Yanmar ZT350 Marine Stern Drive Units Repair Service Manual

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This Workshop Service Repair manual PDF download for the ZT350 Yanmar Marine Stern Drive Units has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


TABLE OF CONTENTS :

Introduction
Safety
General Service Information
Maintenance
Stern Drive
Driveshaft Housing
Gear Housing
Transom Assembly
Shift Cable
Steering
Power Trim System
Propellers
Corrosion Protection
Troubleshooting and Testing


MANUAL SPECIFICATION :

File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : OBZTD-G00100
Total Pages : 333


This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

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Cover
Table of Contents
Introduction
Revision History
Revision Control Table
Safety
Safety Precautions
General Service Information
Responsibilities
Owner / Operator Responsibilities
Dealer / Distributor Responsibilities
Specifications
Identification
Transom Assembly
Stern Drive Assembly
Gear Ratio Identification
Tightening Torques for Standard Bolts and Nuts
Tightening Fasteners
General Tightening Torque
Special Tightening Torques
Transom Assembly
Stern Drive Assembly
Torque Conversion Chart
Universal Joint Nut
Bearing Carrier
Propeller Nut - Outer
Tilt-Up - Limit Spacer
Hose Clamps
Lubricants, Sealers and Adhesives
Special Service Tools
Abbreviations and Symbols
Abbreviations
Symbols
Unit Conversions
Unit Prefixes
Units of Length
Units of Volume
Units of Mass
Units of Force
Units of Torque
Units of Pressure
Units of Power
Units of Temperature
Maintenance
Safety Precautions
Introduction
Checking, Filling and Changing Stern Drive Oil
Checking Stern Drive Oil Reservoir Level
Checking Stern Drive Oil Level
Filling Stern Drive Oil Reservoir
Changing Stern Drive Oil
Checking and Filling Power Trim Pump Fluid
Checking Power Trim Pump Fluid
Filling Power Trim Pump Fluid
Periodic Maintenance
The Importance of Periodic Maintenance
Performing Periodic Maintenance
The Importance of Daily Checks
Yanmar Replacement Parts
Tools Required
Periodic Maintenance Table
General Inspection
Periodic Maintenance Procedures
Weekly
Checking the Water Inlets
Checking the Seawater Inlet Hole
Inspecting the Anodes
Checking the Oil Level
After Initial 50 Hours of Operation
Lubricating the Engine Coupler
Changing the Stern Drive Oil
Every 50 Hours of Operation
Lubricate the Engine Coupler
Every 100 Hours of Operation
Lubricating the Propeller Shaft and Retorqueing the Nut
Retorqueing the Gimbal Ring to Steering Shaft Connection
Inspecting the Bellows and the Clamps
Checking the Engine Alignment
Lubricating the Steering Shaft Bushing
Lubricating the Unit Bearing (Gimbal Housing)
Lubricating the Engine Coupler
Checking the Electrical Circuits for Loose or Damaged Connections
Testing the Y-CaPS Unit Output
Checking the Steering System for Loose, Missing or Damaged Parts
Lubricating the Drive Unit and Universal Joint Shaft Splines and O-Rings
Torqueing the Rear Engine Mount Bolts
Checking the Remote Control for Loose, Missing or Damaged Parts
Lubricating the Shift Cable and the Linkages
Every 250 Hours of Operation
Touching Up the Stern Drive Paint and Spray with Corrosion Guard
Retorqueing the Rear Engine Mounts
Changing the Stern Drive Oil
Every Year
Retorqueing the Gimbal Ring to Steering Shaft Connection
Inspecting the Bellows and the Clamps
Checking the Engine Alignment
Lubricating the Unit Bearing (Gimbal Housing)
Lubricating the Engine Coupler
Checking the Circuit for Loose or Damaged Connections
Testing the Y-CaPS Unit Output
Checking the Steering System for Loose, Missing or Damaged Parts
Checking the Remote Control for Loose, Missing or Damaged Parts
Lubricating the Cable and the Linkages
Touching Up the Stern Drive Paint and Spray with Corrosion Guard
Changing the Stern Drive Oil
Retorqueing the Rear Engine Mounts
Cold Weather (Freezing Temperature), Seasonal and Extended Storage
Stern Drive Lay-Up
Stern Drive Recommissioning
Stern Drive
Safety Precautions
Introduction
Component Identification
Stern Drive Removal from Transom Assembly
Stern Drive Installation to Transom Assembly
Stern Drive Driveshaft Alignment
Driveshaft Housing and Gear Housing Disassembly
Driveshaft Housing and Gear Housing Assembly
Driveshaft Housing
Safety Precautions
Introduction
General Views
Driveshaft Housing Part Diagrams
Driveshaft Housing and Drive Gear
Case Plate and Shifter (Mechanical)
Case Plate and Shifter (Electric)
Driveshaft Housing Disassembly
Upper Gear “B” CMP
Disassembly
Assembly
Case Plate and Shifter
Disassembly - Mechanical Shifter
Assembly - Mechanical Shifter
Disassembly - Electric Shifter
Assembly - Electric Shifter
Filter and Magnet Check
Clutch Shaft Set Disassembly and Inspection
Ring Retainer Assembly
Driveshaft Housing Assembly
Upper Gear Shim Adjustment
Shim Location
Determine T1 Shim Thickness - Gear Adjustment “B” Position
Determine T2 Shim Thickness - Gear Adjustment “A-1” Position
Determine T3 Shim Thickness - Gear Adjustment “A-2” Position
Determine T4 Shim Thickness - Bearing Clearance Adjustment
Setting Gear Backlash
Gear Housing
Safety Precautions
Introduction
General Views
Gear Housing Part Diagrams
Gear Housing Assembly
Disassembly and Inspection
Gear Housing Assembly
Driveshaft CMP Assembly
Transom Assembly
Safety Precautions
Introduction
General Views
Transom Assembly Part Diagrams
Gimbal Housing
Transom Plate
Gimbal Housing Disassembly
Gimbal Housing Assembly
Tilt-Up Limit Spacer
Speedometer Connection
Shift Cable
Safety Precautions
Introduction
Control Cables
Mechanical Shift Cable Parts Diagram
Control Cable Travel
Verify Propeller Rotation with Mechanical Shift System
Shift Cable Installation and Adjustment
Shift Cable Installation for Electric Shift Type
Shift Cable Installation for Mechanical Shift Type
Setting the Cable Length
Installing the Drive Unit Shift Cable
Adjusting the Shift Control Cable
Troubleshooting Shift Problems
Steering
Safety Precautions
Introduction
Power Steering Unit Parts Diagram
Steering Cable Specifications
Installation of Steering Cable
Connecting Steering Cables
Power Steering Unit Installation
Power Steering Hose Installation
Steering Tie Bar Considerations
Internal Tie Bar Only
Internal and External Tie Bar
External Power Steering with an External Tie Bar
Power Trim System
Safety Precautions
Introduction
Power Trim Pump Parts Diagram
Power Trim Cylinders Parts Diagram
Power Trim System
Power Trim Pump Fluid
Power Trim Cylinders
Power Trim Troubleshooting
Power Trim Pump Installation
Trim Position Sender Connection
Trim-In Limiter
Propellers
Safety Precautions
Introduction
Propeller Selection
Propeller and Propeller Accessory Parts Diagrams
Propeller and Propeller Accessories
Propeller Installation
Removing Propellers
Corrosion Protection
Safety Precautions
Introduction
Corrosion Control Parts Diagram
Galvanic Corrosion
Corrosion Control
Shore Power
Underwater Drive Coating
Additional Protection
Gear Housing Anodic Plates
Ventilation Plate Anode
Trim Cylinder Anodes
Propeller Shaft Anode
Yanmar Cathodic Protection System
Corrosion Troubleshooting
Troubleshooting and Testing
Safety Precautions
Introduction
Stern Drive Unit Troubleshooting
Performance Troubleshooting
Power Steering Troubleshooting
Power Trim System Troubleshooting
Stern Drive Testing
Test Preparations
Engine Operation Tests
Out-of-Water Testing
In-Water Testing
Wide Open Throttle Test
Drive Unit Operational Tests

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