Yamaha - Us Rig - Guide 2001

2001 Outboard Rigging Guide
2000 YAMAHA MOTOR CORPORATION, U.S.A.
Printed in U.S.A.
LIT-18865-00-01
2001 Outboard Rigging Guide 2000 by Yamaha Motor Corporation, U.S.A. October 2000 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A.
Specifications, features and options are subject to change without notice. 00-149
Outboard Rigging Guide - 2001

Introduction, General Rigging Information, and Quick Start . . . . . . . . . IntroQuick Start
Standard Equipment, Rigging Kits, & Crate Contents . . . . . . . . . . . . . .
1 2 3 4 5 6 7 8 9 10
Engine Dimensions, Mounting, & Mounting Equipment . . . . . . . . . . . .
Electrical . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Instruments & Gauge Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Tiller Handle Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Remote Control Conversion Kits & Steering Kits . . . . . . . . . . . . . . . . .
Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Fuel Tanks & Accessories, Remote Oil Tank, Remote Oil Fill, Engine Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

SECTION 1 STANDARD EQUIPMENT, RIGGING KITS, AND CRATE CONTENTS 2000 Model Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1 Propeller, Controls, Fuel Tank, & Rigging Items Shipping Location . . . . . . . . . . . . . 1-2 Rigging Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5 2000 Model Outboard Motor Crate Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
SECTION 2 ENGINE DIMENSIONS, MOUNTING, & MOUNTING EQUIPMENT Engine Mounting Dimensions (Transom Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Transom Mounting Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Transom Drill Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Four-Stroke Splash Guards, 40~F100 Splash Plates . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Jet Drive Model Identification and Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jet Drive Engine Mounting, Maintenance, Shift Cable Instruction, Service Info. . . . 2-13 Dual Engine Tie Bar Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Dual Cable Steering Bracket Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Morse Universal Dual Cable Steering Bracket Kit Installation . . . . . . . . . . . . . . . . . 2-39 V4 & V6 Rigging Tube Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 F9.9 Exhaust Well Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44
SECTION 3 ELECTRICAL Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Switch Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Battery Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33

Rectifier - 6 ~ 25HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 5HP Lighting Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Neutral Safety Switch - 30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Remote PT&T Switch - F/T25T, 40T~250HP, C40T~C90 . . . . . . . . . . . . . . . . . . . . 3-41 Boat Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Complete Boat Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67
SECTION 4 REMOTE CONTROLS Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Control Box Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Control Box Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 701 Remote Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 703 Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 704 Binnacle Mount Remote Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 705 Flush Side-Mount Remote Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Remote Control Cables, Remote Conversion Kits 701, 703 . . . . . . . . . . . . . . . . . . . 4-47 Control Box Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48
SECTION 5 INSTRUMENT & GAUGE INSTALLATIONS Digital Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Trim Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Water Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Water Pressure/Temperature Sender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Hour Meter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28

Fuel Management System Gauge/GPS Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Fuel Management Gauge Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Fuel Management Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Twin Engine Fuel Management Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 2001 HPDI Water Detection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Digital Fuel Management Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Fuel Management Gauge Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Fuel Management Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42
SECTION 6 TILLER HANDLE KITS T9.9 Remote Tiller Rigging Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 F15 Tiller Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 F25 Tiller Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 30HP Tiller Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15 F30/F40 3-Cylinder Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . 6-20 40, C40, 50, C50 Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . . . 6-22 F40 4-Cylinder, F/T50 Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . 6-31 C60, C70, 70HP Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . . . . 6-40 C90 & 90HP Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48
SECTION 7 CONVERSION & STEERING KITS Remote Control Attachment Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 6/8HP Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 9.9/15 (2-Stroke) Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 F9.9/T9.9 (4-Stroke) Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . 7-8 F15 Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 F25 Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 25HP Remote Control Attachment Kit - 2 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 25E Remote Control Electrical Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20

25/30HP Remote Control Attachment Kit - 3 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 6/8HP Electric Starter Conversion Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Steering Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Steering Attachment Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
SECTION 8 PROPELLERS Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Propeller Application Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
SECTION 9 RIGGING COMPONENTS/KITS Portable Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Remote Oil Tank Mounting Instructions (2.8 Gal. and 5.0 Gal.) . . . . . . . . . . . . . . . . 9-2 Oil Deck Filler Plate Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Vertical Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Outboard Display Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6
SECTION 10 APPENDICES 6X1 Dual Station System - Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A 6X1 Dual Station System - Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B F30/F40 Tiller Handle, Steering Friction - Installation Guide . . . . . . . . . . . . . . . . . . 10C F80, F100 Tiller Handle, Steering Friction - Installation Manual . . . . . . . . . . . . . . . 10D F80, F100 Tiller Handle, Steering Friction - Owners Manual . . . . . . . . . . . . . . . . . 10E

This Rigging Guide is designed to cover the 2001 Model Year. Anything prior to that is covered in previous Rigging Guides.
IntroQuick Start
INTRODUCTION Yamaha Service assumes that those using this Outboard Rigging Guide manual are aware of standard rigging techniques. This manual provides specialized information for rigging 2001 model Yamaha products; it does provide general rigging instructions. For information about rigging earlier Yamaha outboards, refer to the proper Outboard Rigging Guide or Data edition for the particular year you are rigging. Be aware of all information designated by the following notifications:
CAUTION:
1.
Introduction This will include a brief description, model application, illustrations of components, and additional parts (if any) needed to install the component. This introduction should usually give the rigger information needed to determine which parts should be used. Installation Instructions This will include dimensions, mounting instructions, wiring information, and any other information needed to install the component. Parts Information Where appropriate, there will be an exploded diagram of all parts for a particular component. These exploded diagrams will usually not include part numbers. For the latest part numbers for ordering replacement parts, refer to the parts microfiche, or rigging components microfiche.
2.
A CAUTION indicates special procedures that must be followed to avoid damage to the outboard motor, accessories, boat, test equipment, or tools.
WARNING
A WARNING indicates special procedures that must be followed to avoid injury to persons operating the outboard motor or other components, or to persons installing or repairing the motor 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.

STANDARD ABBREVIATIONS AND SYMBOLS Color Codes The following color code chart would help you with the standard abbreviations. Listed is the Yamaha color codes and their purpose. Also included is the ABYC color code. Which is common to boat wiring systems.
YAMAHA COLOR ABBREVIATION ABYC COLOR ABBREVIATION YAMAHA USE ABYC USE
B or BLK= Black R or RED = Red Y= Yellow L or BLU= Blue
B or BLK = Black R or Red = Red Y= Yellow Bl = Dark Blue
G or GRN= Green
G or GRN= Green
O or ORG= Orange P or Pnk = Pink W or WHT = White Br = Brown
O or ORG= Orange P or Pk = Pink W or WHT = White Br = Brown
Gr = Gray
Gr = Gray Tan Lt Bl = Light Blue Bl/X = Blue/ Stripe G/X = Green /Stripe Except G/Y Y/R = Yellow/Red Pu = Purple B/Y = Black/Yellow
Sb = Sky Blue Lg = Light Green
Ground Battery positive, SW3 Oil warning red light V4 Ignition ON 12v 4-Stroke lighting coil Instrument lights choke choke circuit, Ground potential oil transfer High speed charge coil Tachometer signal Lighting coil lead Knock sensor Trim position sender Oil & overheat signal ground, Trim signal Ignition stop circuit SW1 oil transfer off position V4 Start circuit, Low speed charge coil, Positive + potential to oil transfer pump, SW2 transfer on position V4 Warning circuit lead, Over rev control, 4-Stroke tach None Trim Up Trim Down
Ground Battery Positive Bilge blower Cabin and instrument lights
Bonding wire, earth ground
Accessory feed Fuel gauge sender
Generator Armature, Alternator charge light
Tachometer signal Navigation Lights Water Temperature Oil Pressure Trim Up Trim Down
Y/R = Yellow/Red Pu = Purple B/Y = Black/Yellow B/R = Black/Red
B/W = Black/White G/L = Green/Blue
Diagnostic lead from ECU ECU Ground to enrichment solenoid V76 Thermo sensor Remote oil tank ground return, PBS to tachometer, Low speed charge coil Ignition coil primary lead Crank position sensor ii
Starting Circuit Ignition ON 12v Ignition stop circuit

Color Codes (Contd.)
YAMAHA COLOR ABBREVIATION ABYC COLOR ABBREVIATION YAMAHA USE
Standard Abbreviations and Symbols
ABYC USE
G/R = Green/Red
G/W = Green/White
L/G = Blue/Green
L/R = Blue/Red
L/W = Blue/White
L/Y = Blue/Yellow Pu/R = Purple/Red Pu/B = Purple/Black Pu/Y = Purple/Yellow Pu/G = Purple/Green Pu/L = Purple/Blue Pu/W = Purple/White R/Y = Red/ Yellow
W/R = White/Red W/B = White/Black W/Y = White/Yellow W/G = White/Green W/L = White/Blue W/Br = White/Brown Y/W = Yellow/White
Red oil warning light ground through SW3 in main tank oil sensor to tachometer Crank position sender, Lighting coil lead to rectifier Main tank oil level sensor SW2 oil transfer circuit Main tank oil level sensor SW3. No oil warning circuit Main tank oil level sensor SW1. Oil transfer OFF circuit Shift cut switch OX66#1 injector OX66#2 injector OX66#3 injector OX66#4 injector OX66#5 injector OX66#6 injector Key on power through fuel pump relay, power to ECU, Fuel pump and fuel injectors #1 pulsar V6 #2 pulsar V6 #3 pulsar V6 #4 pulsar V6 #5 pulsar V6 #6 pulsar V6 Electric fuel pump for electric carb system (ECS)
Trim signal
NOTE: For wires which use tracer stripes, the main color is followed by a slash (or dash) then the tracer color. For example: R/G = Red wire with a green tracer stripe Y/Sb = Yellow wire with a sky blue tracer stripe
iii

Measurement In most cases, measurements are given in both metric and US Customary System (feet and inches). The following abbreviations and symbols are used: m = mm = lit = cc = m-kg = meter millimeter liter cubic centimeter meter kilogram ft or in or gal ft-lb = foot = inch = US gallon = foot pounds
Standard Abbreviations and Symbols
Other Symbols The symbol ~ is used to indicate either one figure through another or and following. For example: 2 ~ 15HP would mean the 2, 3, 5, 8, 9.9 and 15 HP motors are included. A notation like 70HP~ means that the 70HP and all larger motors are included. Pro Series, SaltWater Series, and counter-rotation models are included in the previous explanation unless otherwise noted. However, C models will be listed separately. For example: 70HP ~ does not include the C70, but 40HP~90HP and C40T~C90 would include the C60 and C70 in addition to the standard models.
The metric measure is given first, with the US conversion following in parenthesis: 1.0 m (3.3 ft)
iv

MECHANICS METRIC CONVERTER
CONVERSION FACTOR LENGTH-DISTANCE FORMULA
1mm = 0.0394 inch 1 inch = 25.4mm 1km = 0.06214 miles 1 mile = 1.6093 km
SPEED
mm x 0.0394 = inches inches x 25.4 = mm km x 0.6214 = miles mile x 1.6093 = km km/hr x 0.6214 = mph mph x 1.6093 = km/hr kg x 2.2046 = lb lb x 0.4536 = kg gram x 0.0353 = oz oz x 28.3286 = gram (C x 1.8) + 32 = F (F -32) x 5/9 = C [5/9 is approx. 0.555]
1 km/hr = 0.6214 mph 1 mph = 1.6093

WEIGHT
1kg = 2.2046 lb 1 lb = 0.4536 kg 1 gram = 0.0353 oz 1 oz = 28.3286

TEMPERATURE
C = (9/5 + 32) F 9/5 (F -32) = C Note: -40C = -40F 0C = 32F 100C = 212F
PRESSURE
1kg/cm2 = 14.223 psi 1 psi = 0.07031 kg/cm2

TORQUE
psi = kpa divided by 7.03 psi x 0.0731 = kg/cm2 m-kg x 7.233 = ft-lb ft-lb x 0.1383 = m-kg L x 1.057 = qt qt x 0.9461 = L L x 0.2642 gal gal x 3.785 = L cc x 0.03381 = oz oz x 29.577 = cc cc x 0.06103 = ci
1m-kg = 7.233 ft-lb 1ft-lb = 0.1383 m-kg

VOLUME
1 liter (L) - 1.057 qt 1 qt = 0.9461L 1L = 0.2542 gal 1 gal = 3.785 L 1cc* = 0.03381 oz 1 oz = 29.577cc 1cc = 0.06103 ci (cubic inch)
*Or milliliter = ML

1984 AND LATER OUTBOARD MODEL CODE LETTERS
1984 to 2001
The model code designator was standardized in 1991 to the following procedure for all models:
X 1 5 0 T L R Y 2
Model Description
Prop Shaft Horsepower
Trim and Tilt/Starting Method T = Power Trim and Tilt w/Electric Start P = Power Tilt w/Electric Start E = Manual Tilt w/Electric Start M = Manual Tilt w/Manual Start
Shaft Length S L X U J = 15 = 20 = 25 = 30 = Jet Drive Unit
Control Method R = Remote Control H = Tiller Handle
Special Model Variation Code (Used on 25HP Model Year engines) N K J H G F D P Q R S T U V W X Y Z = 1984 = 1985 = 1986 = 1987 = 1988 = 1989 = 1990 = 1991 = 1992 = 1993 = 1994 = 1995 = 1996 = 1997 = 1998 = 1999 = 2000 = 2001 2 = 3 Cyl. 1997 3 = 3 Cyl.
B = Inshore Series Example: C = C Series Model 6 D = Twin Rotating Propellers 9.9 DX= Twin Rotating 200 Propeller 0X66 EFI 250 E = Enduro Series Model F = Four Stroke Engine Model LF = Left Hand Four Stroke L = Left Hand Engine Model LX = Left Hand 0X66 EFI LZ = Left Hand HPDI P = Pro Series Model PX = Pro Series 0X66 EFI S = Saltwater Series Model SX = Saltwater Series 0X66 EFI T = Four Stroke Engine Model with High Thrust V = V Max Series Model VX=V-Max 0X66 EFI VZ =V-Max HPDI X = EFI 0X66 Series Z = HPDI Series
NOTE: Some early model 1984 engines had the designation of AETO.
vi

Engine ID Tag Located on port clamp bracket.
241 )4; 1 ,
,) -
Manufacturing Date Located on starboard clamp bracket.
YAMAHA
$/$ ;) )0)
5 :
6
% & $ 6 )2) 41/1 )2 4 + 6,
),- 1 2);5 ,
,50).6 5-41)
24-.1: 7 /60 *-4
$/$
%&$
NOTE: Primary ID consists of the model prefix, shaft length, and serial number. EPA Control Decal The EPA control decal will appear on all 1998 and newer outboards. This decal identifies engine family information used for EPA Certification. It is located on the port side of the lower cowling.
Explanation of the engine family code:

Z YMXM 3130 2 1 B
Model Year Z = 2001
Manufacturer YMX = Yamaha M = Marine
Displacement Cubic Centimeters
Application 1 = PWC 2 = O/B
Technology 1 = Existing 2 = New
Manufacturer Specification
vii

GENERAL RIGGING INFORMATION Fuel Line Routing and Installation
Fuel System Check
FLOW
OUT IN
UP
ENGINE
1.
Ensure there is an anti-syphon valve or manual shut-off valve located on the fuel tank pickup tube.
FUEL FLOW SENSOR LOCATION PRIMER BULB FILTER FLOW SENSOR
OUT IN
UP
IN OUT
UP
NOTE: An optional feature for the fuel management system is a water detection sender for the water/fuel separator. This provides a visual signal to the consumer to indicate if water is in the fuel system.
2.
Install the fuel line from the fuel tank pickup to the inlet side of the water fuel separator filter. Use only GOOD stainless steel clamps.
NOTE: Ensure that all fuel fittings are sealed with teflon tape or equivalent fuel system sealer. Only apply sealer to the external threads of the fuel fitting. Any sealer on the internal bore could result in fuel system contamination.
WATER DETECTION SENDER
4.
The primer bulb or optional electric fuel primer pump may now be installed.
NOTE: An electrical primer pump must have a bypass tube installed.

TO ENGINE
3.
OPTIONAL: Run fuel line from the outlet side of the water fuel separator to the fuel management sender inlet side. The fuel flow is indicated by the arrows in the following illustration. Install the fuel sender with the side arrow pointing up.
OUT
BYPASS
FROM FUEL FILTER IN
viii

5. Run the fuel line to the engine via rigging tube and grommet. Make sure throughout the route the fuel line is not crushed or pinched, which could cause engine failure. Recommended fuel line is USCG approved A-1. OPTIONAL: Rigging transom flange. For V4 and V6 Rigging Transom Flange (MAR-THRUT-RA-SM). Engine Grommet (MAR-GROMM-ET-02).
1 2 3 4 5 6 7 8 9
10
General Rigging Information
V4 Rigging Tube Grommet
6.
Throttle Cable Shift Cable Main Harness Oil Warning Lead Remote Oil Tank Lead Trim Gauge Lead Battery Leads w/Isolator Lead Oil Hose Fuel Hose Speedometer Hose
1 9 4 5 6 2 3 7 8
10
V4
F80/F100 Tube Grommet Additional Rigging Tube Components Part Number Description
ABB-RIGHS-BK-25 ABB-RIGHS-GY-25 ABB-RIGHS-BE-25 ABB-RIGHS-BK-50 ABB-RIGHS-GY-50

150~250, 2.6L, 3.1L, HPDI Rigging Tube Grommet
Black Rig. Hose, 25 Gray Rig. Hose, 25 Blue Rig. Hose, 25 Black Hose 100 Gray Hose 100
1 2 3 4 5 6 7 8
Throttle Cable Shift Cable Main Harness Trim Gauge, Oil Warning Lead Battery Leads Fuel Hose Speedometer Hose Water Temperature & Water Pressure Sensor
3 8 1
1 2 3 4 6 7 8 9
10
Shift Cable Throttle Cable 10 Pin Main Harness & 5 Oil Warning and Trim Gauge Harness 11 Water Pressure, Remote Oil Tank Lead Battery Cable Harness Temp. Gauge Oil Hose 12 Isolator Fuel Hose Speedometer Hose Harness
2 10 3 4 6 12 5 1 11 11 7 9 8
5 6
F115 Tube Grommet
V6
1 2 3 4 5 6 7 8
Throttle Cable Shift Cable Main Harness Trim Gauge, Oil Warning Lead Battery Leads Fuel Hose Speedometer Hose Water Temperature & Water Pressure Sensor
7 8 3 1 4
HPD1
5
2 4 5 6 1 3 7
9 8
10 12
2 6
2.6L-225/250 hp
ix

Control Cable Installation 1. Choose a mounting location for the control head which will provide comfortable operation and unobstructed movement of the hand lever and control mechanism. NOTE: Minimum clearance below the binnacle control mounting surface for cables is 16. Also, minimum clearance behind the 703 control box for the control cables is 16. 2. Measure from control head position along an unobstructed path to shift and throttle connections. Cable lengths are overall length. When a measurement is in feet and inches, specify 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.
PART NUMBER ABA-CABLE-06-GY ABA-CABLE-07-GY ABA-CABLE-08-GY ABA-CABLE-09-GY ABA-CABLE-10-GY ABA-CABLE-11-GY ABA-CABLE-12-GY ABA-CABLE-13-GY ABA-CABLE-14-GY ABA-CABLE-15-GY ABA-CABLE-16-GY ABA-CABLE-17-GY ABA-CABLE-18-GY ABA-CABLE-19-GY ABA-CABLE-20-GY ABA-CABLE-22-GY ABA-CABLE-24-GY ABA-CABLE-26-GY ABA-CABLE-28-GY ABA-CABLE-30-GY ABA-CABLE-32-GY ABA-CABLE-34-GY ABA-CABLE-36-GY LENGTH 6 FEET 7 FEET 8 FEET 9 FEET 10 FEET 11 FEET 12 FEET 13 FEET 14 FEET 15 FEET 16 FEET 17 FEET 18 FEET 19 FEET 20 FEET 22 FEET 24 FEET 26 FEET 28 FEET 30 FEET 32 FEET 34 FEET 36 FEET
TYPICAL CABLE ROUTING

Cable Measuring Use the following examples as a guide for measurement. Obviously, different boats will require different routing and therefore different lengths.
ALL CABLES MINIMUM 8MM ENGAGEMENT
Adjust the throttle friction so the handles do no slip back while cruising.
Control Box Adjustments Proper control box adjustments are critical for smooth and safe operation. Yamaha uses two types of throttle control. Yamaha outboards 8, F9.9, 25, & 30 pull the throttle cable to open. Yamaha outboards T8, 9.9, 15, 40~C40 and larger push the throttle cable to open. Shift cable control is the same for all outboards. Yamaha 703/704/705 control boxes can be setup as push or pull to open by changing one internal component. Rigging as efficiently as possible means setting up the control box just once, without having to open the box again to readjust the cable ends after hookup to the motor. Refer to the following diagrams for proper cable end adjustments at the control box. Using these settings at the control box will insure the cable ends at the motor will adjust properly.
xi
NOTE: Twin engines using the 704 control box must have the throttle cables synchronized. This is to ensure the engines are running the same RPMs with the throttle handles in line. This is accomplished by adjusting the slack out of either cable to give them the same throw. If cable slack is adjusted and uneven RPM still remains, adjust the pickup cams to help pickup some of the slack.

Gauge Installation
Digital Instructions
Self-check Function: When the main switch is turned on, all line segments are displayed and the warning indicator blinks for a few seconds. On twins only with the dual key switch panel, the alarms will selfcheck for three beeps.
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TTC ECON SYNC
25
5AJ
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24-55 * 60 *766 5 6 /-60-4
TESTING GAUGE LIGHT The 2000~ tachometer requires the Yellow (ignition ON) and the Blue (light wire) to be energized at the same time for light to activate.
xii

Pre-Engine Operation 2-Stroke Engines Premix Fuel: Yamaha recommends the use of Yamalube. If it is not available, use a TCW 3 rated oil. Recommended fuel is 86 octane minimum. Premix fuel and oil is to be used on all outboard motors except 4-stroke and HPDI models. All C-Series engines should have a mixture of 25:1 for the first 10 hours of operation. Oil injected engines are recommended to have a 50:1 mixture for the first 10 hours of operation. Use caution when premixing fuel in the fuel tank. Put 20 percent of the total fuel volume in before adding oil. This ensures proper mixing. NOTE: Ring Free is recommended for all Yamaha engines on a continuous basis. Priming Fuel System Before turning on the key switch, prime the fuel system either by the primer bulb or electric primer pump. This ensures against any fuel leaks. Repair them immediately if found. It is especially important for EFI and HPDI engines to help avoid damage to the VST pump. NOTE: Leaking fuel fittings could result in severe injury or fire. Precision Blend On 90hp engines and below, before filling the oil tank, perform the following steps: 1. Turn the key switch to the ON position and ensure the alarm is operable. 2. While the key is in the ON position, start filling the engine oil tank.
For all 2-stroke 115hp engines and above, perform the following steps: 1. Turn the key to the ON position and test the oil warning system on the multifunction tachometer (see illustration following). 2. Fill the remote oil tank. Watch for the alarms to deactivate.
~99 2-STROKE
~99 4-STROKE
2000~ 2-STROKE
2000~ 4-STROKE
NOTE: Watch for when the oil alarm deactivates. Most units now have the self bleeding line on the oil pump, If not, continue with step 4 on the next column.
xiii

3. 4. Activate the return to port switch on the engine and fill the engine oil tank half way. Turn the key switch to the OFF position. Proceed to bleed the oil pump by loosening the bleed screw (1) to remove air from the oil feed line (see illustration below). 3.
Start the engine and let it run for a couple minutes, then4-3
turn it off, trim the engine until it is level and double check the oil level. NOTE: Always remove the dip stick and wipe it
5.
Next, adjust the oil link arm and double check the synchronization of the throttle plates on the engine (refer to the proper service manual for the synchronization and linkage adjustments).
off with a clean towel. Then, reinsert it to check the oil level. Precision Blend Engines NOTE: If the boat has the deck fill installed for the remote oil tank, ensure the vent is not covered by sealant nor the hose when installed. Bleeding of the oil pump on 2-stroke precision blend
4-Stroke Engines Filling Oil: NOTE: All 4-stroke engines are shipped without oil in the engine. Yamaha recommends the use of Yamalube 4M, 10W-30, 10W-40, SAE: 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 recommended amount of oil per the service manual. 2. Ensure the engine is level before removing the dip stick to check the oil level.* engines is a very important step. Consult service manual or 1999 Marine Tech Guide page 3-27.
*Fill oil to the appropriate level, if necessary.

xiv

Propeller Selection It is very important to select the proper propeller for the application of the engine. Perform the following steps to ensure the proper propeller selection: 1. Determine from the customer the intended use of the boat (e.g., fishing, cruising, towing, auxiliary motor, or high performance.) 2. Ask the customer the usual number of riders and the amount of gear usually stored on board. Select a propeller that will provide peak performance for the customer s engine and application.
Controls 1. Check throttle, shift, and steering for proper operation before starting the engine. 2. 3. 4. The controls should work smoothly - without binding or unusual free play. Look for loose or damaged connections. Check the operation of the starter and stop switches when the outboard motor is in the water.
3.
Engine 1. Check the engine and engine mounting. 2. 3. 4. Look for loose or damaged fasteners. Check the propeller for damage. Check that the battery is in good condition and battery connections are secure.
NOTE: Yamaha recommends to prop the engine to the high end of the RPM range for the customer s normal load. In some cases, if a customer cruises and skis from the same boat, it may be necessary for them to carry different propellers for each application. This ensures peak performance from the engine and adds longevity to the engine. Each change in the pitch will produce an approximately 300~400rpm variance. This would be a good time to check the lower unit lube level. Pre-Operation Checks:
WARNING
CAUTION:
If any item in the pre-operation check is not working properly, have it inspected and repaired before operating the outboard motor. Otherwise, an accident could occur. Fuel/Oil 1. Make sure there is plenty of fuel/oil for the scheduled trip. 2. 3. Make sure there are no fuel or oil leaks nor gas fumes. Be sure the fuel/oil hoses are not being flattened or kinked by objects in the boat and no sharp objects are near the fuel/oil hoses.
Do not start the engine out of the water. Overheating and serious engine damage could occur. 5. Ensure all rigging wires from the dash to the engine are wire tied neatly and safely. When customers see detail taken to route and hang the wires neatly to the engine, they feel they have received a quality rig. NOTE: Be sure not to crush or pinch the fuel line, oil line, speedo line, or water pressure lines when tying up the wires.
CAUTION:
Before engine operation, install a fuel vacuum gauge with a clear hose just before the pulse fuel pumps. Fuel starvation can cause engine failure.
xv

Fuel Pump/Fuel System Testing When a fuel starvation problem is suspected (e.g., engine hesitation or engine stopping), perform the following fuel system test:
Tool Required: Results:
1 Vacuum Gauge 1 T Fitting (P/N 6E5-24378-00-00) 1 2 Clear Fuel Hose (5/16 or 8 mm ID) 1 Long Fuel Hose (10-15) 2 Hose Clamps or Quick Ties
Procedure:
High Vacuum - Move the T fitting to the fuel filter outlet (2) and retest. Continue to the fuel filter inlet (3) and along the remaining fuel filter system until a large drop in vacuum locates the problem. 1. A good clean water separator fuel filter will increase vacuum about 0.5 inch. 2. Small internal passages inside a fuel selector valve, fuel tank pickup, or fuel line fittings may cause excessive fuel restriction and high vacuum. Unstable and slowly rising vacuum readings (especially with a full tank of fuel) usually indicates a restricted vent line.
1.
Connect the piece of clear fuel hose to a side barb of the T fitting (1).
3.
2. Connect the short piece of clear fuel hose to the fuel check valve leading from the fuel filter. If a check valve does not exist, connect the clear fuel hose directly to the fuel filter (see illustration below). 3. Check the vacuum gauge reading after running the engine long enough to stabilize at full power. IMPORTANT: From idle rpm to WOT rpm, the vacuum is not to exceed 4.5 inches for up to 200hp engines and 2.6L, 0X66 engines. The vacuum is not to exceed 6.0 inches for engines greater than 200hp and all 3.1L, 0X66 engines including the V200 3.1L EFI. An anti-siphon valve (required if the fuel system drops below the top of the fuel tank) will cause a 1.5 to 2.5 inches increase in vacuum.
NOTE: If you have a low vacuum reading at WOT rpm - 1 in Hg ~ 3 in Hg, check for air leaks. NOTE: Bubbles in the clear fuel line section indicate an air leak; making for an inaccurate vacuum test. Check all fittings for tightened clamps and a tight fuel filter. NOTE: On EFI engines, install a fuel rail pressure gauge.
xvi
EFI FUEL RAIL GAUGE
VACUUM GAUGE
FUEL VACUUM FLOW
FUEL VACUUM TEST
xvii

Predelivery Checklist
Before operation, go over the PDI Checklist - LIT-18161-01-2K (see illustration below). Fill in the information required. Start the engine and perform operating checks. NOTE: There is nothing more frustrating to a customer than to have problems with a new boat and engine. If the customer experiences problems on delivery, they feel they have received an inferior product. Also, the customers confidence level in Yamaha is greatly diminished.
OUTBOARDSmmmmmmmmmm PREDELIVERY CHECKLISTmmmmmmmmmm mmm2 and 4-Stroke Models

MODEL PROPELLER TYPE/PITCH (P) ______________ (S) _____________ PRIMARY ID (Single/Port) BOAT MAKER/MODEL PRIMARY ID (Starboard) IGNITION KEY NUMBER (P) __________ (S) ___________ HULL ID NUMBER (HIN) TRAILER NUMBER
PREDELIVERY SERVICE CHECK BEFORE OPERATION CHECK DURING OPERATION
RIGGING INSPECTION Engine Mounting (height, proper hardware, secured) Mark Engine Oil Tank Level Harness and Hoses are Secured and Properly Dressed No Air in Oil Injection Lines Instrument Operation/Connections Tight/Lighting Electric Starter Operation Mechanical Steering Operation/Installation Manual/Electric Choke Operation Hydraulic Steering Operation/Bleed Stop Switch/Emergency Switch Operation Fuel Line/Tank Installation/Connections Sealed/Secured Throttle Operation/Friction Adjustment Neutral/Cruising Battery Charged/Secured/Connections Tight Shifting ENGINE SETUP AND INSPECTION Cooling System Water Flow Tiller Handle Installation/Secure Fuel/Oil/Water/Exhaust Leaks Remote Control Operation/Adjustments Power Trim/Tilt Operation Manual Tilt Operation Instrument Operation Power Trim/Tilt Fluid Level Trim Tab Adjustment (retorque after operation) Power Trim/Tilt Operation (control/pan switch) Idle RPM (Single/P) _____ (S) _____ Gear Oil Level In Gear Idle RPM (Single/P)_______ (S) ______ Overheat Warning System (ground sensor lead) Factory-recommended W.O.T. RPM Range ___________ Visual Inspection of Engine W.O.T. RPM (Single/P)_______ (S)_______ 2-Stroke Fuel and Oil Setup All Rigging Harnesses Properly Routed and Secured Premix Fuel for Break-in (except HPDI models) Bleed Oil Injection Pump Oil Pump Linkage Adjustment Oil Transfer (P) _____ (S) ______ Return-to-port Switch Operation Oil Warning System Check VST Operation Fuel Pressure (fill with fuel first) HPDI High Pressure Pump Oil Level 4-Stroke Oil Setup INSPECTORS SIGNATURE DATE Engine Oil Level Low Oil Pressure Warning System (ground sensor lead) DEALER NAME PHONE NUMBER Carburetion (2 and 4-Stroke Models) Carburetor Synchronization DEALERSHIP ADDRESS Throttle Plate Synchronization Manual/Electric Choke Operation
CUSTOMER DELIVERY CHECKLIST

The Above Checklist Completed and Explained by Dealership Operation of Equipment/Boat Accessories Explained Operation/Orientation Ride with Dealership Personnel Owner s Manual(s) and Keys Received Customer Introduced to Service Manager/Writer Return-to-Port Operations (Oil System, RPM Reduction) Gauge Operation/Warning Symbols Explained 2-Stroke: Use of Yamalube 2-M/TC-W3 Oil and Ring Free Emphasized
4-Stroke Use of Yamalube 4-M or Equivalent Rated Oil

and Ring Free Emphasized Engine Break-in Procedure Explained Maintenance/Care Schedule Explained Advised of First Scheduled Maintenance Warranty Coverage Explained to Customer s Satisfaction, Including Customer Responsibilities Under Yamaha Extended Service (Y.E.S.) benefits explained Customer Questions Answered by Dealership Personnel
CUSTOMER SIGNATURE
DATE
CUSTOMER NAME
00-067
Rev. 5/00
WHITE COPY - Dealer
YELLOW COPY - Customer
LIT-18161-01-2K
xviii

Delivery of Unit This is the most important part of ensuring a satisfied customer. Make sure the customer is given an operation orientation of both the boat and engine. Also, be sure to explain the alarm system, return to port operations, engine break-in procedure, and maintenance schedule. If possible, it is a good tactic to take the customer for an orientation ride in their new boat. Be sure to answer all customer questions completely. This is the beginning of a good relationship with your dealership and the customer. From this point on the customer becomes a service client. Engine Break-in Procedure Be sure to express to the customer the importance of performing the engine break-in procedure for a new engine explained for them in their Owner s manual. It is necessary to allow mating surfaces of moving parts to wear-in evenly. Advise the customer that correctly breaking in a new engine will help ensure proper performance and longer engine life.
CAUTION: CAUTION:
Make sure to mix gasoline (petrol) and oil completely, otherwise the engine may be damaged.
Procedure:
1. First 10 minutes: run the engine at idle or fast idle speed only. 2. Next 50 minutes: Do not exceed half throttle (approximately 3,000 rpm). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then immediately reduce the throttle to 3,000 rpm or less. Run EFI engines between 2000-3000 rpm. Do not cruise below 2000 rpm. 3. Second hour: Accelerate at full throttle onto plane, then reduce engine speed to threequarter throttle (approximately 4,000 rpm). Vary engine speed occasionally. Run at full throttle for one minute, then operate at about 10 minutes at three-quarter throttle or less to let the engine cool. 4. Third through tenth hour: Avoid operating at full throttle for more than 5 minutes at a time. Let the engine cool between full throttle runs. Vary engine speed occasionally. Avoid operating EFI engine at 2,000 rpm and below for more than 1 hour at a time. 5. After the first 10 hours, operate the engine normally. Use straight gasoline (petrol) in the fuel tank. For oil injected engines, Yamaha Precision Blend System provides proper lubrication for normal operation. For non-oil injected engines go to normal fuel/oil ratios.
Failure to follow the engine break-in procedure may result in reduced engine life or even severe engine damage. HPDI does not require premix fuel. 2-Stroke Engines Premix fuel must be used during engine breakin in addition to oil in the Precision Blend System. Precision Blend Engines Only After engine break-in, use gasoline (petrol) only. If premix fuel is used continually, the spark plugs could become oil fouled and affect engine performance.
Engine Break-in Time: 10 hours Engine Break-in Premix Ratio Gasoline (petrol): Engine oil = 50:1 Double the oil amount for 25:1
Mixing Ratio Gasoline (0.26 US gal) (Petrol) Engine Oil (0.02 US qt) 50:1 (3.2 US gal) (0.25 US qt) (3.7 US gal) (0.30 US qt) (6.3 US gal) (0.51 US qt)
xix

QUICK START Introduction Quick Start outlines the most common Yamaha components required to install Yamaha outboards. NOTE: The 703 control box includes electrical components and a 16.4 ft. main wiring harness. The switch panel or primary harnesses listed are not required for the 703 control. If a 704 binnacle control, 705 flush mount, or any aftermarket control box is used, a switch panel and primary wiring harness is required.
Quick Start
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 numbers. The Quick Start Details section is a more comprehensive listing of rigging components for the most commonly rigged models and is aimed more at the technician who is new to rigging Yamaha outboards. The section is arranged by small engines, mid-sized engines, single engine V4 & V6 installations, and dual-engine V4 & V6 riggings. For more detailed information and information about models not included in the Quick Start Section, see the other chapters elsewhere in this manual.
xx

COMMONLY USED RIGGING ACCESSORIES
Description Part Number Comments
Quick Start
Fuel Filter Assembly Fuel Filter Assembly w/Alarm Alarm Sensor Only Oil Deck Fill Remote Oil Deck Fill with 45 Neck Remote Oil Tank Adaptor with 45 Neck Rigging Hose 25 Ft. - Black Rigging Hose 25 Ft. - Gray Rigging Hose 25 Ft. - Blue Rigging Hose 100 Ft.- Black Rigging Hose 100 Ft. - Gray Rigging Grommet Rigging Transom Flange 704 Single Binnacle Control Box Spacer 704 Dual Binnacle Control Box Spacer Fuel Management Gauge - Single Engine Fuel Management Gauge - Dual Engines Water Pressure Gauge Water Pressure Gauge Sender Kit Water Pressure Sending Adapter Water Temperature Gauge Water Temperature Gauge Sending Kit Hour Meter - analog Hour Meter - digital
1
ABB-SEPAR-AT-OR MAR-24560-00-00 MAR-10171-30-00 ABB-PLATE-DE-CK ABB-PLATE-45-00 ABB-JOINT-45-00 ABB-RIGHS-BK-25 ABB-RIGHS-GY-25 ABB-RIGHS-BE-25 ABB-RIGHS-BK-50 ABB-RIGHS-GY-50 MAR-GROMM-ET-02 MAR-THRUT-RA-SM 704-48293-00-00 704-48293-10-00 6YR-W0088-52-00 6YR-W0088-64-00 6Y5-83660-00-00 688-63667-00-00 MAR-WPRES-AD-TR 6Y5-83590-00-00 688-83591-00-00 6Y5-83504-01-00 6Y5-83504-11-00
Water separator filter With water alarm for use with fuel management gauge Water alarm sensor* V4/V6 Only V4/V6 Remote Oil Tanks V4/V6 Remote Oil Tanks Cut to length Cut to length Cut to length (2) 50 ft. hoses in box (2) 50 ft. hoses in box Use with rigging hose Use with rigging hose 3/4 Thick w/hardware 3/4 Thick w/hardware 2-Stroke, 115HP~ 2-Stroke, 115HP~ F25HP~Up (EX. 60/70)1 F25HP~Up (EX. 60/70)1 Use with after-market pressure gauge F25HP~Up1 F25HP~Up1
NOTE Only water temperature or water pressure on 90HP and smaller, not both. Both gauges can be used on V4, & V6. *Alarm sensor needed to activate water in gas signal when using Yamahas Multifunction Fuel Management Gauge.
xxi
Quick Start
QUICK START DETAILS Items listed as STD (standard) indicate that item is shipped with the engine either in the crate or in the associated rigging kit. If the part is followed by OPT (optional) that part will need to be ordered to correctly install the package in that particular combination. Crate contents and rigging kit contents can be found at the end of this section. Accessory items such as gauges, alarms, tiller handle conversion kits are listed in the 2000 Outboard Parts and Accessory Catalog (LIT-10080-MR-2K), also in later chapters in this book. Small Model(s) Remote Models T8, 9.9, 15, F9.9, T9.9, F15, F15P, F25, T25, 30
Rigging for Side Mount 701 Manual Control Box

Control Cables1 (2 req.) Control Box (OPT) (Non-electric start models / Pull to Open Throttle) ABA-CABLE-XX-GY 701-48101-51-00
Rigging for Side Mount 703 Control Box

Control Cables1 (2 req.) Control Box F9.9E, T9.9E (OPT) (Main Switch, 7 Pin Main Harness w/Safety Lanyard / Pull to Open Throttle) or 30E Control Box T8, F15, F15P, F25~T25 (OPT) (Main Switch, 10 Pin Main Harness w/Safety Lanyard / Push to Open Throttle) Optional Extension Harness 7 Pin Main Harness 6.6 ft. OPT. (Use as needed) Optional Extension Harness 10 Pin Main Harness 6.6 ft. OPT. (Use as needed) 9.9 ft. OPT. ABA-CABLE-XX-GY 703-48240-12-00 703-48230-12-00 703-48207-15-00 688-82586-11-00 688-82586-11-00 688-8258A-30-00
Installing Engine with 704 Single Binnacle or 705 Flush Mount Control
Control Cables1 (2 req) Single Binnacle T9.9E, F15, 30 (OPT) (Pull to Open Throttle / No PT&T Switch) Single Binnacle T8, F25 (OPT) (Push to Open Throttle / PT&T Switch) or Flush Mount Control T9.9E, F15, 30 (OPT) (Push to Open Throttle ** / No PT&T Switch) or Flush Mount Control T8, F15P, F25 (OPT) (Push Open Throttle / PT&T Switch / 90) Switch Panel Assembly F9.9, T9.9E (1 req.) Switch Panel Assembly 9.9, 15, 30 (1 req.) No Warning Switch Panel Assembly T8, F25~30 (1 req.) With Warning Engine to Main Harness T9.9E (1 req.) Engine to Main Harness F15 (1 req.) 7 Pin Main Harness T9.9E, F15 (1 req.) Optional Extension Harness for 7 Pin Main Harness 10 Pin Main Harness F25, 30 (1 req.) Optional Extension Harness for 10 Pin Main Harness 7 Pin to 10 Pin Adapter Harness (OPT)
1
ABA-CABLE-XX-GY 704-48230-12-00 704-48205-13-00 6X0-48203-11-00 6X0-48206-11-00 6G8-82570-02-00 689-82570-18-00 704-82570-06-00 6G8-82590-00-00 66M-82590-00-00 688-82586-50-00 688-82586-11-00 688-8258A-50-00 688-8258A-10-00 688-8258A-30-00 703-8258A-00-00
6.6 ft. OPT. 6.6 ft. OPT. 9.9 ft. OPT.
NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 2~30 ft. and in 2 ft. increments from 32~50 ft. ** This control box can be converted from push to open throttle to pull to open throttle.
xxii
Quick Start
Mid Size Model(s) 40, C40, F40, 50, C50, F50, T50, 60, C60, 70, C70, F80, 90, C90, F100, F115 Remote Models Rigging for Standard Side Mount 703 Control Box
Control Cables (2 req.) Control Box PT & T (New Switch Main Switch and Safety Lanyard / Push To Open Throttle) OPT Optional Extension Harness for 10 Pin Main Harness 6.6 ft. OPT (Use as needed) 9.8 ft. OPT ABA-CABLE-XX-GY 703-48207-15-00 688-8258A-10-00 688-8258A-30-00
Installing Engine with 704 Single Binnacle or 705 Flush Mount Control Box
Single Binnacle (1 Req.) or Flush Mount (1 Req.) Switch Panel Assembly (1 Req.) Main Harness - 10 Pin (1 Req.) Optional Extension Harness 10 Pin Main Harness (Use as needed) Engine to Tach Harness2 Non-Oil Injected Engines No Four Stroke Engines (OPT 1 Req.) 704-48205-13-00 6X0-48206-11-00 704-82570-05-00 688-8258A-50-00 6K1-8258A-40-00 688-8258A-10-00 688-8258A-30-00 6R3-82553-30-00 6R3-82553-50-00 6R3-82553-70-00 6R3-82553-80-00 6R3-82553-90-00
16.4 ft. OPT 26 ft. OPT 6.6 ft. OPT 9.8 ft. OPT 9.8 ft. OPT 16.4 ft. OPT 22.9 ft. OPT 26.2 ft. OPT 31.2 ft. OPT
9.8 ft. OPT 64D-82553-30-00 16.4 ft. OPT 64D-82553-50-00 Single Gauge Kit - 23.0 ft. STD 64D-82553-70-00 26.2 ft. OPT 64D-82553-80-00 Dual Gauge Kit - 31.2 ft. STD 64D-82553-90-00 NOTE1 Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE2 If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order additional length trim harnesses to connect to the standard harness (two trim harnesses will extend one 64D harness). This applies to the oil lamp, trim and oil tank harnesses from 70~250 models.
Engine to Tach Harness, Trim & Oil Harness2 Models with Oil Injection and Low Oil Warnings on Four Stroke Engines
xxiii

Model(s) V4/V6 115~250 Single Installation All Models 2-Stroke Rigging for Standard Side Mount Control Box
Control Cables1 (2 req.) Control Box with PT & T (New Main Switch and Safety Lanyard / Push to Open Throttle) Optional Extension Harness for 10 Pin Main Harness
Quick Start
ABA-CABLE-XX-GY 703-48207-15-00 688-8258A-10-00 688-8258A-30-00
6 ft. OPT 9.8 ft. OPT
Installing Engine with 704 Single Binnacle or 705 Flush Mount Control Box
Single Binnacle 704-48205-13-00 or Flush Mount (1 Req.) 6X0-48206-11-00 Switch Panel Assembly (New Main Switch and Safety Lanyard) 704-82570-05-00 Main Harness, 10 Pin 16.4 ft. OPT 688-8258A-50-00 (OPT 1 Req. Single Engine) 26 ft. OPT 6K1-8258A-40-00 31.2 ft OPT 61B-8258A-01-00 Optional Extension Harness 10 Pin Main Harness (As Needed) 6.6 ft. OPT 688-8258A-10-00 9.8 ft. OPT 688-8258A-30-00 Engine to Tach Harness, Trim Harness2 9.8 ft. OPT 6R3-82553-30-00 16.4 ft. OPT 6R3-82553-50-00 22.9 ft. OPT 6R3-82553-70-00 26.2 ft. OPT 6R3-82553-80-00 31.2 ft. OPT 6R3-82553-90-00 2 Engine to Tach, Trim & Oil Harness (1 Req.) (STD - Rigging Kit) 9.8 ft. OPT 64D-82553-30-00 16.4 ft. OPT 64D-82553-50-00 Single Gauge Rigging Kit -23 ft. STD 64D-82553-70-00 26.2 ft. OPT 64D-82553-80-00 Dual Gauge Rigging Kit - 31.2 ft. STD 64D-82553-90-00 Engine to Oil Tank Harness2 (1 Req.) (STD - Engine Oil Tank all Precision Blend models) 9.8 ft. OPT 6R3-85721-30-00 16.4 ft. OPT 6R3-85721-50-00 Oil Tank Rigging Kit - 26.2 ft. STD 6R3-85721-80-00 Optional 2.8 Gallon Oil Tank (As Needed) 6YR-W0035-92-00 Optional 5 Gallon Oil Tank (As Needed) 6YR-W0035-C0-00 1 NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE2 If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order additional length trim harnesses to connect to the standard harness (two trim harnesses will extend one 64D harness). This applies to the oil lamp, trim and oil tank harnesses from 70~250 models.
xxiv
Quick Start
Yamahas counter rotation rigging kits when used in conjunction with a standard single gauge rigging kit, or dual gauge kit contain all necessary items to install both engine systems (excluding control cables and accessory items.)
Model(s) LF115, L130~L250 Twin Engine Installation Rigging for Standard Side Mount Control Box
Control Cables (4 Req.) ABA-CABLE-XX-GY Dual Binnacle (1 Req.) ( STD - LH Rigging Kit) 704-48207-04-00 Switch Panel Assembly (1 Req.) (STD - LH Rigging Kit) 6K1-82570-05-00 (Push to Choke Main Switch) Main Harness, 10 Pin (2 Req.) (STD - LH Rigging Kit) Rigging Kit L/H - 26 ft. STD 6K1-8258A-40-00 Rigging Kit L/H - 31.2 ft. STD 61B-8258A-01-00 Optional Extension Harness 10 Pin Main (As Needed) 6.6 ft. OPT 688-8258A-10-00 9.9 ft. OPT 688-8258A-30-00 Engine to Tach, Trim & Oil Harness2 (1 Req.) (STD - LH Rigging Kit) Low Oil Warning F115 9.8 ft. OPT 64D-82553-30-00 16.4 ft. OPT 64D-82553-50-00 Single Gauge Kit - 23 ft. STD 64D-82553-70-00 Dual Gauge Kit - 26.2 ft. STD 64D-82553-80-00 L/H Rigging Kit - 31.2 ft. STD 64D-82553-90-00 Engine to Oil Tank Harness2 (1 Req.) (STD - With Oil Tank. All Precision Blend models) 9.8 ft. OPT 6R3-85721-30-00 16.4 ft. OPT 6R3-85721-50-00 Oil Tank Rigging Kit - 26.2 ft. STD 6R3-85721-80-00 Dual Engine Tie Bar (1 Req.) Shipped in L/H Engine Crate ABA-DUALT-IE-BR Optional 2.8 Gallon Oil Tank (As Needed) 6YR-W0035-92-00 Optional 5 Gallon Oil Tank (As Needed) 6YR-W0035-C0-00 1 NOTE Order control cables using part number ABA-CABLE-XX-GY substituting the correct footage needed in place of the XX. Yamaha control cables in 1 ft. increments from 6~30 ft. and in 2 ft. increments from 32~50 ft. NOTE2 If a longer harness is required, you have two choices. Order from the available harnesses, the length needed, or order two 6R3-82553-30-00 harnesses to extend 9.8 ft. length standard harness that came with the rigging kit. This applies to the oil lamp, trim and oil tank harnesses from 70~250 models. For more details, see the Electrical Section.
xxv

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

2001 MODEL STANDARD EQUIPMENT You have asked for an easy-to-use program to help you get the right rigging equipment for your particular installations. The Yamaha Sales Department is proud to continue the Kitting Program for 2001 with simple control and rigging kit options. This Kitting Program allows you to order the standard equipment specific to your
Basic Standard Equipment
needs. Below, is a list of the basic standard equipment as of the publication date of this book. Additional standard equipment will depend upon the kits you order. Contact your Marketing Representative for full details about the Kitting Program.
8 to 40 F6, F25, F30M~F40M 70-90 115 to 250 (2-Stroke) DX150 L130 ~ L250 LF115 F40J~F115J C40-C90
Fuel Tank in Crate Fuel Pipe in Crate Fuel Pipe, Steering Link Battery Cable, Mounting Bolts - Steering Linkarm (115~2.6L Only) Steering Link, Battery Cable, order with engine 19, 21, 25, or 27 Propellers, Propeller Wrench Tie Bar in Crate, Mounting Bolts Water Pump in Crate Fuel Pipe, Steering Link in Crate
F50, F30T~F115 Fuel Pipe, Steering Link in Crate
1-1

PROPELLER, CONTROLS, FUEL TANK & RIGGING ITEMS SHIPPING LOCATION
MODEL STARTING CODE ID 6A1S 6L5S 67DL 67DS 6E3S 68RL 68RS 6N0S 68TL 68TS 69GL 69GL 69GX 69GX 682CS 6G9L 6G9L 6G9S 6G8L 6G8L 6G8X 6G8X 684CS 66ML 66MS 66ML 66MS 66ML 66ML 6L2L 6L2S 6K9S 65WL 65WL 65WS 65WS 65WL 193528 081842 306528 018358 024846 300580 001185 022778 300867 001237 550101 500101 850101 750101 171885 402547 309197 012208 474408 416517 790075 763983 427330 501999 201837 303182 004665 800141 900111 308064 007540 201906 353272 302523 051830 000479 251743 RIGGING ITEMS N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A CRATE N/A CRATE N/A CRATE N/A N/A N/A CRATE CRATE CRATE N/A CRATE CRATE N/A N/A N/A CRATE N/A N/A N/A N/A CRATE CRATE CRATE N/A
MODEL 2MSHZ 3MSHZ F4MLHZ F4MSHZ 5MSHZ F6MLHZ F6MSHZ 8MSHZ F8MLHZ F8MSHZ T8PLHZ T8PLRZ T8PXHZ T8PXRZ 9.9MSHZ F9.9ELRZ F9.9MLHZ F9.9MSHZ T9.9ELHZ T9.9ELRZ T9.9EXHZ T9.9EXRZ 15MSHZ F15ELHZ F15ESHZ F15MLHZ F15MSHZ F15PLHZ F15PLRZ 25MLHZ 25MSHZ 25MSHZ3 F25ELHZ F25ELRZ F25ESHZ F25ESRZ F25MLHZ
PROPELLER CRATE (7-1/4 x 4) CRATE (7-1/2 x 7) CRATE (7-1/2 x 8) CRATE (7-1/2 x 8) CRATE (7-1/2 x 8) CRATE (8-1/2 x 6-1/2) CRATE (8-1/2 x 6-1/2) CRATE (8-1/2 x 6-1/2) CRATE (8-1/2 x 6-1/2) CRATE (8-1/2 x 6-1/2) CRATE (11-3/4 x 5-3/4) CRATE (11-3/4 x 5-3/4) CRATE (11-3/4 x 5-3/4) CRATE (11-3/4 x 5-3/4) CRATE (9-1/4 x 9) CRATE (9-1/4 x 9) CRATE (9-1/4 x 9) CRATE (9-1/4 x 9) CRATE (11-3/4 x 9-1/4) CRATE (11-3/4 x 9-1/4 CRATE (11-3/4 x 9-1/4) CRATE (11-3/4 x 9-1/4) CRATE (9-1/4 x 9) CRATE (-1/4 x 10-1/2) CRATE (9-1/4 x 10-1/2) CRATE (9-1/4 x 10-1/2) CRATE (9-1/4 x 10-1/2) CRATE (9-1/4 x 10-1/2) CRATE (9-1/4 x 10-1/2) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 14) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 9) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 9) CRATE (9-7/8 x 10-1/2)
CONTROL N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A SEPARATE N/A SEPARATE N/A SEPARATE N/A N/A N/A SEPARATE N/A SEPARATE N/A N/A N/A N/A N/A N/A SEPARATE N/A N/A N/A N/A SEPARATE N/A SEPARATE N/A
FUEL TANK N/A N/A N/A N/A N/A SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE
1-2
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location (Contd.) MODEL STARTING CODE ID 65WS 65WL 6J8L 6J8L 6J8L 6J8S 69HL 6H4L 6H4L 6H4L 67CS 67C 67CL 67CS 67CL 6H5L 6H5L 62Y 62YL 64JL 6H2L 6H2L 6H3L 6H3L 67G 67GL 6H1L 6H1L 67FL 67FX 6E5L 6E5X 68V 68VL 68VX 68WX 6L1L 6L1X 6L6X 303858 702039 800462 312796 707472 702281 421732 406850 474493 363147 495999 352799 304042 504755 360597 310112 703298 407500 731173 301027 000698 503417 446404 904076 151486 840362 761205 462998 409559 110929 400141 493352 550802 930421 050362 RIGGING FUEL TANK SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE N/A N/A N/A SEPARATE N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
MODEL F25MSHZ T25TLRZ 30ELHZ 30ELRZ 30MLHZ 30MSHZ F30TLRZ 40MLHZ 40TLRZ C40TLRZ F40ESRZ F40MJHZ F40MLHZ F40MSHZ F40TLRZ 50TLRZ C50TLRZ F50TJRZ F50TLRZ T50TLRZ 60TLRZ C60TLRZ 70TLRZ C70TLRZ F80TJRZ F80TLRZ 90TLRZ C90TLRZ F100TLRZ F100TXRZ 115TLRZ 115TXRZ F115TJRZ F115TLRZ F115TXRZ LF115TXRZ 130TLRZ 130TXRZ L130TXRZ
PROPELLER CRATE (9-7/8 x 10-1/2) CRATE CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 11-1/4) CRATE (9-7/8 x 11-1/4) ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS N/A ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS N/A ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS N/A ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS N/A ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS
CONTROL N/A SEPARATE N/A SEPARATE N/A N/A SEPARATE N/A SEPARATE SEPARATE SEPARATE N/A N/A N/A SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE L-KIT SEPARATE SEPARATE L-KIT
ITEMS N/A CRATE CRATE CRATE N/A N/A * N/A * * * N/A * * * * * * * * * * * * * * * * * * * * * * * L-KIT * * L-KIT
1-3
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location (Contd.) MODEL STARTING CODE ID 6G4X 6J9L 6G4L 6G4X 65NL 6K0X 6K0X 6G4X 6J9L 6J9L 6G5X 62HL 6G6L 6G6X 6K1X 6K1X 6G6X 66XL 62KX 62JU 62KX 66KL 507530 505024 800223 800376 000578 400254 800376 053385 001807 800363 800101 800105 150468 101510 001204 100513 004647 002839 101976 200762 101976 302579 RIGGING ITEMS * * * * * L-KIT L-KIT * * * * * * * L-KIT L-KIT * * * * * L-KIT *
MODEL 150TXRZ V150TLRZ Z150TLRZ Z150TXRZ DX150TLRZ LX150TXRZ LZ150TXRZ SX150TXRZ VX150TLRZ VZ150TLRZ Z175TXRZ VZ175TLRZ Z200TLRZ Z200TXRZ LX200TXRZ LZ200TXRZ SX200TXRZ VX200TLRZ VZ200TLRZ LX225TXRZ SX225TURZ LX225TXRZ VX225TLRZ
PROPELLER ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS ORDER FROM PARTS (VX-MAX)
CONTROL SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE L-KIT L-KIT SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE L-KIT L-KIT SEPARATE SEPARATE SEPARATE SEPARATE SEPARATE L-KIT SEPARATE
FUEL TANK N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A N/A
*Single Gauge Tachometer Kit or 2-Gauge Tchometer and Speecometer Kit..

NOTE: All left hand rotation models have the Fuel Management System shipped in a separate box. Jet drive models also have the jet pump shipped separately. KEY: N/A CRATE SEPARATE * L KIT ORDER FROM PARTS Model does not include this item as standard equipment or information not available at this time. These items are included in the crate with the unit. These items are user's choice and shipped in a separate box. Single Gauge Tachometer Kit or 2-Gauge Tachometer & Speedometer Kit. Left Hand Rigging Kit. Item is not standard equipment. Order from Yamaha Parts and Accessories.
NOTE: All models that use a rigging kit still have some basic rigging items, such as mounting bolts and a steering are included in the unit crate. Also, all left hand models have the dual engine tie bar included in the crate. 1-4

RIGGING KITS For model year 2001, the rigging kits have not changed. 40hp~250hp 4-Stroke and 2-Stroke still use the same rigging kits. 2-Stroke 115hp and up have the option of a 2.8-gallon or 5.0-gallon remote oil tank. You need to specify which oil tank when ordering. These kits may be ordered at anytime from the sales staff. The rigging kits are as follows: Multi-Function LCD Tachometer Kit or Single Gauge Kit (6YR-W0035-15-00) For use on 2-Stroke and 4-Stroke Engines
Part Number Part Name Qty.
6R3-83621-00-00 64D-82553-70-00 6Y5-83500-T2-00 6Y5-83553-00-00
Mark, 1 Trim/Oil, Harness 23 ft. Meter, Assy Gauge, Harness 1 Fuse
1 1 1 1
Multi-Function LCD Tachometer/Speedometer Kit or 2 Gauge Kit (6YR-W0035-47-00) For use on 2-Stroke and 4-Stroke Engines
6Y5-83553-M0-00 6Y5-82117-00-00 6R3-83621-00-00 64D-82553-80-00 6Y5-83500-T2-00 6Y5-83570-S5-00 6Y5-83557-10-00 90465-11M10-00 90465-13M18-00 61A-28107-14-00
Gauge, Harness 2 Fuse Wire, Lead Mark, 1 Trim/Oil, Harness 26.2 ft. Meter, Assy Speedometer Assy Tube Clamp Clamp Rigging Manual
1 1 1 1 1 1 1 2 10 l
1-5
Rigging Kits
Dual Engine Counter Rotation Kit or Left Hand Engine Rigging Kit (6YR-W0035-67-00) For use with 2-Stroke/4-Stroke Engines
6Y5-83553-00-00 6Y5-82117-00-00 6R3-83621-00-00 64D-82553-90-00 6Y5-83500-T2-00 704-48207-22-00 6K1-82570-05-00 6K1-8258A-40-00 90465-13M18-00 61B-28107-14-00 61B-8258A-01-00 90149-05M05-00 95380-05600-00 92990-05600-00 92990-05100-00 6Y5-83500-F2-00 6Y5-83553-F1-00 6Y5-85752-01-00 90160-06M00-00 703-82531-00-00
Gauge, Harness 1 Fuse Wire, Lead Mark, 1 Trim/Oil, Harness 31.2 ft. Meter, Assy Remote Control Assy Panel Switch Assy Main, Harness 26 ft. Clamp Rigging Manual Main Harness 31.2 ft. Screw Nut Washer Washer Fuel Management Gauge Fuel Management Harness Fuel Management Sender Screw, Round Tap Wire, Lead F. M. to Tach
1 1 1 1 1 1 1 1 10 l 1 4 4 4 4 1 1 2 4 1
REMOTE OIL TANK KITS 2.8 Gallon Oil Tank (6YR-W0035-92-00) 2-Stroke Oil Injected Engines
61A-21708-03-00 6E5-13437-43-00 90465-13M11-00 6E5-2170A-01-00 6Y2-24307-40-00 90450-10M07-00
Oil Tank Sub Assy Mark, Caution Clamp Bracket, Sub. Complete Fuel pipe Complete Hose Clamp Assy
1 1 1 1 1 1
1-6

5.0 Gallon Oil Tank (6YR-W0035-C0-00) 2-Stroke Oil Injected Engines
Rigging Kits
61A-21708-10-00 61A-13437-40-00 90465-13M11-00 6E5-2170A-01-00 6Y2-24307-40-00 90450-10M07-00
Oil Tank Sub Assy Mark, Caution Clamp Bracket, Sub. Complete Fuel Pipe Complete Hose Clamp Assy
1 1 1 1 1 1
TILLER HANDLE KITS Tiller Handle Kit for 40/C40/50/C50 (63D-W0086-Z0-4D)

63D-82586-00-00 6H5-83553-11-00 90465-13M36-00 688-83383-11-00 6H5-83386-00-00 6H5-42724-00-00 688-82540-11-00 63D-82554-00-00 663-82555-01-00 63D-42546-00-00 63D-42541-00-00 90201-08M01-00 63D-42508-00-00 63D-42527-00-00 63D-42526-00-00 63D-42528-00-00 63D-42562-00-00 63D-42561-00-00 682-43318-01-00 90185-10M01-00 97595-08550-00 97595-06416-00 63D-82361-00-00 90161-06M03-00
Tiller Kit Handle Assy Tiller Handle Install. Manual Wire Harness Extension Read Wire Clamp Buzzer Buzzer Stay Grommet Neutral Switch Assy Stay, Neutral Switch Assy Damper, Main Switch Nut Pipe Plate Washer Steering Friction Assy Plate, Friction 3 Plate, Friction 2 Piece, Friction Shaft, Steering Lock Knob, Steering Lock Cover Nut, Lock Bolt Bolt Clamp, Cord Screw
1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 2 1 1 1 1 2 2 1 1
97595-06535-00 90387-06M26-00 90185-10051-00 97013-05010-00 92990-05100-00 95380-05600-00 63D-83728-00-00 90465-15M11-00
Bolt Collar Nylon Lock Nut Bolt Spring Washer Nut Connector Assy Clamp
1 1 2 2 2 2 1 3
F25E, F25T Tiller Handle Available Spring 2001 - (65W-W0086-Z0-4D)
1-7

Tiller Handle Kit for F30/F40 3 Cylinder (67C-W0086-Z1-4D)
Rigging Kits
6F5-82540-00-00 6J8-82554-00-00 90109-06M86-00 65W-44173-00-00 90254-03M05-00 62Y-42725-40-00 63D-83728-00-00 6H5-83553-11-00 6H2-82586-01-00
Tiller Kit Handle Assy. Tiller Handle Install. Manual Neutral Switch Assy. Stay, Neutral Switch Bolt Lever, Shift Control Pin, Slotted Spring Grommet Connector Assy. Wire, Lead Extension Wire Harness
1 1 1 1 2 1 1 1 1 1 1
Steering Friction Assy. 92990-06100-00 Washer 90109-06M88-00 Bolt 67C-42527-00-00 Plate, Friction 95380-05600-00 Nut 90387-05M11-00 Collar 90387-05M05-00 Collar 90119-05M03-00 Bolt, with Washer 90202-10M56-00 Washer, Plate 65W-42528-00-00 Plate, Friction 67C-42525-00-00 Plate, Friction 67C-42561-00-00 Knob, Steering Lock 689-43633-00-00 Cover, Tilt Lever 90209-10M26-00 Washer 90185-10M14-00 Nut, Self-Locking 67C-42562-00-00 Shaft, Steering Lock
1 2 2 1 1 1 1 1 2 2 1 1 1 1 1 1
Tiller Handle Kit for F50/T50 (62Y-W0086-Z0-4D)

6H2-82586-01-00 6H5-83553-11-00 90465-13M36-00 688-83383-11-00 6H5-83386-00-00 62Y-42725-40-00 63D-42546-00-00 63D-42541-00-00 6F5-82540-00-00 62Y-82554-00-00 62Y-82555-00-00 90201-08M01-00 63D-42508-00-00 63D-42527-00-00 63D-42526-00-00 63D-42528-00-00 63D-42562-00-00 63D-42561-00-00 682-43318-01-00 90185-10M01-00 97595-08550-00 97595-06416-00
Tiller Kit Handle Assy Tiller Handle Install. Manual Wire Harness Extension Read Wire Clamp Buzzer Buzzer Stay Grommet Nut Pipe Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch Plate Washer Steering Friction Assy Plate, Friction 3 Plate, Friction 2 Piece, Friction Shaft, Steering Lock Knob, Steering Lock Cover Nut, Lock Bolt Bolt
1 1 1 1 1 1 1 1 2 2 1 1 1 2 1 1 1 2 1 1 1 1 2 2
97013-05010-00 90185-10051-00 62Y-82361-00-00 90161-06M03-00 97595-06535-00 90387-06M26-00 92990-05100-00 95380-05600-00 63D-83728-00-00 90465-13M24-00
Bolt Nylon Lock Nut Clamp, Cord Screw Bolt Collar Spring Washer Nut Connector Assy Clamp
2 2 1 1 1 1 2 2 1 1
1-8

Tiller Handle Kit for 60/C60/C70/70 (6H3-W0086-Z0-4D)
Rigging Kits
Tiller Kit Handle Assy Tiller Handle Install. Manual 6H2-82586-01-00 Wire Harness Extension 6H5-83553-11-00 Read Wire 90465-13M36-00 Clamp 688-83383-11-00 Buzzer 6H5-83386-00-00 Buzzer Stay 6H2-42725-01-00 Grommet 6H3-82540-00-00 Neutral Switch Assy 6H3-82554-00-00 Stay, Neutral Switch 663-82555-01-00 Damper, Main Switch Steering Friction Assy 663-42518-00-00 Shaft, Friction
1 1 1 1 1 1 1 1 1 1 1 1 1
92990-08600-00 663-42528-00-00 90175-06003-00 97080-06035-00 69242-51501-00 90185-08057-00 97013-05010-00 90185-10051-00 92990-05100-00 95380-05600-00 63D-83728-00-00 90464-15M11-00
Plate Washer Piece, Friction Nut, Wing Bolt Rod Nut, Lock Bolt Nylon Lock Nut Spring Washer Nut Connector Assy. Clamp
2 1 1 1 1 1 2 2 2 2 1 3
Tiller Handle Kit for C90/90 (6H3-W0086-Z0-4D)

6H2-82586-01-00 6H5-83553-11-00 90465-13M36-00 688-83383-11-00 6H5-83386-00-00 688-42725-30-00 688-82540-11-00 663-82554-01-00 663-82555-01-00 663-42518-00-00 92990-08600-00 663-42528-00-00 90175-06003-00 97080-06035-00 692-42515-01-00 90185-08057-00 97013-05010-00 90185-10051-00 92990-05100-00 95380-05600-00 63D-83728-00-00 90464-15M11-00
Tiller Kit Handle Assy Tiller Handle Install. Manual Wire Harness Extension Read Wire Clamp Buzzer Buzzer Stay Grommet Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch Steering Friction Assy Shaft, Friction Plate Washer Piece, Friction Nut, Wing Bolt Rod Nut, Lock Bolt Nylon Lock Nut Spring Washer Nut Connector Assy. Clamp
1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 2 2 2 2 1 3
1-9

Tiller Handle Kit for F80/F100 (67G-W0086-Z1-4D)
Rigging Kits
6H2-82586-01-00 6H5-83553-11-00 90465-13M24-00 90465-13M30-00 688-83383-11-00 6H5-83386-00-00 67G-42725-00-00 97595-08530-00 62Y-82555-00-00 67G-82554-00-00 67G-82555-01-00
Tiller Kit Handle Assy Tiller Handle Install. Manual Wire Harness Extension Read Wire Clamp Clamp Buzzer Buzzer Stay Grommet Mark Damper Main Switch Neutral Switch Assy Stay, Neutral Switch
1 1 1 1 1 1 1 1 1 1 1 1 1
6E5-42518-01-00 92990-08600-00 67G-42528-00-00 90175-06003-00 97080-06035-00 6E5-42515-00-00 90185-08057-00 97595-06514-00 63D-83720-00-00
Steering Friction Assy Shaft, Friction Plate Washer Piece, Friction Nut, Wing Bolt Rod Nut, Lock Bolt Connector Assy.
1 1 2 1 1 1 1 2 2 1
Tiller Handle Kit for F115

63D-83728-00-00 688-82540-11-00 67G-82554-01-00 62Y-82555-00-00 97595-06514-00 97595-08530-00 67G-42725-00-00 6H5-83553-11-00 63D-82586-00-00 688-83383-11-00 6H5-83386-00-00
Tiller Kit Handle Assy Tiller Handle Install. Manual Connector Assy. Neutral Switch Assy. Stay, Neutral Switch Damper Main Switch Bolt Mark Grommet Read Wire Wire Harness Extension Buzzer Stay Buzzer
1 1 1 1 1 1 1 1 1 1 1 1 1
6E5-42518-01-00 92995-08600-00 67G-42528-00-00 90175-06003-00 97080-06035-00 6E5-42515-00-00 90185-08057-00 90465-13M30-00 90465-13M24-00 68V-42121-00-4D 90116-10175-00 90185-10051-00
Steering Friction Assy Shaft Friction Plate Washer Piece, Friction Nut, Wing Bolt Rod Nut, Lock Clamp Clamp Bracket Stud Nylon Lock Nut
1 1 1 1 1 1 1 2 1 1 1 2 2
1-10

2001 MODEL OUTBOARD MOTOR CRATE CONTENTS Because the factory does not include a packing list in outboard motor shipping cartons, the following lists are published. Listed are all items inside each crate or carton.
2MSHZ
Part Number Description Qty
T8PLRZ/PXRZ
LIT-18626-04-10 90580-40M02-00 3MSHZ/5MSHZ

Part Number
Owner's Manual Emergency Starter Ass'y
1 1
Description
Qty
LIT-18626-04-10 90580-40M02-00 91490-25030-00 F4MSHZ, MLHZ

Part Number
Owner's Manual Emergency Starter Ass'y Split Pin
1 1 2
Description
Qty
LIT-18626-04-24 90580-40M02-00 91490-25030-00
Owner's Manual Emergency Starter Ass'y Split Pin
1 1 2
F6MSHZ/MLHZ, F8MSHZ/MLHZ
LIT-18626-04-25 6G8-15780-00-00 68T-2814F-00-00 6Y1-24306-53-00 8MSHZ

Part Number
Owner's Manual Emergency Starter Ass'y Spark Plug Box Fuel Pipe Complete
1 1 1 1
Description
Qty
LIT-18626-04-11 90580-40M02-00 6Y1-24306-51-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete
1 1 1
LIT-18626-04-35 6G8-15780-00-00 6Y1-24306-53-00 90185-08057-00 6E5-43145-01-00 90185-09M01-00 90201-10M20-00 93210-16275-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 68T-61351-00-00 6E5-61355-00-00 90201-08MA4-00 90468-18008-00 92995-08600-00 95380-06600-00 97575-08535-00 68T-2414F-00-00 97595-06512-00 663-48344-00-00 68T-48511-00-00 91690-30012-00 68T-48531-00-00 682-48538-50-00 90101-08M88-00 90185-08057-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Nylon Locking Nut Clamp Bracket Cap Nylon Nut Plate Washer O-Ring Hexagon Nut Plate Washer Collar Steering Link Rod Hexagon Bolt Plate Washer Clip Washer Nut Bolt w/Washer Spark Plug Box Bolt w/Washer Cable End (Remote Control) Steering Hook Spring Pin Remote Control Bracket 1 Cable Clamp 1 Bolt Nylon Locking Nut
1 1 1 2 1 2 2 1 1 1 1 1 1 2 1 2 2 1 1 2 1 1 2 1 2 2 1
9.9MSHZ, 15MSHZ
T8PLHZ/PXHZ
LIT-18626-04-35 6G8-15780-00-00 6Y1-24306-53-00 90185-08057-00 90201-08MA4-00 92995-08600-00 68T-2814F-00-00 90101-08M88-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Nylon Locking Nut Plate Washer Washer Spark Plug Box Bolt
1 1 1 2 2 2 1 1
LIT-18626-04-12 6A1-2818N-30-00 90580-50M01-00 6Y1-24306-51-00 F9.9MSHZ, MLHZ

Part Number
Owner's Manual Caution Tag Emergency Starter Ass'y Fuel Pipe Comp.
1 1 1 1
Description
Qty
LIT-18626-04-26 90580-50M01-00 6Y1-24306-51-00 91490-30025-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Split Pin
1 1 1 2
1-11

F9.9ELRZ
2001 Model Outboard Motor Crate Contents
T9.9ELRZ/EXRZ
LIT-18626-04-26 90580-50M01-00 6Y1-24306-51-00 91490-30025-00 6G8-48532-50-00 6G8-48538-50-00 97595-06530-00 97595-06512-00 6G8-48565-50-00 6G8-48511-20-00 97595-06516-00 6G8-26364-00-00 6G8-26363-00-00 6G8-82541-00-00 6G8-83530-00-00 6E5-43145-01-00 90185-09M01-00 90201-10M20-00 93210-16275-00 6G8-61351-00-00 90170-09M03-00 90201-10M63-00 6E5-61355-00-00 90387-10M06-00 6G8-61348-00-00 90185-08057-00 97575-08525-00 T9.9ELHZ, EXHZ
Part Number
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Split Pin Remote Control Brckt 2 Cable Clamp 1 Bolt Bolt Grommet Steering Hook Bolt W/Washer Throttle Cable End 2 Throttle Cable End 1 Wire Lead Pilot Lamp Ass'y Clamp Bracket Cap Nylon Lock Nut Plate Washer O-Ring Steering Link Rod Nut Plate Washer Bolt Collar Plate Nylon Lock Nut Bolt
1 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 2 2 1 1 2 1 1 1 1 2 2
Description
Qty
LIT-18626-04-26 90580-50M01-00 6Y1-24306-51-00 91490-30025-00 6G8-48532-50-00 6G8-48538-50-00 97595-06530-00 97595-06512-00 6G8-48565-50-00 6G8-48511-20-00 97595-06516-00 6G8-61348-00-00 90101-08M88-00 92995-08600-00 90185-08057-00 6G8-26364-00-00 6G8-26363-00-00 6G8-82541-00-00 6G8-83530-00-00 6E5-43145-01-00 6G8-61351-00-00 90170-09M03-00 90201-10M63-00 6E5-61355-00-00 90387-10M06-00 90185-09M01-00 90201-10M20-00 93210-16275-00 90201-08MA4-00 97575-08525-00
Owner's Manual Emergency Starter Assy Fuel Pipe Complete Split Pin Remote Control Bracket 2 Cable Clamp 1 Bolt Bolt Grommet Steering Hook Bolt Plate Bolt Washer Nylon Lock Nut Throttle Cable End 2 Throttle Cable End 1 Wire Lead Pilot Lamp Ass'y Clamp Bracket Cap Steering Link Rod Nut Plate Washer Bolt Collar Nylon Lock Nut Plate Washer O-Ring Plate Washer Bolt
1 1 1 2 1 1 1 2 1 1 2 1 2 2 2 2 2 1 1 1 1 2 1 1 1 2 2 1 1 2
LIT-18626-04-26 90580-50M01-00 91490-30025-00 6G8-43319-03-00 90101-08M88-00 92995-08600-00 90201-08MA4-00 90185-08057-00 6Y1-24306-51-00
Owner's Manual Emergency Starter Ass'y Split Pin Plate Bolt Plate Washer Plate Washer Nylon Lock Nut Fuel Pipe Complete
1 1 2 1 1 8 8 14 1
F15MSHZ/MLHZ, F15ESHZ/ELHZ
LIT-18626-04-27 90580-50M01-00 6Y1-24306-51-00 F15PLHZ

Part Number
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete
1 1 1
Description
Qty
LIT-18626-04-27 6G8-15780-00-00 6Y1-24306-53-00 663-48344-00-00 90468-18008-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Cable End (Remote Control) Clip
1 1 1 2 2
1-12

F15PLRZ
25MSHZ/MSHZ3/MLHZ
LIT-18626-04-27 6G8-15780-00-00 6Y1-24306-53-00 6H3-48538-00-00 63V-48511-01-00 663-48344-00-00 90185-08057-00 90468-18008-00 97575-08535-00 6E5-43145-01-00 90185-09M01-00 90201-10M20-00 93210-16275-00 90387-10M42-00 6E5-61355-00-00 63V-61351-00-00 90170-09M03-00 90201-10M63-00 F25ELRZ
Part Number
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Cable Clamp Steering Hook Cable End (Remote Control) Nylon Locking Nut Clip Bolt w/Washer Clamp Bracket Cap Nylon Nut Plate Washer O-Ring Collar Bolt Steering Link Rod Nut Plate Washer
1 1 1 1 1 2 1 2 1 1 2 2 1 1 1 1 1 1
LIT-18626-04-13 6Ll5-2818N-30-00 6R6-2818N-30-00 90580-50M01-00 6Y1-24306-51-00
Owner's Manual Caution Tag Caution Tag Emergency Starter Ass'y Fuel Pipe Complete
1 1 1 1 1
F25ESRZ
Description
Qty
LIT-18626-04-28 90580-50M01-00 6Y1-24306-51-00 90201-10M20-00 90185-09M01-00 6G5-43145-00-00 663-48344-00-00 90468-18008-00 90101-10M58-00 92995-10600-00 90201-12426-00 90201-10120-00 95380-10600-00 62Y-42727-00-00 6H3-48538-00-00 90185-10051-00 6E5-43145-01-00 93210-16275-00 65W-61351-00-00 90170-09M03-00 90387-10M42-00 90201-10M63-00 90101-09M01-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Plate Washer Nylon Lock Nut Clamp Bracket Cap Cable End (Remote Cont.) Clip Bolt Washer Plate Washer Plate Washer Nut Grommet Cable Clamp Nylon Lock Nut (663) Clamp Bracket Cap O-Ring Steering Link Rod Nut Collar Plate Washer Bolt
1 1 1 2 2 1 2 2 4 8 4 2 8 1 1 2 1 1 1 1 1 1 1
LIT-18626-04-28 677-15780-00-00 6Y1-24306-53-00 663-48344-00-00 6E5-43145-01-00 93210-16275-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 65W-61351-00-00 90201-10120-00 90201-12426-00 90468-18008-00 92995-10600-00 95380-10600-00 6E5-43145-00-00 90101-10M58-00 6H3-48538-00-00 90185-09M01-00 62Y-42727-00-00 90185-10051-00 90201-10M20-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Cable End (Remote Cont.) Clamp Bracket Cap O-Ring Bolt Nut Plate Washer Collar Steering Link Rod Plate Washer Plate Washer Clip Washer Nut Clamp Bracket Cap Bolt Cable Clamp Nylon Nut Grommet Nylon Nut Plate Washer
1 1 1 2 1 1 1 1 1 1 1 2 4 2 8 8 1 4 1 2 1 2 2
F25MSHZ/MLHZ, F25ESHZ/ELHZ
LIT-18626-04-28 90580-50M01-00 6Y1-24306-51-00 6G5-43145-00-00 90185-10051-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Clamp Bracket Cap Nylon Lock Nut
1 1 1 2 2
1-13

F25TLRZ
T25TLRZ
LIT-18626-04-28 90580-50M01-00 6Y1-24306-51-00 90201-10M20-00 90201-10120-00 90185-09M01-00 6G5-43145-00-00 663-48344-00-00 90468-18008-00 90101-12M65-00 92995-12200-00 90201-12426-00 95380-12600-00 62Y-42727-00-00 6H3-48538-00-00 90185-10051-00 6E5-43145-01-00 93210-16275-00 65W-61351-00-00 90170-09M03-00 90387-10M42-00 90201-10M63-00 90101-09M01-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Plate Washer Plate Washer Nylon Lock Nut Clamp Bracket Cap Cable End (Remote Control) Clip Bolt Washer Plate Washer Nut Grommet Cable Clamp Nylon Lock Nut Clamp Bracket Cap O-Ring Steering Link Rod Nut Collar Plate Washer Bolt
1 1 1 2 2 2 1 2 2 4 8 4 8 1 1 2 1 1 1 1 1 1 1
LIT-18626-04-28 677-15780-00-00 6Y1-24306-53-00 663-48344-00-00 6H3-48538-00-00 6G5-43145-01-00 93210-16275-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 65W-61351-00-00 90201-12426-00 90468-18008-00 92995-10600-00 92995-12200-00 95380-12600-00 6G5-43145-00-00 90185-10051-00 90185-09M01-00 90101-12M65-00 90201-10M20-00 30MSHZ/MLHZ
Part Number
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Cable End (Remote Control) Cable Clamp Clamp Bracket Cap O-Ring Bolt Nut Plate Washer Collar Steering Link Rod Plate Washer Clip Washer Washer Nut Clamp Bracket Cap Nylon Nut Nylon Nut Bolt Plate Washer
1 1 1 2 1 1 1 1 1 1 1 1 4 2 8 8 8 1 2 2 4 2
Description
Qty
LIT-18626-04-13 6Ll5-2818N-31-00 90580-50M01-00 6Y1-24306-51-00
Owner's Manual Caution Tag Emergency Starter Ass'y Fuel Pipe Complete
1 1 1 1
30ELHZ
LIT-18626-04-13 6G5-2818N-31-00 6Y1-24306-51-00 90101-10M58-00 92995-10600-00 90201-12426-00 95380-10600-00
Owner s Manual Caution Tag Fuel Pipe Complete Bolt Washer Plate Washer Nut
1 1 1 4 8 4 8
1-14

30ELRZ
40TLRZ
LIT-18626-04/13 6G5-2818N-31-00 6Y1-24306-51-00 90101-10M58-00 92995-10600-00 90201-12426-00 95380-10600-00 6G8-26364-00-00 6G8-26363-00-00 689-61351-01-00 90170-09M03-00 90387-10M42-00 90201-10M63-00 6E5-61355-00-00 90201-10M20-00 90185-09M01-00 6E5-43145-01-00 93210-16275-00
Owner's Manual Caution Tag Fuel Pipe Complete Bolt Plate Washer Plate Washer Nut Wire End 2 Wire End 1 Steering Link Rod Nut Collar Plate Washer Bolt Plate Washer Nylon Lock Nut Clamp Bracket Cap O-Ring
1 1 1 4 8 4 8 1 1 1 1 1 1 1 2 2 1 1
LIT-18626-04-14 6G5-2818N-31-00 90580-50M01-00 6Y1-24306-51-00 6E5-43145-01-00 63D-61351-00-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 90101-12M65-00 90185-09M01-00 90201-12426-00 90201-10M20-00 92995-12200-00 93210-16275-00 95380-12600-00
Owner's Manual Caution Tag Emergency Starter Ass'y Fuel Pipe Complete Clamp Bracket Cap Steering Link Rod Bolt Nut Plate Washer Collar Bolt Nylon Lock Nut Plate Washer Plate Washer Washer O-Ring Nut
1 1 1 1 1 1 1 1 1 1 4 2 4 2 8 1 8
F40MLHZ F30TLRZ
Part Number Description Qty Part Number Description Qty
LIT-18626-04/29 677-15780-00-00 6Y1-24306-53-00 6G5-43145-00-00 67C-48344-00-00 90101-12M65-00 90201-12426-00 90468-18008 92995-12200-00 95380-12600-00 90185-09M01-00 90201-10M20-00 93210-16275-00 6E5-43145-01-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 65W-61351-00-00
Owner's Manual Emergency Starter Assy Fuel Pipe Complete Clamp Bracket Cap Cable End (Remote Control) Bolt Plate Washer Clip Washer Nut Nylon Nut Plate Washer O-Ring Clamp Bracket Cap Bolt Nut Plate Washer Collar Steering Link Rod
1 1 1 1 2 4 4 2 8 8 2 2 1 1 1 1 1 1 1
LIT-18626-04-29 90580-50M01-00 6Y1-24306-51-00 67C-48344-00-00 90468-18008-00 90101-12M65-00 90185-10051-00 90201-12426-00 92995-12200-00 95380-12600-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Remote Control 1 Cable End Clip Bolt Nylon Lock Nut Plate Washer Plate Washer Nut
1 1 1 2 2 4 2 4 8 8
1-15

F40TLRZ
50TLRZ
LIT-18626-04-29 90580-50M01-00 6Y1-24306-51-00 90101-12M65-00 90201-12426-00 92995-12200-00 95380-12600-00 67C-48344-00-00 90468-18008-00 65W-61351-00-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 6E5-43145-01-00 90185-09M01-00 90201-10M20-00 93210-16275-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Bolt Plate Washer Plate Washer Nut Cable End Clip Steering Link Rod Bolt Nut Plate Washer Collar Clamp Bracket Cap Nylon Lock Nut Plate Washer O-Ring
1 1 1 4 4 8 8 2 2 1 1 1 1 1 1 2 2 1
LIT-18626-04-14 677-15780-00-00 6G5-2818N-31-00 6Y1-24306-53-00 90101-12M65-00 92995-12200-00 90201-12426-00 95380-12600-00 90201-10M20-00 90185-09M01-00 6E5-43145-00-00 93210-16275-00 63D-61351-00-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00
Owner's Manual Emergency Starter Ass'y Tag Caution Fuel Pipe Complete Bolt Washer Plate Washer Nut Plate Washer Nylon Nut Clamp Bracket Cap O-Ring Steering Link Rod Bolt Nut Plate Washer Collar
1 1 1 1 4 8 4 8 2 2 1 1 1 1 1 1 1
F50TLRZ C40TLRZ, C50TLRZ

LIT-18626-04-14 6R6-2818N-30-00 689-2818N-30-00 90580-50M01-00 6Y1-24306-51-00 90101-12M65-00 90185-09M01-00 90201-10M20-00 6E5-43145-01-00 93210-16275-00 63D-61351-00-00 90170-09M03-00 90101-09M01-00 90201-10M63-00 90387-10M42-00 90201-12426-00 92995-12200-00 95380-12600-00
Owner's Manual Caution Tag Caution Tag Emergency Starter Ass'y Fuel Pipe Complete Bolt Nylon Lock Nut Plate Washer Clamp Bracket Cap O-Ring Steering Link Rod Nut Bolt Plate Washer Collar Plate Washer Plate Washer Nut
1 1 1 1 1 4 2 2 1 1 1 1 1 1 1 4 8 8
LIT-18626-04-30 90580-50M01-00 6Y1-24306-51-00 6G8-26363-00-00 62Y-42727-00-00 6E5-43145-01-00 6G5-43145-00-00 62Y-48538-00-00 63D-61351-00-00 90101-09M01-00 90170-09M03-00 90201-12426-00 90387-10M42-00 90101-12M65-00 90185-09M01-00 90201-12426-00 90201-10M20-00 92995-12200-00 90201-16275-00 93210-16275-00 95380-12600-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Wire End 1 Grommet Clamp Bracket Cap Clamp Bracket Cap Cable Clamp Steering Link Rod Bolt Nut Plate Washer Collar Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Plate Washer O-Ring Nut
1 1 1 2 1 1 1 1 1 1 1 4 1 4 2 4 2 8 1 1 8
1-16

T50TLRZ
60TLRZ
LIT-18626-04-30 64J-1819K-90-00 64J-2819K-90-00 90580-50M01-00 6Y1-24306-51-00 6G8-26363-00-00 62Y-42727-00-00 6E5-43145-01-00 6G5-43145-00-00 64J-45168-00-00 62Y-48538-00-00 63D-61351-00-00 90101-09M01-00 90170-09M03-00 90201-10M63-00 90387-10M42-00 90101-12M65-00 90185-09M01-00 90201-12426-00 90201-10M20-00 92995-12200-00 93210-16275-00 95380-12600-00 6Y5-82117-00-00 64D-82553-70-00 6Y5-83553-00-00 6Y5-83670-11-00
Owner's Manual Set-Up Manual Splash Plate Install. Manual Emergency Starter Ass'y Fuel Pipe Complete Wire End 1 Grommet Clamp Bracket Cap Clamp Bracket Cap Splash Plate Cable Clamp Steering Link Rod Bolt Nut Plate Washer Collar Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer O-Ring Nut Lead Wire Extension Lead Wire (7M) Lead Wire Trim Meter Ass'y
1 1 1 1 1 2 1 1 1 1 1 1 4 1 1 1 4 2 4 2 8 1 8 1 1 1 1
LIT-18626-04-14 677-15780-00-00 6G5-2818N-31-00 6Y1-24306-53-00 90101-12M65-00 92995-12200-00 90201-12426-00 95380-12600-00 90201-10M20-00 90185-09M01-00 6E5-43145-00-00 93210-16275-00 688-61351-00-00 6E5-61355-00-00 90170-09M03-00 90201-10M63-00 90387-10M42-00
Owner's Manual Emergency Starter Assy Caution Tag Fuel Pipe Complete Bolt Washer Plate Washer Nut Plate Washer Nylon Nut Clamp Bracket Cap O-Ring Steering Link Rod Bolt Nut Plate Washer Collar
1 1 1 1 4 8 4 8 2 2 1 1 1 1 1 1 1
70TLRZ
LIT-18626-04-30 90580-50M01-00 6G5-2818N-31-00 6Y1-24306-51-00 6E5-43145-01-00 90101-12M65-00 90185-09M01-00 90201-12426-00 90201-12200-00 90201-10M20-00 95380-12600-00 93210-16275-00 688-61351-10-00 90170-09M03-00 90201-10M63-00 6E5-61355-00-00 90387-10M42-00
Owner's Manual Emergency Starter Ass'y Caution Tag Fuel Pipe Complete Clamp Bracket Cap Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Nut O-Ring Rod Nut Plate Washer Bolt Collar
1 1 1 1 1 4 2 4 8 2 8 1 1 1 1 1 1
1-17

C60TLRZ, C70TLRZ, C90TLRZ
90TLRZ
LIT-18626-04-34 6R6-2818N-30-00 689-2818N-30-00 90580-50M01-00 6Y1-24306-51-00 688-61351-10-00 6E5-43145-01-00 6E5-61355-00-00 90101-12M65-00 90170-09M03-00 90185-09M01-00 90201-10M20-00 90201-10M63-00 90201-12426-00 90387-10M42-00 92995-12200-00 93210-16275-00 95380-12600-00
Owner's Manual Caution Tag Caution Tag Emergency Starter Ass'y Fuel Pipe Complete Steering Link Rod Clamp Bracket Cap Bolt Bolt Nut Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Plate Washer O-Ring Nut
1 1 1 1 1 1 1 1 4 1 2 2 1 4 1 8 1 8
LIT-18626-04-34 6G5-2818N-31-00 90580-50M01-00 6Y1-24306-51-00 6E5-43145-01-00 688-61351-10-00 6E5-61355-00-00 90101-12M65-00 90170-09M03-00 90185-09M01-00 90201-12426-00 90201-10M20-00 90201-10M63-00 90387-10M42-00 92995-12200-00 93210-16275-00 95380-12600-00
Owner's Manual Caution Tag Emergency Starter Ass'y Fuel Pipe Complete Clamp Bracket Cap Steering Link Rod Bolt Bolt Nut Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Plate Washer O-Ring Nut
1 1 1 1 1 1 4 1 2 4 2 1 1 8 1 8
F100TXRZ F80TLRZ, F100TLRZ

LIT-18626-04-31 90580-50M01-00 6Y2-24307-40-00 67F-82105-00-00 67F-61351-00-00 90170-09M03-00 90387-10M42-00 90185-09M01-00 90201-10M20-00 90201-10M63-00 6E5-43145-01-00 93210-16275-00 95380-12600-00 90201-13M01-00 90201-12M05-00 90101-09M01-00 90101-12M03-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Battery Cable Steering Link Rod Nut Collar Nylon Lock Nut Plate Washer plate Washer Clamp Bracket Cap O-Ring Nut Plate Washer Plate Washer Bolt Bolt x 115
1 1 1 1 1 1 1 2 2 1 1 1 8 8 4 1 4
LIT-18626-04-31 90580-50M01-00 6Y2-24307-40-00 67F-82105-00-00 67F-61351-00-00 90170-09M03-00 90387-10M42-00 90185-09M01-00 90201-10M20-00 90201-10M63-00 6E5-43145-01-00 93210-16275-00 95380-12600-00 90201-13M01-00 90201-12M05-00 90101-09M01-00 90101-12M03-00
Owner's Manual Emergency Starter Ass'y Fuel Pipe Complete Battery Cable Steering Link Rod Nut Collar Nylon Lock Nut Plate Washer plate Washer Clamp Bracket Cap O-Ring Nut Plate Washer Plate Washer Bolt Bolt x 115
1 1 1 1 1 1 1 2 2 1 1 1 8 8 4 1 4
1-18

115TLRZ/TXRZ, 130TLRZ/TXRZ
150TXRZ
LIT-18626-04-16 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 90201-12M05-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90560-12M01-00 93210-16275-00 95380-12600-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Spacer O-Ring Nut
1 1 1 1 1 1 1 4 2 2 4 8 1 1 1 8
L130TXRZ
LIT-18626-04-16 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 90201-12M05-00 90101-12M77-00 90201-12M05-00 90201-13M01-00 95380-12600-00 ABA-DUALT-IE-BR
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Bolt Bolt Plate Washer Plate Washer Nut Tie Bar
1 1 1 1 4 2 4 8 8 1
LIT-18626-04-16 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 64D-82105-00-00 90201-12M05-00 90101-12M77-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90560-12M01-00 92990-06100-00 92990-08100-00 93210-16275-00 95380-12600-00 95380-08700-00 95380-12600-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Battery Cable Bolt Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Spacer Spring Washer Spring Washer O-Ring Nut Nut Nut
1 1 1 1 1 1 1 1 4 2 2 2 4 8 1 1 1 1 1 1 1 8
1-19

DX150TLRZ
SX150TLRZ/TXRZ
LIT-18626-04-19 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 67H-82105-00-00 90101-12M05-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90560-12M01-00 92990-06100-00 93210-16275-00 95380-06700-00 95380-12600-00 65N-45941-00-00 65N-45943-00-00 90465-13M18-00 97595-08516-00 65N-28161-00-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Battery Cable Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Wsher Collar Spacer Spring Washer O-Ring Nut Nut Front Propeller 25 Rear Propeller 25 Clamp Bolt Wrench
1 1 1 1 1 1 1 1 4 2 2 4 8 1 1 1 1 1 8 1 1 10 1 1
LIT-18626-04-21 6G5-2818N-31-00 90580-50M01-00 61A-28107-15-00 6E5-61351-01-00 90387-10M61-00 90560-12M01-00 6E5-61355-00-00 67H-82105-00-00 90101-12M05-00 90101-12M77-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90465-13M18-00 92990-06100-00 6E5-43145-01-00 93210-16275-00 95380-06700-00 97696-08626-00 95380-12600-00
Owner's Manual Caution Tag Emergency Starter Ass'y Rigging Instructions Steering Link Rod Collar Spacer Bolt Battery Cable Bolt Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Clamp Spring Washer Clamp Bracket Cap O-Ring Nut Bolt Nut
1 1 1 1 1 1 1 1 1 4 2 2 2 4 8 10 1 1 1 1 1 8
LX150TXRZ, LX200TXRZ
LIT-18626-04-21 6G5-2818N-31-00 61B-28107-15-00 90580-50M01-00 67H-82105-00-00 90101-12M05-00 90201-12M05-00 90201-13M01-00 90465-13M18-00 92990-06100-00 95380-06700-00 97595-08516-00 90101-12M77-00 95380-12600-00 ABA-DUALT-IE-BR
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Battery Cable Bolt Plate Washer Plate Washer Clamp Spring Washer Nut Bolt Bolt Nut Tie Bar
1 1 1 1 1 4 4 8 10 1 1 1 2 8 1
1-20

V150TLRZ
VX150TLRZ
LIT-18626-04-16 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 67H-82105-00-00 90101-12M05-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90465-11M10-00 90465-13M18-00 ;90560-12M01-00 92990-06100-00 92990-08100-00 93210-16275-00 95380-06700-00 95380-08700-00 95380-12600-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Battery Cable Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Clamp Clamp Spacer Spring Washer Spring Washer O-Ring Nut Nut Nut
1 1 1 1 1 1 1 1 4 2 2 4 8 1 2 10 1 1 1 1 1 1 8
LIT-18626-04-17 6G5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 67H-82105-00-00 90101-12M03-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90560-12M01-00 92990-06100-00 97595-08516-00 93210-16275-00 95380-06700-00 90465-13M18-00 95380-12600-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Battery Cable Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Spacer Spring Washer Bolt O-Ring Nut Clamp Nut
1 1 1 1 1 1 1 1 4 2 2 4 8 1 1 1 1 1 1 10 8
1-21

Z175TXRZ
VX200TLRZ, VX225TLRZ
LIT-18626-04-22 677-15780-00-00 68F-42753-00-00 90601-20022-00 90101-12M05-00 90201-13M01-00 90201-12M05-00 95380-12600-00 90101-12M77-00 90465-13M18-00 68F-28107-10-00 68F-82105-00-00 97595-08516-00 95333-08600-00 92903-08100-00 6E5-61355-00-00 90185-09M01-00 90201-10M20-00 6E5-43145-01-00 93210-16275-00 90387-10M61-00 90560-12M01-00 6E5-61351-01-00
Owner's Manual Emergency Starter Assy Fastener Nylon Clip Bolt Plate Washer Plate Washer Nut Bolt Clamp Rigging Instruction Wire Harness Bolt w/Washer Nut Washer Bolt Nylon Nut Plate Washer Clamp Bracket O-Ring Collar Spacer Steering Link Rod
1 1 1 1 4 12 6 12 2 10 1 1 1 1 1 1 2 2 1 1 1 1 1
LIT-18626-04-20 6Gl5-2818N-31-00 61A-28107-15-00 90580-50M01-00 6E5-43145-01-00 6E5-61351-01-00 6E5-61355-00-00 90101-12M05-00 90185-09M01-00 90201-10M20-00 90201-12M05-00 90201-13M01-00 90387-10M61-00 90465-11M10-00 90465-13M18-00 90465-13M30-00 90560-12M01-00 93210-16275-00 95380-12600-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Clamp Bracket Cap Steering Link Rod Bolt Bolt Nylon Lock Nut Plate Washer Plate Washer Plate Washer Collar Clamp Clamp Clamp Spacer O-Ring Nut
1 1 1 1 1 1 1 4 2 2 4 8 1 2 10 1 1 1 8
LX225TXRZ, LX250TXRZ/TURZ
LIT-18626-04-23 6G5-2818N-31-00 90580-50M01-00 61B-28107-15-00 90101-12M05-00 90201-12M05-00 90201-13M01-00 90465-13M18-00 90465-13M30-00 95380-12600-00 90465-11M10-00 90101-12M77-00 ABA-DUALT-IE-BR
Owner's Manual Caution Tag Emergency Starter Ass'y Rigging Instructions Bolt Plate Washer Plate Washer Clamp Clamp Nut Clamp Bolt Tie Bar
1 1 1 1 4 4 8 10 1 8 2 2 1
1-22

SX225TXRZ/TURZ
SX250TXRZ/TURZ
LIT-18626-04-23 6G5-2818N-31-00 90580-50M01-00 61B-28107-15-00 90101-12M05-00 90201-12M05-00 90201-13M01-00 90465-13M18-00 90465-13M30-00 95380-12600-00 90465-11M10-00 90101-12M77-00 ABA-DUALT-IE-BR
Owner's Manual Caution Tag Emergency Starter Ass'y Rigging Instructions Bolt Plate Washer Plate Washer Clamp Clamp Nut Clamp Bolt Tie Bar
1 1 1 1 4 4 8 10 1 8 2 2 1
LIT-18626-04-23 6G5-2818N-31-00 61B-28107-15-00 90580-50M01-00 90101-12M05-00 90201-12M05-00 90201-13M01-00 90465-11M10 90465-13M30-00 95380-12600-00 90465-13M18-00 90101-12M77-00
Owner's Manual Caution Tag Rigging Instructions Emergency Starter Ass'y Bolt Plate Washer Plate Washer Clamp Clamp Nut Clamp Bolt
1 1 1 1 4 4 8 2 1 8 10 2
1-23

SECTION 2 ENGINE DIMENSIONS, MOUNTING, & MOUNTING EQUIPMENT Engine Mounting Dimensions (Transom Only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1 Transom Mounting Patterns . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6 Transom Drill Fixture . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-10 Four-Stroke Splash Guards, 40~F100 Splash Plates . . . . . . . . . . . . . . . . . . . . . . . . . 2-11 Jet Drive Model Identification and Serial Numbers . . . . . . . . . . . . . . . . . . . . . . . . . 2-12 Jet Drive Engine Mounting, Maintenance, Shift Cable Instruction, Service Info. . . . 2-13 Dual Engine Tie Bar Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-32 Dual Cable Steering Bracket Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-36 Morse Universal Dual Cable Steering Bracket Kit Installation . . . . . . . . . . . . . . . . . 2-39 V4 & V6 Rigging Tube Grommet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-42 F9.9 Exhaust Well Kit Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-44

ENGINE MOUNTING DIMENSIONS (TRANSOM ONLY) Proper mounting of the outboard will mean better performance, maximum reliability, and maximum customer satisfaction. This chapter contains the specifications necessary for motor mounting. For correct mounting, the cavitation plate should be equal to the bottom of the transom, or 25mm+ (1.0 inch). If higher mounting is used for performance applications, it is recommended that a water pressure gauge be installed so pressure can be monitored. When mounting, also make sure the motor has the clearance to provide full movement, from both port to starboard, as well as during trim/tilt functions. NOTE: For bracket application Refer to bracket manufacturer for installation specifications. Transom Dimensions A = Steering Rotation (each way, from cen terline) B C D E F G H I J K L M = Maximum tilt angle (including 12 tran som angle) = Protrusion into boat at maximum tilt = Cavitation plate distance from top of transom = Steering clearance (each way, from cen terline) = Powerhead clearance at rear of motor (each way, from centerline) = Transom thickness (minimum - maxi mum) = Transom bracket height = Chart = Maximum engine depth from top of transom (0 trim) = Powerhead height = Maximum height at full tilt (powerhead) = Protrusion into boat (tiller handle mod els)
2-1
Engine Mounting Dimensions
N 0 P Q R
= Maximum rearward protrusion of power head from transom = Protrusion into boat (remote models) = Maximum rearward protrusion of lower unit from transom (@ level trim) = Distance, propeller shaft from cavitation plate = Minimum twin-engine center-to-center distance
J+K = Overall height M+N= Overall depth (tiller models) N+O = Overall depth (remote models)
Bolt Pattern: Bolt patterns are on the following pages.
2-2

Transom Dimensions
MODEL 2 3 F4 5 F6/8 T8P 8 9.9/15 F9.9 T9.9 F15 F15P F25T T25T F25E F25M 25 2 CYL 25/3 30 40M/T C40T F30T/3 F40/E/T/3 F40/M/3 50, C50 D E 276mm 417mm 16.4in 3.5in 360 76 S: 435mm (17.4in) 105mm 4.1in 360 64 S: 435.1mm (17.1in) 137mm L: 562.1mm (22.1in 5.38in 360 76 S: 444mm (17.5in) 134mm 5.3in 45 66 S: 435.5mm (17.1in) 171.5mm L:562.5mm (22.1in) 6.8in 40 66 S: 556.5mm (21.9in) 171.5mm X:624.5mm (24.6in) 6.8in 60 81 S: 436mm (17.2in) 137mm 5.4in 45 67 S:440mm (17.3in) 143mm 5.6in 37 70 S:432mm (17.0in) 166mm) L:559mm (22.0in) 6.5in 37 70 L:559mm (22.0in) 166mm UL:635mm (25.0in) 6.5in 45 63 S:440mm (17.3in) 183mm L:568mm (22.4in) 7.2in 40 63 L:569.6mm (22.4in) 182.1mm 7.2in F:45 F:61 F:550mm (21.6in) 185mm T:40 T:62 T:5280mm (20.8in) 7.3in 45 64 ER:343mm (13.5in) S:423mm (16.6in) 185mm EH:363mm (14.3in) L:550mm (21.6in) 7.3in
M:363mm (14.3in)
A 360
B 73
C 275mm 10.8in 311mm 12.2in 342mm 13.5in 331 mm 13.0in 271mm 10.7in 271mm 10.7in 287mm 11.3in 314mm 12.4in 270mm 10.6in 270mm 10.6in 475mm 18.7in 308.3mm 12.1in 329mm 12.9in
285.5mm 11.2in 276mm 10.9in 283mm 11.1in 280mm 11.0in 308mm 12.2in 308mm 12.2in 350mm 13.8in 329.4mm 13.0in 400mm 14.8in 400mm 14.8in 296mm 11.7in 310mm 12.2in 340mm 13.4in 313mm 12.3in 313mm 12.3in 340mm 13.4in 345mm 13.6in 321mm 12.6in 405mm 16.0in 331mm 13.0in 388mm 15.3in 409mm 16.1in 406mm 16.0in 406mm 16.0in 406mm 16.0in 396mm 15.6in 396mm 15.6in 419mm 16.5in 420mm 16.5in
G 23~60mm 0.9~2.4in 22~60mm 0.9~2.4in 22~60mm 0.9~2.4in 22~60mm 0.9~2.4in 28~67mm 1.1~2.6in 33~65mm 1.3~2.6in 16~60mm 0.6~2.1in 25~63mm 1.0~2.5in 33~65mm 1.3~2.6in 33~65mm 1.3~2.6in 44mm 1.7in 33!66mm 1.3~2.6in 69mm 2.7in 37~69mm 1.5~2.8in
H 143.7mm 5.7in 136mm 5.4in 136mm 5.4in 136mm 5.4in 207mm 8.1in 326.7mm 12.9in 164mm 6.5in 161mm 6.3in 170mm 6.7in 170mm 6.7in 164mm 6.5in 326.7mm 12.95in 338mm 13.3in 21.8mm 8.6in
I 503mm 16.8in S: 621mm (24.5in) in) S: 498.2mm (19.6in) L: 441.8mm (17.4in) S: 623mm (24.5in) S: 593.5mm (23.4in) L: 669mm (26.3in) L: 716mm (28.2in) X: 756.5mm (29.8in) S: 668mm (26.3in) S: 572mm (22.5in) S: 598mm (23.5in) L: 673mm (26.5in) L: 716mm (28.2in) X: 761mm (30.0in) S: 572mm (22.5in) L: 641mm (25.2in) L: 641mm (25.2in) L:648mm (25.5in) S:615mm (24.2in) L:686mm (27.0in) S:586mm (23.1in) L:655mm (25.8in) S: 584mm (23.0in) L: 648mm (25.5in) M: 579mm (22.8in) T: 709mm (27.9in) S:599.8mm (23.6in) L:665.7mm (26.2in) S:604.1mm (24.0in) L:670.8mm (26.4in) M: 579mm (22.8in) T: 709mm (27.9in) F:709mm (27.9in) T:696mm (27.4in) 696 27.4in L:767mm (30.5in) X:844mm (33.3in) 698mm 27.5in L:773mm (30.5in) X:850mm (33.7in) L:775mm (30.5in) X:850mm (33.5in) L:773mm (30.4in) X:849mm (33.4in) 773mm 30.4in 695mm 27.4in 774mm 30.5in L:774mm (30.5in) X:849mm (33.4in) 768mm 30.2in X:846mm (33.3in) U:923mm (36.3in)
337mm 13.3in 40 70 M:387mm (15.2in) E:375mm (14.8in) 40 M:66 M:433mm (17.0in) T:69 T:387mm (15.2in) 40 353mm 13.9in 40 63 384mm 15.1in 40 M:66 M:433mm (17.0in) T:69 T:387mm (15.2in) 40 35 35 30 35 35 35 35 35 32 32 35 35 69 67 70 67 68 70 70 70 70 70 70 70 70 409mm (16.1in) 403mm (15.9in) 528mm 20.8in 457mm 18.0in 555mm 21.8in 466mm 18.4in 587mm 23.1in 587mm 23.1in 587mm 23.1in 584mm 23.0in 574mm 22.6in 624mm 24.6in 631mm 24.8in 62
40
67
S:419mnm (16.5in) 152mm L:546mm (21.5in) 6.,0in S:424mm (16.7in) 152mm L:545mm (21.5in) 6.0in L:537mm (21.1in) 175mm 6.9in S:410.1mm (16.2in) 189mm L:533mm (21.0in) 7.4in S:410mm (16.1in) 189mm L:533mm (21.0in) 7.4in S:410mm (16.1in) 175mm L:537mm (21.1in) 6.9in 533mm (21.0in) 520mm 20.5in L: 537mm (20.3in) X: 664mm (26.2in) 520mm 20.5in L:516mm (20.3in) X:643mm (25.3in) L:517mm (20.4in) X:644mm (25.4in) L:516mm (20.3in) X:642mm (25.3in) 516mm 20.3in 452mm 17.8in 516mm 20.3in L:516mm (20.3in) X:643mm (25.3in) 515mm 20.3in X:642mm (25.3in) U:768mm (30.2in) 181mm 7.1in 182mm 7.2in 240mm 9.5in 187mm 7.4in 246mm 9.7in 291mm 11.5in 290mm 11.4in 290mm 11.4in 290mm 11.4in 277mm 10.9in 277mm 10.9in 281mm 11.0in 281mm 11.1in
F50, T50 60/70 C60/C70 F80/F100 90/C90 F/LF115 115/130 150 SX150/200 LX150/200 V150 VX150 DX150 VZ150/175 200 Z150~200 LZ150~200 VX200/225 250/3.1L SX225/250 LX225/250
25~70mm 174.3mm .98~2.8in 6.9in 30~66mm 245mm 1.2~2.6in 9.6in M:30~66mm M:245mm (9.6in) (1.2~2.6in) T:355 (14.0in) T:69mm (2.7in) 69mm 338mm 2.7in 13.3in 69mm 338mm 2.7in 13.3in M:30~66mm M:245mm (9.6in) (1.2~2.6in) T:355 (14.0in) T:69mm (2.7in) 69mm (2.7in) 355mm (14.0in) 69mm 2.7in 80mm 3.2in 69mm 2.7in 82mm 3.2in 82mm 3.2in 82mm 3.2in 82mm 3.2in 82mm 3.2in 82mm 3.2in 82mm 3.2in 82mm 3.2in 79mm 3.1in 351mm 13.8in 347mm 13.7in 351mm 13.8in 367mm 14.4in 367mm 14.5in 367mm 14.5in 367mm 14.5in 367mm 14.5in 367mm 14.5in 367mm 14.5in 367mm 14.5in 411mm 16.2in
2-3
2-4

Transom Dimensions
MODEL 2 3 F4 5 F6/8 T8P 8 9.9/15 F9.9 T9.9 F15 F15P F25T T25T F25E F25M 25 2 CYL 25/3 30 40M/T C40T F30T/3 F40/E/T/3 F40/M/3 50, C50 F50/T50 J 614mm 24.2in S:654mm (25.7in) S:643.0mm (25.3in) L:770.0 (30.3in) S:653mm (25.7in) S:681.5mm (26.8in) L:808.5mm (31.8in) L:868mm (34.2in) X:936mm (36.8in) S:682mm (26.9in) S:705mm (27.8in) S:679mm (26.7in) L:824mm (32.4in) L:871mm (34.3in) X:947mm (37.3in) S:706mm (27.8in) L:833mm (32.8in) L:834.6mm (32.9in) 834mm 32.8in S:707mm (27.8in) L:834mm (32.8in) K 302mm 11.9in 343mm 13.7in 386mm 15.2in 358mm 14.1in 317mm 12.5in 317mm 12.5in 295mm 11.6in 335mm 13.2in 293mm 11.5in 293mm 11.5in 375mm 14.8in 372.2mm 14.7in 441mm 17.4in 441mm 17.4in L 397mm 15.6in 419mm 16.5in 511mm 20.1in 459mm 18.1in 528mm 20.8in 528mm 20.8in 470mm 18.5in 526mm 20.7in 556mm 21.9in 556mm 21.9in 589mm 23.2in 586.5mm 23.1in 698mm 27.5in 698mm 27.5in M 331mm 13.0in 317mm 12.5in 342mm 13.5in 333mm 13.1in 601mm 23.7in 601mm 23.7in 439mm 16.9in 479mm 18.9in 440mm 17.3in 571mm 22.5in 528mm 20.8in 517.4mm 20.4in 523mm 17.0in 523mm 17.0in N 276mm 10.9in 311mm 12.2in 375mm 14.8in 344mm 13.5in 430mm 16.9in 430mm 16.9in 363mm 14.3in 393mm 15.5in 439mm 17.3in 439mm 17.2in 475mm 18.7in 483mm 19.0in 580mm 22.8in 580mm 22.8in
O 122mm 4.8in 107mm 4.2in 141.3mm 5.6in 145mm 5.7in 121.5mm 4.8in 121.5mm 4.8in 114mm 4.5in 180mm 7.1in 152mm 6.0in 152mm 2.4in 168mm 6.69in 159.8mm 6.3in 190mm 7.5in 190mm 7.5in
P 164mm 6.5in 223mm 8.8in 259mm 10.2in 252mm 9.9in 355mm 13.9in 366mm 14.4in 359mm 14.1in 355mm 14.0in 356mm 14.0in 356mm 14.0in 356mm 14.0in 363.7mm 14.3in 432mm 17.0in 432mm 17.0in
Q 100mm 3.9in 103mm 4.1in 104mm 4.1in 105mm 4.1in 123mm 4.8in 157mm 6.2in 123mm 4.8in 135mm 5.3in 135mm 5.3in 157mm 6.2in 135mm 5.3in 135mm 5.3in 144mm 5.7in 144mm 5.7in
114mm 15.8in 114mm 15.8in
S:703mm (27.7in) 365mm 584mm 508mm L:830mm (32.7in) 14.4in 23.0in 20.0in S:712mm (28.0in) M:446mm (17.6in) M:657mm (25.9in) 497mm L:833mm (32.8in) E:428mm (16.9in) E:647mm (25.5in) 19.6 S:751mm (29.6in) M:472mm (18.6in) M:683mm (26.9in) L:878mm (34.6in) T:439mm (17.3in) T:688mm (27.1in) S:753.1mm (29.7in) L:876mm (34.5in) L:876mm (34.5in) L:878mm (34.6in) F:876mm(34.5in) T:914mm (35.9in) 464mm 18.3in 493mm 19.4in T:439mm (17.3in) 521mm 20.5in 472mm 18.6in 666mm 26.2in 512mm 20.2in 681mm 26.8in 543mm 21.4in 670mm 26.4in 691mm 27.2in 691mm 27.2in 708mm 27.9in 735mm 28.9in 710mm 28.0in 708mm 763mm 27.9in 30.1in 727mm 763mm 28.6in 30.1in T:688mm (27.1in) 789mm 31.1in 734mm 753mm 28.9in 29.7in 719mm (28.3in) 28.3in 856mm 33.7in 730mm 28.7in 879mm 34.6in 737mm 29.0in 791mm 31.2in 864mm 34.0in 864mm 34.0in 960mm 37.8in 835mm 32.9in 923mm 36.3in 818mm 32.2in 651mm 27.8in 793mm 31.2in 860mm 33.9in
428mm 185mm 402mm 44mm 16.9in 7.3in 15.8in 5.7in 465mm M:198mm (7.8in) 496mm 148mm 570mm 18.3in E:114mm (4.5in) 19.5in 5.8in 22.4in M:490mm(19.3in) M:493mm (19.4in) 175mm 600mm T:527mm (20.7in) T:529mm (20.8in) 6.9in 23.6in 569mm 22.4in 569mm 22.4in T:528mm (20.8in) 576mm 22.7in 547mm (21.5in) 651mm 25.6in 545mm 21.5in 662mm 26.1in 554mm 21.8in 550mm 21.7in 557mm 21.9in 557mm 21.9in 613mm 24.2in 591mm 23.3in 566mm 22.3in 132mm 5.2in 175mm 6.9in T:142 (5.6in) 223mm 8.8in 151mm (5.9in) 171mm 6.7in 180mm 7.1in 115mm 4.5in 177mm 7.0in 179mm 7.0in 179mm 7.0in 179mm 7.0in 180mm 7.1in 180mm 7.1in 179mm 7.0in 181mm 7.1in 521mm 175mm 600mm 20.5in 6.9in 23.6in 521mm 175mm 600mm 20.5in 6.9in 23.6in T:529mm (20.8in) 125mm 600mm 6.9in 23.6in F:532mm (21.0in) F:175mm 600mm T:562mm (22.1in) 6.9in 23.6in T:190mm 7.5in 562mm (22.1in) 191mm 600mm 7.5in 23.6in 574mm 191mm 660mm 22.6in 7.5in 26.0in 547mm 191mm 600mm 21.5in 7.5in 23.6in 631mm 191mm 660mm 24.9in 7.5in 26.0in 631mm 191mm 660mm 24.9in 7.5in 26.0in 647mm 210mm 660mm 25.5in 8.3in 26.0in 647mm 25.5in 717mm 28.2in 646mm 25.5in 646mm 25.5in 685mm 27.0in 673mm 26.5in 210mm 8.3in 210mm 8.3in 210mm 8.3in 210mm 8.3in 216mm 8.5in 216mm 8.5in 660mm 26.0in 660mm 26.0in 660mm 26.0in 660mm 26.0in 660mm 26.0in 660mm 26.0in
60/70 C60/C70 F80/F100
901mm 35.4in L:917mm (36.1in) X:1044mm (41.1in) 90/C90 901mm 35.5in F/LF115 L:929mm (36.6in) X:1056mmd (41.6in) 115/130 L:929mm (36.6in) X:1056mm (41.6in) 150 L:946mm (37.2in) SX150~200 X:1072mm (42.2in) LX150~200 V150 946mm VX150 37.2in DX150 882mm 34.7in VZ150/175 947mm 200 37.3in Z150~200 L:947mm (37.3in) LZ150~200 X:1074mm (42.3in) VX200/225 950mm 250/3.1L 37.4in SX225/250 X:1077mm (42.4in) LX225/250 U:1203mm (47.4in)
2-5

TRANSOM MOUNTING PATTERNS F9.9/T9.9
Transom Mounting Patterns
9.9HP & 15HP
2-6

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)
2-7

25HP (2-Cylinder)
2-8

25X3 (3-Cyl.) 30HP, 40HP (Manual Tilt)
2-9
T25~250 including F30, F40, F50, T50, F80, F100, F115 35hp and up jet drive (transom bracket shape may vary from model to model, however, mounting hole pattern is the same on all models.)
*Not present on V-4, V-6. TRANSOM DRILL FIXTURE YB 34465
Available from: Kent-Moore Phone 1-800-328-6657 Fax 1-800-578-7375
2-10

FOUR STROKE SPLASH GUARDS 40~50, F40~F100 Splash Plates (Spray Guards) Mounting (Optional on 40T, 50HP, F50, F80, & F100) The 1996 ~ newer T50 comes with an engine splash plate mounted on the lower motor mount. A second splash plate is included in the crate to be mounted on the boat if needed. The boat splash plates may be added to the 40T, 50, F/T50, F80 and F100 to reduce excessive spray. Parts Information
Part Number Description Qty Remarks
Four Stroke Splash Guards 40~F100 Splash Plates
F80/F100 Engine Spray Guard
Boat Spray Guard

All F40/4-cyl., F50 & T50 only F80/F100
64J-45168-00-4D Boat Spray Guard 1 64J-45158-00-4D Engine Spray Guard 1
The boat spray guard (splash plate) can reduce spray, when the engine is mounted on a catamaran or pontoon-type boat.
67F-45180-00-4D Engine Spray Guard 1 90201-12M01-00 Plate Washer 2 95380-12700-00 Nut 2
Installation Spray Guards 1. 2. Install the plate between the boat transom and the clamp bracket (see illustration below). Make sure the edge of the boat splash guard is between the engine splash plate (2b) and the engine cavitation plate (c). Make sure the edge of the plate (1a) does not touch the lower case when the motor is fully trimmed in the down position.
3. 1. 2. Install the engine spray guard as shown in the illustration below. Torque the nuts to 43Nm (4.3 m-kg, 31 ft-lb.)
F50/T50 ENGINE SPRAY GUARDS
2-11

JET DRIVE MODEL IDENTIFICATION AND SERIAL NUMBERS Outboard Identification See your Yamaha Outboard Motor Owner's Manual for outboard and motor identification number locations. Jet Drive Identification The Jet Drive Model Letter is stamped on the rear, port-side casing. The Jet Drive Serial Number is stamped on the starboard side of the casing. NOTE: The outboard motor and jet drive model and serial numbers are important when you need to have service performed or place an order for parts. For easy reference, please record these numbers on the inside front cover of your Yamaha
Jet Drive Model Identification & Serial Numbers
As a rule, boat bottom width for your jet drive should be at least 48", and centerline length at least 13'. NOTE: Transom height is especially critical for jetdrive outboards, which are usually mounted 6" to 7" higher than propeller-driven outboards; therefore, it is advisable to use a full transom with your jet drive. Motor Selection Motor Sizing A boat operating at slow speed requires considerably more depth than one that is planing on the surface of the water. It is important, therefore, to use sufficient horsepower and to not overload your boat beyond its ability to plane. The accompanying graph is based on experience obtained with sled-type boats, using an outboard-style jet. Gross weights shown include the motor, hull, fuel, passengers, and all gear. For a given horsepower, loading beyond the listed limits will obviously give reduced performance. Conversely, slight overpowering, based upon anticipated load, will result in quicker planing, reduced throttle settings for a given speed, and subsequently, increased efficiency of operation.
Outboard Motor Owner s Manual. Application and Sizing Hull Selection Best performance is obtained by selecting a light, shallow-draft hull, with a relatively flat (fivedegree angle, or less), wide bottom. Vee or MultiVee hulls are not recommended (additional drag would be placed on the jet drive's water intake housing) because of their greater tendency to produce cavitation. Aluminum boats are preferred because of their weight and durability. These boats typically have optimum hull shapes, too.
NOTE: The performance output levels of jet drive outboards do not reflect true performance compared to propeller-driven outboards of the same powerhead horsepower. The jet drive unit is usually figured to have an output level equal to 70% of the propeller driven unit's. Keep in mind that boat loading, weight, and hull configuration can significantly affect the performance of your jet drive outboard.
2-12

JET DRIVE ENGINE MOUNTING MAINTENANCE, SHIFT CABLE INSTRUCTION, SERVICE INFORMATION Mounting Height Your Yamaha Jet Drive must be mounted 6" to 7" higher on the transom than propellerdriven outboards; therefore, optimum mounting for 15" shafts is on a 20" transom; and for 20" shafts, a 25" transom. The positioning of motor height is important, and must be done carefully. One-quarter inch above the optimum location will allow air to enter the pump and will result in ventilation and power loss. Too low a setting will result in unnecessary drag, water spray, and reduction in speed. The initial height setting is accomplished by placing a yardstick or other straightedge against the boat bottom (not the keel). The top of the leading edge of the water intake is adjusted to line up with the top edge of the straightedge.
Jet Drive Eng. Mtg., Maintenance, Shift Cable Instruction, Service Info.
If smooth operation is obtained with the initial setting, raise the motor in 1/4" steps until ventilation does occur. Then, lower the motor 1/4", and mark and lock that location. This height setting will never need to be changed, regardless of the load being carried.
CAUTION:
Slight ventilation on sharp turns or in rough water is acceptable, but excessive ventilation is harmful to both motor and pump and should be avoided. The motor tilt pin should be set so the engine is in a vertical position when the boat is planing. If the boat rides bow-high, or tends to be stern heavy, tilt the motor down one step. This will point the jet stream lower, giving added lift to the stern. NOTE: If the tilt angle is changed, then the motor height must be rechecked. Transom Elevators In some applications, an elevated transom may be required for proper motor height. When using a bolted-on bracket, set the intake height 1/2" below the bottom of the boat in order to obtain the widest range of adjustability, as shown.
Test Running
CAUTION:
When starting your motor for the first time, make sure water comes out the small hole at the rear, starboard side of the motor, just below the powerhead. If no water exits within a short period of time, shut off the motor and consult your dealer. After making the initial motor-height setting, it is time to test-run the boat. If ventilation occurs (air enters the pump, which causes loss of thrust and motor overrevving), then you must lower the engine 1/4" at a time until smooth operation is obtained.
2-13
1.
Glue two pieces of 3/4" exterior plywood together using waterproof glue. Clamp or nail. Bolt to transom at height shown. Use stainless steel or zinc-plated hardware with flat washers on both sides.
2.

3. Make two diagonal braces from 1/2" electrical conduit. Flatten each end in a vise, and drill 1/4" holes in them. Determine the position and angle of the forward bend. Attach them to the boat in a solid location, such as to the seats or gunwales. Avoid attachment to flexible aluminum panels.
ANTI-CAVITATION PLATES 1ST
2ND
Anti-Cavitation Plates To reduce spray or to further reduce cavitation in rough water, a 1/32" - thick metal plate can be installed to block the entrance of air into the water in front of the jet drive intake scoop. Installation of this plate will also allow a slightly higher motor mounting point, which, of course, will reduce drag. The position for proper mounting is shown in the first part of the accompanying illustration. An alternate mounting position for the plate (with the plate attached to a keel or wedge for use in white water) is shown in the second and third parts of the illustration. The third part shows the width of the plate, as well as the width of the drop-bottom wedge that positions the intake in more solid water. This installation, however, reduces shallow-water capabilities and should be used only when necessary.
3RD
CAUTION:
After any of these procedures are undertaken, the motor height and tilt settings should be checked and reset (as necessary) to avoid excessive cavitation that could lead to impeller damage. NOTE: Either of the above modifications should utilize only marine-grade woods; silicon-base, waterproofing sealing compounds (between components and around screws); and marine-grade paints. Remember, once you adopt one of these modifications, if removed or changed, damage may result to your hull if precautions are not taken to fill and/or waterproof any holes.
2-14

Operating Instructions Shifting
WARNING
WARNING
If you attempt a too tight of a turn at too high a speed, your boat could spin out or even roll over. Running upstream is easier. Running upstream, the river speed is subtracted from the boat speed, and the shore doesn't go by as fast. You can throttle back and maneuver your way through tight areas with good control. At narrow and potentially rough or dangerous passages, you should stop and study the layout, looking downstream, so you will recognize it on the return trip. Once through a bad spot, you may wish to run down and travel back up the same stretch to memorize the course you find to be the best. If you are not sure of a tight area on a downstream run, it is better to drift through on the oars with the motor tipped up, or work the boat through on a rope. Shallow Water Operation The life of both the impeller and water intake housing can be greatly increased by avoiding the intake of sand and gravel. Intake suction will cause your jet drive to work like a dredge when the intake comes within 2 or 3 inches of the bottom. It is best to shut off the motor, drift up to the shore when landing, and shove off with an oar when leaving. You can idle through areas less than 1-foot deep, but there should be more than 1 foot of water under the boat when opening the throttle for cruising or planing. Once planing, boat speed will prevent sucking in gravel. While great suction exists at the water intake, your boat passes over the bottom so quickly that, before rocks, sand, and debris have time to lift, the boat is past the disturbed area. While boating in particularly shallow areas, remember that running on a full plane will make the boat ride higher in the water. This can allow you to travel through areas that might be impossible to traverse at slow speeds. However, be sure you know the type of river bottom before attempting this in case the boat hits bottom or runs aground. You should attempt planing only in areas where the bottom is sand or gravel. If you hit bottom where there are large underwater
The impeller is always engaged and produces a certain amount of thrust while the motor is running. Neutral is achieved when the reverse gate is in a middle position that balances forward and reverse thrust. Since the Neutral position on the shift control may not precisely balance the thrust, be sure to secure the boat to the dock or beach the bow of the boat during cold starts. This avoids the possibility of being thrown off balance as the motor starts. Except for low-speed maneuvering, do not use the reverse gate to slow or stop the boat. The motor will kick up and out of the water, a similar situation to hitting a submerged object in a propellerdriven craft. Remote Control When using a remote control with a fast-idle feature, the throttle can be advanced with the shifter in Neutral for cold engine starts. When using this fast-idle starting feature, the shift cam may not immediately engage when the throttle is returned to the Neutral position. This is due to water pressure action on the reverse gate. After the motor has warmed up for 30 seconds or so, stop the motor, move the throttle lever through the shifting mode until the cam has engaged, place it in Neutral, and restart the motor. Subsequent warm starts in Neutral will not require this operation. Steering Experiment with steering your boat in an open area before attempting downstream river running. Remember, when running downstream, your speed relative to the shore is the boat speed added to the speed of the river. You will find quick response to the helm, but due to its relatively flatbottomed hull and lack of skeg, your boat will tend to skid in turns. You must start your turns early, and use sufficient power to maintain steering control.
2-15

obstacles or sharp rocks, you may damage the boat and motor. If you do run aground, shut the motor off immediately and drag the boat to deeper water. Occasionally, on running aground, a small rock may lodge between the impeller and intake housing wall as you decrease speed, and the motor will come to a stop. Neither starter motor nor starter rope will be able to turn it over. To remove the jam, you can remove the six screws holding the water intake housing to free the rock.
WARNING
Mooring If you tie your boat up at a sandy beach, where the action of waves causes the boat to rise and fall, be sure to tip the motor up, out or the water. Failure to do this will result in the buildup of sand inside the intake housing, around the impeller. It is advisable to tie the boat up and shut off the motor any time it is likely to be idled for a sustained period. Throttle Use As with any outboard, you will get maximum economy by not running at full throttle. Running at one-third to one-half throttle, with the boat at a steep angle, leaving a large wake, will also waste fuel. Trim and Tilt Use It is important for you to learn how to use the Power Trim and Tilt function properly on those models equipped with this feature. The Power Trim and Tilt function is convenient for use while drifting, and when operating at low throttle in very shallow areas. When under power, however, the engine should not be trimmed out in an effort to gain speed as is done with conventional propeller-drive motors. When planing, the engine drive shaft should be either vertical or tucked under and toward the boat in order to provide a good scoop angle for the water intake grille. Tilting the motor outward, beyond a vertical position, reduces the scoop angle, and can cause impeller slippage, as well as cavitation burns on the impeller blades. Manual-tilt models should be adjusted with the tilt pin to provide a vertical engine position while under plane. See TEST RUNNING (page 213).
Be sure to remove the spark plug wires before attempting to remove the intake screen. NOTE: Your jet drive is equipped with a key to protect it in the event of a rock jam. See IMPELLER CLEARANCE SETTING (page 2-17) NOTE: Gravel passing through the pump will wear and round off the leading edges of the impeller blades. For maximum performance, file these edges occasionally to keep them as sharp as when new. See IMPELLER CLEARANCE SETTING (page 2-17). Intake Blockage Occasionally, when either holding or proceeding slowly upstream in a fast-moving shallow area, you will lose power. This is usually caused by suction holding flat rocks, lily pads, paper, or other debris against the intake grille and restricting water intake. If you can quickly stop the motor and restart it, this sort of material will fall away and full power will be restored. If, however, rocks have been jammed between the grille bars, with the motor off, they must be removed by prying them out with a suitable tool.
2-16

Maintenance, Lubrication, and Storage General Occasionally, check all mounting bolts, intake screws, linkage connections, etc., to be sure they are tight. Bearing Lubrication The need for frequent lubrication of your jet drive outboard cannot be overemphasized. We recommend lubrication after each day's use and every 10 hours of operation. Make greasing a regular part of your cleanup. Use only Yamalube Marine grease, or NLGI No. 1-rated grease with a suitable grease gun. The bearing lubrication fitting is located at the top-left-front of the jet drive casing. It is capped with a fitting on the end of the excess-grease exit hose. Pump in enough grease to just fill the hose. To remove the hose from the fitting, press the end cap upward and toward the casing; to refit it, press the hose end cap over the fitting. Every 50 hours, pump in enough extra grease to purge any moisture. The texture of the old grease coming out of the hose will provide you with an indication of conditions inside the bearing housing. (A gradual increase in moisture content indicates seal wear.) If the grease begins to turn a dark, dirty gray, the bearing(s) and seals should be inspected and replaced as necessary. Some discoloration of the grease is normal during the break-in period on a new set of seals. Impeller Clearance Setting When, after use in a watercourse whose bottom is sand and gravel, the clearance between the impeller edge and the water intake casing wall becomes more than about 1/32", one or more of the shim washers that space the impeller can be transferred from the stack underneath to the top of the impeller. This locates the impeller further into the tapered casing to reduce the clearance. Be sure to grease the shaft hole in the impeller, the key, sleeve, and shaft threads any time it becomes necessary to remove the impeller. NOTE: Your jet drive is equipped with a shear key to protect it in the event of a rock jam. This can be located by removing the water intake housing and the drive shaft nut. The key holds the jet drive impeller on the driveshaft. This operation is
2-17
similar to that on a propeller drive. After replacing the key, draw the shaft nut up tight (17 ft-lb.) to remove any play between the impeller and shaft. Note the position of the impeller shim washers and replace them in the same order as removed. Linkage Adjustment Occasionally, check the adjustment of the shift linkage. In "Forward", the reverse gate should be firmly locked. This will eliminate rattle, and prevent wave action from accidentally shifting the gate into reverse. (See "ADJUSTMENTS" [page 2-27] for the proper procedures.) Salt Water Operation Both aluminum and stainless steel have been extensively used in the construction of your jet drive. These and other materials have been either treated or are inherently resistant to corrosion. In addition, the intake grille, special key, and exhaust tube are galvanized to further minimize corrosion. It is recommended, however, that, when not to use, the motor be tipped up so the jet drive casing is out of the water.
When your jet drive is used in salt water more than in fresh, remove all mounting hardware, and grease it at least once every six months. Failure to do this may result in the hardware being difficult, if not impossible, to remove at a later date. NOTE: To facilitate removal of an impeller that has frozen to the driveshaft, use a hammer and a block of wood, and tap the impeller blades in the direction of engine rotation. This will release the shear key. NOTE: A slightly distorted shear key may be reused. Storage Consult your regular Owner's Manual for preparing the motor part of your jet drive for storage. In addition, clean and grease all hardware, and remove and refit the jet drive impeller, greasing the bore, key, and plastic sleeve.
CAUTION:

Location of Main Components
JET DRIVE CASING
2-18

40 and 50 Models
1 56 27 GREASE SPLINES 35 34 36 45 54 GREASE IMPELLER SLEEVE & KEY 39 37 38 53 52 51 '95 & LATER 88 48 40 41 42 47* 44 45 44 31 43 NOT USED ON PRE 95 40MJH 16 6 19 32 20 18 10 6 23 21 87 46 '95 & LATER 88 27 30 28* 15 26 50 49 57 44 61 62 64* 55 65* 43
66 63
GREASE LIGHTLY 60
59 58 56 25 66 67 NOT USED ON PRE 95 40MJH 12 14 77 79 13 11 78 4 5 86 84 74 5 72 83 4 29*
15
16
69 68 71 3 85
33*
17 81 82 80 22 24 10
7 8 76 66 65 75
*Grease all threads

2-19

40 and 50 Models (Contd.)
REF NO. DESCRIPTION QTY.
REF NO. DESCRIPTION
QTY.
1 2 3 4 5 6 7 8 9 10 11 12* 13* 14* 15* 16* 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45
Jet Drive Assembly Main Housing Reverse Gate Pivot Pin, Reverse Gate Nylon Sleeve, Reverse Gate Pivot Pin Bolt, Reverse Gate Fixing Hose, Grease Exit Fitting, Grease Nut Assembly, Exhaust Tube Dowel Pin, 3/16" x 1/2" Shift Cam Bolt Rod End Shifter Bushing (not used '95 and later) Nut, Fiber Lock (1/4-20) Flat Washer (not used '95 and later) Cam Eccentric Drilled Bracket, Cable Support Bolt, Bracket 1/4-20 x 5/8" Flat Washer 1/4" Clamp, Cable Plate, Backing, Cable Clamp Bolt, Cable Clamp Locknut Adapter Plate Dowel Pin, 6mm x 16mm O-Ring Bolt, Adapter Plate 10 x 35mm Bolt, Adapter Plate 3/8-16 x 1/4" Lock Washer M10 Intake Housing Intake Grille Bolt, Intake Housing Driveshaft Special Key, Driveshaft Thrust Ring, Shaft Bearing Nylon Sleeve, Impeller Bore Special Key, Impeller Impeller Shim, Impeller Adjustment Tab Lock Locknut Seal, Shaft Outer Retaining Ring, Inner and Outer Seal Seal, Shaft Inner
1 1 2 2 2 1 1 2 2 1 1 1 1 1 1 1 1 2 2 1 1 2 2 1 2 1 4 1 5 1 1 6 1 1 1 1 1 1 9 1 1 2 4 2
Bearing and Seal Housing Machine Screw, Housing 10-24 x 5/8" Lock Washer #10 Bearing Thrust Washer Collar Backup Washer Upper Seal Carrier O-Ring Retaining Ring Brass Extension Tube Dowel Pin Gasket Steel Plate Gasket Impeller, Water Pump Cartridge Housing, Water Pump Bolt, Short, Housing 5/16-18 x 2-1/4" Bolt, Long, Housing and Adapter Plate 5 /16-18 x 2-3/4" 66 Lock Washer 5/16" 67 Bolt, Adapter Plate 8 x 30mm 68 Shaft Roller 69 Roller Assembly 70 Washer 71 Nut, Nylon 72 Gate Bumper 73 Gate Assembly 74 Exhaust Tube 75 Screw, Flush 76 Washer, Flush 77* Nut, Jam (not used '95 and later) 78 Washer, Spring (not used '95 and later) 79 Nut, Hex (not used '95 and later) 80 Cam Bushing 81 Cam Washer 82 Cam Shim 83 Spring, Cam bumper 84 U-Bolt 85 Screw 86 Spring, Gate Pivot 87 Circlip 88 O-Ring ('95 and later)
46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65
1 2 5 1 1 1 1 1 2 5 1 2 1 1 1 1 1 1 2 6 9 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3
*Not used on pre '95 40MJH

2-20

90, V4, and V6 Models
1
GREASE SPLINES 35 34 36
64* 55 65* 43 63 45 54 37 38 49 87 46 57 56 25 26 30 88 44 61 53 50 59 58 29* 62 GREASE LIGHTLY 60 66
GREASE IMPELLER SLEEVE & KEY 39
40 41 42
48 47* 44 45 44 31 43 27 30 28* 15 12 14
15 13 11 78 79 45
16
69
68 71 3 85
33* 6 19 32 '97 AND LATER SERIAL NUMBER 59500 & UP 20 18 2 10 23 21
16
77 17 81 82
22 24
80 84
86 5 10 72 83
6 74
7 8 76 30 52 51 67 75
6 9
*Grease all threads

2-21

90, V4 & V6 Models (Contd.)
REF NO. DESCRIPTION QTY.
REF NO. DESCRIPTION
QTY.
Jet Drive Assembly Main Housing 1 Reverse Gate 1 Pivot Pin, Reverse Gate 2 Nylon Sleeve, Reverse Gate Pivot Pin 2 Bolt, Reverse Gate Fixing 2 Hose, Grease Exit 1 Fitting, Grease 1 Clamp Assembly, Exhaust Tube 2 Dowel Pin, 3/16" x 1/2" 2 Shift Cam 1 Bolt 1 Rod End 1 Shifter Bushing (not used '95 and later) 1 Nut, Fiber Lock 1/4-20 x 5/8" 1 Flat Washer 1/4" 1 Cam Eccentric Drilled 1 Bracket, Cable Support 1 Bolt, Bracket 1/4-20 x 5/8" 2 Flat Washer 1/4" 2 Clamp, Cable 1 Plate, Backing, Cable Clamp 1 Bolt, Cable Clamp 2 Locknut 2 Adapter Plate 1 Dowel Pin, 6mm x 16mm (65 Model) 2 Dowel Pin, 8 x 12mm (V4/V6) 2 Guide Pin, 3/8" x 1-1/2" (90) 1 Guide Pin, 1/4" x 2" (V4/V6) 1 Bolt, Adapter Plate 10 x 35mm (90/V4-V6) 4/7 29 Bolt, Adapter Plate 3/8-16 x 1-1/4" (90 Model) 1 29 Bolt, Adapter Plate 3/8-16 x 1-1/2" (V4-V6) 8/12 30 Lock Washer M10 (90/v4-V6) 8/12 31 Intake Housing ('96 and earlier has screw-type liner attachment, '97 and later has flange) 1 32 Intake Grille 1 33 Bolt, Intake Housing ('96 and earlier) 6 33a Stud, 3/8" ('97 and later) 6 33b Nut, 5/16-18 Nylock stainless steel ('97 and later) 6 34 Driveshaft 1 35 Woodruff Key, Driveshaft 1 36 Thrust Ring, Shaft Bearing 1 37 Nylon Sleeve, Impeller Bore 1 38 Special Key, Impeller 1 39 Impeller 1 40 Shim Impeller Adjustment 9 41 Tab Lock 1
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 26 27 27 28
42 43 44 45 46 47
48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88
Locknut Seal, Shaft Outer Retaining Ring, Inner and Outer Seal Seal, Shaft Inner Bearing and Seal Housing Bolt, Housing 5/15-18 x 1" ('97 and later) Bolt, Housing 1/4-20 x 7/8" ('96 and earlier) Lock Washer 1/4" (use on '96 and earlier only) Bearing Thrust Washer Bolt, Adapter Plate 3/8-16 x 3" Bolt, Adapter Plate 3/8-16 x 2-3/4" Upper Seal Carrier O-Ring Retaining Ring Aluminum Spacer Dowel Pin Gasket Steel Plate Gasket Impeller, Water Pump Cartridge Housing, Water Pump Bolt, Housing 5/16-18 x 2-1/4" (90/V4-V6) Bolt, Housing 5/16-18 x 3-1/4" Special "D" Washer Bolt, Adapter Plate 3/8-16 x 2-1/4" Shaft Roller Roller Assembly Washer Nut, Nylon Gate Bumper Gate Assembly Exhaust Tube Screw, Flush Washer, Flush Nut, Jam (not used '95 and later) Washer, Spring (not used '95 and later) Nut, Hex (not used '95 and later) Cam Bushing Cam Washer Cam Shim Spring, Cam Bumper U Bolt Screw Spring, Gate Pivot Circlip Bolt, Adapter Plate 8 x 30
1 2 4 2 1
4 4 2 1 1 1 1 2 4 1 2 1 1 1 1 1 1 2/4 2 4 2 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
2-22

Assembly and Installation Refer to the appropriate assembly drawing for the 40 and 50 models, or the 90 and V4/V6 model jet drives. NOTE: Using Yamaha Marine Grease or NLGI No. 1-rated grease, grease all bolt threads, and use lockwashers on all bolts except where noted otherwise. 1. Fit the two 6 x 16mm (90TJR model) or 8 x 12mm (V4-V6) dowel pins in the recesses on top of the 3/4" - thick adapter plate, and install the plate on the bottom of the motor. Torque the 10mm-diameter and 3/8" - diameter bolts to 22 ft-lb.; for the 8mm- diameter bolt, 11 ft-lb. NOTE: 90TJR and V4/V6 model jet drives use a 3/8" by 1-1/12" pin to locate the disconnected shift rod. Grease this pin prior to installation of the adapter plate. 2. Make sure the three O-rings on the bearing housing surface are in place. Line up the three grease passage holes in the bearing housing with the passages in the jet drive casing. 3. Bolt the driveshaft and bearing housing assembly to the jet drive casing. Torque the 5/16-18 x 1 bolts (90TJR and V4/V6 models) to 12 ft-lb. For models '96 and earlier use 1/420 bolts torque to 8 ft-lb. The two 10-24 machine screws (40 and 50 models) should be tightened by hand, using a screwdriver. 4. Invert and support the jet drive casing, so the long end of the driveshaft is standing upright. 5. Install the brass water tube extension onto the copper water tube. 6. Fit the two dowel pins into the aluminum spacer. 7. Using gasket sealer, place the gasket that has two curved slots and one round hole on top of the aluminum housing (note the position of the dowel holes).
8. Place the steel plate (tangs down) on top of the gasket. 9. Tap the special key into place in the driveshaft. 10. Lightly grease the rubber water pump impeller and fit it on the shaft (note the impeller can be fitted only one way). 11. Fit the other gasket over the dowel pins. 12. Slip the steel cartridge into the water pump housing, making sure the tang at the bottom of the carrier registers with the wide slot inside the housing. This ensures the holes for the shaft will line up properly. 13. Place the water pump housing over the end of the shaft, down to the rubber impeller. Subsequently, slowly rotate the driveshaft clockwise, while pressing downward on the housing so the impeller enters the cartridge. NOTE: Do not press so hard that the vanes of the impeller will be damaged. 14. Once the impeller has fully started into the cartridge, cease the rotation and press the housing onto the dowel pins. 15. Grease the bolt threads and start the four bolts, with lockwashers (the 90 and V4/V6 models use special "D" washers) into the jet drive casing; once all are snug, tighten them, using a torque setting of 11 ft-lb. 16. For the 40 and 50-model jet drives, install the plastic shift rod guide in the spline of the shift rod to prevent the rod from rattling. 17. Grease and fit the two 3/16" by 1/2" dowel pins into the jet drive casing, and liberally grease the driveshaft splines and rubber water tube guide. 18. Grease the threads on all securing bolts, and bolt the jet drive assembly to the motor (torque setting on the 5/16"-diameter bolts is 11 ft-lb and the 3/8-diameter bolts is 22 ftlb.).
2-23

19. Prior to main impeller installation, grease the shaft threads, special key, and impeller bore. Place the split plastic sleeve inside the impeller, hold the key in the nose of the impeller with your finger, and slide the assembly onto the driveshaft. 20. Slip the shim washers and the nut retainer over the end of the shaft, against the impeller, and bring the nut up snug by hand. There are nine shim washers. Be sure the nut retainer does not fall into the threads and jam the nut. NOTE: The intake assembly is now temporarily installed to check the impeller clearances (0.79mm [0.031"]). If the clearance is too great, it is necessary to move some of the shim washers to the other side of the impeller to obtain the correct clearance. 21. Torque the nut to 17-ft lb. If the ears of the locknut retainer do not line up with the flats of the nut, remove the nut, invert the washer, retorque the nut, and bend the retainer ears over the flaps of the nut.
CAUTION:
22. Install the intake assembly. Make sure the lowest part of the grille is positioned at the rear. 40 & 50 models: Use six 1/4-20 by 3/4" bolts (no lock washers). The tightening torque is 8 ft-lb. 90, V4, & V6: Use six 5/16-18 nylock stainless steel nuts on the six studs. The tightening torque is 11 ft-lb. Grease the threads. Pumps produced before 1997 have six 5/1618 by 7/8" bolts instead of nuts and studs. The tightening torque is 11 ft-lb. NOTE: The shift-cable anchor clamp is attached to the jetdrive with two 1/4-20 by 5/8" hex-head cap screws which use 1/4" flat washers and locknuts. NOTE: The plastic cable end uses a 1/4" flat washer between the end and the nut.
CAUTION:
Always install all shims on the bottom of a new impeller. Installing shims on top of a new impeller may result in insufficient impeller-toliner clearance. This may cause scoring and impeller or liner damage.
When starting the motor for the first time, watch to see that cooling water comes out the small hole at the rear, starboard side of the motor, just below the powerhead. This is to check your assembly of the water pump and its connections. If no water appears within a few seconds after starting the motor, recheck your pump installation and correct if necessary.
2-24

Jet Drive Eng. Mtg., Maintenance,
95 and Later
REF NO PART NO. DESCRIPTION QTY.
C
G H
63D-J0001-38-20
Shift Cable Assembly
1 1 1 2 1 2 1 1 1
D E A B F
A 63D-JD005-47-00 Cable 4 ft B 6H4-JD005-43-00 Clamp, Cable C 6H4-JD005-61-00 Bolt, Cable Clamp D 63D-JD005-58-02 Screw, Hex Head E F 6H4-JD006-19-00 Nut, Fiberlock 62D-JD005-53-02 Ball Rod End Lock Washer Toothed M5
G 63D-JD006-21-01 Nut, Hex H 6H4-J0006-37-00
2-25

40MJH ('95 and Later) Shift Handle Installation and Adjustment The manual model no longer uses the control rod. The shift handle on the tiller arm has a cable mounted to it to operate the shift gate.
DRILL TEMPLATE
a.
b.
c.
d.
e.
Place the drill template on the tiller arm, holding in place with masking tape at each end. Center punch the two hole locations and drill through using a 3/16 drill. Remove the template. Remove the plastic cover from the shift handle. Center punch for a 3/16 hole on the centerline of the handle. Drill from the inside as close under the upper threaded boss as possible allowing sufficient clearance for a nut to be installed on a screw passing through the hole. Next, attach the cable to the shift gate with the terminal end threaded 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 positioned as far forward as possible). Attach the upper cable clamp to the tiller arm using the two #10-24 x 5/8 bolts and fiberlock nuts. Shift to forward. The roller should be at the end of the cam slot, with the reverse gate linkage in forward. Adjust the ball rod end to reach this position. Install the #10-32 hex head cap screw through the ball rod end and the shift handle capturing the toothed lock washer and nut on the handle inside recess. Shift to reverse and back to forward and verify that the gate cannot be forcibly rotated toward reverse by pulling on the gate by hand. Readjust the rod end (if necessary) to satisfy this condition. Lock the jam nut and reinstall the plastic covers on the handle and tiller.
FORWARD SLOTTED HOLES IN CABLE SUPPORT BRACKET
CAUTION:
Always return the throttle to idle before shifting.
2-26

Adjustments Shift Cam Assembly with Neutral Adjustment A shift mechanism has been incorporated that includes an adjustable shift cam. When properly adjusted and in the neutral position, the forward thrust of the jet outboard will be negligible Neutral Adjustment - All Models a. Loosen the inner pivot bolt for the shift cam. b. Using light finger pressure on the gate, move the gate toward reverse until the cam roller is nested in the neutral notch of the cam. Holding the gate in this position, rotate the eccentric until the gate clears the underside of the nozzle hood by the width of the clearance gage. Keep the high lift side of the eccentric facing in the upper side of the circle during this adjustment. Tighten the bolt to lock the hex cam eccentric in this position. Torque to 8 ~ 9 ft-lbs. Recheck the setting. Adjust the shift cable ends and the cable anchor bracket on the jet drive so the roller is in the neutral nest when the shift handle is in neutral. Tighten both cable and nuts. Shift to forward. The 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, readjust the cable positions, giving less importance to the roller position in neutral. e. If the neutral position is too far out of adjustment, the tendency of the gate to move toward reverse, under water pressure, will put tension on the cable while in neutral. In some remote control boxes, this makes it difficult to reengage the shift mode with the motor running in the high-speed idle, cold-start setting. It is then necessary to stop the motor, operate the shift handle to engage the shifting pin, and then restart the motor.
CLEARANCE GAUGES-FULL SIZE CUT OUT AND USE TO SET ECCENTRIC FOR NEUTRAL POSITION. #1173 LARGE SERIES 2-1/2 EXHAUST PIPE 15/32
#11763 MEDIUM SERIES 2 EXHAUST PIPE
9/16
WARNING
If not properly adjusted, the reverse gate can be engaged by forward motion of the boat. This will cause the engine to kick up and out of the water, a situation similar to hitting a submerged object in a propeller-driven craft. Do not be concerned if, after proper linkage and cable adjustments, the reverse gate does not fully close when the shifter is operated; water pressure will close it all the way during normal operation.
c.
d.
2-27

Trim On some applications, your boat may tend to pull to starboard. This condition can easily be corrected by bending the trailing edge of the flowstraightening fins. The fins are located at the top and bottom of the exhaust tube 1/16" toward the starboard side of the motor. 5.
dents. This will reduce drag and air entrapment. The optimum bottom width is 48 to 60 inches. Beyond 60 inches, the boat rides so high that air is allowed to enter the pump. This is likely in choppy water particularly when running with the wind. Less than 48 inches, on the other hand, can make it difficult to reach planing with a heavy load. A slight vee in the boat bottom gives better steering and helps to keep solid water in the pump. A 3-inch drop at centerline on a 60inch bottom is enough. Beyond that, shallow draft is sacrificed. The power trim is useful to bring a heavy load on plane. Tipping the engine under points the jet stream down, which helps lift the stern. After reaching a plane, trim the engine out until the jet stream is horizontal (the engine driveshaft is vertical).
6.
7.
Idle In most cases, the stock idle adjustments will produce an acceptable neutral. However, since neutral is a balance between forward and reverse forces, some slight creeping of the boat may occur at idle. A minor idle-speed adjustment should correct this tendency. Performance Tips Here are some pointers for obtaining maximum performance from jetdrive outboards: 1. Keep the leading edges of the impeller sharp. Edges that have been blunted by gravel (beyond 1/32-inch) tend to break up the water. This results in slippage and engine overspeeding. 2. Keep the grille bars parallel to prevent large rocks or other debris from entering the impeller, causing damage or possible lodging in the nozzle. Select as light a hull as possible for the intended use. Keep the boat bottom smooth and free of
2-28
CAUTION:
Do not trim the engine out beyond horizontal, so the jet stream points up into the air or the bow lifts. This will reduce the ram angle on the water intake and will cause severe cavitation burns on the impeller blades. Power trim is also useful when running slowly in shallow water, such as when backing off the beach. In these circumstances, the engine can be tilted back 15 to 20 degrees, reducing the tendency to pick up gravel. Keep your eye on the cooling water pilot hole to make sure the engine is getting water. 8. Stainless steel impellers are available. They give extended life in areas where it is difficult to avoid gravel intake. A 4-blade stainless steel impeller is also available. On the high horsepower motors, particularly the V-6s, it gives better acceleration (less slippage and engine overspeed), and enables picking up heavier loads.
3. 4.

If you have trouble locating these impellers on the market, contact your dealer. Some calls have been received regarding difficulty 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 necessary, 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 comfortably touch.
CAUTION:
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 bearing(s), and press the bearing(s) off the driveshaft. 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
2-29

the direction of the thrust faces, and press the new bearings on the shaft, pressing against the inner races only. Press against the thrust ring, locking it in its groove. See the illustrations on the next page. 5. To install the seals, install the inner seal retainer ring first. Place a light film of grease on each surface before pressing in the seals. The round spring of each seal faces outward.
FOR 90 AND V4/V6 MODELS ONLY: Slip the bearing housing over the shaft. Support the bearings and driveshaft, using Yamaha special tool #YB-06205-2. Heat the housing slightly again. It is important to slide the housing on squarely, and do not use a hammer, or in any way apply impact loads to the balls. If you use a hand press, press only against the outer race of the bearings. Only a light press is needed if everything is lined up properly. NOTE: When using special tool #YB06205-2, the housing will slide on only part way; therefore, remove the tool, slide the seal housing into place as a spacer, reinstall the tool, and continue pressing the housing until it fully bottoms out; remove the seal housing assembly. 10. FOR 40 AND 50 MODELS ONLY: Install the spacer washer. FOR 90 AND V4/V6 MODELS ONLY Install the backup washer against the upper bearing, with the dished center section facing upward. 11. Install the upper seal housing assembly being careful not to damage the O-rings as they pass the snap ring groove. Only finger pressure should be necessary here. 12. Install the beveled circlip bevel-side upward. 13. Fit the driveshaft assembly into the jet drive casing, and fill with grease. If using a hand gun, pump very slowly so to not build up internal grease pressure and damage either the seals or the housing.
6. Install the outer seal retaining rings before pressing in the outer seals; align the notched ends of the retaining ring to straddle the small vent hole drilled in the ring groove. 7. Grease all seals. Fill the cavity around the spring in the seals with grease and install the outer seals. 8. Grease the two O-rings and install them, in their grooves, in the upper seal housing. Apply a thin film of grease inside the housing bore to ease entry of the bearing(s) and O-rings. 9. FOR 40 AND 50 MODELS ONLY: Slip the bearing housing over the shaft. Heat the housing slightly again. It is important to slide the housing on squarely, and do not use a hammer, or in any way apply impact loads to the balls. If you use a hand press, press only against the outer race of the bearing. Only a light press is needed if everything is lined up properly.
2-30

40MJH/EJR and 50EJR Models
Liner Replacement NOTE: On pumps produced beginning in 1997, the liner is held in place by a 1/8"-thick flange instead of bolts. 1. 2. Mark the liner bolts for reassembly in the same locations, and remove the bolts. Loosen the liner by tapping on the liner edge with a long drift through the intake grille. Lift out the liner. Drop the new liner into position. Line up one of the liner bolts and lightly thread it in. It may be necessary to tap or press the liner into the intake housing to locate the liner for installation of the remaining bolts. Torque setting for the liner bolts is 11 ft-lb.
3.
90TJR, Vl4-115TJR, & V6-200TJR
NOTE: Be sure to grease the bolt threads prior to assembly. 4. Sand or file off any burrs in the liner/bolt areas.
Reassembly To reassemble your jet drive, follow the assembly procedures in Assembly and Installation (page 2-23).
2-31

DUAL ENGINE TIE BAR KIT INSTALLATION Please read and understand these instructions completely before installation to avoid any possible injury to yourself or damage to the outboard or the accessory. Dual Engine Tie Bar Kit (ABA-DUALT-IE-BR) The tie bar is used to connect dual outboard motors in order to achieve synchronized steering and better engine performance. Tie Bar Kit Application Chart
Dual Engine Tie Bar Kit Installation
MODEL PART NUMBER 25HP~100HP ALL MODELS 115~250HP2-423 LF115~L250
ABA-DUALT-IE-BR (279 ~ 914mm) (11.0in ~ 36.0in) o = Optional Sc = Standard in crate
Sc
NOTE: The LF115 cannot use this tie bar if a Teleflex Center Mount Hydraulic Cylinder (5354) is used.
2-32
REF NO DESCRIPTION ROD - 9/16-18 UNF-2A 9/16 I.D. X 11/16 O.D. Black Vinyl Tubing Tie Rod Terminal Swivel Clevis 9/16-18 SST. Hex Jam Nut 3/8-24 x 1-1/4 Lg. SST. Hex Head Cap Screw 1.0 O.D. x 3/8 I.D. x 1/8 Thk. SST. Retainer Washer 8 Sleeve Bushing 9 3/8-24 SST. Locknut 10 3/8-24 x 1-3/8 Lg. SST. Hex Head Bolt 1 2 3 4 5 6 7
QTY. 1 1 2 2 1 2 2 2 4 2
1.
Assemble swivel clevis to the starboard engine as shown in illustration.
5.
Lightly clamp the threaded tie rod in vise using aluminum or (preferably) wooden pads (to prevent damaging threads) as shown.
2.
Lightly grease the bushing with Yamaha Marine Grease. Be sure swivel clevis is pointing upward.
6. 7. 8.
Install the jam nut on the tie rod. Grease the threads on the end of the tie rod that you installed on the jam nut. Install one tie rod terminal, threading it onto tie rod, until Hole A is covered.
3. 4.
Tighten bolt to 12 ft-lb. and nut to 8 ft-lb. Test the swivel clevis to be sure it swings freely and has a maximum of 1/8" of vertical movement at the swivel clevis bolt hole.
2-33

9. Insert a small nail, cotter pin or small pin in Hole B and continue threading the tie rod terminal onto the tie rod until the pin is lightly clamped. 10. Back the tie rod terminal OFF 1/2 turn and remove pin. 11. Using a wrench on the tie rod terminal flats to prevent the tie rod terminal from turning, tighten the jam nut against tie rod terminal to 30 ft-lb. 12. Attach the starboard rod terminal to the starboard swivel clevis. 13. Tighten the nut to 12 ft-lb. 14. Attach the port engine swivel clevis as explained in Step 1. 15. Place the port rod terminal in the port swivel clevis, install bolt and nut but do not tighten them. 16. Set the engines so the toe-out position is less than 1 inch. (See the illustration below).
NOTE: For best results, your toe-out distance should be set so the twin engines' wake meets approximately 25-50 ft past the stern of the boat.
17. Swing the tie rod up and align it parallel with the tie rod terminal on the port swivel clevis.
18. Place a piece of tape on the threaded rod (aligned in the center of the two holes) on the tie rod terminal. This will be the length of the tie rod. 19. Cut the tie bar at the marked length. Then, deburr the threads of the rod with a die and thread file. Grease the threads with Yamaha Marine Grease. 20. Align the rod as before, and cut the black vinyl tube to the proper length to fit between the rod terminals. 21. Install the black vinyl tube.
2-34

22. Detach the port rod terminal and thread it on the tie rod to the proper toe-out position. NOTE: The end of the rod should be between the two holes on the rod terminal. Adjustments can be made to insure proper toe-out position. 23. Re-attach the rod terminal to the port engine swivel clevis and tighten nut to 12 ft-lb.
WARNING
Recheck all nuts and bolts to assure proper installation and torque. After 2 hours of operation, recheck all bolts and nuts to assure proper installation and torque. At the end of every 50 hours of operation, relube, inspect all parts for wear, proper installation, and torque.
2-35

DUAL CABLE STEERING BRACKET KIT INSTALLATION (ABA-DUALS-TE-ER) Please completely read and understand these installation instructions prior to installation to avoid damage to the outboard motor, boat or accessory. Kit Includes: 1 Steering Cable Mounting Bracket 1 Steering Cable Support Tube 2 Adjustment Nut 2 Locking Tab Washer 1 Bushing 1 Seal 1 Cable Connector 2 Self-locking Nut, 3/8 2 Flat Washer, 3/8 4 Bolt 6 x 15mm NOTE: 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) 2.
Dual Cable Steering Bracket Kit Installation
Steering Arm Installation 1. Install the steering arm to the motor tiller arm using the inner (rearmost) bolt hole and torque to specification. Be sure to use the lock nut as shown in the Yamaha Rigging Specs. (See Illus. 2 below) (See pg 7-26~727 for assembly instructions.)
PIVOT BOLT AND BALL JOINT CONNECTION
NUT
BOLT HEAD STEERING LINK ROD
Assemble the cable connector onto the steering arm. Do not tighten at this time. (See Illus. 3)
STEERING LINK ROD
CABLE CONNECTOR FLAT WASHERS* LOCK NUT*
*Flat washers and lock nut come with the steering link rod.
NOTE: This procedure is best done prior to bolting motor to the transom.
2-36

Steering Cable Installation 1. Lubricate the inside of the engine tilt tube, the inside of the steering cable support tube and the output end of the cable with a coat of Yamaha Marine Grease. Install steering cable No. 1 into engine tilt tube and tighten the holding nut. (See Illus. 4) 3.
Dual Cable Steering Bracket Kit
Slip the large support tube nut and lock washer over cable #2. Apply a coat of marine grease to the cable end. Insert the cable 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)
ILLUSTRATION 6 ILLUSTRATION 4
HOLDING NUT INSTALL STEERING CABLE #2 INSTALL STEERING CABLE #1 ILLUSTRATION 7 ILLUSTRATION 5 M6 X 1 X 15MM LONG (4 required) STEERING CABLE #2
STEERING CABLE #1
SUPPORT TUBE BEARING (Slide into Support Tube) ROD SEAL
BRACKET
TRANSOM MOUNT
4. 2. Install the bracket onto the mounting boss with the (4) 6 x 15mm bolts and torque to 100in. lb.
Install the support tube onto the extended portion of cable #2 and through only one hole in the mounting bracket. Slide the second large nut and the lockwasher over end of the cable and onto the support tube a few turns. Slide the nylon bearing and rod seal cap onto the cable, but not into the steering tube at this time. (See Illus. 7)
2-37

5. Carefully spread both cables to allow installation of the cable connector but do not tighten. (See Illus. 8)
Dual Cable Steering Bracket Kit
Cable Adjustment 1 2. 3. Center motor. Loosen the support tube holding nuts (both ends) approximately 10 turns. Take up any play in the cables by the pushing motor slightly in the direction of a turn to starboard. Tighten the port support tube nut to finger tight, then one additional turn past that, using a wrench. Tighten the starboard support tube nut to 35 ft-lb. and bend the locking tabs on the washers over onto the bracket, as shown.
ILLUSTRATION 8 STEERING LINK ROD
CABLE CONNECTOR
4.
3/8 FLAT WASHER
5.
3/8-24 LOCK NUT
6. Fully install the support tube to the bracket with the second large nut and the lockwasher. Position the starboard end of the support tube so it is approximately even to the starboard end of the tilt tube. (See Illus. 9)
ILLUSTRATION 9 CABLE #2
LARGE WASHER LARGE NUT
7. Tighten the cable #2 support tube nuts at this time and the starboard cable holding nut. 8. Torque the three cable connector nuts at this time. (See Illus. 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 procedures prescribed.
2-38

MORSE UNIVERSAL DUAL CABLE STEERING BRACKET KIT INSTALLATION (ABA-42110-00-00) Please completely read and understand these installation instructions (prior to installation) to avoid damage to the outboard motor, boat or accessory. Kit Includes: 1 Steering Cable Mounting Bracket 1 Steering Cable Support Tube 2 Adjustment Nut 2 Locking Tab Washer 1 Bushing 1 Seal 1 Cable Connector 2 Self-locking Nut, 3/8" 3 Flat Washer, 3/8" 4 Mounting Bolt NOTE: 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) 2.
Morse Universal Dual Cable Steering Bracket Kit Installation
Steering Arm Installation 1. Install the steering arm to the motor tiller arm using the inner (rearmost) bolt hole, and torque to specification. Be sure to use the lock nut, as shown in the rigging specifications. (See Illus. 2)
ILLUSTRATION 2 PIVOT BOLT AND BALL JOINT CONNECTION
LOCK NUT BOLT HEAD STEERING ARM
Assemble the cable connector onto the steering arm, as shown in Illustration 3.
NOTE: DO NOT tighten installation together at this time.

ILLUSTRATION 3 STEERING ARM
CABLE CONNECTOR
FLAT WASHERS * LOCK NUT*
*Flat washers and lock nut come with steering arm.
2-39

Steering Cable Installation Cables 1 and 2 1. Lubricate the inside of the engine tilt tube, the inside of the steering cable support tube and the output end of the cable with a coat of Yamaha Marine Grease. Install steering cable Number 1 into the engine tile tube and tighten the holding nut. (See Illus. 4)
ILLUSTRATION 6
HOLDING NUT INSTALL STEERING CABLE #2
ILLUSTRATION 4
ILLUSTRATION 7 LOCKING TAB WASHER HOLDING NUT INSTALL #1 STEERING CABLE STEERING CABLE #2 LARGE NUT SUPPORT TUBE BEARING (Slide into Support Tube) ILLUSTRATION 5 MOUNTING BOLTS (4 REQUIRED) ROD SEAL
4.
STEERING CABLE #1
MOUNTING BRACKET
TRANSOM MOUNT
Install the support tube onto the extended portion of cable Number 2 and through only one hole in the mounting bracket. Slide the second large nut and the locking tab washer over the end of the cable and onto the support tube a few turns. Slide the nylon bearing and rod seal onto the cable, but not into the steering tube at this time. (See Illus. 7)
2.
Install the bracket onto the mounting boss, with the four (4) mounting bolts provided, and torque to 100in-lbs. (See Illus. 5) Slip the large support tube nut and locking tab washer over cable Number 2. Apply a coat of Yamaha Marine Grease to the cable end. Insert the cable through the mounting bracket holes without the support tube installed. Turn the steering wheel to extend the cables to their full length, then back off 1/4 turn. (See Illus. 6)
2-40
3.

5. Carefully spread both cables to allow installation of the cable connector, but do not tighten at this time. (See Illus. 8)
Cable Adjustment 1. 2. 3. Center the motor. Loosen the support tube holding nuts (both ends) approximately 10 turns. Take up any play in the cables by pushing the motor slightly in the direction of a turn to starboard. Tighten the port support tube nut finger tight, then one additional turn past that, using a wrench. Tighten the starboard support tube nut to 35ft-lbs., and bend the locking tabs on the locking tab washers over onto the mounting bracket or nut, as shown in Illus. 9.
ILLUSTRATION 8 STEERING ARM
CABLE CONNECTOR 3/8 LOCKWASHER
4.
5.
3/8-24 LOCK NUT
6.
Fully install the support tube to the mounting bracket with the second large nut and locking tab washer. Position the starboard end of the support tube so it is approximately even to the starboard end of the tilt tube. (See Illus. 9)
ILLUSTRATION 9 STEERING CABLE #2
LOCKING TAB WASHER LARGE NUT
7. 8.
Tighten the cable number 2 support tube nuts at this time, as well as the cable holding nut. Tighten the three (3) cable connector nuts, torquing to 120in-lbs. Then, back nuts off 1/4 turn. (See Illus. 8) Insert the nylon sleeve into the steering tube and slide the rod seal onto the end of the support tube. (See Illus. 7)
9.
2-41

V4 & V6 RIGGING TUBE GROMMET (MAR-GROMM-ET-02) Installation Instructions: 1. Prior to installing grommet, pass all cables, fuel/oil lines and electrical harnesses through the rigging hose that has been previously cut to length. 2. 3. Be sure all items move freely inside the hose and no kinks occur in the fuel and oil lines. Pass all items through the threaded end side of the grommet. Do not install onto the hose at this time. Finish installing the engine, and attach all harnesses, cables and hoses to their proper locations as prescribed in the Yamaha Rigging Guide. Place a bead of silicone sealant (not a polysulfide based product) onto the bottom side of the grommet where it seats into the lower pan. Apply another bead on top of the grommet, prior to installing the retainer, then tighten the 2 retaining screws and removed any excess sealant. Note: Both the stainless angle bracket and rubber grommet (previously removed) will not be reused. Prior to threading on the hose, do a final check of all hose and cable routing. If you are using a threaded transom plate, thread the rigging tube into it first. On the engine grommet side, apply a small bead of silicone sealant to the first few threads of the hose and install. Remember the thread is left hand so you will rotate the hose to the left, (facing the front of the engine). Thread the rigging tube into the grommet until it seats.
V4 & V6 Rigging Tube Grommet
IMPORTANT! After installation, be sure to check for any contact of the grommet to the boat's transom or bracket. This is done by tilting fully and turning the engine from starboard to port to be sure that no contact occurs. A broken grommet will allow water intrusion into the engine and could lead to engine damage or failure. New rigging tube grommet for V4 & V6.
4.
Optional Part Number Description
5.
6.
ABB-RIGHS-BK-25 ABB-RIGHS-GY-25 ABB-RIGHS-BE-25 ABB-RIGHS-BK-50 ABB-RIGHS-GY-50
Black Rigging Hose, 25 Gray Rigging Hose, 25 Blue Rigging Hose, 25 Black Hose 100 Gray Hose 100
7.
For model year 2001, Yamaha has expanded the model line-up that come standard with the rigging grommet that was offered in 2000 for the HPDI and F115 engines. The F80/F100, all V-4 and V-6 models have received this change.
8.
2-42

150~250, 3.1L, 2.6L, HPDI, OX66 Rigging Tube Grommet 1 Shift Cable 2 Throttle Cable 3 10 Pin Main Harness 4 & 5 Oil Warning and Trim Gauge Harness (combined for '96) 6 Remote Oil Tank Lead 7 Battery Cable Harness 8 Oil Hose 9 Fuel Hose 10 Speedometer Hose 11 Water Pressure 12 Misc. Water Temperature
1 2 3 4 5 6 7 8 9
V4 & V6 Rigging Tube Grommet
V4 Rigging Tube Grommet

Throttle Cable Shift Cable Main Harness Oil Warning Lead Remote Oil Tank Lead Trim Gauge Lead Battery Leads w/Isolator Lead Oil Hose Fuel Hose 10 Speedometer Hose
1 9 4 5 6 2 3 7 8
10
V4
2 10 12 4 6 5 1 11 12 2 4 5 6 1 3 7 9 8 3 7 HPDI 9 8
F80/F100 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Trim Gauge & Oil Warning Lead 5 Battery Leads 6 Fuel Hose 7 Speedometer Hose 8 Water Temperature & Water Pressure Sensor
3 8 1
5 6
10 11
V6-225/250 hp
F115 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Trim Gauge & Oil Warning Lead 5 Battery Leads 6 Fuel Hose 7 Speedometer Hose 8 Water Temperature & Water Pressure Sensor
7 5 4 2 6 8 3 1
2-43

F9.9 EXHAUST WELL KIT INSTALLATION (6G8-W4537-00-00) When mounting the F9.9 on a boat, the type of the boat should be taken into consideration. Mounting The Outboard Motor 1. Anti-cavitation plate position. Normally, the engine is so mounted that the anti-cavitation plate is 0 ~ 2.5cm (0 ~ 1in) below the keel line. But in the case of the F9.9, the anti-cavitation plate should be 5cm (2in) below the water surface.
F9.9 Exhaust Well Kit Installation
NOTE: a. Tighten the bolts completely. b. After mounting the outboard motor on the boat, bolt the clamp bracket to the boat. c. Apply a sealing compound to the drilled holes and bolts and tighten the bolts. 2. Install the attachment in the idling gas hole. (Illus. #2)
ILLUSTRATION 2
LT
3.
Connect the blow-by gas exhaust pipe (option). (Illus. #3)
ILLUSTRATION 3
NOTE: After mounting the outboard motor on the boat, bolt the clamp bracket to the boat. Mounting On a Well-type Boat 1. When the boat is a well-type, the engine should be mounted in the following manner. Mount the engine on the boat and secure it with clamp bolts. (Illus. #1)
ILLUSTRATION 1 BLOW BY GAS PIPE
4.
Connect the hose to the attachment. (Illus. #4)
ILLUSTRATION 4
2-44

5. Lock the steering handle. (Illus. #5)
ILLUSTRATION 5
F9.9 Exhaust Well Kit Installation
7.
Bring the idling exhaust gas exhaust pipe out of the boat. (Illus #7)
ILLUSTRATION 7
YAMAHA
6. Bring the blow-by gas exhaust pipe out of the boat. (Illus. #6)
ILLUSTRATION 6
NOTE: a. Secure the hose to the hull so it does not move.
NOTE: a. Clamp the hose to the hull so it does not move. b. Route the hose so it inclines downward.
2-45

SECTION 3 ELECTRICAL Wire Harnesses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1 Switch Panel Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8 Battery Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-22 Electrical Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-33 Rectifier - 6 ~ 25HP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-34 Voltage Regulator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-36 5HP Lighting Coil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-37 Neutral Safety Switch - 30E . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-40 Remote PT&T Switch - F/T25T, 40T~250HP, C40T~C90 . . . . . . . . . . . . . . . . . . . . 3-41 Boat Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-43 Complete Boat Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67

WIRE HARNESSES
F25T F80/100 F15 40T To F25E 90 F115 FT50 F40T C40T To C115 2-Stroke 115~ 250 V4 V6 L130 To L250
REF. NO. DESCRIPTION
F9.9
9.9 15
25 30
PART NUMBER
T8
T9.9
Primary Engine Harness For Use With Switch Panel 1 7 pin 2-1 10 Pin 5m 2-2 10 Pin 8m 3-2 10 Pin 9.9m 4 7 Pin To 10 Pin Adapter 5 12 Pin 2.5m For Tiller Models Primary Engine Harness Extensions
Needed With Switch Panel 688-82586-50-00 688-8258A-50-00 O 6K1-8258A-40-00 O 61B-8258A-01-00 O 703-8258A-00-00 6H5-83553-11-00 Used to Increase Length of Main Harness 688-82586-11-00 688-8258A-10-00 688-8258A-30-00 6R3-85721-30-00 6R3-85721-50-00 6R3-85721-80-00 Extensions 6Y5-82149-00-00 6Y5-82117-00-00 6Y5-82521-00-00 6Y5-83553-10-00 6G8-81949-00-00 682-84380-00-00 6G8-82590-00-00 6G8-82541-00-00 64D-82105-00-00 O O Sc * Or O + = Not 225X/250 = Optional Recommended = Optional = Except F25T Sc O O O O Or Or O O O Or Or O O
O O
O O
O Sk O
O Sk O O
O Sk O
O Sk O
O O Sk
6 7 Pin 2m 7-1 10 Pin 2m 7-2 10 Pin 3m Oil Harness 8-1 Oil Tank Lead 3m 8-2 Oil Tank Lead 5m 8-3 Oil Tank Lead 8m Instrument Panel 9-1 Blue Lead 9-2 Black Lead 9-3 Yellow Lead Special Harnesses 10 Tachometer Harness 11 T9.9M Rectifier Connection to Battery 12 Rectifier To Battery W/Connector 13 Remote Conversion Harness on P/H 14 Oil Light Harness 15 V6 Battery Cable Sc = Standard in Crate Sk = Standard in Standard Rigging Kit if ordered with engine. Ss = Standard, Shipped Separate D =With Oil Tank
O O O O O
O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O O
(Continued on next page)
3-1

WIRE HARNESSES (Contd.)
F25T F80/100 F15 40T To F25E 90 F115 FT50 F40T
Wire Harnesses
2-Stroke 115~ C40T To C115 250 V4 V6 L130 To L250
REF. NO. DESCRIPTION
F9.9
9.9 15
25 30
PART NUMBER
T8
T9.9
Control Box Adapters 16 17 Aftermarket Harness To 704/705 Box Aftermarket Control To Main Harness Instrument Panel 18 19 Gauge (One Fuse) Gauge (Two Fuses) 6Y5-83553-00-00 6Y5-83553-M0-00 64D-82553-50-00 64D-82553-70-00 64D-82553-80-00 O O 1 2 O 1 2 O O O O O O O O O O O O O O = Not 225X/250 = Optional Recommended = Optional = Except F25T 1 2 Ss Ss O Ss = Single Gauge Kit = Dual Gauge Kit 1+ 2+ O 1+ 2+ O O O O O O 1 2 1 2 2 O 1 2 O O O O O O O O O O 1 2 O 1 2 Sk O O O O O O O O O 704-85721-00-00 704-82541-10-00 O O O O O O O O O O O O
20-1 Trim & Oil Gauge Lead 5m * 20-2 Trim & Oil Gauge Lead 7m * 20-3 Trim & Oil Gauge Lead 8m * Extensions 21-1 Trim Gauge Lead 3m 21-2 Trim Gauge Lead 5m 21-3 Trim Gauge Lead 7m 21-4 Trim Gauge Lead 8m 21-5 Trim Gauge Lead 9.5m 22-1 Oil Gauge Lead 5m 22-2 Oil Gauge Lead 7m 22-3 Oil Gauge Lead 8m 22-4 Oil Gauge Lead 9.5m 23 PT & T Switch Lead Extension 2m Fuel Management 24-1 F.M. Meter to Sender** 5m 24-2 F.M. Meter to Sender ** 8m 25 26 Sender Extension 3m F.M. Meter to Tach.
20-4 Trim & Oil Gauge Lead 9.5m * 64D-82553-90-00 6R3-82553-30-00 6R3-82553-50-00 6R3-82553-70-00 6R3-82553-80-00 6R3-82553-90-00 6R3-82521-50-00 6R3-82521-70-00 6R3-82521-80-00 6R3-82521-90-00 6H5-82553-00-00 6Y5-83553-F0-00 6Y5-83553-F1-00 6X1-82531-00-00 703-82531-00-00 * Or O +
Sc = Standard in Crate Sk = Standard in Standard Rigging Kit if ordered with engine. Ss = Standard, Shipped Separate D =With Oil Tank
* The combined 64D Trim & Oil Lead uses the same connectors as the separate 6R3 Oil Gauge Lead and the 6R3 Trim Gauge Leads. The 64D Harness and the 6R3 Harnesses are fully interchangeable as a set. That is one 6R3 Oil Gauge Harness and one 6R3 Trim Gauge Harness of the same length can be used to replace a 64D Trim & Oil Lead of the same length. In addition, the 6R3 Harnesses can be used as extensions with a 64D Harness. ** F.M. Meter to Sender Harness included with fuel management kit is -F1 8m long. For replacement -F0 5m must be used with extensions.
3-2

Primary Engine Harness For Use W/Switch Panel 1. 7-Pin Main Harness 688-82586-50-00 (5M, 16.4ft)
Wire Harnesses
3-2. Main Harness 10-Pin, 9.9M 61B-8258A-00-00 (9.9M, 31.2ft)
4.
7 to 10-Pin Adapter 703-8258A-00-00
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)
5.
12-Pin Main Harness for Tiller Models, 2.5M 6H5-83553-11-00 (2.5M, 8.2ft)
3-3

Primary Engine Harness Extensions 6. 7-Pin, 2M Extension (main harness) 688-82586-11-00 (2M, 6.6ft) TANK HARNESSES
Wire Harnesses
8-1. Oil Tank Lead, 3M 6R3-85721-30-00 (3M, 9.8ft) 8-2. Oil Tank Lead, 5M 6R3-85721-50-00 (5M, 16.4ft) 8-3. Oil Tank Lead, 8M 6R3-85721-80-00 (8M, 26.2ft)
7-1. 10-Pin 2M Extension (main harness) 688-8258A-10-00 (2M, 6.6ft) 7-2. 10-Pin 3M Extension (main harness) 688-8258A-30-00 (3M, 9.8ft)
Instrument Panel Harnesses 9-1. Accessory Blue Lead 6Y5-82149-00-00 (12V-lights) 9-2. Accessory Black Lead 6Y5-82117-00-00 (Ground) 9-3. Accessory Yellow Lead 6Y5-82521-00-00 (12v-key ON)
3-4

Special Harnesses 10. Tachometer Harness (no remote) 6Y5-83553-10-00 (5M, 16.4ft)
Wire Harnesses
14. Oil Light Harness - F/T9.9M 6G8-82541-00-00 (2.5M, 8.2ft)
15. V6 Battery Cable 64D-82105-00-00 (3.2M, 10.6ft)
11. Rectifier to Battery - T9.9M 6G8-81949-00-00 (2.8M, 9.3ft)
12. Rectifier to Battery w/ Connector 682-84338-00-00 (6.05M, 19.8ft)
Control Box Adapters 16. Aftermarket Harness (to 704/705 box) 704-85721-00-00
13. Remote Conversion Harness - T9.9 6G8-82590-00-00 (7.6M, 24.9ft)
17. Aftermarket Control to Main Harness 704-82541-10-00
3-5

18. Gauge Harness (one fuse) 6Y5-83553-00-00 (all except V4/V6) Extensions
Wire Harnesses
21-1. Trim Gauge Lead - 3M 6R3-82553-30-00 (3M, 9.8ft) 21-2. Trim Gauge Lead - 5M 6R3-82553-50-00 (5M, 16.4ft) 21-3. Trim Gauge Lead - 7M 6R3-82553-70-00 (7M, 23ft) 21-4. Trim Gauge Lead - 8M 6R3-82553-80-00 (8M, 26.3ft) 19. Gauge Harness (2-fuses) 6Y5-83553-M0-00 (all V4/V6) 21-5. Trim Gauge Lead - 9M 6R3-82553-90-00 (9.5M, 31.2ft)
20-1. Trim & Oil Lead - 5M 64D-82553-50-00 (5M, 16.4ft) 20-2. Trim & Oil Lead - 7M 64D-82553-70-00 (7M, 23ft) 20-3. Trim & Oil Lead - 8M 64D-82553-80-00 (8M, 26.3ft) 20-4. Trim & Oil Lead - 9.5M 64D-82553-90-00 (9.5M, 31.2ft)
22-1. Oil Gauge Lead - 5M 6R3-82521-50-00 (5M, 16.4ft) 22-2. Oil Gauge Lead - 7M 6R3-82521-70-00 (7M, 23ft) 22-3. Oil Gauge Lead - 8M 6R3-82521-80-00 (8M, 26.2ft) 22-4. Oil Gauge Lead - 9.5M 6R3-82521-90-00 (9.5M, 31.2ft)
3-6

23. PT & T Switch Lead Extension 6H5-82553-00-00 (2M, 6.6ft) 26 F.M. Meter to Tach. 703-82531-00-00
Wire Harnesses
**F.M.l Meter to Sender Harness included with fuel management kit is: -F1, 8m long. For replacement, -F0, 5m must be used with extensions. Fuel Management 24-1. F.M. Meter to Sender - 5M** 6Y5-83533-F0-00 (5M, 16.4ft) 24-2. F.M. Meter to Sender - 8M** 6Y5-83533-F1-00 (8M, 26.2ft)
25.
Sender Extension 6X1-82531-00-00 (3M, 9.8ft)
3-7

SWITCH PANEL ASSEMBLIES For switch panel part numbers and descriptions, refer to the chart on the following pages. Single The single panel assembly is for use with any remote control except the 703 standard side mount control box. Yamaha makes available single panels that vary in function and model application. T9.9E - This switch panel features the ignition switch, emergency stop lanyard, and an oil pressure light. 9.9 ~ 30HP - There are two panels available with the same function, but different configuration. Both panels feature the ignition switch, emergency stop lanyard, choke control. F30 ~ F115, 40 ~ 90, 9.9 ~ 200HP, C40T ~ C90 - The panel features the ignition switch, emergency stop lanyard, choke control, and warning horn. Dual Engine Systems The panel assembly is used on dual engine systems. All feature a unified emergency stop lanyard, two ignition switches, and a warning buzzer.
NOTE: Do not use a dual switch panel with the 40~90HP, LF115 or C40T~C90 models. The overheat and low oil warning system on these panels are not compatible with these models. Accessory Panels Yamaha offers three accessory panels. Oil warning light panel for the T9.9ELR Single ignition key switch with push-for choke activation Emergency stop lanyard panel - single
SWITCH PANELS Push to Choke Main Switch with Warning Horn 704-82570-06-00 6K1-82570-05-00 64D-82570-02-00 64D-82570-10-00 689-82570-18-00 Single Main Switch w/Stop Switch on Panel Dual Main Switch w/Single Stop Switch on Panel Single Main Switch Only (Small Square Panel) Single Stop Switch Only (Small Square Panel) Single Main Switch w/Stop Switch on Panel (No Horn for Small Models)
Standard Main Switch with Oil Pressure Light, No Choke, No Warning Horn 6G8-82570-02-00 6G8-83530-00-00 Single Main Switch, Oil Light and Stop Switch on Panel (F9.9/T9.9) Oil Light on Panel Only - Used with 703 Control (F9.9/T9.9)
3-8

SWITCH PANELS
Switch Panels
2-Stroke
Description
Part Number
F9.9 T9.9
T8 9.9 15 F15
25 30
F25E 40E
40T~90 T25~T50 F25T~F115
C40 To C90
115 To 250 V4 V6
LF115 L130 To L250
Switch Panel W/Push To Choke Single Twin Single No Horn Main Sw Only Stop Sw Only Switch Panel W/Oil Light Single W/Oil Light Oil Light Only O +
Needed With Binnacle Or Flush Control 704-82570-06-00 6K1-82570-05-00 689-82570-18-00 64D-82570-02-00 64D-82570-10-00 O O O O O O O O O O O O O O O O O O O O O Sk
6G8-82570-02-00 6G8-83530-00-00
O O
= Optional = Except F25T/F25E
3-9

Switch Panel Mounting Instructions Mounting 1. Select a mounting location so that the switch panel assembly is in easy reach from the helm. Cut a hole in the instrument panel as indicated in the mounting diagram. Using a 2-1/8 inch hole saw, where indicated. Connect the wire harness to the switch panel assembly as shown in the correct wiring diagram in the Boat Wiring Diagrams Section of this manual, and pass the harness back through the hole. Secure the switch panel assembly to the instrument panel with screws, washers, and nuts; or wood screws as required. Wiring
Switch Panels
For wiring information and diagrams, refer to the Boat Wiring Diagrams section of the Electrical Chapter elsewhere in this manual.
2.
3.
4.
SAMPLE ONLY! Actual pattern may vary with panel selected.
3-10

Single Switch Panel Assembly 689-82570-18-00 (1998~: 9.9E ~ 30HP) Single panel with push-to-choke ignition switch and lanyard.
Switch Panels
704-82570-06-00 C40T~C60, 9.9~250HP Single panel with push-to-choke ignition switch, lanyard, and warning horn.
REF NO PART NUMBER 10 11 12 13 14 15 16 17 18 19 20 21 22 704-82570-06-00 704-82510-06-00 688-82575-01-00 682-82556-00-00 640-82581-00-00 97303-05012-00 92903-05100-00 95303-05700-00 658-83383-11-00 90149-05M05-00 95380-05600-00 92990-05100-00 92990-05600-00 DESCRIPTION Panel Switch Assy Main Switch Assy Engine Stop Switch Assy Stopper Stay, Cord Clamp Bolt Washer, Spring Nut Buzzer Screw Nut Washer, Spring Washer, Plate QTY. 1 1 1 1 1 1 1 1 1 4 4 4 4
3-11

SINGLE SWITCH PANEL ASSEMBLY DRILL TEMPLATE (Actual Size)
Switch Panels
8.5 mm (.33 in)
2x
51 mm (2.02 in)
22.5 mm (1.01 in )
110 mm (4.33 in)
44.5 mm (1.75 in)
93 mm (3.66 in)
CUT OUT THE SHADED PORTION
22.5 mm (1.01 in ) 51 mm (2.0 in) 68 mm (2.67 in)
8.5 mm (.33 in)
3-12

6K1-82570-05-00 (1998~: L130) Dual panel with push-to-choke ignition switches, common lanyard, and warning horn.
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6K1-82570-05-00 6K1-82571-01-00 6K1-82510-04-00 6K1-82575-00-00 682-82556-00-00 6K1-83614-01-00 688-83383-11-00 6K1-85830-01-00 98580-06020-00 92995-06100-00 95380-06600-00 98580-05010-00 92990-05100-00 95380-05600-00 90149-05M05-00 95380-05600-00 92990-05100-00 92990-05600-00
Switch Panels
DESCRIPTION Panel Switch Assy Panel, Switch Main Switch Assy Engine Stop Switch Assy Stopper Stay Buzzer Control Unit Assy Screw, Pan Head Washer, Spring Nut Screw, Pan Head Washer, Spring Nut Screw Nut Washer, Spring Washer, Plate
QTY. 1 1 2 1 1 1 2 1 2 2 2 2 2 2 4 4 4 4
3-13

DUAL: SWITCH PANEL ASSEMBLY DRILL TEMPLATE (Actual Size)
Switch Panels
128 mm (5.04 in) 27 mm (1.06 in) 40 mm (1.46 in) 27 mm (1.06 in)
27 mm (1.06 in) DRILL TEMPLATE 6x 54mm (2.12 in)

3-14
27 mm (1.06 in)
93 mm (3.66 in)

Switch Panel Assembly with Oil Light 6G8-82570-02-00 (T9.9)
REF NO PART NUMBER 2 3 4 5 6 7 8 9 10 11 12 13 14 6G8-82570-02-00 6G8-82571-01-00 68882-57501-00 68282-55600-00 66382-58101-00 6G8-83582-01-00 6G8-82510-00-00 98903-04008-00 92903-04100-00 90149-05M05-00 95380-05600-00 92990-05100-00 92990-05600-00
Switch Panels
DESCRIPTION Panel Switch Assy Panel, Switch Engine Stop Switch Assy Stopper Stay, Cord Clamp Pilot Light Assy Main Switch Assy Screw, Bind Washer, Spring Screw Nut Washer, Spring Washer, Plate
QTY. 1 1 1 1 1 1 1 1 1 4 4 4 4
NOTE: Use Drill Template on page 3-??????.
3-15

Four Stroke Switch Panel T9.9 (6G8-82570-02-00) DRILL TEMPLATE (Actual Size)
Switch Panels
; ;
4.5 in (116mm) 5 in (130mm)
1 in
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2-1/8 in.
27mm
2.12 in (54mm)
2.7 in (68mm)
3-16

Oil Lamp Panel Assembly (T9.9ELR) 6G8-83530-00-00
Switch Panels
3-17

Oil Lamp DRILL TEMPLATE (Actual Size)
Switch Panels
68 mm (2.67 in) 7.7 mm (.31 in) 52 mm (2.06 in) 7.7 mm (.31 in)
13.7 mm (.82 in) 56 mm (2.2 in) 41 mm (1.58 in) 14.3 mm (.56 in)
19 mm (.75 in)
30 mm (1.17 in )
4x
5.1 mm (.2 in)
3-18

Single Main Ignition Switch Panel (Option 9.9~250) 64D-82570-02-00
Switch Panels
Single Emergency Stop Lanyard Panel (Option 9.9 ~ 250) 64D-82570-10-00
3-19

Single Main Ignition Switch Panel (Option 9.9~250) DRILL TEMPLATE (Actual Size)
64D-82570-02-00
Switch Panels
3-20

Single Emergency Stop Lanyard Panel (Option 9.9~250) DRILL TEMPLATE (Actual Size)
64D-82570-10-00
Switch Panels
3-21

BATTERY INSTALLATIONS 2.6L EFI Battery Cable Installation The battery cables are not mounted on the engine, but are in a separate box in the crate. This allows for the battery cable to be rigged to the boat along with the other rigging leads. It is then attached to the engine when it is installed on the boat. Install the cables as follows: 1. Position the battery cable in the boat so the location tape is where the engine rigging grommet will be located. Positive Negative
NOTE: Do not connect the battery cable to the battery until all rigging is complete. 2. After installation of the engine to the boat, 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 rigging grommet. Run the battery cable to the starter motor. The negative battery cable will be connected to the post on the starter housing (up top and to the rear). The positive battery cable end will be connected to the terminal block that is secure to the upper rear starter motor bolt. Right below the starter motor mounting bolt is the terminal block. Secure both cables to their appropriate terminals. Coat both posts with anti-corrosion grease/spray. Place rubber caps over both terminals. Next, secure the battery cable to the fuse box. There are 2 wire clamps located on the cover to secure the battery cable in place.
3.
4.
5.
3-22

F80/100/115/HPDI Battery Cable Installation The battery cables are not mounted on the engine, but are in a separate box in the crate. This allows for the battery cable to be rigged to the boat along with the other rigging leads. It is then attached to the engine when it is installed on the boat. Install the cables as follows: 1. Position the battery cable in the boat so the location tape is where the engine rigging grommet will be located. NOTE: Do not connect the battery cable to the battery until all rigging is complete. 2. After installation of the engine, route the battery cable through the engine rigging grommet located on the port side of the lower pan. Ensure the cable is in its proper position in the grommet. Run the battery cable to the starboard side of the engine pan just in front of the air box. Remove the fuse box cover. Bring the battery cables from the lower pan up to the starter motor. The positive terminal on the battery cable will be installed on relay #2, which is located on front side of the starter motor. The negative battery cable terminal will mount on the bottom of the starter housing. Just in front of the lower mounting bolt is the negative battery terminal bolt. Secure the battery cables to the appropriate terminals, then coat them with anti-corrosion grease/coating. Place the rubber cap over the terminal. Then, reinstall the fuse box cover when rigging is complete.
CAUTION:
Battery Installations
Be careful not to over-tighten positive battery cable post damage/breakage could occur to starter relay. NOTE: Torque both posts to 6 ft-lbs.
3. 4. 5.
6.
3-23

Recommended Battery Size
Engine Size HP Class Minimum Battery Specification Amp Hour Cold Cranking
Reserve
50 & Smaller T9.9/F9.9, F25 40 to 130 HP Including F30~F115 & T25~T50 HPDI SX150 & SX200/PX150/DX150, V6, 2.6L, OX66 3.1L OX66 VX200~SX250
40AH 40AH 70AH 100AH 100AH 100AH
210 Amps 380 Amps 380 Amps 512 Amps 512 Amps 512 Amps
59 Minutes 124 Minutes 124 Minutes 182 Minutes 182 Minutes 182 Minutes
NOTE: Using a deep cycle, maintenance-free, or gel cell battery for starting is not recommended! These batteries are not designed for high starter current discharge or continuous charging on most outboards and usually have short life. Gel cell batteries require special controlled charging and may not be compatible with the Yamaha charging system. Marine, cranking types 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 minimum specifications are not met, the engine could experience electrical component issues.
3-24

Battery Isolator Wiring For model year 2001, Yamaha has changed the battery isolator leads. The 3.1L Salt Water Series 225/250hp, carburetor 150/V150 and all HPDI engines will remain the same. The OX66 V-Max 200/225/250hp and OX66 2.6L engines have received a change as pointed out below.
BATTERY ISOLATOR LEADS 2000 13.3 ft 3 Not Required
Length Number of Wires Isolator Lead Required
2001 11.0 ft 2 Requires Part # 68F-81949-00-00
OX66 V-Max 200/225/250hp will come with a new battery cable. The battery cable length has also been changed.
2000 67H-81949-00-00 2001 68F-81949-00-00
Part Number
Type of Installation 1 Motor 2 Batteries & No Battery Switch 2 Motors 3 Batteries & No Battery Switch 1 Motor 2 Batteries & On/Off Battery Switch 2 Motors 3 Batteries & On/Off Battery Switch 2 Motors 3 Batteries & 1/Both/2 Battery Switch Bass Boat 12/24 Volt Trolling Motor (3 pin plug) Bass Boat 12/24 Volt Trolling Motor (4 pin plug) Bass Boat 24 Volt ONLY Trolling Motor WARNING
Refer To Page 3-26 Page 3-26 Page 3-27 Page 3-28 Page 3-29 Page 3-30 Page 3-31 Page 3-32
The battery isolator cannot be used on a 24/36 volt trolling motor system. A short could result causing a fire. Consult the trolling manufacturer for wiring recommendations.
3-25

Dual Battery Installation (Recommended Battery Wiring Without Accessory Battery Switch)
WARNING
2.
Improper battery connections or wire size selection may result in a fire. 1. When one battery is used, connect the two red cables to the (+) terminal. If the smaller red cables is left unconnected, an accidental contact of the red cable with the (-) terminal of the battery will form a short circuit and may cause a fire.
When using an accessory battery, a negative connecting cable must be installed between the accessory battery and the main battery. This cable must be equivalent to the main battery cable.
3-26

Dual Battery Installation
(Recommended Battery Wiring with Accessory Battery, Selector Switch)

WARNING
Improper battery connections or wire size selection may result in a fire. 1. When one battery is used, connect the two red cables to the (+) terminal. If the smaller red cable is left unconnected, an accidental contact of the red cable with the (-) terminal of the battery will form a short circuit and may cause a fire. 2. When using an accessory battery, a negative connecting cable must be installed between the accessory battery and the main battery. This cable must be made from wire equivalent to the main battery cable. Use of a smaller wire could lead to a fire.
BATTERY SWITCH SELECTION MODE SYSTEM OFF NORMAL OPERATION BACK-UP CRANKING SWITCH POSITION OFF BATTERY 1 BATTERY 2
NOTE: 1. SWITCH POSITION BOTH SHOULD NOT BE USED FOR BACK-UP CRANKING. If Battery 1 is discharged and the BOTH position is selected, then Battery 2 will discharge into Battery 1. 2. Switch #2 is not required, the battery 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 #3 can be installed to shut off electrical power to the accessories.
3-27
(Recommended Battery Wiring with Accessory Battery Shut Off Switch)

WARNING
Improper battery connections or wire size selection may result in a fire. 1. When one battery is used, connect the two red cables to the (+) terminal. If the smaller red cable is left unconnected, an accidental contact of the red cable with the (-) terminal of the battery will form a short circuit and may cause a fire. 2. When using an accessory battery, a negative connecting cable must be installed between the accessory battery and the main battery. This cable must be equivalent to the main battery cable. If the battery is wired differently than shown below, a larger negative corrective wire is required.
1 Primary starting battery shut off switch (single battery high current type) 2 Optional auxiliary battery shut off switch (minimum capacity 80 amps) 3 Accessory shut off switch (capacity determined by current requirements of accessories and wire size used) 4 Optional twin engines with three batteries, the isolator leads from both engines could be wired to the accessory battery for electronics.
Motor (S Side) Multifunction meter power (red) lead
Motor (P Side)
Red Fuse 10A Red Engine Red On Off 2 Black 1 Red

OPT
On
Off 1
4 Black
Battery 1 for cranking Negative Connecting Cable
Battery 3 for Accessory Accessory
Battery 2 for cranking 3 Battery Cable Small Wire
NOTE: Switch #2 is not required, the battery isolator on the motor will prevent current from flowing to the electrical components on the engine, even if this lead remains connected to the battery. However, the switch #3 can be installed to shut off electrical power to the accessories.
3-28

Twin Engine
BATTERY SWITCH SELECTION MODE SYSTEM OFF NORMAL OPERATION BACK-UP CRANKING SWITCH #1 POSITION OFF BATTERY 1 BATTERY 2 SWITCH #2 POSITION OFF BATTERY 2 BATTERY 1
NOTE: 1. SWITCH POSITION BOTH SHOULD NOT BE USED FOR BACK-UP CRANKING. If Battery 1 is discharged and the BOTH position is selected, then Battery 2 will discharge into Battery 1. 2. Switch #3 is not required, the battery isolator on the motor will prevent current from flowing to the electrical components on the engine, even if the small wire remains connected to the battery. However, the Switch #4 can be installed to shut off electrical power to the accessories. Optional: Isolator lead 3 from both engines could be hooked to the accessory battery.
3-29

Typical 12/24 Volt Trolling Motor (3 pin plug)
NOTE: If only two batteries are used, and one is being used for starting, do not use the battery isolator. Damage to the engines electrical system could occur.
WARNING
To reduce the risk of electrical short and fire: The positive isolation lead must be at least 12 gauge wire. The negative lead between batteries must be the same size as the battery cable if the second battery will be used for starting. The negative lead between batteries must be at least 12 gauge if the second battery will be used to power a trolling motor.
3-30

Typical 12/24 Volt Trolling Motor (4 pin plug)
NOTE: If only two batteries are used, and one is being used for starting, do not use the battery isolator. Damage to the engines electrical system could occur.
WARNING
3-31

Typical 24 Volt Only Trolling Motor
WARNING
NOTE: If only two batteries are used, and one is being used for starting, do not use the battery isolator. Damage to the electrical system of the engine could occur.
NOTE: The battery isolator cannot be used on a 24/36 volt trolling motor system. A short could result causing a fire. Consult the trolling motor manufacturer for wiring recommendations.
3-32

ELECTRICAL CONNECTORS Special bullet connectors and spade terminals are available in a kit or individually in packs of 50. This kit will allow you to make factory-like connections.
Telephone 1-800-328-6657 Fax 1-800-578-7375
Lead Wires Yamaha lead wires allow quicker and easier rigging by providing two additional female receptacles. These wire leads are available in yellow, black, and blue.
Description Part Number
Yellow Lead Wire Black Lead Wire Blue Lead Wire
6Y5-82521-00-00 6Y5-82117-00-00 6Y5-82149-00-00
3-33

RECTIFIER 6HP~25HP The rectifier allows the lighting coil to recharge the battery as well as supply electrical current to other accessories or components that might be on board. Yamaha offers the rectifier as optional equipment for the models listed below (it is standard on T9.9 models).
Part Number Applicable Model
3.
Mount the rectifier onto the bracket using the two other bolts and washers.
NOTE: Be sure the rectifier lead wires exit from the bottom. 4. 5. Locate the electrical wire connection cover and remove it. Dislodge the three green wire connectors (originating from the lighting coil) from the retainer (under the connection cover). Connect the two primary green wires with the green wire leads from the rectifier.
6G8-81960-A1-00 6G1-81970-00-00
F9.9 6, 8, 9.9, 15, 25HP
NOTE: For additional parts required for installation, see the list on the next page.
NOTE: The extra green wire connector from the lighting coil will remain unused. 6. Pass the red and black battery lead wires through the slits in the rubber grommet at the front of the motor pan.
WARNING
Do not connect the battery lead wires to the battery at this point. 7. Connect the black eye-terminal lead wires from the rectifier and battery to bolts on the motor for grounding purposes. 8. Rectifier Installation Example (For F9.9) 1. Remove the motor cover and locate the mounting boss (empty bolt hole) on the starboard side of the motor. NOTE: The mounting boss is forward of the number one spark plug and just to the rear of the electrical wire connection cover. 2. Mount the bracket onto the mounting boss by the center hole in the bracket with a bolt and washer. Connect one red lead wire from the fuse holder assembly to either of the two red lead wires from the rectifier.
NOTE: The other red lead wire from the rectifier will remain unused. 9. Connect the red lead wire from the battery to the red lead wire from the other end of the fuse holder assembly.
10. Insert all the wire connectors into the retainer and reinstall the electrical connection cover. NOTE: Be sure not to pinch any wires underneath the connection cover. 11. Install the fuse holder assembly into the hook on top of the electrical connection cover.
NOTE: The bracket has a support key that engages the stem of the mounting boss to ensure proper bracket placement.
3-34

Wiring Connect the wiring as shown in the diagrams.
Rectifier 6HP~25HP
Ref. No..
Description
1 2 3 4 5 6
Battery Wire Connection Cover Fuse Holder Assembly Rectifier/Regulator Bracket Lighting Coil
Additional Parts Required Part Number Description Remarks Model Qty.
6G8-81949-00-00 6G8-82150-00-00 6G8-81948-00-00 97095-06016-00 92990-06600-00 6G1-81975-00-00 98580-05525-00 92990-05600-00 90105-06M23-00 6E7-15771-80-94 6G1-42724-10-00
Lead Wire Fuse Holder Assy Bracket Bolt Washer Plate, Rectifier Fitting Screw, Panhead Washer Bolt Stay Grommet
Connects fuse holder assembly to battery Connects rectifier and lead wire Mounts rectifier and regulator assembly For mounting bracket For mounting bracket Mounts rectifier Mounts rectifier Use with above screw Mounts plate Mounts rectifier For wire lead
All All F9.9 F9.9 F9.9 6&8 6,8,9.9,15,25 6,8,9.9,15,25 6,8,25 9.9,15 6,8,25
1 1 1 3 3 1 1 1 2 1 1
3-35

VOLTAGE REGULATOR If the lighting coil is used to power the lights without a battery, consider installing a voltage regulator. A voltage regulator will stabilize the power output of the coil and help prevent blown bulbs caused by power surges. NOTE: The voltage regulator controls the AC voltage of the lighting coil. It does not rectify the output to DC and cannot be used with a battery. Usually, the voltage regulator is not required when using a battery with small outboards, because the battery will dampen any voltage spikes.
Part Number Applicable Models Installation Mounting
1.
Select a suitable location near the motor and secure the voltage regulator to the boat.
NOTE: The inside of the transom may be a good location for the voltage regulator provided it is not in an area subjected to a lot of water splash.
Wiring
1. 2.
Connect the yellow leads to the leads from the lighting coil. Connect the red and black leads to the lights.
663-81910-10-00
5HP~40HP (Manual)
NOTE: The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage output from the rectifier to the battery. NOTE: On 4/5HP models, a lighting coil must be installed. All other applicable models have a standard lighting coil.
WARNING
When using a battery, a rectifier assembly must be used to prevent damage to the lighting coil.
3-36

5HP LIGHTING COIL The lighting coil will allow the motor to produce additional electrical current. With a voltage regulator, the lighting coil can be used to directly power lights or other accessories on a boat. Maximum output of the lighting coil is 60 watts. The lighting coil can also be used to charge the battery when a rectifier is added.
Part Number Applicable Models CLOCKWISE
6E0-81303-80-00
5 HP 3. Using the flywheel puller, remove the flywheel. The flywheel puller bolts should be inserted into the hole marked "P."
NOTE: All other motors come with a lighting coil as standard equipment. Installation 1. Remove the recoil starter mounting bolts, and remove the starter assembly. 2. Loosen the flywheel nut using the flywheel holder and a socket wrench.
CAUTION:
Loosen the flywheel nut out only to the end of the crankshaft until the flywheel has broken loose. This will prevent the flywheel from completely popping off. Once the flywheel is loose, the nut can be removed.
CAUTION:
The main thrust must be made in the direction of the arrow. If not, the flywheel holder can slip off.
4. 5.
Remove the woodruff key from the crankshaft keyway. Install the lighting coil onto the magneto base with the two screws.
3-37
5HP Lighting Coil
6. In order to properly route the wiring for the lighting coil, remove the two bolts and pull out the magneto base. NOTE: The magneto base is integrated with the oil seal housing. When removing the magneto base, it is best to gently tap its underside with a plastic hammer. 7. Remove the stay screw on the back of the magneto base, and remove the grommet.
10. Make sure the O-ring in the groove of the magneto base is installed correctly. Slip the magneto base over the boss located between the cylinder and crankcase. 11. Align the bolt holes in the cylinder block with the holes in the magneto base, then reinstall and tighten the bolts. 12. Reinstall the woodruff key in the crankshaft. Reinstall the flywheel rotor on the crankshaft so the woodruff key fits in the keyway on the rotor. 13. Using the flywheel magneto holder and a socket head wrench, tighten the flywheel nut. Tightening Torque: 4.5 m-kg (32 ft-lb.)
8.
Pass the wire leads of the lighting coil through the grommet, then reinstall the grommet into the magneto base.
9. Secure the wire leads with the stay. The ground lead should be secured with the stay screw.
3-38

14. Reinstall the recoil starter onto the magneto base and tighten the bolts.
5HP Lighting Coil
NOTE: The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage input from the rectifier to the battery.
Wiring
1. Connect the wire leads as shown in the diagrams.
NOTE: The rectifier can also be used with the Yamaha Voltage Regulator (663-81910-10-00) to ensure proper voltage input from the rectifier to the battery.
3-39

30HP 3 CYL. NEUTRAL SAFETY SWITCH 688-82540-11-00 To avoid accidentally starting the motor while in gear, a neutral safety switch must be installed if you are using a control box without start-in-gear protection like the 701.
Part Number Applicable Models
5. Connect the extension wire lead (P/N: 6H482553-00-00) to the leads of the neutral safety switch. 6. Route the extension leads around the front of the bottom cowling to the right side of the motor, opposite the CDI unit. Secure the wires with cable ties to keep them clear of moving parts in the throttle and shift linkages. 7. Remove the terminal cover (spare fuse is attached). At the connector, disconnect the brown wire coming from the starter solenoid relay. Connect each of the two wires to the appropriate leads from the neutral safety switch. 8. Reinstall the carburetors, being careful not to pinch any oil lines. Also, make sure the carburetor flange o-rings are properly seated. Connect the oil pump link, choke solenoid shaft, and the fuel line. Tighten the six mounting bolts and install the air box. 9. Verify that all wires are properly and securely connected and reinstall the terminal cover. 10. Reinstall the control cable and flywheel covers and the upper cowling. 11. Test the operation of the neutral safety switch. The unit should start only when in neutral.
688-82540-11-00
30HP when 704 switch panel is used
Additional Parts Required Part Number Applicable Models Qty
6J8-82554-00-00 97095-06012-00 6H4-82553-00-00

Installation
Stay 6mm Bolt Extension Wire Lead
1 2 1
1. 2.
Remove the upper cowling, flywheel cover, and carburetor air box from the motor. It will be necessary to remove the three carburetor assemblies to install the neutral safety switch. Shut off the fuel supply, and disconnect the choke rod from the lower part of the carburetor assembly. Detach the oil pump link, and disconnect the fuel line at the fuel filter. Remove the six bolts holding the carburetors to the intake manifold, and carefully remove the carburetors. The choke solenoid shaft will pull out of the choke solenoid as the carburetors are removed. Install the neutral safety switch in its bracket so, when the assembly is mounted, the button on the switch faces toward the rear. Install the switch and bracket on the bottom cowling with the two 6mm bolts provided. Remove the control cable cover from the front right corner of the bottom cowling. Confirm the proper location of the switch by operating the shift lever. The switch button should be pressed by the cam on the end of the shift lever when the lever is moved to neutral.
3-40
3.
4.

F/T25T, 40T~250HP, C40T~C90 (REMOTE POWER TRIM AND TILT SWITCH) - 688-82563-10-00
REF NO 1
DESCRIPTION Tilt Switch
QTY. 1
The power trim/tilt switch is used to trim the motor for performance, or to tilt the motor for transport or storage purposes when using remote controls without a built-in switch. All Yamaha remote control models feature a built-in power trim/tilt switch except the model 701 and C models without power tilt. The switch would be needed when using other aftermarket remote controls without a built-in trim/tilt switch, or when using a tiller handle model. The Yamaha power trim/tilt switch can be mounted on the instrument panel for easy access from the helm. Through the use of extension wires, the trim/tilt switch can be mounted anywhere on the boat. This would allow, for example, a fisherman to trim the motor while casting off the front of the boat. The power trim/tilt switch connects to the main instrument harness with wire leads that are included.
Thin Instrument Panel Installation (maximum 2mm (0.08in)
1.
Select a mounting location so the power trim/tilt switch is easy to reach from the helm. Be sure there is sufficient clearance behind the instrument panel for the switch. When installing the power trim/tilt switch into a thin instrument panel, make a hole 13mm (0.5in) in diameter as shown in the mounting diagram. Secure the switch with the cap and plate.
2.
3.
Additional Parts Required Part Number Applicable Models Qty
Part Number
Applicable Models
97780-40116-00 688-82388-00-00
Panhead Tapping Screw Plate
2 1
688-82563-10-00
FT25T, 40T~250HP, C40T~C90 3-41

Mounting
Think Instrument Panel Installation (over 2mm (0.08in)
Remote PT&T Switch F/T25T, 40T~250HP, C40T~C90
For electric tiller model wiring, see the wiring diagrams in the Boat Wiring Diagrams Section.
1.
Select a mounting location so the power trim/tilt switch is easy to reach from the helm. Be sure there is sufficient clearance behind the instrument panel for the switch. When installing the power trim/tilt switch into a thick instrument panel, make a hole 40mm (1.57in) high and 13mm (0.5in) wide as shown in the mounting diagram. Secure the switch with the wood screws as shown.
2.
3.
TEMPLATE (Actual Size) 13 mm (.5 in)
40 mm (1.57 in)
3-42

BOAT WIRING DIAGRAMS The following wiring diagrams cover most common remote control configurations. These include diagrams using either the 703 control box with built-in electrics, or switch panel wiring required when either the 704 binnacle or 705 flush-mount control box is used. For details on harness part numbers, component dimensions, and mounting instructions, see the individual section covering the component in question. Page 1. T9.9 with 703 Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-44 2. T9.9 with Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-45 3. 9.9 ~ 30HP, 30 ~ C40 ~98 with 703 Control, 10-pin and Analog Tachometer . . . . . . . . . . . 3-46 4. 9.9 ~ 30HP, 30 ~ C40 ~98 with 10-pin Switch Panel and Analog Tachometer . . . . . . . . . . . 3-47 5. 9.9 ~ 30HP with 7-pin Harness Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-48 6. 40E, 50HP with 703 Control and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-49 7. 40E, 50HP with Switch Panel and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-50 8. F40, F50, T50, F80~F100, F115 with 703 Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-51 9. F40, F50, T50, F80/100, F115 with Switch Panel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-52 10. C40 ~ C150 with 703 Control and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-53 11. C40 ~ C150 with Switch Panel and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-54 12. 40T ~ 90HP, C40~C115 with 703 Control and Multifunction Gauges . . . . . . . . . . . . . . . . . . 3-55 13. 40T ~ 90HP, C40~C115 with Switch Panel and Multifunction Gauges . . . . . . . . . . . . . . . . . 3-56 14. 115 ~ 250HP with 703 Control and Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-57 15. 115 ~ 250HP with Switch Panel and Analog Gauges . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-58 16. 115 ~ 250HP with 703 Control and with Multifunction Gauges . . . . . . . . . . . . . . . . . . . . . . 3-59 17. 115 ~ 250HP with Switch Panel and with Multifunction Gauges . . . . . . . . . . . . . . . . . . . . . . 3-60 18. 115 ~ 250HP with 703 Control and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-61 19. 115 ~ 250HP with Switch Panel and Analog Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-62 20. 704 Dual Control with Dual Switch Panel (All Twin Engines) . . . . . . . . . . . . . . . . . . . . . . . 3-63 21. 40TLH, 50TLH, P60TLH, and P75TLH, F40~F100 Tiller Models Multifunction Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-64 22. F40, F50TLH, & T50, F40~F100 Tiller Model Analog Tachometer . . . . . . . . . . . . . . . . . . . 3-65 23. After Market Dash Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-66 COMPLETE BOAT WIRING DIAGRAMS 19. 70 ~ 90HP, F80~F115 Single Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-67 20. V4/V6 Single Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-68 & 3-69 21. V4/V6, F115 Dual Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-70 & 3-71 22. V6 HPDI Single Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-72 23. V6 HPDI Dual Engine . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-73
3-43

T9.9 with 703 Control
Boat Wiring Diagrams
3-44

T9.9 with Switch Panel
3-45

9.9 ~ 30HP, 30 ~ C40 ~ 98 with 703 Control, 10-pin and Analog Tachometer
3-46
9.9 ~ 30HP, 30 ~ C40 ~ 98 with 10-pin Switch Panel and Analog Tachometer
3-47

Wiring 9.9 ~ 30HP with 7 Pin Harness Switch Panel
3-48

40E, 50HP with 703 Control & Analog Tachometer (Except 40T or P50)
3-49

40E, 50HP with Switch Panel & Analog Tachometer (Except 40T or P50)
3-50
F40, F50, T50, F80/100, F115 with 703 Control Box and Analog Tachometer
3-51
F40, F50, T50, F80/100, F115 with Switch Panel and Analog Tachometer
3-52

C40 ~ C150 with 703 Control and Analog Tachometer
3-53

C40 ~ C150 with Switch Panel and Analog Tachometer
3-54
40T ~ 90HP with 703 Control and Multifunction Gauges C40~C115
3-55
*OPTIONAL ON C40~C90 May connect Gray wire to GRN/WHT wire and set dip switch #3 for 4-stroke operation. This will allow gauge not to flash a yellow warning.
40T ~ 90HP with Switch Panel and Multifunction Gauges C40~C115
3-56
*OPTIONAL ON C40~C90 May connect Gray wire to GRN/WHT wire and set dip switch #3 for 4-stroke operation. This will allow gauge not to flash a yellow warning.

115HP ~ 250HP Wiring with 703 Control and Analog Gauges
3-57

115HP ~ 250HP Wiring with Switch Panel and Analog Gauges
3-58
115HP ~ 250HP Wiring with 703 Control and with Multifunction Gauges 2-Stroke
3-59
115HP ~ 250HP Wiring with Switch Panel and with Multifunction Gauges 2-Stroke
3-60
115HP ~ 250HP Wiring with 703 Control and Analog Tachometer 2-Stroke 3-69
3-61
115HP ~ 250HP Wiring with Switch Panel and Analog Tachometer 2-Stroke
3-62

Dual Control Boxes 704 Dual Control with Dual Switch Panel (All Twin Engines)
*Wiring same if panel with or without separate choke switch is used. NOTE: All other wiring (tachometer, speedometer, etc.) is the same as individual engines.
3-63

Tiller Models with PT&T 40TLHW, 50TLHW, P60TLHW, P75TLHW, (F40~F100)
3-64
(UNUSED)

F40, F50TLH, T50, F80~F100 Tiller Model Analog Tachometer
3-65
(UNUSED)

After Market Dash Wiring
3-66

COMPLETE BOAT WIRING DIAGRAMS 70~90HP, F80~F115
3-67

V4/V6 Single Engine
Complete Boat Wiring Diagrams
3-68

V4/V6 Single Engine (Contd.)
3-69

V4/V6, F115 Dual Engine
3-70

V4/V6, F115 Dual Engine (Contd.)
3-71

V6 HPDI Single Engine
3-72

V6 HPDI Dual Engine
3-73

SECTION 4 REMOTE CONTROLS Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1 Control Box Illustrations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2 Control Box Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3 701 Remote Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4 703 Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8 704 Binnacle Mount Remote Control Assemblies . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18 705 Flush Side-Mount Remote Control Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 4-32 Remote Control Cables, Remote Conversion Kits 701, 703 . . . . . . . . . . . . . . . . . . . 4-47 Control Box Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-48

CONTROL BOXES 701 Control Box 701-48101-51-00 701-48130-02-00 Pull to open throttle. Non electric start models, starboard mount only. (PULL/MANUAL) Push to open throttle. Non electric start models, starboard mount only. (PUSH/MANUAL)
703 Standard Control Box 703-48230-12-00 703-48207-15-00 Pull to open throttle. 7-pin harness with push to choke main switch. (PULL/7-PIN/CHOKE) Push to open throttle. 10-pin harness, push to choke main switch and power trim & tilt switch. (PUSH/10-PIN/CHOKE/PT&T)
704 Single Binnacle Control Box 704-48205-13-00 Push to open throttle with power trim and tilt switch. Can be converted to pull to open throttle. (SNG BINN/PUSH/PT&T)
704 Dual Binnacle Control Box 704-48207-31-00 Push to open throttle with power trim and tilt switch. Can be converted to pull to open throttle. (DUAL BINN/PUSH/PT&T)
705 Flush Mount Control Box 6X0-48206-11-00 Push to open throttle with power trim and tilt switch. Note: 90 quick throw handle movement. (FLUSH/PUSH/PT&T/90)
NOTE:
8, F9.9, T9.9, 25, & 30 use a pull to open throttle control with a 7 pin harness. T8~9.9, 15, and 40hp to 250hp use a push to open throttle control with a 10 pin harness. The 9.9 and 15 use a 7 pin to 10 pin adapter harness. The trim switch will not operate on models without power tilt or power trim. All Prime Start Engines - The choke function has no affect on Prime Start. (Refer to chart on page 4-3)
4-1

CONTROL BOX ILLUSTRATIONS 701 704 Dual Binnacle
Kit Part Number 682-84380-00-00
703
705
704 Single Binnacle
4-2

CONTROL BOX APPLICATIONS
T8P F25T F40T 40T To 90 F80 F100 F115 V4* V6** LF115 L130 To L250 LX250
Description
Part Number
F9.9 T9.9
9.9 15
25 30
F15E F25E 40E
C40T~ To C115
701 Pull - No Elec. 701 Push - No Elec. 703 Pull 7 Pin/Choke 703 Push 10 Pin/Main Sw Choke Single Binnacle Dual Binnacle Flush Side Mnt 90 7-Pin to 10-Pin Adapter
701-48101-51-00 701-48130-02-00 703-48230-12-00 703-48240-12-00 703-48207-15-00
O O Or Or U
O Or U Sk Except F25 Sk O O O Sk Except F25 Sk O O Sk Sk
704-48205-13-00 704-48207-31-00 6X0-48206-11-00 703-8258A-00-00
Sk O O
Sk O O Sk
NOTE: * V4s include 115, 130 ** V6s include DX150, V150, VX150, VZ150, Z150, SX150, Z175, VZ175, SX200, VX200, VZ200, Z200, SX225, VX225, SX250, VX250
O Or Sc Sk U
= Optional = Optional Recommended = Standard in Crate = Standard in Standard Rigging Kit, if ordered with engine. = User s Choice
4-3

701 REMOTE CONTROL ASSEMBLY 701 Remote Control & Pull/Manual Assembly (701-48101-51-00)
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 701-48101-51-00 701-48235-00-0 701-48197-10-00 701-48252-00-00 701-48234-00-00 701-48221-00-00 701-48196-11-00 701-48236-00-0 702-48237-00-00 702-48238-00-00 701-48249-00-00 701-48248-00-00 701-48152-11-00 701-48152-20-00 701-48243-00-00 701-48198-10-00 701-48198-00-00 98580-05010-00 701-48268-00-00 701-48213-00-00 98780-06025-00 701-48255-00-00 97080-06018-00 702-48288-00-00 701-48246-00-00 92990-06300-00 701-48229-00-00 701-48222-00-00 98580-05555-00 701-48266-00-00 701-48232-00-00 701-48189-11-00 98580-05010-00 701-48153-12-00 701-48271-00-00 701-48271-10-00 93430-06024-00 703-48345-01-00 701-48261-00-00 701-48261-20-00 701-48358-00-00 701-82550-50-00 701-48138-50-00 701-48126-00-00 701-48133-00-00 98580-05020-00 701-48283-00-00 701-82594-00-00 701-48291-00-00 701-48287-00-00 95380-06600-00 701-48280-00-00
DESCRIPTION Remote Control Assy Bushing Washer, Wave Roller, Cam Bushing 1 Lever, Control Washer, Wave Roller, Detent Adaptor Spring, Detent Adaptor, Spring Roller, Free Accel. Knob, Free Accel. (Right) Knob, Free Accel. (Left) Bushing Washer, Wave Scrwe Screw, Pan Head Spacer Back Plate 2 Screw Flat Head Collar Bolt Washer, Plain Spacer Washer, Internal Tooth Grip, Control Lever Grip, Control Lever Screw, Pan Head Spacer Gear Retainer Screw, Pan Head Shaft, Free Accel. Arm, Shift (Right) Arm, Shift (Left) Circlip Cable End, Rem. Control 2 Arm, Throttle (Right) Arm, Throttle (Right) Push Anchor, Cable Engine Stop Switch Assy. Cap Graphic Plate, Link Screw, Pan Head Screw Clamp Attachment Washer Nut Neutral Lock Kit
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 3 4 1 1 2 1 2 1 2 1 1 1 2 1 1 1 2 1 1 1 3 2 1 1 1 1 1 1 1 2 1 1 1 3 1 1
4-4

701 Side Mount Remote Control Installation For smaller manual start motors, the 701 side mount control is the perfect answer. It features a forward/reverse lever and separate fast idle lever without the electrical connections of the 703.
701 Remote Control Assy.
Installation of Remote Control Cables 1. Loosen the four screws and remove the back plate.
2.
Preparation 1. Select a mounting location for the remote control which offers ease of use from the helm, and allows full movement of the control lever. Choose an unobstructed path for the cables that will allow them to be routed as straight as possible with no sharp bends. Measure from the control head to the shift and throttle connections on the motor. Yamaha remote control cables are available in lengths from 6 feet to 36 feet.
Screw in the cable end about 11mm (0.43in) over the threaded end of each remote control cable, and secure it with the locknut. Use Yamaha Marine Grease to coat the hole in the end of each cable end.
WARNING
If the cable is not screwed in at least 8mm, the cable joint could break. This could cause loss of control and an accident.
2.
3.
Fit the groove around the outer shift control cable (over the ridge and around the clamp). Next, fit the cable end over the pin on the end of the shift arm.
4-5

4. Secure the cable end to the pin with the circlip.
Mounting 1. Mount the 701 remote control as shown in the illustration.
5. Fit the anchor over the ridge and around the clamp.
2.
Verify that there is sufficient clearance for the full movement of the hand control and control mechanism. Route the cables as straight as possible from the control to the motor along the path previously chosen. There should be no bends of less than a 4-inch radius. The cables should be supported with cable hangers, or, for long runs, by running them through conduit.
Throttle Connection Proper adjustment of the throttle cable(s) will help ensure long component life. Proper adjustment is achieved when the engine speed remains at idle during shifting and will only increase when the hand lever is moved beyond the shift detent. 1. Make sure the engine is running at the correct idle speed. Adjust if necessary.
6. Likewise, connect the throttle control cable (for the throttle) to the throttle arm.
CAUTION:
The throttle cable should not be connected to the engine when making idle adjustments. The cable, if connected, may cause the engine idle speed or idle ignition timing to be incorrect. 2. Place the hand lever of the control in the neutral detent. 7. Secure the back plate with the four screws. 3. Place the carburetor arm lightly against the idle stop.
4-6

4. Adjust the throttle cable terminal (at the motor end) and line up with the hole or pin on the throttle arm. Connect the terminal to the arm. 2.
Operate the hand lever several times to verify proper operation. Make sure that the Forward, Neutral, and Reverse positions on the hand lever correspond to the same position of the motor shift arm.
CAUTION:
If full throttle is still reached before hitting the stop in the control, the travel should be limited by stop of some sort under the hand lever. Excess pressure on the hand lever at full throttle could damage the cable, control, or motor. Shift Cable Connection Proper adjustment of the shift cable will result in a better operating control. 1. Attach the control cable to the shift arm in the motor.
CAUTION:
Over-jamming the shift stop at either end of the lever travel may cause excessive wear of the control or engine components, a heavy feel of the hand lever, or overstress and damage the cable. Do not force shift the motor when it is not running. Damage to the control, cables, or motor may occur.
4-7

703 REMOTE CONTROL ASSEMBLIES 703 Remote Control (T9.9ER) [Pull 7-Pin] (703-48240-12-00)
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 703-48261-01-00 703-48153-00-00 703-48235-00-00 703-48268-00-00 703-48264-00-00 95380-05600-00 97380-05025-00 703-48265-00-00 93430-06024-00 703-48245-00-00 703-48252-00-00 701-48248-00-00 703-48198-00-00 703-48243-00-00 703-48236-00-00 703-48189-00-00 703-48236-0-00 703-48345-01-00 703-48358-00-00 703-48244-00-00 703-48238-00-00 703-48246-00-00 703-48227-00-00 703-82594-00-00 703-48226-00-00 703-48222-00-00 703-48223-00-00 703-48225-00-00 703-48219-00-00 703-48281-00-00 703-48282-00-00 97095-08030-00 92990-08600-00 98580-04010-00 98580-04006-00 98580-05010-00 98580-03015-00 703-48291-10-00 95380-06600-00 703-48293-10-00 701-48287-00-00 703-48215-00-00 702-48217-00-00 703-82510-30-00 DESCRIPTION Remote Control Assembly (7P) w/PT/T Sw Arm, Throttle Shaft, Free Accel. Bushing Spacer Throttle, Friction Nut Bolt Shaft, Friction Circlip Plate, Lock Roller, Cam Roller, Free Accel. Washer, Wave Bushing Bushing 1 Retainer Bushing 1 Cable End, Rem. Control 2 Anchor, Cable Spring, Free Accel. Spring, Detent Spacer Spring, Neutral Lock Clamp Plate, Stopper Grip, Control Lever, Single Lock, Neutral Cover Cover, Lead Screw Screw Bolt Washer, Plate Screw, Pan Head Screw, Pan Head Screw, Pan Head Screw, Pan Head Screw, (M6) Nut Spacer, Remote Control Single Washer Graphic Mark Main Switch Assy. (7P) For Prime Start Model QTY.
1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 2 1 1 2 1 1 5 1 1 1 1 1 1 1 1 2 7 1 1 3 2 1 2 3 3 1 3 1 1 1
4-8

703 Remote Control (T9.9ER) [Pull 7-Pin] (703-48240-12-00) Continued
REF NO PART NUMBER 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 703-82531-00-00 688-82575-01-00 682-82556-00-00 688-82586-21-00 703-82540-00-00 703-83383-A0-00 703-48284-00-00 90464-13080-00 703-82592-00-00 703-82563-01-00 703-48221-00-00 703-48152-00-00 703-48212-00-00 703-48213-00-00 703-48271-00-00 703-48211-01-00 703-48232-00-00 93430-06024-00 703-82542-00-00 703-48218-00-00
DESCRIPTION Wire, Lead Engine Stop Switch Assy. Stopper Extension, Wire Harness L:5M (7P) Neutral Switch Assembly Buzzer Grommet Clamp Band Trim & Tilt Switch Assy Lever, Control Knob, Free Accel. Back Plate 1 Back Plate 2 Arm, Shift Housing Gear Circlip Cap Graphic
QTY. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1
4-9

703 REMOTE CONTROL (T9.9ER) [PULL 10-PIN] (703-48207-15-00) REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 703-48261-01-00 703-48153-00-00 703-48235-00-00 703-48268-00-00 703-48264-00-00 95380-05600-00 97380-05025-00 703-48265-00-00 93430-06024-00 703-48245-00-00 703-48252-00-00 701-48248-00-00 703-48198-00-00 703-48243-00-00 703-48236-00-00 703-48189-00-00 703-48236-0-00 703-48345-01-00 703-48358-00-00 703-48244-00-00 703-48238-00-00 703-48246-00-00 703-48227-00-00 703-82594-00-00 703-48226-00-00 703-48222-00-00 703-48223-00-00 703-48225-00-00 703-48219-00-00 703-48281-00-00 703-48282-00-00 97095-08030-00 92990-08600-00 98580-04010-00 98580-04006-00 98580-05010-00 98580-03015-00 703-48291-10-00 95380-06600-00 703-48293-10-00 701-48287-00-00 703-48215-00-00 702-48217-00-00 703-82510-11-00
DESCRIPTION Remote Control Assembly (10P) w/PT/T Sw Arm, Throttle Shaft, Free Accel. Bushing Spacer Throttle, Friction Nut Bolt Shaft, Friction Circlip Plate, Lock Roller, Cam Roller, Free Accel. Washer, Wave Bushing Bushing 1 Retainer Bushing 1 Cable End, Rem. Control 2 Anchor, Cable Spring, Free Accel. Spring, Detent Spacer Spring, Neutral Lock Clamp Plate, Stopper Grip, Control Lever, Single Lock, Neutral Cover Cover, Lead Screw Screw Bolt Washer, Plate Screw, Pan Head Screw, Pan Head Screw, Pan Head Screw, Pan Head Screw, (M6) Nut Spacer, Remote Control Single Washer Graphic Mark Main Switch Assy. (10P) For Prime Start Model
QTY.
1 1 1 1 1 1 1 1 1 3 1 1 1 1 1 2 1 1 2 1 1 5 1 1 1 1 1 1 1 1 2 7 1 1 3 2 1 2 3 3 1 3 1 1 1
4-10
703 REMOTE CONTROL (T9.9ER) [PULL 10-PIN] (703-48207-15-00) Continued REF NO PART NUMBER 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 703-82531-00-00 688-82575-01-00 682-82556-00-00 688-8258A-20-00 703-82540-00-00 703-83383-A0-00 703-48284-00-00 90464-13080-00 703-82592-00-00 703-82563-01-00 703-48221-00-00 703-48152-00-00 703-48212-00-00 703-48213-00-00 703-48271-00-00 703-48211-01-00 703-48232-00-00 93430-06024-00 703-82542-00-00 703-48218-00-00
DESCRIPTION Wire, Lead Engine Stop Switch Assy. Stopper Extension, Wire Harness L:5M (10P) Neutral Switch Assembly Buzzer Grommet Clamp Band Trim & Tilt Switch Assy Lever, Control Knob, Free Accel. Back Plate 1 Back Plate 2 Arm, Shift Housing Gear Circlip Cap Graphic
QTY. 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 2 1 1
4-11

703 Side Mounts Remote Control Installation The 703 side mount remote control is standard for 30hp and larger motors (except the manual and tiller models). In addition to throttle and shift control, the 703 features an ignition switch, emergency stop switch, and, on applicable models, a power 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 control lever. Choose an unobstructed path for the cables that will allow them to be routed as straight as possible with no sharp bends. Measure from the control head to the shift and throttle connections on the motor. Allow an additional four feet cable length for the loop. Yamaha remote control cables are available in lengths from 6 feet to 36 feet.
2.
4-12

Installation of Remote Control Cables 1. Pinch the wire cover with your fingers and pull it off. 4.
Insert the remote control cable for shifting into the housing clamp so that the groove on its end fits over the ridge in the clamp. Fit the cable joint over the pin on the end of the shift arm and lock it with a circlip.
2.
Loosen the two screws as shown and remove the lower back panel.
5. 6.
Fit the grommet in the clamp groove as shown in the previous illustration. Connect the remote control cable for the throttle to the throttle arm of the control in the same way as the shift cable.
3.
For installation of cable joints, see page 4-47. Tighten the lock nuts before installing the cable joints, apply Yamaha Marine Grease to the threaded holes in the cable joints. 7. Reinstall the lower back panel with the two screws and replace the wire cover.
4-13

Reassembly for Port Side Application (Optional) The 703 control can be used for left (port) side applications if it is reassembled as instructed in this section. 3.
Place a punch on the bolt head and tap it with a hammer to remove the control lever from the control box.
LOOSEN BOLT
4.
Loosen the two screws (as shown) and remove the neutral lock holder.
USE PUNCH AND HAMMER HERE
1. 2.
Pinch the wire cover with your fingers and pull it off. Using a 12mm socket wrench, loosen the bolt on the back side of the control as shown.
NEUTRAL LOCK HOLDER
5.
Invert the remote control box and reinstall the neutral lock holder 180 degrees from its previous position. Tightening Torque: 0.12 0.15m-kg (0.87 ~ 1.1 ft-lb.)
6.
Reinstall the control lever on the opposite (back) side. Secure it by retightening the bolt, making sure that the washer is properly in place. Tightening Troque: 0.6 ~ 0.65m-kg (4.3 ~ 4.7 ft-lb.)
7.
Make sure that the power-trim-and-tilt lead wires are not twisted or slackened, and reinstall and wire cover.
4-14

Reassembly for Opposite Throttle Action (Optional) The 703 controls come properly assembled for either push-to-open or pull-to-open throttle types, depending on the model used. If a 703 control is to be used with a model with the opposite throttle action, the control will need to be reassembled to operate properly.
CAUTION:
3.
Remove the two screws holding the neutral throttle lever, and remove the throttle drum. Rotate the drum 180 degrees and reinstall it using the same two screws. Tightening Torque: 0.15 ~ 0.18m-kg (1.1 ~ 1.3 ft-lb.)
NOTE: Use care so that the roller does not jump out due to spring force.
When reinstalling parts, apply Yamaha Marine Grease to moving parts and contact surfaces. 1. 2. Pinch the wire cover with your fingers and pull it off. Remove the screws as shown, and then remove both upper and lower back panels.
4-15

4. Remove the throttle arm for the push-toopen throttle and install the type for the pull-to-open throttle, or vice versa, as shown in the illustration. Mounting 1.
Mount the 703 remote control as shown in the illustration.
2.
Verify that there is sufficient clearance for the full movement of the hand control and control mechanism. Route the cable as straight as possible from the control to the motor along the path previously chosen. There should be no bends of less than a 4-inch radius. The cables should be supported with cable hangers or, for long runs, by running them through conduit.
3.
Throttle Connection NOTE: Be sure to install the proper cam roller and bushing for the type of throttle being used. 5. 6. Reinstall the two back plates with the screws. Reinstall the wire cover. Proper adjustment of the throttle cable(s) will help ensure long component life. Proper adjustment is achieved when the engine speed remains at idle during shifting and will only increase when the hand lever is moved beyond the shift detent. 1. Make sure the engine is running at the correct idle speed. Adjust if necessary.
CAUTION:
The throttle cable should not be connected to the engine when making idle adjustments. The cable, if connected, may cause the engine idle speed or idle ignition timing to be incorrect.
4-16

2. 3. 4. Place the hand lever of the control in the neutral detent. Place the carburetor arm lightly against the idle stop. Adjust the throttle cable terminal (at the motor end) to line up with the hole or pin on the carburetor arm. Connect the terminal to the arm.
Shift Cable Connection Proper adjustment of the shift cable will result in a better operating control. 1. Attach the control cable to the shift arm in the motor. 2. Operate the hand lever several times to verify proper operation. Make sure that the Forward, Neutral, and Reverse positions on the hand lever correspond to the same position of the motor shift arm.
CAUTION:
If full throttle is still reached before hitting the stop in the control, the travel should be limited by stop of some sort under the hand lever. Excess pressure on the hand lever at full throttle could damage the cable, control, or motor.
CAUTION:
Over-jamming the shift stop at either end of the lever travel may cause excessive wear of the control or engine components, a heavy feel of the hand lever, or overstress and damage the cable. Do not force shift the motor when it is not running. Damage to the control, cables, or motor may occur.
4-17

704 BINNACLE MOUNT REMOTE CONTROL ASSEMBLIES 704 Single Binnacle Mount Remote Control Assembly (704-48205-13-00)
REF NO PART NUMBER
DESCRIPTION
QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 4-18
704-48205-13-00 Remote Control Assy Single 98580-05016-00 Screw, Pan Head EL8-48251-00-00 Plate, Cam 704-48265-00-00 Shaft, Friction 701-48246-00 Spacer 93430-06024-00 Circlip 92990-10600-00 Washer, Plate EL8-48259-00-00 Circlip 704-48262-00-00 Shaft, Throttle 704-48264-00-00 Throttle, Friction 704-48266-00-00 Spacer 704-82540-00-00 Neutral Switch Assy 98580-03014-00 Screw, Pan Head EL8-48281-00-00 Screw 704-48215-00-00 Graphic 704-48281-00-00 Screw 98580-05525-00 Screw, Pan Head 704-48261-00-00 Arm, Throttle EL8-48191-00-00 Washer 1 98580-05540-00 Screw, Pan Head 97395-06018-00 Bolt 703-48345-01-00 Cable End, Remote Control 2 704-48287-00-00 Washer 95380-05600-00 Nut EL8-48271-00-00 Arm, Shift EL8-48127-00-00 Screw 1 703-48358-00-00 Anchor, Cable EL8-48231-00-00 Housing, Gear EL8-48241-00-00 Arm, Drive EL8-48254-00-00 Stopper, Throttle Adjust 98780-06020-00 Screw, Flat Head EL8-48158-00-00 Spring 1 98580-04006-00 Screw, Pan Head 98780-05018-00 Screw, Flat Head EL8-48244-00-00 Spring, Free Accel. EL8-48245-00-00 Plate, Lock 703-48263-00-00 Bushing 704-48222-00-00 Grip, Control Lever
1 6 1 1 1 3 1 2 1 1 1 1 2 1 1 1 2 1 1 4 3 2 4 4 1 9 1 1 1 1 2 1 1 4 1 1 1 1
704 Binnacle Mount Remote Control Assy.
704 Single Binnacle Mount Remote Control Assembly (704-48205-13-00) Continued REF NO PART NUMBER
DESCRIPTION
QTY.
39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70
704-82594-00-00 704-48228-00-00 704-82563-A0-00 704-48229-00-00 92990-05300-00 95380-06600-00 701-48248-00-00 703-48238-00-00 EL8-48232-00-00 EL8-48164-00-00 704-48242-00-00 704-48225-00-00 704-48192-00-00 97890-06018-00 92990-06300-00 702-48263-00-00 EL8-48279-00-00 704-48193-00-00 EL8-48234-00-00 704-48219-00-00 704-48144-00-00 704-48176-00 703-48192-00-00 EL8-48233-00-00 703-48235-00-00 704-48282-00-00 EL8-48153-10-00 704-48166-00-00 704-48284-00-00 704-82541-10-00 704-48221-00-00 704-48119-00-00
Clamp Holder, Switch Trim & Tilt Switch Assy Grip, Control Lever Washer, Internal Tooth Nut Roller, Free Accel. Spring, Detent Gear Pin 2 Shift, Drive Cover Washer 2 Screw, Pan Head Washer, Internal Tooth Bushing Circlip 2 Washer 3 Bushing 1 Cover, Lead Plate, Stopper 2 Grommet Washer 2 Gear 2 Bushing Screw Shaft, Free Accel. Plug Grommet Wire, Lead Lever, Control Cover
1 1 1 1 3 2 1 5 1 1 1 1 1 2 2 1 1 1 1 1 2 1 1 1 1 4 1 1 2 1 1 1
4-19
704 DUAL BINNACLE MOUNT REMOTE CONTROL ASSEMBLY (704-48205-31-00) REF NO PART NUMBER QTY.
DESCRIPTION
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 4-20 98580-05016-00 EL8-48251-00-00 704-48265-00-00 701-48246-00-00 93430-06024-00 92990-10600-00 EL8-48259-00-00 704-48262-00-00 704-48264-00-00 704-48266-00-00 6XE-82540-10-00 6A5-48129-10-00 EL8-48281-00-00 704-48215-10-00 704-48281-00-00 98580-05525-00 704-48261-00-00 EL8-48191-00-00 98580-05540-00 97080-06018-00 703-48345-01-00 704-48287-00-00 95380-05600-00 EL8-48271-00-00 EL8-48127-00-00 703-48358-00-00 EL8-48231-00-00 EL8-48241-00-00 EL8-48254-00-00 98780-06020-00 EL8-48158-00-00 98580-04006-00 98780-05018-00 EL8-48244-00-00 EL8-48245-00-00 703-48263-00-00 704-48222-00-00 704-82594-00-00 704-48228-00-00 704-82563-G0-00
Remote Control Assy Dual Screw, Pan Head Plate, Cam Shaft, Friction Spacer Circlip Washer, Plate Circlip Shaft, Throttle Throttle, Friction Spacer Neutral Switch Assy Screw, Pan Head Screw Graphic Screw Screw, Pan Head Arm, Throttle Washer 1 Screw, Pan Head Bolt Cable End, Remote Control 2 Washer Nut Arm, Shift Screw 1 Anchor, Cable Housing, Gear Arm, Drive Stopper, Throttle Adjust Screw, Flat Head Spring 1 Screw, Pan Head Screw, Flat Head Spring, Free Accel. Plate, Lock Bushing Grip, Control Lever Clamp Holder, Switch Trim/Tilt Switch Assy
1 12 2 2 2 8 2 4 2 2 2 1 4 2 1 2 4 2 2 4 6 4 4 4 2 16 2 2 2 2 4 2 2 4 2 2 2 2 1 1 1
704 Dual Binnacle Mount Remote Control Assembly (704-48205-31-00) - Continued REF NO PART NUMBER
DESCRIPTION
QTY.
42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79
704-48229-00-00 92990-05300-00 95380-06600-00 701-48248-00-00 703-48238-00-00 EL8-48232-00-00 EL8-48164-00-00 704-48242-00-00 704-48225-00-00 704-48192-00-00 97880-06018-00 92990-06300-00 702-48263-00-00 EL8-48279-00-00 704-48193-00-00 EL8-48234-00-00 704-48219-00-00 704-48144-00-00 704-48176-10-00 703-48192-00-00 EL8-48233-00-00 703-48235-00-00 704-48282-00-00 EL8-48153-10-00 704-48166-00-00 704-48284-00-00 704-81950-00-00 704-82590-00-00 704-82590-10-00 704-48229-10-00 704-82563-E0-00 704-48228-10-00 98580-05555-00 704-48156-00-00 704-82563-F0-00 704-82563-E0-00 704-48285-00-00 704-48286-00-00 704-87107-00-00 704-87107-00-00
80 704-48221-00-00 81 704-48119-20-00 4-21
Grip, Control Lever Washer, Internal Tooth Nut Roller, Free Accel. Spring, Detent Gear Pin 2 Shift, Drive Cover Washer 2 Screw, Pan Washer, Internal Tooth Bushing Circlip 2 Washer 3 Bushing 1 Cover, Lead Plate, Stopper 2 Grommet Washer 2 Gear 2 Bushing Screw Shaft, Free Accel. Plug Grommet Relay Assy Wire Harness Assy Wire Harness Assy Grip, Control Lever Trim/Tilt Switch Assy Holder Switch Screw, Pan Head Nut 1 Trim/Tilt Switch Assy Trim/Tilt Switch Assy (704-48207-31) Grommet 2 Grommet 3 Plate, Shift Condenser Assy (704-48207-31) Lever Control Cover
1 6 4 2 10 2 2 2 2 2 4 4 2 2 2 2 2 2 1 2 2 2 4 2 2 4 1 1 1 1 1 1 3 1 1 1 1 2 2 1 2 1

704 Binnacle Mount Remote Control (Single & Dual)
704 Single
704 Dual
Manufactured by Yamaha for precise control of Yamaha outboards. Features a thumb-operated trim-tilt switch on the handle, forward/reverse lever, neutral lock for fast idling (with touch button fast idle release), corrosion-resistant upper casing and a fully enclosed lower casing. Wired for fast and convenient installation.
A revolutionary design puts dual engine trim and tilt in a single synchronized thumb-operated trim/tilt switch on the left lever - a Yamaha exclusive. Additionally, separate trim/tilt switches for each engine are mounted on the control body. The 704 dual lever control shares all the other features listed with the single lever model.
4-22

Preparation Choose a mounting location for the control head which will provide comfortable operation and unobstructed movement of the hand lever and control mechanism. Provide clearance to grasp hand lever and pull out for neutral throttle operation. NOTE: Minimum clearance below mounting surface for cables is 16". Use the template to cut appropriate (single or twin) mounting holes as shown on pages 4-24 and 4-25. NOTE: The remote control box should be installed on the right side of the steering wheel.
After determining the positions of remote control box mounting holes, drill the holes. 1. Make five 20mm (0.79 in) diameter holes in the positions shown. 2. 3. Circumscribe the four holes (other than one hole projecting to the left). Cut off along the line.
CAUTION:
Be careful not to make the projecting hole for the 704 dual binnacle in the wrong position, or leads could be cut during installation.
704 Control Box Spacers
4-23

704 Single
24.5 mm (.96 in )
24.5 mm (.96 in )
4-Dia. 6 mm (.24 in)
76.5 mm (3.01 in )
59 mm (2.32 in )
59 mm (2.32 in )
76.5 mm (3.01 in )
;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;; ;;;;;;;;;;
24.5 mm (0.96 in ) 24.5 mm (0.96 in )
28.5 mm (1.1 in )
28.5 mm (1.1 in )
4-24

PROJECTION HOLE
4-Dia. 6 mm (.24 in)
76.5 mm (3.01 in )
69 mm (2.72 in ) 59 mm (2.32 in )
59 mm (2.32 in ) 69 mm (2.72 in )
76.5 mm (3.01 in )
;;;; ;;;; ;;;;;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;;;;;;;; ;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;; ;;;;;;;;;;;;;;;;;;;
44 mm (1.73 in ) 44 mm (1.73 in )
4-Dia. 6 mm (0.24 in)
54.6 mm (2.15 in )
54.6 mm (2.15 in )
DUAL
4-25

704 Binnacle Remote Control Installation
WARNING
Installing the Remote Control Cables

CAUTION:
Incorrect selection or installation of a remote control may result in sudden and unexpected loss of control, thus resulting in a serious accident. Select the proper position for the remote control box, and stick the template on the selected position, then drill holes through it. When selecting the control box position, keep the following in mind: The remote control box should be set in a position so as not to interfere with the operation of the control lever and switches. Make sure the remote control cables are not obstructed. Allow enough space so that the bottom of the remote control box does not contact any other parts. Provide enough space so that the remote control cables can be routed without being bent sharply. The radius of a cable bend should be more than 101mm (4.0 in).
Cable connection should be started first from the remote control box side. If started from the engine side, cable adjustment will be impossible in some cases. 1. 2. Loosen the four screws securing the cover and remove it from the body. Loosen the five screws and remove the mounting flange, packing, and back plate.
NOTE: The mounting flange on the back plate side should also be removed.
CAUTION:
Sharp bends (less than 101mm - 4.0in radius) of the cables will obstruct the smooth movement of the cables and shorten cable life.
3.
For installation of the cable joints, (accessories) see page 4-47. Tighten the lock nuts before installing the cable joints, apply Yamaha Marine Grease to the threaded holes in the cable joints.
WARNING
If the cable is not screwed in at least 8mm, the cable joint could break. This could cause loss of control and an accident.
4-26

6.
Connect the remote control cable for the throttle to the throttle arm in the same manner.
YAMAHA MARINE GREASE
4.
Insert the outer sheave of the remote control cable for shifting into the housing clamp so that the groove on its end fits over the ridge in the clamp. Fit the cable joint over the pin, on the end of the shift arm, and lock it with the circlip. Fit the grommet (accessory) in the clamp groove.
7.
Secure the back plate and mounting flange firmly, with the five screws, and fit the packing in place. After installing the remote control cables, temporarily secure the remote control box to the predetermined position with the screws and nuts (accessories).
5.
8.
4-27

9. Installing the remote control cables for twin engines: To install the remote control cables for twin engines, loosen the three screws securing the two remote control boxes, then connect the cables in the same manner as in the case of the single engine model. After connecting the cables, secure the two remote control boxes with the three screws.
How To Change From The Push-To-Open Throttle Type To The Pull-To-Open Type The remote control box permits the change from the push-to-open throttle to the pull-to-open by performing the following procedure:
CAUTION:
When reinstalling parts, apply Yamaha Marine Grease to moving parts and contact surfaces of parts. 1. 2. 3. Remove the cover from the body. Loosen the five screws and remove the mounting flange, packing and back plate. Remove the four screws and remove the dwell plate retainer.
DWELL PLATE RETAINER
Next, temporarily secure the remote control boxes to the predetermined position with the screws and nuts (accessories). Peel the paper off the back of the packing, 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.
PACKING
MOUNTING FLANGE
BACK PLATE
4.
Remove the circlips and remove the dwell plate. Position the throttle arm assembly so it turns downward.
4-28

5. Remove the two screws and remove the throttle lever assembly. Position the throttle lever assembly so it faces downward and secure it with the two screws. Tightening Torque: 0.5 ~ 0.8m-kg (3.6 ~ 5.8 ft-lb.)
How To Change The Control Lever Position

WARNING
When using a right-hand remote control box for a left-handed one without changing the arrangement of the inner parts, do not forget that the control levers have to be moved in opposite directions from each other for proper operation. You can change the control lever position from the right side to the left side or vice versa.
6.
Align both the cam groove (for pull-to-open) in the dwell plate and the roller in the throttle lever assembly, with the specified position, and lock the throttle arm assembly and dwell plate with the circlip.
NOTE: Make sure the circlip is correctly fitted in place. 1. Remove the cover, packing, mounting flange, back plate, and dwell plate from the remote control box according to steps 1~4. Remove the circlip and plain washer from the throttle shaft, loosen the adjusting screw, and remove the throttle arm assembly and bushing.
2.
7. 8.
Secure the dwell plate retainer with the four screws. Install the mounting flange, back plate, and packing with the five screws.
NOTE: When installing the back plate, use care so the wire harness is not pinched. 9. Install the cover on the body.
4-29

3. Remove the brake arm assembly together with the plain washer and circlip. 4. Loosen the two hexagon head bolts and remove the throttle shaft. 7.
Loosen the locknuts, and reverse the right and left stopper bolt positions. Secure the bolts with the two locknuts. Tightening Torque: 0.5 ~ 0.8m-kg (3.6 ~ 5.8ft-lb)
CAUTION:
Do not allow the stopper bolt to project 8.0mm (0.3 in) or more from the nut surface. Otherwise, the stopper will contact the cover.
5. Loosen the hexagon head bolt, and install the shift assembly while holding it in an inverted position. Tightening Torque: 0.5 ~ 0.8m-kg (3.6 ~ 5.8ft-lb) 6. Install the throttle shaft, on the opposite side to the original position, with the two hexagon head bolts. Tightening Torque: 0.5 ~ 0.8m-kg (3.6 ~ 5.8 ft-lb.)
4-30

8. Install the brake arm assembly (with the plain washer and the circlip) on the throttle shaft. Install the bushing in the brake arm assembly, then install the throttle arm assembly onto the throttle shaft.
Throttle Opening Adjustment The remote control box is capable of adjusting the throttle opening in the following manner: 1. 2. Loosen the four screws securing the cover and remove it from the body. Loosen the locknut, and adjust the throttle opening by turning the stopper bolt.
NOTE: Turning the bolt clockwise decreases the throttle opening. Turning the bolt counterclockwise increases the throttle opening.
9. Install the plain washer and circlip onto the throttle shaft. 10. Align the cam groove (for push-to-open) in the dwell plate, and the roller in the throttle lever assembly, with the specified position, and hold the throttle arm assembly and dwell plate with the circlip. NOTE: Make sure the circlip is correctly fitted in place.
CAUTION:
Do not allow the stopper bolt to project 8.0mm (0.3 in) or more from the nut surface. Otherwise, the stopper will contact the cover. 3. After the adjustment, tighten the locknut.
11. Install the dwell plate retainer, mounting flange, back plate, packing, and cover according to steps 7~9. 4.
Tightening Torque: 0.5 ~ 0.8m-kg, (3.6 ~ 5.8ft0lb) Secure the cover to the body with the four screws.
4-31

705 FLUSH SIDE MOUNT REMOTE CONTROL ASSEMBLY (PUSH TO-OPEN)
REF NO PART NUMBER 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 6X0-48252-00-00 6X0-48138-00-00 93430-06024-00 92990-10600-00 EL8-48259-00-00 6X0-48265-00-00 6X0-48262-00-00 6X0-48264-00-00 6X0-48187-00-00 95380-06600-00 95380-06600-00 704-48266-00-00 704-82540-00-00 98580-03015-00 EL8-48281-00-00 704-48281-00-00 97890-05025-00 6X0-48261-00-00 EL8-48191-00-00 97380-06018-00 703-48345-01-00 EL8-48271-00-00 EL8-48127-00-00 703-48358-00-00 EL8-48231-00-00 6X0-48241-00-00 EL8-48254-00-00 92780-06020-00 EL8-48158-00-00 98580-04005-00 EL8-48244-00-00 EL8-48245-00-00 704-48178-00-00 701-48248-00-00 704-48238-00-00 6X0-48121-00-00 EL8-48164-00-00 EL8-48242-10-00 702-48263-00-00 EL8-48279-00-00 704-48193-00-00 EL8-48234-00-00 703-48192-00-00 EL8-48233-00-00 702-48235-00-00 6X0-48153-00-00 6X0-48222-00-00
DESCRIPTION Remote Cotrol Assy (90) Plate, Cam Cap, Lock Arm Circlip Washer Circlip Shaft, Friction Shaft, Throttle Throttle, Friction Plate, Adjust Nut Nut Spacer Neutral Switch Assy Screw Screw 1 Screw 1 Screw Arm, Throttle Washer Bolt Cable End, Rem. Control Arm, Shift Screw Anchor, Cable Housing, Gear Arm, Drive Stopper Screw Spring 1 Screw Spring, Free Accel. Plate, Lock Plate, Shift Roller, Free Accel. Spring, Detent Gear 1 Pin 2 Shaft, Drive Bushing 4 Circlip 2 Washer 3 Bushing 1 Washer 2 Gear 2 Bushing Shaft, Accel. Grip, Control Lever
QTY. 1 1 1 3 1 2 1 1 1 1 1 2 1 1 2 1 1 2 1 1 3 2 1 9 1 1 1 1 2 1 1 1 1 1 1 5 1 1 1 1 1 1 1 1 1 1 1 1
4-32
Outboard Rigging Guide - 2001705 Flush Side Mount Remote Control Assy.
705 FLUSH SIDE MOUNT REMOTE CONTROL ASSEMBLY (Push-to-Open) (Contd.)
REF NO PART NUMBER 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 703-48227-00-00 98580-05008-00 98580-04010-00 6X0-82563-00-00 6X0-48266-00-00 6X0-48127-00-00 6X0-48223-00-00 6X0-48221-00-00 6X0-48245-00-00 704-48225-00-00 6X0-48155-00-00 92990-05300-00 6X0-48281-00-00 6X0-48193-00-00 97890-06035-00 6X0-48128-00-00 6X0-48156-00-00 701-48287-00-00 6X0-48129-00-00 6X0-48215-00-00 6E0-44191-11-00 704-82541-10-00 6X0-48116-00-00 92990-04300-00 EL8-48281-00-00
DESCRIPTION Spring Screw, Pan Head Screw, Pan Head Trim Switch Assy Washer Screw Lock, Neutral Lever, Control Plate, Lock Cover Plunger Washer Screw Washer Screw, Pan Head Screw 2 Nut 1 Washer 1 Screw 3 Graphic Indicator, Shift Wire, Lead Bushing Washer Screw 2
QTY. 1 1 1 1 1 1 1 1 1 1 1 6 6 1 3 3 3 3 4 1 1 1 1 1 1
4-33

705 Flush Side Mount Remote Control (6X0-48206-11-00) Introduction Manufactured by Yamaha for precise control of Yamaha outboards. Features a thumb-operated trim/tilt switch on the handle, forward/reverse lever, neutral lock for fast idling (with touch button fast idle release), corrosion-resistant upper casing and a fully enclosed lower casing. Wired for fast and convenient installation.
705 Flush Side Mount Remote Control Assy.
NOTE: Depending on the specification, some models are not equipped with the power trim and tilt switch.
4-34

Operation 1. Forward and reverse First pull up the neutral interlock trigger. To shift into forward and reverse, rotate the control lever downward about 35 (detent position) to the: F side and R side, respectively. When the control lever is further rotated downward, the throttle opens.
THROTTLE ADJUSTABLE RANGE
CAUTION:
2.
Free accelerator Set the control lever to neutral (N) and while pushing the free accelerator button, rotate the control lever. The throttle can be opened without shifting into any gear.
It is impossible to operate the free accelerator button unless the control lever is in neutral. After operating the free accelerator button, set the control lever to neutral (N), and the free accelerator button will move automatically to its set position so it can be freely turned to forward and reverse. NOTE: Control mounts are on the inside edge of the mounting flange. Hull wall thickness in mounting area must not exceed 30mm (1.18 in). A minimum of 93mm (3.66 in) is required behind wall to mount and install control.
NOTE: The control lever must be rotated more than 35 from neutral; otherwise, the throttle cannot be opened.
4-35

3. Throttle Opening Adjustment The remote control box is capable of adjusting the throttle opening in the following manner: a. Loosen the locknut, and adjust the throttle opening by turning the stopper bolt. Turning the bolt clockwise decreases the throttle opening. Turning the bolt counterclockwise increases the throttle opening.
CAUTION:

4. Control Lever Tension Adjustment By turning in or out the throttle friction screw at the rear of the remote control box, the stiffness of the control lever can be adjusted. Turning the screw to the right makes the control lever stiff to turn, and turning it to the left makes the lever easier to turn.
Do not allow the stopper bolt to project 11mm (0.4 in) or more from the nut surface. Otherwise, the stopper contacts the cover. b. After adjusting, tighten the locknut. Tightening Torque: 5~8 Nm 0.5~0.8m-kg, (3.6~5.8ft-lb) 1 Locknut 2 Stopper Bolt
5.
Power Trim and Tilt Switch The power trim and tilt switch is attached to the control lever grip and twin cover. Pushing it UP trims up and tilts up the engine, and pushing it DOWN trims down and tilts down the engine.
NOTE: While the switch button is being pressed, the trim/tilt motor turns and adjusts the engine mounting angle. When the switch button is released, the engine will stop in its position.
4-36

6. Neutral Switch The neutral switch keeps the engine from starting when gears are shifted. When the control lever is in Forward or Reverse, the engine cannot be started by operating the main switch.
When selecting the control box position, keep the following in mind: a. The remote control box should be set in a position in which it does not obstruct the operations of the control lever and switches. Make sure there is not obstruction on the path of the remote control cables. b. Allow a space for the remote control box so it does not contact any parts related to the steering system. c. Provide a space so the remote control cables can be routed without bending sharply. The radius of a cable bend should be more than 200mm (7.87 in). 1 Wire Harness 2 Remote Control Cable
Installing the Remote Cotrol Box

WARNING
Incorrect selection or installation of a remote control may result in sudden and unexpected loss of control, thus resulting in a serious accident.
d. The angle of the remote control box can be changed 30 each time in reference to the control lever. NOTE: On the model with the power trim and tilt switch, use special care so electrical wires are correctly routed. 1. Remote Control Box Position Select the proper position for the remote control box, and stick the template on the selected position, then drill holes through it.
4-37

CAUTION:
Sharp bends (less than 200mm [7.87 in] in radius) of the cables will obstruct a smooth movement of the cables and shorten cable life.
b. Screw in the cable joint (accessories). See page 4-47. Tighten the locknuts. Before installing the cable joints, apply Yamaha Marine Grease to the threaded holes in the cable joints. 1 Remote Control Cable 2 Cable Joint 3 Lock Nut NOTE: Screw the cable joint into the shaded area (at least 8mm).
2.
Installing the Remote Control Cables
CAUTION:
Cable connection should be started first from the remote control box side. If started from the engine side, cable adjustment will be impossible in some cases. a. Loosen the five screws and remove the back plate. 1 Screw 2 Back Plate
c. Insert the remote control outer cable for shifting into the housing clamp so the groove on its end fits over the ridge in the clamp. Fit the cable joint over the pin, on the end of the shift arm, and lock it with the circlip. d. Fit the grommet (accessory) in the clamp groove. e. Connect the remote control cable for the throttle arm in the same manner.
4-38

f. Hold the back plate firmly with the five screws.
b. Tightly bolt the base to the remote control box. Tightening Torque: 30 ~ 45 cm-kg 1 Cover 3 Hole 5 Washer 2 Base 4 Screw
3.
Securing and Installing Accessories on the Remote Control Box. a. Set the remote control box so it's mounting holes align with the mounting holes in the base. 1 Mounting Hole
c. Install the remote control box to the mounting plate (hull) with screws and nuts. When the mounting plate thickness is less than 20mm, use the screws, nuts, and washers. When 20mm or more, use the wooden screws. Tightening Torque: 50 ~ 80 cm-kg NOTE: When the mounting plate (hull) is more than 30mm, the installation of the remote control box is impossible. 1 Screw 2 Plain Washer 3 Nut 4 Wooden Screw
4-39
g. Install the cover on the base. NOTE: Align the adjusting screw holes in the cover and the base, and install the cover. 1 Cover 2 Neutral Lock Holder 3 Adjusting Screw Holes 4 Trim Switch Wire
d. On the model with the trim switch, wind the trim switch wire two turns counterclockwise around the boss at the lower end of the control lever. Make sure the whitetaped portion of the wire is positioned at the lower end of the control lever. 1 Trim Switch Wire 2 White Tape h. Install the control lever on the remote control box. NOTE: When installing the control lever, wind the trim switch wire two turns counterclockwise, as shown below. Make sure the wire is not twisted and the white-taped portion is positioned at the hole. If the wire is twisted or wound incorrectly, it may break. Coil the wire so that windings do not cross each other. e. Pass the trim switch wire through the holes in the mounting plate and base, and bring them to the back of the mounting plate. f. Bring the white-taped portion of the trim switch wire to the hole in the neutral lock holder, and insert the neutral lock holder into the base.
4-40

i. Place the plain washer around the boss of the control lever and fasten it with the screws and washers. Tightening Torque: 30 ~ 45 cm-kg
Connecting the Remote Control Cable to the Engine and Fixing the Remote Control Box to the Hull 1. According to the instructions 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 control lever to Neutral. Operate the control lever a few times and check to see that the lever is turned to Forward or Reverse until it stops the gear shift once (about 35). When the lever is turned further from this position to Forward, the throttle fully opens. Next, make sure that when the control lever is returned to Neutral, the throttle is completely closed. If not fully closed, adjust the positions of cable joints, on the engine side, and install them again.
2.
j. Install the shaft button in the hole in the accelerator shaft and install the free accelerator button.
NOTE: The cable joints (on the engine side) must be screwed in at least 8mm (03 in) over the remote control cables.
k. Turn the adjusting screw into the remote control box through the hole in the cover. 1 Shaft Button 2 Free Accelerator Button
4-41

3. Move the control lever several times from lock to lock and make sure that when it is returned to the neutral position the throttle lever (on the engine side) is set to the fully closed position. If not in the neutral position, the cable end (on the engine side) must be adjusted. Next, push the free accelerator button, turn the control lever downward until it stops, then make sure that when it is returned to the neutral position, the free accelerator button is automatically reset. If not, the throttle lever (on the engine side) is forced against the stopper or it is not in the fully-closed position. Adjust the cables so the free accelerator button can reset automatically.
Change from the Push-To-Open Throttle Type to the Pull-To-Open Throttle Type The remote control box permits the change from the push-to-open throttle type to the pull-to-open type by changing some of the parts positions. This manual discusses the procedure for changing from the push-to-open throttle type to the pull-toopen type. Therefore, if it has to be changed from the pull-to-open type to the push-to-open type, simply reverse the procedure.
CAUTION:
NOTE: The cable joints (on the engine side) must be screwed in at least 8mm (0.3 in) over the remote control cables.
When reinstalling Marine Grease to surfaces of parts. 1. Loosen the five plate. 1 Screw 2 Back Plate
parts, apply the Yamaha moving parts and contact screws and remove the back 3 Dwell Plate Retainer
After connecting the cables to the engine, move the control lever from lock to lock several times and check for good operation of the engine and remote control box. Next, firmly secure the remote control box (which is temporarily held with the screws) to the hull.
2.
Remove the four screws and remove the dwell plate retainer. 1 Circlip 3 Dwell Plate 2 Cam Plate 4 Throttle Arm Assembly
CAUTION:
Check that the cables are not sharply bent (less than 200mm [7.87 in] in radius) or unnecessarily bent. (The number of bends should be minimized.) Also, check that no portions of the cables are clamped so hard as to deform the cable outers.
4-42

3. Remove the circlip, and remove the dwell plate and cam plate. Then, shift the throttle arm assembly position slightly backward. Remove the two screws and remove the throttle lever assembly. Then, change the throttle lever assembly position by turning it clockwise and secure it with the two screws. Tightening Torque: 5~8Nm (0.5~0.8m-kg, 3.6~5.8 ft-lb) 1 Screw 2 Throttle Lever Assembly 5.
4.
Turn the dwell plate 180 so the cam groove is on the PULL side, and align the throttle lever roller with the specified position, then secure the throttle arm assembly and dowel plate with the circlip. 1Dwell Plate 3Groove for Push-to-Open 2Cam Plate 4Groove for Pull-to-Open
NOTE: Make sure the circlip is correctly fitted in place.
6. 7.
Secure the dwell plate retainer with the four screws. Install the mounting flange, back plate and packing with the five screws. 1 Wire Harness
NOTE: When installing the back plate, use care so the wire harness is not pinched.
4-43

Change in the Control Lever Position
WARNING
2.
Remove the circlip and plain washer from the throttle shaft, loosen the adjusting screw, and remove the throttle arm assembly and bushing. Remove the brake disk and brake shoe assembly. 1 Circlip 2 Plain Washer 3 Throttle Arm Assembly 4 Brake Shoe Assembly 5 Brake Disk 6 Adjusting Screw
When using the right-hand remote control box as the left-hand without changing the arrangement of the inner parts, do not forget that the control levers have to be moved in opposite directions to each other. The remote control box permits to change the control lever position from the right side to the left side or vice versa. 1. Remove the cover, packing, mounting flange, back plate, dwell plate, and cam plate out of the remote control box according to steps 1, 2, 3, and 5 (page 4-42 & 4-43).
3.
4.
Loosen the two hexagon head bolts and remove the throttle shaft. 1 Throttle Shaft
4-44

5. Loosen the hexagon head bolt, and install the shift arm assembly, while holding it in an inverted position. 1 Hexagon Head Bolt 2 Washer 3 Shift Arm Assembly Tightening Torque: 5 ~ 8 Nm (0.5~0.8m-kg, 3.6~5.8 ft-lb.)
CAUTION:
Do not allow the stopper bolt to project 11mm (0.4 in) or more from the nut surface. Otherwise, the stopper contacts the cover. 8. Set the brake disk and brake shoe assembly on the throttle arm assembly, and install the throttle shaft. NOTE: Push in the brake shoe hook until it fits into the hole in the throttle shaft. 1 Throttle Shaft 2 Hexagon Head Bolt 3 Circlip 4 Brake Disk 5 Brake Shoe 6 Hook
6.
Using the two hexagon head bolts, install the throttle shaft on the opposite side to the original position. Tightening Torque: 5~8 Nm (0.5 ~ 0.8m-kg, 3.6~5.8 ft-lb) Loosen the locknuts, reverse the right and left stopper bolt positions, and secure the bolts with the two locknuts. 1 Stopper Bolt Tightening Torque 5~8 Nm (0.5~0.8m-kg, 3.6~5.8 ft-lb) 9. Install the plain washer and circlip on the throttle shaft. 10. Make sure the cam plate aligns with the cam groove (for push-to-open throttle) and the throttle lever roller. 11. Install the dwell plate retainer, mounting flange, back plate, packing and cover according to steps 5, 6, and 7 (page 4-43).
7.
4-45

Notes On Storage To ensure a longer life of the remote control box, be sure to take the following steps when storing it for a long period of time. 1. Remove the cable joints and apply Yamaha Marine Grease to the threaded portion of the inner cable. 1 Remote Control Cable 2 Cable Joint
2.
Also, apply Yamaha Marine Grease to inner parts of the remote control box, particularly to contact surfaces of moving parts. If any rust is found, remove it and apply the grease.
4-46

REMOTE CONTROL CABLES Yamaha remote control cables are available in lengths from 6 feet to 36 feet. The cables utilize 10-32 threaded ends. Measure from the location of the remote control box to the outboard motor along an unobstructed path that will allow the cables to be routed as straight as possible. Avoid sharp bends, and be sure to allow for an additional loop of approximately three feet, if necessary.
Part Number ABA-CABLE-06-GY ABA-CABLE-07-GY ABA-CABLE-08-GY ABA-CABLE-09-GY ABA-CABLE-10-GY ABA-CABLE-11-GY ABA-CABLE-12-GY ABA-CABLE-13-GY ABA-CABLE-14-GY ABA-CABLE-15-GY ABA-CABLE-16-GY ABA-CABLE-17-GY ABA-CABLE-18-GY ABA-CABLE-19-GY ABA-CABLE-20-GY ABA-CABLE-22-GY ABA-CABLE-24-GY ABA-CABLE-26-GY ABA-CABLE-28-GY ABA-CABLE-30-GY ABA-CABLE-32-GY ABA-CABLE-34-GY ABA-CABLE-36-GY Additional Parts Required Control Part Number Description Length 6 FEET 7 FEET 8 FEET 9 FEET 10 FEET 11 FEET 12 FEET 13 FEET 14 FEET 15 FEET 16 FEET 17 FEET 18 FEET 19 FEET 20 FEET 22 FEET 24 FEET 26 FEET 28 FEET 30 FEET 32 FEET 34 FEET 36 FEET
Cable Measuring Use the following examples as a guide for measurement. Obviously, different boats will required different routing and therefore different lengths.
THRU TRANSOM
TRANSOM WELL
All Controls 701 Control See Note
703 Control
ABA-CABLE-XX-GY 6G1-48501-50-00 6G8-48501-03-00 63V-48501-00-00 6L2-48501-10-00 6H4-48501-80-00 6L2-48501-10-00
Control Cable of XX ft length - Need 2 6-8HP Remote conversion kit FT/F9.9hp Remote conversion kit 9.9-15hp Remote conversion kit 25HP Remote conversion kit 40HP Manual Remote conversion kit 25HP Remote conversion kit
NOTE: A switch panel is required for manual models if used on a 9.9 to 25hp electric model.
4-47

CONTROL BOX ADJUSTMENTS Proper control box adjustments are critical for smooth and safe operation. Yamaha uses two types of throttle control. Yamaha outboards; 8, F9.9, T9.9, 20, 25, & 30 pull the throttle cable to open. Yamaha outboards T8, 9.9, 15, 40 ~ C40 and larger push the throttle cable to open. Shift cable control is the same for all outboards. Yamaha 704/705 control boxes can be setup as push to open or pull to open by changing one internal component. Rigging as efficiently as possible means setting up the control box just once, without having to open up the box again to readjust the cable ends after hookup to the motor. Refer to the following diagrams for proper cable end adjustments at the control box. Using these settings at the control box will ensure the cable ends at the motor will adjust properly.
ALL CABLES AND ENGINES
4-48

SECTION 5 INSTRUMENT & GAUGE INSTALLATIONS Digital Instruments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1 Tachometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2 Speedometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-7 Trim Meter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-13 Water Pressure Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16 Water Temperature Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-19 Water Pressure/Temperature Sender Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 Voltmeter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24 Hour Meter Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-26 Fuel Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28 Fuel Management System Gauge/GPS Hook Up . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-30 Fuel Management Gauge Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-31 Fuel Management Gauge Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32 Twin Engine Fuel Management Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-34 2001 HPDI Water Detection Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36 Digital Fuel Management Gauge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Fuel Management Gauge Operation Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-39 Fuel Management Gauge Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-42

DIGITAL INSTRUMENTS Self-check Function: When the main switch is turned on, all indicating segments are displayed and the warning indicator blinks for a few seconds. Only dual engines with a dual key switch panel have the alarm self-check with three beeps
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TTC ECON SYNC
25
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24-55 * 60 *766 5 6 /-60-4
NOTE: When testing the 2000 tachometer light, the power must be supplied to the Yellow (ignition ON) and Blue light at the same time.
5-1

TACHOMETER A properly operating tachometer is essential for suitable outboard performance. Engine RPM can be monitored for most efficient operation and excessively high engine speed can be avoided. In dual-engine applications, the tachometers can be used to set the throttle of each engine accurately. Yamaha has three types of tachometers; two Pro Series, one with oil lights, and one for the F40, F50, T50, F80, F100, F115 4-stroke; and a multifunction digital tachometer. For 40~250 all 2stroke and 4-stroke models. The multi-function gauge combines Yamaha high quality and advanced technology in this state-ofthe-art digital combination meter. Its large, two digit, liquid crystal display provides quick, easy monitoring day or night. Included in this gauge is an easy-to-read trim indicator, which blacks out if the engine is over trimmed, and prominently displayed oil warnings.
6 C40~ C70 6hp to 25 F/T9.9 25W3 (2-Cyl) F15 (3 Cyl) 4 POLE
2000~
Tachometer
NOTE: The multi-function digital gauge will not properly work on the 6 ~ 30HP engines. The tachometer will not function properly and the oil lights and trim gauge will not work.
~99
POLE
12 POLE 90 to 250
Description
Part Number
30 50T F/T25 & to F30~ 70 50EJ 70 F115
C90
Analog Tachometers Pro w/o Oil Pro with Oil Relay Unit Required For Oil Lights Four-Stroke Digital Tachometers Multifunction
6Y5-83540-14-00 6Y5-83540-05-00 6Y5-81950-02-00 6Y5-83540-20-00 6Y5-83500-T2-00
O O O O O O O O S C40 C70 S 40
only
O*
S
Except for F25
NOTE: New tachometers usually come set at 12 pole. Always check pole setting before installation. O = Optional S = Standard with rigging kit if ordered with engine * For C models, instrument harness required (6Y5-83553-M0-00)
5-2

Mounting 1. Select a mounting location so the tachometer is easy to read from the operating position. Be sure there is sufficient clearance behind the panel for the meter. Make a 3-3/8 inch diameter hole in the desired location. Remove the fitting plate from the meter, fit the meter into the panel, and install the fitting plate over the mounting studs. Place the washers over the studs, and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand.
Tachometer
2. 3.
4.
NOTE: If the dashboard has a thickness of more than 13mm (0.50 in) and it is impossible to secure the meter with the fitting plate, cut the fitting plate so the meter may be installed. Pro Series Tachometer
1
7 7 6 2 3
REF NO 1 2 3 4 5 6 7 8 9
PART NUMBER 6Y5-83517-00-00 6Y5-83536-10-00 6Y5-83523-00-00 6Y5-83514-00-00 6Y5-83509-10-00 6Y5-83518-00-00 95380-05600-00 92990-05100-00
DESCRIPTION Tachometer Assembly Bulb (12V-1.7W, T10) Socket, Meter Damper Plate, Fitting Socket Cord Assembly Bulb (12V-1.7W, T6.5) Nut Washer, Spring
QTY. 1 1 1 1 1 1 2 2 2
5 9 8
Component parts
5-3

Wiring Refer to the following illustrations for basic wiring. For detailed wiring information, refer to the diagrams in the Boat Wiring Diagrams in the Electrical Section 3 of this manual.
Tachometer
NOTE: A special relay, Part number 6Y581950-02-00, is required when using the Pro Series analog tachometer with oil lights.
5-4

Digital Multi-function Tachometer
Tachometer
5-5

Calibration For Number Of Poles The tachometer indicates the engine speed by receiving the pulses from the lighting coil. The flywheel magnetos used in Yamaha outboards vary in number of poles used: 4-pole, 6-pole, and 12-pole. It is necessary to change the calibration switch(es) on the back of the meter to correspond to the particular motor being used. To calibrate the tachometer for the motor being used, remove the rubber grommet from the back of the meter and set the calibration switch(es). The analog tachometer has a rotating switch that can be turned with a slotted-head screwdriver as illustrated. The digital meter uses toggle dipswitches. After setting the tachometer to the proper pole value, reinstall the grommet. The pole settings for each engine is given on the chart at the beginning of the Tachometer section.
Tachometer
NO.
DIP SWITCH FUNCTION
SW.1
TRIM SENSOR TYPE
SW.2
GENERATOR TYPE
SW.3
ENGINE TYPE
ON OFF
*2 LEAD *3 LEAD
6 POLE 12 POLE
4 STROKE 2 STROKE
* NUMBER OF LEAD WIRES ON TRIM SENSOR ON
1 2 3 FACTORY SETTINGS
6Y5-83500-T2-00
5-6

SPEEDOMETER The speedometer provides the operator with an approximation of the speed being traveled. This is useful for planning the length of a trip and adding to the general enjoyment of boating. Yamaha speedometers use the stock pitot tube on the 30hp and larger motors. The optional speedometer sending unit should be used with the 25hp motor. The speedometers are available in 3-3/8 inch sizes to match the size of the tachometer. There are two calibrations available, either 0~50 or 0~75 mph calibrations. The multi-function speedometer (standard with all V4/V6's) uses LCD readouts for speed, time, distance, fuel level, and has warning features for low fuel and low battery voltage. The speed can be calibrated for mph, kph, and knots. When installing and using boat speedometers, it is important to remember that they indicate an approximate speed of the boat through the water by measuring the impact force of the water with a pressure gauge. This impact force will vary with the density of the water and the speed of the impact. The density can vary by the purity of the water (salt, fresh, algae) and the temperature of the water. The speed of water impact can vary by the location of the speedometer pickup and its relation to the water flow off the area of the boat in front of the pickup. Because of these variables, the true speed of a boat can vary from the indicated speed on the meter. NOTE: In high-performance applications where the engine has been mounted in an elevated position, it may be necessary to use an optional speed sender to obtain a correct reading.
6Y5-83570-S5-00
Additional Parts Required Part Number Description Remarks Qty
6Y5-83553-00-00 6Y5-83553-M0-00
Wire, Lead (Optional) Wire, Lead (Optional)
Standard on 50hp and up Standard on V4/V6
1 1
5-7

Speedometer Installation Speedometer Mounting 1. Select a mounting location so the speedometer is easy to read from the helm. Be sure there is sufficient clearance behind the instrument panel for the meter. Depending on the diameter of the speedometer being mounted, make a 3-3/8 inch diameter hole in the desired location. Remove the fitting plate from the meter, fit the meter into the panel, and install the fitting plate over the mounting studs. Place the washers over the studs, and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand. Speedometer Tube Routing
Speedometer
2.
3.
4.
NOTE: If the instrument panel has a thickness of more than 13mm (0.5 in) and it is impossible to secure the meter with the fitting plate, cut the fitting plate so the meter can be installed.
Be sure to route the speedometer tube carefully to avoid crimping or damage.
23
24 25
26 29 27
REF NO PART NUMBER 23 24 688-83516-00-00 25 6Y5-83536-10-00 26 6Y5-83523-00-00 27 6Y5-83514-00-00 28 688-83557-00-00 29 90465-11M10-00 30 95303-05600-00 31 92903-05100-00 Component parts
DESCRIPTION Speedometer Assy Bulb (12V-1.7W, T10) Socket, Meter Damper Plate, Fitting Tube Clamp Nut Washer, Spring
QTY. 1 1 1 1 1 1 2 2 2
31 30
28 29
5-8

Speedometer Installation 3-3/8 Inch Analog Speedometer
Speedometer
Multi-Function Speedometer
(NOTE: For additional information, refer to multi-function tachometer wiring)
5-9

Speedometer Wiring Analog Speedometer 1. Connect the wiring as shown. The same lead wire used for the tachometer can be used. NOTE: If an aftermarket instrument light switch is used, connect it as shown. Otherwise, connect the yellow and blue leads together. The instrument light will then come on when the main switch is in the ON position.
Speedometer
Multi-Function Digital Speedometer For wiring information and diagrams, refer to the Boat Wiring Diagrams in the Electrical Section 3 of this manual. Speedometer Calibration Calibrate the multi-function speedometer according to the illustration below.
FUEL MANAGEMENT ADAPTOR PLUG
2. After installation, connect the power and check the operation of the instrument light.
5-10

Speedometer Tube Installation Speedometer Tube Routing The speedometer tube must be routed carefully to avoid crimping or damage. 30HP and 40HP (Except 40T) 1. As illustrated, route the tube on the inside of the swivel bracket. 40T ~ 250HP
Speedometer
NOTE: The speedometer tube comes installed as standard equipment, routed to the clamp bracket area. Cut off about 3mm (0.12) from the end of the nipple to open it, and connect it to the tube coming from the speedometer. Be sure to secure the tube with the quick tie provided.
2.
Locate the sensor tube coming from the lower unit, and cut off 3mm (0.12) from the tip of the nipple to open it. Connect the speedometer tube to the nipple and tighten with the quick tie provided. Route the tube to the speedometer and secure it.
3.
NOTE: Before securing the tube, be sure to tilt the engine up and down to make sure the tube is not stretched or pinched by other parts.
5-11

Additional Information About Marine Speedometer Operation The typical marine speedometer, including all Yamaha marine speedometers, use the pressure of water impacting a pitot tube to indicate the speed at which the water or boat is traveling. This pressure is directly related to the density of the water and the square of the speed. Fortunately, the density of the water, even between salt water and fresh water, does not vary enough to affect the speedometer reading. Also, this applied pressure does not vary with either the size or shape of the pitot or the manufacturer of the speedometer. Because the relationship between pressure and speed is a factor of the square of the speed, very low pressures are produced at low speed (1.4 psi at 10mph), and moderately high pressures are produced at high speed (92 psi at 80 mph). Many factors (such as the position of the pitot tube, boat design, and engine mounting position) can cause inaccurate or inconsistent readings of the speedometer. This is because these factors can affect the speed of the water at the location of the pitot compared to the actual speed of the boat. Also, if the sensing hose contains any trapped water, the resulting weight of this trapped water and height of the gauge in the dash can further affect the speedometer accuracy. Because of all of these possible variations, the only way to accurately check and calibrate a boat speedometer is to compare the reading with a radar gun. NOTES: 1. It is very difficult for any speedometer to accurately indicate speeds below 30 mph because of the low pressures produced. A digital speedometer like the Yamaha Multifunction Speedometer can more accurately indicate these speeds. 2. The pressure required to indicate speeds of less than 9 mph is less than 1 psi. For the Yamaha Multifunction Speedometer to indicate 5 mph, only 1/2 psi is required. This is also the pressure produced by a tube filled with water to a height of 12 inches! This can cause the speedometer to register around 5mph, when the boat is stopped. If this
5-12
Speedometer
occurs, first clear the speedometer tube of water. If the gauge still shows a reading higher than zero when at rest, clear the gauge by turning the ignition off for 5 seconds and then turning it on again. This will reset the gauge to zero. 3. A speedometer sensing hose can easily have sections of trapped water. If these sections are located mostly on the down side of the hose (as indicated below), the resulting pressure will prevent the gauge from returning to zero. (A hose that is twisted is more likely to contain sections of water on the down side of the hose.) Any water on the up side of the hose will lower the speed indication and counteract any pressure from water trapped in the down side of the hose.
4.
5.
A speed sensing hose containing only air will be slower responding because the air must be compressed. However, it will be more accurate because there will be no trapped water. Note that the specialized speedometers used by professional water-skiers usually have a large reservoir located in their speed sensing line to separate the water from the air and dampen the gauge action. A speedometer hose filled completely with water will react very rapidly, but weight of the water in the tube will reduce the indicated speed, especially at lower speeds.
6.

TRIM METER
REF NO 10 11 12 13 14
PART NUMBER 6Y5-83670-12-00 6Yl5-83518-00-00 6Y5-83536-00-00 6Y5-83577-00-00 688-83664-00-00
DESCRIPTION Trim Meter Assy Bulb (12V-1.7W, T6.5) Socket, Meter Plate, Fitting Damper
QTY. 1 1 1 1 1
Component parts
For model year 2001, Yamaha has introduced a new OEM standard 2-wire trim sender on all power trim and tilt engines. We have pointed out the changes that will take place to accomodate the new trim senders below. For 2001, the new Pro Series trim gauge part number is 6Y5-83670-12-00.
The multifunction tachometer factory settings will be changed. The gauge has not changed. If you have 2000 rigging kits in stock, you will only need to change the dip switch settings accordingly.
When adjusting the trim sender and the gauge is very erratic, verify the dip switch settings. If you have the wrong setting for either 2 or 3 wire senders, the trim bars will not operate normally.
5-13

Trim Meter Installation
Trim Meter
Mounting 1. Select a mounting location so the meter is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter. Make a 2-1/6 in. hole in the desired location.
2.
3.
Remove the fitting plate from the meter, fit the meter into the panel, and install over the mounting studs. Place the washers over the studs, and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand.
4.
5-14

Trim Meter Sender Adjustment
Checking Adjusting
Trim Meter
1.
1.
When checking the trim sender, connect the lead wires of the trim sender and move the lever up and down. The trim sender needle should point to the UP position when the level is set to B and the DOWN position when set to A.
For a down position adjustment, loosen the trim sender screws and make an adjustment so the needle aligns with the marking line indicating DOWN.
2.
The trim sender lever position (angle) and the trim meter needle relate as shown in the previous illustration. They should be adjusted so the needle aligns with the marking line indicating DOWN. If this adjustment is made with the needle below the line, the engine cannot be trimmed up as required.
NOTE: Install the trim meter so it tilts 50 to 80. Also, avoid placing any strong magnet or magnetized object near the trim sender.
NOTE: To adjust the trim sender bracket position, loosen the bolts and turn the bracket on pivot J and tighten the bolts. The bolt positions will be changed from G to G' and from H to H'.
Additional Parts Required
Part Number 6R3-83672-01-00 97885-06016-00 6Y5-83553-00-00 1E6-82151-00-00 6R3-82553-10-00 6R3-82553-30-00 6R3-82553-57-00 6R3-82553-70-00 6R3-82553-80-00 6R3-82553-90-00 90465-11M10-00 Description Trim Sender Pan Head Screw Lead Wire Fuse (10A) Wire Lead Extension Wire Lead Extension Wire Lead Extension Wire Lead Extension Wire Lead Extension Wire Lead Extension Clamp Qty 1 1 1 1 1 1 1 1 1 1 3
5-15

WATER PRESSURE GAUGE The water pressure gauge provides a warning for the boat operator when there is a problem with the cooling system. Problems can be discovered before extensive engine damage occurs. On high performance applications where the engine is mounted in an elevated position, it is highly recommended that the water pressure gauge be used. While operating, the water pressure must not drop below 11 psi during full throttle operation. The Yamaha Water Pressure Gauge uses a sensor installed on the motor, which is connected to the gauge by a hose. NOTE: For all 30hp~90hp applications, the same sender mounting hole is used for either the water temperature gauge or the water pressure gauge. Both gauges cannot be used together on one engine. However, on V4~V6 units, it is possible to use both gauges with one engine.
Part Number Model Application
NOTE: The operating water pressure of the P60, C60, & 70hp is lower than other applicable models. Therefore, the water pressure gauge should not be used on this model.
Additional Parts Required Part Number Model Application Qty
6Y5-83660-10-00
F25~250 (Except P60, C60, & 70hp)
NOTE: There is now available an aftermarket water pressure gauge fitting (P/N: MARWPRES-AD-TR).
688-83667-00-00 Sender/ Hose 90601-31402-00 Nylon Clip 14 97780-40116-00 Panhead Tapping Screw
1 As Needed As Needed
NOTE: The nut with a ferrule for the water pressure hose is 663-83668-00-00.
REF NO PART NUMBER 26 27 6Y5-83518-00-00 28 29 30 31 32 33 34 35 36 6Y5-83536-00-00 688-83664-00-00 688-83665-00-00 688-83667-00-00 688-83666-00-00 663-83668-00-00 90430-14115-00 90601-31402-00 97780-40116-00
DESCRIPTION QTY. Water Pressure Meter Assy 1 Bulb, Meter (T6.5, 12V-1.7W) 1 Socket, Meter 1 Damper 1 Plate, Fitting 1 Sender 1 Tube 1 Nut, Nipple 2 Gasket 1 Clip 14 5 Screw, Tapping 5
Component parts
5-16

Installation
Water Pressure Gauge
Mounting 1 Select a mounting location so the gauge is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter and hose. Make a 2-1/6 inch diameter hole in the desired location. Remove the fitting plate from the meter, fit the meter into the panel, and install the fitting plate over the mounting studs. Place the washers over the studs, and then evenly tighten the mounting nuts until the meter can no longer be rotated by hand. NOTE: If the instrument panel has a thickness of more than 13mm (0.5 in) and it is impossible to secure the meter with the fitting plate, cut the fitting plate so the meter can be installed.
2. 3.
4.
5-17

Sender Installation 1. Remove the screw plug from the cylinder head and install the pressure sender. Be careful not to overtighten the sender. The location of the plug for each model is shown on page 5-21 & 5-22: NOTE: To install the sender on the 30hp cylinder head cover, drill a 11.5mm (0.453 in) hole, and cut threads of 14mm x 1.5mm.
CAUTION:
Water Pressure Gauge
3.
Connect the pressure sender to the water pressure meter by the tube. Clamp the tube to the hull with clips and screws so it is not flattened or kinked.
If installing a water temperature sender and a water pressure sender together on one engine: Be sure the water pressure sender is installed on the port side. If it is installed on the starboard side, the sensor tube could break or bend.
CAUTION:
Wiring 1. Connect the wires as shown:
After installing the 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.
NOTE: If an aftermarket instrument light switch is to be used, connect it as shown. Otherwise, connect the yellow and blue leads together. The instrument light will then come on when the main switch is in the ON position. Maintenance Instructions 1. If the water pressure sensor is clogged with salt or some other substance, clean it with a wire. When the boat is kept out of the water for a long time, drain the water completely out of the tube.
2.
5-18

WATER TEMPERATURE GAUGE
REF NO 10 11 12 13 14 15 16 17 18
PART NUMBER 6Y5-83518-00-00 6Y5-83536-00-00 688-83664-00-00 6Y5-83544-00-00 688-83591-00-00 90430-14115-00 663-83553-Y0-00 663-83553-A0-00
DESCRIPTION Water Temperature Assy Bulb, Meter Socket, Meter Damper Plate, Fitting Thermo Unit Gasket Wire, Lead Wire, Lead
QTY. 1 1 1 1 1 1 1 1 1
Component parts
The water temperature gauge uses a sensor on the cylinder head to indicate the temperature of the cooling water inside the powerhead. The meter has a red zone to indicate overheating so problems can be corrected before severe engine damage occurs. NOTE: For all 30hp~90hp applications, the same sender mounting hole is used for either the water temperature gauge or the water pressure gauge. Both gauges cannot be used together on one engine. However, on V4~V6 units, it is possible to use both gauges with one engine.
Part Number Model Application Additional Parts Required Part Number Model Application Qty
6Y5-83590-00-00
F25~250
NOTE: The 30hp requires drilling and tapping the cylinder head for sensor installation.
CAUTION:
688-83591-00-00 Thermo Unit (23 Ft) 90430-14115-00 Gasket
1 1
If the needle rises above the shaded area, the engine is in danger of overheating. Slow down the engine to the specified trolling speed.
5-19

Installation
Water Temperature Gauge
Mounting 1. Select a mounting location so the gauge is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter. 2. Make a 2-1/6 inch diameter hole in the desired location.
3. Remove the fitting plate from the meter, fit the meter into the panel, and install the fitting plate over the mounting studs. 4. Place the washers over the studs, then evenly tighten the mounting nuts until the meter can no longer be rotated by hand.
5-20

Wiring 1. Connect the wiring as shown using the appropriate lead wire.
Water Temperature Gauge
NOTE: If an instrument light switch is to be used, connect it as shown. Otherwise, connect the yellow and blue leads together. The instrument light will then come on when the main switch is in the ON position. 2. After installation, connect the power and check the operation of the instrument light.
CAUTION:
NOTE: When testing the thermosensor, set at 900~1000 at room temperature.
If the needle rises above the shaded area, the engine is in danger of overheating. Slow down the engine to the specified trolling speed.
5-21

Water Pressure/Temperature Sender Installation 1. Remove the screw plug from the cylinder head and install the temperature sender (on water pressure sender). Be sure not to overtighten the sender. The location of the plug for each model is shown below:
Water Pressure/Temperature Sender Installation
NOTE: Aftermarket water pressure gauge adapter (P/N: MAR-WPRES-AD-TR)
NOTE: To install the sender on the 30hp cylinder head cover, drill a 11.5mm (0.453 in) hole, and cut threads of 14mm x 1.5mm.
C60, C70, 70HP
5-22

CAUTION:
Water Pressure/Temperature Sender Installation
If installing a water temperature sender and a water pressure sender together on one engine: Be sure the water pressure sender is installed on the port side. If it is installed on the starboard side, the sensor tube could break or bend.
FOR WATER PRESSURE SENSOR
F40, F50, T50
V4, V6, 2.6L
CAUTION:
After installing the temperature sender, be sure to check for water leakage.
2.
Bring out the temperature sender lead wire through the bottom cowling grommet.
INSTALL SENSOR HERE
F25
5-23

VOLTMETER - (6Y5-83503-00-00)
REF NO 35 36 37 38 39
PART NUMBER 6Y5-83544-00-00 688-83664-00-00 6Y5-83536-00-00 6Y5-83518-00-00
DESCRIPTION Voltmeter Assy Plate Damper Socket, Meter Bulb, Meter
QTY. 1 1 1 1 1
Component parts
The voltmeter provides information about the charging condition of the battery.
Parts Number Applicable Models
6Y5-83503-00-00
All electric remote models
NOTE: The voltmeter can be used with any engine converted to full remote operation. NOTES ABOUT VOLTAGE READINGS: Models smaller than 75hp have no voltage regulator. Extended operation or operating with a bad battery can produce 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 operation may show voltage readings around 16 volts. This is not a problem with properly maintained marine batteries. Installation
5-24

Mounting 1. Select a mounting location so the voltmeter is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter. Make a 2-1/6 inch hole in the desired location. Remove the fitting plate from the meter, fit the meter into the panel, and install over the mounting studs. Place the washers over the studs, then evenly tighten the mounting nuts until the meter can no longer be rotated by hand. Wiring 1. Connect the wires as shown:
Voltmeter
2. 3.
4.
NOTE: If an aftermarket instrument light switch is to be used, connect it as shown. Otherwise, connect the yellow and blue leads together. The instrument light will then come on when the main switch is in the ON position.
NOTE: If the instrument panel has a thickness of more than 13mm (0.5 in) and it is impossible to secure the gauge with the fitting place, cut the fitting plate so the meter can be installed.
5-25

HOUR METER KIT (6Y5-83504-11-00) For Model Year 2001, Yamaha has developed a new digital hour meter. It mounts in the same 2 1/16-diameter hole. The gauge sports the traditional Yamaha styling. Part No. 6Y5-83504-11-00
10000 Hr 1000 Hr 100 Hr 10 Hr 1 Hr 1 Min
OLD ANALOG
REF NO 16 17 18 19 20 21 22
PART NUMBER 6Y5-83504-10-00 688-83664-00-00 6Y5-83577-00-00 6Y5-83518-00-00 6Y5-83536-00-00 663-83553-A0-00 663-83553-Y0-00
DESCRIPTION Hour Meter Assy Damper Plate, Fitting Bulb (12V-1.7W,T6.5) Socket, Meter Wire, Lead Wire, Lead
QTY. 1 1 1 1 1 1 1
Component parts
The hour meter provides the operator with useful at-a-glance information. It monitors the number of hours a motor has been used since original installation. Also, the meter allows the operator to keep track of the number of hours the motor was used on one day, and even how much time is required to reach a given destination. The Yamaha Hour Meter has been designed for use with electric start motors and is easy to install. Installation
5-26

Mounting 1. Select a mounting location so the hour meter is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the meter. 2. Make a 2-1/6 inch hole in the desired location. 3. Remove the fitting plate from the meter, fit the meter into the panel, and install over the mounting studs. 4. Place the washers over the studs, then evenly tighten the mounting nuts until the meter can no longer be rotated by hand. NOTE: If the instrument panel has a thickness of more than 13mm (0.5 in) and it is impossible to secure the meter with the fitting plate, cut the fitting plate so the meter can be installed. Wiring
Hour Meter Kit
Connect the wires as shown: Counting time while engine is running.
Counting time while main switch is ON.
5-27

FUEL GAUGE (Pro-Type) - (6Y5-85750-10-00)
REF NO 28 29 30 31 32 33 34
PART NUMBER 6Y5l-83518-00-00 6Y5-83536-00-00 688-83664-00-00 6Y5-83544-00-00 95303-04600-00 92990-04100-0
DESCRIPTION Fuel Meter Assy Bulb, Meter Socket, Meter Damper Plate, Fitting Nut Washer, Spring
QTY. 1 1 1 1 1 2 2
Component parts
The fuel gauge indicates the amount of fuel remaining in the fuel tank. This information will help the boater estimate the amount of cruising time available before refueling. The Yamaha Fuel Gauge can be used from the helm by installing an aftermarket fuel tank sensor and making connection to the battery, or by using the existing A.B.Y.C. sender (with a resistance of 30~240) found in most permanently installed tanks.
Parts Number Applicable Models
6Y5-85750-10-00
All boats w/built-in tank
Installation
5-28

Mounting 1. Select a mounting location so the fuel gauge is easy to read from the helm. Be sure there is sufficient clearance behind the panel for the gauge. Make a 2-1/6 inch hole in the desired location.
WHT
Fuel Gauge
Wiring 1. Connect the wires as shown:
2. 3.
Remove the fitting plate from the gauge, fit the gauge into the panel, and install over the mounting studs. Place the washers over the studs, then evenly tighten the mounting nuts until the gauge can no longer be rotated by hand.
4.
NOTE: If the instrument panel has a thickness of more than 13mm (0.5 in) and it is impossible to secure the gauge with the fitting plate, cut the fitting plate so the meter can be installed.
NOTE: If an instrument light switch is to be used, connect it as shown. Otherwise, connect the yellow and blue leads together. The instrument light will then come on when the main switch is in the ON position.
5-29

FUEL MANAGEMENT GAUGE (Input for MPG from GPS or Multifunction Speedometer) The fuel management gauge can receive data from either a GPS or the multifunction speedometer. It cannot be hooked to both. This option has been available since 1998. The same signal lead part #6Y5-87122-S0-00 is used for either application. If you are using input from the multifunction speedometer no modification is required to the lead. If you are using the GPS for the input signal, modification will be required which is explained below.
Indication +3% +2% +1% 0% -1% -2% -3% -4% l/h (liters) Gph(gallon) Speedometer GPS
Modification Procedure 1. 2. Cut off three prong connector. Remove the black plug and install it on the speedometer to plug the hole in the back of the gauge. The white wire is the signal lead which needs to be connected to the NMEA 0183 output lead of the GPS unit.
3.
NOTE: All GPS units utilize different harnesses, terminals and color codes on the output signal. Always connect the white wire to whatever the GPS manufacturer recommends. Do Not Use Red and Black wires. Try and keep the wire length to a minimum. Long lengths could affect the operation of the system. If the cable length needs extending, use coaxial cable.
3-PRONG CONNECTOR
6Y5-87122-S0-00
RED
BLACK PLUG
BLACK
5-30

Fuel Management Gauge V4-V6 Only
FUEL MANAGEMENT GAUGE ASSEMBLY SYSTEM Part Number Description
Fuel Management Gauge
Remarks
6Y5-W0088-53-00 6Y5-W0088-64-00
Parts Identification Part Number
Single F/M Kit Dual F/M Kit
Single Engine Dual Engine
Description
Remarks
6Y5-83500-F2-00* 6Y5-83553-F1-00 6Y5-85752-01-00 703-82531-00-00 90465-13H39-00 95480-06363-00
Meter Assembly Extension, Wire Lead Fuel Sender Extension, Wire Lead Clamp Screw
1 1 2 (1 in Single Kit) 1 4 (2 in Single Kit) 4 (2 in Single Kit)
Kit Contents:
* F.M. Meter to Sender Harness included with fuel management kits is -F1 8m long. For replacement F0 5m must be used with extensions. (F0 and F1 are in Parts stock.)
Optional Parts Part Number Description Dual Engine Kit:
6X1-82531-00-00 MAR-24560-00-00 MAR-24564-00-00 MAR-24563-00-00 MAR-10171-30-00
Extension, Wire Lead (fuel flow sensor, 9.8 ft. [3M]) Fuel/Water Separator, complete assembly w/sensor Filter w/bowl and sensor Filter Only Sensor Only
5-31

Installation Gauge Location Pick a location in the dash for the fuel management gauge. Make sure the gauge will not be more than 10 inches from the speedometer if the speedometer will be used for MPG calculation. A sample gauge layout is illustrated.
For each gauge: 1. Cut a 3-3/8 inch diameter hole in the dash panel. A paper pattern is printed on this page. 2. 3 Connect the wiring harness to the meter through the hole. Attach the fitting plate to the meter, then evenly tighten the mounting nuts.
In order for the Miles-per-gallon function of this system to operate, it is necessary to connect the 4pin round connector of the management gauge to the receiving connector of the new style multifunction speedometer or GPS. They must be connected to the same power source. The maximum reach of these connector harnesses combined is 10 inches when speedo is used. No extensions should be used, or the gauge can malfunction because of electronic interference from radios or other devices. Gauge Installation Install the instruments in the dashboard. If no dashboard is available, install them in a place protected from water spray.
WARNING
Disconnect the battery leads before installing or disconnecting electrical components. Otherwise, you could be shocked or an electrical short could cause a fire.
5-32

Sensor Placement & Installation 1. Locate the sensor after the filter and before the primer bulb (if equipped) or engine.
FUEL FLOW SENSOR LOCATION
PRIMER BULB FILTER ON/OFF FUEL VALVE OR ANTI-SYPHON VALVE FLOW SENSOR
2.
Place the sensor with the UP mark facing upward.
3. 4.
Use a fuel joint that has a 3/8 inch diameter or larger hose nipple. Secure all fuel hose ends with a good quality stainless hose clamp. These are not supplied.
NOTE: Make sure the sensor is mounted so the fuel flows in the right direction.
SEAL THREADS WITH TEFLON TAPE OR EQUIVALENT
Rigging Notes: A. Make sure to install the fuel flow sensor between the engine and the fuel filter (refer to the illustration). B. On twin-engine installations, make sure the multifunction speedometer, fuel management gauge, and GPS are connected to the same key on power source. C. If a fuel primer is used, install it between the fuel sensor and the engine. All connections should be tight and all lines free of air. Any air leakage in the fuel tank pickup or sensor lines and connections will cause incorrect readings. D. If the fuel line is used for a kicker supply, make sure to install a shut-off valve in line or sensor ventilation could occur.
5-33

Twin Engine Fuel Management Gauge The fuel management gauge operates only on one engine of a twin engine installation. No wiring is connected to the second ignition source. The fuel management gauge and speedometer must be connected to one common power source. The power source must be supplied by one ignition switch.
NOTE: The following part numbers are shown on page 3-39 in the 1999 Outboard Rigging Guide. They can be ordered from Kent-Moore at 1-(800)-345-2233.
* * * *
* *
5-34

Wiring 1. The green and green/white wires on the fuel management gauge are for engine synchronization and are connected to the tachometer(s). On single engine installations, the green/white wire will not be used. The black and white/red wires on the flow sensor harness are for the optional fuel/water separator warning.
G/W = (Green/White) To the G (Green) wire from the PORT Multifunction Tachometer (on twin-engine installations) B = (Black) Connect both black wires to a good ground L = (Blue) Connect to the (Blue) wire from the multifunction speedometer light circuit Y = (Yellow) Connect this wire and the (Yellow) wire to the multifunction speedometer to the same KEY ON POWER source. NOTE: Be sure that both the fuel management system and speedometer yellow wires are connected to the same power source and are activated at the same time. 3. Connect the 3-wire plug at the sensor side of the harness to the sensor. The GREEN taped lead will attach to this starboard flow sensor. In the case of twin-engine applications, the RED taped lead will attach to the port sensor.
2.
Rigging Notes: Refer to the wiring diagram on the following page for proper wire connections. 1. Connect the 6-pin extension harness to the matching connector on the back of the Management Gauge. 2. Now connect the following wires: R - (Red) 12 volt POSITIVE Battery source G = (Green) To the G (Green) wire from the Multifunction STBD Tachometer
5-35

2001 HPDI Water Detection Switch The HPDI engines were introduced with a new warning feature. The engines come standard with water detection switch mounted on the engine. When water is present the switch will activate and the alarm will sound along with a reduction of engine rpms. A harness, Part No. 68F-83553-00-00, has been developed that allows for a visual warning. This harness is connected to the Fuel Management Gauge. It will activate the current water in fuel symbol present on that gauge.
This harness comes standard in the engine crate on all left-hand rotation HPDI engines. The wire diagrams are as follows: This harness will work on either a single engine application or twins. The harness will plug into the white/red wire that is located on the starboard side of the engine harness. Remove the cap and plug in the black connector from the harness.
Run the harness through the rigging grommet. The bullet connectors will plug inline with the fuel management harness. They will connect with the sensor wires that are provided in the harness for the water detection sensors that are optional for the water/fuel separating filters. (Part No. MAR-10171-30-0).
5-36

The diagram below shows the recommended wiring for the water detection harness without using the optional water/fuel filter sensors.
The diagram below shows the recommended wiring with the use of the optional water/fuel filter sensors.
NOTE: If the boat is wired as above and the boat water/fuel-separating filter detects water, only the visual warning will activate on the Fuel Management gauge. Only the water detection switch on the engine will activate the alarm and rpm reduction.
5-37

NOTE: Make sure all gauges are connected to the same KEY ON power source. * Use these connectors only on twin-engine installations. ** Optional fuel/water separator w/filter and sensor (Part Number: MAR-24560-00-00).
5-38

Digital Fuel Management Gauge Notes on Fuel Consumption: 1. Fuel consumption will vary greatly with boat design, weight, propeller used, engine trim angle, sea conditions (including wind), and throttle position. Fuel consumption will also vary slightly with the type of water (salt, fresh, and contaminate levels), air temperature and humidity, cleanliness of the boat bottom, engine mounting height, skill of the operator, and individual gasoline formulation (winter or summer fuel and amount of additives). The Yamaha Digital Speedometer and Fuel Management Meter calculates speed, miles traveled, and fuel economy by water movement at the stern of the boat. This distance can vary greatly from the actual distance traveled because of water currents, sea swells, and the condition of the water speed sensor (partially plugged or damaged). Individual engines may vary slightly in their fuel consumption because of manufacturing variations. These variations can be even greater if the engines are of different year models. In addition, variations in propellers, even of the same basic dimensions of the same design, can cause a slight variation in fuel consumption.
Fuel Management Gauge Operation Instructions The Yamaha Fuel Management Gauge System consists of a fuel flow meter, fuel consumption meter, fuel economy meter, twin engine speed synchronizer for dual installations, and an optional water separator warning indicator that detects water in the fuel filter.
2.
Meter Self-Check Function After the main switch is first turned on, all portions of the meter come on a check. After a few seconds, the meter will change to normal operation. Watch the meter when turning on the main switch to make sure all segments are activated.
3.
5-39

Fuel Flow Meter The meter displays fuel flow within one hour, at the rate of current engine operation. If two engines are installed on the boat, the meter will display total fuel flow of both port and starboard engines. It also displays PS indication at the same time. By pressing the Set button, the meter will display fuel flow for the Starboard engine and indicate S. By pressing the Set button again, the meter will display the fuel flow for the Port engine and indicate this with a P showing. By pressing the Set button again, the meter will return to the total fuel flow indication (PS). NOTE: The meter displays gallon/hour and liter/hour depending upon operator preference. Select the desired unit of measurement by setting the selector switch on the back of the meter during installation. The fuel consumption meter and fuel economy meter will display the same unit of measurement.
FUEL FLOW METER
NOTE: The fuel consumption is kept in memory by battery power. The stored data will be lost if the battery is disconnected.
FUEL CONSUMPTION METER
Fuel Economy Push and release the Mode button until the indicator on the face of the meter points to ECON. The meter will display the distance per liter or gallon for the operator's reference when cruising. NOTE: If dual-engines are installed on the boat, the meter will display only the total fuel economy of both engines.
Fuel Consumption Meter Push and release the Mode button until the indicator on the face of the meter points to total (TTL). The meter will display the total amount of fuel consumed after the meter was last reset. To reset the total fuel consumption to 0, press the Set and Mode buttons together.
5-40

Twin-engine Speed Synchronization Push and release the Mode button until the indicator on the face of the gauge points to SYNC. The meter will display the difference of engine speed (RPM) between the Port and Starboard engines for reference for synchronizing the two engines' speeds.
Water Separator Warning Indication NOTE: This indicator operates only when an optional water separator with sensor has been installed. If the water which has been separated from the fuel in the water trap exceeds a specific volume, the indicator will blink to signal the water should be drained or the filter changed.
1.
2. 3. 4. 5.
1. Port side engine speed is higher. 2. Port side engine speed is slightly higher. 3. Engine speed is synchronized evenly between Port and Starboard engines. 4. Starboard engine speed is slightly higher. 5. Starboard engine speed is higher. NOTE: If the two engine speeds are not synchronized while cruising, they can be synchronized by adjusting the trim angle or throttle position.
5-41

Fuel Management Meter 1. Remove the cap on the back of the gauge 1. 2. Selector switch 2 (for fuel measurement). The meter displays gallons/hour and liter/hour depending on operator preference. Select the desired unit of measurement by setting the selector switch on the back of the meter. NOTE: The fuel consumption meter and fuel economy meter will indicate the same unit of measurement. The selector switch 3 controls input supply from the seperator or GPS. 1. Calibration Fuel Management Meter Calibration 2. 3. 4.
Remove the cap 1 to access the switches. The fuel management switch 2 can be set to either gallons per hour (gph) or liters per hour (1/h). NOTE: The fuel consumption meter and fuel economy meter will always indicate the same unit of measurement. 3. Selector switches 4 (for fuel flow calibration). If the amount of fuel consumed differs from that indicated on the meter, it can be calibrated to the correct amount. If the amount of fuel used differs from what is indicated on the meter, calibrate it to the correct amount by: Fill the tank and operate the boat. Use about 75% of the fuel in the tank. Refill the tank and record the amount used: Compare the actual amount of fuel used with the gauge reading. If there is a difference, use the formula below to figure the difference as a percentage. Refer to the illustration and adjust the switches to calibrate the gauges.
Example: Actual Amount of Fuel Used: Fuel Management Gauge Indicates Difference = 1:00 gallon / 50 gallons = 0.02 or 2% Therefore, 1 gallon is 2% of the actual 50 gallons used. To calibrate the gauge, set the switches for 2% (because the gauge was showing more fuel than was actually used). If the gauge was showing less fuel than was used, the switches would then be set for a + percentage. 50 gallons 51 gallons +1 gallon
5-42

SECTION 6 TILLER HANDLE KITS T9.9 Remote Tiller Rigging Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-1 F15 Tiller Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-6 F25 Tiller Handle Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-10 30HP Tiller 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 60, C60, C70, 70HP Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . 6-40 C90 & 90HP Tiller Handle, Steering Friction Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-48 F30/F40 Tiller Handle, Steering Friction - Installation Manual . . . . . . . . . . . . . . . . . . 6A F80, F100 Tiller Handle, Steering Friction - Installation Manual . . . . . . . . . . . . . . . . 6B F80, F100 Tiller Handle, Steering Friction - Owner s Manual . . . . . . . . . . . . . . . . . . 6C

T9.9 REMOTE TILLER RIGGING KIT (6G8-W4831-01-00)
REF NO 1 2 3 4 5 6 PART NUMBER 6G8-48311-11-00 6G8-48321-10-00 90445-20ME5-00 6G8-82550-10-00 DESCRIPTION QTY. Remote Tiller Rigging Kit 1 Cable 1 Cable 1 Damper 1 Stop Switch Assy 1 Grommet
Component parts
NOTE: This kit is intended to be used only with the 2m (6.6 ft) cables provided. The steering handle on the T9.9 models can be removed from the motor and used as a remote control unit for the throttle, shifter, and the stop switch. The remote tiller rigging kit provides the necessary cables, hose (cable sheath), and stop switch assembly to relocate the steering handle. Removal 1. Remove the screw holding the CDI cover, then remove the CDI cover.
2.
Remove the stop switch leads (white and black).
3.
Disconnect the throttle control and shift control cables.
6-1

4. To remove the bracket on the control panel that holds the control cables, remove the two screws (with washer), fitting plate, and then the bracket. Also, remove the emergency stop switch. 6.
T9.9 Remote Tiller Rigging Kit
Remove the wave washer, the washer, and the steering handle assembly. To remove the cables from the ring nut, route the cable ends through the slit in the ring nut. Remove the bushing.
5.
To remove the tiller handle, remove the ring nut as follows: Turn the 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. 7. Unbolt the steering handle 2 from steering handle 1 as shown below.
NOTE: This procedure may need to be repeated several times for the ring nut to come off.
6-2

8. Remove the rubber steering grip. Remove the screw in the end of the handle, and along with the plastic and steel washers, the compression spring. Also, remove the steering grip friction piece and the steering grip.
10. Remove the bolt, washer, shift arm, wave washer, cotter pin, washer, and the detent roller as shown. Disconnect the shift cable, throttle cable, and stop switch.
NOTE: To remove the steering grip, turn it to the left and pull it out of the steering handle.
Installation 9. Remove the two screws holding the two halves of the steering handle together. 1. Install the new stop switch in the steering handle and tighten the nut. Tightening Torque: 0.4m-kg (2.9 ft-lbs)
6-3

2. Install the new throttle cable, being sure to fit the inner cable end in the groove and the outer cable end into the hole as shown. Also, install the new shift cable, the detent roller, the washer and the cotter pin on the shift arm.
S T E E R A I NN GD H L E (L E F T ) 2
5.
Reinstall the components of the steering handle grip. Reinstall the handle grip, the friction piece, the compression spring, the steel washer, the plastic washer, and the screw. Reinstall the rubber steering handle grip. Pass the shift cable, throttle cable, and stop switch leads through the vinyl hose (sheath). Install the new cables and switch lead in the bracket on the control panel. Reinstall the fitting plate with the screws. Put the grommet in the hole left by the emergency stop switch.
6. 7.
W A V E
W A S H E R B O L T
S H IF T N U T
A R M
W A S H E R
T H R O T T L E C A B L E
S H IF T
C A B L E
3.
Put the wave washer in place, then reinstall the shift arm (with cable attached) on the steering handle with the bolt. Be sure to align the shift lever shaft end with the hole in the shift arm. Fit the shift arm detent roller to the N position of the detent spring.
S T O P S W IT C H
B R A C K E T L E A D
7 S C R E W A N D W A S H E R
NOTE: Be sure to put the nut in place for the steering handle grip before continuing.
F IT T IN G P L A T E
4.
Reinstall the other half of the steering handle. Make sure the inner and outer cables of both the throttle and shift control cables are properly in place. Verify proper movement of the shift lever once the handle has been reassembled.
6-4

8. Install the cable ends on the cables. Screw the end of the cable into the cable joint a minimum of 8mm (0.3mm) and lock it with the lock nut.
S H IF T C A B L E
Installing the Control Handle 1. Select a location near the steering wheel or tiller handle for the control handle. Be sure there will be easy access to the stop switch and shift lever, and that the throttle operation will not be hindered. Install the control handle using a strong bracket which will firmly hold the handle in place.
2.
WARNING
I f the cable is not screwed in at least 8mm, the cable joint could break. T his could cause loss of control and an accident. N O TIf E the:cable end is fitted to the pin marked with R, the shift cable will not move smoothly. 9. Adjust the throttle cable end and fit it to the pin marked M on the accelerator arm. 4. 3. Route the 2m cables so they do not have any sharp bends. The minimum radius should be 16 inches. Make sure the cables are not under any strain. If the control handle is mounted on a tiller handle, care should be taken that the cables are not strained or pinched during tiller movement.
N O TDo E not : fit the cable end to the pin marked with R on the accelerator arm.
T H R O T T L E C A B L E
10. Reconnect the white and black stop switch leads (see Removal, step 2) and reinstall the CDI cover.
6-5

F15 TILLER HANDLE KIT (66M-W0084-00-4D)
REF NO PART NUMBER
F15 Tiller Handle Kit
DESCRIPTION
QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
66M-W0084-00-4D 65W-42101-00-4D 65W-42101-01-4D 90109-06M86-00 65W-42138-00-00 65W-42159-00-00 6G1-42126-00-00 65W-42125-00-00 91490-16010-00 66M-42177-00-00 66M-42119-00-00 689-42137-20-00 90269-02M09-00 90149-05M13-00 92903-10600-00 90501-23215-00 90386-08032-00 66M-26311-00-00 90446-10M87-00 90386-40MA0-00 90201-43M00-00 90206-43M22-00 90202-43M57-00 90386-40M99-00 66M-42131-00-00 66M-42131-01-00 90185-08057-00 95780-10300-00 95380-08600-00 95380-10700-00 66M-44111-00-00 97595-06530-00 90206-10M04-00 90387-06M78-00 66M-44124-00-00 92990-06200-00 90468-18008-00 6E0-44191-11-00 65W-44173-00-00 9169030320-00 65W-82575-00-00 682-82556-00-00 689-8257Y-00-00
Component parts
Handle Steering Assy Handle, Steering Handle, Steering Bolt Lever, Throttle Stay Friction, Steering Handle Grip Bolt, Friction Adjusting Pin, Cotter Rubber, Handle Grip, Steering Handle Indicator, Throttle Rivet Screw Washer, Plate Spring, Compression Bush Cable, Throttle 1 Hose Bush Washer, Plate Washer, Wave Washer, Plate Bush Cover, Handle Steering Cover, Handle Steering Nut, Self-locking Nut, Flange Nut Nut Handle, Gear Shift Bolt, With Washer Washer, Wave Collar Link, Shift Rod Washer Clip Indicator, Shift Lever, Shift Control Pin, Spring Engine Stop Switch Assy. Stopper Cap
1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
6-6

F15 Tiller Handle Kit Additional Parts Required
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 PART NUMBER 66M-42508-00-00 93700-06M03-00 66M-42527-00-00 90109-08M91-00 65W-42562-00-00 66M-42561-00-00 689-43633-00-00 90202-10M56-00 65W-42528-00-00 90209-10M26-00 90185-10M14-00 90387-05M11-00 90109-05M89-00
DESCRIPTION Steering Friction Assy. Nipple, Grease Plate, Friction Bolt Shaft, Steering Lock Knob, Steering Lock cover, Tilt Lever Washer, Plate Plate, Friction Washer Nut, Self-locking Collar Bolt
QTY. 1 1 1 2 1 1 1 1 2 1 1 1 1
Component parts
6-7

STEERING HANDLE ASSY (F15) EXPLODED DIAGRAM
REMOVAL AND INSTALLATION CHART

STEP PROCEDURE/PART NAME STEERING HANDLE ASSY REMOVAL QTY. SERVICE POINTS
Follow the Step order for removal.
Flywheel magneto cover (for EH models) Manual 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 fullyopened) and then tighten the locknuts.
2 3 4 5 6
Engine Stop Switch Lead (for MH/EH models) Grommet Locknut Nut Plate
1 1 1 1
N O T E : Tighten the nut to the specified torque. Then while still holding this nut, tighten the locknut to the specified torque.
7 8
Bushing Steering Handle Assy (for MH/EH models) 6-8
1 1

STEERING HANDLE ASSY (F15)
EXPLODED DIAGRAM
STEP
PROCEDURE/PART NAME STEERING HANDLE ASSY DISASSEMBLY
QTY.
SERVICE POINTS
Follow the Step order for disassembly.
1 2 3 4 5 6 7 8 9
10 11 12 13 14 15 16 17 18
Steering Handle Assy. Manual starter (for MH models) Plastic Washer Metal Washer Wave Washer Metal Washer Bushing Steering Handle Bracket Friction Adjusting Screw Screw Steering Grip Washer Spring Bushing Bolt Plate Throttle Shaft Friction Piece Throttle Cable Engine Stop Switch 6-9
1 1 2 2 1 1 1 1 1 1 1 1 2 1 1 1 2 1
Self tapping bolt: M8
Reverse the disassembly steps for assembly

F25 TILLER HANDLE KIT (65W-W0084-01-4D)
REF NO PART NUMBER
DESCRIPTION
QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39
65W-W0084-01-4D 65W-44111-00-00 95895-06016-00 90206-f12M00-00 90201-12M34-00 65W-42123-00-00 65W-44124-00-00 92990-06200-00 90468-18008-00 6E0-44191-11-00 65W-42101-00-4D 90109-06M86-00 65W-42138-00-00 65W-42159-00-00 6G1-42126-00-00 65W-42125-00-00 91490-16010-00 6F6-42177-A0-00 664-42119-00-00 6H2-42137-00-00 6J0-42137-00-00 90269-02M09-00 90149-05M13-00 92903-10600-00 90501-23215-00 90386-08032-00 65W-26311-00-00 90446-10M86-00 90446-14M88-00 90386-40MA0-00 90201-43M00-00 90206-43M22-00 90202-43M57-00 90386-40M99-00 65W-42131-00-00 90185-08057-00 95380-08600-00 65W-42121-00-4D 65W-44173-00-00 91690-30320-00
Component parts
Handle Steering Assy Handle, Gear Shift Bolt, Flane Washer, Wave Washer, Plate Bolt, Handle Joint Link, Shift Rod Washer Clip Indicator, Shift Handle, Steering Bolt Lever, Throttle Stay Friction, Steering Handle Grip Bolt, Friction Adjusting Pin, Cotter Rubber, Handle Grip, Steering Handle Indicator, Throttle Indicator, Throttle Rivet Screw Washer, Plate Spring, Compression Bush Cable, Throttle 1 Hose Hose Bush Washer, Plate Washer, Wave Washer, Plate Bush Cover, Handle Steering Nut, Self-locking Nut Bracket Lever, Shift Control Pin, Spring
1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1
6-10

F25 Tiller Handle Kit Additional Parts Required
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14
PART NUMBER 65W-42508-00-00 65W-42527-00-00 90109-06M50-00 92990-06100-00 65W-42561-00-00 689-43633-00-00 97595-05516-00 90387-05M11-00 90185-10M14-00 65W-42562-00-00 90202-10M56-00 65W-42528-00-00 90209-10M26-00 93700-06M03-00
DESCRIPTION Steering Friction Assy. Plate, Friction Bolt Washer, Spring Knob, Steering Lock1 Cover, Tilt Lever Bolt, With Washer Collar Nut, Self-locking Shaft, Steering Lock Washer, Plate Plate, Friction Washer Nipple, Grease
QTY. 1 1 2 2 1 1 1 1 1 1 1 2 1 1
Component parts
6-11

F25 ELECTRICAL (65W-85790-00-00)
REF NO PART NUMBER
DESCRIPTION
QTY.
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30
65W-85790-00-00 65W-85757-00-00 97595-06512-00 90465-11M10-00 65W-82590-00-00 65W-82590-20-00 65W-82590-30-00 97595-06516-00 90465-08M08-00 90465-08M51-00 6N7-83557-00-00 97595-06516-00 97595-05516-00 65W-82105-00-00 6G8-82150-00-00 663-82151-00-00 6G5-82152-00-00 6H1-82563-10-00 6E5-82587-00-00 62Y-83614-00-00 90109-06M86-00 61A-81950-00-00 97575-06520-00 65W-81948-00-00 6A0-82317-00-00 624-42542-00-00 95895-06030-00 90201-12M16-00 65W-81949-00-00 682-82119-01-00 97575-06516-00 90465-11M10-00
Thermosensor Assy Retainer Bolt Clamp Wire Harness Assy Wire Harness Assy Wire Harness Assy Bolt Camp Clamp Tube Bolt Bolt, With Washer Wire Harness Fuse Holder Assy Fuse (12V-20A) Holder, Fuse Trim & Tilt Switch Assy Gasket Bracket Bolt Relay Assembly Bolt, With Washer Bracket Damper, Ignition Coil Pipe Bolt, Flange Washer, Plate Wire, Lead Cover, Lead Wire Bolt, With Washer Clamp
1 1 1 1 1 1 1 1 3 1 1 2 1 1 1 1 1 1 1 1 2 1 2 1 2 2 2 2 1 4 1 1
Component parts
6-12

F25 STEERING HANDLE EXPLODED DIAGRAM

STEP PROCEDURE/PART NAME STEERING HANDLE REMOVAL QTY. SERVICE POINTS
Flywheel magneto cover assy.
Follow the Step order for removal. Refer to FLYWHEEL MAGNETO in Chapter 5. 2 N O T E : When adjusting the Throttle Cables, make sure the throttle control cam stopper a touches the bracket stopper b (when thethrottle is fully-opened) and then tighten the locknuts.
Throttle Cable
2 3 4 5
Engine Stop Switch Lead Shift Link Rod Steering Handle Assy. Grommet
1 1 1 1
Reverse the removal steps for installation.
6-13

F25 STEERING HANDLE EXPLODED DIAGRAM

STEP PROCEDURE/PART NAME STEERING HANDLE DISASSEMBLY QTY. SERVICE POINTS
Follow the Step order for removal. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 2 1 Reverse the disassembly steps for installation 6-14
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
Shift Link Rod Shift Lever Cable Guide Bushing Plastic Washer Wave Washer Metal Washer Bushing Tiller Handle Bracket Steering Bracket Friction Piece Steering Grip Spring Bushing Throttle Shaft Friction Piece Throttle Cable Engine Stop Switch

30HP TILLER HANDLE KIT (6L2-W0084-10-4D)
REF NO PART NUMBER
30HP Tiller Handle Kit
DESCRIPTION
QTY.
2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32
6G1-42111-11-4D 6E0-44191-11-00 90206-36M21-00 90202-36M55-00 90386-33M96-00 90386-44M97-00 6G1-42131-01-00 97095-06020-00 6G1-42125-01-00 6G1-42126-00-00 91490-16010-00 664-42119-00-00 6F6-42177-A0-00 6J8-42137-00-00 90269-02M09-00 90501-23215-00 92903-10600-00 90149-05M13-00 90386-08032-00 6G1-42138-01-00 6E0-42159-02-00 97885-05012-00 6J8-26301-00-00
6J8-44111-01-4D 6J8-44125-00-00 682-44132-00-00 91690-30318-00 90386-06M12-00 6J8-44124-00-00 92990-06200-00 91490-20012-00
Component parts
Handle Steering Assy Handle, Steering Indicator, Shift Washer, Wave Washer, Plate Bush Bush Cover, Handle Steering Bolt Bolt, FrictionAdjusting Friction, Steer Hndl Grip Pin, Cotter Grip, Steering Handle Rubber, Handle Indicator, Throttle Rivet Spring, Compression Washer, Plate Screw Bush Lever, Throttle Stay Screw, Pan Head Throttle Cable Assy Handle, Gear Shift Lever Shift Rod Bushing Pin, Spring Bush Link, Shift Rod Washer Pin, Cotter
1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2
1 1 2 1 1 1 1 1
30EH Tiller Switch Kit Additional Parts Required

REF NO PART NUMBER 2 689-81870-00-00 3 6J8-42724-40-00 4 6H3-82540-00-00 5 6J8-82554-00-00 6 6H4-82553-00-00 7 97013-06012-00 8 90464-23M22-00 9 689-82575-04-00 10 6J8-82531-00-00 11 6J8-42719-20-00 12 92990-06200-00 13 91490-20012-00 14 6J8-41211-00-00 15 90501-08M66-00 16 97980-04120-00 Component parts DESCRIPTION Starting Switch Assy Grommet Neutral Switch Neutral Switch Stay Extension Wire Lead Bolt Clamp Emergency Stop Switch Wire, Lead Front Lower Panel Washer Cotter Pin Link, Accelerator Spring Screw, Pan Head QTY. 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1
6-15

30HP Tiller Handle Kit 6L2-W0084-10-4D The Yamaha tiller handle kit (optional for the 30HP, 3-cylinder) lets you steer your boat from the stern. N O T The E :30HP manually operated outboard comes equipped with a tiller handle steering system. Tiller Handle Kit Application Chart
Part Number 30HP Electric
WARNING
6J8-W0084-00-4D
O = Optional
C atch any fuel that may drain from the hose ( or carburetors when removed) in a suitable container. D o not perform this operation near an open flame, heater, or while smoking. G asoline is highly flammable and can cause serious injury to you or anything else in the surrounding area if a fire or an explosion occurs. 3. Remove the six bolts holding the carburetors to the intake manifold, and carefully remove the carburetors. The choke solenoid shaft will pull out of the choke solenoid as the carburetors are removed. If desired, the choke solenoid and shaft may both be removed as they will be no longer used. 4. Install the neutral safety switch in its bracket so, when the assembly is mounted, the button on the switch faces towards the rear. Install the switch and bracket on the bottom cowling with the two 6mm bolts. Remove the control cable cover from the front right corner of the bottom cowling, and confirm the proper location of the switch by operating the shift lever. The switch button should be pressed by the cam on the end of the shift lever only when the lever is moved to neutral. Remove the handle bracket, grommet, and control face plate from the front of the motor. Locate and install the new face plate on the front panel. Loosely install the tiller handle assembly, inserting the throttle cables and shift rod through the opening left by the grommet at the left side of the face plate. Make sure the rod and cables are in their proper channels in the grommet, then insert the grommet. Install the shift rod through the lower hole in the shift lever, and secure it with a flat washer and cotter pin. Tighten the tiller handle bolts.
5. Installation 6. 1. 2. Remove the upper cowling, flywheel cover, and carburetor air box from the motor. It will be necessary to remove the three carburetor assemblies to install the neutral safety switch. Shut off the fuel supply, and disconnect the choke rod from the lower part of the carburetor assembly. Detach the oil pump link, and disconnect the fuel line at the fuel filter. 7.
8.
6-16

9. Route the throttle cables toward the throttle cam assembly. Disconnect the links for the throttle and magneto controls.
15. Locate the new brown wire extension lead (Part Number: 6H4-82553-00-00) and connect the two wires at either end of it to the neutral safety switch. 16. Route all wires (from the left side near the panel) around the front of the bottom cowling and continue around the cowling to the right side of the motor, opposite the CDI unit. Secure these wires (along their route) with cable ties to keep them clear of moving parts in the throttle and shift linkages. 17. Reinstall the carburetors, being careful not to pinch any oil lines. Also, make sure the carburetor flange o-rings are properly seated, and connect the oil pump link, choke solenoid shaft (if retained), and the fuel line. Tighten the six mounting bolts, and install the air box. 18. Move the shift lever to the forward position. 19. Turn the throttle grip to full open (counterclockwise), and check to see that the center of the throttle roller lines up with the wideopen-throttle mark on the throttle cam. If they are not in line, loosen the lock nut on the pull throttle cable, adjust the cable adjuster until the mark lines up as shown, and retighten the lock nut.
10. Remove the throttle cam assembly, with its bracket, by removing the pivot bolt and 6mm retaining bolt. Install the throttle cables on the throttle cam assembly (the pull cable is mounted in the forward position on the assembly). Make sure the outer cables are properly attached in the cutouts of the bottom part of the bracket. 11. Remount the throttle cam assembly and bracket (setting the throttle at the idle position will make this operation easier). Tighten all bolts, and reattach the links. The throttle cables will be adjusted after the carburetors are reinstalled. 12. Locate and install the emergency stop switch through the front panel, next to the choke. 13. Remove the beauty cover from the front left corner of the bottom cowling, and install the starter switch. 14. Remove the 6mm nuts, flat washers, and clamp that secure the bracket for the wire harness grommet. Pull the battery cable through the 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.
6-17

20. Loosen the lock nut on the push throttle cable, adjust the cable adjuster until there is 3mm (0.12 in) slack in the inner cable (as shown), and retighten the lock nut.
21. Remove the terminal cover (spare fuse is attached), disconnect the main harness (complete with plug), and remove it and the old grommet from the motor. N O TIt E will : be easier if you disconnect the various wires as you are ready to install the new ones as instructed below.
T H E R M O S W IT C H
Do not tighten the bolts that retain the black ground wires until the next instruction. 22. Locate the new pink/black wire lead set (Part Number: 6J8-82531-00-00), and 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 remaining to be connected near the CDI box. Connect the pink wire leading from the CDI box* and the pink lead that goes to the oil level gauge (tank switch) and oil warning light* to the pink T leads. Connect the single black (ground) male butt connector lead to the black thermoswitch wire. Install one of the black leads with the ring terminal under the appropriate cylinder head bolt*, and tighten the bolt to specification (1st torque 1.5kg-cm [11 ft-lb.]); 2nd torque - 2.8kg-m [20 ft-lb.]), Install the other ring-terminal black lead under the head of the ground bolt that is located behind the terminal cover. *The same color wire lead in the harness you removed in step 21 was disconnected at this point.
6-18

23. Hook up the starter switch by connecting its brown lead to one of the brown leads from the neutral safety switch (connect them where they meet at the terminal cover area). Connect its red lead to connector at the junction of the red leads from the rectifier and fuse holder.* Connect the other brown lead from the neutral safety switch to the lead from the starter solenoid.* When these leads are properly installed, the engine should start only when the shift lever is in neutral. *The same color wire lead in the harness you removed in step 21 was disconnected at this point. 24. Connect the white lead from the emergency stop switch to the white wire from the CDI box.* Make sure all ground (black) wires are beneath the appropriate bolt under the terminal cover,* and tighten the bolt. *The same color wire lead in the harness you removed in step 21 was disconnected at this point.
N O TThe E blue : choke solenoid lead is no longer used and should be secured away from all moving parts. In addition, a replacement for the green wire from the lighting coil to the plug in the original harness is not necessary. One of the pink wires (from the thermoswitch to harness plug) is eliminated, as well (See schematic below). 25. Verify that all wires are properly connected, and reinstall the terminal cover. 26. Reinstall the control cable, flywheel covers, and the upper cowling. 27. Test all functions of the tiller handle (under operating conditions) to make sure they operate properly. 28. Collect and return all removed and unused parts to the customer for possible later use.
6-19
Steer. Friction Kit F30/F40 Tiller Handle
STEERING FRICTION KIT (67C-W0084-00-4D) F30/F40 TILLER HANDLE
6-20
Steer. Friction Kit F30/F40 Tiller Handle
STEERING FRICTION KIT (67C-W0084-00-4D) F30/F40 TILLER HANDLE [Contd.]

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 PART NUMBER 67C-W0084-4D-00 67C-42121-00-04D 90101-12M09-00 92990-12200-00 90206-12M22-00 90387-12M02-00 90386-12M93-00 92990-12600-00 90185-12M12-00 67G-42111-00-4D 67C-44100-00-00 67C-44104-00-00 67G-48261-00-00 67C-42115-00-00 650-42152-00-94 91690-30025-00 67G-42159-00-00 67C-44113-00-00 63D-48236-00-00 67C-48119-00-00 67G-42153-00-00 67G-44132-00-00 63D-48237-00-00 98785-05014-00 63D-48238-00-00 97095-06030-00 92995-06600-00 97095-06014-00 92995-06600-00 67G-48531-00-00 97095-06014-00 67C-48321-00-00 90468-10005-00 66R-48538-00-00 97095-06014-00 DESCRIPTION Handle Steering Assy Bracket Bolt Washer, Plain Washer, Wave Collar Bush Washer, Plate Nut, Self-Locking Handle, Steering Shift Link Assy . Plate Comp. . Arm Throttle . Shaft, Steering Handle . . Gear . . Pin, Spring . . Stay . Cam Plate, Handle . Roller, Detent . Cover . Shaft, Throttle Control . Bushing . Adaptor . Screw, Flat Hed . Spring, Detent Bolt Washer Bolt Washer Bracket, Remote Control 1 Bolt Cable Clip Clamp, Cable 1 Bolt QTY. 1 1 1 2 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 2 1 1 1 1 1 1 1 1 REF NO 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 PART NUMBER 67C-26301-00-00 63D-48538-00-00 90468-10005-00 67G-44159-00-4D 90386-26MA3-00 97095-08040-00 92995-08600-00 67G-44173-00-00 90159-06M18-00 6G8-44191-00-00 67G-42131-00-00 97885-06016-00 92995-06600-00 97885-06040-00 92995-06600-00 63D-42725-00-00 63D-42126-00-00 63D-48154-00-00+ 95380-06600-00 91490-20010-00 664-42119-00-00 6J0-42137-00-00 90269-02M09-00 6G1-42177-00-00 90386-08032-00 90501-23215-00 92903-10600-00 90149-05M13-00 DESCRIPTION QTY. Throttle Cable Assy 1 Clamp, Cable 1 1 Clip 1 Handle, gear shift 1 Bush 1 Bolt 1 Washer 1 Lever, Shift Control 1 Screw, with Washer 2 Indicator, Shift 1 Cover, Handle Steering 1 Screw, Pan Head 5 Washer 5 Screw, Pan Head 2 Washer 2 Grommet 1 Friction, Steering Handle Grip 1 Knob, Throttle 1 Nut, Hexagon 1 Pin, Cotter 1 Grip,. Steering Handle 1 Indicator, Throttle 1 Rivet 1 Rubber, Handle 1 Bush 1 Spring, Compression 1 Washer, Plate 1 Screw 1
Component parts
6-21
Outboard Rigging Guide - 2001 Steer. Friction Kit 40, C40, 50, C50 Tiller Handle
STEERING FRICTION KIT (63D-42508-00-00) 40, C40, 50, C50 TILLER HANDLE (63D-W0086-Z0-4D)
6-22
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) [Contd.]
REF NO PART NUMBER 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 63D-42121-00-4D 63D-42111-01-4D 6H2-42137-00-00 6K5-42137-00-00 90269-02M09-00 63D-44100-11-00 63D-44104-00-00 63D-48261-00-00 63D-42115-00-00 650-42152-00-94 91690-30025-00 63D-42159-00-00 98580-06016-00 99001-08600-00 63D-44113-00-00 63D-48236-00-00 63D-48119-00-00 63D-42153-00-00 63D-44132-00-00 63D-48118-00-00 63D-48237-00-00 98780-05014-00 63D-48238-00-00 63D-42181-00-00 63D-44114-00-00 97095-06016-00 92990-06600-00 63D-42725-00-00 62Y-48321-00-00 62Y-26301-00-00 90101-12M09-00 92990-12200-00 63D-48531-00-00 63D-48538-00-00 90464-09M42-00 97095-06016-00 92990-06600-00 90386-12M93-00 90386-29M95-00 92990-12600-00 90206-12M22-00 90185-12058-00 90387-12M02-00 63D-42126-00-00 63D-48154-00-00 95380-06600-00 91490-20015-00 6G8-44191-00-00 90202-24M53-00 97395-08040-00 92990-08600-00 63Dl-44159-01-00 90159-06M18-00 63D-44173-00-00 664-42119-00-00 REF NO 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110
DESCRIPTION QTY. Handle Steering Assy 1 Bracket 1 Handle, Steering 1 Indicator, Throttle 1 Indicator, Throttle 1 Rivet 1 Shift Link Assy 1 Plate Comp. 1 Arm, Throttle 1 Shaft, Steering Handle 1 Gear 1 Pin, Spring 1 Stay 1 Screw, Pan Head 2 Circlip 1 Cam Plate, Handle 1 Roller, Detent 1 Cover 1 Shaft, Throttle Control 1 Bushing 1 Clip, Shift Lever 1 Adaptor 1 Screw, Flat Head 2 Spring, Detent 1 Washer 2 Stopper 1 Bolt 4 Washer, Plate 4 Grommet 1 Cable 1 Throttle Cable Assy 1 Bolt 1 Washer, Plain 1 Bracket, Remote Control 1 Clamp, Cable 1 2 Clamp 1 Bolt 2 Washer, Plate 2 Bush 2 Bush 1 Washer, Plate 1 Washer, Wave 1 Nut, Self-locking 1 Collar 1 Friction, Steer Handle Grip 1 Knob, Throttle 1 Nut 1 Pin, Cotter 1 Indicator, Shift 1 Washer, Plate 1 Bolt (97095-08040-00) 1 Washer, plate 1 Handle, Gear Shift 1 Screw, with Washer 2 Lever, Shift Control 1 Grip, Steering Handle 1
PART NUMBER 6G1-42177-00-00 90149-05M13-00 92990-10600-00 90501-23215-00 90386-08032-00 93430-04M03-00 63D-42131-10-00 90480-14M14-00 97885-06016-00 92990-06600-00 97885-06040-00 92990-06600-00 6H5-82510-00-00 63D-82575-00-00 6K5-82575-02-00 682-82556-00-00 689-8257Y-00-00 97095-06025-00 92995-06100-00 63D-8252F-01-4D 63D-8252E-01-4D 97095-06030-00 92990-06600-00 63D-24367-00-00 63D-24364-00-00 97095-06020-00 92995-06100-00 97885-06012-00 90465-13M36-00 688-82540-11-00 63D-82554-00-00 663-82555-01-00 63D-82586-00-00 63D-82563-00-00 92995-06600-00 97885-06016-00 63D-42527-00-00 63D-42546-00-00 63D-42541-00-00 90201-08M01-00 92995-08600-00 97395-08050-00 63D-42526-00-00 63D-42528-00-00 63D-42562-00-00 90185-10M01-00 63D-42561-00-00 682-43318-01-00 97095-06016-00 92995-06100-00 90464-15M11-00 688-83383-11-00 6H5-83386-00-00 97013-05010-00 90990-05100-00 90185-10051-00
DESCRIPTION Rubber, Handle Screw Washer, Plate Spring, Compression Bush Circlip Cover, Handle Steering Grommet Screw, Pan Head Washer, Plate Screw, Pan Head Washer, Plate Main Switch Assy Engine Stop Switch Assy Engine Stop Switch Assy Stopper Cap Bolt Washer, Spring Cover, Main Switch Cover, Main Switch Bolt Washer, Plate Clamp, Fuel Pipe 2 Stay Bolt Washer, Spring Screw, Pan Head Clamp Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch Extension, Wire Harness Trim & Tilt Switch Washer, Plain Screw, Pan Head Plate, Friction Nut Damper Washer, Plate Washer Bolt Plate, Friction Plate, Friction Shaft, Steering Lock Nut, Self-locking Knob, Steering Lock Cover Bolt Washer, Spring Zip Tie Buzzer Buzzer Stay Bolt Spring Washer Nut
QTY. 1 1 1 1 1 2 1 1 4 4 3 3 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 2 1 1 1 1 2 2 1 1 1 2 2 2
Component parts
6-23
Disconnect the oil level gauge coupler 6, the trim sender coupler 7 , and the power trim/tilt switch lead coupler 8. N O T E : T he steering friction in this kit will not fit the 40E R ( without P T &T ) . T his model has a standard equipment steering friction on the side of the swivel bracket. 40, 50 Tiller Handle Installation Instructions Preparation for Remote Control Model 5. 1. Remove the steering hook 1.
Neutral Switch Remote Control Model 2. Remove the fitting plate 1 and grommet 2 1. 2. Install neutral switch assembly 1 and slip plate 2. Install the neutral switch stay 3.
3. 4.
Remove the shift cable joint 3 and throttle cable joint 4. Disconnect the wire harness coupler 5.
N O T Install E : the stay 3 with the washer and bolt.
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3. 4. Disconnect the brown lead terminals 4. Connect the neutral switch lead terminals 5. 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.
S tart-in-gear protection will not operate without the neutral switch leads connected.
Installation 1. Install the tiller handle assembly 1 and nut 2. T orque: N ut - 38N m ( 3.8 m-kg, 2 7 ft-lb.) N O TPass E : the engine stop switch lead through the grommet, then install them to the bottom cowling. Align the taped end a of the battery cable and the extension wire lead with the end of the grommet. (A) Manual starter model (B) Electric start model without instruments (C) Electric start model with instruments
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3. 5. Install the fitting plate 1 and bolt 2. T orque: B olt - 8N m ( 0.8m-kg, 5.8 ft-lb.) 6. Check the shift operation for unsmooth operation. Diagnose and repair the problem if the operation is not smooth. Adjust the throttle cable joint position. a. Turn the throttle grip fully closed. b. Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a.
N O TAfter E : installing the fitting plate, lift the tiller handle straight up.
4. Adjust the shift cable joint position. a. Turn the shift handle 1 in neutral position. b. Align the center of the set pin 2 with the mark a on the bracket.
c. Adjust the position of the cable joint until its hole aligns with the set pin. d. Install the clip 2 and tighten the lock nut 3.
WARNING
WARNING
T he cable joint should be screwed in more than 8mm ( 0.31 in) . N O TPut E the : UP mark upward.
T he cable joint should be screwed in more than 8mm ( 0.31 in) . N O T Put E :the UP mark upward. (Manual starter model only).
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7. Check the throttle for its fully open position. a. Turn the shift handle to the in-gear position. b. Turn the throttle grip fully open. c. Check the throttle valve lever so it contacts the fully opening stopper. 10. For electric start models with instruments (Illust. C), connect the extension wire harness coupler 1, main switch wire lead coupler 2, trim sender lead coupler 3, oil level gauge coupler 4, power trim/tilt switch lead coupler 5, clamp 6, and zip tie 7. N O TFit E the : extension wire lead in the clamp. Clamp the wire leads as shown.
8.
On manual start models (See Illust. A) connect the clamp 1, engine stop switch lead (black) 2, and the engine stop switch lead (white) 3.
Throttle Friction 1. 9. On electric start models without instruments (See Illust. B), connect the main switch coupler 1 and zip tie 2. Adjust the friction control nut 1 according to the following chart.
N O TFit Ethe : main switch lead in the clamp and clamp the wire leads as shown.
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Completion Check Static Check 1. Check the shift operation. Make sure the shift action is smooth for Forward, Neutral and Reverse. Dynamic Check
CAUTION:
T he engine is going to be started for checking. M ake sure the engine has an adequate supply of cooling water. B efore checking, make sure the following conditions are met: L ock plate is installed to the engine stop switch. S hift position is in neutral. I nsert the key into the main switch, with the key in the O F F position. T hrottle control is fully closed.
2.
Check the throttle operation for smoothness from fully closed to fully open.
5.
N O TShift E :forward and then check the throttle operation. 3. Check steering friction to make sure proper friction is obtained. Move the tiller handle tilt up/down and check that the cables and wires are not stretched. 4. Check the power trim/tilt switch. a. Connect the battery. b. Push and hold the switch to UP, the motor will tilt up. c. Push and hold the switch to DN, the motor will tilt down. d. Release the switch, the motor will stop at its current position.
Check the start in gear protection. a. Shift in forward/reverse b. Turn the key to START. The starting motor should not turn over. c. Shift into neutral. d. Turn the key to START. The starting motor will then turn over.
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6. Check the main switch. a. Turn the main switch to ON from OFF then to START. The starting motor will turn, then the engine will start. b. Turn the main switch to OFF from ON. The running engine will stop. Steering Friction (63D-42508-00-00) 1. 2. Remove the cap 1. Install the nut 2. T orque: N ut - 2 0N m ( 2 .0m-kg, 14 ft-lb.)
7. Check the engine stop switch. a. Run the engine. b. Pull the lanyard off the lock plate. The running engine will stop.
3.
Install the collar 1, friction plate 2, washer 3, and bolt (M8) 4.
4. 8. Check for steady engine speed. a. Run the engine at idle. b. Steer the tiller handle. c. Tilt the tiller handle up/down. d. Make sure the engine speed remains steady under the above conditions.
Install the bolt (M6) 1.
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5. Adjust the friction force. a. Turn the friction lever 1 fully to the left a. b. Turn the nut 2 to adjust the steering fricion force to the user's preference according to the following chart: 7. Install the fuel hose 1.
WARNING
F it the fuel hose securely in the clamp.
c. Turn the friction lever fully to the right b, and check that the tiller becomes free from friction. d. If not, repeat the above steps.
8.
Install the battery lead 1, extension wire harness 2 under the shift cable 3, and throttle cable b.
N O T Set E the : battery lead 1 extension wire harness 2 under the shift cable a and throttle cable b. 9. Install the screw 3.
6.
Check steering movement for smooth operation.
N O TWith E :the friction lever turned fully to the right, check the tiller for smooth movement.
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F40 4-Cyl. F/T50 TILLER HANDLE KIT (62Y-W0086-Z0-4D)
F40 4-Cyl, F/T50 Tiller Handle Kit
6-31

F40 4-Cyl., F/T50 Tiller Handle Kit [Contd.]
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 62Y-W0086-20-4D 63D-42121-00-4D 63D-42111-00-4D 6H2-42137-00-00 90269-02M09-00 63D-44100-10-00 63D-44104-00-00 63D-48261-00-00 63D-42115-00-00 650-42152-00-94 91690-30025-00 63D-42159-00-00 98580-06016-00 99001-08600-00 63D-44113-00-00 63D-48236-00-00 63D-48119-00-00 63D-42153-00-00 63D-44132-00-00 63D-48118-00-00 63D-48237-00-00 98780-05014-00 63D-48238-00-00 63D-42181-00-00 63D-44114-00-00 97095-06016-00 92990-06600-00 63D-42725-00-00 62Y-48321-00-00 62Y-26301-00-00 90101-12M09-00 92990-12200-00 63D-48531-00-00 63D-48538-00-00 90464-09M42-00 97095-06016-00 92990-06600-00 90386-12M93-00 90386-29M95-00 92990-12600-00 90206-12M21-00 90185-12058-00 90387-12M02-00 63D-42126-00-00 63D-48154-00-00 95380-06600-00 91490-20015-00 6G8-44191-00-00 90202-24M53-00 97395-08040-00 92990-08600-00 63D-44159-00-00 90159-06M18-00 63D-44173-00-00 664-42119-00-00 6G1-42177-00-00 90149-05M13-00 92990-10600-00 90501-23215-00 90386-08032-00 DESCRIPTION Handle Steering Assy Bracket Handle, Steering Indicator, Throttle Rivet Shift Link Assy Plate Comp. Arm, Throttle Shaft, Steering Handle Gear Pin, Spring Stay Screw, Pan Head Circlip Cam Plate, Handle Roller, Detent Cover Shaft, Throttle Control Bushing Clip, Shift Lever Adaptor Screw, Flat Head Spring, Detent Washer Stopper Bolt Washer, Plate Grommet Cable Throttle Cable Assy Bolt Washer, Plain Bracket, Remote Control Clamp, Cable 1 Clamp Bolt Washer, Plate Bush Bush Washer, Plate Washer, Wave Nut, Self-locking Collar Friction, Steer Hndl Grip Knob, Throttle Nut Pin, Cotter Indicator, Shift Washer, Plate Bolt (97095-08040-00) Washer, plate Handle, Gear Shift Screw, with Washer Lever, Shift Control Grip, Steering Handle Rubber, Handle Screw Washer, Plate Spring, Compression Bush QTY. 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 2 1 4 4 1 1 1 1 1 1 2 1 2 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 REF NO 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 98 99 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116
F40 4-Cyl., F/T50 Tiller Handle Kit
PART NUMBER 93430-04M03-00 63D-42131-10-00 90480-14M14-00 97885-06016-00 92990-06600-00 97885-06040-00 92990-06600-00 6H3-82540-00-00 62Y-82554-00-00 62Y-82555-00-00 97395-06014-00 92990-06600-00 6H2-82586-01-00 6H5-82510-00-00 63D-82575-00-00 682-82556-00-00 689-8257Y-00-00 97095-06025-00 92995-06100-00 63D-8252F-00-4D 63D-8252E-00-4D 97885-06025-00 92995-06100-00 97095-06020-00 92995-06100-00 97885-06012-00 90465-13M36-00 630-82563-00-00 97805-06016-00 92995-06600-00 63D-42508-00-00 63D-42527-00-00 63D-42546-00-00 63D-42541-00-00 90201-08M01-00 97095-08050-00 92990-08600-00 63D-42526-00-00 63D-4252800-00 63D-42562-00 90185-10M01-00 63D-42561-00-00 682-43318-01-00 97095-06016-00 92995-06100-00 62Y-82361-00-00 90161-06M03-00 97095-06035-00 92990-06600-00 90387-06M26-00 90464-15M11-00 688-83383-11-00 6H4-83386-00-00 97013-05010-00 90990-05100-00 90185-10051-00
DESCRIPTION Circlip Cover, Handle Steering Grommet Screw, Pan Head Washer, Plate Screw, Pan Head Washer, Plate Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch 1 Bolt Washer, Plate Extension, Wire Harness Main Switch Assy Engine Stop Switch Assy Stopper Cap Bolt Washer, Spring Cover, Main Switch Cover, Main Switch Screw, Pan Head Washer, Spring Bolt Washer, Spring Screw, Pan Head Clamp Trim & Tilt Switch Screw, Pan Head Washer, Plain Steering Friction Assy Plate, Friction Nut Damper Washer, Plate Bolt Washer, Plate Plate, Friction Plate, Friction Shaft, Steering Lock Nut, Self-locking Knob, Steering Lock Cover Bolt Washer, Spring Clamp, Cord Screw, Tapping Bolt Washer, Plate Collar Zip Tie Buzzer Buzzer Stay Bolt Spring Washer Nut
QTY. 2 1 1 4 4 3 3 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 2 2 1 2 1 1 1 1 2 2 1 1 1 1 1 1 1 1 2 2 2
Component parts
6-32

F50 Tiller Handle Installation Instructions Preparation for Remote Control Model 1. Remove the steering hook 1. 5.
Disconnect the wire harness coupler 8.
6. 2. Remove the fitting plate 2.
Disconnect the overheat, oil warning lead 10 coupler 9, the trim sender lead coupler 10, and the power trim/tilt switch leads coupler 11 11.
3. Remove the grommet 3, cable stopper 4, and rubber seal 5.
4. Remove the shift cable joint 6 and throttle cable joint 7.
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Neutral Switch Remote Control Model 1. Install the neutral switch ass'y 1 and the slip plate 2. 2. Install the neutral switch stay 2. N O T Install E : the stay 3 with the washer and bolt. 3.
Disconnect the brown lead terminal 4 and the brown/blue lead terminal 5.
4.
Connect the neutral switch lead terminals 6.

WARNING
S tart in gear protection will not operate without the neutral switch leads connected. Installation 1. Install the tiller handle assembly 1 and nut 2. T orque: N ut - 38N m ( 3.8m-kg, 2 7 ft-lb)
2.
Install the following: 1 Grommet 2 Main Switch Leads 3 Battery Cable 4 Power Trim, Tilt Switch Leads 5 Extension Wire Harness
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N O TAlign E : the taped end a (see illustration 2 below) of the battery cable and the extension wire lead with the end of the grommet. 5.
Adjust the shift cable joint position. a. Turn the shift handle 1 to the neutral position. b. Align the center of the set pin 2 with the mark a on the bracket.
IL L U S . 1
IL L U S . 2
3.
Install the cable stopper 1, rubber seal 2, and remote control cables 3.
WARNING
M ake sure the cable joint is screwed in more than 8mm ( 0.31 in) . 6. Check the shift control for smooth operation. 7. 4. Install the fitting plate 1 and bolt 2. T orque: B olt - 8N m ( 0.8m-kg, 5.8 ft-lb.) Adjust the throttle cable joint position. a. Turn the throttle grip fully closed. b. Align the mark a on the throttle lever with the mark b on the shift bracket. c. Adjust the position of the cable joint until its hole aligns with the set pin. d. Install the clip 1 and tighten the lock nut 2.
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WARNING
Electric Start Model without Instruments (A) M ake sure the cable joint is screwed in more than 8mm ( 0.31in) . 9. Connect the main switch coupler 1 and the zip tie 2. N O TFit Ethe : main switch coupler to the clamp, then clamp the wire leads as shown.
Electric Start Model with Instruments (B) 10. Connect the following: 1 Extension Wire Harness Coupler 2 Main Switch Wire Lead Couplers 3 Trim Sender Lead Coupler 4 Overheat, Oil Warning Lead Coupler 5 Power Trim/Tilt Switch Lead Coupler 6 Zip Tie
8. Check the throttle for its full-open position and correct if necessary. a. Turn the shift handle in gear position. b. Turn the throttle grip fully open. c. Check the throttle valve lever so it contacts the full-opening stopper.
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N O T Fit E the : extension wire harness coupler into the zip tie, then zip tie the wire leads as shown. 3.
Install the following: 1 Collar 2 Friction plate
3 Washer 4 Bolt (M8)
4.
Install the bolt (M6) 1.
5.
Adjust the friction force. a. Turn the friction lever 1 fully to the left a. b. Turn the nut 2 in or out to adjust the steering friction force to the user's preference according to the following:6-29
Steering Friction (63D-42508-00-00) 1. 2. Remove the cap 1. Install the nut 2. T orque: N ut - 2 0N m ( 2 .0m-kg, 14ft-lb)
c. Turn the friction lever fully to the right b, and check that the tiller becomes free of friction. d. If not, repeat the above steps.
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6. Check the steering movement for smooth operation.
Completion Check Static Check 1. Check the shift operation. Make sure the shift action is smooth for Forward, Neutral and Reverse.
N O TWith E :the friction lever turned fully to the right, check the tiller for smooth movement.
7.
Install the fuel hose 1.
WARNING
2.
F it the fuel hose into the clamp securely. 8. Install the battery lead 2 and extension wire harness 3 under the shift cable a and throttle cable b.
Check the throttle operation for smoothness from fully closed to fully open.
N O TShift E :forward and then check the throttle operation. 3. Check steering friction to make sure proper friction is obtained. Move the tiller handle tilt up/down and check that the cables and wires are not stretched. Check the power trim/tilt switch. a. Connect the battery. b. Push and hold the switch to UP, the motor will tilt up. c. Push and hold the switch to DN, the motor will tilt down. d. Release the switch, the motor will stop at its current position.
N O T Set E : the battery lead 2 and extension wire harness 3 under the shift cable a and throttle cable b. 9. Install the screw 4.
4.
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Dynamic Check
CAUTION:
6.
T he engine is going to be started for checking. T herefore, the engine should be supplied cooling water. Before performing the dynamic check, make sure the following conditions are met: Lock plate is installed to the engine stop switch. Shift position is neutral. Insert the key into the main switch, and turn to the OFF position. Throttle control is fully closed. 7.
Check the main switch. a. Turn the main switch to ON from OFF then to START. The starter motor turns over then the engine will start. b. Turn the main switch to OFF from ON. The running engine should stop.
Check the engine stop switch. a. Run the engine. b. Pull the lanyard off the lock plate. The running engine will stop.
5.
Check the start in gear 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.
8.
Check for steady engine speed. a. Run the engine at idle. b. Steer the tiller handle. c. Tilt up/down the tiller handle. Make sure a steady engine speed is kept.
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60, C60/C70/70 Tiller Handle & Steering Friction Kit
STEERING FRICTION KIT 60/C60/C70/70 TILLER HANDLE (6H3-W0086-Z0-4D)
6-40

60, C60/C70/70 Tiller Handle & Steering Friction Kit [Contd.]
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 PART NUMBER 6H3-W0086-Z0-4D 63D-42111-01-4D 664-42119-00-00 6G1-42177-00-00 6H2-42137-00-00 90269-02M09-00 90149-05M13-00 92990-10600-00 90501-23215-00 90386-08032-00 6H3-26301-00-00 63D-42121-10-4D 90101-12M09-00 92990-12200-00 90386-12M93-00 90206-12M22-00 90185-12058-00 6G8-44191-00-00 63D-44159-01-00 63D-44100-11-00 63D-44104-00-00 63D-48261-00-00 63D-42115-00-00 650-42152-00-94 91690-30025-00 63D-42159-00-00 98580-06016-00 93430-08006-00 63D-44113-00-00 63D-48236-00-00 63D-48119-00-00 63D-42153-00-00 63D-44132-00-00 63D-48118-00-00 63D-48237-00-00 98785-05014-00 63D-48238-00-00 63D-42181-00-00 97095-06016-00 92995-06600-00 63D-42725-00-00 63D-44173-00-00 90159-06M18-00 97095-08040-00 92995-08600-00 6H3-48321-01-00 90386-29M95-00 90202-24M53-00 63D-48531-00-00 63D-48538-00-00 97095-06016-00 92995-06600-00 90387-12M02-00 92990-12600-00 63D-42126-00-00 63D-48154-00-00 95380-06600-00 91490-20010-00 90464-09M42-00 DESCRIPTION Handle Steering Assy Handle, Steering Grip, Steering Handle Rubber, Handle Indicator, Throttle Rivet Screw Washer, Plate Spring, Compression Bush Throttle Cable Assy Bracket Bolt Washer, Plain Bush Washer, Wave Nut, Self-locking Indicator, Shift Handle, Gear Shift Shift Link Assy Plate Comp. Arm, Throttle Shaft, Steering Handle Gear Pin, Spring Stay Screw, Pan Head Circlip Cam Plate, Handle Roller, Detent Cover Shaft, Throttle Control Bushing Clip, Shift Lever Adaptor Screw, Flat Head Spring, Detent Washer Bolt Washer Grommet Lever, Shfit Control Screw, With Washer Bolt Washer Cable Bush Washer, Plate Bracket, Remote Control 1 Clamp, Cable 1 Bolt Washer Collar Washer, Plate Friction, Steering Handle Grip Knob, Throttle Nut Pin, Cotter Clamp QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 2 4 4 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 REF NO PART NUMBER 60 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 93430-04M03-00 63D-42131-10-00 90480-14M14-00 97885-06016-00 92995-06600-00 97885-06040-00 92995-06600-00 663-42518-00-00 663-42528-00-00 97080-06035-00 90175-06003-00 692-42515-01-00 92990-08600-00 90185-08057-00 63D-44114-00-00 6H5-82510-00-00 63D-82575-00-00 682-82556-00-00 689-8257Y-00-00 6H3-82540-00-00 6H3-82554-00-00 663-82555-01-00 97885-06012-00 63D-8252E-01-4D 63D-8252F-01-4D 97885-06025-00 92995-06100-00 97095-06025-00 92995-06100-00 97095-06020-00 92995-06100-00 90167-06M00-00 92990-06200-00 6H2-82586-01-00 90465-13M36-00
DESCRIPTION Circlip Cover, Handle Steering Grommet Screw, Pan Head Washer Screw, Pan Head Washer Shaft, Friction Plate, Friction Bolt Nut, Wing Rod, Steering Washer, Plate Nut, Self-locking Stopper Main Switch Assy Engine Stop Switch Assy. Stopper Cap Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch Screw, Pan Head Cover, Main Switch Cover, Main Switch Screw, Pan Head Washer, Spring Bolt Washer, Spring Bolt Washer, Spring Screw, Tapping Washer Extension, Wire Harness Clamp
QTY. 2 1 1 4 4 3 3 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 1 1
Component parts
6-41

Neutral Switch (for 70hp model) 1. 2. Install the neutral switch assembly 1 and slip plate 2. Install the neutral switch stay 3. 4.
Disconnect the power trim/tilt switch lead coupler 5.
N O TInstall E : the stay 3 with washer and the bolt. 3. Disconnect the brown lead terminals 4. 5. Connect the neutral switch lead terminals 6.
WARNING
S tart in gear protection will not operate without the neutral switch leads connected.
6-42

Tiller Handle 1. Remove (for 70hp model) the steering hook 1.
N O T E : a. Pass the wire harness and remote control cables through the grommet, and refit the grommet. b. Fit the cable clamp 7 to the outer remote control cables. c. Align the taped end a of the battery lead and the extension wire harness with the end of the grommet.
N O TUse E the : removed nut for handle installation. 2. Install the tiller handle assembly 2 and nut 3. T orque: 38N m ( 3.8m-kg, 2 7 ft-lb.) 4. Install the fitting plate 1 and bolt 2. N O TAfter E : installing the fitting plate, lift the tiller handle straight up. T orque: 8N m ( 0.8m-kg, 5.8ft-lb.)
3.
Install the following: 1 Grommet 2 Throttle Cable 3 Shift Cable 4 Extension Wire Harness 5 Main Switch Wire Leads 6 Battery Leads 7 Power Trim/Tilt Switch Leads
6-43

5. Adjust the shift cable joint position. a. Turn the shift handle 1 in neutral position. b. Align the center of the set pin 2 with the mark a on the bracket. c. Adjust the position of the cable joint until its hole aligns with the set pin. 7.
Adjust the throttle cable joint position. a. Turn the throttle grip fully close. b. Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a. c. Adjust the position of the cable joint until its hole aligns with the set pin. d. Install the clip 2 and tighten the lock nut 3.
IL L U S . A
d. Install the clip 3 and tighten the lock nut 4.

WARNING
T he cable joint should be screwed in more than 8mm ( 0.31 in) .
WARNING
T he cable joint should be screwed in more than 8mm ( 0.31in) . 8. 6. Check shifting for smooth operation. Check the throttle for fully-open position ( I llus. B ) a. Turn the shift handle in gear position. b. Turn the throttle grip fully open. c. Check the throttle valve lever so it contacts the fully opening stopper 4 ( I llus. A . )
IL L U S . B
6-44

9. Connect the following: 1 Main Switch Wire Lead Coupler 2 Extension Wire Harness Coupler 3 Oil Level Gauge Lead Coupler 4 Trim Sender Lead Coupler 5 Power Trim/Tilt Switch Lead Coupler 6 Zip Tie 7 Clamp ( I llus. D )
I llus. C
Steering Friction 1. Remove the end cap 1.
2. 3.
Install the bolt 1 and wing nut 2. Install the friction controller 3, link rod 4, washer 5, and the nylon nut 6.
N O T E : a. Fit the extension wire harness and main switch wire leads. b. Clamp the wire leads as shown.
I llus. D
N O TThe E steering : friction can be installed on the port side or starboard side.
6-45

4. Adjust the friction control nut 1 according to the following:
Check tiller handle tilt up/down. Make sure the cables and wires are not stretched.
Throttle Friction 1. Adjust the friction control nut 1 as follows: 4. Check the power trim/tilt switch. a. Connect the battery. b. Push and hold the switch to UP, the motor will tilt up. c. Push and hold the switch to DN, the motor will tilt down. d. Release the switch, the motor will stop at its current position.
Dynamic Check
CAUTION:
Completion Check Static Check 1. Check for smooth shifting in Forward, Neutral and Reverse. 2. Check the throttle for smooth operation from fully closed to fully open. N O TShift E :in forward and then check the throttle operation. 3. Check the steering friction to make sure proper friction is obtained.
6-46
T he engine is going to be started for checking. T herefore the engine should be supplied cooling water. Testing condition Lock plate is installed to the engine stop switch. Shift position is neutral. Insert the key into the main switch, its position is OFF. Throttle control is fully closed.

7.
Check the engine stop switch. a. Run the engine. b. Pull the lanyard off the lock plate. The running engine will stop.
5.
Check start-in-gear protection. a. Shift in forward/reverse. b. Turn the key to START. The starter motor should not turn over. c. Shift into neutral. d. Turn the key to the START position. The starter motor should turn over.
8.
Check for steady engine speed. a. Run the engine at idle. b. Steer the tiller handle. c. Tilt up/down the tiller handle. Make sure that steady engine speed is kept.
6. Check the main switch. a. Turn the main switch to ON from OFF then to START. The starter motor starts the engine. b. Turn the main switch to OFF from ON. The running engine will stop.
6-47
C90/90 Tiller Handle & Steering Friction Kit
C90/90 TILLER HANDLE KIT (6H1-W0086-Z0-4D) & STEERING FRICTION
6-48

C90/90 Tiller Handle & Steering Friction Kit [Contd.]
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 6H1-W0086-Z0-4D 63D-42111-01-4D 664-42119-00-00 6G1-42177-00-00 6H2-42137-00-00 90269-02M09-00 90149-05M13-00 92903-10600-00 90501-23215-00 90386-08032-00 6H1-26301-01-00 63D-42121-10-4D 90101-12M09-00 92990-12200-00 90386-12M93-00 90206-12M22-00 90185-12058-00 6G8-44191-00-00 63D-44159-01-4D 63D-44100-01-00 63D-44104-00-00 63D-48261-00-00 63D-42115-00-00 650-42152-00-94 91690-30025-00 63D-42159-00-00 98580-06016-00 93430-08006-00 63D-44113-00-00 63D-48236-00-00 63D-48119-00-00 63D-42153-00-00 63D-44132-00-00 63D-48118-00-00 63D-48237-00-00 98780-05014-00 63D-48238-00-00 63D-42181-00-00 97095-06016-00 92990-06600-00 63D-42725-00-00 63D-44173-00-00 90159-06M18-00 97095-08040-00 92995-08600-00 6H1-48321-00-00 90386-29M95-00 90202-24M53-00 63D-48531-00-00 63D-48538-00-00 97095-06016-00 92990-06600-00 90387-12M02-00 92990-12600-00 63D-42126-00-00 63D-48154-00-00 95380-06600-00 91490-20010-00 90464-09M42-00 93430-04M03-00 REF NO PART NUMBER 61 62 63 64 65 66 67 68 69 70 71 72 73 74 75 76 77 78 79 80 81 82 83 84 85 86 87 88 89 90 91 92 93 94 95 96 97 63D-42131-10-00 90480-14M14-00 97885-06016-00 92990-06600-00 97885-06040-00 92990-06600-00 663-42518-00-00 663-42528-00-00 97080-06035-00 90175-06003-00 692-42515-01-00 92990-08600-00 90185-08057-00 6H3-82510-11-00 63D-82575-00-00 682-82556-00-00 689-8257Y-00-00 97885-06012-00 697-8252E-01-4D 697-8252F-f01-4D 97885-06025-00 92995-06100-00 97095-06030-00 92995-06100-00 97095-06020-00 92995-06100-00 90464-15M11-00 90465-13M36-00 688-82540-11-00 663-82554-01-00 663-82555-01-00 90464-15M11-00 688-83383-11-00 6H5-83386-00-00 97013-05010-00 90990-05100-00 90185-10051-00
DESCRIPTION Handle Steering Assy Handle, Steering Grip, SteeringHandle Rubber, Handle Indicator, Throttle Rivet Screw Washer,m Plate Spring, Compression Bush Throttle Cable Assy Bracket Bolt Washer, Plain Bush Washer, Wave Nut, Self-locking Indicator, Shift Handle, Gear Shift Shift Link Assy Plate Comp. Arm, Throttle Shaft, SteeringHandle Gear Pin, Spring Stay Screw, Pan Head Circlip Cam Plate, Handle Roller, Detent Cover Shaft, Throttle Control Bushing Clip, Shift Lever Adaptor Screw, Flat Head Spring, Detent Washer Bolt Washer, Plate Grommet Lever, Shift Control Screw, With Washer Bolt Washer Cable Bush Washer, Plate Bracket, Remote Control 1 Clamp, Cable 1 Bolt Washer, Plate Collar Washer, Plate Friction, SteeringHandle Grip Knob, Throttle Nut Pin, Cotter Clamp Circlip
QTY. 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 1 1 1 1 2 1 2 4 4 1 1 2 1 1 1 1 1 1 2 2 2 1 1 1 1 1 1 1 2
DESCRIPTION Cover, Handle Steering Grommet Screw, Pan Head Washer, Plate Screw, Pan Head Washer, Plate Shaft, Friction Plate, Friction Bolt Nut, Wing Rod, Steering 1 Washer, Plate Nut, Self-locking Main Switch Assy Engine Stop Switch Assy Stiopper Cap Screw, Pan Head Cover, Main Switch Cover, Main Switch Screw, Pan Head Washer, Spring Bolt Washer, Spring Bolt Washer, Spring Clamp Clamp Neutral Switch Assy Stay, Neutral Switch Damper, Main Switch Zip Tie Buzzer Buzzer Stay Bolt Spring Washer Nut
QTY. 1 1 4 4 3 3 1 1 1 1 1 2 2 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2
Component parts
6-49

INSTALLATION Neutral Switch 1. Install the neutral switch assembly 1 and slip plate 2. 2. Install the neutral switch stay 3. N O T Remove E : the washer and bolt from the shifter bracket, then install the stay with the removed washer and bolt. 3. Disconnect the brown lead terminals 4. 4. Connect neutral switch lead 5.
WARNING
S tart in gear protection will not operate without the neutral switch leads connected. 5. Disconnect the power trim/tilt switch lead coupler 6.
6-50

Tiller Handle 1. Remove the steering hook 1. 4.
Install the cable clamp 1.
N O TThe E removed : nut should be used for the handle installation, so keep it for the installation.
5.
Install the fitting plate 1 and bolt 2.
2.
Install the tiller handle assembly 1 and nut 2. 2 T orque: N ut - 40N m ( 4.0 m-kg, 2 9 ft-lb.)
N O TAfter E : securing the fitting plate, lift the tiller handle straight up and check that the cables and wires are not stretched. T orque: N ut - 8N m ( 0.8m-kg, 5.8ft-lb) 3. Install the following: 1 Grommet 2 Shift Cable 3 Throttle Cable 4 Battery Cable 5 Extension Wire Harness 6 Main Switch Harness 7 Power Trim/Tilt Switch Leads
N O TAlign E : the taped end a of the battery cable and the extension wire harness with the end of the grommet.
6-51

6. Adjust the shift cable joint position. a. Turn the shift handle 1 to the neutral position. b. Align the center of the set pin 2 with the mark a on the bracket. c. Adjust the position of the cable joint until its hole aligns with the set pin.
WARNING
M ake sure the cable joint is screwed in more than 8mm ( 0.31in) .
d. Install the clip 3 and tighten the lock nut 4.

WARNING
M ake sure the cable joint is screwed in more than 8mm ( 0.31 in) . 9.
Check the throttle for its fully open position and correct if necessary. a. Turn the shift handle in forward position. b. Turn the throttle grip fully open. c. Check the throttle valve lever so that it contacts the full-open stopper 1.
1
7. 8.
Check for smooth shift operation. If the shift operation is not smooth, diagnose and repair. Adjust the throttle cable joint position. a. Turn the throttle grip fully close. b. Turn the magneto control lever 1 so its adjusting screw contacts the fully retarding stopper a. c. Adjust the position of the cable joint until its hole aligns with the set pin. d. Install the clip 2 and tighten the lock nut 3.
10. Connect the main switch harness 1, oil level gauge lead 2, trim sensor lead 3, and power trim/tilt switch coupler 4.
6-52

11. Tie down with a zip tie 5. 1. 2. 1 4 3.
Remove the end cap 1. Install the bolt 1 and wing nut 3. Install the friction controller 3, link rod 4, washer 5, and nylon nut 6.
N O TThe E steering : friction can be installed on port side or starboard side.
12. Close the clamp 7.
Throttle Friction 1. Adjust the friction control nut 1 according to the following diagram: 4. Adjust the steering friction control nut 1 according to the following diagram.
Steering Friction
6-53

Completion Check Static Check 1. 2. Check the shift operation for smooth shifting into Forward, Neutral and Reverse. Check the throttle operation for smooth operation from fully closed to fully open. Dynamic Check
CAUTION:
T he engine is going to be started for checking. T herefore the engine should be supplied cooling water. Before performing the dynamic check, make sure the following conditions are met: Lock plate is installed to the engine stop switch. Shift position is neutral. Insert the key into the main switch, and turn to the OFF position. Throttle control is fully closed.
N O T Shift E : into forward and then check the throttle operation.
5.
3.
Check the steering friction for proper friction, then check the tiller handle tilt up/down motion and make sure the cables and wires are not stretched. Check the power trim/tilt switch. a. Connect the battery. b. Push and hold the switch to UP, the motor will tilt up. c. Push and hold the switch to DN, the motor will tilt down. d. Release the switch, the motor will stop at its current position.
Check the start in gear 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.
4.
6-54

6. Check the main switch. a. Turn the main switch to ON from OFF then to START. The starter motor turns over, then the engine will start. b. Turn the main switch to OFF from 8.
Check for steady engine speed. a. Run the engine at idle. b. Steer the tiller handle. c. Tilt up/down the tiller handle. Make sure a steady engine speed is kept.
ON. The running engine should stop. 7. Check the engine stop switch. a. Run the engine.
b. Pull the lanyard off the lock plate. The running engine will stop.
6-55
Outboards F30, F40

TILLER HANDLE, STEERING FRICTION
INSTALLATION MANUAL
6A-1

TILLER HANDLE (For manual start model)
Ref. No. 1
Parts Name Tiller Handle Assy
Qty. 1 PREPARATION 1. Remove: Lock plate 1
Remarks
2.
Remove: Fitting plate 2
6A-2

INSTALLATION 1. Install: Tiller handle assy 1 Nuts 2 Nut: 38 Nm (3.8 mkg, 27 ftlb)
2.
Install: 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 Bolt: 10 Nm (1.0 mkg, 7.2 ftlb)
5.
Adjust: Shift cable joint position
Adjustment steps: Turn the shift handle 1 in neutral postion.
6A-3

Align the set pin 2 as shown. Adjust the position of the cable joint 3 until its hole aligns with the set pin. Install the clip 4 and tighten the lock nut 5.
WARNING The cable joint should be screwed in more than 8.0mm (0.31 in).
6.
Check: Shift operation Unsmooth operation Repair.
7.
Adjust: Throttle cable joint position
Adjustment steps: Turn the throttle grip fully close. Align the throttle lever 1 as shown. Adjust the position of the cable joint 2 until its hole aligns with the set pin. Install the clip 3 and tighten the lock nut 4. WARNING The cable joint should be screwed in more than 8.0mm (0.31 in).
8. Check: Fully open position Incorrect Repair.

Checking steps: Turn the shift handle in gear position. Turn the throttle grip fully open. Check the throttle valve lever so that it contacts the fully opening stopper.
9. Connect: Engine stop switch connectors 1
6A-4

OPTION - TILLER HANDLE AND STEERING FRICTIO KIT (For remote control model)
Ref. No. 1 2 3 4 5 6 7 8 9 10 11
Parts Name Tiller Handle Assy Neutral Switch Neutral Switch Stay Bolt Shift Control Lever Spring Pin Grommet Steering Friction Assy Bolt with Washer Extension, Wire Harness Wire Harness
Qty. 1 1 1 2 1 1 1 1 2 1 1
Remarks
M6
M5 10 pin - 12 pin A To buzzer B To trim meter C To tachometer D To PTT switch
12
Connector assy 6A-5

PREPARATION 1. Remove: Steering hook 1
2.
Remove: Fitting plate 2
3.
Remove: Grommet 3 Cable stopper 4 Rubber seal 5
4.
Remove: Shift cable joint 6 Throttle cable joint 7 Disconnect: Wire harness coupler 8
5.
6.
Disconnect: Overheat and oil warning lamp coupler 9 Trim sensor coupler 10 (for PTT model)
NOTE: The bottom cowling overhet and oil warning lights will not be able to be operated. 6A-6

7. Remove: Flywheel magnet cover 1 Starter motor 2
8.
Remove: Shift rod lever assy 3
9.
Remove: Grease nipples 1 Clamp 2
NEUTRAL SWITCH 1. Install: Shift control lever 1 Spring pin 2 Shift rod lever assy 3
2.
Install: Neutral switch 1 Neutral switch stay 2 Bolts (M6) 3 Bolt: 10 Nm (1.0 mkg, 7.2 ftlb)
6A-7

3. Disconnect: Brown lead connector 1
4.
Connect: Neutral switch connectors 2
STEERING FRICTION 1. Install: Steering friction assy 1 Clamp 2 Bolt with washers (M5) 3
TILLER HANDLE 1. Install: Tiller handle assy 1 Nuts 2 Bolt with washers (M5) 3 Nut: 38 Nm (3.8 mkg, 27 ftlb)
2.
Install: Grommet 1 Main switch leads 2 Battery cable 3 PTT switch lead (for PTT model) 4 Extension wire harness 5
NOTE: Align the taped end a of the battery cable and the extension wire lead with the end of the grommet. 3. Install: Cable stopper 1 Rubber seal 2 Remote control cables 3
6A-8

4. Install: Fitting plate 1 Bolts 2 Bolt: 10 Nm (1.0 mkg, 7.2 ftlb)
5.
Adjust: Shift cable joint position
Adjustment steps: Turn the shift handle 1 in neutral position. Align the set pin 2 as shown. Adjust the position of the cable joint 3 until its hole aligns with the set pin. Install the clip 4 and tighten the lock nut 5. WARNING The cable joint should be screwed in more than 8.0mm (0.31 in).
6.
Check: Shift operation Unsmooth operation Repair.
7.
Adjustment steps: Turn the throttle grip fully close. Align the throttle lever 1 as shown. Adjust the position of the cable joint 2 until its hole aligns with the set pin. Install the clip 3 and tighten the lock nut 4. WARNING The cable joint should be screwed in more than 8.0mm (0.31 in). 6A-9

8. Check: Fully open positionn Incorrect Repair.
Checking steps: Turn the shift handle in gear position. Turn the throttle grip fully open. Check the throttle valve lever so that it contacts the fully opening stopper. 9. Connect: Main switch connectors 1
10. Connect: Extension 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)
6A-10

13. Install: Starter motor 1 Flywheel magnet cover 2
14 Check: Friction force Turn the friction lever 1 to a or b. Incorrect Retighten the nut 2. a a Friction is increased. Friction is decreased.
Nut: 5 Nm (0.5 mkg, 3.6 ftlb)
15. Check: Steering movement 1 Unsmooth Repair. NOTE: With the friction lver turned fully to the left, check the tiller for smooth movement.
6A-11
Outboards F80, F100

INSTALLATION MANUAL
67G-2819K-10
6B-1
NOTE: This manual is for use by Yamaha dealers and the Owners Manual, which is located inside, is for use by the customer. Remove the Owners Manual and distribute it to the customer.
6B-2
Ref. No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21
Parts Name Tiller handle assembly Zip tie Neutral switch Damper plate Switch stay Bolt Friction rod Link rod Bolt Washer Nut Friction control Bolt Wing nut Extension, wire harness Wire harness Connector assembly Grommet Zip tie Buzzer Buzzer stay
Qty. 1 1 1 1 1 2 1 1 1 3 2 1 1 1 1 1 1 1 1 1 1
Remarks
Steering friction set
10 pin 12 pin 12 pin for buzzer, tachometer and trim meter
6B-3

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

E 6. Remove: Bolt 1 Grommet retaining plate 2 Bolt 3 Hose locating plate 4 Grommet 5 Bolt 6 Cable clamp 7
7.
Disconnect: Overheat and oil warning lead coupler 1 Trailer switch coupler 2
NEUTRAL SWITCH 1. Install: Neutral switch assembly 1 Damper plate 2 Neutral switch stay 3 Bolt 4 NOTE: Move the shift lever to the forward position for operation. 2. Disconnect: Brown lead connector 1
3.
Connect: Neutral switch lead connectors 1
WARNING
Start in gear protection will not be obtained without the neutral switch leads connection.
6B-5

E INSTALLATION 1. Install: Tiller handle assembly 1 Nut 2 Nut: 38 Nm (3.8 mkg, 27 ftlb)
2.
Install: Grommet 1 Fuel Hose 2 Battery wire harness 3 Speedometer hose 4 Main switch leads 5 PTT switch lead 6 Extension wire harness 7 Shift control cable 8 Throttle control cable 9 Connect: Main switch lead connectors 1 Zip tie 2 Zip tie 3
3.
NOTE: Pass the shift control cable 4 and throttle control cable 5 under the tiller handle assembly.
4.
Connect: Extension wire harness coupler 1 Overheat and oil warning lead coupler 2 Trim sensor lead coupler 3
6B-6

E 5. Connect: Trailer/PTT switch couplers 1 Install: Intake silencer Throttle control assembly CDI unit cover Junction box covers Flywheel cover
6.
NOTE: Refer to PREPARATION section.
7.
Install: Shift control 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 Cable clamp bolt: 8 Nm (0.8 mkg, 5.8 ftlb) Hose retaining plate: 8 Nm (0.8 mkg, 5.8 ftlb) Grommet retaining plate: 8 Nm (0.8 mkg, 5.8 ftlb)
8.
Check: Shift operation Incorrect Adjust. Adjust: Shift cable joint position
9.
Adjustment steps: Align the center of the set pin a with the mark b on the bracket c.
6B-7

E Loosen the locknut 1 and remove the clip 2. Remove shift cable joint 3 from the set pin a. Position the shift lever 4 in the neutral position. Adjust the position of the shift cable joint until it aligns with the set pin.
WARNING
The shift cable joint must be screwed in at least 8mm (0.31 in). Install the shift cable joint 1 onto the set pin a. Install the clip 2 and tighten the locknut 3. Move the shift lever to the forward, neutral and reverse positions and make sure it shifts smoothly and correctly. If the shifting operation is unsmooth or incorrect, repeat the above procedure. 10. Check: Fully closed position Incorrect Adjust. Checking steps: Fully close the throttle. Check that the throttle control lever 1 touches the fully-closed stopper 2. 11. Adjust: Throttle cable joint position Adjustment steps: Contact the throttle control lever 1 with the fully-closed stopper 2. Loosen the locknut 3 and remove the clip 4. Remove throttle cable joint 5 from the set pin a. Turn the throttle grip fully-closed position. Adjust the position of the throttle cable joint until it aligns with the set pin.
WARNING
The throttle cable joint must be screwed in at least 8mm (0.31 in). Install the throttle cable joint 1 onto the set pin a. Install the clip 2 and tighten the locknut 3.
6B-8

E
STEERING FRICTION
1. Install: Bolt 1 Wing nut 2 Friction controller 3 Link rod 4 Bolt 5 Washers 6 Nut 7
NOTE: Tighten the nut so that the link rod can pivot, and so that it is not too loose.
COMPILATION CHECK
STATIC CHECK 1. Check: Shift operation Smooth shifting for forward, neutral and reverse. 2. Check: Throttle operation Smooth operation from fully close to fully open. NOTE: Shift in forward and then check the throttle operation. 3. Check: Steering friction Proper friction is obtained. Proper friction is obtained and that there is no interference with the hull. Tiller handle tilt up/down Cables and wires are not stretched.
DYNAMIC CHECK
CAUTION:
The engine is going to be started for checking. Therefore the engine should be supplied cooling water. Standard condition: Lock plate is installed to the engine stop switch. Shift position is neutral. Insert the key into the main switch, its position is OFF. Throttle control is fully closed.
6B-9

E 1. Check: Start in gear protection
Checking steps: Shift in forward/reverse. Turn the key to START. The starting motor will not be turned. Shift in neutral. Turn the key to START. The starting motor will be turned. 2. Check: Main switch
Checking steps: Turn the main switch to ON from 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.
3.
Check:
Checking steps: Run the engine. Pull the lanyard and off the lock plate. The running engine will be stopped. Engine stop switch
Checking steps: Run the engine in idling. Steer the tiller handle. Tilt up/down the tiller handle. Steady engine speed is kept. 4. Check: Steady engine speed
Checking steps: Turn the main switch to ON. Push and hold the switch, UP The motor will tilt up. DN The motor will tilt down. Release the switch. The motor will stop its current position.
6B-10

6. E Check: Throttle position sensor (TPS) output voltage (at idle speed) Out of specification Refer to SERVICE MANUAL. Output voltage (P O): 0.7 + 0.02V
Checking steps: Connect the test harness. Connect the tester leads to the test harness (P O). Start the engine and measure the voltage at engine idling speed. NOTE: Set the ditital tester to the manual range. In the auto range the voltage changes cannot be accurately measured.
6B-11
Outboards F80, F100

OWNERS MANUAL
6C-1

E
FEATURES
6C-2

E
STEERING FRICTION
1. Adjust: Friction control nut 1 Steering friction to be; Increased Decreased
THROTTLE FRICTION
1. Adjust: Friction control nut 1 Throttle friction to be; Increased Decreased
PTT SWITCH
Operation steps: Turn the main switch to ON. Push and hold the switch. UP DN Tilt up Tilt down
ENGINE START
Operation steps: Install the lanyard lock plate 1 to engine stop switch 2. Turn the main switch to ON from OFF then to START.
6C-3

SECTION 7 CONVERSION & STEERING KITS Remote Control Attachment Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-1 6/8HP Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2 9.9/15 (2-Stroke) Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . 7-4 F9.9/T9.9 (4-Stroke) Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . 7-8 F15 Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-12 F25 Remote Control Attachment Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-14 25HP Remote Control Attachment Kit - 2 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-17 25E Remote Control Electrical Conversion . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20 25/30HP Remote Control Attachment Kit - 3 Cyl. . . . . . . . . . . . . . . . . . . . . . . . . . 7-23 6/8HP Electric Starter Conversion Kit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-26 Steering Hooks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-31 Steering Attachment Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33

REMOTE CONTROL ATTACHMENT KITS
Model Mechanical Kit Electrical Kit/Part Notes
6 & 8hp 9.9/15
F9.9/T9.9
6G1-48501-50-00 63V-48501-00-00 63V-48511-01-00 63V-61350-00-00 63V-43131-10-00 6G8-48501-03-00 6G8-W4831-01-00 66M-48501-00-00 63V-48511-01-00 63V-61350-00-00 63V-43131-10-00 6L2-48501-11-00 689-61350-02-00 6J8-48511-51-4D
N/A N/A
6G8-82590-00-00 F15
25E
Throttle & Shift 1 Throttle & Shift Steering Hook Steering Arm Longer Steering Tilt Tube Throttle & Shift 7-Pin Engine Harness Remote Tiller Kit (6 ft) Throttle & Shift Steering Hook Steering Arm Longer Steering Tilt Tube Throttle & Shift Steering Arm Steering Hook 1 req. 1 req. 1 req. 1 req. 2 req. 2 req. 1 req. 4 req. 4 req. 1 req. 2 req. 2 req. 1 req. 1 req. 1 req. 1 req. 1 req.
6L2-42725-50-00 6L2-86111-00-00 682-86117-00-00 6L2-86115-00-00 98580-05008-00 92990-05600-00 90480-10155-00 98580-04008-00 92990-04200-00 6L2-86112-00-00 97013-06012-00 92990-06100-00 93210-03261-00 97013-06012-00 92990-06100-00 6L2-82590-00-00 6K3-83557-00-00 F25 65W-48501-00-00 65W-48511-00-00 65W-61350-00-00 65W-48501-00-00
Electric starter items (refer to installation instructions later in this section)
ER: 65W-82590-20-00 TR: 65W-82590-30-00 30 6J8-48501-03-4D 689-61350-02-00 6J8-48511-51-4D 6H3-82540-00-00 6H4-82553-00-00 6J8-82554-00-00 97013-06012-00
Throttle & Shift Steering Hook Steering Arm Remote Attachment Engine Harness ER Engine Harness TR Throttle & Shift Steering Arm Steering Hook 3 Neutral Switch 3 Wire Lead 3 Neutral Switch Bracket 3 Bolt
1: The longer steering tube for the 9.9/F15/15 is 69mm (2.72) longer than the original and is required to properly cenN ote ter the steering. If not used, the engine may not turn equally to port and starboard. 2: Required for relocating electric start functions to the helm. (Electric conversion kit 6L2-W0087-11-XX is no longer N ote available). 3: Required if using 701 remote control without start in gear protection. N ote
7-1

6/8HP REMOTE CONTROL ATTACHMENT KIT (6G1-48501-50-00)
REF NO PART NUMBER 1 2 6G1-48531-50-00 3 682-48538-50-00 4 91690-30012-00 5 90105-06M23-00 6 6G1-41631-50-EK 7 6G1-41635-50-00 8 91690-400160-00 9 90386-10009-00 10 6G1-41632-50-94 11 90202-10024-00 12 90206-10M12-00 13 97313-05014-00 14 92990-05600-00 15 6G1-41633-50-94 16 6G1-41238-50-00 17 6H1-41237-00-00 18 90202-05088-00 19 91490-25015-00 20 97780-50520-00 21 682-48340-50-00 22 682-48344-50-00 23 617-48361-90-00 24 90501-10264-00 25 92990-08600-00 26 91690-30012-00 27 682-48330-50-00 28 682-48346-50-00 29 617-48331-91-00 30 90501-10071-00 31 92990-08600-00 32 91690-30012-00 Component parts DESCRIPTION QTY. Remote Control Attach. Kit 1 Remote Control Bracket 1 1 Cable Clamp 2 Spring Pin 2 Bolt 2 Magneto Control Lever 1 1 Link Connecting Shaft 1 Spring Pin 1 Bushing 1 Magneto Control Lever 2 1 Plate Washer 2 Wave Washer 1 Bolt 1 Washer 1 Magneto Control Lever 3 1 Link Joint 1 1 Link Joint 2 1 Washer 1 Cotter Pin 1 Screw 1 Throttle Cable End Assembly 1 Remote Control Cable End 1 1 Cable Hook 1 Spring 1 Washer 1 Spring Pin 1 Shift Cable End Assembly 1 Remote Control Cable End 1 Cable Hook 1 Spring 1 Washer 1 Spring Pin 1
Installation 1. Install the magneto control lever 1 and the magneto control lever 2 through the bottom cowling. N O TBe E sure : to grease all the washers, bushings and the shaft as shown. Use Yamaha Marine Grease. 2. Install the magneto control lever 3 onto the magneto control shaft as shown in the preceding illustration. 3. Place the throttle grip in the fully closed position. Place the magneto control lever 2 in the fully closed position so it contacts the bottom stopper.
7-2

4. Adjust the accelerator link to properly fit between the magneto control lever 1 and magneto control lever 3 as shown (distance A). 7. 8.
6/8HP Remote Control Attach. Kit
Fit the remote control cables to the bracket and secure them with the cable clamp. Install the throttle cable joint and the shift cable joint to the magneto control lever 1 and shift handle respectively, as shown.
5. 6.
Install the bracket onto the bottom cowling. Screw the cable joint to the end of the throttle remote control cable a minimum of 8mm (0.31in). Do the same with the cable joint for the shift cable. 9. Verify proper action of the levers and the remote control box. Be sure the cables are not pinched or strained as the motor is moved from side to side or when being placed in the tilt position.
N O T If E there : is insufficient freeplay in the cable to screw it in 8mm, decrease the amount the cable is screwed in on the remote control box side. Be sure to tighten the locknut for each cable joint.
WARNING
I f the cable is not screwed in at least 8mm, the cable joint could break. T his could cause loss of control and an accident.
7-3

9.9/15 (2-STROKE) REMOTE CONTROL ATTACHMENT KIT (63V-48501-00-00)
12 13 11 12 13 17 2 2 16 15 8 9
15 2 3 11 2 1 75 19 18 6 2 5 2 4 2 0 19 19 2 0 6 75 2 6 14 18
5 10 2 4 3
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26
PART NUMBER 63V-48511-00 97395-08020-00 92995-08600-00 63V-48501-00-00 63V-48531-00-00 682-48538-50-00 91590-30012-00 97095-06016-00 92990-06600-00 95380-06600-00 663-48344-00 90468-18008-00 90201-08M12-00 63V-42154-00 90386-10025-00 90206-10M04-00 90201-10M02-00 63V-42192-00 90201-04M06-00 91490-20010-00 63V-48534-00-00 95780-08300-00 63V-48544-00 97885-05012-00 92990-05600-00 90386-10009-00
DESCRIPTION QTY. Hook, Steering 1 Bolt 1 Washer 1 Remote Control Attach. Assy 1 Bracket, Remote Control 1 1 Clamp, Cable 1 2 Pin, Spring 2 Bolt 2 Washer, Plate 2 Nut 2 Cable End, Remote Control 2 Clip 2 Washer, Plate 2 Lever, Throttle Control 1 Bush 2 Washer, Wave 1 Washer, Plate 1 Rod 2 1 Washer, Plate 2 Pin, Cotter 2 Throttle Lecer, Control 1 Nut, Flange 1 Lever, Shift Control 1 Screw, Pan Head 1 Washer, Plate 1 Bush 1
Component parts
7-4

Preparation 1. Remove: Grommet a Grommet b Screw c
9.9/15 (2-Stroke) Remote Control Attach. Kit
Remote Control Attachment Assembly 1. Install: Bushing 12 Lever 11 Rod 15 Plane Washer Cotter Pin 17
16
2.
Install: Throttle Lever 18 Plane Washer 14 Wave Washer 13 Flange Nut 19

Flange Nut 19Tightening Torque: 8 Nm (0.8 mkg)
Steering Hook 1. Install: Steering Hook 1 Bolt 2 Nylon Nut 33

Bolt: 2 Tightening Torque: 18 Nm (1.8 mkg)
WARNING
17 B end the cotter pin
ends securely.
19
14 13
12
18
2
6 12 11 15
16 17
33
17
2 0 2 2
2 1 4 242
16
5 3 7
7-5

3. Install: Bushing 22 Shift Lever Screw 21
Clamp Bracket Bolt

20
1.
Replace: Clamp Bracket Bolt
23
Screw 21 Tightening Torque: 3.5 Nm (0.35 mkg)
Nut a Tightening Torque: 13 Nm (1.3 mkg)
4.
Install: Cable Clamp 4 Spring Pin 5 Remote Control Bracket 3 Bolt 6 Nut 7
Bolt 6 Tightening Torque: 8 Nm (0.8 mkg)
2 3
19
14
13
Remote Control Cable

12
1.
18 6 12 11 15
Install: Cable End 8 Connect: Shift Cable a Throttle Cable b Cable End 8 Plane Washer 10 Clip 9
9 8
2.
16 17 2 0 2 2 2 1 4 242 16
17
5 3 7
8 b 3
18 10 9
2 0
7-6

3. Adjust: Shift cable joint position
9 8
4.
8 b 3
8mm ( 0.31 in)
18 10 9
2 0
A djustment S tep: Place the remote control lever of the remote control box in Neutral Position. Place the shift lever 20 in Neutral position. Install the shift cable a to the remote control bracket 3. Adjust the position of the cable end 8 until its hole aligns with the set pin of the shift lever 20 . Insert the clip 9 from the upside of the set pin.
WARNING
A djustment S tep: Place the remote control lever of the remote control box in Neutral Position. Install the throttle cable 6 to the remote control bracket 3. Place the throttle control grip to the fully closed position. Adjust the position of the cable end 8 until its hole aligns with the set pin of the throttle lever 18 . Insert the clip 9 from the upside of the set pin.
WARNING
8 should be screwed in T he cable end more than 8mm ( 0.31 in) . 9 should be installed from the T he clip up side as shown in the illustration.
8 should be screwed in T he cable end more than 8mm ( 0.31 in) . 9 should be installed from the T he clip up side as shown in the illustration.
7-7

F9.9/T9.9 (4-Stroke) REMOTE CONTROL ATTACHMENT KIT (6G8-48501-03-00)
REF NO PART NUMBER 1 2 6G8-48531-51-00 3 6G8-48532-50-00 4 6G8-48538-50-00 5 97395-06030-00 6 92990-06600-00 7 97395-06012-00 8 6G8-48565-50-00 9 90387-06M73-00 10 93430-04M03-00 11 6G8-48351-51-00 12 6G8-26363-00-00 13 6G8-26364-00-00 14 6G8-48511-00-00 15 97395-06016-00 16 92990-06600-00 17 6G8-48511-10-00 18 97395-06106-00 19 92990-06600-00 Component parts DESCRIPTION Remote Control Attach Assy Remote Control Bracket 1 Remote Control Bracket 2 Cable Clamp 1 Bolt Plate Washer Bolt Grommet Collar Circlip Rubber Seal Cable End Cable End 2 Steering Hook Bolt Plate Washer Steering Hook Bolt Plate Washer QTY. 1 1 1 1 1 3 2 1 1 1 1 1 1 1 2 2 1 2 2
Additional Parts Required

REF NO. PART NUMBER DESCRIPTION QTY.
1 2 3 4 5 6 7 8 9 10
6G8-82570-02-00 6G8-82590-00-00 688-82586-51-00 701-48101-50-00 6G8-26363-00-00 6G8-26364-00-00 6G8-48511-00-00 97095-06016-00 97990-06600-00 6G8-48511-10-00 Rope Type Ball Post Type
Switch Panel Assembly* Wire Harness* Extension Harness (16.5 ft)* 701 Remote Control Box Wire End 1 Wire End 2 Steering Hook Bolt Washer Steering Hook
1 1 1 1 2 2 1 1 1 1
Component Parts
* Electric Model Only
7-8

Removal 1. Disconnect the cable joints from the engine. Loosen the locknut, and remove the cable joints and the locknuts from the control cables.
F9.9/T9.9 Remote Control Attach. Kit
4. Remove the steering handle. Do this by first removing the white and black leads of the stop switch, behind the CDI unit cover.
N O TAfter E : removing the stop switch from the engine, use the emergency stop switch on the bottom cowling to stop the engine. 5. Turn the steering handle backward. 2. Remove the screws and fitting plate. 6. Fit a slotted-head screwdriver into the slit in the ring nut. 7. Set the screwdriver using the steering bracket as a fulcrum. 8. Turn the steering handle forward and loosen the ring nut. 9. Repeat this operation until the ring nut comes off. 10. Remove the washers. 3. Remove the parts shown in the illustration. 11. Pull out the steering handle assembly. When removing the throttle and shift cables from the ring nut, route the cable ends through the slit in the ring nut.
7-9

12. Remove the ring nut. 2.
Pass the remote control cables through the bottom cowling.
Installation 1. Fit the grommet into fitting plate 1 and install the parts as shown in the illustration. 3. Install the remote control bracket onto the bottom cowling, and tighten the nuts.
Screw the remote control cable a minimum of 8mm (0.31in) into the cable joint. If there is insufficient freeplay in the cable to screw it in 8mm, 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.
WARNING
4.
Secure fitting plate 1 onto the remote control bracket with the bolts.
I f the cable is not screwed in at least 8mm, the cable joint could break. T his could cause loss of control and an accident. Fit fitting plate 1 and 2 into the grooves around the cable.
7-10

5. Install the collar on the shift handle pin and clip the circlip. Connect the shift cable joint to the R mark side of the shift lever, and lock it with the lock plate. 7. 8.
Install the stop switch in the motor pan. Reconnect the white and black leads (see Removal, step 4). Reinstall the CDI cover.
6.
Connect the throttle cable joint to the R mark on the throttle lever, and lock it with the lock plate.
7-11

F15 REMOTE CONTROL ATTACHMENT KIT (66M-48501-00-00)
11 12 1
8 12 2 6 5 3 4 8 7 10
B C
13
1 2
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13
PART NUMBER 65W-44142-00-00 91690-30320-00 65W-44125-00-00 90387-06M29-00 90201-06M31-00 97595-06525-00 66M-44192-00-00 90201-05M06-00 90468-18008-00 90468-10005-00 663-48344-00-00 90468-18008-00 6H3-48538-00-00
DESCRIPTION Seal Joint Pin, Spring Lever, Shift Rod Collar Washer, Plate Bolt, with Washer Joint, Rod 1 Washer, Plate Clip Clip Cable End, Remote Control Clip Clamp, Cable 1
QTY. 1 1 1 1 1 1 1 1 1 1 1 2 1
Component parts
Installation
(Refer to illustration on page 7-10)
F15 Additional Parts Required The following information would allow the engine to be started and stopped from a 703 control box.
PART NUMBER DESCRIPTION QTY
A. Install the remote control as shown in the next page illustration. B. Make sure the remote control cable end is screwed in more than 8mm (0.31in). C. Connect the throttle (1) when the throttle is fully closed and connect the shift cable (2) when the outboard is in neutral. *Reusable Parts
66M-82590-00-00 Wire Harness Assy 66M-42725-20-00 Grommet (for a wire harness assy) 6G1-42725-00-00 Grommet (instead of a starting switch assy) 65W-81870-00)
1 1
REF NO PART NUMBER 12 66M-86111-00-00 13 66M-86116-00-00 14 66M-86112-00-00 15 97980-05208-00 16 97595-06516-00 17 90480-10M13-00 18 66M-86117-00-00 19 93210-03261-00 Component parts
DESCRIPTION
QTY.
Coil, Solenoid
Wire Pull
1
1
Stay, Solenoid Screw with Washer Bolt Grommet Hook O-ring
1 2 2 1 1 1
7-12

F15 ELECTRICAL KIT
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 PART NUMBER 6G1-81941-10-00 6G1-81952-00-00 66M-82117-00-00 65W-8182B-00-00 66M-82105-00-00 95380-08700-00 92990-08600-00 65W-81870-00-00 8G1-42725-00-00 6H3-82540-00-00 90109-06M86-00 6J8-82564-00-00 66M-86111-00-00 66M-6116-00-00 66M-86112-00-00 97980-05208-00 97505-06518-00 90480-10M13-00 66M-86117-00-00 93210-03261-00 66M-82590-00-00 DESCRIPTION Starter Relay Assy Holder, Relay Wire, Lead Nut, Special Wire Harness Nut Washer, Plate Starting Switch Assy Grommet Neutral Switch Assy Bolt Stay, Neutral Switch Coil, Solenoid . Wire, Pull Stay, Solenoid Screw, with Washer Bolt, with Washer Grommet Hook, Wire Pull O-Ring Wire Harness Assy QTY. 1 1 1 1 1 1 1 1 1 1 2 1 1 1 1 2 2 1 1 1 1
F15 Electrical Kit
Component parts
7-13
F15/F25 Remote Control Attach. Kit
F25 REMOTE CONTROL ATTACHMENT KIT (65W-48501-00-00)

REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 PART NUMBER 91690-30320-00 65W-44142-00-00 91690-30320-00 90387-06M29-00 90201-06M31-00 97595-06525-00 65W-44192-00-00 90201-05M06-00 90468-10005-00 90468-18008-00 663-48344-00-00 90468-18008-00 6H3-48538-00-00 65W-42725-10-00 65W-26326-00-00 6H1-42726-10-00 6G1-42725-00-00 65W-42726-00-00 65W-82590-00-00 DESCRIPTION Pin, Spring Seal Pin, Spring Collar Washer, Plate 1 Bolt, With Washer Joint, Rod 1 Washer, Plate Clip Clip Cable End, Remote Control Clip Clamp, Cable 1 Grommet Grommet Grommet Grommet Grommet Wire Harness Assembly QTY. 1 1 1 1 1 1 2 1 1 2 2 1 1 1 1 1 1 1
Component parts
Installation
(Refer to illustration on page 7-10)
A. Install the remote control as shown in the next page illustration. B. Make sure the remote control cable end is screwed in more than 8mm (0.31in). C. Connect the throttle (1) when the throttle is fully closed and connect the shift cable (2) when the outboard is in neutral. *Reusable Parts
7-14

REMOVAL
7-15

INSTALLATION
B
B.D. mm (0.31 in) 11

A
12 1
8 12 2 6 5 3 4 8 7 10
B C
13
1 19 14 18 16 2
17 20 16
7-16

25HP REMOTE CONTROL ATTACHMENT KIT 2 CYL. (6L2-48501-11-00)
REF NO 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 PART NUMBER 6L2-48544-01-00 6L2-48534-01-00 90386-10009-00 95780-08300-00 6L2-42154-01-00 6L2-42191-01-00 6L2-42192-20-00 90202-05088-00 91490-20010-00 6L2-48531-00-00 682-48538-50-00 91690-30012-00 90105-06M23-00 6G8-26363-00-00 6G8-26364-00-00 DESCRIPTION Remote Control Attach. Kit Shift Control Lever Throttle Control Lever Bushing Flange Nut Control Joint Rod 1 Rod 2 Plate Washer Cotter Pin Remote Control Bracket 1 Cable Clamp 1 Spring Pin Washer-Based Bolt Cable End Lock Plate QTY. 1 1 1 4 4 2 1 1 2 2 1 2 2 2 2 2
Component parts
Installation 1. Remove the grommet and plugs from the bottom cowling. A Grommet B Plug
3.
Remove the oil tank mounting bolts and the fuel filter nut. By using adhesive tape, attach the oil tank and fuel filter nearby where they will not impede servicing work. C Oil Tank D Fuel Filter
4. 2. Install remote control bracket 1 to the place where the plugs have been removed. 1 Remote Control Bracket 2 Washer-based bolt
Insert rod 2 into the hole in the throttle joint control, fit the bushing, and install rod 2 on the bottom link. 4 Bushing 8 Rod 2 6 Joint, control
N O TWhen E : fitting rod 2 to the shift rod link, shift into Reverse and fully open the throttle.
7-17

5. Install the bushing and throttle control lever into the throttle joint control, and secure it with the nut flange. 3 Lever, Throttle Control 4 Bushing 5 Nut, Flange 7.
25HP Remote Control Attach. Kit
Install rod 1 on the shift rod link E. Then, loosen bolt F to allow a small amount of gap between shift rod link and crankcase, and insert rod 1. 7 Rod 1.
N O TFor E this : operation, shift into Reverse and fully open the throttle.
6.
Insert rod 1 into the hole in the shift joint control, fit the bushing, and install it on the bottom cowling. Apply grease and install the bushing and shift joint control from outside, then secure it with the nut flange. 2 Lever, Shift Control 4 Bushing 5 Nut, Flange 6 Joint, Control 7 Rod 1
8.
Slip the plate washers 9, respectively, over rods 1 and 2, and lock each rod with the cotter pin. Retighten bolt F (which was loosened in 7 above).
9.
Connect the remote control cables to remote control bracket 1. (Connect the shift cable first.) G Shift Cable H Throttle Cable
N O TFit Ethe : groove in the cable over the recess of the bracket and clamp the cable.
7-18

10. Screw a cable joint in each remote control cable. Then, align the opening of the cable joint with the control lever and secure the cable to the joint using the lock nut. Slide the lock plate to secure the cable joint. I Cable Joint J Lock Plate
CAUTION:
A (Nut)
B (Bolt)
General Torque Specifications Nm m-kg ft-lb.
8mm 10mm 12mm 14mm 17mm
M5 M6 M8 M10 M12
5.0 8.0 18 36 43
0.5 0.8 1.8 3.6 4.3
3.6 5.8 13 25 31
S crew in the cable joint so its flat end is at least 8mm away from the end of the cable.
11. Operate the shift and throttle cables to check that they are not caught and move smoothly. After confirmation, reinstall the oil tank and fuel filter.
7-19

25E REMOTE CONTROL CONVERSION KIT - 2-Cylinder
REF NO PART NUMBER 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 6L2-42725-50 6L2-86111-00 682-86117-00 6L2-86115-00 98580-05008 92990-05600 90480-10155 98580-04008 92990-04200 6L2-86112-00 97013-06012 92990-06100 93210-03261 97013-06012 92990-06100 6L2-82590-00 6K3-83557-00 DESCRIPTION Grommet Coil, Solenoid Hook, Wire Pull Holder, Solenoid Screw, Pan Head (7G3A) Washer, Plain (646) Grommet (664) Screw, Pan Head (713) YBS66-4 Washer, Pplain Stay, Solenoid Bolt (661) YBS67-6 Washer, Spring O-ring (663) Bolt 9661) YBS67-6 Washer, Spring Wire Harness Assy Tube QTY. 1 1 1 1 2 2 1 4 4 1 2 2 1 1 1 1 1
Component parts
Installation 1. Install the following parts on the choke solenoid assembly. 1 Screw 2 Plain Washer 3 Bracket 4 Grommet 5 Extension Bolt
2.
Loosen the four screws and remove the silencer cover.
3.
Loosen the four bolts securing the carburetor.
N O T For E easy : installation of the choke solenoid, it is unnecessary to remove the carburetor.
7-20

4. Install the choke solenoid in the specified position, as shown below. 1 Choke Solenoid Bracket 2 Bolt 3 Spring Washer 6.
Replace the grommet 3 . Pass the wire harness and battery cord through the grommet, and fit the grommet in the bottom cowling. 1 Wire Harness 2 Battery Cord 3 Grommet
5.
Install the choke solenoid on the bracket with four screws. Connect the grounding wire to the starter mount bracket, and install the tension bolt on the carburetor choke rod. 1 Bracket 2 Choke Solenoid Assembly 3 Screw and Plain Washer 4 Grounding Wire (black) 5 Extension bolt 6 O-ring
N O T Fit E the : O-ring 6 in the groove in the choke rod so the extension bolt will not come off.
7-21

7. According to the wiring diagram, connect the wires correctly. Next, place the cover over the clamp.
8.
Retighten the four bolts (which were loosened in #4 on the previous page) securing the carburetor.
9.
Reinstall the silencer cover (which was removed in #2 on the previous page), and retighten the four screws.
7-22

25/30HP 3-Cylinder Remote Control Attachment Kit (6J8-48501-03-4D)
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 92990-08100-00 6J8-48534-00-00 6J8-48544-01-00 6J8-44177-00-00 91690-30016-00 6J8-44173-02-00 6J8-48531-00-00 6J8-48531-00-00 6J8-48532-00-00 682-48538-50-00 91690-30012-00 90109-06M29-00 90179-06M12-00 6G8-26363-00-00 6G8-26364-00-00 6J8-42723-50-00 6J8-42846-00-00 6J8-42724-10-00 6J8-48511-50-EK DESCRIPTION Remote Control Attach. Assy Washer, Spring Control Throttle Lever Shift Control Lever Washer Spring Pin Shift Control Lever Joint Remote Control Bracket 1 Remote Control Bracket 2 Cable Clamp 1 Spring Pin Bolt Nut Cable End Cable End 2 Bottom Cover Screw Grommet Steering Hook QTY. 1 1 1 1 1 1 1 1 1 1 1 1 2 2 2 1 1 1 1 1
Component parts
Installation 1. Remove the cover from the bottom cowling and extract a rubber grommet and a plastic blind plug as shown in the illustration below.
2.
Disconnect the link joint first.
N O TAbove E : parts are no longer used.
3.
Remove the nut from the throttle control lever shaft and re-install parts with the throttle control lever as shown in the illus. below.
N O TApply E : Yamaha Marine Grease with reinstallation.

YA M A H A M A R I N E G R E
7-23

4. Insert the link rod onto the joint hole and hold it vertically. Apply Yamaha Marine Grease before assembly.
YA M A H A M A R IN E G R E A S E
8.
Install the rubber grommet in the bottom cowling. Route the wire harness through the grommet if it is necessary.
5. Apply Yamaha Marine Grease to the shift control lever (inner) and install it to the bottom cowling and the link rod. 6. Insert the shift control lever (outer), with the plastic washer, to the rectangular hole in the shift control lever (inner).
YA M A H A M A R IN E G R E A S E
9.
The parts shown below should be assembled separately, as a sub-assembly and installed to the bottom cowling.
10. Connect the remote control cables to the remote control bracket (shift side first). 7. Align the spring pin holes and drive the spring pin into the hole by using a pin punch and a hammer. N O TFit Ein:place the throttle cable and the shift cable to the bracket, and hold them with the clamp.
7-24

11. Screw in the cable joint (over the remote control cable) a minimum of 8mm (0.31 in). Align joint hole with the cable joint set pin, and lock it with the lock nut. Lock the cable joint to the cable joint set pin with this lock plate.
12. Fit the new cover.
Additional Parts Required Part Number Description
6J8-48511-51-4D WARNING
Steering Hook (Manual Model Only)
I f the cable is not screwed in at least 8mm, the cable joint could break. T his could cause loss of control and an accident.
7-25

6/8HP ELECTRIC STARTER CONVERSION KIT (6G1-W0086-80-00)
REF NO PART NUMBER 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 682-81800-11-00 97313-08025-00 92990-08600-00 682-81822-43-94 97313-06025-00 97313-06020-00 97313-06030-00 92903-06600-00 6G1-81941-10-00 6G1-81952-00-00 6G1-81945-00-00 90105-06M14-00 689-81870-00-00 6G1-82590-00-00 6G1-82105-00-00 6G1-82117-00-00 682-42724-00-00 6G1-82362-00-00 90105-06M23-00 6G1-81970-61-00 98503-05025-00 92990-05600-00 6F5-82540-00-00 6G1-82554-00-00 90105-06M23-00 6G1-44125-00-00 DESCRIPTION Electric Starter Kit Electric Motor Ass'y Bolt Washer Electric Motor Bracket Bolt Bolt Bolt Washer Starter Relay Ass'y Starter Relay Holder Switch Fitting Plate Bolt Starting Switch Ass'y Wire Harness Ass'y Wire Lead Ass'y Lead Wire Grommet Clamp Bolt Rectifier Ass'y Panhead Screw Washer Neutral Switch Ass'y Neutral Switch Stay Bolt Shift Rod 2 Lever QTY. 1 1 2 2 1 1 2 1 4 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1 1
Component parts
The electric starter kit allows owners of 6hp and 8hp motors to enjoy the convenience of electric starting. The kit includes the starter motor, starter switch, rectifier, and all necessary brackets and wiring. A battery will also be required for complete installation.
Installation 1. Loosen the nut holding the starter stop plunger to the manual starter assembly, then pull the cable out.
7-26

2. Remove the three bolts holding the manual starter assembly and lift off the assembly. 6.
6/8HP Electric Starter Conversion Kit
Disconnect the carburetor linkage. Remove the two carburetor mounting bolts. Remove the carburetor and air box.
3. 4.
Remove the tool kit from its holder. Remove the holder from the powerhead. Disconnect the choke linkage by pulling it out of the holder. Also, remove the fuel line at the inside of the front panel.
7.
Remove the two bolts and the screw which hold the shift shaft lever to the bottom cowling. Install the shift rod lever 2 with the cotter pin on the port side. Reinstall the two bolts and screw.
5.
Remove the three screws holding the front panel. Pull the panel out to gain access to the carburetor mounting screws.
8.
Install the neutral switch to the stay as shown.
N O TThe E neutral : switch will be easier to install if the shift handle is in the FORWARD position.
7-27

9. Mount the starter motor on the bracket as shown below. Install the lead wire (larger end) on the connection on the bottom of the starter motor. Also, install the switch fitting plate to the bracket with the lead wires from the starter relay and rectifier.
11. Install the grommet on the battery lead assembly and then route the lead through the front panel as shown below.
10. Install the starter relay in the rubber holder and mount it on the fitting plate. The rectifier should be mounted above the relay. Mount the bracket assembly on the engine as shown. N O T The E : mounting bolts are of different lengths. The two shortest bolts should be mounted in the upper and lower holes on the left side. The one longest bolt should be installed in the upper right hole after the battery cable is installed (see next step). The remaining bolt is installed in the lower right hole.
12. Connect the lead wire (with the white tracer) to the left connection on the starter relay. Install the other battery lead wire on the starter bracket with the long bolt. Connect the lead wire (from the bottom of the starter) to the right connection on the relay.
7-28

13. Connect the color-coded leads of the wire harness to the components of the bracket assembly. The wire harness end with the red male lead contains the connections for the starter side of the powerhead. Refer to the wiring diagram. 14. Route the harness around to the other side of the powerhead underneath the throttle cables and clamp it to the bottom cowling. Remove the lighting coil leads from the sheath and plug them in to the green leads from the harness. Route the harness through the sheath. 15. Remove the grommet and install the starting switch on the front panel and connect the wiring as shown in the wiring diagram. Also, connect the leads for the neutral switch.
16. Reinstall the carburetor and reconnect the throttle and choke linkage. 17. Replace the front panel with the three screws and reconnect the fuel line. 18. Reinstall the manual starter assembly, then reinstall the starter stop plunger. 19. Verify proper operation of the electric starter, manual starter, choke and stop switch. Make sure the motor will only start when the shift lever is in neutral position.
7-29

Wiring Be sure the wiring is connected as shown in the following diagram:
7-30

STEERING HOOKS A steering hook is necessary in order to guide any boat from the helm. Some Yamaha outboard motors come with a steering hook as standard equipment, or are designed to accommodate a hook for later adaptation to remote steering. This is the case with the 25hp and 40hp (manual) motors. Different steering hook designs are used on Yamaha outboard motors. N O T The E : steering hook is permanently attached on 115hp models and larger.
PART NUMBER
F/ T9.9
9.9 F30 15 F40(3) F15 25HP F25 30HP C40
40E F40(4) C50 T50 F50
C60 70HP C70
C90 F80 90HP F100
6G8-48511-20-00 63V-48511-01-00 689-48511-01-00 65W-48511-00-00 6J8-48511-51-4D 63D-48511-00-4D 6H3-48511-51-4D 688-48511-11-4D 67F-61351-00-00

x = 25HP (ER Model)
= Standard Equipment
PART NUMBER 97075-08035-00 92995-08600-00 90185-05000-00 97075-10040-00 92990-10600-00 90185-10-51-00 90185-10051-00 90116-10175-00
o = Optional Equipment
Additional Parts Required DESCRIPTION Bolt Washer Nut Bolt Washer Nut Nut Stud REMARKS These items must be ordered for 9.9~F15 applications on the steering hook. These items must be ordered for 25hp and 30/40 applications on the steering hook. These items must be ordered for 30hp-90hp and C75 applications on the steering hook. QTY 1 1 1 1 1 1 2 2
N O TThe E steering : hook is permanently attached on 115hp models and larger.
7-31

Installation Mount the steering hook onto the steering bracket as shown below: 25HP and C40 T9.9
Steering Hooks
9.9, 15, and F15
N O TWhen E : a steering hook is standard equipment on any particular model it should already be attached to that motor when you receive it in the crate. On the 25hp and 40hp manual, the steering hook (not standard) will need to be installed as shown above. 30HP F25
40HP~90HP, including C Series, and F80/F100/F115
7-32

STEERING ATTACHMENT KITS The steering attachment kit connects the engine with the steering cable. The steering cable is connected to the steering wheel, which enables the operator to guide the boat from the helm. There is a Yamaha Steering Attachment Kit made for every outboard (from the 9.9hp model and up). The kit consists of a steering link rod, nuts, bolts, and washers to attach the steering hook to the steering cable.
Application Chart F25 9.9, 15, F30 F15 F40(3) 25HP, 30HP C40/50/40, F80/ C50, F40 (4) 70HP~90HP, F100/ 115HP~250HP, F50/T50 C60~C90HP F115 C115HP~C150 F/T9.9
N O TSome E : steering system components (such as wheels and steering cables), are not offered by Yamaha Parts and Accessories. However, Yamaha outboard motors are made to industry specifications to facilitate completing your steering system with readily available aftermarket product.
PART NUMBER
63V-61350-00-00 65W-61350-00-00 689-61350-02-00 63D-61350-00-00 688-61350-10-00 67F-61350-00-00 6E5-61350-02-00 6G8-61350-00-00
= Standard on Remote Models
7-33

Installation 1. Remove and discard the caps from both ends of the hollow steering/tilt tube. F/T9.9
Steering Attachment Kits
2. Route the steering cable through the steering/tilt tube and attach the cable to the tube with the securing nut that is on the steering cable.
F25
3. Fit the O-ring and cap nut on the other end of the steering/tilt tube. N O T The E :O-ring and cap mentioned above serve to keep inside the hollow steering/tilt tube and water outside the tube.
C40
Attach the steering link rod assembly to the steering hook and steering cable as shown: 9.9/15/F15
7-34

25HP (ER Model), 30HP ~ 90HP Including C Series 115~250HP
F80/F100/F115
25HP~90HP/F80/F100/F115
N O TThere E : are two holes in the steering hook. For best results in steering, use the inner hole to attach the steering link rod.
115~250HP
7-35

SECTION 8 PROPELLERS Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Propeller Application Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

PROPELLERS Yamaha propellers are specifically designed to match the characteristics of Yamaha Outboard Motors. Special computer-assisted design ensures the best possible performance. Yamaha props are available in plastic, aluminum, and stainless steel for many different applications: Saltwater Series This new breed of stainless steel props are designed exclusively for offshore fishing boats and feature highly polished, larger design. The aggressive rake angle and extra cupping on the blades provide superior mid-range fuel efficiency and excellent anti-cavitation performance. For the offshore fisherman, these features mean improved cruising range and better handling in rough seas. GYT-3 and 4 Performance Series These new props are produced using the one piece investment casting technique for superior strength and consistent blade shape. The use of 15-5 stainless steel, high carbon alloy, offers durability, resilience, and excellent corrosion resistance. The progressive pitch design and highly cupped blades reduce cavitation for increased efficiency and performance. The through-hub exhaust system on the larger hub 3-blade propellers are supplemented with specially designed outlets located at the leading edge of each blade 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 maintaining nearly the same top speed as a comparable 3blade propeller. GYT props fit all 60~250hp Yamaha Outboards. Counter-rotation models are also available. Pro Series High Performance These stainless steel props offer more cup for better acceleration, more bow lift, and improved top end performance. It allows higher transom mounting, yet does not increase steering torque. Standard Stainless Steel Stronger and more durable than aluminum with through-hub exhaust. Designed for shallow water use. Weedless Designed for use in shallow water. Eliminates weed buildup around the propeller hub. Available in aluminum for Yamaha 4hp & 5hp models, and stainless steel for 25hp & 30hp motors. Left Hand Counter-rotating Designed for dual engine systems. Stainless steel construction. Perfectly matched to Yamaha right hand propellers. Dual Thrust A Yamaha exclusive. Specially designed for sailboats and other large displacement boats. Redirects exhaust so the blades cut through clean water, for higher efficiency. Thrust in improved over conventional propellers; up to 70% in reverse, and 10% in forward.
T he 4-blade V 6 performance propellers use an exhaust hub smaller than the gear case exhaust outlet. T his allows exhaust to exit around the hub at low speed and increased acceleration.
8-1

Location of Letter Codes & Pitches The location of the letter code and pitch on the propeller varies. To find this information on aluminum and stainless steel propellers, use the illustration and the corresponding table below. The circles numbered in the illustration indicate the location of the letter code and corresponds with the far left column in the table.
Propellers
Location of Letter Codes on Aluminum and Some Selected Stainless Steel Propellers (1994~)
T25 F30 C60~C90 F40(3) T50~130 C40/55 F80/100 40/50 115
HP
F4 F8 T8 9.9/F15 F25 4/5 6/8 T9.9 F9.9/15 25/30 R AL X J AL X
V6
225X DX150 L150/ L225 250 L130 D150 L200 L250 T KL MF/MR ML TL
Type A BS BA N Mat'l AL AL AL AL 1 2 3 4 X X X X
F G AL SST AL SST X X X SST X X X
K M AL SST AL SST X X X X SST X X X X
X X
X X
X X
X X
X X
X SST
8-2

PROPELLER APPLICATION CHARTS Small Engines
MODEL DIA. PITCH DESCRIPTION PART NUMBER
2 3 4/F4/5 6/8 F8 T9.9 T8
F9.9/9.9/15/F15
7-1/4 7-1/4 7-1/4 7-1/2 7-1/2 9 8-1/2 8-1/2 11-3/4 11-3/4 11-3/4 11-3/4 9-3/4 9-3/4 9-1/4 9-1/4 9-3/4 9-1/4
4 7-1/4 8-1/4 7 8 7 6-1/2 7-1/2 9-1/4 9-1/4 11 12-1/4 6-1/2 8 8 9 9-3/4 10-1/2
Plastic, Std Aluminum, Std Aluminum Aluminum, Std Aluminum Aluminum, Dual Thrust Aluminum Aluminum Plastic, Dual Thrust Aluminum, Dual Thrust Std. Plastic, Dual Thrust Plastic, Dual Thrust Aluminum, Dual Thrust Aluminum, Dual Thrust Aluminum Aluminum, Std Aluminum Aluminum
6A1-45943-00-00 6L5-45945-00-EL 6L5-45947-00-EL 6E0-45943-01-EL 6E0-45941-01-EL 6G1-W4591-01-EL 6G1-45947-00-EL 6G1-45943-00-EL 6G8-45943-00-00 6G8-45947-00-EL 6G8-45941-00-00 6G8-45945-00-00 683-W4592-02-EL 683-W4591-02-EL 683-45947-00-EL 683-45952-00-EL 683-45952-00-EL 683-45943-00-EL
Propellers for the 25Z3, F25 & 30

DIAM. PITCH DESCRIPTION PART NUMBER
10-5/8 9-7/8 9-7/8 9-7/8 9-7/8 9-7/8 9-7/8 9-7/8 9-1/8
8-1/4 8 9 10-1/2 11-1/4 12 13 14 13
Aluminum, Dual Thrust Aluminum Aluminum Aluminum Aluminum, Std. [C25, 30] Aluminum, Std. [25] Aluminum, Std. [C30] Aluminum Stainless Steel, Weedless
6J8-W4591-00-EL 664-45943-01-EL 664-45941-01-EL 664-45945-00-EL 664-45947-01-EL 664-45954-00-EL 664-45949-02-EL 664-45952-00-EL 664-45970-00-98
8-3

Propellers for the T25, F30, 40, C40, F40, C50, F50
DIAM. PITCH DESCRIPTION
Propeller Application Charts
PART NUMBER
12-1/4 11-5/8 10-5/8 10-3/8 10-1/4 11-1/4 10 10-3/4 10-3/4 12 11-3/4 11-1/2 10-1/4 10-1/4 10-1/4
9 11 12 13 14 14 15 16 17 11 12 13 14 15 16
Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel
663-45956-01-EL 663-45947-02-EL 6H5-45952-00-EL 6H5-45945-00-EL 6H5-45958-00-EL 663-45958-01-EL 6H5-45943-00-EL 663-45949-01-EL 663-45941-01-EL 663-45972-60-98 663-45970-60-98 663-45974-60-98 663-45930-00-98 663-45976-00-98 663-45978-00-98
8-4

Propellers for the T50, 60, C60, C70, F80, 90, C90, F100, 115, F115, & 130
PART NUMBER
14 13-5/8 13-1/2 13-1/4 13 12-5/8 13 13-1/2 3-1/2 13 13 13 13 13 13-1/4 13-1/4 13-1/4 13-1/4 13-1/2 13-1/2 13-1/2 13-1/4 13-1/4 13-1/4 13-1/4
11 13 15 17 19 21 23 14 16 17 19 21 23 25 18 20 22 24 19 21 23 18 20 22 23
Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel GYT 3 Blade GYT 3 Blade GYT 3 Blade GYT 3 Blade Pro Series Pro Series Pro Series GYT 4 Blade GYT 4 Blade GYT 4 Blade GYT 4 Blade
* * * *
6E5-45954-00-EL 6E5-45949-00-EL 6E5-45947-00-EL 6E5-45945-01-EL 6E5-45941-00-EL 6E5-45943-00-EL 6E5-45952-00-EL 688-45932-60-98 688-45978-60-98 688-45930-01-98 688-45970-03-98 688-45972-02-98 688-45974-02-98 688-45976-01-98 MAR-GYT3B-V4-18 MAR-GYT3B-V4-20 MAR-GYT3B-V4-22 MAR-GYT3B-V4-24 62A-45974-00-00 62A-45970-00-00 62A-45972-00-00 MAR-GYT4B-V4-18 MAR-GYT4B-V4-20 MAR-GYT4B-V4-22 MAR-GYT4B-V4-23
*May require replacement of trim tab with 6E5-45371-10-00
Propellers for the LF115 and L130

13 13 13
17 19 21
Stainless Steel Stainless Steel Stainless Steel
6L6-45930-00-98 6L6-45970-00-98 6L6-45972-00-98
8-5
Propellers for the 150, SX150, V150, VX150, VZ150, Z150, V175, Z175, SX200, VX200, Z200, SX225, VX225, SX250
15-1/4 14-5/8 14-1/2 14 14 13-1/2 15-3/4 15-1/4 13-3/4 13-3/4 13-3/4 13-3/8 13-3/8 14-1/4 14-1/4 14-1/4 14-1/4 14-1/4 14-1/4 14-1/4 14-1/2 14-1/2 14-1/2 14-1/2 13-3/4 13-3/4 13-3/4 13-3/4 13-3/4 14-1/2 15-1/4 15-1/4 14-7/8 14-7/8 15 14-1/2 14-1/2
15 16 17 19 21 23 13 15 17 19 21 23 25 16 18 20 22 24 26 28 21 23 25 27 18 20 22 24 26 15 17 19 21 23 17 19 21
Aluminum Aluminum Aluminum Aluminum Aluminum Aluminum Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel GYT 3 Blade GYT 3 Blade GYT 3 Blade GYT 3 Blade GYT 3 Blade GYT 3 Blade GYT 3 Blade Pro Series Pro Series HD Hub Pro Series HD Hub Pro Series GYT 4 Blade GYT 4 Blade GYT 4 Blade GYT 4 Blade GYT 4 Blade Saltwater Series Saltwater Series Saltwater Series Saltwater Series Saltwater Series Stainless Steel, Heavy Duty Stainless Steel, Heavy Duty Stainless Steel, Heavy Duty
Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless Polished Stainless
6G5-45941-00-98 6G5-45952-00-98 6G5-45947-01-98 6G5-45945-01-98 6G5-45943-01-98 6G5-45949-00-98 6G5-45932-00-98 6G5-45970-02-98 6G5-45978-03-98 6G5-45974-03-98 6G5-45972-02-98 6G5-45976-01-98 6G5-45930-00-98 MAR-GYT3B-V6-16 MAR-GYT3B-V6-18 MAR-GYT3B-V6-20 MAR-GYT3B-V6-22 MAR-GYT3B-V6-24 MAR-GYT3B-V6-26 MAR-GYT3B-V6-28 6J9-45976-B0-00 6J9-45972-B0-00 66K-45972-B0-00 66K-45970-B0-00 MAR-GYT4B-V6-18 MAR-GYT4B-V6-20 MAR-GYT4B-V6-22 MAR-GYT4B-V6-24 MAR-GYT4B-V6-26 6R4-45976-00-00 6R4-45978-00-00 6R4-45970-00-00 6R4-45972-00-00 6R4-45974-00-00 61A-45978-00-98 61A-45974-00-98 61A-45972-00-98
8-6

Propellers for the D150, DX150
PART NUMBER
14 13 14 13 14 13 14 13
19 19 21 21 25 25 27 27
Front TRP Rear TRP Front TRP Rear TRP Front TRP Rear TRP Front TRP Rear TRP
MAR-TRP14-19-FR MAR-TRP13-19-RR MAR-TRP14-21-F2 MAR-TRP13-21-R2 65N-45941-00-00 65N-45943-00-00 65N-45945-00-00 65N-45947-00-00
8-7

Propellers for the LX150, LZ150, LX200, LZ200, LX225, LX250
PART NUMBER
14-1/2 14 15-1/4 13-3/4 13-3/4 13-3/4 13-3/8 14-1/4 14-1/4 14-1/4 14-1/2 15-1/4 15-1/4 14-7/8 14-7/8 15 14-1/2 14-1/2
17 19 15 17 19 21 23 18 20 22 15 17 19 21 23 17 19 21
Aluminum Aluminum Stainless Steel Stainless Steel Stainless Steel Stainless Steel Stainless Steel GYT 3 Blade GYT 3 Blade GYT 3 Blade Saltwater Series Saltwater Series Saltwater Series Saltwater Series Saltwater Series Stainless Steel, Heavy Duty Stainless Steel, Heavy Duty Stainless Steel, Heavy Duty
6K1-45947-00-98 6K1-45945-00-98 6K1-45970-01-98 6K1-45978-01-98 6K1-45974-01-98 6K1-45972-01-98 6K1-45976-00-98 MAR-GYT3B-L6-18 MAR-GYT3B-L6-20 MAR-GYT3B-L6-22 6R1-45976-A0-00 6R1-45978-A0-00 6R1-45970-A0-00 6R1-45972-A0-00 6R1-45974-A0-00 61B-45978-00-98 61B-45974-00-98 61B-45972-00-98
8-8
NOTES
NOTES

SECTION 9 RIGGING COMPONENTS/KITS Portable Fuel Tank . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-1 Remote Oil Tank Mounting Instructions (2.8 Gal. and 5.0 Gal.) . . . . . . . . . . . . . . . . 9-2 Oil Deck Filler Plate Mounting Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-4 Vertical Starter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5 Outboard Display Stands . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-6

PORTABLE FUEL TANK Yamaha offers two different types of portable fuel tanks. One series is galvanized metal and the other is the Scepter heavy-duty plastic. Provided here are their part numbers and also replacement part numbers. Along with the fuel tanks, the fuel line part numbers and their accessories are supplied below.
SCEPTER FUEL TANK 3.2 Gallon Tank Assy Fuel Pick Up Cap/ Fuel Gauge Fuel Meter Gasket Seal Pan Head Screw Fuel Connector 6Yl-24201-00-XX 97951-24261-00 97760-10000-00 6Y1-24268-00-00 6Y1-24329-00-00 98586-05016-00 6.6 Gallon 6YK-24201-00-XX 97951-24262-00 97760-00000-00 6Y1-24268-00-00 6Y1-24329-00-00 98586-05016-00
ABA-FCONN-CT-OR ABA-FCONN-CT-OR
GALVANIZED FUEL TANK 3.7 Gallon Tank Assy Fuel Cap Fuel Meters Seal Gasket 6Y4-W2420-42-24 6Y1-24210-00-00 6Y4-24260-02-00 6Y1-24329-00-00 6Y1-24268-00-00
6.3 Gallon 6Y1-W2420-42-24 6Y1-24210-00-00 6Y1-24260-02-00 6Y1-24329-00-00 6Y1-24268-00-00
FUEL LINES 5~100HP Engines 115~250HP Engines 6Y1-24306-51-00 6Y2-24306-51-00
FITTINGS, PRIMER BULBS Fittings 5~100HP Engines Primer Bulbs 6G1-24305-01-00 6Y1-24360-51-00
115~250HP Engines 6Y2-24305-02-00 6Y2-24360-51-00
9-1

REMOTE OIL TANK MOUNTING INSTRUCTIONS (2.8 Gal. and 5.0 Gal.) Remote Oil Tank 2.8 Gallon (61A-21708-03-00)
A remote oil tank bracket should be used to secure the oil tank at the desired mounting location.
N O TWhen E : installing the oil tank and routing the oil lines between the engine and the remote oil tank, be sure to keep the lines from being pinched off.
Sub-Oil Tank Holder (6E5-21734-01-33) Used for 2.8 Gal. and 5.0 Gal. Tanks
CAUTION:
B e careful not to overtighten the bracket bolt.
9-2

5.0 Gallon Oil Tank Assembly (6YR-W0035-C0-00)
Remote Oil Tank Mounting Instr.
N O T 5-Gallon E : oil tank (components and pump) in same bracket as 2.8-gallon tank. Tank extends an additional 3.5 to each side.
9-3

OIL DECK FILLER PLATE (ABB-PLATE-DE-CK) Straight Neck (ABB-PLATE-45-00) 45 Filler Neck 1. Locate the place where you wish to install the filler cap assembly. Make sure the hose has a clear path between the filler cap assembly and the oil tank. b. Be sure the nozzle stop (inside the neck of the filler cap) does not cover vent hole.
N O T ItEis :recommended that the oil tank be positioned aft of the filler cap assembly. Do not mount on a level surface. Mount on a sloped surface so any water will drain away from the filler. 2. Cut a 2" hole for the filler cap assembly. 3. Position the filler cap assembly in the hole, and mark the three screw holes for drilling. 8. After cutting the hose to the proper length, install two hose clamps on each end of the hose and fit the ends to the filler cap assembly and the oil tank fitting. Make sure the hose is pushed all the way onto the cap assembly and fitting, and tighten the clamps thoroughly.
Qty.
N O T Position E : the open area of the splint flange to the overboard side of the vessel. 4. 5. Drill the screw holes. Install the filler cap assembly. Use sealant.
N O TMake E : sure the vent hole is not 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 prevent leakage. Use oil-resistant, 1-1/2" I.D. hose between the filler cap assembly and the oil tank fitting. a. Be sure the 1/16" in. vent hole in the filler cap neck is not obstructed when hose is attached.
KIT CONTENTS Ref. Description
1 2
Filler Cap Ass'y: Deck plate with cap Oil Tank Reducer Fitting w/Gasket (6E5-24478-01-00) Optional Parts Oil Tank Reducer 45 (ABB-JOINT-45-00)
1 1
7.
N O THose, E : Hose Clamps, & Mounting Screws not supplied.
9-4

VERTICAL STARTER The sailboat owner will appreciate the convenience of the optional vertical starter. Simply bolt it to the motor and it redirects the starter rope to pull vertically.
Vertical Starter Installation 1. Remove the starter assembly. 2. Remove the cover from the starter handle.
6E0-15758-80-EK 6G1-15758-80-EK 6G1-15758-80-4D 6E7-15758-80-EK 6E7-15758-80-4D
4/5HP 6HP & 8HP ~ 93 6/8HP 94~ 9.9 & 15HP ~ 93 94~9.9-15
3. Untie the knot in the rope and remove the handle. Pull the rope out of the guide while holding the sheave. 4. Turn the sheave drum clockwise until the starter spring is free. 5. Remove the original wire guide from the starter case. 6. Install the vertical starter onto the starter case. 7. Insert the rope through the vertical starter and starter handle holes respectively. Knot the ends and install the cover into the starter handle. 8. Pass the starter rope through the cut. 9. Wind the spring up two turns counterclockwise with the starter rope. 10. Slowly release the sheave drum clockwise, then roll in the starter rope. 11. Install the starter assembly onto the cylinder block.
9-5

OUTBOARD DISPLAY STANDS Outboard display stands are useful sales tools. Potential owners are able to get an up-close look at the motor while it sits on these handsome stands.
ABA-STAND-00-SM ABA-STAND-00-MD ABA-STAND-00-LG
2~8HP (small size) 9.9~30HP, C25~30 (medium size) 40~250, C40~C150, E48~E75, T9.9 (large size)
Part Name
Description
Qty
L.H. Main Support R.H. Main Support Skeg Base Plate Upper Support Bolt Upper Support Hex Nut Skeg Base Plate Pinch Bolt Skeg Base Plate Pinch Hex Nut Skeg Base Plate Acorn Nut Skeg Base Plate Lock Washer
5/16 ~ 18 UNC Hex Head 5/16 ~ 18 UNC 1/4 ~ 20 UNC x 1-1/4 Large Hex Head 1/4 ~ 20 UNC 1/16 ~ 18 UNC 5/16~
1 1 1 1 1 1 1 4 4
9-6

Display Stand Assembly 1. Install the skeg base plate as shown. 2.
Outboard Display Stands
N O TBe Esure : the upper cavitation plate support slot faces inboard. 2. Insert the two studs of the right-hand display stand supports through the two holes of the skeg base plate. Place one lock washer and one acorn nut onto each stud and tighten. Then, repeat the procedure for the left-hand side. T ightening T orque: 2 .0m-kg ( 14.0 ft-lb.)
Take the display stand in hand and align the outboard's cavitation plates, (LH & RH) and skeg with that of the cavitation plate supports and skeg support on the display stand. Slide the stand onto the motor from the rear.
N O TItE may : be necessary to remove the prop before fitting the display stand to the motor. Also, when installing the display stand, note that the cavitation plate supports are off-set to the rear of the display stand.
CAUTION:
D o not over-tighten. T he outboard or display stand could be damaged. Outboard Motor Installation 1. Place the outboard motor onto 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.
WARNING
B efore proceeding to the next step, be certain the outboard is secure on the lift to prevent possible bodily injury to yourself and/or damage to the outboard motor or accessory.
9-7

3. Insert the upper support bolt through the tubes located directly under the cavitation supports of the left and right-hand main supports. Place one nut onto the bolt and tighten. T ightening T orque: 1.1m-kg ( 8.0ft-lb.)
CAUTION:
Outboard Display Stands
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. O utboard or display stand could be damaged.
CAUTION:
D o not over-tighten. T he outboard or stand could be damaged.

WARNING
A n outboard motor on a display stand can be bumped over, causing injury or damage. L agbolt the display stand to the floor through the two pre-drilled holed in the stand base. D o not modify the display stand. M odification could make the display stand unsafe to use or could damage the outboard motor.
9-8

SECTION 10 APPENDICES 6X1 Dual Station System - Installation Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10A 6X1 Dual Station System - Service Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B
10
Outboards
6X1
DUAL STATION SYSTEM INSTALLATION MANUAL
YAMAHA MOTOR CO., LTD. 6X1-28199-Y2

10A-1
6X1 Dual Station System INSTALLATION MANUAL 1991 by Yamaha Motor CO., LTD. 1st Edition, July 1991 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan
10A-2
NOTICE
The 6X1 Dual Station System has been developed for use in boats with two helm stations, such as off-shore fishing boats with tuna towers. The Dual Station System allows control of throttle and shifting of the outboard motor(s) from either station. For the correct installation and checking of the 6X1 dual station system, please read this manual carefully and thoroughly. Also, for the proper operation, maintenance and care of the 6X1 dual station system, please read the Owners manual 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! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person installing inspecting or repairing the dual station control system or boat.
CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the boat or dual station control system. NOTE: A NOTE provides key information to make procedures easier or clearer.
Specifications given in this manual may be subject to change without notice.
10A-3
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 115ETXD 130ETLD 130ETXD L130ETXD 150ETLD 150ETXD L150ETXD PRO V 150LD 175ETLD 175ETXD : : : : : : : : : : : 385950~ 721100~ 302500~ 701450~ 700550~ 406000~ 755500~ 702000~ 350101~ 402800~ 753500~ 200ETLD 200ETXD P200TLRP L200ETXD 225ETLD 225ETXD 250ETXD 250TURP L250ETXD L250TURQ : : : : : : : : : : 403500~ 757400~ 300101~ 702750~ 350101~ 750101~ 700101~ 800101~ 700101~ 800101~
An additional adapter (Part Number 6X1-81950-90) must be used with the 6X1 Dual Station System if it will be used on YAMAHA Outboard Motors earlier than those listed. The adapter enables the shift cut system of the actuator to control the CDI unit to reduce engine rpm during shifting. For installation details, refer to page 30. WARNING The adapter must be used on all 1989 and earlier models. Otherwise, it could be impossible to shift out of gear under load because engine rpm may not be reduced during shifting. This could result in an accident.
10A-4
CONTENTS
NOTICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 GENERAL INFORMATION . . . . . . . . . . WIRING AND COMPONENT PARTS Single Engine System . . . . . . . . . Twin Engine System . . . . . . . . . . CONTROL FUNCTIONS . . . . . . . . . . DIGITAL TACHOMETER . . . . . . . DUAL STATION JUNCTION UNIT ACTUATOR . . . . . . . . . . . . . . . . . SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 3 3 3 3 4
INSTALLING INSTRUMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 DIGITAL TACHOMETER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 PREPARATION BEFORE RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 CONTROL CABLE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 ACTUATOR INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 RECOMMENDED JUNCTION UNIT AND ACTUATOR LOCATION . . . . . . . . . . . . . . . . . . . 9 ATTACHING THE IDENTIFICATION LABELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 RIGGING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 CONNECTING THE CABLES-SUMMARY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 A. Connecting the Cables to the Remote Control Boxes . . . . . . . . . . . . . . . . . . . . . . . . 12 B. Connecting the Cables to the Dual Station Junction Unit . . . . . . . . . . . . . . . . . . . . . 12 C. Connecting the Throttle Cable to the Dual Station Junction Unit . . . . . . . . . . . . . . . . 15 D. Connecting the Shift Cable to the Actuator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15 E. Connecting the Cables to the Outboard Motor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 CONNECTING THE WIRE HARNESSES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CONNECTING THE TEN POLE CONNECTOR THE SWITCH PANEL AND THE ENGINE AND ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 CONNECTING THE THREE POLE CONNECTOR BETWEEN THE JUNCTION UNIT AND THE ACTUATOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 TESTING . . . . . . . . . . . . . . . . . . . . . . . . TESTING SHIFTING OPERATION . . . CHECKING ACTUATOR OPERATION SHIFT VOLTAGE ADJUSTMENT . . . . SHIFT STROKE ADJUSTMENT . . . . . TESTING THROTTLE OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 19 20 21 24 26
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . OPTIONAL MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . FASTENING THE JUNCTION UNIT AND THE ACTUATOR TO THE CABIN FLOOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . WIRING DIAGRAM . . . . . . . . . . . . . . . FIRST STATION (Single engine) . . . SECOND STATION (Single engine) FIRST STATION (Twin engine) . . . . SECOND STATION (Twin engine) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . 27 . . . . . . . . . . . . . . . . . . . . . 28 . . . . . . . . . . . . . . . . . . . . . 30 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 31 32 33 34
10A-5
GENERAL INFORMATION
WIRING AND COMPONENT PARTS Single engine system:
Second station
10A-6
Twin engine system:

Second station
10A-7
CONTROL FUNCTIONS
DIGITAL TACHOMETER This meter is integrated with the tachometer, trim-meter and oil-level warning meter. 1 Tachometer 2 Trim-meter 3 Oil-level warning indicator Tachometer This meter indicates the engine speed. Readings are digitally displayed in hundreds (100) of rpm. Trim-meter The trim level is shown by segments; 11 segments (for the trim zone) and 2 segments (for the tilt zone). Oil level indicator This indicator shows the quantity of engine oil remaining in the oil tank. DUAL STATION JUNCTION UNIT This unit allows changeover of control between the first and second stations. Whenever the controls lever at one remote control box is placed in either forward or reverse, the control lever at the other remote control box is locked at the neutral position. When free acceleration is used, the control levers of both remote control boxes are locked. ACTUATOR The actuator uses an electric servo system to have the dual station system perform the shifting operation. The shifting motion of the remote control lever is transmitted to the junction unit mechanically through cable, and then electrically to the servo-motor which controls the shifting mechanism on the engine according to the lever movement.
10A-8
115~200-hp
SWITCH PANEL 1 2 3 4 5 Main switch Choke switch Engine start button Engine stop button Engine stop switch
115~200-hp First station (except Prime Start models): When the engines are cold and need the activation of the choke switch, they must be started from the first station.
225~250-hp
115~200-hp Second station (except Prime Start models): When the main switches are turned on and the engines are sufficiently warm, they can be started from the second station too.
Prime Start models: The engines can be started from either station, but the main switches must be turned on in the first station before the main switches in the second station will work.
10A-9
For the single engine switch panel Second station
INSTALLING INSTRUMENT
SWITCH PANEL WARNING Disconnect the battery leads before installing or disconnecting electrical components.
115~200-hp First station
CAUTION: Install the switch panel on the dashboard in a position allowing easy access from the helmsmans seat. If the boat has no dashboard, install the switch panel in an accessible position protected from water spray.
1)
225~250-hp
2)
3)
4)
115~200-hp For the twin engine switch panel
Cut a hole in the instrument panel as indicated in this mounting diagram. Using a correct inch hole saw, make holes and then cut out the center portion as shown. Connect the wiring-harness to the switch panel assembly, and pass it back through the hole. Secure the switch panel assembly to the instrument panel with the screws, washers and nuts provided. Connect the wiring-harness to the coupling, lining up the arrow and triangle and lock the connection with the wiringharness lock.
225~250-hp
10A-10
DIGITAL TACHOMETER NOTE: Before installing the tachometer, make sure the terminal plate is set to the 12-pole position. If it is set on the other side, the tachometer will not show correct measurement. 1) Install the digital meter onto the dashboard. If no dashboard is available, use a wooden board having a thickness of 2~11mm in place of the dashboard. Select a place for installation which is free from splashes. Evenly tighten the mounting nuts on both right and left sides. For wiring, refer to the WIRING section.
2) 3) 4)
10A-11
PREPARATION BEFORE RIGGING

CONTROL CABLE INFORMATION The throttle and shift control cables are constructed of an inner cable and an outer tube (cable) which guides the inner cable. Some space must be provided between the inner cables and the tube to allow the inner cable to move freely. When a control cable is bent, this space between the inner cable and the tube allows some additional movement of the inner cable as it is pushed and then pulled. This additional movement is called end play. The amount of end play in a control cable is determined by the angle 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 working properly, so cables must be installed carefully. WARNING The Dual Station junction unit will not work properly if the control cables have excessive end play. Improper operation of the junction unit can cause improper throttle and shift control. Make sure excessive end play is eliminated.
To prevent excessive end play, these cable selection recommendations should be followed:
1.
Use quality cables To reduce the internal space and reduce the resulting end play to a minimum, always use YAMAHA CONTROL CABLES or cables of equivalent design and quality.
10A-12
2.
Keep cable length to a minimum Naturally, the longer the cables the more bends they usually have and this results in more end play. Follow these recommendations:
MAXIMUM LENGTH JUNCTION UNIT TO ENGINE . . . . . . . . . . . . . . 26 FEET MAXIMUM LENGTH JUNCTION UNIT TO UPPER STATION . . . . . . . 22 FEET MAXIMUM LENGTH JUNCTION UNIT TO LOWER STATION . . . . . . 22 FEET MAXIMUM LENGTH ACTUATOR TO ENGINE . . . . . . . . . . . . . . . . . . 26 FEET TOTAL LENGTH OF ALL THREE THROTTLE CABLES . 50 FEET
3.
Avoid excessive bends in cables The following recommendations are for quality YAMAHA cables.
MAXIMUM BENDS IN ONE CABLE . . . 1-1/2 TURNS or 6~90 TURNS or 540 MINIMUM BEND RADIUS . . . . . . 8 INCHES
10A-13
ACTUATOR INSTALLATION WARNING Do not mount the actuator in a location which prevents operation of the emergency lever and emergency manual shift lever. This would prevent the operator of the boat from being able to override the shift acutator manually if the system is not functioning correctly. CAUTION: Observe the following requirements when installing the actuator: Keep the actuator out of water or water spray. Do not mount the actuator where ambient temperature is greater than 65C (150F). Do not make sharp bends in the cables where they enter the actuator. If necessary, make the bend less by tilting the actuator. Do not loop the cables. NOTE: If necessary, use the optional actuator mounting bracket (ABA-DSBKT-00-00). This Lbracket will allow vertical mounting on a horizontal surface or horizontal mounting on a vertical surface. RECOMMENDED JUNCTION UNIT AND ACTUATOR LOCATION The mounting location for the junction unit and actuator should be selected with the following recommendations in mind: 1) The shortest possible cables should go to the motors, with the least number of bends. Since the cables for the lower station are usually the shortest, these cables can be lengthened or bent, if necessary, to produce shorter and straighter cables going to the motor. 2) The cables from the motor must enter the junction unit and actuator with as little bend as possible. If required, mount the junction unit and actuator at an angle to produce smooth bends, even if this is not cosmetically satisfactory. Do not loop the cables into the motors or into the junction unit and actuator. 3) If possible, mount the shift actuator unit in the stern of the boat to allow for shorter shirt cables.
NOTE: If necessary, use the optional mounting bracket for the actuator, see page 27 for instructions. 10A-14
ATTACHING THE IDENTIFICATION LABELS 1) Attaching the labels to the cables (in case of a single engine installation, use only the Throttle and Shift labels.)
Attach the labels to their corresponding cables.
2)
Two identical labels are provided for each identification. Attach them to both ends of the cable. Attach the labels to the JUNCTION UNIT AND ACTUATOR (In case of a single engine installation, the JUNCTION UNIT AND ACTUATOR need not be identified by labels.
Attach the label to the JUNCTION UNIT AND ACTUATOR at a convenient place for easy reference. Remove the junction cover to attach the labels.
10A-15
RIGGING
CONNECTING THE CABLES-SUMMARY Connecting the cables in the following order: A: B: C. D. E. 704 remote control boxes Remote control box cables to junction unit Throttle cable to junction unit Shift cable to actuator Outboard motor cable ends
NOTE: Before connecting the cables, set the remote control box and the outboard to the neutral position for the shift cable and to the fully closed position for the throttle cable.
10A-16
A. CONNECTING THE CABLES TO THE REMOTE CONTROL BOXES NOTE: Additional rigging information on the 704 control boxes is contained in the 704 Remote Control Box Operation Manual. 1) Install the upper and lower 704 shift and throttle cable ends 13mm on to the cables. Tighten jam nuts, then install the cable ends on the 704 control boxes. B. CONNECTING THE CABLES TO THE DUAL STATION JUNCTION UNIT 1. Removing the cover 1) Remove the cover and the three rubber plugs.
2.
Connecting the control box throttle cables to the junction unit 1) Install the dual station brass barrel cables ends on the throttle cables from the 704 control boxes. When setting the 135mm length specified, pull slightly on the cable to eliminate any backlash. This will ensure that the throttle returns correctly to idle.
2) Remove the throttle side cover and clamp cover as shown:
NOTE: Fold the two tabs on the cover inward and lift the cover open. This is the easiest way to open the cover.
10A-17
3) Remove the upper clamps
4) Install both throttle cables into the junction unit. When doing this, pull slightly on the cables and note the location of the holder slots to the grooves in the cables. If required, readjust the brass cable ends until both cables align the same. CAUTION: Confirm that the positioning mark on the rack coincides with the positioning mark on the base. If there is an offset make an adjustment by changing the position of the cable end piece or the clamp. Make sure that the cable is pulled tightly during adjustment. Remember that the cable end piece should be screwed in at least 8mm. Install the clamp so that the side of the clamp identified by the arrow mark directs the center of the junction unit. 5) Securing the cables. 1 Pass the cable through the opening in the rack. 2 Fit the cable end groove in the rack groove. 3 Position the rod clamp in place. 4 Pull the cable with force and place the C hub in the clamp. 5 Position the upper clamps. 6) Replace the cover and the clamp cover. NOTE: To install the clamp cover, press it with force from above. CAUTION: After installation, confirm that the clamp cover is firmly fitted in place. Insure the rod nuts are properly tightened against brass barrel cable ends to prevent them from working loose and turning. 10A-18
3.
Installing the control box shift cables to the junction unit. 1) Install the dual station brass barrel ends on the shift cables from the 704 control boxes. When doing this, pull slightly on the cable to eliminate any backlash and then push slightly in order to find the center point. Use this center point to adjust the brass cable end to the 169mm length shown. After adjustment, secure the cable end piece with the rod nut. 2) Move the remote control lever between forward and reverse positions at the first station several times and place the shift cam in the junction unit in neutral. Check if the grooves on the cam and cable end are offset each other. Repeat the check at the second station. If grooves are offset, use the following steps to eliminate the offset. 3) Remove cable clamp and pull out the shift cable. 4) Loosen the rod nut on the cable and move the cable end so that the offset is eliminated. 5) Install the shift cables into the junction box in the same manner as the installation of the throttle cable.
CAUTION: Install the clamp so that the side indicated by the arrow mark directs the center of the junction box. If the clamp groove does not fit the C hub groove, make an adjustment by changing the position of the cable end piece or the clamp. Remember that the cable end piece should be screwed in at least 8mm. CAUTION: After installation, confirm that the clamp cover is firmly fitted in place. Insure the rod nuts are properly tightened against brass barrel cable ends to prevent them from working loose and turning. 6) Replace the cover and the clamp covers. 10A-19
C. CONNECTING THE OUTBOARD THROTTLE CABLE TO THE JUNCTION UNIT 1) Install the outboard throttle cable ends 16mm on to the cable. Tighten jam nut, then install the cable ends on the junction unit. CAUTION: When changing the cable end piece position. It should be screwed in at least 8mm. 2) Secure the cable and install the clamp fixing plate.
D. CONNECTING THE SHIFT CABLE TO THE ACTUATOR 1) Determine installation location of the actuator. Fix the actuator by referring the instructions in ACTUATOR INSTALLATION page 8. 2) Remove four screws securing the cover of the actuator, and then the cover.
3) Screw cable end on the shift cable so that the edge of the cable end is in between 7 and 8mm (0.28~0.31 in.) from the end of the shift cable, and tighten the rod nut. NOTE: Check shift cable end play. If over 15mm (0.59 in.), refer to page 24 for stroke adjustment. 4) Confirm that the positioning mark on the base coincides with the shift rack end.
10A-20
5) Run the shift cable through the shift rack and fix the cable at the end with the rod clamp. 6) Bring the groove of the shift cable to that at the actuator side and install the cable. 7) Install the water prevention cap by referring the illustrations. 8) Fix the actuator cover using the four screws. Bolt: 6.5 Nm (0.65 mkg, 4.61 ftlb)
E. CONNECTING THE CABLE TO THE OUTBOARD MOTOR 1. Connecting the throttle cable to the outboard motor. 115~225-hp 1) Install the motors throttle cable in the outboard motor. Again, when doing this, pull slightly on the cable to eliminate any backlash when installing. This will ensure that the throttle returns correctly idle. CAUTION: In stall the throttle cable while pulling it in the direction of F2 with the throttle arm pressed by finger in the direction of F1. (This is done to ensure the proper fully closed position of the throttle lever of the outboard.) At this time, check that the cable groove fits in the cable C hub groove. When changing the cable end piece position. It should be screwed in at least 8mm. 2) Secure the cable. 250-hp 1) Adjust the throttle roller installation position so the roller contacts the accelerator cam at the alignment mark. Then connect the throttle cable to the outboard motor.
10A-21
2.
Connecting the shift cable to the outboard motor. 1) Install the motors shift cables in the outboard motor. Again, when doing this, pull slightly on the cable to eliminate any backlash and then push slightly in order to find the center point.
CAUTION: Make certain that the clamp groove fits in the C hub groove of the shift cable without applying any force to the cable and shift arm. If a proper fit is not achieved, change the position of the cable end piece. After making any adjustment, always check to make sure the cable end is screwed in at least 8mm. 2) Secure the cable. NOTE: The cable ends at the motor may require fine adjustments later after rigging and testing. 3) Adjust the shift cable by referring the instructions in CHECKING ACTUATOR OPERATION. Page 17.
10A-22
CONNECTING THE WIRE HARNESS CAUTION: Length of the extension wire harness should be 6m (20 ft.) or less. Use of longer harness may cause defective operation of the acutator.
1.
CONNECTING THE WIRE HARNESSES FOR THE UPPER STATIONS 1) Feed the wire harness between the first and second station. If may be necessary to disconnect the individual bullet connectors located near the multipin connectors for the second station.
CAUTION: Ensure that the proper wire color codes are maintained when reconnecting the individual bullet connectors or improper operation may result. 2) Connect the matching connectors for the second station control, switch panel, and instruments. 2. CONNECTING THE WIRING FOR THE LOWER STATION 1) Connect the matching connectors for the first station control, switch panel, and instruments. 2) Connect the matching connectors between the dual station harness and the engine wire harnesses. 3. CONNECT THE SHIFT ACTUATOR AND JUNCTION UNIT 1) Connect the actuator main wire harness between the dual station main wire harness and the engine main wire harness matching connector plugs. Connect the ten-pole connector to the actuator unit. 2) Connect the three-pole connector between the junction unit and the actuator.
10A-23
TESTING
WARNING Dual Station controls must be tested after rigging. Improperly installed or adjusted components could operate incorrectly, which would increase the chance for loss of control and an accident. Test the operation with the boat properly supported on land. The engine must be off and the lanyard removed before performing this test. Remove the spark plug caps to prevent engine starting. Otherwise, accident or injury could occur if the engine starts while turning the propeller by hand. CAUTION: After making any adjustment, always check to make sure the cable end is screwed in at least 8mm. TESTING SHIFT OPERATION When testing shift operation, use two people. With the engine off, and the lanyard and spark-plug caps removed, turn the ignition ON. Position one person at the engine to rotate the propeller and verify correct operation. The second person should operate the controls. NOTE: Because shift operation is performed while the engine is not running, the clutch dog may not engage the forward or reverse gear perfectly. The warning buzzer will sound after about four seconds if the gear has not been engaged. 1. 2. Turn the main switch to ON and remove the engine stop switch lockplate from the stop switch. Operate the first station in the following sequence and observe operation: 1) Shift 2) Shift to neutral 3) Shift to reverse 4) Shift to neutral If incorrect operation is observed, make adjustments in the motor shift cable end at the outboard motor. Operate the second station in the following sequence and observe operation: 1) Shift to forward 2) Shift to neutral 3) Shift to reverse 4) Shift to neutral If incorrect operation is observed at the second station, while the first station is operating correctly, make adjustments in the second station remote control shift cable at the junction unit. Again operate the first station and repeat until correct operation is obtained.
3. 4.
5.
6.
If correct operation is still not obtained, adjust the actuator by referring to the instructions in the following CHECK AND ADJUSTMENTS. CHECKING ACTUATOR OPERATION . . . . . . . . . . . . . . 10A-25 SHIFT VOLTAGE ADJUSTMENT . . . . . . . . . . . . . . . . . . 10A-26 SHIFT STROKE ADJUSTMENT . . . . . . . . . . . . . . . . . . 10A-30 10A-24
CHECKING ACTUATOR OPERATION 1) Turn the main switch to ON and adjust the cable lengths at engine side according to the following specifications with the remote control lever at neutral, forward and reverse position.
Shift Neutral Forward Reverse
Specification in mm (in.) V4/V6 : 198mm (7.80 in.) 250-hp : 189mm (7.40 in.) To be shorter than neutral measurement by 26 (1.02) or over To be longer than neutral measurement by 26 (1.02) or over
For neutral shift, adjust the length at cable end in the actuator. For forward shift, refer to SHIFT STROKE ADJUSTMENT. Page 24.
WARNING Before the following checks, be sure that no person and obstacle are around the outboard. Propeller may turn if the cable length is out of the above specifications. 2) Place the remote control lever on forward and turn the main switch to start to check that the engine is not started. Repeat the same check at reverse position. In case the engine is started, check the neutral switch is the remote control box.
WARNING Do not use the outboard in case the engine is started at either the forward or reverse shift.
10A-25
3) Place the remote control lever in neutral and turn the main switch to start to check that the engine is started. In case the engine is not started, refer to the SHIFT VOLTAGE ADJUSTMENT. Page 21.
SHIFT VOLTAGE ADJUSTMENT In case the engine is started at either forward or reverse shift through the cable lengths are within the specifications, check the shift voltage by using the following procedure. 1) Connect the throttle sensor adjusting lead, special tool No. YB-06443 in between the two sensors on the junction unit and the actuator. 2) Turn the main switch to ON and check the voltage between the sensors according to the following specifications with the remote control lever at neutral, forward and reverse positions.
Shift Neutral Forward Reverse Specifications in V 2.45 + 0.25 3.95 + 0.25 0.95 + 0.25
If any of the voltage is out of specifications, adjust the location of the shift rack in the junction unit.
10A-26
3) Remove three screws securing the shift side cover. 4) Remove two tabs on junction unit shift side and pull out the cable clamps.
5) Move the remote control lever between forward and reverse positions at the first station several times and place the shift cam in the junction unit in neutral. Check if the grooves on the cam and cable end are offset each other. Repeat the check at the second station. 6) If the grooves are not offset, either of the sensors may be defective. Adjust the sensor position, or replace the sensor if unadjustable. If grooves are offset, use the following steps to eliminate the offset.
7) Remove cable clamp and pull out the shift cable. 8) Loosen the rod nut on the cable and move the cable end so that the offset is eliminated. NOTE: At neutral, the distance from the clamp groove of the shift cable to the edge of the cable end is 169mm (0.67 in.) when properly adjusted. 9) Run shift cable through shift rack and fix it with the cable clamp.
10A-27
10) Move the remote control lever between forward and reverse positions at the first station several times and place the shift rack in the junction unit in neutral. Check if the grooves on the rack and cable end are offset each other. Repeat the check at the second station. 11) If still offset, repeat the above steps 4) to 10) until the offset is eliminated. 12) Install the cable clamp, move the remote control lever between forward and reverse positions at the first station several times and check that the voltage is within the specification.
13) Install the clamp covers and the side cover.
10A-28
SHIFT STROKE ADJUSTMENT If the engine shift cable is over 12 feet in length, it may be necessary to adjust the actuator shift stroke travel to compensate for excessive cable end play. Shift cable end play can be measured by holding one end of the cable while lightly pushing and pulling the opposite end. If cable movement (end play) exceeds 15mm (0.6 in), adjust actuator stroke as described below. 1) Loosen the four screws securing the actuator cover and remove the cover. 2) Move the emergency lever (red) fully in the direction indicated by the arrow.
3) Move the adjusting pin and spacer of the shift sensor lever from hole M (the standard location) to hole L (for longer travel). CAUTION: Do not use the pin location S (short travel). This will result in travel less than standard and may result in improper or incomplete shifting. NOTE: Shift strokes at the holes are as shown below.
Adjust pin location Hole (S) Hole (M) Hole (L) Shift stroke in mm (in.) 60 (2.36) 70 (2.76) 80 (3.15)
4) Return the emergency lever to its home position.
10A-29
5) Remove shift cable from the actuator cam and turn main switch to ON. NOTE: The actuator should move the shift cam to neutral position automatically.
6) Confirm that the shift position at engine side is in neutral and then install the shift cable on the shift cam at actuator side.
7) Move the remote control lever from neutral to estimated forward and reverse positions to check that the outboard shifts securely. 8) In case the outboard will not shift with the adjusting pin and hole (L), the cable may be defective or the cable end play is excessive. Replace the cable if it is defective.
9) After confirming that the outboard shifts, turn the main switch to OFF. Install water prevention cap and then actuator cover. Screw: 1.5 Nm (0.15 mkg, 1.1 ftlb)
10A-30
TESTING THROTTLE OPERATION When testing the throttle operation, use two people. With the engine off, the main switch off and the lanyard removed, position one person at the engine with the cowling removed to observe throttle movement to verify correct operation. The second person should operate the controls. 1. Operate the first station in the following sequence and observe operation: 1) Shift to forward and move the lever to full throttle. 2) Shift to neutral and check to see that the throttle returns to the idle position at the engine. 3) Shift to reverse and open throttle part way. 4) Shift to neutral and check to see that the throttle returns to the idle position at the engine. 2. If incorrect operation is observed, make adjustments in the motor throttle cable end at the outboard motor. Operate the second station in the following sequence and observe operation: 1) Shift to forward and move the lever to full throttle. 2) Shift to neutral and check to see that the throttle returns to the idle position at the engine. 3) Shift to reverse and open throttle part way. 4) Shift to neutral and check to see that the throttle returns to the idle position at the engine. 4. If incorrect is observed at the upper station, while the lower station is operating correctly, make adjustments in the upper remote control throttle cable at the junction unit.
3.
WARNING Insure that the engine throttle cable returns to idle whenever the control is returned to neutral. If necessary, make adjustments in the motor throttle cable end adjustment. 5. Again operate the first station and repeat until correct operation is obtained.
10A-31
INSTALLATION
OPTIONAL MOUNTING BRACKET MOUNTING BRACKET (p/n ABA-DSBKT-00-00) If only limited space is available to mount either the junction unit and or the actuator, an optional mounting bracket is available. This bracket is not supplied with mounting hardware. Use either the extra hardware supplied with the dual station system kit or contact a local supplier for appropriate hardware for your specific installation. CAUTION: Choose hardware that will hold the bracket securely to the boat without the chance of breaking loose. Otherwise the junction unit or actuator could be damaged.
10A-32
FASTENING THE JUNCTION UNIT AND THE ACTUATOR TO THE CABIN FLOOR 1. Fastening the units using bolts 1) Bore holes, each 8.5mm (0.335 in.) in diameter, in the cabin floor using a template. 2) Tighten the hexagon headed bolts. Screw: 1.5 Nm (0.15 mkg, 1.1 ftlb)
1-A Using an optional mounting bracket 1) Select a place for installation which is recommended location. 2) Bore holes, each 3mm (0.118 in.) in diameter, in the cabin floor referring illustration.
3) Secure the mounting bracket to the cabin floor with screws. 4) Secure the junction unit and actuator to the mounting bracket with hexagon headed bolts.
2.
Fastening the units using wood screws. 1) Bore holes, each 3mm (0.0118 in.) in diameter, in the cabin floor using a template. 2) Tighten the wood screws. Screw: 5.8 Nm (0.58 mkg, 4.1 ftlb)
2.
INSTALLING THE COVER (Junction unit only) Place a rubber plug over each cable and install the cover.
10A-33
After all the installation is completed, check that the cables are properly connected as shown below.
10A-34
ADAPTER WARNING This adapter is required for older Yamaha outboards. Refer to the Applicable Models section for details. Installation instructions: 1) Remove the top cowling and remove the cover from the CDI unit on the outboard motor. 2) Remove the white wire on the CDI from the main harness. CAUTION: On V-6 models (except V6 EXCEL), do not remove the white wire located beneath the CDI unit that connects the CDI to the control unit. This is the wrong white wire. The shift cut system will not function if this wire is used. 3) Cut the eye terminal from the end of the white wire and install a male bullet connector. 4) Connect the adapter wires as follows: White wire to the white wire with the new buller connector. White/black wire to the CDI terminal that the white wire was removed from. Red wire to the red wire terminal of the rectifier regulator Black wire to the black wire terminal of the CDI. 5) Change the grommet for the black wire from a 1-hole to a 2-hole type. 6) Clamp the adapter to the main wire harness with a tie clamp. 7) Reinstall the CDI cover and the cowling. 8) Start the engine and make sure that it can be stopped by the main switch, by the stop switch, and by pulling the engine stop switch lanyard. WARNING The adapter must be connected correctly. Be sure the main switch, engine stop switch, and the engine stop switch lanyard to stop the engine properly. Ensure that all electrical connections are tight and will not vibrate loose during normal operation. Otherwise, the engine may not stop, which could result in an accident. 10A-35
1 2 3 4 5
Adapter Rectifier-regulator CDI unit To ignition coil To flywheel magneto
6 To starter relay and PTT relay 7 Clamp 8 Control unit
WIRING DIAGRAM
FIRST STATION (Single engine)
10A-36
SECOND STATION (Single engine)
10A-37
10A-38
10A-39
Outboards
6X1
DUAL STATION SYSTEM
SERVICE GUIDE
10B-1
6X1 Dual Station System SERVICE GUIDE 1991 by Yamaha Motor CO., LTD. 1st Edition, October 1991 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Co., Ltd. is expressly prohibited. Printed in Japan
10B-2
NOTICE
The 6X1 Dual Station System has been developed for use in boats with two helm stations, such as off-shore fishing boats with tuna towers. The Dual Station System allows control of throttle and shifting of the outboard motor(s) from either station. Particularly important information is distinguished in this manual by the following notations. The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person installing inspecting or repairing the dual station control system or boat. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the boat or dual station control system. NOTE: A NOTE provides key information to make procedures easier or clearer.
Specifications given in this manual may be subject to change without notice. APPLICABLE MODELS The 6X1 Dual Station System is designed to be used with 1990 and later YAMAHA outboard motors with the following serial numbers and higher: Engine Serial Numbers:
115ETLD 115ETXD 130ETLD 130ETXD L130ETXD 150ETLD 150ETXD L150ETXD PRO V 150LD 175ETLD 175ETXD : : : : : : : : : : : 385950~ 721100~ 302500~ 701450~ 700550~ 406000~ 755500~ 702000~ 350101~ 402800~ 753500~ 200ETLD 200ETXD P200TLRP L200ETXD 225ETLD 225ETXD 250ETXD 250TURP L250ETXD L250TURQ : : : : : : : : : : 403500~ 757400~ 300101~ 702750~ 350101~ 750101~ 700101~ 800101~ 700101~ 800101~
An additional adapter (Part Number 6X1-81950-90) must be used with the 6X1 Dual Station System if it will be used on YAMAHA Outboard Motors earlier than those listed. The adapter enables the shift cut system of the actuator to control the CDI unit to reduce engine rpm during shifting. For installation details, refer to page 29. WARNING The adapter must be used on all 1989 and earlier models. Otherwise, it could be impossible to shift out of gear under load because engine rpm may not be reduced during shifting. This could result in an accident. 10B-3
10B-4
CONTENTS
EXTERNAL VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-6 OUTLINE OF FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-6 FEATURES AND BENEFITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-7 ELECTRIC SHIFTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-7 EMERGENCY MANUAL SHIFT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-8 SHIFT CUT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-9 AUTOMATIC INTERLOCK SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-10 SECOND STATION SWITCH PANEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-11 WARNING FUNCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-12 1. Shift disengagement failure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-12 2. Shift engagement failure warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-15 WARNING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-18 1. Monitoring of starting period . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-18 2. Stalled engine warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-18 3. Engine stop switch ON . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-19 4. Overheat warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10B-19 5. Oil level warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-20 6. Stopping the engine at the second station . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-20 OPTIONAL PARTS INFORMATION EXTENSION WIRE HARNESS . ADAPTER . . . . . . . . . . . . . . . . MOUNTING BRACKET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-21 10B-21 10B-21 10B-21
TECHNICAL TIPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-22 SHIFT MOTOR WILL NOT OPERATE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-22 1. Emergency manual shift system . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-22 RIGGING INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ALL COMPONENTS IN ONE PACKAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . PREPARATION OF INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1. Attaching the cable identification marks . . . . . . . . . . . . . . . . . . . . . . . . . 2. Arranging the remote control cables, wire harnesses and steering cables 3. Precautions when routing cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SERVICE PROCEDURES . . . . . . . . . . . . CHECKING ACTUATOR OPERATION SHIFT VOLTAGE ADJUSTMENT . . . . SHIFT STROKE ADJUSTMENT . . . . . ADAPTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-24 . . . . . . . 10B-24 . . . . . . . 10B-25 . . . . . . . 10B-25 . . . . . . . 10B-26 . . . . . . . 10B-27 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-28 10B-28 10B-29 10B-32 10B-34
SPECIAL SERVICE TOOL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-35 THROTTLE SENSOR ADJUSTING LEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-35 SPECIFICATIONS AND MAINTENANCE DATA SPECIFICATIONS . . . . . . . . . . . . . . . . . . . MAINTENANCE DATA . . . . . . . . . . . . . . . . REPLACEMENT PARTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-36 10B-36 10B-36 10B-36
WIRING DIAGRAM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10B-37 10B-5

EXTERNAL VIEW
OUTLINE OF FEATURES
10B-6

FEATURES AND BENEFITS
ELECTRIC SHIFTING SYSTEM The dual station system uses an electric servo system to have the system perform the shifting operation. The shifting motion of the remote control lever is transmitted to the junction unit mechanically through cable, and then electrically to the servomotor which controls the shifting mechanism according to the lever movements. The change of shift angle is converted to a voltage by the sensor in the junction unit. Then, the servomotor is actuated according to the voltage differences between the voltage and a voltage detected by the sensor in the acutator side.
10B-7

EMERGENCY MANUAL SHIFT SYSTEM The emergency manual shift system is provided against failure in shifting with the remote control lever. 1 Emergency lever (red) 2 Shift rack 3 Emergency manual shift lever Lifting up the emergency lever 1 moves the shaft of the rack 2 to disengage the rack from the motor side pinion and engage the rack with the pinion on the emergency manual shift lever 3. Then, the outboard can be shifted by using the emergency manual shift lever 3. Turning the emergency lever 1 clockwise/counterclockwise by approximately 5/12 shifts the outboard motor forward/revers. NOTE: The emergency manual shift lever 3 must be moved in the direction opposite to the remote control lever.
10B-8

SHIFT CUT SYSTEM The shift cut system limits engine speed below 1000 rpm at shifting to ease the operator. The system limits the engine speed while the servomotor operates. The system is applicable immediately to those outboard models listed in the SAFETY INFORMATION. When installing the system in the outboard models not shown in the list, the specific adapter must be used. The adapter is available with extra charge. For the installation of the shift cut system on the outboard not listed in the SAFETY INFORMATION and controlled with the 6X1 DUAL STATION SYSTEM INSTALLATION MANUAL, consult your YAMAHA dealer. WARNING Without the adapter, use of the shift cut system on those models not listed in the SAFETY INFORMATION disable the system.
10B-9

AUTOMATIC INTERLOCK SYSTEM The dual station unit allows automatic switching of throttle and shift control between the first and second stations. It is also designed to minimize operating loads. Due to the automatic interlock system, if the throttle and shift control have been set at one station, the settings cannot be altered at the other station. In other words, the throttle and shift control can be set at one station only if the throttle and shift levers at the other station are in neutral.
10B-10

SECOND STATION SWITCH PANEL The switch panel of the second station has one start button (two start buttons on the twin engine model), one stop button (two stop buttons on the twin engine model) for engine control and one emergency stop switch. An alarm buzzer on the rear of the switch panel sounds if the warning system is activated.
10B-11

WARNING FUNCTIONS This dual station control system has a shift disengagement failure warning and a shift engagement failure warning functions. Buzzer on the remote control box or the switch panel warns of the failure.
1. Shift disengagement failure warning. In case shifting into neutral has become impossible during running. The buzzer should sound. Engine should be slowed. The outboard will not shift though the remote control levers can be moved.
NOTE: No visual warning is provided. The following are possible causes of the shifting failure. A wire disconnection in the power source of the actuator or the reduction of the actuator operating voltage. Failure of sensors on the actuator or in the junction unit, or wire disconnection in those components. Failure of actuator or its related components.
NOTE: As long as the battery is able to energize the outboard, it is able to power the shift motor. Twin engine installation is equipped with a specific shift disengagement failure warning system. At this time, the actuator operates to return the shift to neutral and stop the shifting motor automatically.
10B-12

In case the buzzer sounds, engine is slowed and the outboard will not shift perform the following steps. 1. 2. Move to a safe area and turn the main switch to OFF. Check battery terminal for looseness and disconnection. Tighten or connect the terminal if necessary. Check sensor wire terminal for looseness and disconnection. Connect the terminal if necessary. Turn the main switch to ON to check that the outboard shifts into neutral. If the outboard shifts, the cruising can be continued. In case it will not shift yet, use emergency lever and emergency manual shift lever to shift the outboard into neutral and then start the engine. For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23. Run to the nearest port immediately and consult your YAMAHA dealer.
3.
4. 5. 6.
7.
WARNING Do not cruise if the emergency lever and emergency manual shift lever have to be used. The emergency means are designed exclusively for running to a service available port immediately.
In case either of the twin engines in the twin engine installation has become a warning state which causes engine speed to be reduced, the speed of other engine is also reduced at the same time. NOTE: The circuit for this control is built in the unit in the switch panel.
10B-13
Power failure or shift disengagement failure warning. In case of power failure or shift disengagement failure on either of the two outboards; The buzzers for both of the outboards should sound. Speeds of the two engines should be reduced to about 2000 rpm. The warning outboard will not shift though the remote control levers can be moved.
NOTE: No visual warning is provided.
In case the power failure or shift disengagement failure has occurred on either of the two outboards, perform the following steps. 1. 2. Turn the main switch for each outboard to OFF. Check battery terminal for looseness and disconnection on the warning outboard. If the fuse has been burned out, replace it referring to your outboard motor owners manual. Check sensor wire terminal for looseness and disconnection on the warning outboard.
3.
4.
Turn the main switch for the warning outboard to ON and check that the outboard shifts into neutral. If the outboard shifts, the cruising can be continued.
5.
10B-14
6.
In case it will not shift yet, use emergency lever and emergency manual shift lever of the warning outboard to shift it into neutral and then start the engine. For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23.
7.
Run to the nearest port immediately and consult your YAMAHA dealer.
WARNING Do not cruise if the emergency lever and emergency manual shift lever have to be used. The emergency means are designed exclusively for running to a service available port immediately. The following are the possible causes of the shifting failure. A wire disconnection in the power source of the actuator or reduction to the actuator operating voltage. Failure of sensors on the actuator or in the junction unit, or wire disconnection in those components. Failure of actuator or its related components.
2. Shift engagement failure warning In case the outboard will not shift into forward or reverse through the control lever is moved. The buzzer should start to sound within four seconds after moving the remote control lever. Engine speed cannot be increased though the remote control lever is moved.
NOTE: NO visual warning is provided.
10B-15

In case the buzzer sounds and the outboard cannot be shifted with remote control lever; 1. Return the remote control lever to the neutral position and retry the shifting. If the outboard shifts, the cruising can be continued.
2.
In case it will not shift yet, use emergency lever and emergency manual shift lever to shift the outboard, run to the nearest port immediately and consult your YAMAHA dealer. For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23. WARNING
Do not cruise if the emergency lever and emergency manual shift lever have to be used. The emergency means are designed exclusively for running to a service available port immediately. Normally the shift motor is able to shift from neutral to forward or reverse within 0.3 seconds from its actuation moment. If the shift operation is performed while the engine is not running, the dogclutch may not engage the forward or reverse gear perfectly, causing the warning to occur at shifting.
NOTE: The circuit for this control is built in the unit in the switch panel. In case either of the outboards will not shift into forward or reverse within four seconds after moving the remote control lever; The buzzers of both of the outboards should sound. Engine speed cannot be increased though the remote control lever is moved.
NOTE: No visual warning is provided.
10B-16

In case the buzzers sounds and the engine speed cannot be increased; 1. Return the remote control lever to the neutral position and retry the shifting. If the outboard shifts, the cruising can be continued. In case it will not shift yet, use emergency lever and emergency manual shift lever to shift the outboard, run to the nearest port immediately and consult your YAMAHA dealer. For operations of the emergency lever and emergency manual shift lever, refer to page 10B-22~23.
2.
10B-17

WARNING SYSTEM A warning buzzer is provided for the second station. With the addition of the second station mode, the warning system functions as follows. 1. Monitoring of starting period (Main switch ON)
NOTE: If there is a problem, the indicator corresponding to the problem does not light up and the buzzer does not sound. 2. Stalled engine warning
This warning is issued if an engine stalls or fails to start.
The warning ends once the engine is restarted.
10B-18

3. Engine stop switch ON (Lock plate OFF)
4.
The warning ends when the engine is restarted with the lock plate ON or when the main switch is turned off. Overheat warning (Thermo switch ON)
NOTE: In the case of a twin engine system, the buzzers for both the starboard and port side engines sound when the shift lever is in either forward or reverse. When the shift lever is placed in neutral, the only buzzer that sounds is for the engine whose thermo switch is turned on. The warning ends once the engine is sufficiently cooled. 10B-19

5. Oil level warning (Oil level sensor ON
NOTE: In the case of a twin engine system, the buzzers for both the starboard and port side engines sound when the shift lever is in either forward or reverse. When the shift lever is placed in neutral, the only buzzer that sounds is for the engine whose oil level is low. 6. The warning ends when engine oil is replenished. (Always turn off the main switch when replenishing engine oil.) Stopping the engine at the second station (Stop switch ON)
NOTE: When stopping the engine from the second station, press the stop switch for at least 1 second to completely stop the rotation of the engine. If the stop switch is pressed only momentarily, the stalled engine warning described above will activate. 10B-20

OPTIONAL PARTS INFORMATION
EXTENSION WIRE HARNESS 1 3P Harness 2 10P Harness
ADAPTER For installation of the adapter, refer to page 10B-34.
MOUNTING BRACKET P/NO. ABA-DSBKT-00-00 For installation of the mounting bracket, refer to DUAL STATION SYSTEM INSTALLATION MANUAL.
10B-21
TECHNICAL TIPS
SHIFT MOTOR WILL NOT OPERATE 1. Emergency manual shift system Emergency lever and emergency manual shift lever are provided against failure in shifting with the remote control lever. NOTE: It is recommended to use a person specifically for operating these lever. The person operating these levers and the person operating the remote control lever for the adjusting the engine speed should keep close contact with each other so that the shifting operation is made at a lower speed. The levers must be operated while the engine is running.
WARNING 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 accident may result. Do not cruise if the emergency lever and emergency manual shift lever have to be used. The emergency means are designed exclusively for running to a service available port immediately.
1 Emergency lever (red) 2 Emergency manual shift lever Operating procedure at shift engagement failure NOTE: The outboard is in neutral and the engine is running. 1) 2) Move the lever 1 fully in the direction indicated by an arrow. Turn the emergency manual shift lever 2 clockwise (forward)/counterclockwise (reverse) by approximately 5/12 of a turn until the outboards shifts.
10B-22
NOTE: The emergency manual shift lever 2 must be moved in the direction opposite to the remote control lever. Moving the emergency manual shift lever 2 in the same direction as the remote control lever causes the buzzer to sound.
Operating procedure at shift disengagement failure NOTE: The engine is running and the outboard is in forward or reverse. 1) Move the emergency lever 1 fully as indicated by an arrow.
2.) Move the emergency manual shift lever 2 to neutral. The outboard should shift into neutral. 3) 4) The emergency lever 1 fully against the arrow. When shifting forward or reverse again, follow the steps in the operating procedure at shift engagement failure.
10B-23

RIGGING INSTRUCTIONS
ALL COMPONENTS IN ONE PACKAGE The 6X1 dual station includes a 704 remote control box, digital tachometer, switch panel, wire harness, dual station unit and actuator. These components, which have been selected and purchased separately in the past, are supplied in a single package, thereby offering the customer and the dealer greater convenience.
10B-24

PREPARATION OF INSTALLATION 1. Attaching marks the cable identification
Connect the cables in the following sequence as illustrated below.
NOTE: Before connecting the cable, be sure to move the shift levers on the remote control box and the engine to neutral.
10B-25

2. Arranging the remote control cables, wire harnesses and steering cables
10B-26

3. Precautions when routing cables When rigging the second station, pass each cable and wire harness up through the pipe as illustrated below. Wire harness: 1 Pass a rope through the pipe and tie it to the wire harness. Remove the bullet terminals at the front of the wire harness and remove the connectors. 2 Wrap the end of the wire harness with tape to keep it from being caught in the pipe. 3 Pull the rope gently so that the wire harness will not catch inside the pipe. 4 Connect the bullet terminals as they were originally. Remote control cable: 1 Attach a cable end piece to the end of the cable. NOTE: The end piece should be screwed in at least 8mm. 2 Pull the cable gently, just as you did with the wire harness. NOTE: The cable should be bent as little as possible. No more than three bends at a right angle (200mm in radius) are allowed. 3 Tie the rope around the end of the steering cable and pull it gently through the pipe.
10B-27

SERVICE PROCEDURES
CHECKING ACTUATOR OPERATION 1) Turn the main switch to ON and adjust the cable lengths at engine side according to the following specifications with the remote control lever at neutral, forward and reverse position.
Shift Neutral Forward Reverse
Specification in mm (in.) V4/V6 : 198 mm (7.80 in.) 250-hp : 189 mm (7.40 in.) To be shorter than neutral measurement by 26 (1.02) or over To be longer than neutral measurement by 26 (1.02) or over
For neutral shift, adjust the length at cable end in the actuator. For forward shift, refer to SHIFT STROKE ADJUSTMENT. Page 10B-32. WARNING Before the following checks, be sure that no person and obstacle are around the outboard. Propeller may turn if the cable length is out of the above specifications.
2)
Place the remote control lever on forward and turn the main switch to start to check that the engine is not started. Repeat the same check at reverse position. In case the engine is started, check the neutral switch is the neutral control box.
WARNING Do not use the outboard in case the engine is started at either the forward or reverse shift.
10B-28

3) Place the remote control lever in neutral and turn the main switch to start to check that the engine is started. In case the engine is not started, refer to the SHIFT VOLTAGE ADJUSTMENT. Page 10B-29.
SHIFT VOLTAGE ADJUSTMENT In case the engine is started at either forward or reverse shift through the cable lengths are within the specifications, check the shift voltage by using the following procedure. 1) Connect the throttle sensor adjusting lead, special tool No. YB-06443 in between the two sensors on the junction unit and the actuator.
2)
Turn the main switch to ON and check the voltage between the sensors according to the following specifications with the remote control lever at neutral, forward and reverse positions.
Shift Neutral Forward Reverse Specifications in V 2.45 + 0.25 3.95 + 0.25 0.95 + 0.25
If any of the voltages is out of the specifications, adjust the location of the shift rack in the junction unit.
10B-29

3) 4) Remove three screws securing the shift side cover. Remove two tabs on junction unit shift side and pull out the cable clamps.
5)
Move the remote control lever between forward and reverse positions at the first station several times and place the shift cam in the junction unit in neutral. Check if the grooves on the cam and cable end are offset each other. Repeat the check at the second station.
6)
If the grooves are not offset, either of the sensors may be defective. Adjust the sensor position, or replace the sensor if unadjustable. If grooves are offset, use the following steps to eliminate the offset.
7) 8)
Remove cable clamp and pull out the shift cable. Loosen the rod nut on the cable and move the cable end so that the offset is eliminated.
NOTE: At neutral, the distance from the clamp groove of the shift cable to the edge of the cable end is 169 mm (0.67 in.) when properly adjusted. 9) Run shift cable through shift rack and fix it with the cable clamp.
10B-30

10) Move the remote control lever between forward and reverse positions at the first station several times and place the shift rack in the junction unit in neutral. Check if the grooves on the rack and cable end are offset each other. 11) If still offset, repeat the above steps 4) to 10) until the offset is eliminated.
12) Install the cable clamp, move the remote control lever between forward and reverse positions at the first station several times and check that the voltage is within the specification.
13) Install the clamp covers and the side cover.
10B-31

SHIFT STROKE ADJUSTMENT If the engine shift cable is over 12 feet in length, it may be necessary to adjust the actuator shift stroke travel to compensate for excessive cable end play. Shift cable end play can be measured by holding one end of the cable while lightly pushing and pulling the opposite end. If cable movement (end play) exceeds 15 mm (0.6 in), adjust actuator stroke as described below. 1) 2) Loosen the four screws securing the actuator cover and remove the cover. Move the emergency lever (red) fully in the direction indicated by the arrow.
3)
Move the adjusting pin and spacer of the shift sensor lever from the hole M (the standard location) to hole L (for longer travel).
CAUTION: Do not use the pin location S (short travel). This will result in travel less than standard and may result in improper or incomplete shifting. NOTE: Shift strokes at the holes are as shown below.
Adjust pin location Hole (S) Hole (M) Hole (L) Shift stroke in mm (in.) 60 (2.36) 70 (2.76) 80 (3.15)
The values are valid only when the shift stroke at junction unit is 70 mm (2.76 in.). 4) Return the emergency lever to its home position.
10B-32

5) Remove shift cable from the actuator cam and turn main switch to ON.
NOTE: The actuator should move the shift cam to neutral position automatically.
6)
Confirm that the shift position at engine side is in neutral and then install the shift cable on the shift cam at actuator side.
7)
Move the remote control lever from neutral to estimated forward and reverse positions to check that the outboard shifts securely. In case the outboard will not shift with the adjusting pin and hole (L), the cable may be defective or the cable end play is excessive. Replace the cable if it is defective.
8)
9)
After confirming that the outboard shifts, turn the main switch to OFF. Install water prevention cap and then actuator cover.
Screw: 1.5 Nm (0.15mkg, 1.1 ftlb)
10B-33

ADAPTER WARNING This adapter is required for older Yamaha outboards. Refer to the Applicable Models section for details.
Installation instructions: 1) Remove the top cowling and remove the cover from the CDI unit on the outboard motor. Remove the white wire on the CDI from the main harness.
2)
CAUTION: On V-6 models (except V6 EXCEL), do not remove the white wire located beneath the CDI unit that connects the CDI to the control unit. This is the wrong white wire. The shift 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. Connect the adapter wire as follows: 5) 6)
1 2 3 4 5 Adapter Rectifier-regulator CDI unit To ignition coil To flywheel magneto 6 To starter relay and PTT relay 7 Clamp 8 Control unit
4)
White wire to the white wire with the new bullet connector. Green wire to the green wire the new bullet connector. White/black wire to the CDI terminal that the white wire was removed from. Red wire to the red wire terminal of the rectifier regulator Black wire to the black wire terminal of the CDI.
Change the grommet for the black wire from a 1-hole to a 2-hole type. Clamp the adapter to the main wire harness with a tie clamp. Reinstall the CDI cover and the cowling. Start the engine and make sure that it can be stopped by the main switch, by the stop switch, and by pulling the engine stop switch lanyard.
7) 8)
10B-34

WARNING The adapter must be connected correctly. Be sure the main switch, engine stop switch, and the engine stop switch lanyard to stop the engine properly. Ensure that all electrical connections are tight and will not vibrate loose during normal operation. Otherwise, the engine may not stop, which could result in an accident.
SPECIAL SERVICE TOOL

THROTTLE SENSOR ADJUSTING LEAD (YB-06443)
10B-35

SPECIFICATIONS AND MAINTENANCE DATA
SPECIFICATIONS The 6X1 Dual Station System differs from a conventional single-station control in the following ways: In a conventional outboard control, cables connect directly from the remote control to the engine (or both engines in a dual engine rig). In the Dual Station System, two remote control stations connect first to a junction box. The SHIFT control for both remote controls is by cable to the junction box. However, an electrical signal from the junction box then controls the servo in the dual-station actuator to shift the engine by a separate cable. Emergency manual shifting of the actuator is possible in case of electrical failure. The THROTTLE control for both stations go to the junction box. Then one set of cables control the throttle on the engine. There is an automatic interlock which prevents one control from being used while the other is in use. The engine can be started from either station as long as the key is on at the lower station. There is no choke control on the upper station, however, if the engine requires manual choke control. The engine can be stopped from either station by pushing the stop switch or by pulling the engine stop switch lanyard. If the dual station system malfunctions, the dual station system responds by sounding the buzzer in the remote control and, if over a certain engine speed, by reducing engine rpm. There is a shift cut system that reduces engine speed to below 1,000 rpm during shifting to make shifting easier.
MAINTENANCE DATA Frequency of maintenance operations may be adjusted according to the operating conditions, but the following table gives general guidelines. The mark (G) indicates the check-ups which you may carry out yourself. The mark (O) indicates work to be carried out by your Yamaha dealer.
Intervals Item Shift cable Throttle cable Shift sensors Wiring & Connector Grease points Bolts & Nuts Battery
REPLACEMENT PARTS If replacement parts are necessary, use only genuine Yamaha parts or equivalents of the same type and of equivalent strength and materials. Any part of inferior quality may malfunction, and the resulting loss of control could endanger the operator and passengers.
Inspection/Adjustment Inspection/Adjustment Inspection/Adjustment Inspection/Reconnect Greasing Retightening Inspection
Initial 50 hours 10 hours (3 months) O O O G G G G G G
Every 100 hours 200 hours (6 months) (1 year) O O O G G G G
10B-36

WIRING DIAGRAM
FIRST STATION (Single engine)
1 2 3 4 5
Switch panel Engine stop switch Main switch Choke switch Remote control box
6 7 8 9
Neutral switch P.T.T. switch Buzzer Fuel sender 10 Lamp switch (option)
11 Wire harness 12 Digital tachometer 13 Digital speedometer 14 Actuator 15 Control unit
16 Sensor 17 Junction unit
10B-37

SECOND STATION (Single engine)
1 2 3 4 5
Switch panel Stop switch Start switch Engine stop switch Remote control box
6 7 8 9
P.T.T. switch Neutral switch Buzzer Digital tachometer
10B-38
10B-39
10B-40

F A X C O R R E C T IO N S H E E T
If an error is found in this book, please make copies of this page and FAX to Yamaha:
DEALER NUMBER: _____________________ DATE: _________________________________ SECTION _______________________________ PAGE # _______________ DETAILED EXPLANATION OF ERROR: _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ _____________________________________________________________________________ When completed, please FAX to
A T T N : Yamaha T echnical S ervice 7 7 0-42 0-6 105

Yamaha - Us Rig - Guide 2001

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Yamaha - Us Rig - Guide 2001

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2001 Outboard Rigging Guide

2000 YAMAHA MOTOR CORPORATION, U.S.A.

Outboard Rigging Guide - 2001

Standard Equipment, Rigging Kits, & Crate Contents . . . . . . . . . . . . . .

Engine Dimensions, Mounting, & Mounting Equipment . . . . . . . . . . . .

Instruments & Gauge Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Tiller Handle Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

Remote Control Conversion Kits & Steering Kits . . . . . . . . . . . . . . . . .

Outboard Rigging Guide - 2001

Outboard Rigging Guide - 2001

Outboard Rigging Guide - 2001

Outboard Rigging Guide - 2001

SECTION 8 PROPELLERS Propellers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1 Propeller Application Charts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3

Outboard Rigging Guide - 2001

Outboard Rigging Guide - 2001

B or BLK= Black R or RED = Red Y= Yellow L or BLU= Blue

B or BLK = Black R or Red = Red Y= Yellow Bl = Dark Blue

O or ORG= Orange P or Pnk = Pink W or WHT = White Br = Brown

O or ORG= Orange P or Pk = Pink W or WHT = White Br = Brown

Sb = Sky Blue Lg = Light Green

Ground Battery Positive Bilge blower Cabin and instrument lights

Bonding wire, earth ground

Accessory feed Fuel gauge sender

Generator Armature, Alternator charge light

Y/R = Yellow/Red Pu = Purple B/Y = Black/Yellow B/R = Black/Red

B/W = Black/White G/L = Green/Blue

Starting Circuit Ignition ON 12v Ignition stop circuit

Outboard Rigging Guide - 2001

Standard Abbreviations and Symbols

Outboard Rigging Guide - 2001

Standard Abbreviations and Symbols

Outboard Rigging Guide - 2001

1 km/hr = 0.6214 mph 1 mph = 1.6093

1kg = 2.2046 lb 1 lb = 0.4536 kg 1 gram = 0.0353 oz 1 oz = 28.3286

1kg/cm2 = 14.223 psi 1 psi = 0.07031 kg/cm2

1m-kg = 7.233 ft-lb 1ft-lb = 0.1383 m-kg

Outboard Rigging Guide - 2001

Prop Shaft Horsepower

Shaft Length S L X U J = 15 = 20 = 25 = 30 = Jet Drive Unit

Control Method R = Remote Control H = Tiller Handle

Outboard Rigging Guide - 2001

Manufacturing Date Located on starboard clamp bracket.

   % & $ 6 )2) 41/1 )2 4 + 6,

24-.1: 7 /60 *-4

Explanation of the engine family code:

Model Year Z = 2001

Manufacturer YMX = Yamaha M = Marine

Displacement Cubic Centimeters

Application 1 = PWC 2 = O/B

Technology 1 = Existing 2 = New

Outboard Rigging Guide - 2001

NOTE: An electrical primer pump must have a bypass tube installed.

FROM FUEL FILTER IN

Outboard Rigging Guide - 2001

General Rigging Information

V4 Rigging Tube Grommet

ABB-RIGHS-BK-25 ABB-RIGHS-GY-25 ABB-RIGHS-BE-25 ABB-RIGHS-BK-50 ABB-RIGHS-GY-50

F115 Tube Grommet

Outboard Rigging Guide - 2001

General Rigging Information

TYPICAL CABLE ROUTING

Outboard Rigging Guide - 2001

% & $ 6 )2) 41/1 )2 4 + 6,

; 8 1/ 161 / - /1 - 52--, 51/ ) /4 1 /9 /O 641 2 1 ,1+)61 *9 1 7 1 )61

-), $2 " 564 2 ! -), 564 7 *-4 . -), 914-5 641 5- 5 4

4 8 )+ 72 ; 8 1/ 161 /4 7 , * .79 5- 5 4 1 7 1 )61

;) )0) D # # FD 75) E A D ! ! J -74 2& ( =KJE?= EA ) $;# &!#% 5"

24-55 * 60 *766 5 6 /-60-4 0 74 1 76-5 ! .1: