Yamaha ME422STI User manual

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

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and
their trained mechanics when performing maintenance procedures and repairs to
Yamaha equipment. It has been written to suit the needs of persons who have a
basic understanding of the mechanical and electrical concepts and procedures
inherent in the work, for without such knowledge attempted repairs or service to the
equipment could render it unsafe or 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 this manual.
ME422STI
ENGINE SERVICE MANUAL
© 2005 Yamaha Motor Co., Ltd.
1st Edition, November, 2005
All rights reserved. Any reprinting or
unauthorized use without the written
permission of Yamaha Motor Co., Ltd. is
expressly prohibited.
Printed in Japan

HOW TO USE THIS MANUAL
MANUAL FORMAT
This manual provides the mechanic with descriptions of the operations of disassembly, repair,
assembly and check, each of which is presented in a sequential, step-by-step procedure.
To assist you in finding your way around this manual, the section title and major heading is
given at the head of each page.
A table of contents is provided on the first page of each section.
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 procedure are numbered: 1), 2), 3).
Parts shown in the illustrations are identified as: 1, 2, 3.
REFERENCES
These have been kept to a minimum. References to other sections of the manual include the
relevant page number.

¡¡
¡¡
¡WARNING
Failure to follow WARNING instructions could result in severe injury or death to the marine
vehicle operator, a bystander, or a person checking or repairing the Stern Drive.
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!

CONSTRUCTION OF THIS MANUAL
This manual consists of chapters for the main categories of subjects. (See “Symbols” on the
next page.)
1st title 1: This is a chapter with its symbol on the upper right of each page.
2nd title 2: This title appears on the top of the each page, to the left of the chapter symbol.
3rd title 3: This title appears only in the chapter “Periodic check and adjustment”.
All the procedures in this manual are organized in a sequential, step-by-step order. The infor-
mation has been compiled to provide the mechanic with an easy-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 4are 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 6indicates a part name. A circled lower case letter indicates data or an
alignment mark 7. Illustrations are sometimes labeled with an upper case letter 8.
¡An arrow 9indicates the course of action required to remedy the started condition of a
component.
EXPLODED DIAGRAM
Each chapter begins with exploded diagrams which facilitate correct disassembly and assem-
bly.

SYMBOLS
Symbols 1to Aare designed as thumb-tabs
and indicate the content of a chapter.
1General information
2Specifications
3Periodic check and adjustment
4Engine removal and installation
5Engine
6Fuel system
7Exhaust system
8Cooling system
9Lubrication system
0Turbocharger
APower steering system
BElectrical system
CTroubleshooting
Symbols Dto Jindicate specific data:
DSpecial tool
ERecommended fuel
FLubricant
GEngine speed
HTightening torque
ISpecified value, service, limit
JResistance (Ω), Voltage (V), Electric cur-
rent (A)
Symbols Kand Lin an exploded diagram
indicate grade of lubricant and location of
lubrication point:
KApply Yamaha gear-case lubricant
LApply water resistant grease (Yamaha
marine grease A, Yamaha marine grease)
Symbols Mand Nin an exploded diagram
indicate grade of sealing or locking agent,
and location of application point:
MApply LOCTITE®No. 243, 271, 572
NApply Three Bond®TB-1207B, 1322, 1324
NOTE:
Some of the above symbols may not appear
in this manual.
12
34
56
78
90
AB
CD
EF
GH
IJ
K
N
L
M
T.R
A
LT
LT
G
TB
GEN
INFO SPEC
CHK
ADJ
REM
INST
ENG
OVER FUEL
EXHT COOL
LUB TURB
STEER
ELEC –
+
TRBL

CONTENTS
GENERAL INFORMATION 1
GEN
INFO
SPECIFICATIONS 2SPEC
PERIODIC CHECK AND
ADJUSTMENT 3
CHK
ADJ
ENGINE REMOVAL AND
INSTALLATION 4
REM
INST
ENGINE OVERHAUL 5
ENG
OVER
FUEL SYSTEM 6FUEL
EXHAUST SYSTEM 7EXHT
COOLING SYSTEM 8COOL
LUBRICATION SYSTEM 9
LUB
TURBOCHARGER
10
TURB

INDEX
POWER STEERING SYSTEM
11
STEER
ELECTRICAL SYSTEM
12
ELEC
TROUBLESHOOTING
13
TRBL
SHTG
– +