Outboard
Rigging
Guide
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.
Standard Equipment, Rigging Kits, & Crate Contents . . . .
Engine Dimensions, Mounting, & Mounting Equipment . . . .
Electrical . . . .
Remote Controls . . . .
Instruments & Gauge Installations . . . .
Tiller Handle Kits . . . .
Remote Control Conversion Kits & Steering Kits . . . .
Propellers . . . .
Fuel Tanks & Accessories, Remote Oil Tank,
Remote Oil Fill, Engine Stands . . . .
Appendices . . . .
Quick
Start
1
2
4
5
6
7
8
9
3
10
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
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 - Owner’s Manual . . . 10E
INTRODUCTION
Yamaha Service assumes that those using this Outboard Rigging Guide manual are aware of standard rigging techniques. This manual pro-vides specialized information for rigging 2001 model Yamaha products; it does provide general rigging instructions. For information about rig-ging earlier Yamaha outboards, refer to the prop-er Outboard Rigging Guide or Data edition for the particular year you are rigging.
Be aware of all information designated by the fol-lowing notifications:
A CAUTION indicates special procedures that must be followed to avoid damage to the out-board motor, accessories, boat, test equipment, or tools.
A WARNING indicates special procedures that must be followed to avoid injury to persons operating the outboard motor or other compo-nents, 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 b o a t handling and proper a c c i d e n t - prevention measures.
1. Introduction
This will include a brief description, model application, illustrations of components, and additional parts (if any) needed to install the component. This introduction should usually give the rigger information needed to deter-mine which parts should be used.
2. Installation Instructions
This will include dimensions, mounting instructions, wiring information, and any other information needed to install the com-ponent.
3 Parts Information
Where appropriate, there will be an exploded diagram of all parts for a particular compo-nent. 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 compo-nents microfiche. CAUTION: WARNING
Intro-Quick
Start
This Rigging Guide is designed to cover the2001 Model Year. Anything prior to that is cov-ered in previous Rigging Guides.
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 ABYC COLOR
ABBREVIATION ABBREVIATION YAMAHA USE ABYC USE
B or BLK= Black B or BLK = Black Ground Ground
R or RED = Red R or Red = Red Battery positive, Battery Positive SW3 Oil warning red light V4
Y= Yellow Y= Yellow Ignition ON 12v Bilge blower 4-Stroke lighting coil
L or BLU= Blue Bl = Dark Blue Instrument lights choke Cabin and instrument lights choke circuit,
Ground potential oil transfer High speed charge coil
G or GRN= Green G or GRN= Green Tachometer signal Bonding wire, earth ground Lighting coil lead
Knock sensor
O or ORG= Orange O or ORG= Orange Trim position sender Accessory feed P or Pnk = Pink P or Pk = Pink Oil & overheat signal ground, Fuel gauge sender
Trim signal
W or WHT = White W or WHT = White Ignition stop circuit
SW1 oil transfer off position V4
Br = Brown Br = Brown Start circuit, Generator Armature, Low speed charge coil, Alternator charge light Positive “+” potential
to oil transfer pump,
SW2 transfer on position V4
Gr = Gray Gr = Gray Warning circuit lead, Tachometer signal Over rev control, 4-Stroke tach Navigation Lights
Tan None Water Temperature
Sb = Sky Blue Lt Bl = Light Blue Trim Up Oil Pressure
Bl/X = Blue/ Stripe Trim Up
Lg = Light Green Trim Down
G/X = Green /Stripe Trim Down
Except G/Y
Y/R = Yellow/Red Y/R = Yellow/Red Diagnostic lead from Starting Circuit ECU
Pu = Purple Pu = Purple ECU Ground to Ignition ON 12v enrichment solenoid V76
B/Y = Black/Yellow B/Y = Black/Yellow Thermo sensor Ignition stop circuit B/R = Black/Red Remote oil tank ground
return, PBS to tachometer, Low speed charge coil
Color Codes (Cont’d.)
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
YAMAHA COLOR ABYC COLOR
ABBREVIATION ABBREVIATION YAMAHA USE ABYC USE
G/R = Green/Red Red oil warning light ground through SW3 in main tank oil sensor to tachometer
G/W = Green/White Crank position sender, Lighting coil lead to rectifier
L/G = Blue/Green Main tank oil level sensor SW2 oil transfer circuit
L/R = Blue/Red Main tank oil level sensor SW3.
No oil warning circuit L/W = Blue/White Main tank oil level sensor
SW1.
Oil transfer OFF circuit L/Y = Blue/Yellow Shift cut switch
Pu/R = Purple/Red OX66#1 injector Pu/B = Purple/Black OX66#2 injector Pu/Y = Purple/Yellow OX66#3 injector Pu/G = Purple/Green OX66#4 injector Pu/L = Purple/Blue OX66#5 injector Pu/W = Purple/White OX66#6 injector
R/Y = Red/ Yellow Key on power through fuel pump relay, power to ECU, Fuel pump and fuel injectors W/R = White/Red #1 pulsar V6
W/B = White/Black #2 pulsar V6 W/Y = White/Yellow #3 pulsar V6 W/G = White/Green #4 pulsar V6 W/L = White/Blue #5 pulsar V6
W/Br = White/Brown #6 pulsar V6 Trim signal Y/W = Yellow/White Electric fuel pump for
Measurement
In most cases, measurements are given in both metric and US Customary System (feet and inch-es). The following abbreviations and symbols are used:
m = meter ft or ’ = foot mm = millimeter in or ” = inch lit = liter gal = US gallon cc = cubic centimeter ft-lb = foot pounds m-kg = meter kilogram
The metric measure is given first, with the US conversion following in parenthesis: 1.0 m (3.3 ft)
Other Symbols
The symbol “~” is used to indicate either one fig-ure through another or “and following.” For example:
2 ~ 15HP would mean the 2, 3, 5, 8, 9.9 and 15 HP motors are included. A notation like “70HP~” means that the 70HP and all larger motors are included. Pro Series, SaltWater Series, and counter-rotation models are included in the previ-ous explanation 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.
MECHANIC’S METRIC CONVERTER
*Or milliliter = ML
CONVERSION FACTOR FORMULA
LENGTH-DISTANCE 1mm = 0.0394 inch mm x 0.0394 = inches 1 inch = 25.4mm inches x 25.4 = mm 1km = 0.06214 miles km x 0.6214 = miles 1 mile = 1.6093 km mile x 1.6093 = km SPEED 1 km/hr = 0.6214 mph km/hr x 0.6214 = mph 1 mph = 1.6093 mph x 1.6093 = km/hr WEIGHT 1kg = 2.2046 lb kg x 2.2046 = lb 1 lb = 0.4536 kg lb x 0.4536 = kg 1 gram = 0.0353 oz gram x 0.0353 = oz 1 oz = 28.3286 oz x 28.3286 = gram TEMPERATURE °C = (9/5 + 32) °F (°C x 1.8) + 32 = °F 9/5 (°F -32) = °C (°F -32) x 5/9 = °C [5/9 is approx. 0.555] Note: -40°C = -40°F 0°C = 32°F 100°C = 212°F PRESSURE
1kg/cm2= 14.223 psi psi = kpa divided by 7.03 1 psi = 0.07031 kg/cm2 psi x 0.0731 = kg/cm2 TORQUE 1m-kg = 7.233 ft-lb m-kg x 7.233 = ft-lb 1ft-lb = 0.1383 m-kg ft-lb x 0.1383 = m-kg VOLUME 1 liter (L) - 1.057 qt L x 1.057 = qt 1 qt = 0.9461L qt x 0.9461 = L 1L = 0.2542 gal L x 0.2642 gal 1 gal = 3.785 L gal x 3.785 = L 1cc* = 0.03381 oz cc x 0.03381 = oz 1 oz = 29.577cc oz x 29.577 = cc 1cc = 0.06103 ci (cubic inch) cc x 0.06103 = ci
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:
NOTE: Some early model 1984 engines had the designation of “AETO.”
X 1 5 0 T L R Y 2 Special Model Variation Code (Used on Prop Shaft 25HP
Model Description Horsepower Trim and Tilt/Starting Method Shaft Length Control Method Model Year engines)
B = Inshore Series Example: T = Power Trim and Tilt S = 15” R = Remote Control N = 1984 2 = 3 Cyl. C = C Series Model 6 w/Electric Start L = 20” H = Tiller Handle K = 1985 1997 D = Twin Rotating Propellers 9.9 P = Power Tilt w/Electric Start X = 25” J = 1986
DX= Twin Rotating 200 E = Manual Tilt w/Electric Start U = 30” H = 1987 3 = 3 Cyl. Propeller 0X66 EFI 250 M = Manual Tilt w/Manual Start J = Jet Drive G = 1988
E = Enduro Series Model Unit F = 1989
F = Four Stroke Engine Model D = 1990
LF = Left Hand Four Stroke P = 1991
L = Left Hand Engine Model Q = 1992
LX = Left Hand 0X66 EFI R = 1993
LZ = Left Hand HPDI S = 1994
P = Pro Series Model T = 1995
PX = Pro Series 0X66 EFI U = 1996
S = Saltwater Series Model V = 1997
SX = Saltwater Series 0X66 W = 1998
EFI X = 1999
T = Four Stroke Engine Y = 2000
Model with High Thrust Z = 2001
V = V Max Series Model VX=V-Max 0X66 EFI VZ =V-Max HPDI X = EFI 0X66 Series Z = HPDI Series
Engine ID Tag
Located on port clamp bracket.
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:
6G6
S X 2 0 0 T L R Z L 0 0 1 7 8 6
YAMAHA MOTOR CO., LTD MADE IN JAPAN
PAYS D'ORIGINE JAPON YAMAHA PRIMARY I.D.: MODEL NAME MODEL PREFIX: 6G6 SHAFT LENGTH: L SERIAL NUMBER: 001786 Z YMXM 3130 2 1 B
Model Year Manufacturer Displacement Application Technology Manufacturer Z = 2001 YMX = Yamaha Cubic Centimeters 1 = PWC 1 = Existing Specification
M = Marine 2 = O/B 2 = New
Manufacturing Date
GENERAL RIGGING INFORMATION Fuel Line Routing and Installation Fuel System Check
1. Ensure there is an anti-syphon valve or man-ual shut-off valve located on the fuel tank pickup tube.
2. Install the fuel line from the fuel tank pickup to the inlet side of the water fuel separator fil-ter. 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.
3. OPTIONAL: Run fuel line from the outlet side of the water fuel separator to the fuel management sender inlet side. The fuel flow is indicated by the arrows in the following illustration. Install the fuel sender with the side arrow pointing up.
NOTE: An optional feature for the fuel
manage-ment system is a water detection sender for the water/fuel separator. This provides a visual signal to the consumer to indicate if water is in the fuel system.
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.
FILTER FLOW SENSOR PRIMER BULB FUEL FLOW SENSOR LOCATION
UP IN OUT UP IN OUT UP IN OUT FLOW ENGINE FROM FUEL OUT TO ENGINE BYPASS WATER DETECTION SENDER
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.
6. OPTIONAL: Rigging transom flange. For
V4 and V6 Rigging Transom Flange (MAR-THRUT-RA-SM). Engine Grommet (MAR-GROMM-ET-02).
Additional Rigging Tube Components
150~250, 2.6L, 3.1L, HPDI Rigging Tube Grommet
1 Shift Cable 2 Throttle Cable 3 10 Pin Main Harness
4 & 5 Oil Warning and Trim Gauge Harness
6 Remote Oil Tank Lead Water Pressure,
7 Battery Cable Harness Temp. Gauge
8 Oil Hose
9 Fuel Hose Isolator
Speedometer Hose Harness
V4 Rigging Tube Grommet
1 Throttle Cable 2 Shift Cable 3 Main Harness 4 Oil Warning Lead 5 Remote Oil Tank Lead 6 Trim Gauge Lead
7 Battery Leads w/Isolator Lead 8 Oil Hose 9 Fuel Hose Speedometer Hose F80/F100 Tube Grommet 1 Throttle Cable 2 Shift Cable 3 Main Harness
4 Trim Gauge, Oil Warning Lead 5 Battery Leads
6 Fuel Hose
7 Speedometer Hose
8 Water Temperature & Water Pressure Sensor
F115 Tube Grommet
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
Part Number Description
ABB-RIGHS-BK-25 Black Rig. Hose, 25’ ABB-RIGHS-GY-25 Gray Rig. Hose, 25’ ABB-RIGHS-BE-25 Blue Rig. Hose, 25’ ABB-RIGHS-BK-50 Black Hose 100’ ABB-RIGHS-GY-50 Gray Hose 100’
2 3 4 5 6 7 8 9 10 V4 1 V6 2.6L-225/250 hp 1 10 4 5 2 1 5 2 10 4 6 6 7 7 8 8 9 9 3 3 12 12 11 11 HPD1 10 10 1 4 2 6 5 7 3 8 3 1 7 8 5 4 2 6 11 12
Control Cable Installation
1. Choose a mounting location for the control head which will provide comfortable opera-tion 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 con-nections. 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.
TYPICAL CABLE ROUTING
PART NUMBER LENGTH
ABA-CABLE-06-GY 6 FEET ABA-CABLE-07-GY 7 FEET ABA-CABLE-08-GY 8 FEET ABA-CABLE-09-GY 9 FEET ABA-CABLE-10-GY 10 FEET ABA-CABLE-11-GY 11 FEET ABA-CABLE-12-GY 12 FEET ABA-CABLE-13-GY 13 FEET ABA-CABLE-14-GY 14 FEET ABA-CABLE-15-GY 15 FEET ABA-CABLE-16-GY 16 FEET ABA-CABLE-17-GY 17 FEET ABA-CABLE-18-GY 18 FEET ABA-CABLE-19-GY 19 FEET ABA-CABLE-20-GY 20 FEET ABA-CABLE-22-GY 22 FEET ABA-CABLE-24-GY 24 FEET ABA-CABLE-26-GY 26 FEET ABA-CABLE-28-GY 28 FEET ABA-CABLE-30-GY 30 FEET ABA-CABLE-32-GY 32 FEET ABA-CABLE-34-GY 34 FEET ABA-CABLE-36-GY 36 FEET
Cable Measuring
Use the following examples as a guide for mea-surement. Obviously, different boats will require different routing and therefore different lengths.
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 larg-er push the throttle cable to open. Shift cable con-trol 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 dia-grams for proper cable end adjustments at the control box. Using these settings at the control box will insure the cable ends at the motor will adjust properly.
Adjust the throttle friction so the handles do no slip back while cruising.
NOTE: Twin engines using the 704 control box
must have the throttle cables synchronized. This is to ensure the engines are running the same RPM’s 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.
ALL CABLES
MINIMUM 8MM ENGAGEMENT
Gauge Installation Digital Instructions
Self-check Function: When the main switch is turned on, all line segments are displayed and the
warn-ing indicator blinks for a few seconds. On twins only with the dual key switch panel, the alarms will self-check for three beeps.
TESTING GAUGE LIGHT
The 2000~ tachometer requires the Yellow (ignition ON) and the Blue (light wire) to be energized at the
LEAD IDENTIFICATION REAR SWITCH SETTINGS RESETTING TACHOMETER SPEEDOMETER R: 12V BACKUP Y: +12V IGNITION B: GROUND B W
}
FUELSENSOR L: ILLUMINATION FUEL MANAGEMENT SPEED DATA R: 12V BACKUP Y: +12V IGNITION B: GROUND FLOW SENSOR G: OUTBOARD 1 G/W:OUTBOARD2 L: ILLUMINATION 6Y5-83500-T2 -00 NO. SW.1 SW.2 SW.3 DIP SWITCH FUNCTION TRIM SENSORTYPETACHOMETER TYPE ENGINETYPE
ON *2 LEAD *3 LEAD 6 POLE 12 POLE 4 STROKE 2 STROKE OFF
* NUMBER OF LEAD WIRES ON TRIM SENSOR
1 2 3 FACTORY SETTINGS ON km/h mph (mile h) knot nautical mile ( ) 5-105Ω U,S.A. 30-230Ω EUROPE 180-0Ω 6Y5-83570-S4-00 YAMAHA INDICATION GPH (GALLON) SPEEDOMETER GPS GPH +3% +2% +1% 0% -1% -2% -3% -4% /h 6Y5-83500-F2-00 PRESS BOTH BUTTONS TOGETHER Set mode
TOTAL FUEL CONSUMPTION
FUEL MANAGEMENT TTC ECON SYNC l/h sph km: l mpg TRIPMETER CLOCK PRESS BOTH BUTTONS TOGETHER 2. MINUTES 3. FIX 1. HOUR 1 1 2 2 1 1 2 Set mode Set mode TRIP TIMEBATT TRIP TIMEBATT PS Y: +12V IGNITION G: ENGINE SPEED SIGNAL G/R G/W OIL
}
}
O Gy P B/W TRIM INDICATION L: ILLUMINATION 2-STROKE 4-STROKE The Yamaha Digital Tachometer incorporates a double 2-way toggle dip-switch.The left-hand switch is for the Trim Sender Signal.
The Upper 2 Lead Sender position is set for the 2001 product line.
The Lower 3 Lead Sender position is set for the Yamaha Trim Sender Operation-2000 and below. The Center switch is for the pole setting for 2-stroke or 4-stroke engines. The Down position is 12 pole.
The right switch is for 2-stroke or 4-stroke oil warning.
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 inject-ed engines are recommendinject-ed to have a 50:1 mix-ture for the first 10 hours of operation. Use cau-tion 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 impor-tant for EFI and HPDI engines to help avoid dam-age to the VST pump.
NOTE: Leaking fuel fittings could result in severe injury or fire.
Precision Blend
On 90hp engines and below, before filling the oil tank, perform the following steps:
1. Turn the key switch to the ON position and ensure the alarm is operable.
2. While the key is in the ON position, start fill-ing the engine oil tank.
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.
For all 2-stroke 115hp engines and above, per-form 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 4-STROKE ~99 2-STROKE
2000~ 4-STROKE 2000~ 2-STROKE
3. Activate the return to port switch on the engine and fill the engine oil tank half way. 4. 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).
5. Next, adjust the oil link arm and double check the synchronization of the throttle plates on the engine (refer to the proper service manu-al for the synchronization and linkage adjust-ments).
4-Stroke Engines Filling Oil:
NOTE: All 4-stroke engines are shipped with-out oil in the engine. Yamaha recommends the
use of Yamalube™ 4M, 10W-30, 10W-40, SAE: SE, SF, SG, or SH.
Perform the following steps when adding oil to the engine:
1. Remove the oil filler cap. Place 3/4 of the rec-ommended amount of oil per the service manual.
2. Ensure the engine is level before removing the dip stick to check the oil level.*
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
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
engines is a very important step. Consult service manual or 1999 Marine Tech Guide page 3-27.
Propeller Selection
It is very important to select the proper propeller for the application of the engine. Perform the fol-lowing steps to ensure the proper propeller selec-tion:
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.
3. Select a propeller that will provide peak per-formance for the customer’s engine and application.
NOTE: Yamaha recommends to prop the engine
to the high end of the RPM range for the cus-tomer’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 perfor-mance 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:
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. Make sure there are no fuel or oil leaks nor gas fumes.
3. Be sure the fuel/oil hoses are not being flat-tened or kinked by objects in the boat and no sharp objects are near the fuel/oil hoses.
Controls
1. Check throttle, shift, and steering for proper operation before starting the engine.
2. The controls should work smoothly - without binding or unusual free play.
3. Look for loose or damaged connections. 4. Check the operation of the starter and stop
switches when the outboard motor is in the water.
Engine
1. Check the engine and engine mounting. 2. Look for loose or damaged fasteners. 3. Check the propeller for damage.
4. Check that the battery is in good condition and battery connections are secure.
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.
Before engine operation, install a fuel vacuum gauge with a clear hose just before the pulse fuel pumps. Fuel starvation can cause engine failure.
CAUTION:
WARNING
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: 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:
1. Connect the piece of clear fuel hose to a side barb of the “T” fitting (1).
2. Connect the short piece of clear fuel hose to the fuel check valve leading from the fuel fil-ter. 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 run-ning 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 vac-uum 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.
Results:
High Vacuum - Move the “T” fitting to the fuel
filter outlet (2) and retest. Continue to the fuel fil-ter inlet (3) and along the remaining fuel filfil-ter 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.
3. Unstable and slowly rising vacuum readings (especially with a full tank of fuel) usually indicates a restricted vent line.
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
indi-cate 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
FUEL VACUUM FLOW FUEL VACUUM TEST
EFI FUEL RAIL GAUGE
VACUUM GAUGE
Predelivery Checklist
Before operation, go over the PDI Checklist - LIT-18161-01-2K (see illustration below). Fill in the infor-mation 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 customer’s confidence level in Yamaha is greatly diminished.
OUTBOARDSmmmmmmmmmm
PREDELIVERY CHECKLISTmmmmmmmmmm mmm2 and 4-Stroke Models
MODEL PRIMARY ID (Single/Port) PRIMARY ID (Starboard) HULL ID NUMBER (HIN)
PROPELLER TYPE/PITCH BOAT MAKER/MODEL IGNITION KEY NUMBER TRAILER NUMBER
(P) ______________ (S) _____________ (P) __________ (S) ___________
00-067 Rev. 5/00 WHITE COPY - Dealer YELLOW COPY - Customer LIT-18161-01-2K
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 ❏ Engine Oil Level
❏ Low Oil Pressure Warning System (ground sensor lead)
Carburetion (2 and 4-Stroke Models) ❏ Carburetor Synchronization
❏ Throttle Plate Synchronization
❏ Manual/Electric Choke Operation
CUSTOMER DELIVERY CHECKLIST
❏ The Above Checklist Completed and Explained by Dealership ❏ 4-Stroke Use of Yamalube 4-M or Equivalent Rated Oil
❏ Operation of Equipment/Boat Accessories Explained and Ring Free Emphasized
❏ Operation/Orientation Ride with Dealership Personnel ❏ Engine Break-in Procedure Explained
❏ Owner’s Manual(s) and Keys Received ❏ Maintenance/Care Schedule Explained
❏ Customer Introduced to Service Manager/Writer ❏ Advised of First Scheduled Maintenance
❏ Return-to-Port Operations (Oil System, RPM Reduction) ❏ Warranty Coverage Explained to Customer’s Satisfaction,
❏ Gauge Operation/Warning Symbols Explained Including Customer Responsibilities Under
❏ 2-Stroke: Use of Yamalube 2-M/TC-W3®Oil and Ring Free ❏ Yamaha Extended Service (Y.E.S.) benefits explained ❏ Emphasized ❏ Customer Questions Answered by Dealership Personnel
CUSTOMER SIGNATURE DATE
CUSTOMER NAME
INSPECTOR’S SIGNATURE DATE
DEALER NAME PHONE NUMBER
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 sys-tem, return to port operations, engine break-in procedure, and maintenance schedule. If possible, it is a good tactic to take the customer for an ori-entation ride in their new boat. Be sure to answer all customer questions completely. This is the beginning of a good relationship with your deal-ership 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 cus-tomer that correctly breaking in a new engine will help ensure proper performance and longer engine life.
• 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 break-in break-in addition to oil break-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.
Make sure to mix gasoline (petrol) and oil com-pletely, otherwise the engine may be damaged.
Procedure:
1. First 10 minutes: run the engine at idle or fast idle speed only.
2. Next 50 minutes: Do not exceed half throttle (approximately 3,000 rpm). Vary engine speed occasionally. If you have an easy-planing boat, accelerate at full throttle onto plane, then 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 three-quarter 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
operat-ing 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 nor-mally. Use straight gasoline (petrol) in the fuel tank. For oil injected engines, Yamaha
Precision Blend System provides proper
lubri-cation for normal operation. For non-oil
injected engines go to normal fuel/oil ratios.
CAUTION:
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 50:1
Ratio
Gasoline (0.26 US gal) (3.2 US gal) (3.7 US gal) (6.3 US gal) (Petrol)
Engine Oil (0.02 US qt) (0.25 US qt) (0.30 US qt) (0.51 US qt)
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 con-trol box is used, a switch panel and primary wiring harness is required.
The Commonly Used Rigging Accessories chart lists many frequently used components, like gauges, fuel filters, riggings hoses, and optional control box spacers with their Yamaha part num-bers.
The Quick Start Details section is a more com-prehensive listing of rigging components for the most commonly rigged models and is aimed more at the technician who is new to rigging Yamaha outboards. The section is arranged by small engines, mid-sized engines, single engine V4 & V6 installations, and dual-engine V4 & V6 rig-gings.
For more detailed information and information about models not included in the Quick Start Section, see the other chapters elsewhere in this manual.
COMMONLY USED RIGGING ACCESSORIES
NOTE 1 Only water temperature or water pressure on 90HP and smaller, not both. Both gauges can be
used on V4, & V6.
*Alarm sensor needed to activate water in gas signal when using Yamaha’s Multifunction Fuel Management Gauge.
Description Part Number Comments
Fuel Filter Assembly ABB-SEPAR-AT-OR Water separator filter
Fuel Filter Assembly w/Alarm MAR-24560-00-00 With water alarm for use with fuel management gauge Alarm Sensor Only MAR-10171-30-00 Water alarm sensor* Oil Deck Fill ABB-PLATE-DE-CK V4/V6 Only
Remote Oil Deck Fill with 45° Neck ABB-PLATE-45-00 V4/V6 Remote Oil Tanks Remote Oil Tank Adaptor with 45° Neck ABB-JOINT-45-00 V4/V6 Remote Oil Tanks Rigging Hose 25 Ft. - Black ABB-RIGHS-BK-25 Cut to length
Rigging Hose 25 Ft. - Gray ABB-RIGHS-GY-25 Cut to length Rigging Hose 25 Ft. - Blue ABB-RIGHS-BE-25 Cut to length
Rigging Hose 100 Ft.- Black ABB-RIGHS-BK-50 (2) 50 ft. hoses in box Rigging Hose 100 Ft. - Gray ABB-RIGHS-GY-50 (2) 50 ft. hoses in box Rigging Grommet MAR-GROMM-ET-02 Use with rigging hose Rigging Transom Flange MAR-THRUT-RA-SM Use with rigging hose 704 Single Binnacle Control Box Spacer 704-48293-00-00 3/4” Thick w/hardware 704 Dual Binnacle Control Box Spacer 704-48293-10-00 3/4” Thick w/hardware Fuel Management Gauge - Single Engine 6YR-W0088-52-00 2-Stroke, 115HP~ Fuel Management Gauge - Dual Engines 6YR-W0088-64-00 2-Stroke, 115HP~ Water Pressure Gauge 6Y5-83660-00-00 F25HP~Up (EX. 60/70)1 Water Pressure Gauge Sender Kit 688-63667-00-00 F25HP~Up (EX. 60/70)1
Water Pressure Sending Adapter MAR-WPRES-AD-TR Use with after-market pressure gauge Water Temperature Gauge 6Y5-83590-00-00 F25HP~Up1
Water Temperature Gauge Sending Kit 688-83591-00-00 F25HP~Up1 Hour Meter - analog 6Y5-83504-01-00
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 cor-rectly 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) T8, 9.9, 15, F9.9, T9.9, F15, F15P, F25, T25, 30
Remote Models
Rigging for Side Mount 701 Manual Control Box
Control Cables1(2 req.) ABA-CABLE-XX-GY
Control Box (OPT) 701-48101-51-00
(Non-electric start models / Pull to Open Throttle)
Rigging for Side Mount 703 Control Box
Control Cables1(2 req.) ABA-CABLE-XX-GY
Control Box F9.9E, T9.9E (OPT) 703-48240-12-00
(Main Switch, 7 Pin Main Harness w/Safety Lanyard / Pull to Open Throttle)
or 30E 703-48230-12-00
Control Box T8, F15, F15P, F25~T25 (OPT) 703-48207-15-00 (Main Switch, 10 Pin Main Harness w/Safety Lanyard / Push to Open Throttle)
Optional Extension Harness 7 Pin Main Harness 6.6 ft. OPT. 688-82586-11-00 (Use as needed)
Optional Extension Harness 10 Pin Main Harness 6.6 ft. OPT. 688-82586-11-00
(Use as needed) 9.9 ft. OPT. 688-8258A-30-00
Installing Engine with 704 Single Binnacle or 705 Flush Mount Control
Control Cables1(2 req) ABA-CABLE-XX-GY
Single Binnacle T9.9E, F15, 30 (OPT) 704-48230-12-00 (Pull to Open Throttle / No PT&T Switch)
Single Binnacle T8, F25 (OPT) 704-48205-13-00
(Push to Open Throttle / PT&T Switch)
or
Flush Mount Control T9.9E, F15, 30 (OPT) 6X0-48203-11-00 (Push to Open Throttle ** / No PT&T Switch)
or
Flush Mount Control T8, F15P, F25 (OPT) 6X0-48206-11-00 (Push Open Throttle / PT&T Switch / 90°)
Switch Panel Assembly F9.9, T9.9E (1 req.) 6G8-82570-02-00 Switch Panel Assembly 9.9, 15, 30 (1 req.) No Warning 689-82570-18-00 Switch Panel Assembly T8, F25~30 (1 req.) With Warning 704-82570-06-00 Engine to Main Harness T9.9E (1 req.) 6G8-82590-00-00 Engine to Main Harness F15 (1 req.) 66M-82590-00-00 7 Pin Main Harness T9.9E, F15 (1 req.) 688-82586-50-00 Optional Extension Harness for 7 Pin Main Harness 6.6 ft. OPT. 688-82586-11-00 10 Pin Main Harness F25, 30 (1 req.) 688-8258A-50-00 Optional Extension Harness for 10 Pin Main Harness 6.6 ft. OPT. 688-8258A-10-00 9.9 ft. OPT. 688-8258A-30-00 7 Pin to 10 Pin Adapter Harness (OPT) 703-8258A-00-00
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.) ABA-CABLE-XX-GY
Control Box PT & T
(New Switch Main Switch and Safety Lanyard / Push To Open Throttle) OPT 703-48207-15-00 Optional Extension Harness for 10 Pin Main Harness 6.6 ft. OPT 688-8258A-10-00
(Use as needed) 9.8 ft. OPT 688-8258A-30-00
Installing Engine with 704 Single Binnacle or 705 Flush Mount Control Box
Single Binnacle (1 Req.) 704-48205-13-00
or
Flush Mount (1 Req.) 6X0-48206-11-00
Switch Panel Assembly (1 Req.) 704-82570-05-00
Main Harness - 10 Pin (1 Req.) 16.4 ft. OPT 688-8258A-50-00 26 ft. OPT 6K1-8258A-40-00 Optional Extension Harness 10 Pin Main Harness 6.6 ft. OPT 688-8258A-10-00
(Use as needed) 9.8 ft. OPT 688-8258A-30-00
Engine to Tach Harness2Non-Oil Injected Engines
No Four Stroke Engines (OPT 1 Req.) 9.8 ft. OPT 6R3-82553-30-00 16.4 ft. OPT 6R3-82553-50-00 22.9 ft. OPT 6R3-82553-70-00 26.2 ft. OPT 6R3-82553-80-00 31.2 ft. OPT 6R3-82553-90-00 Engine to Tach Harness, Trim & Oil Harness2
Models with Oil Injection and Low Oil Warnings on
Four Stroke Engines 9.8 ft. OPT 64D-82553-30-00 16.4 ft. OPT 64D-82553-50-00 Single 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 NOTE1Order 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.
NOTE2If 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.
Model(s) V4/V6 115~250 Single Installation All Models — 2-Stroke Rigging for Standard Side Mount Control Box
Control Cables1(2 req.) ABA-CABLE-XX-GY
Control Box with PT & T
(New Main Switch and Safety Lanyard / Push to Open Throttle) 703-48207-15-00 Optional Extension Harness for 10 Pin Main Harness 6 ft. OPT 688-8258A-10-00
9.8 ft. OPT 688-8258A-30-00
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 Engine to Tach, Trim & Oil Harness2 (1 Req.) (STD - Rigging Kit)
9.8 ft. OPT 64D-82553-30-00 16.4 ft. OPT 64D-82553-50-00 Single Gauge Rigging Kit -23 ft. STD 64D-82553-70-00 26.2 ft. OPT 64D-82553-80-00 Dual Gauge Rigging Kit - 31.2 ft. STD 64D-82553-90-00 Engine to Oil Tank Harness2
(1 Req.) (STD - Engine Oil Tank all Precision Blend 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 NOTE1Order 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.
NOTE2If 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.
Yamaha’s 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 NOTE1Order 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.
NOTE2If 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.
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
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
needs. Below, is a list of the basic standard equip-ment 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.
Basic Standard Equipment
8 to 40 Fuel Tank in Crate F6, F25,
F30M~F40M Fuel Pipe in Crate
F50, F30T~F115 Fuel Pipe, Steering Link in Crate 70-90 Fuel Pipe, Steering Link
115 to 250 Battery Cable, Mounting Bolts - Steering Linkarm (115~2.6L Only) (2-Stroke)
DX150 Steering Link, Battery Cable, order with engine 19”, 21”, 25”, or 27” Propellers, Propeller Wrench
L130 ~ L250 Tie Bar in Crate, Mounting Bolts LF115
F40J~F115J Water Pump in Crate
C40-C90 Fuel Pipe, Steering Link in Crate 2001 MODEL STANDARD EQUIPMENT
PROPELLER, CONTROLS, FUEL TANK & RIGGING ITEMS SHIPPING LOCATION
MODEL STARTING RIGGING
MODEL CODE ID PROPELLER CONTROL FUEL TANK ITEMS
2MSHZ 6A1S 193528 CRATE (7-1/4 x 4) N/A N/A N/A 3MSHZ 6L5S 081842 CRATE (7-1/2 x 7) N/A N/A N/A F4MLHZ 67DL 306528 CRATE (7-1/2 x 8) N/A N/A N/A F4MSHZ 67DS 018358 CRATE (7-1/2 x 8) N/A N/A N/A 5MSHZ 6E3S 024846 CRATE (7-1/2 x 8) N/A N/A N/A F6MLHZ 68RL 300580 CRATE (8-1/2 x 6-1/2) N/A SEPARATE N/A F6MSHZ 68RS 001185 CRATE (8-1/2 x 6-1/2) N/A SEPARATE N/A 8MSHZ 6N0S 022778 CRATE (8-1/2 x 6-1/2) N/A SEPARATE N/A F8MLHZ 68TL 300867 CRATE (8-1/2 x 6-1/2) N/A SEPARATE N/A F8MSHZ 68TS 001237 CRATE (8-1/2 x 6-1/2) N/A SEPARATE N/A T8PLHZ 69GL 550101 CRATE (11-3/4 x 5-3/4) N/A SEPARATE N/A T8PLRZ 69GL 500101 CRATE (11-3/4 x 5-3/4) SEPARATE SEPARATE CRATE T8PXHZ 69GX 850101 CRATE (11-3/4 x 5-3/4) N/A SEPARATE N/A T8PXRZ 69GX 750101 CRATE (11-3/4 x 5-3/4) SEPARATE SEPARATE CRATE 9.9MSHZ 682CS 171885 CRATE (9-1/4 x 9) N/A SEPARATE N/A F9.9ELRZ 6G9L 402547 CRATE (9-1/4 x 9) SEPARATE SEPARATE CRATE F9.9MLHZ 6G9L 309197 CRATE (9-1/4 x 9) N/A SEPARATE N/A F9.9MSHZ 6G9S 012208 CRATE (9-1/4 x 9) N/A SEPARATE N/A T9.9ELHZ 6G8L 474408 CRATE (11-3/4 x 9-1/4) N/A SEPARATE N/A T9.9ELRZ 6G8L 416517 CRATE (11-3/4 x 9-1/4 SEPARATE SEPARATE CRATE T9.9EXHZ 6G8X 790075 CRATE (11-3/4 x 9-1/4) N/A SEPARATE CRATE T9.9EXRZ 6G8X 763983 CRATE (11-3/4 x 9-1/4) SEPARATE SEPARATE CRATE 15MSHZ 684CS 427330 CRATE (9-1/4 x 9) N/A SEPARATE N/A F15ELHZ 66ML 501999 CRATE (-1/4 x 10-1/2) N/A SEPARATE CRATE F15ESHZ 66MS 201837 CRATE (9-1/4 x 10-1/2) N/A SEPARATE CRATE F15MLHZ 66ML 303182 CRATE (9-1/4 x 10-1/2) N/A SEPARATE N/A F15MSHZ 66MS 004665 CRATE (9-1/4 x 10-1/2) N/A SEPARATE N/A F15PLHZ 66ML 800141 CRATE (9-1/4 x 10-1/2) N/A SEPARATE N/A F15PLRZ 66ML 900111 CRATE (9-1/4 x 10-1/2) SEPARATE SEPARATE CRATE 25MLHZ 6L2L 308064 CRATE (9-7/8 x 11-1/4) N/A SEPARATE N/A 25MSHZ 6L2S 007540 CRATE (9-7/8 x 11-1/4) N/A SEPARATE N/A 25MSHZ3 6K9S 201906 CRATE (9-7/8 x 14) N/A SEPARATE N/A F25ELHZ 65WL 353272 CRATE (9-7/8 x 11-1/4) N/A SEPARATE N/A F25ELRZ 65WL 302523 CRATE (9-7/8 x 9) SEPARATE SEPARATE CRATE F25ESHZ 65WS 051830 CRATE (9-7/8 x 11-1/4) N/A SEPARATE CRATE F25ESRZ 65WS 000479 CRATE (9-7/8 x 9) SEPARATE SEPARATE CRATE
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location (Cont’d.)
MODEL STARTING RIGGING
MODEL CODE ID PROPELLER CONTROL FUEL TANK ITEMS
F25MSHZ 65WS 151486 CRATE (9-7/8 x 10-1/2) N/A SEPARATE N/A T25TLRZ 65WL 840362 CRATE SEPARATE SEPARATE CRATE 30ELHZ 6J8L 761205 CRATE (9-7/8 x 11-1/4) N/A SEPARATE CRATE 30ELRZ 6J8L 462998 CRATE (9-7/8 x 11-1/4) SEPARATE SEPARATE CRATE 30MLHZ 6J8L 409559 CRATE (9-7/8 x 11-1/4) N/A SEPARATE N/A 30MSHZ 6J8S 110929 CRATE (9-7/8 x 11-1/4) N/A SEPARATE N/A F30TLRZ 69HL 400141 CRATE (9-7/8 x 11-1/4) SEPARATE SEPARATE * 40MLHZ 6H4L 493352 ORDER FROM PARTS N/A SEPARATE N/A 40TLRZ 6H4L 550802 ORDER FROM PARTS SEPARATE N/A * C40TLRZ 6H4L 930421 ORDER FROM PARTS SEPARATE N/A * F40ESRZ 67CS 050362 ORDER FROM PARTS SEPARATE N/A *
F40MJHZ 67C N/A N/A SEPARATE N/A
F40MLHZ 67CL 301027 ORDER FROM PARTS N/A N/A * F40MSHZ 67CS 000698 ORDER FROM PARTS N/A N/A * F40TLRZ 67CL 503417 ORDER FROM PARTS SEPARATE N/A * 50TLRZ 6H5L 446404 ORDER FROM PARTS SEPARATE N/A * C50TLRZ 6H5L 904076 ORDER FROM PARTS SEPARATE N/A *
F50TJRZ 62Y N/A SEPARATE N/A *
F50TLRZ 62YL 421732 ORDER FROM PARTS SEPARATE N/A * T50TLRZ 64JL 406850 ORDER FROM PARTS SEPARATE N/A * 60TLRZ 6H2L 474493 ORDER FROM PARTS SEPARATE N/A * C60TLRZ 6H2L 363147 ORDER FROM PARTS SEPARATE N/A * 70TLRZ 6H3L 495999 ORDER FROM PARTS SEPARATE N/A * C70TLRZ 6H3L 352799 ORDER FROM PARTS SEPARATE N/A *
F80TJRZ 67G N/A SEPARATE N/A *
F80TLRZ 67GL 304042 ORDER FROM PARTS SEPARATE N/A * 90TLRZ 6H1L 504755 ORDER FROM PARTS SEPARATE N/A * C90TLRZ 6H1L 360597 ORDER FROM PARTS SEPARATE N/A * F100TLRZ 67FL 310112 ORDER FROM PARTS SEPARATE N/A * F100TXRZ 67FX 703298 ORDER FROM PARTS SEPARATE N/A * 115TLRZ 6E5L 407500 ORDER FROM PARTS SEPARATE N/A * 115TXRZ 6E5X 731173 ORDER FROM PARTS SEPARATE N/A *
F115TJRZ 68V N/A SEPARATE N/A *
F115TLRZ 68VL 303858 ORDER FROM PARTS SEPARATE N/A * F115TXRZ 68VX 702039 ORDER FROM PARTS SEPARATE N/A * LF115TXRZ 68WX 800462 ORDER FROM PARTS L-KIT N/A L-KIT 130TLRZ 6L1L 312796 ORDER FROM PARTS SEPARATE N/A * 130TXRZ 6L1X 707472 ORDER FROM PARTS SEPARATE N/A * L130TXRZ 6L6X 702281 ORDER FROM PARTS L-KIT N/A L-KIT
Propeller, Controls, Fuel Tank & Rigging Items Shipping Location (Cont’d.)
MODEL STARTING RIGGING
MODEL CODE ID PROPELLER CONTROL FUEL TANK ITEMS
150TXRZ 6G4X 507530 ORDER FROM PARTS SEPARATE N/A * V150TLRZ 6J9L 505024 ORDER FROM PARTS SEPARATE N/A * Z150TLRZ 6G4L 800223 ORDER FROM PARTS SEPARATE N/A * Z150TXRZ 6G4X 800376 ORDER FROM PARTS SEPARATE N/A * DX150TLRZ 65NL 000578 ORDER FROM PARTS SEPARATE N/A * LX150TXRZ 6K0X 400254 ORDER FROM PARTS L-KIT N/A L-KIT LZ150TXRZ 6K0X 800376 ORDER FROM PARTS L-KIT N/A L-KIT SX150TXRZ 6G4X 053385 ORDER FROM PARTS SEPARATE N/A * VX150TLRZ 6J9L 001807 ORDER FROM PARTS SEPARATE N/A * VZ150TLRZ 6J9L 800363 ORDER FROM PARTS SEPARATE N/A * Z175TXRZ 6G5X 800101 ORDER FROM PARTS SEPARATE N/A * VZ175TLRZ 62HL 800105 ORDER FROM PARTS SEPARATE N/A * Z200TLRZ 6G6L 150468 ORDER FROM PARTS SEPARATE N/A * Z200TXRZ 6G6X 101510 ORDER FROM PARTS SEPARATE N/A * LX200TXRZ 6K1X 001204 ORDER FROM PARTS L-KIT N/A L-KIT LZ200TXRZ 6K1X 100513 ORDER FROM PARTS L-KIT N/A L-KIT SX200TXRZ 6G6X 004647 ORDER FROM PARTS SEPARATE N/A * VX200TLRZ 66XL 002839 ORDER FROM PARTS SEPARATE N/A *
VZ200TLRZ ORDER FROM PARTS SEPARATE N/A *
LX225TXRZ 62KX 101976 ORDER FROM PARTS SEPARATE N/A * SX225TURZ 62JU 200762 ORDER FROM PARTS SEPARATE N/A * LX225TXRZ 62KX 101976 ORDER FROM PARTS L-KIT N/A L-KIT VX225TLRZ 66KL 302579 ORDER FROM PARTS SEPARATE N/A *
(VX-MAX)
*Single Gauge 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 Model does not include this item as standard equipment or information not available at this time.
CRATE These items are included in the crate with the unit.
SEPARATE These items are user's choice and shipped in a separate box. * Single Gauge Tachometer Kit or 2-Gauge Tachometer
& Speedometer Kit.
L KIT Left Hand Rigging Kit.
ORDER FROM PARTS Item is not standard equipment. Order from Yamaha Parts and Accessories.
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
Multi-Function LCD Tachometer/Speedometer Kit or 2 Gauge Kit (6YR-W0035-47-00) For use on 2-Stroke and 4-Stroke Engines
Part Number Part Name Qty.
6R3-83621-00-00 Mark, 1 1
64D-82553-70-00 Trim/Oil, Harness 23 ft. 1 6Y5-83500-T2-00 Meter, Ass’y 1 6Y5-83553-00-00 Gauge, Harness 1 Fuse 1
Part Number Part Name Qty.
6Y5-83553-M0-00 Gauge, Harness 2 Fuse 1
6Y5-82117-00-00 Wire, Lead 1
6R3-83621-00-00 Mark, 1 1
64D-82553-80-00 Trim/Oil, Harness 26.2 ft. 1 6Y5-83500-T2-00 Meter, Ass’y 1 6Y5-83570-S5-00 Speedometer Ass’y 1
6Y5-83557-10-00 Tube 1
90465-11M10-00 Clamp 2
90465-13M18-00 Clamp 10
Dual Engine Counter Rotation Kit or Left Hand Engine Rigging Kit (6YR-W0035-67-00) For use with 2-Stroke/4-Stroke Engines
REMOTE OIL TANK KITS
2.8 Gallon Oil Tank (6YR-W0035-92-00) 2-Stroke Oil Injected Engines
Part Number Part Name Qty.
6Y5-83553-00-00 Gauge, Harness 1 Fuse 1
6Y5-82117-00-00 Wire, Lead 1
6R3-83621-00-00 Mark, 1 1
64D-82553-90-00 Trim/Oil, Harness 31.2 ft. 1 6Y5-83500-T2-00 Meter, Ass’y 1 704-48207-22-00 Remote Control Ass’y 1 6K1-82570-05-00 Panel Switch Ass’y 1 6K1-8258A-40-00 Main, Harness 26 ft. 1
90465-13M18-00 Clamp 10
61B-28107-14-00 Rigging Manual l 61B-8258A-01-00 Main Harness 31.2 ft. 1
90149-05M05-00 Screw 4
95380-05600-00 Nut 4
92990-05600-00 Washer 4
92990-05100-00 Washer 4
6Y5-83500-F2-00 Fuel Management Gauge 1 6Y5-83553-F1-00 Fuel Management Harness 1 6Y5-85752-01-00 Fuel Management Sender 2 90160-06M00-00 Screw, Round Tap 4 703-82531-00-00 Wire, Lead F. M. to Tach 1
Part Number Part Name Qty.
61A-21708-03-00 Oil Tank Sub Ass’y 1 6E5-13437-43-00 Mark, Caution 1
90465-13M11-00 Clamp 1
6E5-2170A-01-00 Bracket, Sub. Complete 1 6Y2-24307-40-00 Fuel pipe Complete 1 90450-10M07-00 Hose Clamp Ass’y 1
5.0 Gallon Oil Tank (6YR-W0035-C0-00) 2-Stroke Oil Injected Engines
TILLER HANDLE KITS
Tiller Handle Kit for 40/C40/50/C50 (63D-W0086-Z0-4D)
Part Number Part Name Qty.
61A-21708-10-00 Oil Tank Sub Ass’y 1 61A-13437-40-00 Mark, Caution 1
90465-13M11-00 Clamp 1
6E5-2170A-01-00 Bracket, Sub. Complete 1 6Y2-24307-40-00 Fuel Pipe Complete 1 90450-10M07-00 Hose Clamp Ass’y 1
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 63D-82586-00-00 Wire Harness Extension 1
6H5-83553-11-00 Read Wire 1
90465-13M36-00 Clamp 1
688-83383-11-00 Buzzer 1
6H5-83386-00-00 Buzzer Stay 1
6H5-42724-00-00 Grommet 1
688-82540-11-00 Neutral Switch Ass’y 1 63D-82554-00-00 Stay, Neutral Switch Ass’y 1 663-82555-01-00 Damper, Main Switch 1
63D-42546-00-00 Nut 2
63D-42541-00-00 Pipe 2
90201-08M01-00 Plate Washer 2 63D-42508-00-00 Steering Friction Ass’y 1 • 63D-42527-00-00 • Plate, Friction 3 1 • 63D-42526-00-00 • Plate, Friction 2 1 • 63D-42528-00-00 • Piece, Friction 2 • 63D-42562-00-00 • Shaft, Steering Lock 1 • 63D-42561-00-00 • Knob, Steering Lock 1
• 682-43318-01-00 • Cover 1 • 90185-10M01-00 • Nut, Lock 1 97595-08550-00 Bolt 2 97595-06416-00 Bolt 2 63D-82361-00-00 Clamp, Cord 1 90161-06M03-00 Screw 1 97595-06535-00 Bolt 1 90387-06M26-00 Collar 1
90185-10051-00 Nylon Lock Nut 2
97013-05010-00 Bolt 2
92990-05100-00 Spring Washer 2
95380-05600-00 Nut 2
63D-83728-00-00 Connector Ass’y 1
90465-15M11-00 Clamp 3
F25E, F25T Tiller Handle -
Tiller Handle Kit for F30/F40 3 Cylinder (67C-W0086-Z1-4D)
Tiller Handle Kit for F50/T50 (62Y-W0086-Z0-4D)
Part Number Part Name Qty.
Tiller Kit Handle Ass’y. 1 Tiller Handle Install. Manual 1 6F5-82540-00-00 Neutral Switch Ass’y. 1 6J8-82554-00-00 Stay, Neutral Switch 1
90109-06M86-00 Bolt 2
65W-44173-00-00 Lever, Shift Control 1 90254-03M05-00 Pin, Slotted Spring 1
62Y-42725-40-00 Grommet 1
63D-83728-00-00 Connector Ass’y. 1
6H5-83553-11-00 Wire, Lead 1
6H2-82586-01-00 Extension Wire Harness 1
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 6H2-82586-01-00 Wire Harness Extension 1
6H5-83553-11-00 Read Wire 1 90465-13M36-00 Clamp 1 688-83383-11-00 Buzzer 1 6H5-83386-00-00 Buzzer Stay 1 62Y-42725-40-00 Grommet 1 63D-42546-00-00 Nut 2 63D-42541-00-00 Pipe 2
6F5-82540-00-00 Neutral Switch Ass’y 1 62Y-82554-00-00 Stay, Neutral Switch 1 62Y-82555-00-00 Damper, Main Switch 1 90201-08M01-00 Plate Washer 2 63D-42508-00-00 Steering Friction Ass’y 1 • 63D-42527-00-00 • Plate, Friction 3 1 • 63D-42526-00-00 • Plate, Friction 2 1 • 63D-42528-00-00 • Piece, Friction 2 • 63D-42562-00-00 • Shaft, Steering Lock 1 • 63D-42561-00-00 • Knob, Steering Lock 1
• 682-43318-01-00 • Cover 1
• 90185-10M01-00 • Nut, Lock 1
97013-05010-00 Bolt 2
90185-10051-00 Nylon Lock Nut 2 62Y-82361-00-00 Clamp, Cord 1
90161-06M03-00 Screw 1 97595-06535-00 Bolt 1 90387-06M26-00 Collar 1 92990-05100-00 Spring Washer 2 95380-05600-00 Nut 2 63D-83728-00-00 Connector Ass’y 1 90465-13M24-00 Clamp 1
Steering Friction Ass’y. 1
• 92990-06100-00 • Washer 2 • 90109-06M88-00 • Bolt 2 • 67C-42527-00-00 • Plate, Friction 1 • 95380-05600-00 • Nut 1 • 90387-05M11-00 • Collar 1 • 90387-05M05-00 • Collar 1
• 90119-05M03-00 • Bolt, with Washer 1 • 90202-10M56-00 • Washer, Plate 2 • 65W-42528-00-00 • Plate, Friction 2 • 67C-42525-00-00 • Plate, Friction 1 • 67C-42561-00-00 • Knob, Steering Lock 1 • 689-43633-00-00 • Cover, Tilt Lever 1
• 90209-10M26-00 • Washer 1
• 90185-10M14-00 • Nut, Self-Locking 1 • 67C-42562-00-00 • Shaft, Steering Lock 1
Tiller Handle Kit for 60/C60/C70/70 (6H3-W0086-Z0-4D)
Tiller Handle Kit for C90/90 (6H3-W0086-Z0-4D)
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 6H2-82586-01-00 Wire Harness Extension 1
6H5-83553-11-00 Read Wire 1
90465-13M36-00 Clamp 1
688-83383-11-00 Buzzer 1
6H5-83386-00-00 Buzzer Stay 1
6H2-42725-01-00 Grommet 1
6H3-82540-00-00 Neutral Switch Ass’y 1 6H3-82554-00-00 Stay, Neutral Switch 1 663-82555-01-00 Damper, Main Switch 1 Steering Friction Ass’y 1 • 663-42518-00-00 • Shaft, Friction 1 • 92990-08600-00 • Plate Washer 2 • 663-42528-00-00 • Piece, Friction 1 • 90175-06003-00 • Nut, Wing 1 • 97080-06035-00 • Bolt 1 • 69242-51501-00 • Rod 1 • 90185-08057-00 • Nut, Lock 1 97013-05010-00 Bolt 2
90185-10051-00 Nylon Lock Nut 2 92990-05100-00 Spring Washer 2
95380-05600-00 Nut 2
63D-83728-00-00 Connector Ass’y. 1
90464-15M11-00 Clamp 3
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 6H2-82586-01-00 Wire Harness Extension 1
6H5-83553-11-00 Read Wire 1
90465-13M36-00 Clamp 1
688-83383-11-00 Buzzer 1
6H5-83386-00-00 Buzzer Stay 1
688-42725-30-00 Grommet 1
688-82540-11-00 Neutral Switch Ass’y 1 663-82554-01-00 Stay, Neutral Switch 1 663-82555-01-00 Damper, Main Switch 1 Steering Friction Ass’y 1 • 663-42518-00-00 • Shaft, Friction 1 • 92990-08600-00 • Plate Washer 2 • 663-42528-00-00 • Piece, Friction 1 • 90175-06003-00 • Nut, Wing 1 • 97080-06035-00 • Bolt 1 • 692-42515-01-00 • Rod 1 • 90185-08057-00 • Nut, Lock 1 97013-05010-00 Bolt 2
90185-10051-00 Nylon Lock Nut 2 92990-05100-00 Spring Washer 2
95380-05600-00 Nut 2
63D-83728-00-00 Connector Ass’y. 1
Tiller Handle Kit for F80/F100 (67G-W0086-Z1-4D)
Tiller Handle Kit for F115
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 6H2-82586-01-00 Wire Harness Extension 1
6H5-83553-11-00 Read Wire 1 90465-13M24-00 Clamp 1 90465-13M30-00 Clamp 1 688-83383-11-00 Buzzer 1 6H5-83386-00-00 Buzzer Stay 1 67G-42725-00-00 Grommet 1 97595-08530-00 Mark 1
62Y-82555-00-00 Damper Main Switch 1 67G-82554-00-00 Neutral Switch Ass’y 1 67G-82555-01-00 Stay, Neutral Switch 1
Steering Friction Ass’y 1 • 6E5-42518-01-00 • Shaft, Friction 1 • 92990-08600-00 • Plate Washer 2 • 67G-42528-00-00 • Piece, Friction 1 • 90175-06003-00 • Nut, Wing 1 • 97080-06035-00 • Bolt 1 • 6E5-42515-00-00 • Rod 1 • 90185-08057-00 • Nut, Lock 2 97595-06514-00 Bolt 2 63D-83720-00-00 Connector Ass’y. 1
Part Number Part Name Qty.
Tiller Kit Handle Ass’y 1 Tiller Handle Install. Manual 1 63D-83728-00-00 Connector Ass’y. 1 688-82540-11-00 Neutral Switch Ass’y. 1 67G-82554-01-00 Stay, Neutral Switch 1 62Y-82555-00-00 Damper Main Switch 1
97595-06514-00 Bolt 1
97595-08530-00 Mark 1
67G-42725-00-00 Grommet 1
6H5-83553-11-00 Read Wire 1
63D-82586-00-00 Wire Harness Extension 1
688-83383-11-00 Buzzer 1
6H5-83386-00-00 Stay Buzzer 1
Steering Friction Ass’y 1 • 6E5-42518-01-00 • Shaft Friction 1 • 92995-08600-00 • Plate Washer 1 • 67G-42528-00-00 • Piece, Friction 1 • 90175-06003-00 • Nut, Wing 1 • 97080-06035-00 • Bolt 1 • 6E5-42515-00-00 • Rod 1 • 90185-08057-00 • Nut, Lock 2 90465-13M30-00 Clamp 1 90465-13M24-00 Clamp 1 68V-42121-00-4D Bracket 1 90116-10175-00 Stud 2
