Yamaha T8 Quick start guide

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 . . . . . . . . .
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Intro-
Quick
Start
1
2
4
5
6
7
8
9
3
10

Outboard Rigging Guide - 2001
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

Outboard Rigging Guide - 2001
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

Outboard Rigging Guide - 2001
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

Outboard Rigging Guide - 2001
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

i
Outboard Rigging Guide - 2001
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.
AWARNING 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 boat
handling and proper accident-prevention
measures.
1. Introduction
This will include a brief description, model
application, illustrations of components, and
additional parts (if any) needed to install the
component. This introduction should usually
give the rigger information needed to deter-
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 the
2001 Model Year. Anything prior to that is cov-
ered in previous Rigging Guides.

ii
Outboard Rigging Guide - 2001
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
B/W = Black/White Ignition coil primary lead
G/L = Green/Blue Crank position sensor

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
iii
Outboard Rigging Guide - 2001 Standard Abbreviations and Symbols
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
electric carb system (ECS)

iv
Outboard Rigging Guide - 2001 Standard Abbreviations and Symbols
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 ~ 15HPwould 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.

v
Outboard Rigging Guide - 2001
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/cm2psi 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.”
vi
Outboard Rigging Guide - 2001
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

vii
Outboard Rigging Guide - 2001
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
SX200TLRZ
L001786
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
Located on starboard clamp bracket.

viii
Outboard Rigging Guide - 2001
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
FILTER IN
OUT
TO ENGINE
BYPASS
WATER
DETECTION
SENDER

ix
Outboard Rigging Guide - 2001 General Rigging Information
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 RiggingTube Components
150~250, 2.6L, 3.1L, HPDI
Rigging Tube Grommet
1Shift Cable
2Throttle Cable
310 Pin Main Harness
4&5Oil Warning and Trim Gauge Harness
6Remote Oil Tank Lead Water Pressure,
7Battery Cable Harness Temp. Gauge
8Oil Hose
9Fuel Hose Isolator
Speedometer Hose Harness
V4 RiggingTube Grommet
1Throttle Cable
2Shift Cable
3Main Harness
4Oil Warning Lead
5Remote Oil Tank Lead
6Trim Gauge Lead
7Battery Leads w/Isolator Lead
8Oil Hose
9Fuel Hose
Speedometer Hose
F80/F100 Tube Grommet
1Throttle Cable
2Shift Cable
3Main Harness
4Trim Gauge, Oil Warning Lead
5Battery Leads
6Fuel Hose
7Speedometer Hose
8Water Temperature & Water Pressure Sensor
F115 Tube Grommet
1Throttle Cable
2Shift Cable
3Main Harness
4Trim Gauge, Oil Warning Lead
5Battery Leads
6Fuel Hose
7Speedometer Hose
8Water 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
67
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
78
5
4
2
6
11
12

x
Outboard Rigging Guide - 2001 General Rigging Information
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

xi
Outboard Rigging Guide - 2001 General Rigging Information
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