2004 115TLRC-overheat alarm while cold

[luckyer]

Ok, just completed an install with a low hour (159) 2004 Yamaha 115TLRC. New harness, new keyswitch, new multi munction tach with adapter harness, new 704 binnacle. Oil levels and lights-fine, motor cranks over, trim works. Turn on the key, Tach flashes, then settles in, but the overheat alarm will not turn off and the icon on the tach continue to turn on. Motor is stone cold. Thermo switches test OK as well as do not stop buzzer/light when disconnected? I have re-checked all connections/plugs for corrosion. ( none to be found?) Ground is solid (If it was not it would not crank either)

Any ideas on what else to check/look at?

I don't want to start motor until this is resolved.

Thanks ...

Luckyer

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

this is gonna get interesting.
but first I need to know the part number of the oil/trim harness. the adapter harness and the full tachometer part number.
not all the new stuff is comptible with 04 and older engines.

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Yeah, I am already perplexed.

10-704-82750-08-00 Main switch with Buzzer
10-6X3-8258A-00-00 10P/Main Harness 16ft
10-6y5-85335-10-00 Adapter interphase
10-6yr-W0035-92-00 Remote Oil Tank
10-6YR-W0035-E2-00 Tachometer Rig Kit 2
10-704-48205-P1-00 Single Premium Binnacle

The oil trim harness came with the tank (blue connector on flat cable hooked to blue connector on motor- all colors line up), the adapter harness is plugged in to the 2 white connectors on the motor, plugged to Tach, exposed ground pigtail,-Grounded to block.

The only thing that I noticed is the Orange wire from the 4 prong off the motor does not hook up to anything. 4 prong to a 3 prong. All other wires/colors match up.

Bad Tach? Bad key switch? Wrong components?

Anything I can measure for voltage/ohms?

Thanks for your help!

Lucky

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

yes, I think ya got the wrong rigging kit, check the tach part number,like I asked,
the 6y5-8350T-90 is not reccomended for use with 04 and older engines. for pre 05 models the 6y5-8350T-81 or -82 tachs and use the trim/oil harness part number 68f-82553-XX-00(XX is length in feet or meters as required). no other adapters are required.
this is from page 6-25 of the 2007 marine technical guide. the rigging guide will have more information but I dont have one here.
I do remember most of the bullitens I read though
the tach kit you purchased should have the 6y5-8350T-90 tach which is not reccomended for 04 and older and it will have the 6y5 trim harness which isnt compatible and for using a pre 05 engine what your doing wont work without cutting up the harness.
so yep, ya got sold the wrong stuff for an 04 engine.

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Now I am totally confused.

I went outside and there are no Part numbers on my Tach, nor on the tach box or rigging kit box.

This is from my supplier-????
Yamaha TACHOMETER RIG KIT
TACHOMETER RIG KIT, also will need for motors 1994-2004 (ONLY) adapter 6Y5-85335-10-00.

OK, so now I am on the hunt for :

6y5-8350T-81 or -82 multifunction tach
68f-82553-XX-00 Trim/Oil Harness (16ft-same length as 10P)
(16)

Remove and replace Oil trim harness- with no adapter.
Remove and replace tach with correct model number tach.

I do not want to chop up anything, doing so makes "ME" the problem later if something goes wrong.

Thanks for the advise. I just hope my supplier is as easy in trying to get this exchanged/replaced/credited.

Lucky

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

the rigging kit you bought may not work,
I have had some applications where the harness adapter ended up under the hood instead of under the console.
straight off page 6-25 of the 2007 marine technical guide and the -E2 kit you bought contains the -90 tach.it the 68F harness has two square connectors at each end and is correct for your application the 6y5 harness has only one square connector at each end and is incorrect for your application. I have had to cut up a few late style harness's to make the tachs work. in the 05/06 marine tech guide is a guide wiring setup on what the harness wire colors do when changing to the -90 style tach.
does your trim extension harness have 2 square connectors at each end ?
and does your tach have one square connector and a few bullet connectors ?

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Tach has a few bullets -(3 i think) and one square connector.

Harness has one end on motor side- (Using adapter to mount to 2 white plugs) one has 3 wires , the other has 4. Other end is one plug- going to square connector on Tach.

Bullets connect to key switch, with red wire off key switch unused.

If I remember correctly, -I have been staring at this for 2 days looking for a mistake, so I may be a little off.

Is there a tach kit with the -81 or -82 tach and the harnesses
? Like maybe 6yr-w0035-E1, as the price for the -81 tach and harness are over $400, priced separatley.

Thanks again for all your help.

Lucky

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

are you looking at it right now?
I got insomnia anyway.

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

It's actually downstairs and outside, something else I can confirm that would help you diagnosis?

I would like to make it work if possible/easily and reliable, as I may be stuck for what I have purcased, cause "sorry electical parts are not returnable", especially if it just involves a few splice/but connectors...but a massive re-do...I would prefer to fight with supplier and do it right.

lucky

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

This just clicked:

I have had some applications where the harness adapter ended up under the hood instead of under the console

This is where mine is located. With the black ground pigtail, set to ground.

Lucky

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

here is where its gonna get tricky.
something is shorting out the pink wire in the 10 pin harness or the gray wire on the engine side of the trim harness.
unplug all your adapters at the engine side and turn the key on and see if the alarm is still on.
on the engine you have 3 square connectors, the blue one is for the remote oil tnk and is of no concern here.
on the other two
one has a green/red the other either green or green/white.
the green is normally grounded with the key on and can be checked with a DVM. this sets the oil bar full right and if its open the center bar lights alerting the operator of low remote level but sets no alarms.
the green red is low engine tank level and is normally open, if grounded it sets the far left bar and the audible via the pink wire in the 10 pin harness.
the other connector has an orange,a pink a gray and a black.
ornge is not used and may not even be there on the 04 model.
was a 5V reference for the 3 wire trim sender.
gray is the overhet visual indicate and if taken to ground will set the audible and the overheat visual.
pink on that little square one is trim send and black is just a ground for the trim sender.
so first we will isolate the motor side.
unplug all the guage harness's from the engine,turn the key on, buzzer should not sound.
if it does we have other issues.
if it does not we can rewire that adapther and make it work.
any questions so far, and be aware my A key sometimes wont work, or my fingers are dyslexic

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Based on what you have told me and what I have described, this should fix the problem.

Tachometer Part# 6Y5-8350T-82-00

Tach/Trim Harness# 68F-82553-90-00

2 Fuse Gauge Harness# 6Y5-83553-M0-00

Or do you have some double top secret solution in mind. LOL

Lucky

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

if ya dont mind dropping a dime PM and ill shoot ya the phone # and you can give me a shout in the next 10 minutes or so. like I say the insomnia is killing me and I hope this pack of smokes lasts a while
I am getting ready to live the american dream .
be in debt up to my eyes and its killing me
but intersting things like wiring is what I love and why I get them all at work
what your trying to do will work just you may have to shift some wiring around in that adapter harness.

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

I have isolated it down to those 3 connectors.

Blue- disconnect no change.

Disconnect 2 (green red wire white plug- no change
Disconnect 4 wire plug- audible off- No sure about visual. (Will check Tommorrow afternoon)

The Gray/black stripe wire when disconnected stops the audible, but the visual is still flashing.

The orange wire terminates at the plug end. All other colors in both white plugs match up to harness.

I traced all wires, unplugged all connectors, checked for corrosion, looked for kinks/chafing to ground, just about everywhere I could reached. Found nothing.

I will follow your disconnect procedure tomorrow afternoon and report back, exactly what did what/when.

Again thanks so much...

Hope the insomia goes away.....

Lucky

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

PM sent

 

[rodbolt]

Re: 2004 115TLRC-overheat alarm while cold

did you reset the dip switches on the tach when you took it out of the box.
from the factory its set up for 12 pole alt which you want, 2 wire trim which you want and 4 stroke which you dont want.
if set up for 4 stroke and you use it on two stroke the visuals blink at you.
ok now we kind got a handle on what the wires do at the engine side of the two square harness connectors. remember the blue one is for the remote tank and leave it alone.
now at the tach, you should have a green/red a green/white a gry and a pink.
on the tach pink will eventually go to the pink at the engine side square connector, gray will go to the engine side gray, green red will go to the engine side green red and green white will go to the engine side green/white or green.
if you look very closely at the pin side of the adapter connectors you will see a tiny plastic latch, use a pick and while applying pressure to pull the wire out of the connector move the latch awy from the pin and the wire will slip out of the connector.
you can rewire the harness adapter by moving the pins around.
somewhere I think your running the adapter harness gray wire to ground.
remember electrons dont care about insulation color but they do need to be directed to the correct conductor.
the new harness colors seem to change colors between the engine and the tach now

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Yes, I re-set the tach to Up, down, down..2 lead, 12 pole, 2 stroke,..Like I pm's you, I will look at tomorrow afternoon, map out and be ready to follow your lead.

Lucky- Hopefully !

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Rodbolt,
This is where I got:
With adapter in place:
Pink from Tach stays Pink till Motor Pink on 4 prong plug

Grey from Tach stays Grey till Motor Grey on 4 prong plug-then turns to Grey/black right after plug

Green/Red from Tach stays Green/Red till Motor Green/Red on 2of4 prong plug

Green/white from Tach turn green in Harness turns Green white on adapter to Green/Black on 2of4 prong plug

Orange from Motor- terminates at Motor Plug

Tach bullets-
Blue to Blue
Yellow to Yellow
Green to Green
Black to 2 blacks

Removing all connectors/harness from motor end with key on results in:
No Audible
No Temp Icon
Left Bar, Middle Bar-Flash, Right-no Bar

I have the harness with me, have pick and see how to move the pins.

ideas?

Lucky

 

[luckyer]

Re: 2004 115TLRC-overheat alarm while cold

Rodbolt,

Tested adapter...Gave me funny color changes on Continuity. So I Removed wrapping/black tape, what apears to be grey wire running straight through adapter is actually a bullet connector joining the Green/white and the Gray wire together. Could this be part of my problem?

Lucky

 

[loyoki]

Re: 2004 115TLRC-overheat alarm while cold

Are you sure it is overheat alarm ?
Because when you fill your F115 with new oil, when you start your engine after the job, alarm of oil low could be on.
After running a few minutes, when you start it again, it is OK.