Yanmar ZT350 Stern Drive Service Manual

Description

• Model List:
  • ZT350 Stern Drive

• 1. Table of Contents
• 2. Introduction
• 2.1. Revision History
• 2.1.1. Revision Control Table
• 2.2. Safety Precautions
• 3. General Service Information
• 3.1. Responsibilities
• 3.1.1. Owner / Operator Responsibilities
• 3.1.2. Dealer / Distributor Responsibilities
• 3.2. Specifications
• 3.3. Identification
• 3.3.1. Transom Assembly
• 3.3.2. Stern Drive Assembly
• 3.4. Tightening Torques for Standard Bolts and Nuts
• 3.4.1. Tightening Fasteners
• 3.4.2. General Tightening Torque
• 3.4.3. Special Tightening Torques
• 3.4.4. Torque Conversion Chart
• 3.4.5. Hose Clamps
• 3.5. Lubricants, Sealers and Adhesives
• 3.6. Special Service Tools
• 3.7. Abbreviations and Symbols
• 3.7.1. Abbreviations
• 3.7.2. Symbols
• 3.8. Unit Conversions
• 3.8.1. Unit Prefixes
• 3.8.2. Units of Length
• 3.8.3. Units of Volume
• 3.8.4. Units of Mass
• 3.8.5. Units of Force
• 3.8.6. Units of Torque
• 3.8.7. Units of Pressure
• 3.8.8. Units of Power
• 3.8.9. Units of Temperature
• 4. Maintenance
• 4.1. Safety Precautions
• 4.2. Introduction
• 4.3. Checking, Filling and Changing Stern Drive Oil
• 4.3.1. Checking Stern Drive Oil Reservoir Level
• 4.3.2. Checking Stern Drive Oil Level
• 4.3.3. Filling Stern Drive Oil Reservoir
• 4.3.4. Changing Stern Drive Oil
• 4.4. Checking and Filling Power Trim Pump Fluid
• 4.4.1. Checking Power Trim Pump Fluid
• 4.4.2. Filling Power Trim Pump Fluid
• 4.5. Periodic Maintenance
• 4.5.1. The Importance of Periodic Maintenance
• 4.5.2. Performing Periodic Maintenance
• 4.5.3. The Importance of Daily Checks
• 4.5.4. Yanmar Replacement Parts
• 4.5.5. Tools Required
• 4.6. Periodic Maintenance Table
• 4.7. General Inspection
• 4.8. Periodic Maintenance Procedures
• 4.8.1. Checking the Water Inlets
• 4.8.2. Checking the Seawater Inlet Hole
• 4.8.3. Inspecting the Anodes
• 4.8.4. Checking the Oil Level
• 4.8.5. After Initial 50 Hours of Operation
• 4.8.6. Every 50 Hours of Operation
• 4.8.7. Every 100 Hours of Operation
• 4.8.8. Every 250 Hours of Operation
• 4.8.9. Every Year
• 4.9. Cold Weather (Freezing Temperature), Seasonal and Extended Storage
• 4.9.1. Stern Drive Lay-Up
• 4.9.2. Stern Drive Recommissioning
• 5. Stern Drive
• 5.1. Safety Precautions
• 5.2. Introduction
• 5.3. Component Identification
• 5.4. Stern Drive Removal from Transom Assembly
• 5.5. Stern Drive Installation to Transom Assembly
• 5.6. Stern Drive Driveshaft Alignment
• 5.7. Driveshaft Housing and Gear Housing Disassembly
• 5.8. Driveshaft Housing and Gear Housing Assembly
• 6. Driveshaft Housing
• 6.1. Safety Precautions
• 6.2. Introduction
• 6.3. General Views
• 6.4. Driveshaft Housing Part Diagrams
• 6.4.1. Driveshaft Housing and Drive Gear
• 6.4.2. Case Plate and Shifter (Mechanical)
• 6.4.3. Case Plate and Shifter (Electric)
• 6.5. Driveshaft Housing Disassembly
• 6.6. Upper Gear B CMP
• 6.6.1. Disassembly
• 6.6.2. Assembly
• 6.7. Case Plate and Shifter
• 6.7.1. Disassembly – Mechanical Shifter
• 6.7.2. Assembly – Mechanical Shifter
• 6.7.3. Disassembly – Electric Shifter
• 6.7.4. Assembly – Electric Shifter
• 6.7.5. Filter and Magnet Check
• 6.8. Clutch Shaft Set Disassembly and Inspection
• 6.8.1. Ring Retainer Assembly
• 6.9. Driveshaft Housing Assembly
• 6.10. Upper Gear Shim Adjustment
• 6.10.1. Shim Location
• 6.10.2. Determine T1 Shim Thickness – Gear Adjustment B Position
• 6.10.3. Determine T2 Shim Thickness – Gear Adjustment A-1 Position
• 6.10.4. Determine T3 Shim Thickness – Gear Adjustment A-2 Position
• 6.10.5. Determine T4 Shim Thickness – Bearing Clearance Adjustment
• 6.10.6. Setting Gear Backlash
• 7. Gear Housing
• 7.1. Safety Precautions
• 7.2. Introduction
• 7.3. General Views
• 7.4. Gear Housing Part Diagrams
• 7.4.1. Gear Housing Assembly
• 7.5. Disassembly and Inspection
• 7.6. Gear Housing Assembly
• 7.6.1. Driveshaft CMP Assembly
• 8. Transom Assembly
• 8.1. Safety Precautions
• 8.2. Introduction
• 8.3. General Views
• 8.4. Transom Assembly Part Diagrams
• 8.4.1. Gimbal Housing
• 8.4.2. Transom Plate
• 8.5. Gimbal Housing Disassembly
• 8.6. Gimbal Housing Assembly
• 8.7. Tilt-Up Limit Spacer
• 8.8. Speedometer Connection
• 9. Shift Cable
• 9.1. Safety Precautions
• 9.2. Introduction
• 9.3. Control Cables
• 9.3.1. Mechanical Shift Cable Parts Diagram
• 9.3.2. Control Cable Travel
• 9.3.3. Verify Propeller Rotation with Mechanical Shift System
• 9.4. Shift Cable Installation and Adjustment
• 9.4.1. Shift Cable Installation for Electric Shift Type
• 9.4.2. Shift Cable Installation for Mechanical Shift Type
• 9.4.3. Setting the Cable Length
• 9.4.4. Installing the Drive Unit Shift Cable
• 9.4.5. Adjusting the Shift Control Cable
• 9.4.6. Troubleshooting Shift Problems
• 10. Steering
• 10.1. Safety Precautions
• 10.2. Introduction
• 10.3. Power Steering Unit Parts Diagram
• 10.4. Steering Cable Specifications
• 10.5. Installation of Steering Cable
• 10.6. Connecting Steering Cables
• 10.7. Power Steering Unit Installation
• 10.8. Power Steering Hose Installation
• 10.9. Steering Tie Bar Considerations
• 10.9.1. Internal Tie Bar Only
• 10.9.2. Internal and External Tie Bar
• 10.9.3. External Power Steering with an External Tie Bar
• 11. Power Trim System
• 11.1. Safety Precautions
• 11.2. Introduction
• 11.3. Power Trim Pump Parts Diagram
• 11.4. Power Trim Cylinders Parts Diagram
• 11.5. Power Trim System
• 11.6. Power Trim Pump Fluid
• 11.7. Power Trim Cylinders
• 11.8. Power Trim Troubleshooting
• 11.9. Power Trim Pump Installation
• 11.10. Trim Position Sender Connection
• 11.11. Trim-In Limiter
• 12. Propellers
• 12.1. Safety Precautions
• 12.2. Introduction
• 12.3. Propeller Selection
• 12.3.1. Propeller and Propeller Accessory Parts Diagrams
• 12.4. Propeller Installation
• 12.5. Removing Propellers
• 13. Corrosion Protection
• 13.1. Safety Precautions
• 13.2. Introduction
• 13.3. Corrosion Control Parts Diagram
• 13.4. Galvanic Corrosion
• 13.5. Corrosion Control
• 13.6. Shore Power
• 13.7. Underwater Drive Coating
• 13.8. Additional Protection
• 13.9. Gear Housing Anodic Plates
• 13.10. Ventilation Plate Anode
• 13.11. Trim Cylinder Anodes
• 13.12. Propeller Shaft Anode
• 13.13. Yanmar Cathodic Protection System
• 13.14. Corrosion Troubleshooting
• 14. Troubleshooting and Testing
• 14.1. Safety Precautions
• 14.2. Introduction
• 14.3. Stern Drive Unit Troubleshooting
• 14.4. Performance Troubleshooting
• 14.5. Power Steering Troubleshooting
• 14.6. Power Trim System Troubleshooting
• 14.7. Stern Drive Testing
• 14.7.1. Test Preparations
• 14.7.2. Engine Operation Tests
• 14.7.3. Out-of-Water Testing
• 14.7.4. In-Water Testing
• 14.7.5. Wide Open Throttle Test
• 14.7.6. Drive Unit Operational Tests