Imv3 Rev4 Master Book 29dec08
Imv3 Rev4 Master Book 29dec08
Imv3 Rev4 Master Book 29dec08
INSTALLATION MANUAL
Volume 3
BY, BY2, LH, LP, LY, CX, SY Series and ZT350
Marine Installation Manual - Volume 3
P/N 0FMPE-U00304
MARINE
INSTALLATION
MANUAL
6BY2
Marine Installation Manual - Volume 3
Page
Engine Specifications .....................................................................2
Engine Room Space for Service ....................................................3
Marine Gear / Stern Drive Specifications .......................................4
Flywheel Housing Dimensions (Borg Warner Flange)....................7
Flywheel Housing Dimensions (Stern Drive) ..................................8
Fuel System Specifications ............................................................9
Piping Diagram .............................................................................10
Cooling System Specifications .....................................................11
Air Intake and Exhaust Specifications ..........................................13
Mixing Elbow ................................................................................14
Alarm System Specifications ........................................................15
Remote Control System ...............................................................15
Electrical System ..........................................................................16
Standard Alternator Data..............................................................17
Performance Curves.....................................................................20
Engine Mount ...............................................................................22
Installation Specifications .............................................................23
Cold Starting Aids.........................................................................23
Water Heater Tank Connection ....................................................24
Heat Insulation Requirements ......................................................24
Optional Accessories....................................................................24
70 mm
(2.8 in.)
(21.65 in.)
550 mm
239.8 mm
(9.45 in.)
159.8 mm
(6.3 in.)
267 mm
(14.5 in.)
0006581
Figure - 1
The installer is responsible for ensuring that there is sufficient engine room space to access the engine for
service and repair.
Superstructures and connected components should be installed so that the engine can be removed, fitted
and serviced without time being lost to any obstructions.
The following components must be easy to access:
• Fuel filter(s) • Coolant pump
• Fuel system components for bleeding the fuel • Heat exchanger
system
• Complete seawater pump assembly (to access
• Air filter impeller and filter)
• Engine oil filter(s) • Zinc anodes
• Oil fill port and dipstick • Batteries
• Engine oil drain plug • Starter motor
• Marine Gear or Sail-Drive oil fill port / dipstick • Alternator
• Coolant tank fill port • Turbocharger
• Coolant drain cock(s)
S
1064 (41.89)
1001 (39.41)
145 (5.71)
279 (10.98)
287 (11.3)
716 (28.19)
847.45 (33.36)
709 (27.91)
700 (27.56)
A
716.48 (28.21)
203 (7.99)
(C16)
VIEW
Ansicht S
(G6)
SECTION A-A
Schnitt A-A
548.5 (21.59)
(1.81)
46
15.5 (.61)
SAE 20/40-26
0006541
Unit: mm (in.)
Figure - 2
Stern Drive
614.5 (24.19)
1001 (39.41)
145 (5.71)
279 (10.98)
287 (11.3)
716 (28.19)
709 (27.91)
700 (27.56)
240 (9.45) 460 (18.11)
373 (14.69)
802 (31.57)
761 (29.96)
203.99 (8.03)
429 (16.89)
894 (35.2)
(5.87)
149.1 (2.8)
(3.71)
94.21
71.1
0006495
Unit: mm (in.)
Figure - 3
119 (4.69)
235 (9.25)
0006489
Figure - 4
Unit: mm (in.)
220 (8.66)
241.3 (9.5)
10.3 (.406)
0006490
Figure - 5
Unit: mm (in.)
Piping Diagram
Fuel Flow
(9)
(8)
(15)
(10)
(7)
(11) (2)
(3)
(14)
(6)
(12)
(1)
(13)
(4)
(16)
0006510
(5)
1. Fuel Inlet from Tank 10. Fuel Injector Return Hose
2. Fuel Filter (10 micron) 11. Common Rail Return Line
3. Fuel Feed Pump 12. Return Fuel Tee with Back Pressure Valve
4. Inlet Fuel Temperature Sensor 13. Return Fuel to Fuel Tank with Over Pressure
5. High-Pressure Fuel Pump Valve
6. High-Pressure Fuel Supply Line 14. Fuel Pressure Sensor
7. High-Pressure Fuel Common Rail 15. Fuel Pressure Regulator (ECU-Controlled)
8. Fuel Injection Line 16. Fuel Measuring Unit (ECU-Controlled)
9. Fuel Injector
Figure - 6
Cooling Flow
(2) (3)
(1)
(6)
(4)
(7)
(5)
(12)
(9)
(13)
(8)
(11)
(10)
0006511
Figure - 7
Parameter Data
6BY2-220 6BY2-260
Exhaust Pipe
Outer 102 mm
Diameter (4.0 in.)
Connection
Air Volume
Necessary for 950 m3/h
Combustion at (33549 ft3/h)
WOT
Maximum Air 4.0 kPa
Inlet 408 mmAq
Depression (16.06 in.Aq)
Maximum 45 kPa
Back Pressure 4589 mmAq
(180.67 in.Aq)
EPA Exhaust Location: Mixing Elbow
Test Port G 1/4 - 19 BSPP
Sizes or
G 3/8 - 19 BSPP4*
600°C 650°C
Maximum (1112°F) (1202°F)
Output at rated speed at rated speed
Exhaust
Temperature 700°C 700°C
Before (1292°F) (1292°F)
Turbocharger at full load at full load
2000 rpm 2000 rpm
Maximum
1950 / 2150
Turbocharger 2000 / 2200
mbar
Boost mbar
(28.3 / 31.2
Pressure (29.0 / 31.9 psi)
psi)
(min/max)
Maximum
Engine Room 60°C
Ambient (140°F)
Temperature
Mixing Elbow
410.5 (16.16)
351 (13.82) 3)
.7
(4
0
12
404.5 (15.93)
ø1 .02
(ø
02 )
336 (13.23)
4
(10.83)
275.1
436.1 (17.17)
ø1 .0
(ø
02 2)
4
700.4 (27.57)
615.5 (24.23)
464.5 (18.29)
223.3
(8.79)
(ø 4. 02
ø1 02
328 (12.91)
559.4 (22.02)
486.9 (19.17)
)
(ø 4 .0
ø102 )
2
574.2 (22.61)
506.9 (19,92)
775.3 (30.52)
732.8 (28.85)
0006602
Unit = mm (in.)
2 3 0 100
84 PSi
1 4 (3)
0 2615
X1000 RPM
100 250
11 4 Fah
0003327
1. Tachometer
2. Engine Oil Pressure Meter
3. Multi-function Meter (Coolant Temperature,
Lube Oil Temperature, Fuel Temperature,
Boost Pressure, Voltage, Load Factor,
Throttle Valve, Fuel Consumption Rate and
Gear Shift Position)
Figure - 8
kW
N•m
rpm
Figure - 9
Wiring Diagram
B+
(3) (4) (5) (8) (9) (10)
(7)
F2 F1 F6 (6) F4 F3 F5
X1/C
X1/B
(211, 224)
182
207
234
(12) (11)
157
K1
ϑ 132
(48)
X1/R
(44) ϑ (1)
p
X1/G (43) 154
232 (13)
(47) (42) K2
X1/D
(46) 107
(15)
106 220 (14)
180
(45) K3
139
(16) 187
(2) (16)
(41) 115
162 (53)
124 X1/H
(40) 114
X1/L
243
245 X1/F
(18)
X1/W X1/V (37) X1/N 252
256
BOSCH
X1/O
X1/M
171
(20)
(39) (38) 230
ZME
183
(35) 130
ϑ (34)
149
(21)
p
156
(50) 173
151 (22)
111
175
178
103
(23)
F7 211
127
KL87
(33)
150
(24)
F8 251
(51) 174
KL31
X1/Q
X1/A X1/U (53)
(52) (27)
(28) X1/S X1/T
0003303
(29)
Figure - 10
1
NEVER connect any additional devices to F2. F6
may be used however, it is not switched.
Performance Curves
6BY2-220
600 200
525 175
450 150
375 125
torque
torque [Nm]
power [kW]
300 100
power
225 75
150 50
75 25
0 0
0 1000 2000 3000 4000
engine speed [rpm]
0006528
Figure - 11
6BY2-260
600 200
525 175
450 150
torque
375 125
torque [Nm]
power
power [kW]
300 100
225 75
150 50
75 25
0 0
0 1000 2000 3000 4000
engine speed [rpm]
0006527
Figure - 12
265
260
255
specific fuel consumption [g/kWh]
250
245
240
235
230
225
220
215
210
205
200
500 1000 1500 2000 2500 3000 3500 4000 4500
engine speed [rpm]
0006579
Figure - 13
6BY2-260
specific fuel consumption
270
265
260
255
specific fuel consumption [g/kWh]
250
245
240
235
230
225
220
215
210
205
200
500 1000 1500 2000 2500 3000 3500 4000 4500
engine speed [rpm]
0006580
Figure - 14
Marine Installation Manual - Volume 3 SEPT 2008 (Rev. 4) 6BY2 - 21
6BY2 6BY2
Engine Mount
10
(.39)
T IG H T E N T O 1 1 0 N m
( 8 1 L b - F t) O N
A S S E M B LY
T I GHT EN TO 50 N m
(3 7 L b -Ft ) O N
ASSE MBLY 157
(6.18)
49
(1 .9 3 ) 4
(.1 6 )
2 0 (. 79)
75
(2 .9 5 ) 13 30
(.5 1 ) (1.18)
13
(.51)
0006604
Unit: mm (in.)
Figure - 15
Inclination Angle
Static Running Peak
Unit = degree
β 0-8 max 20 25
λ 0 -5 -10
α 0 20 30
0004144
Figure - 16
Optional Accessories
The following is a list of the 6BY2 series optional
accessories.
• Yanmar digital display
• Yanmar rocker switch panel (1st station)
• Yanmar interface module, HARNESS
• Yanmar control head
• Yanmar NMEA, terminal and T-connector,
CABLE
Page
Safety .................................................................................................. 4
Notice to Vessel OEM & Equipment Installer ...................................... 9
Sales and Technical Assistance.................................................... 9
Lubricants / Sealants / Adhesives ............................................... 10
Special Tools ............................................................................... 11
Trim-In Limiter ............................................................................. 11
Steering Tie Bar Considerations ....................................................... 12
Internal Tie Bar Only.................................................................... 12
Internal and External Tie Bar....................................................... 12
External Power Steering with an External Tie Bar....................... 12
Corrosion Control .............................................................................. 12
Shore Power................................................................................ 12
Antifouling Paint........................................................................... 13
Painting the Transom and Stern-Drive ........................................ 13
Vessel Design Considerations .......................................................... 14
Transom Thickness ..................................................................... 14
Laying Out the Transom Cutout .................................................. 14
Vessel Engine Mount Position..................................................... 14
Selecting an Engine Exhaust System.......................................... 15
Positioning the Drive Unit .................................................................. 16
Locating the Crankshaft Vertical Centerline -
Single Engine Installation ............................................................ 16
Locating the Crankshaft Vertical Centerline -
Dual Engine Installation............................................................... 16
Finding the Crankshaft Horizontal Centerline (X-Dimension)...... 17
Cutting the Vessel Transom ........................................................ 19
Checking the Transom Thickness ............................................... 20
SAFETY
Yanmar considers safety of great importance and Indicates a hazardous situation which, if not
recommends that anyone that comes into close avoided, will result in death or serious injury.
contact with its products, such as those who install,
operate, maintain or service Yanmar products,
exercise care, common sense and comply with the
safety information in this manual and on the engine Indicates a hazardous situation which, if not
and stern-drive's safety labels. Keep the labels avoided, could result in death or serious injury.
from becoming dirty or torn and replace them if they
are lost or damaged. Also, if you need to replace a
part that has a label attached to it, make sure you Indicates a hazardous situation which, if not
order the new part and label at the same time. avoided, could result in minor or moderate
injury.
This safety alert symbol appears
with most safety statements. It
General Information
There is no substitute for common sense and
The safety messages that follow have DANGER
careful practices. Improper practices or
level hazards. These safety messages describe
carelessness can cause burns, cuts, mutilation,
a hazardous situation which, if not avoided, will
asphyxiation, other bodily injury or death. This
result in death or serious injury.
information contains general safety precautions
and guidelines that must be followed to reduce risk NEVER permit anyone to install or
to personal safety. Special safety precautions are operate the engine or stern-drive
listed in specific procedures. Read and understand without proper training.
all of the safety precautions before operation or
performing repairs or maintenance.
• Read and understand the Operation Manual
information before you install, operate or service
the engine or stern-drive to ensure that you follow
safe operating practices and maintenance
procedures.
• Safety signs and labels are additional reminders
for safe operating and maintenance techniques.
• See your authorized Yanmar marine dealer or
distributor for additional training.
Crush Hazard
ALWAYS use lifting equipment with
sufficient capacity to lift the stern-drive.
Exposure Hazard
ALWAYS wear personal protective
equipment including appropriate
clothing, gloves, work shoes, eye
and hearing protection as required
by the task at hand.
ALWAYS be environmentally
responsible. Follow the guidelines of
the EPA or other governmental
agencies for the proper disposal of
hazardous materials such as
lubrication oil, diesel fuel and engine coolant.
Consult the local authorities or reclamation facility.
NOTICE TO VESSEL OEM & We could not possibly know of and advise the
marine trade of all conceivable procedures or
EQUIPMENT INSTALLER methods by which a service might be performed, or
This Installation Manual contains safety information of every possible hazard and / or results of each
designed to: procedure or method. We have not undertaken any
such wide evaluation. Therefore, anyone who uses
• Make you aware of the hazards associated with a procedure or method not described by the
the installation of the ZT350 stern-drive. manufacturer must first satisfy himself that neither
his safety, nor the safety of the product, will be
• Inform you of the risk of injury associated with
endangered by the installation or servicing
those hazards.
procedure selected.
• Tell you how to avoid or reduce the risk of injury.
All information, illustrations and specifications
• Prior to work, read and understand the section(s) contained in this manual are based on the latest
of this manual that pertain to the job. production information available at the time of
publication. However, Yanmar Marine International
• Read and follow all safety warnings. reserves the right to change, alter or otherwise
NOTICE: Indicates critical information or improve the product at any time without obligation
instructions that are necessary for proper or prior notice.
installation and / or operation.
Sales and Technical Assistance
Note: See the appropriate Yanmar Technical The Yanmar dealer / distributor network is trained
Manual for application to assist with any sales or technical issues. This
recommendations. includes application engineering and service
This Installation Manual has been written and information.
published by Yanmar Marine International to assist
If you have an issue with the application of our
boat manufacturer's and service personnel when
product that cannot be resolved, contact your
installing the products described herein.
Yanmar Distributor Service Engineer. All requests
It is assumed that these personnel are familiar with for assistance should be directed to your local
the installation procedures for these products, or Yanmar distributor. The distributor for your area
like or similar products, manufactured by Yanmar can be found by using the service locator on the
Marine International. It is also assumed that they Yanmar website (www.yanmarmarine.com) or by
have been trained in the recommended installation contacting Yanmar Marine International.
procedures for these products, which includes the
use of mechanics hand tools and any special tools
that might be required.
Special Tools
0006039
0006498
Antifouling Paint
NOTICE: Corrosion damage that results from the
improper application of marine paint or antifouling
paint is not covered by the Yanmar limited warranty.
Observe the following precautions when applying
antifouling or marine paint to the transom of the (1)
boat hull. (2)
• NEVER paint the anodes of installed on the stern-
drive.
• NEVER paint the Y-CaPS reference electrode 0006341
and / or anode.
• NEVER wash the stern-drive with a high pressure Figure - 1
washer. This could damage the coating on the 1 – Painted Vessel Transom
reference wire. 2 – Minimum 40 mm (1-1/2 in.) of unpainted area
around transom assembly.
• NEVER paint the stern-drive with a material that
contains copper or tin. NOTICE: The drive unit and transom assembly can
be painted with a good quality marine paint or an
• NEVER paint over drain holes, anodes, Y-CaPS anti-fouling paint that does not contain copper or
or other items specified by the anode any other material that could conduct electrical
manufacturer. current. NEVER paint drain holes, anodes, Y-CaPS
or items specified by the vessel manufacturer.
Painting the Transom and Stern-
NOTICE: NEVER wash the stern-drive with a
Drive power washer because it can damage the coating
Corrosion damage that results from improper on the reference wire and increase corrosion.
application of anti-fouling paint will not be covered
by the warranty.
Anti-fouling paint may be applied to the vessel hull
and the vessel transom.
NOTICE: NEVER paint the anodes or Y-CaPS
electrode. Painting these components will render
them ineffective as galvanic corrosion inhibitors.
NOTICE: Use copper-based paint as anti-fouling
protection for the vessel hull or vessel transom, as
long as it is not prohibited by law in the area where
the vessel will be operated. If using copper- or tin-
based anti-fouling paint, avoid an electrical
interconnection between the Yanmar product,
anodic blocks, or Y-CaPS and the paint by allowing
a minimum of 40 mm (1-1/2 in.) of UNPAINTED
area on the transom of the vessel and around these
items.
VESSEL DESIGN
CONSIDERATIONS (3) (3)
(1)
(2)
ALWAYS adhere to all applicable marine
regulations such as the United States Coast (4)
Guard (USCG), European Union-Recreational
Craft Directive (EU-RCD), and so on and the (5) 0006042
standards they reference such as the American
Boat and Yacht Council (ABYC), Society of Figure - 2
Automotive Engineers (SAE), International
Standards Organization (ISO), and so on, when 1 – Transom Thickness
2 – Transom Angle
designing and constructing the boat and the
3 – Transom plate coverage 203 mm (8.0 in.)
boat components, such as the engine from the center.
compartment, fuel delivery system and exhaust 4 – Inner Surface
system. 5 – Outer Surface
When choosing a vessel that will potentially be
Transom Thickness
modified for the installation of the ZT350 stern-
drive, ensure that the vessel transom meets the See Checking the Transom Thickness on
following criteria: page ZT350-20.
• Transom thickness should be between 51 and 57 Laying Out the Transom Cutout
mm (2 - 2.25 in.).
See Positioning the Drive Unit on page ZT350-16.
• The inner and outer surface of the transom
should be parallel to within 3 mm (0.125 in.). Vessel Engine Mount Position
• The inner surface of the transom is flat to within 3 The engine mount position should allow for a
mm (0.125 in.). minimum of 6 mm (0.25 in.) of vertical adjustment
on the front mounts of the engine.
• The outer surface of the transom is flat to within 2
mm (0.075 in.). Note: The mounting hardware that is
incorporated with the engine usually
• The transom angle is between 10 and 16° (13° is allows for some adjustment. However, it
ideal). is good practice to ensure that the
engine mount points that hold the engine
• Ensure that there is enough flat surface area on
in the vessel are all in parallel planes.
the transom to apply the transom plate. This
would be 203 mm (8 in.) on either side of the • Tie a string from the front right mount position
center line of the transom. and the left rear mount position.
• Tie a string from the left front mount position
and the right rear mount position.
• The strings should touch at the point of
intersection.
(5)
(1) (2) (2)
(4)
(2)
(1)
(3)
(1)
(5)
(3) 0006044
0006043 Figure - 4
Figure - 3 1 – 1/2 minimum distance between the
1 – 305 mm (12 in.) crankshaft centerlines.
2 – Identical Side Marks 2 – Transom Vertical Centerline
3 – Compass Arc 3 – Dual Engine Crankshaft Vertical Centerlines
4 – Arc Intersection Points
5 – Crankshaft Vertical Centerline
NOTICE: When the X-dimension is increased, the Use the 90° tool as follows:
pulling power for skiing is decreased. During 1. Place the 90° tool along the boat bottom at the
testing, increase the X-dimension in 13 mm (1/2 in.) vertical centerline.
increments until preferred performance is achieved.
2. Locate the point at which the top of the 90° tool
Never increase the X-dimension by more than: contacts the transom on the vertical centerline.
3. This is the crankshaft horizontal centerline or X-
Maximum Increase in X-Dimension
dimension.
ZT350 25 mm (1 in.)
(3)
(1) 0006046B
Figure - 7
(2)
1 – 90° tool along the boat bottom at the vertical (3)
centerline. 0006047A
Figure - 9
1 – Vertical Centerline
2 – X-Dimension that corresponds to the
transom angle selected from the chart.
3 – Crankshaft Horizontal Centerline
Template
0006039
Figure - 11
1. Drill two 6 mm (1/4 in.) pilot holes at a 60° angle
for the hole saw guides.
2. Use a hole saw to cut the two 51 mm (2 in.)
holes for the steering lever cutout.
NOTICE: If the hole saw cutout is made incorrectly,
stern-drive steering lever may come in contact with
the transom causing limited steering travel.
(1)
(2)
0006048
Figure - 10 (2)
0006049
Figure - 12
1 – 51 mm (2 in.) Steering Lever Cutout
2 – 60° from the surface of the transom
(3)
0006052
Figure - 15
(1)
1 – Measuring Transom Flatness
2 – Measuring Transom Thickness
(2)
3 – Suitable tool to check for uniform transom
thickness.
(4)
Transom Specifications
(2)
(1)
0006051
Figure - 14
(1) (4)
(2)
(3)
(1) (1)
5 7
(5)
3 2
1 4
8 6
0006053
Figure - 16
1 – Locknuts and Flat Washers (8 ea.) 4 – Transom Plate Bonding Wire
2 – Steering Lever Bonding Wire 5 – Torque Sequence
3 – Bolt
Figure - 18
1 – Seawater Hose Fitting
2 – Connector (Seawater)
1. Install the fitting gasket (connector).
2. Install the connector (seawater).
(3) (4)
(5) 3. Install J-clip if oil reservoir hose assembly will
be routed to the port side.
4. Install the lock washers and connector
(2) (seawater) bolts.
0006054 5. Torque the bolts.
Figure - 17 Seawater Inlet Fitting Bolt Torque
1 – Male Quick Connect N·m lb-in.
2 – Female Quick Connect 6 53
3 – Barbed Fitting
4 – Tie Strap
5 – Hose (2)
4. Secure the hose to the transom with the hose
clip and screw.
(1)
5. Ensure that the hose NEVER contacts the (3)
steering system components, the engine
coupler or the drive shaft. CAUTION! Avoid
water leaking into the boat. The
speedometer hose is filled with water,
especially during boat operation. Hose
(4)
contact with moving or rotating engine parts 0006056
0006058
Figure - 21
1 – Bolts
2 – Lock Washer
3 – Plate (Seawater Inlet)
(3) 4 – Gasket
(2)
(1)
0006499
Figure - 20
1 – Hose Insert Tool
2 – Insert
3 – Gimbal Housing
(2)
(4) (3)
(4)
(3)
0006059
Figure - 22
(1)
1 – Gimbal Housing
2 – Speedometer Hose
3 – Water Hose
4 – Trim Sender Limit Switch Wires (5)
WARNING! Avoid water leaking into the boat. 0006060
Damage to U-joint bellows could result from
water entering the boat. Do not damage the U- Figure - 23
joint bellows when removing the section of the 1 – Water Hose
water hose attached between the gimbal 2 – Speedometer Hose
housing and bell housing. 3 – Clip
4 – Trim Sender Limit Switch Wires
Note: Move the trim sender limit switch wires 5 – Measurement: 127 mm (5 in.)
and speedometer hose to avoid
damaging them when cutting the inlet
drive shaft water hose. The existing tie
strap and clip can be reused if they are
moved and repositioned after the hose is
cut.
1. Cut completely through the inlet water hose 127
mm (5 in.) in front of the aft end of the hose
where it is fitted into the bell housing. Do not
damage the U-joint bellows.
2. Discard the loose hose piece.
3. Secure the trim sender limit switch wires and
speedometer hose to the remaining section of
water hose using the existing tie strap and clip.
(1)
(4)
(5)
(2)
(3) 0006062
Figure - 25
(3) 0006061
1 – Plate (Seawater Inlet)
Figure - 24 2 – ACCEPTABLE Positions
3 – Quick Release Button
1 – Gimbal Housing Hose Assembly 4 – NOT ACCEPTABLE Position
2 – Quick Connector 90° 5 – Quick Connector 90°
3 – Gimbal Housing Fitting
NOTICE: NEVER let the hose come in contact
CAUTION! Avoid drive unit damage. The with the steering system components, the engine
quick release button on oil reservoir 90° hose coupler or the drive shaft.
fitting may not lock on gimbal housing if
touching or depressed by connector 3. The oil reservoir hose assembly can be routed
(seawater), or plate (seawater inlet) if toward the port side of the engine.
equipped. Ensure that the quick release 4. Secure the hose assembly at the top side of the
button NEVER contacts the plate, or connector (seawater), or plate (seawater inlet),
connector if equipped. Failure to do so may using the hose J-clip.
result in a loose 90° fitting, a loss of gear lube
and / or damage to the drive unit. (1)
(2)
0006063
Figure - 26
1 – Oil Reservoir Hose
2 – Hose J-Clip
(3)
(4)
(1)
0006064
Figure - 27
1 – J-Clips 0006065
Figure - 30
• Use fasteners that are appropriate for the
mounting surface to install the mounting bracket. 1 – Power Steering Bushings
(2)
(1) (2)
0006066
Figure - 29
1 – Mounting Bolt Location
2 – Shift Plate
5. Install the upper and lower pivot bolts along (1) (2)
with the lock tab washers. Ensure that the lock
tab washer tangs straddle the ridge on the inner
transom plate.
Upper Pivot Bolt and Tab Washer Shown (Lower
Similar).
Figure - 33
(2)
1 – Bent Tab
2 – Pivot Bolt
9. Wear eye protection while moving the spool
barrel cable guide tube in the directions shown
in Figure - 34. It will be less difficult to pull it out
or push it in during the following installation
steps. CAUTION! Moving the spool barrel
cable guide tube with the hoses
disconnected will leak fluid from the ports.
0006069
Wear eye protection to avoid injury.
Figure - 32
(1) (2)
1 – Locking Washer Tang
2 – Ridge
6. Turn the pivot bolts all the way in by hand.
Ensure that the steering assembly pivots freely.
7. Torque the pivot bolts.
Upper and Lower Pivot Bolt Torque
N·m lb-ft
35 26 (1)
(2)
8. Bend the locking washer tabs against the
corresponding flats on the bolt heads.
Note: It may be necessary to tighten the pivot
bolts a little more to align the flats on bolt
head with the tabs on the washer.
0006071
Figure - 34
1 – Port
2 – Spool Barrel Cable Guide Tube
(1)
0006073
Figure - 36
1 – Steering Cable and Outer Casing
(1)
(2)
(6) (5)
(7)
0006074
Figure - 37
1 – Clevis Pin 5 – Cotter Pin
2 – Spool Barrel Cable Guide Tube 6 – Clevis
3 – Cable Coupler Nut 7 – Steering Cable End
4 – Steering Cable
• Close to the battery so that the trim pump battery 2. Connect the power trim pump control harness
leads can be connected. to the trim pump connector.
(1)
(2) 0006077
(3) Figure - 40
0006075
1 – Trim Limit Switch Wires
Figure - 38 2 – Wire Retainer and Tie Strap (obtain locally)
(2)
0006080
Figure - 43
1 – Bolts and Lock Washers
0006078
2 – Exhaust Block-Off Plate
Figure - 41
Exhaust Block-Off Plate Bolt Torque
1 – Gimbal Housing Exhaust Tube Mating
N·m lb-ft
Surface
2 – O-Ring 30 22
(1)
0006079
Figure - 42
1 – Engine Exhaust Tube
Please refer to the relevant manual for the correct
tightening torque.
0006085
Figure - 44
1 – Steel Washer (obtain locally)
2 – Corrected Engine Mount
3 – Hard Rubber Washer
Figure - 47
1 – Insert this end of the alignment tool through
the gimbal housing assembly.
2 – Alignment Shaft
3 – 90° Increments
(1) (2) 2. If the Alignment Tool does not fit, remove it and
carefully adjust engine mounts as necessary.
NOTICE: Turn both front engine mount
adjustment nuts an equal amount in the direction
required to align the engine.
To Adjust the Engine Up or Down:
(a) Loosen locknuts on mounts.
(b) Turn adjusting nuts as necessary.
(c) Temporarily tighten locknuts.
To Move the Engine to the Left or Right:
0006082
(a) The locknuts on mounts should be loose.
(b) Move the engine in the slotted mount holes
Figure - 46
as necessary, if equipped.
1 – The end of the alignment shaft is inserted 3. Attempt to insert the solid end of the Alignment
through the gimbal housing assembly. Tool through the gimbal bearing and into the
2 – Alignment Shaft
engine coupler splines again.
3 – Unit Bearing (Gimbal Housing)
4 – Engine Coupler
(2)
(1)
(1) (2) (3) (4)
0006089
(3)
Figure - 50
1 – BROWN Wire - From the electrode on the
0006087
transom assembly.
Figure - 48 2 – BLACK Wire - From the engine harness, if
equipped, or to the negative (-) battery
1 – Engine Ground Stud terminal.
2 – Inner Transom Plate Grounding Screw 3 – RED Wire - Connect (other end) to the
3 – Engine Bonding Wire positive (+) battery terminal.
4 – YELLOW Wire - From the anode on the
Trim Position Sender Connection transom assembly.
Connect the trim position sender leads from the 2. Connect wires the to Y-CaPS electrode.
gimbal housing to the leads from the engine 3. Apply a thin coat of sealant to all wire
harness. connections.
Signal to Gauge
RED Liquid Type Neoprene or Silicon Sealant
(1) (2)
GND BLK Where Used Part Number
0006088 Electrical Connections Obtain Locally
Figure - 49
1 – From the engine harness. (Refer to the
appropriate Engine and Control System
Installation Manual.)
2 – From the gimbal housing.
(1) (2)
(5) (3)
(4)
0006090
Figure - 51
1 – BLACK Wire - From the engine harness, if 3 – YELLOW Lead - From the anode on the
equipped, or to the negative (-) battery transom assembly.
terminal. 4 – Y-CaPS Electrode Connector
2 – RED Wire - To the positive (+) battery 5 – BROWN Wire - From the electrode on the
terminal. transom assembly.
0006094
Figure - 55
1 – Studs (6 ea.)
0006093
Figure - 54
1 – Return Hose
2 – Pressure Hose
NOTICE: NEVER let the hose come in contact with
the steering system components, the engine
coupler, the U-joint shaft or the drive shaft. Secure
the hoses to avoid contact with hot or moving
components.
2. Lubricate the drive unit pilot, U-joint shaft O- Lithium Grease with PTFE
rings, and drive shaft splines.
Where Used Part Number
(1) O-Ring Seals Obtain Locally
(2) (1)
(2)
(3)
0006095
Figure - 56
1 – Drive Unit Pilot
2 – O-Rings
3 – Splines
(1)
(2)
(2)
0006096
Figure - 57
1 – U-Joint Bellows (Clean)
2 – O-Ring Seals (Lubricate)
(1)
(2)
(1)
0006099
Figure - 61
1 – Slider (Shift Linkage)
0006098 2 – Wire (obtain locally)
Figure - 59 Electric Shift Type
Don’t pull the connector wire from the driveshaft
1 – Shift Cable housing end by 20 mm or more.
Electric Shift Type
Don’t pull the shift cable, it doesn’t expand and
contract.
(1)
0006501
(1)
Figure - 62
1 – 20 mm Max
0006500
Figure - 60
1 – Shift Cable
(2)
(1)
(3) 0006100
Figure - 63
Electric Shift Type
Connect the wires that are the same color.
(1) (2)
0006502
Figure - 64
1. Drive Unit Side 4. White Wire
2. Transom Assembly Side 5. Orange Wire
3. Black Wire
(1) (2)
(3)
0006504
0006101
Figure - 67
Figure - 65
1 – Drive Unit
Electric Shift Type 2 – Transom Assembly
After the cable is connected, push it into the 3 – Wire
housing. Figure - 68 shows where to store the connectors
(Figure - 68, (1)) after the drive unit has been
installed.
0006503
Figure - 66 (1)
0006505
Figure - 68
9. Place the drive unit in position on the bell (d) Slide the drive unit all-the-way into the bell
housing and install as follows: housing.
(a) Position the trim cylinders so that they point (e) Secure the drive unit to the bell housing with
straight back. 5 flat washers and 6 locknuts.
(b) Position the drive unit so that the U-joint
shaft aligns with the bell housing bore.
(c) Guide the U-joint shaft through the bearing
in the gimbal housing and into the engine (1)
coupler. Make sure that the slider engages
the bell housing shift cable assembly. (2)
(1)
CAUTION! DO NOT allow the edge of the bell (1)
housing (Figure - 69, (1)) and the edge of the
drive shaft housing (Figure - 69, (2)) on the
stern-drive to contact when installing the stern-
drive. 0006102
Figure - 70
1 – Locknut and Flat Washer
2 – Locknut Only
(f) Torque the drive unit locknuts.
Drive Unit Locknut Torque
N·m lb-ft
60 44
0006506
Figure - 69
(1)
0006103A
Figure - 71
1 – Rubber Bushing (4 ea.)
2 – Large Inner Diameter Flat Washer (2 ea.) 0006363A
(1)
(2)
(1) (4)
0006103B
Figure - 72
1 – Rubber Bushing (4 ea.)
2 – Small Inner Diameter Flat Washer (2 ea.)
3 – Locknut (2 ea.) 0006363B
17. Remove the oil reservoir cap and fill the 18. Fill the reservoir to the “OPERATING RANGE”
reservoir with lubricant (GL5 Hypoid Gear Oil). (Full) line.
(1) 19. Install the oil reservoir cap. Ensure that the
rubber gasket is inside the reservoir cap. Do not
over-tighten the cap.
20. Recheck the oil level after the first use.
0006364
Figure - 75
1 – Oil Reservoir Cap
(7)
(1)
(2)
(8)
(4)
(3)
(3) (5) (6)
0006507
Figure - 76
1 – Speedometer Hose 5 – Cable Band A*
2 – Trim Sender Wire 6 – Cable Band B**
3 – Engine Cooling Hose 7 – Straight Area
4 – Bell Housing 8 – Exhaust Opening
*This cable band attaches the Speedometer Hose (1) and the Trim Sender Wire (2) to the Engine Cooling Hose (3). The
fixed place is the Straight Area (7) of the Engine Cooling Hose (3). The Speedometer Hose (1) passes the port side of the
Engine Cooling Hose (3), and it passes the port side of the Exhaust Opening (8).
**This cable band attaches the Speedometer Hose (1) to the Bell Housing (4).
1. Raise the drive unit to gain access to the area POWER TRIM SYSTEM /
between the gimbal housing and the drive unit,
immediately on top of the transom end of the STEERING HELM AND CABLE
antiventilation plate.
2. Insert the speedometer tube fitting into the
Control System
opening on the topside of the ventilation plate in Use the appropriate control panel or in-handle trim
position as illustrated. control arrangement (for instance Teleflex controls)
with the power trim system. Install the trim control
according to the instructions included with the
power trim system.
Pump Location
(1)
Select a mounting location for the trim pump that
meets the following requirements:
• Within a comfortable reach of the hydraulic hoses
(coming from the gimbal housing assembly).
• Close enough to the battery so trim pump battery
(2) leads can be connected.
0006365
• Allows easy access to the trim pump oil fill and
Figure - 77 vent locations.
1 – Speedometer Tube Fitting • In an area where the pump will not be exposed to
2 – Opening water.
3. With the fitting fully seated, turn the handle to
• Mount the trim pump so that when the steering
the left to a tightly seated position.
wheel is turned either to the right or left the power
assist steering cylinder does not come in contact
with trim pump.
(3)
(2)
(1) (4)
(5) (7)
(6)
(12)
(9)
0006388
Figure - 79
1 – Coupler / Nut - 7/8 UNF - 28 Thread 10 – 1-3/8 in. (34.9 mm) Maximum
2 – 298 mm (11-3/4 in.) Minimum 11 – 15.9 mm (5/8 in.) Diameter Tube
3 – Interface Point 12 – Cable Travel:
4 – 12.7 mm (1/2 in.) Maximum Mid-Travel Position - 429 mm (16-7/8 in.)
5 – 10.7 mm (27/64 in.) Minimum Flat Total travel to be 203 mm (8 in.) minimum to
6 – 3.1 mm (7/64 in.) Minimum Radius 228 mm (9 in.) maximum.
7 – 15.9 mm (5/8 in.) Maximum Diameter End Travel each side of mid-travel position - 102
Fitting mm (4 in.) minimum, 114 mm (4-1/2 in.)
8 – 9.5 mm (3/8 in.) maximum.
9 – 9.8 mm (3/8 in.) Diameter Through Hole
(chamfered each side)
(5)
(1)
(7) (4)
(2)
(3) (6)
0006437
Figure - 80
1 – Rotary or rack helm 5 – Steering lever
2 – Minimum 20 cm (8 in.) bend radius 6 – Steering Cable
3 – Plus or minus 25 mm (1 in.) free motion of 7 – Power Steering Cylinder
cable housing and power steering valve
4 – NEVER tie down or clamp within 90 cm (3 ft)
of the power steering cylinder.
CAUTION! Be sure the steering cable is correctly installed. Verify that all cable bends, free motion of
cable housing and restraints of the cable are within specifications. Incorrect installation of the
steering cable could result in erratic or loss of steering.
0006367
Figure - 81
NOTICE: Route the cable away from sharp bends
and moving parts. NEVER fasten items to the shift
cables.
(5) (3)
(6)
(1)
(2)
(7)
(4) (3)
(3) (3)
(5) (4)
(5) (4)
(3) (3)
(6) (7)
(4)
(5)
(3)
0006508
Figure - 82
1 – FORWARD connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P
2 – REVERSE connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P
3 – Black: for earth signal (negative)
4 – White: for REVERSE signal
5 – Orange: for FORWARD signal
6 – Name tag: FORWARD
7 – Name tag: REVERSE
(2) (1)
(1)
0006368
Figure - 83
1 – Stud
2 – 76 mm (3 in.) - Center of the pivot bolt to the
center of the stud.
(2)
0006369
Figure - 84
1 – Lock Nut
2 – 180.6 mm (7-7/64 in) - The control cable
barrel center and the center of the
attachment hole.
Figure - 87
(1)
1 – Stud
2 – Control Cable Barrel
3 – Backlash Center
4 – Control Cable End Guide
5 – Clevis Pin
4. Install the shift control cable.
5. Install the washer and cotter pin to secure the
(2) (3) barrel. Spread the ends of the cotter pin.
0006371 6. Install the clevis pin.
7. Install the cotter pin into the clevis pin. Spread
Figure - 86
the ends of the cotter pin.
NOTICE: Keep center mark 1 aligned with sleeve
(2) (3)
end face when making the following adjustment. (4)
(1)
(3)
0006375
Figure - 90
1 – Barrel Retainer Cotter Pin
(1)
2 – 205.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control
(3) cable barrel center and the shift lever stud
0006374 center.
Figure - 89 3 – Shift Lever Stud
15. Ensure that all of the cotter pins are secure and
1 – Barrel Retainer Cotter Pin
2 – 155.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control that the ends of the cotter pins are spread
cable barrel center and the shift lever stud completely.
center. 16. Lubricate the shift cable pivot points.
3 – Shift Lever Stud
SAE 30W Engine Oil
11. Shift the remote control into REVERSE.
Where Used Part Number
12. Measure the distance between the control
Shift Cable Pivot Points Obtain Locally
cable barrel center and the shift lever stud
center. This distance should be 205.6 ± 1.5 mm
(8-3/32 ± 1/16 in).
13. If the distance does not satisfy the dimension,
loosen the shift lever stud and slide the stud up
or down, until the distance is within the stated
dimension.
14. When the adjustment is correct, tighten the
stud.
Troubleshooting Shift Problems 4. Never strap or clamp the control cables to any
other cables or rigid structure within 1000 mm
Note: Use the following information to (3 ft) of the control box. Make sure there are no
troubleshoot hard shifting or chucking / kinks in the cable.
roughing when shifting into forward gear.
5. Ensure that there is enough clearance for cable
1. When installing the control box into the side movement when the control box is installed in
panel of the boat, ensure that the cables have the side panel. The cables must have room to
enough clearance to operate (Figure - 91). This move up and down when the control handle is
is necessary because the cables move up and shifted into either FORWARD or REVERSE.
down when the shift handle is moved. If the
6. Ensure that the engine was not set down on the
control box is mounted too far back toward any
intermediate shift cable during installation; this
fiberglass structure, the cables will be interfered
will crush the inner cable tubing and cause
with. This will cause very hard shifting.
improper and / or stiff shifting.
7. NEVER fasten the shift cable with straps or
clamps to any other cable within 1500 mm (5
ft.) of the shift plate.
8. Avoid over-tightening the shift cable to the
transom with any type of plastic clips or
fasteners within 1500 mm (5 ft.) of the shift
plate.
0006376
9. Do not over-tighten the throttle or shift cable
Figure - 91 attaching nuts at the engine end. Barrel and
cable end must be free to rotate on the
2. Route the shift cable from the control box mounting stud.
through the side gunnel of the hull without
inducing any extremely sharp bends Note: Lubricate attaching points with engine oil.
(Figure - 91) to prevent stiff shifting.
SAE 30W Engine Oil
3. Before installing the shift cable into the
Where Used Part Number
control box, extend the stainless rod eye
Shift Cable Pivot Points Obtain Locally
end of the cable and coat it with lubricant
(Figure - 92, (1)). Move it back and forth to
10. The drive unit shift cable must be routed to
allow even distribution of the lubricant.
allow sufficient length for connection to shift
(1) plate.
Note: Make a final check of the adjustments
with the boat in the water and with the
engine running. If this cannot be done, or
is not done at the manufacturing facility,
make arrangements with the dealer to do
this as part of the pre-delivery inspection.
(1) 0006377
Figure - 92
1 – Lubrication Point
Check the Power Trim Pump Fluid 3. The oil level is low if it is below the MIN line
(Figure - 95, (1)) on the reservoir. Fill as
NOTICE: ALWAYS check the oil level with stern- necessary with the specified fluid. See Fill the
drive in the full DOWN / TRIM-IN position. Power Trim Pump Fluid on page ZT350-60.
1. Place the stern-drive in full Down / TRIM-IN
position.
2. Observe the oil level in the reservoir. The oil
level should be maintained within the MIN and
MAX lines on the reservoir (Figure - 94, (2)).
(1)
0006013
Figure - 95
(2)
0006012
Figure - 94
1 – Reservoir
2 – MIN and MAX Lines
(3)
(2)
(2)
(1)
0006336
Figure - 97
(3)
1 – Oil Reservoir
2 – ADD Line
3 – OPERATING RANGE Line
NOTICE: If any water is visible at the bottom
of the oil reservoir or appears at the oil fill /
000
drain plug and / or if oil appears discolored,
Figure - 96 contact your authorized Yanmar Marine
dealer or distributor immediately. Both
1 – Fill Cap Assembly
conditions may indicate a water leak
2 – MIN and MAX Lines
3 – Reservoir
somewhere in the stern-drive.
(1)
(2)
0006337
Figure - 98
1 – Oil Reservoir Cap
2 – OPERATING RANGE Line
Pitch is the angle of the blades expressed in the WARNING! To prevent accidental start-up,
theoretical distance a propeller travels in each complete the following before installing or
revolution. If for example the pitch is 20, each removing the propeller:
revolution of the propeller pushes the vessel 20 in. ◆ Put the remote control to the NEUTRAL
through the water. A 28 pitch is considered “higher” position.
pitched and a 20 pitch propeller is considered ◆ Put the main switch to OFF position and
“lower” pitched. A smaller pitch propeller should be remove the key.
selected for water skiing or for heavy loads. WARNING! NEVER use your hand to hold the
propeller when loosening the nut. Put a wood
block between the antiventilation plate and the
propeller blade to prevent the propeller from
turning.
Problems associated with propellers include
ventilation, cavitation and blow-out. These
problems have similar symptoms and are best
diagnosed by an expert. If a propeller related
problem develops, see your Yanmar Marine dealer
or distributor.
(4)
(3)
(1)
(7)
(8)
0006015
Figure - 100
1 – Rear Propeller Nut 5 – Front Propeller
2 – Rear Propeller 6 – Front Propeller Thrust Hub
3 – Rear Propeller Thrust Hub 7 – Propeller Shaft Anode
4 – Front Propeller Nut 8 – Propeller Shaft Anode Bolt and Washer
(2)
0006384
Figure - 101
1 – Typical Flushing Attachment (Obtain
Locally)
2 – Water Hose
3. See Test Preparations on page ZT350-66 for Drive Unit Operational Tests
other checks.
WARNING! NEVER leave the helm unattended
In-Water Testing when performing tests with the boat in the
water.
The following information is for engine operation
tests with the boat in the water. CAUTION! Instruments can warn of engine
problems. Watch the temperature gauge on the
WARNING! NEVER leave the helm unattended dash to ensure that the engine does not
when testing the vessel in the water. overheat to avoid engine damage.
NOTICE: The water level must be above the 1. Refer to the Engine Operation Manual and start
seawater inlet holes on the drive unit or the the engine.
through-the-hull pickup.
2. Operate the engine at IDLE rpm until it reaches
1. On engines with a drive unit seawater inlet: The normal operating temperature.
water level must be above the seawater inlet 3. Turn the steering wheel to starboard, then to
holes on the drive unit. port, and ensure that the drive unit turns the
correct way.
4. Check the power steering system for a lugging
(1) condition (engine rpm drops and / or the power
steering pump tone changes).
(2) 5. Turn the steering wheel to the LEFT (Port) until
it stops and then continue to apply pressure. If
0006385 the pump lugs, check the following:
Figure - 102 (a) Check for an obstruction between the gimbal
ring and the gimbal housing, and all moving
1 – Minimum Water Level steering components.
2 – Water Inlet Holes
(b) Ensure that the steering lever is not
2. On engines with a through-the-hull seawater contacting the cutout in the transom. Modify
inlet: Ensure that the water level is above the the cutout if there is contact between the
seawater inlet holes on the through-the-hull transom and the cutout.
seawater inlet.
6. Turn the steering wheel to the RIGHT
Wide Open Throttle Test (starboard) until it stops and then continue to
apply pressure. If the pump lugs, check the
NOTICE: Follow the Engine Operation Manual to
following:
operate the engine at full throttle before the break-
in period is complete. (a) Check for an obstruction between gimbal
ring and gimbal housing, and all moving
1. To test if the correct propeller has been steering components.
installed, operate the boat with a full load
(b) Ensure that the steering lever is not
onboard at wide open throttle (WOT) and check
contacting the cutout in the transom. Modify
the rpm with an accurate tachometer. Engine
the cutout if there is contact between the
rpm should be near top of the specified range
transom and the cutout.
so that engine speed will not fall below
specifications under a heavy load. If the engine 7. Check steering cable end dimension with the
speed is too high, replace the propeller with a cable FULLY EXTENDED. See Steering Helm
higher pitch propeller. and Cable on page ZT350-49 for proper
steering cable dimensions.
2. See Test Preparations on page ZT350-66 for
other checks. 8. Turn the engine off.
(1)
(2)
(3)
(4)
0006387
Figure - 104
1 – Underside of Anticavitation Plate
2 – First Anode Cavity Drain Passage
3 – Second Anode Cavity Drain Passage
4 – Speedometer Pitot Hole