Yamaha Z300A Manual

Z300A
LZ300A
SUPPLEMENTARY
SERVICE MANUAL
292211 6D0-28197-3F-1X

NOTICE
This Supplementary Service Manual has been prepared to introduce new service and new data
information for the Z300 and LZ300 which are based on the Z250 and LZ250. For complete informa-
tion on service procedures, it is necessary to use this Supplementary Service Manual together with
the following manual.
Important information 1
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
WARNING
Failure to follow WARNING instructions could result in severe injury or death to the machine
operator, a bystander, or a person inspecting or repairing the outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
CAUTION:
USE UNLEADED STRAIGHT GASOLINE ONLY
• Gasoline containing lead can cause performance loss and engine damage.
• Do not use gasoline mixed with oil during the break-in period or anytime thereafter.
YAMALUBE 2-STROKE OUTBOARD OIL IS RECOMMENDED.
Z250D, LZ250D SERVICE MANUAL: 60V-28197-3E-11
Z300A, LZ300A
SUPPLEMENTARY SERVICE MANUAL
©2003 by Yamaha Motor Co., Ltd.
1st Edition, July 2003
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in the Netherlands

Contents
General information 1
GEN
INFO
Specifications 2
SPEC
Periodic checks and adjustments 3
CHK
ADJ
Fuel system 4
FUEL
Power unit 5
POWR
Lower unit 6
LOWR
Bracket unit 7
BRKT
Electrical systems 8
ELEC
Troubleshooting 9
TRBL
SHTG
Index
–+

6D03F1X
General information
How to use this manual.................................................................................... 1
Manual format............................................................................................... 1
Symbols........................................................................................................ 2
Identification...................................................................................................... 3
Applicable models ........................................................................................ 3
Serial number ............................................................................................... 3
Features and benefits....................................................................................... 4
Crankcase and cylinders .............................................................................. 4
Intake system ............................................................................................... 6
Upper case ................................................................................................... 8
Lower case ................................................................................................... 9
ECM (Electronic Control Module) ............................................................... 10
Wiring harness connector holder................................................................ 10
Propeller selection .......................................................................................... 11
Propeller size.............................................................................................. 11
Selection..................................................................................................... 11
Predelivery checks ......................................................................................... 12
Checking the fuel system ........................................................................... 12
Checking the gear oil level ......................................................................... 12
Checking the engine oil level...................................................................... 12
Checking the battery................................................................................... 12
Checking the outboard motor mounting height........................................... 13
Checking the remote control cables ........................................................... 13
Checking the steering system .................................................................... 14
Checking the gear shift and throttle operation............................................ 14
Checking the power trim and tilt system..................................................... 14
Checking the engine start switch and engine stop lanyard switch ............. 14
Checking the cooling water pilot hole ......................................................... 15
Test run ...................................................................................................... 15
Break-in ...................................................................................................... 15
After test run ............................................................................................... 15

6D03F1X
Specifications
General specifications.................................................................................... 16
Maintenance specifications ........................................................................... 18
Power unit................................................................................................... 18
Lower unit ................................................................................................... 20
Electrical ..................................................................................................... 20
Dimensions................................................................................................. 23
Tightening torques.......................................................................................... 25
Specified torques........................................................................................ 25
General torques.......................................................................................... 27
Periodic checks and adjustments
Special service tools ...................................................................................... 28
Maintenance interval chart............................................................................. 31
Oil injection system ........................................................................................ 32
Adjusting the oil pump link rod.................................................................... 32
Lower unit ........................................................................................................ 32
Checking the lower unit for air leakage ...................................................... 32
General............................................................................................................. 33
Lubricating the outboard motor................................................................... 33
Fuel system
Fuel filter .......................................................................................................... 35

6D03F1X
Power unit
Power unit........................................................................................................ 36
Removing the power unit............................................................................ 37
Crankcase........................................................................................................ 39
Removing the crankcase covers ................................................................ 40
Installing the crankcase covers .................................................................. 40
Installing the power unit.............................................................................. 40
Lower unit
Propeller shaft housing (regular rotation model) ........................................ 43
Shimming (regular rotation model) ............................................................... 45
Selecting the pinion shims.......................................................................... 46
Backlash (regular rotation model)................................................................. 47
Measuring the forward and reverse gear backlash .................................... 47
Propeller shaft housing (counter rotation model) ....................................... 50
Drive shaft and lower case (counter rotation model) .................................. 52
Disassembling the reverse gear ................................................................. 54
Assembling the lower case......................................................................... 54
Shimming (counter rotation model) .............................................................. 56
Selecting the pinion shims.......................................................................... 57
Backlash (counter rotation model)................................................................ 58
Measuring the forward and reverse gear backlash .................................... 58
Bracket unit
Bottom cowling ............................................................................................... 61
Upper case, steering arm, swivel bracket, and clamp brackets................. 64
Power trim and tilt unit ................................................................................... 69
Checking the hydraulic pressure ................................................................ 69

6D03F1X
Electrical systems
Electrical components.................................................................................... 72
Port view..................................................................................................... 72
Top view ..................................................................................................... 73
Troubleshooting
Self-diagnosis.................................................................................................. 74
Diagnosing the electronic control system ................................................... 74
Wiring diagram

GEN
INFO General information
16D03F1X
How to use this manual 1
Only chapters containing revisions or additional items in the base manual have been included in this
manual.
All special service tools introduced in this manual are mentioned in Chapter 3.
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
1Parts are shown and detailed in an exploded diagram and are listed in the components list.
2Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4The components list consists of part names and part quantities, as well as bolt and screw dimen-
sions.
5Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
LOWR Lower unit
6-5 62Y5A11
Lower unit
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2 Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR Lower unit
6-19 62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2using a press.
CAUTION:
•Do not press the drive shaft threads a
directly.
•Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the for-
ward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Drive shaft holder 4 1: 90890-06518
Pinion nut holder 2: 90890-06505
Socket adapter 2 3: 90890-06507
Bearing inner race attachment 3:
90890-06639
S62Y6850K
Bearing separator 1: 90890-06534
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
S62Y6740K
5
4
321

6D03F1X 2
Symbols
The symbols below are designed to indicate the content of a chapter.
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
Electrical systems
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
–+
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Cin an exploded diagram indicate the grade of lubricant and the lubrication point.
7Apply 2-stroke outboard motor oil
8Apply gear oil
9Apply water resistant grease (Yamaha grease A)
0Apply molybdenum disulfide grease
AApply corrosion resistant grease
(Yamaha grease D)
BApply low temperature resistant grease
(Yamaha grease C)
CApply injector grease
Symbols Dto Iin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
DApply Gasket Maker
EApply Yamabond No. 4
FApply LOCTITE 271 (red)
GApply LOCTITE 242 (blue)
HApply LOCTITE 572
IApply silicon sealant
123456
T
R
.
.
7890ABC
E G
A M
D
C I
DEFGHI
GM
4
271
LT
242
LT
572
LT SS
How to use this manual
1
2
3
4
5
6
7
8
9

GEN
INFO General information
36D03F1X
Identification 1
Applicable models
This manual covers the following models.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
Applicable models
Z300AETO, LZ300AETO
Model name Approved
model code
Starting
serial No.
Z300AETO 6D0 X: 1000001–
U: 1000001–
LZ300AETO 6D1 X: 1000001–