Yamaha V-6 OFFSHORE OUTBOARDS FourStrake User manual

MODEL AQ, AQSHO SERIES
ASSEMBLY INSTRUCTIONS
YAMAHA 200-250 HP, V6, 2 STROKE, 3.1 L
200-250 HP, V6, 4 STROKE, 4.2 L
1
1. Place the engine on the transom of your boat so that it is mounted vertically, in the normal fashion. Remove the
bolts holding the gearbox to the exhaust housing and remove gearbox assembly.
2. Remove the water pump assembly from the propeller drive, including the lower stainless steel plate, dowel pins,
and impeller drive key.
3. Install the jet driveshaft assembly into the spiral pump housing locking it in place with the four 5/16-18 x 1
bolts with lock washers. Use grease on the threads. Tighten to 15 ft-lbs.
4. Install the water pump assembly on top of the 3/4 inch thick aluminum adapter and stainless steel plate. The
stainless steel plate design was changed recently. The front extends beyond the pump housing and interferes
with the adapter plate. Cut off the section that extends beyond the pump housing. Be sure also to install the
water pump impeller drive key removed from the propeller drive. Lock in place using four 5/16-18 x 2-1/2 bolts
and lockwashers. Grease the threads. Tighten to 10 ft-lbs. The tapered thrust ring assembly above the water
pump on the propeller drive is not used on the jet drive.
5. The large 3/4 inch adapter plate is attached to the exhaust housing to hold the jet drive. A 1/4 x 2 inch plastic
shift rod guide in the front of the plate guides the disconnected shift rod. Two 8 x 12MM dowels locate the
plate, seven M10 x 34MM bolts with lock washers secure it. Grease the bolt threads and the end of the pin
where it slides in the shift rod. Tighten to 22 ft-lbs.
6. Next, attach the jet drive to the motor. Two 3/16 x 1/2 dowel pins center the jet drive on the adapter plate. Four
3/8-16 bolts from below and one 3/8-16 x 1-1/2 bolt from above rear with lockwashers are used. Select the
lower bolt lengths to suit the different counter bore depths so that all bolts enter the adapter plate the same
depth. The upper rear bolt is reached through the trim tab opening in the motor exhaust housing.
Grease the bolt threads, driveshaft spline generously, and rubber water tube pilot and guide the jet into place.
Tighten to 22 ft-lbs.
7. Next, install the impeller. Grease the shaft threads, key and impeller bore. Place the plastic sleeve inside the
impeller, hold the key in the nose of the impeller with your forefinger and slide onto the driveshaft. Install the
eight shim washers, and nut retainer on the shaft, up against the impeller, and bring the nut up snug by hand. Be
careful that the retainer does not fall into the thread groove and jam the nut.
Then bump the nut up snug with a wrench. If the ears of the retainer do not line up with the flats on the nut, spin
the nut off, turn the retainer over and tighten the nut again. In one of these two positions you will have
alignment and can fold the ears up against the nut to retain it. The flat in the retainer is angled to the ears to
allow this.
When, after use in sand and gravel, the blade clearance becomes more than about 1/32 inch between the
impeller edge and the water intake liner, one or more of the stainless shim washers can be transferred from the
bottom stack to the top of the impeller, which moves the impeller down into the tapered casing to reduce the
clearance.
Shims should not be used above the impeller on new installations, where no wear has occurred, unless the
blade clearance exceeds 1/32 inch. Insufficient blade clearance will do more harm than good from any
performance gains it might provide.
8. Place the intake casing in position with the lower end at the rear and tighten the six nuts. No lockwashers are
used. Grease the threads.
9. Attach the shift cable and cable anchor bracket to the jet drive.

MODEL AQ, AQSHO SERIES
ASSEMBLY INSTRUCTIONS
YAMAHA 200-250 HP, V6, 2 STROKE, 3.1 L
200-250 HP, V6, 4 STROKE, 4.2 L
2
10. With the shift handle in forward and the reverse gate in forward, with the cam roller at the end of the slot, adjust
the cable and/or cable anchor position to this condition. Shift to reverse and back to forward. The roller should
be at the end of the cam slot such that the gate cannot be forcibly rotated toward reverse. Pull on the gate by
hand to verify this.
If this forward lock condition is not met, readjust the cable positions.
11. When converting to jet drive, your motor will have to be raised to the height shown in the diagram pg. 3, using
a straight edge under the boat. Test run the boat and then raise or lower the motor 5/16 inch at a time to obtain
best results.
The motor has three sets of upper mounting holes. You will use one set to begin with. Mark pencil lines on the
boat transom through the other sets. Then if you wish to go up or down 5/16 inch, you can drill one alternate set
of holes 5/16 inch up or down from the pencil marks. By alternating between these two sets of transom holes
and the three sets of motor holes, the motor can be moved in 5/16 inch increments over almost one inch. The
transom height should e about 26 inches measured vertically from the boat bottom.
If you raise it too much it will suck air and cavitate, either on start up or when banking on turns. When
cavitating, the motor overspeeds in spurts and shakes considerably in the motor mount. This is not a normal
condition and should be avoided by proper adjustment of motor height on each individual boat. If you lower it
too much you will have excessive drag, therefore mount the motor as high as possible without allowing
cavitation.
SETTING MOTOR HEIGHT
CAUTION
When starting the engine for the first time, watch to see that the cooling water comes out of the small hole
at the rear side of the engine just below the power head. This is to check your assembly of the cooling
water pump and its connections.

MODEL AQ, AQSHO SERIES
ASSEMBLY INSTRUCTIONS
YAMAHA 200-250 HP, V6, 2 STROKE, 3.1 L
200-250 HP, V6, 4 STROKE, 4.2 L
3
MAINTENANCE AND LUBRICATION
See last page.
CAUTION
V4 and V6 Drives
It is important on high HP installations to mount the motor at the correct height and t o use the power tilt
properly.
Power tilt is convenient for drifting and when operating at low throttle in very shallow area. When under power
however, the engine should not be tilted out in an effort to gain speed as is done with propellers.
The engine driveshaft should be vertical when planing or tilted toward the boat in order to provide a scooping
angle on the water intake grill. Tilting the motor out beyond a vertical position reduces the scoop angle and can
cause impeller slippage and cavitation burns on the impeller blades.
When running in a bay, lake or wide river in windy conditions, particularly when running with the wind the jet
can suck in air when jumping across the wave crests. This will result in overspeeding and causes sever strain on
the driveshaft when the engine is suddenly brought back to normal speed as the impeller once again grabs solid
water.
If your boat is used frequently under these conditions, the engine height should be set lower than normal to
minimize overspeeding. Running at reduced throttle will help when winds are strong. You can also experiment
with a plate extending from the hull bottom to the top of the leading edge of the water intake as shown in
paragraph 7 of the owner’s manual. This tends to reduce air intake as well as to reduce spray.
A water intake fin kit, part # 1726 will soon be available. The purpose of these fins is to ram more water into
the intake and to shield the forward sides of the intake from the entrance of air. There is a noticeable reduction
of engine overspeeding when running with the wind on a heavy chop. To a lesser degree, the fins provide some
rudder effect when operating at low speeds. This is not a cure all for cavitation and it is still necessary to set the
engine height and angle properly and to minimize obstructions or imperfections in the hull ahead of the intake.
GOOD BOATING AND HAVE FUN!
Specialty Manufacturing Company
Outboard Jets
2035 Edison Avenue
San Leandro, CA 94577

MODEL AQ, AQSHO
ANODE KIT 1693

MODEL AQ AND AQ SHO YAMAHA
AQ V6 2 STROKE AND V6 4 STROKE 3.1 L
AQ SHO V6 4 STROKE 4.2 L
REF QTY PART DESCRIPTION REF QTY PART DESCRIPTION
NO. NO.
1 1 938 PUMP ADAPTER AA 51 4 517 SPIROLOX RR-150S
2 4 603 BOLT HEX HD 5/16-18 X 2 1/2 52 2 506 SEAL INNER
3 1 1611 ADAPTER PLATE AQ 53 2 507 SEAL OUTER 6324-S
4 1 943 SHIFT ROD GUIDE AA-ROD 54 2 527 O RING 568-141 3/32X2 5/16X2 1/2
5 2 615 DOWEL PIN 8 X 12M 55 1 393.5 BEARING CARRIER W/SEALS & O RINGS 5/16
6 12 636 WASHER SPRING LOCK M10 56 3 521 O RING 568-011 1/16X5/16X7/16
7 7 592 BOLT HEX HD M10-1.25 X 35MM 57 4 602.1 BOLT HEX HD 5/16-18 X 1 PATCH
8 2 631 DOWEL PIN 3/16 X 1/2 58 1 1721 IMPELLER 7 5/8 STAINLESS
9 2 608 BOLT HEX HD 3/8-16 X 2 1/4 59 1 136 SHAFT SLEEVE PLASTIC LARGE
10 1 609 BOLT HEX HD 3/8-16 X 2 3/4 60 1 434 IMPELLER TEE KEY - SQUARE
11 1 610 BOLT HEX HD 3/8-16 X 3 60 1 1706 IMPELLER TEE KEY - 1/2 ROUND
12 1 607 BOLT HEX HD 3/8-16 X 1 1/2 61 8 121 SHIM WASHERS
1610.01 VOLUTE WITH GATE AQ 62 1 781 NUT KEEPER LARGE 2 PER BAG
13 1 1609.01 VOLUTE WITH EXHAUST TUBE AQ 63 1 122.1 SHAFT NUT 3/4-16 BRASS
14 1 128 EXHAUST TUBE ASSY LARGE 2 1/2 1603.01 INTAKE ASSY FLANGED WITH GRILL BAR & LINER
15 1 845 CLIP EXHAUST TUBE 1 3/8 64 1 1605 LINER FLANGED 7 5/8
16 2 621 NYLOC 10-32 65 1 1602.01 INTAKE PAINTED ONLY 7 5/8
19 1 553.2 BALL END 1/4X10-32 CABLE 66 2 1667 GRILL ROD
20 1 975 LUBE HOSE ASSY 67 10 1622 GRILL BAR X-LARGE
21 1 539 ZIRC FITTING 1/4-28 68 6 1319 STUD - INTAKE LARGE
22 1 550 GREASE GUN 69 6 625 NYLOC 5/16-18
23 1 552 GREASE 10 OZ TUBE NO. 630-AA 171.1 BRACKET ASSY AQ, AW W/CLAMP & HARDWARE
24 1 1172.01 REVERSE GATE LARGE 70 1 156.1 BRACKET CABLE SUPPORT AQ, AW
25 2 536 NYLINER 1/2 ID X 13/16 71 1 542 SHIM MORSE A035777
26 1 1178 SPRING GATE PIVOT 1/2 72 1 543 CLAMP CHRYS 154317
27 2 823 PIN GATE PIVOT 1/2 LARGE 73 2 561 FL HD SLOTTED 10-24 X 5/8
28 1 1043 SHAFT ROLLER 74 8 640 WASHER SPRING LOCK 5/16
29 2 624 NYLOC 1/4-28 75 2 572 BOLT HEX HD 1/4-20 X 5/8
30 1 1042 ROLLER ASS
Y
76 2 619 NYLOC 10-24
31 3 635 1/4 WASHER AN960C416 77 1 1719 TORSIONAL DAMPER 3/4
32 1 1034 SHIFT CAM LARGE 78 1 1024 BOLT HEX HD M8-1.25 X 12MM
33 1 623 NYLOC 1/4-20 79 1 1025 WASHER FIBER M8
34 1 573 BOLT HEX HD 1/4-20 X 3/4
35 1 1037 BUSHING CAM
36 1 1038 WASHER CAM MODEL AQ SHO - BALANCE OF
37 2 1039 SHIM - CAM PARTS SAME AS MODEL AQ
38 1 1036 CAM ECCENTRIC DRILLED
39 1 574.1 BOLT HEX HD 1/4-20 X 1 PATCH 19 1 2128.1 OFFSET ASSY AQ SHO CAM
40 2 574 BOLT HEX HD 1/4-20 X 3/4 PATCH 44 1 2126 SHAFT ONLY, AQ SHO 20T 31 1/2 LG
41 1 1170 SPRING GATE BUMPER 2127.1 SHAFT ASSY COMPLETE, AQ SHO 20T 5/16
42 1 1497 GATE BUMPER 171.2 BRACKET ASSY AQ SHO
43 1 559.2 FIL HD SLOTTED 10-32 X 1 1/4 PATCH 70 1 156.2 BRACKET CABLE SUPT AQ SHO
44 1 1614 SHAFT ONLY, AQ 20T 30 15/16 LG
1615.1 SHAFT ASSY COMPLETE, AQ 20T 5/16
44 1 1729 SHAFT ONLY, AQX 20T 35 15/16 LG
1730.1 SHAFT ASSY COMPLETE, AQX 20T 5/16
45 1 41 SHAFT BEARING THRUST RING
46 2 502 BEARING 7305B-UA
47 1 511 TRUARC 5100-98
48 1 404 BACKUP WASHER
49 1 513 TRUARC N5002-250ZD
50 1 432 UPPER SEAL CARRIER W/SEALS & O RINGS
SIZE TORQUE
1/4-20 (M6) 8-9 FT-LBS
5/16-18 (M8) 12 FT-LBS
3/8-16 (M10) 22 FT-LBS
BEARING, SEAL, SNAP & “O” RING KIT
2 BRG 462.2
- 81 -

MAINTENANCE AND LUBRICATION
OUTBOARD JET DRIVE
3
BEARING LUBRICATION
A grease gun and tube of grease is supplied with your jet drive. We recommend greasing
the bearing every 10 hours. Make greasing a part of your cleanup after the days use.
Pump in just enough grease to fill the lube hose. Then reconnect the lube hose coupling to
the zerk grease fitting.
Every 30-40 hours, pump in extra grease so as to purge any moisture. The texture of the
grease coming out gives an indication of conditions inside the bearing housing. A gradual
increase in moisture content indicates seal wear. If the grease begins to turn dark, dirty
gray, the bearing and seals should be inspected and replaced if necessary. Some
discoloration of the grease is normal during the break in period on new sets of seals.
We have selected a water resistant grease of the proper consistency for this application. If
you use a substitute grease, be sure it is water resistant and of the same consistency.
IMPELLER
Your jet drive is equipped with a key to protect the unit in the event of a rock jam. This can be
reached by removing the water intake, and then the driveshaft nut, similar to a propeller drive.
After replacing the key, pull the shaft nut up tight to remove any play between the impeller and
shaft. Note the position of the impeller shim washers, and replace them in the same order.
REVERSE GATE MECHANISM
Occasionally check adjustment of the gate shifting linkage. In “forward” the gate should be
firmly locked in position. Pull on the gate by hand to verify this. This will prevent wave action
from accidentally shifting the gate into reverse as the boat is violently maneuvered
GENERAL
Check all mounting bolts, intake screws, linkage connections, etc., occasionally to be sure they
are tight.
SALT WATER USE
Aluminum and stainless steel have been used in the construction of your jet drive. These
materials have either been treated or are inherently resistant to corrosion. It is recommended,
however, that when not in use the motor be tipped up so that the jet unit is out of the water.
When used in salt water more than in fresh water, remove mounting hardware, grease, and
reassemble once a year. Failure to do this may result in hardware that is difficult if not
impossible to remove at a later date.
GUARANTEE
Due to inflexible government regulation, we do not have a written warranty. We have, however,
a good reputation for fairness with our customers which we intend to maintain. If you think you
have a warranty situation, regarding material, workmanship, call us before making repairs.
Specialty Manufacturing Company
Outboard Jets
2035 Edison Avenue
San Leandro, CA 94577