The lighting coil will allow the motor to produce additional electrical current. With a voltage regu-lator, the lighting coil can be used to directly power lights or other accessories on a boat.
Maximum output of the lighting coil is 60 watts.
The lighting coil can also be used to charge the battery when a rectifier is added.
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.
The main thrust must be made in the direction of the arrow. If not, the flywheel holder can slip off.
3. Using the flywheel puller, remove the fly-wheel. The flywheel puller bolts should be inserted into the hole marked "P."
Loosen the flywheel nut out only to the end of the crankshaft until the flywheel has broken loose. This will prevent the flywheel from com-pletely popping off. Once the flywheel is loose, the nut can be removed.
4. Remove the woodruff key from the crank-shaft keyway.
5. Install the lighting coil onto the magneto base with the two screws.
Part Number Applicable Models
6E0-81303-80-00 5 HP
CAUTION:
CAUTION:
CLOCKWISE
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.
8. Pass the wire leads of the lighting coil through the grommet, then reinstall the grom-met into the magneto base.
9. Secure the wire leads with the stay. The ground lead should be secured with the stay screw.
10. Make sure the O-ring in the groove of the magneto base is installed 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 rein-stall 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.)
14. Reinstall the recoil starter onto the magneto base and tighten the bolts.
Wiring
1. Connect the wire leads as shown in the dia-grams.
NOTE: The voltage regulator can also be used with the Yamaha rectifier to assure proper voltage input from the rectifier to the battery.
NOTE: The 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.
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.
Additional Parts Required
Installation
1. Remove the upper cowling, flywheel cover, and carburetor air box from the motor.
2. It will be necessary to remove the three car-buretor assemblies to install the neutral safe-ty switch. Shut off the fuel supply, and dis-connect 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.
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 carbure-tors are removed.
4. 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
5. Connect the extension wire lead (P/N: 6H4-82553-00-00) to the leads of the neutral safe-ty 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 link-ages.
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 car-buretor 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 secure-ly connected and reinstall the terminal cover.
10. Reinstall the control cable and flywheel cov-ers and the upper cowling.
11. Test the operation of the neutral safety switch. The unit should start only when in neutral.
Part Number Applicable Models 688-82540-11-00 30HP when 704 switch
panel is used
Part Number Applicable Models Qty
6J8-82554-00-00 Stay 1
97095-06012-00 6mm Bolt 2
6H4-82553-00-00 Extension Wire Lead 1
F/T25T, 40T~250HP, C40T~C90
(REMOTE POWER TRIM AND TILT SWITCH) - 688-82563-10-00
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 mod-els without power tilt. The switch would be need-ed 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 mount-ed 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.
2. 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.
3. Secure the switch with the cap and plate.
Additional Parts Required REF
NO DESCRIPTION QTY.
1 Tilt Switch 1
Part Number Applicable Models 688-82563-10-00 FT25T, 40T~250HP,
C40T~C90
Part Number Applicable Models Qty 97780-40116-00 Panhead Tapping Screw 2
688-82388-00-00 Plate 1
Mounting
Think Instrument Panel Installation (over 2mm (0.08in)
1. Select a mounting location so the power trim/tilt switch is easy to reach from the helm.
Be sure there is sufficient clearance behind the instrument panel for the switch.
2. When installing the power trim/tilt switch into a thick instrument panel, make a hole 40mm (1.57in) high and 13mm (0.5in) wide as shown in the mounting diagram.
3. Secure the switch with the wood screws as shown.
For electric tiller model wiring, see the wiring diagrams in the Boat Wiring Diagrams Section.
40 mm (1.57 in)
13 mm (.5 in) TEMPLATE (Actual Size)