Yanmar ZT350 series User manual

ZT350
series
INSTALLATION MANUAL
ZT350 Installation Manual
P/N: 0FZTD-G00100
STERN-DRIVE

ii ZT350 Installation Manual
© 2007 Yanmar Marine International
Disclaimers:
All information, illustrations and specifications in this manual are based on the latest information available
at the time of publishing. The illustrations used in this manual are intended as representative reference
views only. Moreover, because of our continuous product improvement policy, we may modify information,
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, including photocopying, recording, taping, or information storage and retrieval systems -
without the written permission of Yanmar Marine International.
© 2007 Yanmar Marine International
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© 2007 Yanmar Marine International
ZT350 Installation Manual
TABLE OF
CONTENTS
Page
Safety.................................................................................................... 1-1
General Information ............................................................................ 2-1
Notice to Vessel OEM & Equipment Installer .................................. 2-2
Sales and Technical Assistance................................................ 2-2
Tightening Torques for Standard Bolts and Nuts ...................... 2-3
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
Vessel Design...................................................................................... 3-1
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

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© 2007 Yanmar Marine International
Installing Engine and Drive Unit ........................................................ 4-1
Positioning the Drive Unit................................................................ 4-3
Locating the Crankshaft Vertical Centerline - Single
Engine Installation ..................................................................... 4-3
Locating the Crankshaft Vertical Centerline - Dual
Engine Installation ..................................................................... 4-3
Finding the Crankshaft Horizontal Centerline (X-Dimension).... 4-4
Cutting the Vessel Transom ...................................................... 4-6
Checking the Transom Thickness ............................................. 4-7
Installing 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
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 Connection ........................................... 4-25
Trim Position Sender Connection............................................ 4-25
Y-CaPS Controller Connection................................................ 4-25
Hydraulic Connections .................................................................. 4-27
Oil Reservoir............................................................................ 4-27
Power Steering Hoses............................................................. 4-28
Installing the Drive Unit ................................................................. 4-29
Speedometer Connection........................................................ 4-33
Remote Controls ................................................................................. 5-1
Power Trim System......................................................................... 5-2
Control System.......................................................................... 5-2
Pump Location .......................................................................... 5-2
Steering Helm and Cable ................................................................ 5-2
Steering Cable Specifications ................................................... 5-2
Installation of Steering Cable .................................................... 5-4

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© 2007 Yanmar Marine International
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
Pre-Delivery ......................................................................................... 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-of-Water Testing............................................................... 6-10
In-Water Testing ...................................................................... 6-11
Drive Unit Operational Tests ................................................... 6-11
Cold Weather (Freezing Temperature), Seasonal and
Extended Storage.................................................................... 6-13