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ME422STI

ENGINE SER

VICE MANU

AL

300902-

ME422STI

N60-28197-ZH-11

ENGINE

SERVICE MANUAL

070026

Printed in Japan

Nov. 2005-0.5 × 1

YAMAHA MOTOR CO., LTD.

（ME422STI）

（E）

Printed on recycled paper

E

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2
3
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Summary of Contents for ME422STI

Page 1: ...ME422STI ENGINE SERVICE MANUAL 300902 ME422STI N60 28197 ZH 11 ENGINE SERVICE MANUAL 070026 Printed in Japan Nov 2005 0 5 1 YAMAHA MOTOR CO LTD ME422STI E Printed on recycled paper E ...

Page 2: ...unfit for use Because Yamaha has a policy of continuously improving its products models may differ in detail from the descriptions and illustrations given in this publication Use only the latest edition of this manual Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures and these are incorporated in successive editions of thi...

Page 3: ...on ILLUSTRATIONS Some illustrations in this manual may differ from the model you have This is because a proce dure described may relate to several models though only one is illustrated The name of the model described will be mentioned in the description To help you identify components and understand the correct procedures of disassembly and assembly exploded diagrams are provided Steps in the proc...

Page 4: ...rive CAUTION A CAUTION indicates special precautions that must be taken to avoid damage to the Sterm Drive NOTE A NOTE provides key information to make procedures easier or clearer INPORTANT INFORMATION In this Service Manual particularly important information is distinguished in the following ways The safety Alert Symbol means ATTENTION BECOME ALERT YOUR SAFETY IS INVOLVED ...

Page 5: ...y to read handy reference that contains comprehensive explanations of all disassembly check repair and assembly proce dures Important procedures including removing checking and assembling steps 4 are explained in detail IMPORTANT FEATURES Important engine data and information about special tools framed in a box together with an illustrative symbol 5 A circled numeral 6 indicates a part name A circ...

Page 6: ...cified value service limit J Resistance Ω Voltage V Electric cur rent A Symbols K and L in an exploded diagram indicate grade of lubricant and location of lubrication point K Apply Yamaha gear case lubricant L Apply water resistant grease Yamaha marine grease A Yamaha marine grease Symbols M and N in an exploded diagram indicate grade of sealing or locking agent and location of application point M...

Page 7: ... SPECIFICATIONS 2 SPEC PERIODIC CHECK AND ADJUSTMENT 3 CHK ADJ ENGINE REMOVAL AND INSTALLATION 4 REM INST ENGINE OVERHAUL 5 ENG OVER FUEL SYSTEM 6 FUEL EXHAUST SYSTEM 7 EXHT COOLING SYSTEM 8 COOL LUBRICATION SYSTEM 9 LUB TURBOCHARGER 10 TURB ...

Page 8: ......

Page 9: ...INDEX POWER STEERING SYSTEM 11 STEER ELECTRICAL SYSTEM 12 ELEC TROUBLESHOOTING 13 TRBL SHTG ...

Page 10: ......

Page 11: ... Check Engine Alignment 1 4 Check Drive Belts 1 4 Check Engine Oil 1 4 Check Fuel System 1 4 Check Engine Exterior 1 4 Check Battery and Electrical Connections 1 4 Check Remote Control Operation 1 4 Perform Test Run 1 5 OFF SEASON STORAGE 1 5 Engine 1 5 Drain Cooling System 1 7 Preparation After Storage 1 8 CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE 1 9 INTERNATIONAL SYSTEM OF UNITS SI 1 11 D...

Page 12: ...The model and serial number plate is located on the header tank The different models can be identified by checking the model and serial number plate and using the following table PROPELLER AND ENGINE ROTA TION DO NOT rely on propeller rotation to be in the same direction as engine rotation Engine rotation is determined by looking at the flywheel end of the engine The Yamaha engines covered in this...

Page 13: ...ry protection Avoid wearing loose clothing and jewelry Prevent Battery Explosion Batteries produce explosive gases Keep sparks and flames away from batteries Check battery electrolyte level using a flash light Never check battery state of charge by con necting the battery posts with a conductor Use a voltmeter or hydrometer Always dis connect the negative cable first and re connect it last DO NOT ...

Page 14: ...ey are not being worked on to prevent foreign materials from entering and damaging the engine Cleaning and protection of machined sur faces and friction areas are part of the repair procedure this is considered standard shop practice Operate Stern Drive Safely Remove the propeller DO NOT operate engine without cooling water supplied to the water inlet ports on the drive unit ...

Page 15: ... Check Fuel System Make sure all fuel lines and hoses are connected and do not leak If water separator warning light comes on drain the water from the water sepa rator 4 Check Engine Exterior Touch up any painted surfaces with matching paint Replace any parts damaged in shipping Check Battery and Electrical Connec tions Check the battery fluid level Check if the battery is fully charged Verify tha...

Page 16: ...ing out the following storage preparation be sure to flush the cooling sys tem thoroughly Refer to Cooling System Flushing on page 3 42 1 Warm up the engine to normal operat ing temperature 2 Stop the engine drain the engine oil and replace the oil filter 1 WARNING When working in the engine compartment run the bilge blower if the boat has one If not insure that the engine compartment is sufficien...

Page 17: ...the oil separator 3 and blow by hose 4 then reinstall it securely 10 After turning off the main switch turn the battery switch OFF if the boat is equipped with one or disconnect the battery cables from the terminals 12 Lubricate the shift and throttle cables and the linking mechanisms CAUTION If the battery is stored without being prop erly charged there is a danger that it will freeze A stored ba...

Page 18: ...r 8 NOTE When draining coolant cover all electri cal parts and accessories with a plastic cover to prevent them from getting wet After draining the coolant remove the drain bolt on the bottom of the boat to drain any coolant that has collected in the bilge provided the boat is on land If the boat is in the water use a bilge pump in stead After draining rinse thoroughly with clean water and dry If ...

Page 19: ...GINE Refer to CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE on page 1 9 1 Tighten the drain plugs of the water cool ing system Check the condition of the cooling system hoses Check if the hose clamps are in good condition and tight ened securely 2 Check the condition of the drive belts on the alternator 1 and circulation pump 2 Adjust the tension of the drive belts to the specified deflection 3 ...

Page 20: ...ugs of the cooling system are securely tightened and that no water leakings into the bilge 3 Check the battery fluid level Refer to Battery Check on page 3 43 Check that the battery terminals are not loose corroded or damaged Securely fasten the battery to the boat WARNING Explosive battery fumes may collect in the engine compartment Before starting the engine ventilate the engine compartment If t...

Page 21: ... leaking from any part of the engine 5 Check the oil level Refer to DE DHD STERN DRIVE SERVICE MANUAL in the drive unit and make sure no oil is leaking from the unit 6 Check that the drive belts are not loose cracked or damaged in any way Refer to Drive Belt Check on page 3 21 7 Check the oil level in the power steering pump Refer to DE DHD STERN DRIVE SERVICE MANUAL CHECKS BEFORE LAUNCHING AND ST...

Page 22: ... e g amount of energy related to the force The abbreviation SI stands for the French expression of International System of Units Le System International d Unites Description of SI Units in This Service Manual Both SI units and gravitational system of units are indicated in this service manual e g Tightening torque 98 N m 10 kgf m 71 lbf ft Examples for major units INTERNATIONAL SYSTEM OF UNITS SI ...

Page 23: ...nter bolt 150 Arm 25 Claw No 6 Craw No 1 Attachment REMARKS To valve clearance adjustment Page 3 14 To measure compression Page 3 19 To check injection timing Page 3 28 Page 5 11 5 20 5 22 5 23 To remove camshaft timing pulley oil pump drive gear crankshaft timing gear and injection pump drive gear bearing To remove camshaft timing pulley oil pump drive gear crankshaft timing gear and injection pu...

Page 24: ...y and injec tion pump drive gear To install injection pump drive gear oil seal Page 5 24 To install crankshaft front oil seal Page 5 24 5 25 To install injection pump oil seal Page 5 24 5 25 To mount crankshaft timing gear and oil pump drive gear Page 5 26 5 27 Flange base Flange holder Puller C set Hanger 150 Slide arm Center bolt 100 Center bolt 150 Claw No 2 Crankshaft pulley replacer Oil seal ...

Page 25: ...and install connecting rod bush To measure injection nozzle Page 6 7 6 8 To measure injection nozzle Page 6 7 Valve spring compressor Valve guide bush re mover and replacer set Valve guide bush re mover and replacer 8 Handle set Handle 200 Oil pan seal cutter Connecting rod bush remover and replacer Remover and replacer Guide Base 2 spring base Attachment measure 09202 70020 09201 10000 09201 0108...

Page 26: ...lternator pul ley Page 12 29 12 35 To remove alternator rectifier end fram and starter motor armature bearing Page 12 17 12 30 To remove alternator rotor bearing Page 12 34 Master spring seat Power steering fluid pressure gauge set Alternator wrench Alternator bearing puller Alternator bearing puller 95093 10330 from DENSO PSG 6TB from BANZAI 09820 63010 09286 46011 09820 00021 ...

Page 27: ...tool Piston oil heater Piston vise Piston ring compressor Straight edge Square gauge Plasti gauge Surface plate Digital circuit tester Oil pressure gauge Thickness gauge Filler gauge Torque wrench Dial gauge Magnetic base Heater gun Flat chisel Diesel compression gauge set Diesel tacho tester Nozzle tester Snap ring plier Pin punch Thermometer REMARKS 0 25 mm 25 50 mm 50 75 mm 75 100 mm 50 150 mm ...

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