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PRE-DELIVERY

ZT350 Installation Manual

6-5

Pre-Delivery Preparation

12/05

Fill the Stern-Drive with Oil

NOTICE: If more than 60 ml (2 fl oz) of gear oil is
required to fill the reservoir, a seal may be leaking.
Damage to the stern-drive may occur because of
lack of lubrication. Contact your authorized Yanmar
Marine dealer or distributor.

1. Remove the oil reservoir cap

(Figure 6-6, (1))

2. Fill the oil reservoir to the OPERATING RANGE

(Figure 6-6, (2))

(full) line with specified fluid.

NOTICE: Do not overfill

Figure 6-6

Figure 6-6

1 – Oil Reservoir Cap
2 – OPERATING RANGE Line

3. When replacing the cap, ensure that the rubber

gasket is inside the oil reservoir cap and install
the cap. Do not over-tighten.

0006337

(2)

(1)

GL-5 Hypoid Gear Oil

Where Used

Oil Reservoir

Summary of Contents for ZT350 series

Page 1: ...ZT350 series INSTALLATION MANUAL ZT350 Installation Manual P N 0FZTD G00100 STERN DRIVE ...

Page 2: ...ion illustrations and or specifications to explain and or exemplify a product service or maintenance improvement We reserve the right to make any change at any time Yanmar and are registered trademarks of Yanmar Co Ltd in Japan the United States and or other countries All Rights Reserved No part of this publication may be reproduced or used in any form by any means graphic electronic or mechanical...

Page 3: ... Sealants Adhesives 2 3 Special Tools 2 4 Trim In Limiter 2 4 Steering Tie Bar Considerations 2 5 Internal Tie Bar Only 2 5 Internal and External Tie Bar 2 5 External Power Steering with an External Tie Bar 2 5 Corrosion Control 2 5 Shore Power 2 5 Antifouling Paint 2 6 Painting the Transom and Stern Drive 2 6 Vessel Design 3 1 Vessel Design Considerations 3 2 Transom Thickness 3 2 Laying Out the ...

Page 4: ...cting the Oil Reservoir Hose 4 13 Installing the Oil Reservoir 4 14 Installing the Shift Plate 4 14 Installing the Steering System 4 15 Connecting the Steering Cables 4 18 Installing the Power Trim Pump 4 20 Exhaust Options 4 21 Through the Propeller Exhaust 4 21 Alternate Exhaust System 4 21 Installing the Engine 4 22 Aligning the Engine 4 23 Electrical Connections 4 25 Engine Bonding Wire Connec...

Page 5: ...ivery 6 1 Pre Delivery Preparation 6 2 Power Steering Fluid 6 2 Battery Connections 6 2 Check the Power Trim Pump Fluid 6 3 Fill the Power Trim Pump Fluid 6 4 Check the Stern Drive Oil Level 6 4 Fill the Stern Drive with Oil 6 5 Propeller Selection 6 6 General Propeller Installations 6 7 Installing the Propellers 6 8 Removing the Propeller 6 9 Test Preparations 6 10 Engine Operation Tests 6 10 Out...

Page 6: ...vi ZT350 Installation Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 7: ...eplace a part that has a label attached to it make sure you order the new part and label at the same time Indicates a hazardous situation which if not avoided will result in death or serious injury Indicates a hazardous situation which if not avoided could result in death or serious injury Indicates a hazardous situation which if not avoided could result in minor or moderate injury Indicates a sit...

Page 8: ...ded will result in death or serious injury NEVER permit anyone to install or operate the engine or stern drive without proper training 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 an...

Page 9: ...eller for an engine that is shut down may rotate if any of the other engines are running Rotating parts can cause severe injury or death NEVER wear jewelry unbuttoned cuffs ties or loose fitting clothing and ALWAYS tie long hair back when working near moving rotating parts such as the flywheel propeller or PTO shaft Keep hands feet and tools away from all moving parts To prevent accidental equipme...

Page 10: ...ed or disconnect the negative battery cable before servicing the equipment ALWAYS keep the electrical connectors and terminals clean Check the electrical harnesses for cracks abrasions and damaged or corroded connectors The safety messages that follow have CAUTION level hazards These safety messages describe a hazardous situation which if not avoided could result in minor or moderate injury Poor L...

Page 11: ...or waterways Before operating the engine check stern drive oil level If the stern drive oil temperature is too high stop engine immediately and check the stern drive oil level and check the oil cooler for proper coolant and water flow Always tighten components to the specified torque Loose parts can cause equipment damage or cause it to operate improperly Only use replacement parts specified Other...

Page 12: ...SAFETY 1 6 ZT350 Installation Manual 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 13: ...er 2 2 Sales and Technical Assistance 2 2 Lubricants Sealants Adhesives 2 3 Special Tools 2 4 Trim In Limiter 2 4 Steering Tie Bar Considerations 2 5 Internal Tie Bar Only 2 5 Internal and External Tie Bar 2 5 External Power Steering with an External Tie Bar 2 5 Corrosion Control 2 5 Shore Power 2 5 Antifouling Paint 2 6 Painting the Transom and Stern Drive 2 6 ...

Page 14: ...res for these products which includes the use of mechanics hand tools and any special tools that might be required We could not possibly know of and advise the marine trade of all conceivable procedures or methods by which a service might be performed or of every possible hazard and or results of each procedure or method We have not undertaken any such wide evaluation Therefore anyone who uses a p...

Page 15: ...d Part Number UREA Grease Water Resistant Type NLGI 2 Ex Rykon Premium Grease EP Power Steering Bushings Obtain Locally Upper and Lower Pivot Bolts Clevis Pin Steering Cable End Propeller Shaft Splines Steering Cable and Clevis Liquid Type Neoprene or Silicon Sealant Electrical Connections Y CaPS Connections Multipurpose Heavy Duty Type Lithium Grease NLGI 2 Ex Valvoline Multipurpose Grease GM Dri...

Page 16: ...ant enough to unseat the operator and or passengers This creates an unsafe situation This condition is primarily a result of vessel design and can only be reduced with thorough performance testing by the manufacturer OEM of the vessel However shifting hull weight to the stern may be helpful in controlling this tendency To help reduce the effect of stern lift a Trim In limiter is available for the ...

Page 17: ...nents and may result in an increase of the play in boat steering External Power Steering with an External Tie Bar This system is recommended for vessels that operate at speeds of 70 knots 80 mph or greater or for the ultimate in reduced steering backlash This system does not use an internal tie bar but requires dual trim control equipment See Internal and External Tie Bar on page 2 5 CORROSION CON...

Page 18: ...ssel 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 a...

Page 19: ...mar Marine International ZT350 Installation Manual Section 3 VESSEL DESIGN Page Vessel Design Considerations 3 2 Transom Thickness 3 2 Laying Out the Transom Cutout 3 2 Vessel Engine Mount Position 3 2 Selecting an Engine Exhaust System 3 3 ...

Page 20: ...om is flat to within 3 mm 0 125 in The outer surface of the transom is flat to within 2 mm 0 075 in The transom angle is between 10 and 16 13 is ideal Ensure that there is enough flat surface area on the transom to apply the transom plate This would be 203 mm 8 in on either side of the center line of the transom Figure 3 1 Figure 3 1 1 Transom Thickness 2 Transom Angle 3 Transom plate coverage 203...

Page 21: ...t type of engine exhaust system will be used with the ZT350 Stern Drive The following chart describes the parts required for each system See Exhaust Options on page 4 21 Engine Exhaust System Transom Exhaust Transom Exhaust Bellows or Tube Through the Transom Exhaust Exhaust Cover Plate Exhaust Tube Through the Hull Exhaust Through the Propeller Exhaust Engine Exhaust Pipe ...

Page 22: ...VESSEL DESIGN 3 4 ZT350 Installation Manual Vessel Design Considerations 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 23: ...ng the Transom Assembly 4 8 Connecting the Speedometer Pickup 4 10 Drive Unit Seawater Pickup 4 10 Alternate Seawater Pickup 4 11 Connecting the Inlet Water Hose 4 12 Connecting the Oil Reservoir Hose 4 13 Installing the Oil Reservoir 4 14 Installing the Shift Plate 4 14 Installing the Steering System 4 15 Connecting the Steering Cables 4 18 Installing the Power Trim Pump 4 20 Exhaust Options 4 21...

Page 24: ...NGINE AND DRIVE UNIT 4 2 ZT350 Installation Manual 2007 Yanmar Marine International Hydraulic Connections 4 27 Oil Reservoir 4 27 Power Steering Hoses 4 28 Installing the Drive Unit 4 29 Speedometer Connection 4 33 ...

Page 25: ...he crankshaft vertical centerline through the intersection points of the two arcs Figure 4 1 Figure 4 1 1 305 mm 12 in 2 Identical Side Marks 3 Compass Arc 4 Arc Intersection Points 5 Crankshaft Vertical Centerline Locating the Crankshaft Vertical Centerline Dual Engine Installation Locate and mark the transom vertical centerline See Locating the Crankshaft Vertical Centerline Single Engine Instal...

Page 26: ...ngine temperature gauge to prevent the engine from overheating NOTICE Damage to Yanmar products caused by a crankshaft horizontal centerline that is too high will not be covered by Yanmar warranty The 90 Tool Method Construct the 90 tool as shown in Figure 4 3 Figure 4 3 Figure 4 3 1 345 mm 13 9 16 in 2 1 2 m 4 ft NOTICE The 345 mm 13 9 16 in dimension should only be raised or lowered after proper...

Page 27: ...the following chart to determine the X dimension 1 On the vertical crankshaft centerline measure up from the bottom of the vessel transom to the X dimension selected from the chart 2 This point is the crankshaft horizontal centerline at the X dimension 3 Draw a line perpendicular to the vertical centerline at the crankshaft horizontal centerline Figure 4 6 Figure 4 6 Figure 4 7 Figure 4 7 1 Vertic...

Page 28: ...nes of the template or the drilling fixture align with the marks determined previously See Positioning the Drive Unit on page 4 3 Template Figure 4 8 Figure 4 8 Transom Cutout and Drill Fixture Figure 4 9 Figure 4 9 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 i...

Page 29: ...e transom surface 8 ea Checking the Transom Thickness Ensure that the transom thickness and surface dimensions conform to specifications listed previously and to the chart below See Vessel Design Considerations on page 3 2 Figure 4 12 Figure 4 12 Figure 4 13 Figure 4 13 1 Measuring Transom Flatness 2 Measuring Transom Thickness 3 Suitable tool to check for uniform transom thickness 1 Measured in t...

Page 30: ...hold it in place NOTICE Tighten the transom assembly fasteners using an X pattern torque sequence Tighten in small increments and go around the pattern several times until the proper torque is achieved 3 Secure the transom assembly with hardware as shown in Figure 4 14 4 Torque the transom plate bolt 5 Attach the bonding wires NOTICE The steering lever bonding wire must be positioned as shown in F...

Page 31: ...ual 4 9 Installing the Transom Assembly 12 05 2007 Yanmar Marine International Figure 4 14 Figure 4 14 1 Locknuts and Flat Washers 8 ea 2 Steering Lever Bonding Wire 3 Bolt 4 Transom Plate Bonding Wire 5 Torque Sequence 1 1 2 1 4 3 1 2 3 4 5 7 6 8 5 0006053 ...

Page 32: ...eedometer hose is filled with water especially during boat operation Hose contact with moving or rotating engine parts could cause damage to the hose resulting in water leaking into boat NEVER let the speedometer hose come in contact with the steering system components the engine coupler or the drive shaft Drive Unit Seawater Pickup Seawater for engine cooling may be supplied through the drive uni...

Page 33: ...epending upon application and boat configuration a through the hull or through the transom seawater pickup must be used CAUTION Avoid overheating the drive unit The drive unit water inlet holes must be allowed to flow water without being obstructed or overheating damage to drive unit may result NEVER dead end the water hose from the bell housing The hose must be cut as recommended 1 Use pliers to ...

Page 34: ... trim sender limit switch wires 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 Disc...

Page 35: ...to do so may result in a loose 90 fitting a loss of gear lube and or damage to the drive unit 2 Position the quick release button on the 90 hose fitting away from the connector seawater or plate seawater inlet if equipped The release button must not contact the connector seawater or plate seawater inlet if equipped Figure 4 23 Figure 4 23 1 Plate Seawater Inlet 2 ACCEPTABLE Positions 3 Quick Relea...

Page 36: ...nd engine coupler 1 Install the oil reservoir bracket in the specified location and secure with lag screws and flat washers 2 Install the oil reservoir in the bracket Secure the reservoir with the retaining strap Figure 4 26 Figure 4 26 1 Bracket Oil Reservoir 2 Oil Reservoir and Cap 3 Strap Oil Reservoir 4 Lag Screw and Flat Washer obtain locally Installing the Shift Plate NOTICE The shift plate ...

Page 37: ...ck Tab Washers 2 Upper and Lower Pivot Bolt 4 Position the steering assembly so that the pivot bolts will fit in the bushings in the power steering cylinder 5 Install the upper and lower pivot bolts along 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 4 30 Figure 4 30 1 Locking...

Page 38: ...hown in Figure 4 32 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 Wear eye protection to avoid injury Figure 4 32 Figure 4 32 1 Port 2 Spool Barrel Cable Guide Tube 10 Connect the clevis to the steering lever 11 Lubricate the clevis pin Spread...

Page 39: ...e International CAUTION The steering cable and outer casing must move freely for the steering system to function properly Never fasten any items to the steering cable and or the outer casing Figure 4 34 Figure 4 34 1 Steering Cable and Outer Casing UREA Grease Water Resistant Type NLGI 2 Where Used Clevis Pin 1 0006073 ...

Page 40: ...own in Figure 4 35 NOTICE The flat surfaces of the spool barrel cable guide tube must be positioned horizontally to prevent feedback in the steering system 3 Use a wrench to hold the flat surfaces of the spool barrel cable guide tube horizontally 4 Torque the coupler nut Ensure that the flat surfaces are still aligned horizontally after torque is applied to the coupler nut UREA Grease Water Resist...

Page 41: ...tion Manual 4 19 Installing the Transom Assembly 12 05 2007 Yanmar Marine International Figure 4 35 1 Clevis Pin 2 Spool Barrel Cable Guide Tube 3 Cable Coupler Nut 4 Steering Cable 5 Cotter Pin 6 Clevis 7 Steering Cable End 7 6 5 1 2 2 3 4 0006074 ...

Page 42: ...Make hydraulic connections as quickly as possible to prevent oil from leaking out of the system 1 Connect the hydraulic hoses to the trim pump Ensure that the quick connect fittings completely seat when connecting the hoses Figure 4 35 Figure 4 36 1 Hydraulic Hose UP hose 2 Quick Connect Fittings 3 Hydraulic Hose DOWN hose Note An adapter harness may be needed to connect the remote control trim pu...

Page 43: ...ing must be properly seated in the groove Figure 4 38 Figure 4 39 1 Gimbal Housing Exhaust Tube Mating Surface 2 O Ring Install the engine exhaust tube as shown in Figure 4 40 Figure 4 39 Figure 4 40 1 Engine Exhaust Tube Alternate Exhaust System 1 Install the exhaust block off plate as shown in Figure 4 41 using the four bolts and lock washers 2 Torque the cover plate bolts Figure 4 40 Figure 4 4...

Page 44: ...roper shifting 3 Align the rear engine mounts with the inner transom plate mounts 4 Set the engine on the front engine mounts and inner transom plate mounts Do not relieve the hoist tension at this time NOTICE Engine attaching hardware must be installed in the sequence illustrated Install and torque rear engine mounting bolts with hardware as illustrated Figure 4 41 Figure 4 42 1 Steel Washer obta...

Page 45: ... Unit Bearing Gimbal Housing 4 Engine Coupler Figure 4 44 Figure 4 45 1 Insert this end of the alignment tool through the gimbal housing assembly 2 Alignment Shaft 3 90 Increments 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 t...

Page 46: ...plines 6 Repeat this process until the Alignment Tool installs easily slides freely with two fingers all the way into and out of engine coupler splines Never twist the alignment tool into position 7 Torque the rear engine mount bolts 8 Fasten the front mount assemblies to the boat stringers using appropriate hardware as per manufacturer s design specifications a Torque both front mount locking nut...

Page 47: ...ds from the engine harness Figure 4 46 Figure 4 47 1 From the engine harness Refer to the appropriate Engine and Control System Installation Manual 2 From the gimbal housing Y CaPS Controller Connection Cathodic Protection System 1 Connect the wires to the Y CaPS controller assembly NOTICE The opposite end of the RED wire and BLACK wire must be connected directly to the battery terminals NEVER con...

Page 48: ...tional Figure 4 48 Figure 4 49 1 BLACK Wire From the engine harness if equipped or to the negative battery terminal 2 RED Wire To the positive battery terminal 3 YELLOW Lead From the anode on the transom assembly 4 Y CaPS Electrode Connector 5 BROWN Wire From the electrode on the transom assembly 0006090 2 1 5 3 4 ...

Page 49: ...transom plate Figure 4 49 Figure 4 50 1 Oil Reservoir hose assembly 2 Quick connect fitting Male and female quick connect fittings have check valve 3 Gimbal housing hose assembly 3 Fasten the quick connect fitting between gimbal housing hose assembly and the oil reservoir hose assembly Figure 4 50 Figure 4 51 1 Quick Connect if equipped 2 Oil Reservoir Hose 3 Clamp 4 Fitting 5 Oil Reservoir 4 Rout...

Page 50: ...hoses away from extreme heat without any kinks in the hoses and without stress on the hose fittings 1 Attach both hydraulic hose fittings to the steering control valve 2 Ensure that the quick connect fittings are securely engaged 3 Position the hoses as illustrated Figure 4 51 Figure 4 52 1 Return Hose 2 Pressure Hose NOTICE NEVER let the hose come in contact with the steering system components th...

Page 51: ...lot U joint shaft O rings and drive shaft splines Figure 4 54 1 Drive Unit Pilot 2 O Rings 3 Splines 3 Ensure that the drive shaft U joint bellows are clean and free of debris Apply lubricant to O ring seals Figure 4 53 Figure 4 55 1 U Joint Bellows 2 O Ring Seals Lithium Grease with PTFE Where Used Part Number Bell Housing Studs Obtain Locally 0006094 1 Multipurpose Heavy Duty Type Grease NLGI 2 ...

Page 52: ... into the bell housing the shift cable must be connected to the jaws of the shift linkage assembly in the drive unit 5 Pull the shift cable out as far as it moves by hand Figure 4 55 Figure 4 57 1 Shift Cable 6 Pull the slider shift linkage out as far as it goes with a piece of wire Figure 4 56 Figure 4 58 1 Slider Shift Linkage 2 Wire obtain locally 7 Follow steps 1 2 and 3 in Figure 4 59 to conn...

Page 53: ...er to align the U joint shaft splines with the splines in the engine coupling d Slide the drive unit all the way into the bell housing e Secure the drive unit to the bell housing with 5 flat washers and 6 locknuts Figure 4 59 Figure 4 61 1 Locknut and Flat Washer 2 Locknut Only f Torque the drive unit locknuts 10 Remove the eye bolt from the top cover and replace the plug and washer to prevent cor...

Page 54: ...2 ea 15 Open the oil valve screw in the drive shaft housing before the engine is operated the first time Figure 4 62 Figure 4 64 1 Oil Valve Screw Figure 4 63 Figure 4 65 1 9 mm Wrench hold the nut 2 Screwdriver turn left one rotation 16 Hold the nut with the wrench and turn the valve screw one turn counterclockwise Lithium Grease with PTFE Where Used Part Number Anchor Pin Threads Obtain Locally ...

Page 55: ...20 Recheck the oil level after the first use Speedometer Connection 1 Raise the drive unit to gain access to the area between the gimbal housing and the drive unit immediately on top of the transom end of the antiventilation plate 2 Insert the speedometer tube fitting into the opening on the topside of the ventilation plate in position as illustrated Figure 4 65 Figure 4 67 1 Speedometer Tube Fitt...

Page 56: ...INSTALLING ENGINE AND DRIVE UNIT 4 34 ZT350 Installation Manual Installing the Drive Unit 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 57: ...n 5 2 Steering Helm and Cable 5 2 Steering Cable Specifications 5 2 Installation of Steering Cable 5 4 Throttle and Shift Cables 5 5 Shift and Throttle Cable Travel 5 5 Verify Propeller Rotation with Mechanical Shift System 5 5 Shift Cable Installation and Adjustment 5 6 Setting the Cable Length 5 6 Install the Drive Unit Shift Cable 5 6 Troubleshooting Shift Problems 5 9 ...

Page 58: ...utlined in the NMMA certification handbook Yanmar recommends using the steering cable with a coupler nut There must also be a means of locking it to the guide tube as specified in the ABYC requirements WARNING Failure to use a steering cable locking device could cause a loss of steering Yanmar recommends using the steering cable with a self locking coupler nut Use an external locking device if usi...

Page 59: ... 64 in Minimum Flat 6 3 1 mm 7 64 in Minimum Radius 7 15 9 mm 5 8 in Maximum Diameter End Fitting 8 9 5 mm 3 8 in 9 9 8 mm 3 8 in Diameter Through Hole chamfered each side 10 1 3 8 in 34 9 mm Maximum 11 15 9 mm 5 8 in Diameter Tube 12 Cable Travel Mid Travel Position 429 mm 16 7 8 in Total travel to be 203 mm 8 in minimum to 228 mm 9 in maximum Travel each side of mid travel position 102 mm 4 in m...

Page 60: ...any interferences with other objects NEVER tie down or clamp the steering cable within 90 cm 3 ft of the power steering cylinder Figure 5 2 4 Figure 5 2 Figure 5 2 1 Rotary or rack helm 2 Minimum 20 cm 8 in bend radius 3 Plus or minus 25 mm 1 in free motion of cable housing and power steering valve 4 NEVER tie down or clamp within 90 cm 3 ft of the power steering cylinder 5 Steering lever 6 Steeri...

Page 61: ...o 77 mm 3 1 32 in with a 50 to 70 N 11 to 16 lb load applied to the cable end Verify Propeller Rotation with Mechanical Shift System NOTICE Use this method to verify the correct propeller rotation RH or LH for this drive unit The front propeller on the drive unit is always LH Rotation and the rear propeller is always RH Rotation The shift cable end guide must move in direction 1 shown in Figure 5 ...

Page 62: ...e Cable Length Find the NEUTRAL position at the shift cable for the drive unit Measure the distance between the control cable barrel center and the center of the attachment hole of the cable end Adjust it at the screw of the attachment if necessary and then lock the nut This distance should be 180 6 mm 7 7 64 in Figure 5 5 Figure 5 5 1 Lock Nut 2 180 6 mm 7 7 64 in The control cable barrel center ...

Page 63: ...he control cable end guide CAUTION NEVER attempt to install or remove the shift control cable barrel from the stud without first removing the end guide clevis pin from the shift lever and removing the cable Attempting to bend the shift control cable to install or remove the barrel will put undue stress on the cable end guide and shift lever Damage to both could occur 3 Remove the shift control cab...

Page 64: ...e between the control 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 Figure 5 11 Figure 5 11 1 Barrel Retainer Cotter Pin 2 205 6 1 5 ...

Page 65: ...e there are no kinks in the cable 5 Ensure that there is enough clearance for cable movement when the control box is installed in the side panel The cables must have room to move up and down when the control handle is shifted into either FORWARD or REVERSE 6 Ensure that the engine was not set down on the intermediate shift cable during installation this will crush the inner cable tubing and cause ...

Page 66: ...REMOTE CONTROLS 5 10 ZT350 Installation Manual Shift Cable Installation and Adjustment 2007 Yanmar Marine International This Page Intentionally Left Blank ...

Page 67: ... 6 3 Fill the Power Trim Pump Fluid 6 4 Check the Stern Drive Oil Level 6 4 Fill the Stern Drive with Oil 6 5 Propeller Selection 6 6 General Propeller Installations 6 7 Installing the Propellers 6 8 Removing the Propeller 6 9 Test Preparations 6 10 Engine Operation Tests 6 10 Out of Water Testing 6 10 In Water Testing 6 11 Drive Unit Operational Tests 6 11 Cold Weather Freezing Temperature Season...

Page 68: ...ON NEVER operate the engine and power steering without fluid or the pump will be damaged Battery Connections NOTICE The engine electrical system is negative ground 1 Position the battery as close to the engine as possible 2 Connect the engine positive battery cable usually RED to the positive battery terminal 3 Connect the engine negative battery cable usually Black to the negative battery termina...

Page 69: ...ve 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 6 2 2 Figure 6 2 Figure 6 2 1 Reservoir 2 MIN and MAX Lines 3 The oil level is low if it is below the MIN line Figure 6 3 1 on the reservoir Fill as necessary with the specified fluid See Fill the Power Trim Pump Fluid on page 6 4 Figure ...

Page 70: ...heck the Stern Drive Oil Level Note The oil level will rise and fall during operation Check the oil level before starting when the engine is cold 1 Check the stern drive lube oil level Figure 6 5 Keep the oil level at or near the OPERATING RANGE full line on the oil reservoir 2 The oil level is low if it is below the ADD line on the oil reservoir Fill as needed with the specified oil See Fill the ...

Page 71: ...lack of lubrication Contact your authorized Yanmar Marine dealer or distributor 1 Remove the oil reservoir cap Figure 6 6 1 2 Fill the oil reservoir to the OPERATING RANGE Figure 6 6 2 full line with specified fluid NOTICE Do not overfill Figure 6 6 Figure 6 6 1 Oil Reservoir Cap 2 OPERATING RANGE Line 3 When replacing the cap ensure that the rubber gasket is inside the oil reservoir cap and insta...

Page 72: ... considered lower pitched A smaller pitch propeller should be selected for water skiing or for heavy loads Keep these guidelines in mind when selecting a propeller NOTICE NEVER attempt to change propellers until after determining the average load and individual requirements Your Yanmar dealer or distributor is most qualified to help you select a propeller Engine rpm must be within the recommended ...

Page 73: ...severe injury Place a block of wood between the anti ventilation plate and the propeller to protect hands from the propeller blades and to prevent the propeller from turning when removing and tightening the propeller nut NOTICE Installation is correct when at least 2 threads of the propeller shaft are exposed through the propeller locknut after applying torque to the locknut Place a block of wood ...

Page 74: ...e International Installing the Propellers Figure 6 8 Figure 6 8 1 Rear Propeller Nut 2 Rear Propeller 3 Rear Propeller Thrust Hub 4 Front Propeller Nut 5 Front Propeller 6 Front Propeller Thrust Hub 7 Propeller Shaft Anode 8 Propeller Shaft Anode Bolt and Washer 0006015 8 7 1 2 3 4 5 6 ...

Page 75: ...lt with a washer Torque the bolt Removing the Propeller WARNING The Remote Control must be in NEUTRAL and the starter key removed from the switch before removing and or installing the propeller 1 Place a wood block between the propeller blades and the antiventilation plate to prevent rotation WARNING Place a block of wood between the antiventilation plate and the propeller to protect hands from pr...

Page 76: ... when the engine is shut down 5 Check the drive unit oil level in the oil reservoir 6 Test the audio warning system if equipped Engine Operation Tests WARNING If engine is to be tested with the boat out of the water the propeller must be removed to avoid injury CAUTION Overheating from insufficient coolant will cause engine and drive unit damage Ensure that there is sufficient water available at t...

Page 77: ...VER leave the helm unattended when performing tests with the boat in the water CAUTION Instruments can warn of engine problems Watch the temperature gauge on the dash to ensure that the engine does not overheat to avoid engine damage 1 Refer to the Engine Operation Manual and start the engine 2 Operate the engine at IDLE rpm until it reaches normal operating temperature 3 Turn the steering wheel t...

Page 78: ...f 15 Check the power steering fluid level and add as necessary CAUTION If the power package will not be used for an extended period of time or will be exposed to freezing temperatures drain the water from the drive unit ALWAYS drain water to prevent corrosion and freeze damage to the engine and or the drive unit If the power package will not be used for an extended period of time or will be expose...

Page 79: ...nmar Warranty Use a piece of wire to check the water drain passages in the drive unit to ensure that they are open Figure 6 12 Figure 6 12 1 Underside of Anticavitation Plate 2 First Anode Cavity Drain Passage 3 Second Anode Cavity Drain Passage 4 Speedometer Pitot Hole CAUTION The drive unit should be stored in the FULL DOWN IN position The U joint bellows may develop a set if the unit is stored ...

Page 80: ...PRE DELIVERY 6 14 ZT350 Installation Manual Pre Delivery Preparation 2007 Yanmar Marine International This Page Intentionally Left Blank ...

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