WARNING 20 20 A djustment S tep...

Page 369: ...End 1 13 6G8 26364 00 00 Cable End 2 1 14 6G8 48511 00 00 Steering Hook 1 15 97395 06016 00 Bolt 2 16 92990 06600 00 Plate Washer 2 17 6G8 48511 10 00 Steering Hook 1 18 97395 06106 00 Bolt 2 19 92990...

Page 370: ...the CDI unit cover N O T E After removing the stop switch from the engine use the emergency stop switch on the bot tom cowling to stop the engine 5 Turn the steering handle backward 6 Fit a slotted h...

Page 371: ...decrease the amount of the cable to screw it in on the remote control box side Be sure to tighten the locknut for each cable joint I f the cable is not screwed in at least 8mm the cable joint could b...

Page 372: ...lip Connect the shift cable joint to the R mark side of the shift lever and lock it with the lock plate 6 Connect the throttle cable joint to the R mark on the throttle lever and lock it with the lock...

Page 373: ...ext page illustration B Make sure the remote control cable end is screwed in more than 8mm 0 31in C Connect the throttle 1 when the throttle is fully closed and connect the shift cable 2 when the outb...

Page 374: ...Washer Plate 1 8 65W 81870 00 00 Starting Switch Ass y 1 8G1 42725 00 00 Grommet 1 9 6H3 82540 00 00 Neutral Switch Ass y 1 10 90109 06M86 00 Bolt 2 11 6J8 82564 00 00 Stay Neutral Switch 1 12 66M 86...

Page 375: ...1 11 663 48344 00 00 Cable End Remote Control 2 12 90468 18008 00 Clip 2 13 6H3 48538 00 00 Clamp Cable 1 1 14 65W 42725 10 00 Grommet 1 15 65W 26326 00 00 Grommet 1 16 6H1 42726 10 00 Grommet 1 17 6...

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

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

Page 378: ...06M23 00 Washer Based Bolt 2 15 6G8 26363 00 00 Cable End 2 16 6G8 26364 00 00 Lock Plate 2 Component parts Installation 1 Remove the grommet and plugs from the bot tom cowling A Grommet B Plug 2 Inst...

Page 379: ...Lever Shift Control 4 Bushing 5 Nut Flange 6 Joint Control 7 Rod 1 7 Install rod 1 on the shift rod link E Then loosen bolt F to allow a small amount of gap between shift rod link and crankcase and in...

Page 380: ...to secure the cable joint I Cable Joint J Lock Plate S crew in the cable joint so its flat end is at least 8mm away from the end of the cable 11 Operate the shift and throttle cables to check that th...

Page 381: ...4 11 6L2 86112 00 Stay Solenoid 1 12 97013 06012 Bolt 661 2 13 92990 06100 YBS67 6 Washer Spring 2 14 93210 03261 O ring 663 1 15 97013 06012 Bolt 9661 1 16 92990 06100 YBS67 6 Washer Spring 1 17 6L2...

Page 382: ...wire to the starter mount bracket and install the ten sion bolt on the carburetor choke rod 1 Bracket 2 Choke Solenoid Assembly 3 Screw and Plain Washer 4 Grounding Wire black 5 Extension bolt 6 O ri...

Page 383: ...wiring diagram connect the wires correctly Next place the cover over the clamp 8 Retighten the four bolts which were loos ened in 4 on the previous page securing the carburetor 9 Reinstall the silenc...

Page 384: ...DESCRIPTION QTY 1 Remote Control Attach Ass y 1 2 92990 08100 00 Washer Spring 1 3 6J8 48534 00 00 Control Throttle Lever 1 4 6J8 48544 01 00 Shift Control Lever 1 5 6J8 44177 00 00 Washer 1 6 91690...

Page 385: ...l lever inner 7 Align the spring pin holes and drive the spring pin into the hole by using a pin punch and a hammer 8 Install the rubber grommet in the bottom cowling Route the wire harness through th...

Page 386: ...he cable joint set pin and lock it with the lock nut Lock the cable joint to the cable joint set pin with this lock plate I f the cable is not screwed in at least 8mm the cable joint could break T his...

Page 387: ...Ass y 1 15 6G1 82105 00 00 Wire Lead Ass y 1 16 6G1 82117 00 00 Lead Wire 1 17 682 42724 00 00 Grommet 1 18 6G1 82362 00 00 Clamp 1 19 90105 06M23 00 Bolt 1 20 6G1 81970 61 00 Rectifier Ass y 1 21 98...

Page 388: ...the three screws holding the front panel Pull the panel out to gain access to the carburetor mounting screws 6 Disconnect the carburetor linkage Remove the two carburetor mounting bolts Remove the car...

Page 389: ...as shown N O T E The mounting bolts are of different lengths The two shortest bolts should be mount ed in the upper and lower holes on the left side The one longest bolt should be installed in the up...

Page 390: ...sheath and plug them in to the green leads from the har ness Route the harness through the sheath 15 Remove the grommet and install the starting switch on the front panel and connect the wiring as sho...

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

Page 392: ...t These items must be ordered for 25hp and 30 40 applications on the 1 92990 10600 00 Washer steering hook 1 90185 10 51 00 Nut 1 90185 10051 00 Nut These items must be ordered for 30hp 90hp and C75 a...

Page 393: ...C40 N O T E When a steering hook is standard equip ment on any particular model it should already be attached to that motor when you receive it in the crate On the 25hp and 40hp manual the steering h...

Page 394: ...ng hook to the steering cable Application Chart Standard on Remote Models N O T E Some steering system components such as wheels and steering cables are not offered by Yamaha Parts and Accessories How...

Page 395: ...t tube and attach the cable to the tube with the securing nut that is on the steer ing cable 3 Fit the O ring and cap nut on the other end of the steering tilt tube N O T E The O ring and cap mentione...

Page 396: ...1 25HP ER Model 30HP 90HP Including C Series F80 F100 F115 N O T E There are two holes in the steering hook For best results in steering use the inner hole to attach the steering link rod 115 250HP 25...

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

Page 398: ...for enhanced acceleration and low speed operation The 4 blade is designed to improve performance and handling on a variety of boats The 4 blade prop will improve hole shot performance while maintain...

Page 399: ...ate the location of the letter code and corresponds with the far left column in the table Location of Letter Codes on Aluminum and Some Selected Stainless Steel Propellers 1994 T25 F30 C60 C90 F40 3 T...

Page 400: ...47 00 EL 11 3 4 11 Plastic Dual Thrust 6G8 45941 00 00 11 3 4 12 1 4 Plastic Dual Thrust 6G8 45945 00 00 F9 9 9 9 15 F15 9 3 4 6 1 2 Aluminum Dual Thrust 683 W4592 02 EL 9 3 4 8 Aluminum Dual Thrust 6...

Page 401: ...8 13 Aluminum 6H5 45945 00 EL 10 1 4 14 Aluminum 6H5 45958 00 EL 11 1 4 14 Aluminum 663 45958 01 EL 10 15 Aluminum 6H5 45943 00 EL 10 3 4 16 Aluminum 663 45949 01 EL 10 3 4 17 Aluminum 663 45941 01 E...

Page 402: ...60 98 13 17 Stainless Steel 688 45930 01 98 13 19 Stainless Steel 688 45970 03 98 13 21 Stainless Steel 688 45972 02 98 13 23 Stainless Steel 688 45974 02 98 13 25 Stainless Steel 688 45976 01 98 13 1...

Page 403: ...Polished Stainless MAR GYT3B V6 24 14 1 4 26 GYT 3 Blade Polished Stainless MAR GYT3B V6 26 14 1 4 28 GYT 3 Blade Polished Stainless MAR GYT3B V6 28 14 1 2 21 Pro Series Polished Stainless 6J9 45976...

Page 404: ...0 DIAM PITCH DESCRIPTION PART NUMBER 14 19 Front TRP MAR TRP14 19 FR 13 19 Rear TRP MAR TRP13 19 RR 14 21 Front TRP MAR TRP14 21 F2 13 21 Rear TRP MAR TRP13 21 R2 14 25 Front TRP 65N 45941 00 00 13 25...

Page 405: ...ainless Steel 6K1 45972 01 98 13 3 8 23 Stainless Steel 6K1 45976 00 98 14 1 4 18 GYT 3 Blade MAR GYT3B L6 18 14 1 4 20 GYT 3 Blade MAR GYT3B L6 20 14 1 4 22 GYT 3 Blade MAR GYT3B L6 22 14 1 2 15 Salt...

Page 406: ...NOTES...

Page 407: ...NOTES...

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

Page 409: ...el Gauge 97760 10000 00 97760 00000 00 Fuel Meter Gasket 6Y1 24268 00 00 6Y1 24268 00 00 Seal 6Y1 24329 00 00 6Y1 24329 00 00 Pan Head Screw 98586 05016 00 98586 05016 00 Fuel Connector ABA FCONN CT O...

Page 410: ...et should be used to secure the oil tank at the desired mounting location Sub Oil Tank Holder 6E5 21734 01 33 Used for 2 8 Gal and 5 0 Gal Tanks B e careful not to overtighten the bracket bolt N O T E...

Page 411: ...ging 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...

Page 412: ...t blocked by sealant or other material from the boat deck 6 Remove the original Yamaha Oil Tank Cap and install the reducer fitting in its place Be sure the fitting is tight on the oil tank to pre ven...

Page 413: ...ter spring is free 5 Remove the original wire guide from the starter case 6 Install the vertical starter onto the starter case 7 Insert the rope through the vertical starter and starter handle holes r...

Page 414: ...HP small size ABA STAND 00 MD 9 9 30HP C25 30 medium size ABA STAND 00 LG 40 250 C40 C150 E48 E75 T9 9 large size Part Name Description Qty L H Main Support 1 R H Main Support 1 Skeg Base Plate 1 Uppe...

Page 415: ...a hydraulic lift with the motor in a vertical upright position allowing an approximate clearance between the tip of the skeg and the floor of one foot B efore proceeding to the next step be certain t...

Page 416: ...d be damaged 4 Insert the lower skeg support pinch bolt through the rear hole of the skeg plate Place one hex nut onto the bolt and tighten D o not over tighten T he outboard or stand could be damaged...

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

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

Page 419: ...NSTALLATION 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 prohibite...

Page 420: ...carefully and thoroughly Particularly important information is distinguished in this manual by the following notations The Safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED Fail...

Page 421: ...O V 150LD 350101 L250ETXD 700101 175ETLD 402800 L250TURQ 800101 175ETXD 753500 An additional adapter Part Number 6X1 81950 90 must be used with the 6X1 Dual Station System if it will be used on YAMAHA...

Page 422: ...t 12 C Connecting the Throttle Cable to the Dual Station Junction Unit 15 D Connecting the Shift Cable to the Actuator 15 E Connecting the Cables to the Outboard Motor 16 CONNECTING THE WIRE HARNESSES...

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

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

Page 425: ...NCTION UNIT This unit allows changeover of control between the first and second stations Whenever the controls lever at one remote control box is placed in either forward or reverse the control lever...

Page 426: ...ey must be start ed from the first station 115 200 hp Second station except Prime Start models When the main switches are turned on and the engines are sufficiently warm they can be started from the s...

Page 427: ...mounting diagram Using a correct inch hole saw make holes and then cut out the center portion as shown 2 Connect the wiring harness to the switch panel assembly and pass it back through the hole 3 Sec...

Page 428: ...r will not show correct measurement 1 Install the digital meter onto the dash board If no dashboard is available use a wooden board having a thickness of 2 11mm in place of the dashboard 2 Select a pl...

Page 429: ...le of the bend s in the cable the number of bends and the quality of the cable which control the amount of space between the inner cable and the tube Too much end play can prevent controls from work i...

Page 430: ...E 26 FEET MAXIMUM LENGTH JUNCTION UNIT TO UPPER STATION 22 FEET MAXIMUM LENGTH JUNCTION UNIT TO LOWER STATION 22 FEET MAXIMUM LENGTH ACTUATOR TO ENGINE 26 FEET TOTAL LENGTH OF ALL THREE THROTTLE CABLE...

Page 431: ...ing on a ver tical surface RECOMMENDED JUNCTION UNIT AND ACTUATOR LOCATION The mounting location for the junction unit and actuator should be selected with the following recommendations in mind 1 The...

Page 432: ...Two identical labels are provided for each identification Attach them to both ends of the cable 2 Attach the labels to the JUNCTION UNIT AND ACTUATOR In case of a single engine installation the JUNCTI...

Page 433: ...mote 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 ou...

Page 434: ...UNCTION UNIT 1 Removing the cover 1 Remove the cover and the three rubber plugs 2 Connecting the control box throttle cables to the junction unit 1 Install the dual station brass barrel cables ends on...

Page 435: ...that the cable end piece should be screwed in at least 8mm Install the clamp so that the side of the clamp identified by the arrow mark directs the center of the junction unit 5 Securing the cables 1...

Page 436: ...ion If grooves are offset use the following steps to eliminate the offset 3 Remove cable clamp and pull out the shift cable 4 Loosen the rod nut on the cable and move the cable end so that the offset...

Page 437: ...TUATOR 1 Determine installation location of the actuator Fix the actuator by referring the instructions in ACTUATOR INSTAL LATION page 8 2 Remove four screws securing the cover of the actuator and the...

Page 438: ...liminate any backlash when installing This will ensure that the throttle returns correctly idle In stall the throttle cable while pulling it in the direction of F2 with the throttle arm pressed by fin...

Page 439: ...the C hub groove of the shift cable without applying any force to the cable and shift arm If a proper fit is not achieved change the position of the cable end piece After making any adjustment always...

Page 440: ...rs or improper opera tion may result 2 Connect the matching connectors for the second station control switch panel and instruments 2 CONNECTING THE WIRING FOR THE LOWER STATION 1 Connect the matching...

Page 441: ...ot engage the forward or reverse gear perfectly The warning buzzer will sound after about four sec onds if the gear has not been engaged 1 Turn the main switch to ON and remove the engine stop switch...

Page 442: ...r may turn if the cable length is out of the above specifications 2 Place the remote control lever on for ward and turn the main switch to start to check that the engine is not started Repeat the same...

Page 443: ...volt age by using the following procedure 1 Connect the throttle sensor adjusting lead special tool No YB 06443 in between the two sensors on the junc tion unit and the actuator 2 Turn the main switc...

Page 444: ...e second station 6 If the grooves are not offset either of the sensors may be defective Adjust the sensor position or replace the sensor if unadjustable If grooves are offset use the following steps t...

Page 445: ...and cable end are offset each other Repeat the check at the second station 11 If still offset repeat the above steps 4 to 10 until the offset is eliminated 12 Install the cable clamp move the remote c...

Page 446: ...four screws securing the actuator cover and remove the cover 2 Move the emergency lever red fully in the direction indicated by the arrow 3 Move the adjusting pin and spacer of the shift sensor lever...

Page 447: ...side 7 Move the remote control lever from neutral to estimated forward and reverse positions to check that the out board shifts securely 8 In case the outboard will not shift with the adjusting pin a...

Page 448: ...is observed make adjustments in the motor throttle cable end at the outboard motor 3 Operate the second station in the following sequence and observe operation 1 Shift to forward and move the lever to...

Page 449: ...is available This bracket is not supplied with mounting hardware Use either the extra hardware supplied with the dual station system kit or contact a local sup plier for appropriate hardware for your...

Page 450: ...mm 0 118 in in diameter in the cabin floor referring illustration 3 Secure the mounting bracket to the cabin floor with screws 4 Secure the junction unit and actuator to the mounting bracket with hexa...

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

Page 452: ...a male bullet con nector 4 Connect the adapter wires as follows White wire to the white wire with the new buller connector White black wire to the CDI terminal that the white wire was removed from Red...

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

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

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

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

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

Page 458: ...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...

Page 459: ...thout notice APPLICABLE MODELS The 6X1 Dual Station System is designed to be used with 1990 and later YAMAHA outboard motors with the following serial numbers and higher Engine Serial Numbers 115ETLD...

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

Page 461: ...TS INFORMATION 10B 21 EXTENSION WIRE HARNESS 10B 21 ADAPTER 10B 21 MOUNTING BRACKET 10B 21 TECHNICAL TIPS 10B 22 SHIFT MOTOR WILL NOT OPERATE 10B 22 1 Emergency manual shift system 10B 22 RIGGING INST...

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

Page 463: ...ntrol lever is transmitted to the junction unit mechanically through cable and then electrically to the servomotor which controls the shifting mechanism according to the lever movements The change of...

Page 464: ...r 1 moves the shaft of the rack 2 to disengage the rack from the motor side pinion and engage the rack with the pinion on the emergency manual shift lever 3 Then the outboard can be shifted by using t...

Page 465: ...TY INFORMA TION When installing the system in the outboard models not shown in the list the specific adapter must be used The adapter is available with extra charge For the installation of the shift c...

Page 466: ...designed to min imize operating loads Due to the automatic interlock system if the throttle and shift control have been set at one station the settings cannot be altered at the other station In other...

Page 467: ...start button two start buttons on the twin engine model one stop button two stop but tons on the twin engine model for engine con trol and one emergency stop switch An alarm buzzer on the rear of the...

Page 468: ...can be moved NOTE No visual warning is provided The following are possible causes of the shift ing failure A wire disconnection in the power source of the actuator or the reduction of the actu ator o...

Page 469: ...ift yet use emergency lever and emergency manual shift lever to shift the outboard into neutral and then start the engine For operations of the emergency lever and emergency manual shift lever refer t...

Page 470: ...the power failure or shift disengage ment failure has occurred on either of the two outboards perform the following steps 1 Turn the main switch for each outboard to OFF 2 Check battery terminal for l...

Page 471: ...ice available port immediately The following are the possible causes of the shifting failure A wire disconnection in the power source of the actuator or reduction to the actuator operating voltage Fai...

Page 472: ...lever have to be used The emergency means are designed exclusively for running to a service avail able port immediately Normally the shift motor is able to shift from neutral to forward or reverse wit...

Page 473: ...osition and retry the shifting If the outboard shifts the cruising can be contin ued 2 In case it will not shift yet use emergency lever and emergency manual shift lever to shift the outboard run to t...

Page 474: ...mode the warning system functions as follows 1 Monitoring of starting period Main switch ON NOTE If there is a problem the indicator corresponding to the problem does not light up and the buzzer does...

Page 475: ...d off 4 Overheat warning Thermo switch ON NOTE In the case of a twin engine system the buzzers for both the starboard and port side engines sound when the shift lever is in either forward or reverse W...

Page 476: ...whose oil level is low The warning ends when engine oil is replenished Always turn off the main switch when replenishing engine oil 6 Stopping the engine at the second station Stop switch ON NOTE Whe...

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

Page 478: ...e is running Do not attempt emergency manual shift override if you cannot perform shifting and steering operations well enough to react to hazards in your way An acci dent may result Do not cruise if...

Page 479: ...Operating procedure at shift disengagement failure NOTE The engine is running and the outboard is in forward or reverse 1 Move the emergency lever 1 fully as indi cated by an arrow 2 Move the emergenc...

Page 480: ...l station includes a 704 remote control box digital tachometer switch panel wire harness dual station unit and actuator These components which have been selected and purchased separately in the past a...

Page 481: ...N OF INSTALLATION 1 Attaching the cable identification marks Connect the cables in the following sequence as illustrated below NOTE Before connecting the cable be sure to move the shift levers on the...

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

Page 483: ...tape to keep it from being caught in the pipe 3 Pull the rope gently so that the wire har ness will not catch inside the pipe 4 Connect the bullet terminals as they were originally Remote control cabl...

Page 484: ...re around the out board Propeller may turn if the cable length is out of the above specifications 2 Place the remote control lever on forward and turn the main switch to start to check that the engine...

Page 485: ...ions check the shift volt age by using the following procedure 1 Connect the throttle sensor adjusting lead special tool No YB 06443 in between the two sensors on the junction unit and the actuator 2...

Page 486: ...Repeat the check at the second station 6 If the grooves are not offset either of the sensors may be defective Adjust the sensor position or replace the sensor if unadjustable If grooves are offset use...

Page 487: ...neutral Check if the grooves on the rack and cable end are offset each other 11 If still offset repeat the above steps 4 to 10 until the offset is eliminated 12 Install the cable clamp move the remot...

Page 488: ...the actu ator cover and remove the cover 2 Move the emergency lever red fully in the direction indicated by the arrow 3 Move the adjusting pin and spacer of the shift sensor lever from the hole M the...

Page 489: ...shift cam at actuator side 7 Move the remote control lever from neutral to estimated forward and reverse positions to check that the outboard shifts securely 8 In case the outboard will not shift with...

Page 490: ...ft cut system will not function if this wire is used 3 Cut the eye terminal from the end of the white and green wires and install two male bullet connectors 4 Connect the adapter wire as follows White...

Page 491: ...p switch and the engine stop switch lanyard to stop the engine properly Ensure that all electrical connections are tight and will not vibrate loose during normal operation Otherwise the engine may not...

Page 492: ...Yamaha dealer There is an automatic interlock which pre vents one control from being used while the other is in use The engine can be started from either sta tion as long as the key is on at the lower...

Page 493: ...1 Switch panel 6 Neutral switch Wire harness Sensor 2 Engine stop switch 7 P T T switch Digital tachometer Junction unit 3 Main switch 8 Buzzer Digital speedometer 4 Choke switch 9 Fuel sender Actuato...

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 contro...

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

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

Page 497: ...____________________________________________________________ _____________________________________________________________________________ _____________________________________________________________...

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