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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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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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

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ZT350 Installation Manual 1-1
© 2007 Yanmar Marine International
ZT350 Installation Manual Section 1
SAFETY
Yanmar considers safety of great importance and
recommends that anyone that comes into close
contact with its products, such as those who install,
operate, maintain or service Yanmar products,
exercise care, common sense and comply with the
safety information in this manual and on the engine
and stern-drive's safety labels. Keep the labels from
becoming dirty or torn and replace them if they are
lost or damaged. Also, if you need to replace a part
that has a label attached to it, make sure you order
the new part and label at the same time.
Indicates a hazardous situation which, if not
avoided, will result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a hazardous situation which, if not
avoided, could result in minor or moderate
injury.
Indicates a situation which can cause damage to
the engine and stern-drive, personal property
and / or the environment or cause the equipment to
operate improperly.
A
This safety alert symbol appears
with most safety statements. It
means attention, become alert, your
safety is involved! Please read and
abide by the message that follows
the safety alert symbol.

SAFETY
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© 2007 Yanmar Marine International
General Information
There is no substitute for common sense and
careful practices. Improper practices or
carelessness can cause burns, cuts, mutilation,
asphyxiation, other bodily injury or death. This
information contains general safety precautions
and guidelines that must be followed to reduce risk
to personal safety. Special safety precautions are
listed in specific procedures. Read and understand
all of the safety precautions before operation or
performing repairs or maintenance.
The safety messages that follow have DANGER
level hazards. These safety messages describe
a hazardous situation which, if not avoided, will
result in death or serious injury.
NEVER permit anyone to install or
operate the engine or stern-drive
without proper training.
• Read and understand the Operation Manual
information before you install, operate or service
the engine or stern-drive to ensure that you follow
safe operating practices and maintenance
procedures.
• Safety signs and labels are additional reminders
for safe operating and maintenance techniques.
• See your authorized Yanmar marine dealer or
distributor for additional training.
Crush Hazard
ALWAYS use lifting equipment with
sufficient capacity to lift the stern-drive.
NEVER stand under hoisted stern-drive. If the hoist
mechanism fails, the stern-drive will fall on you,
causing serious injury or death.
NEVER support the stern-drive with equipment not
designed to support the weight of the stern-drive
such as wooden pieces, blocks or by only using a
jack.

SAFETY
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The safety messages that follow have
WARNING level hazards. These safety
messages describe a hazardous situation
which, if not avoided, could result in death or
serious injury.
Explosion Hazard
While the engine is running or the
battery is charging, hydrogen gas is
being produced and can be easily
ignited. Keep the area around the
battery well-ventilated and keep sparks,
open flame and any other form of ignition out of the
area.
Fire Hazard
Undersized wiring systems can cause
an electrical fire.
Sever Hazard
NEVER service the stern-drive while
under tow or if the engine is running at
idle speed. The propeller may rotate
under these circumstances.
If the vessel has more than one engine, NEVER
service a stern-drive if either of the engines are
running. In multi-engine configurations, the
propeller for an engine that is shut down may rotate
if any of the other engines are running.
Rotating parts can cause severe injury or death.
NEVER wear jewelry, unbuttoned cuffs, ties or
loose-fitting clothing, and ALWAYS tie long hair
back when working near moving / rotating parts
such as the flywheel, propeller or PTO shaft. Keep
hands, feet and tools away from all moving parts.
To prevent accidental equipment movement,
NEVER start the engine in gear.
Before starting the engine, ALWAYS make sure that
all bystanders are clear of the area. Keep children
and pets away while the engine is operating.
Always remove any tools or shop rags used during
maintenance from the area before operation.
Stop the engine before you begin to service the
stern-drive and secure the propeller so it will not
turn.
Alcohol and Drug Hazard
NEVER operate the engine while
under the influence of alcohol or drugs
or when feeling ill.
Exposure Hazard
ALWAYS wear personal protective
equipment including appropriate
clothing, gloves, work shoes, eye
and hearing protection as required
by the task at hand.

SAFETY
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Entanglement Hazard
NEVER leave the key in the key switch
when servicing the engine or
stern-drive. Someone may accidentally
start the engine and not realize you are
servicing it.
NEVER operate or service the engine while
wearing a headset to listen to music or the radio
because it will be difficult to hear the warning
signals.
Burn Hazard
Some of the engine and stern-drive
surfaces become very hot during
operation and shortly after shut-down.
Keep hands and other body parts away
from hot surfaces.
Exhaust Hazard
NEVER block windows, vents, or other
means of ventilation if the engine is
operating in an enclosed area. All
internal combustion engines create
carbon monoxide gas during operation and special
precautions are required to avoid carbon monoxide
poisoning.
Electrical Shock Hazard
ALWAYS turn off the battery switch (if
equipped) or disconnect the negative
battery cable before servicing the
equipment.
ALWAYS keep the electrical connectors and
terminals clean. Check the electrical harnesses for
cracks, abrasions, and damaged or corroded
connectors.
The safety messages that follow have CAUTION
level hazards. These safety messages describe
a hazardous situation which, if not avoided,
could result in minor or moderate injury.
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages on portable
safety lamps.
To o l H a z a rd
ALWAYS use tools appropriate for the task at hand
and use the correct size tool for loosening or
tightening machine parts.
Flying Object Hazard
ALWAYS wear eye protection when
servicing the stern-drive or when using
compressed air or high-pressure water.
Dust, flying debris, compressed air,
pressurized water or steam may injure
your eyes.
Slipping and Tripping Hazard
Ensure that adequate floor space is
set aside for servicing stern-drive. The
floor space must be flat and free of
holes.
Keep floor free of dust, mud, spilled liquids and
parts to help prevent slipping and tripping.