Yanmar ZT350 series User manual

ZT350
series
OPERATION MANUAL
P/N: 0AZTD-G00100
STERN-DRIVE

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 without notice. 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.
© 2008 Yanmar Marine International
0108
ii ZT350 Operation Manual
© 2008 Yanmar Marine International

TABLE OF
CONTENTS
Page
Introduction .............................................................. 1
Record of Ownership .............................................. 2
Safety ....................................................................... 3
Safety Precautions ................................................. 3
General Information ......................................... 4
Before You Operate ......................................... 4
During Operation and Maintenance ..................... 5
Product Overview ..................................................... 11
Overview ............................................................ 11
Owner / Operator Responsibilities ...................... 11
New Stern-Drive Break-In: ................................ 11
Dealer / Distributor Responsibilities .................... 11
Component Identification ........................................ 12
Location of Serial Numbers .............................. 13
Corrosion Protection .............................................. 14
Galvanic Corrosion ......................................... 14
Corrosion Control ........................................... 14
Shore Power ................................................. 14
Underwater Drive Coating ................................ 15
Additional Protection ....................................... 15
Gear Housing Anodic Plates ............................. 16
Ventilation Plate Anode ................................... 16
Trim Cylinder Anodes ...................................... 16
Propeller Shaft Anode ..................................... 16
Features and Controls ........................................... 17
Remote Controls ............................................ 17
Power Trim ................................................... 17
Stern-Drive Trim Angle .................................... 18
Trim and Tilt / Trailering Switch ......................... 18
Electrical System ........................................... 19
ZT350 Operation Manual iii
© 2008 Yanmar Marine International

Stern-Drive Operation ............................................... 21
Propeller Selection ................................................ 23
Installing the Propellers .......................................... 24
Removing the Propeller .......................................... 25
Daily Checks ....................................................... 26
Visual Checks ............................................... 26
Check the Stern-Drive Oil Level ......................... 26
Check the Power Trim Pump Fluid ..................... 27
Maintenance ............................................................ 29
Periodic Maintenance ............................................ 32
The Importance of Periodic Maintenance ............. 32
Performing Periodic Maintenance ...................... 32
The Importance of Daily Checks ........................ 32
Yanmar Replacement Parts .............................. 32
Tools Required .............................................. 32
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help ......................................... 32
Tightening Fasteners ............................................. 32
Torque Charts ...................................................... 33
Standard Torque Values .................................. 33
Torque Specifications ..................................... 33
Periodic Maintenance Table .................................... 34
General Inspection ................................................ 36
Power Trim Pump Fluid .......................................... 36
Periodic Maintenance Procedures ............................ 37
Weekly ........................................................ 37
After Initial 50 Hours of Operation ...................... 38
Every 50 Hours of Operation ............................. 39
Every 100 Hours of Operation ........................... 39
Every 250 Hours of Operation ........................... 43
Every Year .................................................... 47
Troubleshooting ....................................................... 49
Long-Term Storage ................................................... 51
Cold Weather (Freezing Temperature), Seasonal and
Extended Storage ................................................. 51
Stern-Drive Lay Up ......................................... 51
Stern-Drive Recommissioning ........................... 52
TABLE OF CONTENTS
iv ZT350 Operation Manual
© 2008 Yanmar Marine International

INTRODUCTION
Welcome to the world of Yanmar Marine!
Yanmar Marine offers engines, stern-drive
systems and accessories for all types of
vessels, from runabouts to sailboats, and
from cruisers to mega yachts. In marine
leisure boating, the worldwide reputation of
Yanmar Marine is second to none.
Yanmar stern-drives are designed for a wide
range of applications and are designed to
reduce vibration and make your cruising
more pleasurable.
To help you enjoy your Yanmar Marine
products for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you operate your vessel to
ensure that safe operating practices and
maintenance procedures are followed.
• Keep this Operation Manual in a
convenient place for easy access.
• If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
vessel and remain with it.
• Constant efforts are made to improve the
quality and performance of Yanmar
products, so some details included in this
Operation Manual may differ slightly from
your stern-drive. If you have any
questions about these differences,
please contact your authorized Yanmar
Marine dealer or distributor.
ZT350 Operation Manual 1
© 2008 Yanmar Marine International

RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.
Stern-Drive Model:
Stern-Drive Transom Assembly Serial No.:
Stern-Drive Unit Serial No.:
Stern-Drive Gear Ratio:
Date Purchased:
Engine Model:
Engine Horsepower:
Propeller Number:
Propeller Pitch:
Propeller Diameter:
Hull Identification Number (HIN):
Boat Manufacturer:
Boat Model:
Dealer:
Dealer Phone:
INTRODUCTION
2ZT350 Operation Manual
© 2008 Yanmar Marine International

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.
!
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 PRECAUTIONS
!
DANGER
Indicates a hazardous situation which, if
not avoided, will result in death or
serious injury.
!
WARNING
Indicates a hazardous situation which, if
not avoided, could result in death or
serious injury.
!
CAUTION
Indicates a hazardous situation which, if
not avoided, could result in minor or
moderate injury.
NOTICE
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.
ZT350 Operation Manual 3
© 2008 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.
Before You Operate
!
DANGER
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 this Operation
Manual before you 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.
SAFETY
4ZT350 Operation Manual
© 2008 Yanmar Marine International

During Operation and
Maintenance
!
DANGER
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.
Fire Hazard
Ensure that appropriate fire
detection and extinguishing
equipment are installed and
checked periodically for
proper operation.
Crush Hazard
ALWAYS use lifting
equipment with sufficient
capacity to lift the stern-drive.
NEVER stand under a 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.
!
WARNING
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.
SAFETY
ZT350 Operation Manual 5
© 2008 Yanmar Marine International

!
WARNING
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 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.
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 shutdown. Keep
hands and other body parts
away from hot surfaces.
SAFETY
6ZT350 Operation Manual
© 2008 Yanmar Marine International

!
WARNING
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.
!
CAUTION
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.
NEVER permit anyone to
install or operate the stern-
drive or engine without proper
training. Safety signs and
labels are additional
reminders for safe service and maintenance
techniques. Read and understand this
Operation Manual before you operate or
service the stern-drive to ensure that you
follow safe servicing practices and
maintenance procedures.
Poor Lighting Hazard
Ensure that the work area is adequately
illuminated. ALWAYS install wire cages on
portable safety lamps.
Tool Hazard
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.
SAFETY
ZT350 Operation Manual 7
© 2008 Yanmar Marine International

!
CAUTION
Slipping and Tripping Hazard
Ensure that adequate floor
space is set aside for servicing
the stern-drive. The floor
space must be flat and free of
holes.
Keep the floor free of dust, mud, spilled
liquids and parts to help prevent slipping and
tripping.
NOTICE
The safety messages that follow have
NOTICE level hazards.
It is important to perform the daily checks as
listed in this Operation Manual.
Periodic maintenance prevents unexpected
downtime, reduces the number of accidents
due to poor engine or stern-drive
performance and can help extend the life of
the engine and stern-drive.
ALWAYS be environmentally
responsible. Follow the
guidelines of the EPA or other
governmental agencies for
the proper disposal of
hazardous materials such as lubrication oil,
diesel fuel and engine coolant. Consult the
local authorities or reclamation facility.
NEVER dispose of hazardous materials by
dumping them into a sewer, on the ground
or into ground water or waterways.
Before operating the engine, check stern-
drive oil level.
If the stern-drive oil temperature is too high,
stop engine immediately and check the
stern-drive oil level and check the oil cooler
for proper coolant and water flow.
Always tighten components to the specified
torque. Loose parts can cause equipment
damage or cause it to operate improperly.
Only use replacement parts specified. Other
replacement parts may affect warranty
coverage.
NEVER attempt to modify the stern-drive’s
design or safety features.
Failure to comply may impair the stern-
drive’s safety and performance
characteristics and shorten the stern-drive’s
life. Any alterations to this stern-drive may
affect the warranty coverage of your stern-
drive.
SAFETY
8ZT350 Operation Manual
© 2008 Yanmar Marine International

NOTICE
NEVER use the stern-drive lifting eye to lift
the engine and stern-drive as an assembly.
Use the engine lifting eyes to lift the engine
and stern-drive. Only use the stern-drive
lifting eye to lift the stern-drive as a separate
component.
SAFETY
ZT350 Operation Manual 9
© 2008 Yanmar Marine International

This Page Intentionally Left Blank
SAFETY
10 ZT350 Operation Manual
© 2008 Yanmar Marine International

PRODUCT OVERVIEW
OVERVIEW
Owner / Operator
Responsibilities
The operator must, and assumes all
responsibility to:
• Read and understand the operation
manual prior to operating the stern drive;
• Perform all safety checks as necessary to
ensure safe operation;
• Comply with and follow all lubrication and
maintenance instructions and
recommendations; and
• Have an authorized Yanmar Marine
dealer / distributor perform periodic
checkups.
Conducting normal maintenance service
and replacing consumable parts as
necessary is the responsibility of the owner /
operator and necessary to provide the best
durability, performance and dependability of
the stern drive while keeping your overall
operating expenses to a minimum.
Individual operating habits and usage may
increase the frequency of performing
maintenance service condition. Monitor
conditions frequently to determine if the
maintenance intervals suggested in the
manual are frequent enough for stern drive.
New Stern-Drive Break-In:
• On the initial engine start-up, allow the
engine to idle for approximately 15
minutes while you check for proper stern-
drive function and stern-drive oil leaks.
• During the break-in period, carefully
observe stern-drive indicators (if any) for
proper stern-drive function.
• During the break-in period, check the
stern-drive oil levels frequently.
Dealer / Distributor
Responsibilities
In general, a dealer's responsibilities to the
customer include predelivery inspection
and preparation such as:
• Ensure that the vessel is properly
equipped.
• Prior to delivery, make certain that the
Yanmar stern-drive and other equipment
are in proper operating condition.
• Make all necessary adjustments for
maximum efficiency.
• Familiarize the customer with the
on-board equipment.
• Explain and demonstrate the operation of
the stern-drive and vessel.
ZT350 Operation Manual 11
© 2008 Yanmar Marine International

COMPONENT
IDENTIFICATION
0006029
(3)
(2)
(6)
(5)
(4)
(7)
(1)
Figure 1
1 – Steering System Location
2 – Transom Assembly
3 – Drive Unit
4 – Antiventilation Plate
5 – Trim Cylinder
6 – Speedometer Pitot Hole
7 – Y-CaPS Electrode
PRODUCT OVERVIEW
12 ZT350 Operation Manual
© 2008 Yanmar Marine International

Location of Serial Numbers
The serial numbers are the manufacturer's
keys to numerous engineering details which
apply to your Yanmar stern-drive. When
contacting Yanmar about service, always
specify model and serial numbers.
0006017
(2)
(1)
Figure 2
1 – Transom Assembly Serial Number 2 – Drive Unit Serial Number
PRODUCT OVERVIEW
ZT350 Operation Manual 13
© 2008 Yanmar Marine International

CORROSION PROTECTION
Galvanic Corrosion
Galvanic corrosion results whenever two or
more dissimilar metals (like those found on
the stern-drive) are submerged in a
conductive solution, such as saltwater,
polluted water or water with a high mineral
content because a chemical reaction takes
place causing electrical current to flow
between the metals. The electrical current
flow causes the metal that is most
chemically active, or anodic, to erode. If not
controlled, galvanic corrosion may corrode
stern-drive components.
Corrosion Control
It is the boat designer’s responsibility and/or
the re-powering engineer’s responsibility to
design the proper systems and equipment
to control and reduce the possibility of
galvanic corrosion.
To help control the effects of galvanic
corrosion, Yanmar Marine ZT350 stern-
drives come with several anodes and an
electronic anticorrosion system (Y-CaPS)
that protect the stern-drive in moderate
corrosive conditions. However, it is
essential that the owner/operator frequently
monitor the anodes for wear, inspect the
stern drive for corrosion and replace the
anodes often enough to provide a sacrificial
surface for the electrical current to attack.
Galvanic isolators are also available from
the aftermarket (not supplied by Yanmar) to
block stray current while still providing a path
to ground for dangerous shock currents.
The rate of corrosion depends on numerous
factors, such as:
• the number, size and location of anodes
on the stern-drive and vessel;
• the marina environment such as stray
current in the water, fresh or salt water and
use and isolation of shore power;
• improper application of marine paint or
antifouling paint;
• failure to repaint damaged areas; and
• how the vessel is bonded.
Please check with the boat builder, dealer or
other professional to determine if your
vessel and/or stern drive is adequately
protected from galvanic corrosion.
If anodes erode quickly or if signs of
corrosion are evident, the owner should take
immediate corrective action. Yanmar
recommends consulting an engineer
specializing in marine electricity and
corrosion control to determine the best way
to correct the rapid erosion of the anodes.
Shore Power
Vessels that are connected to shore power
require additional protection to prevent
destructive low voltage galvanic currents
from passing through the shore power
ground wire. Galvanic isolators are available
from the aftermarket (not supplied by
Yanmar) to block these currents while still
providing a path to ground for dangerous
shock currents. NOTICE: If the AC shore
power ground is not isolated from the
boat ground, the Y-CaPS and anodes
may be unable to neutralize the
increased galvanic potential. Corrosion
damage that results from the improper
system design or application is not
covered by the Yanmar limited warranty.
PRODUCT OVERVIEW
14 ZT350 Operation Manual
© 2008 Yanmar Marine International

Underwater Drive Coating
The lower gear case coating may be
damaged when hit by objects in the water,
or when having deposits removed from it.
The underwater coating must be inspected
at least once per year and when it is believed
that an object was hit that may have caused
damage. Repair and repaint damaged
areas immediately.
Observe the following precautions when
applying antifouling or marine paint to the
transom of the boat hull:
• ALWAYS follow the paint/coating
manufacturer's directions for surface
preparation and application.
• ALWAYS use a high quality primer and
topcoat paint specifically designed for
aluminum outboards or stern-drives.
• NEVER paint the anodes installed on the
stern-drive.
• NEVER paint the Y-CaPS reference
electrode and / or anode.
• NEVER wash the stern-drive with a high
pressure washer. This could damage the
coating on the reference wire.
• NEVER paint the stern-drive with a
material that contains copper or tin.
• NEVER paint over drain holes, anodes, Y-
CaPS or other items specified by the
anode Manufacturer.
Contact your authorized Yanmar Marine
dealer or distributor for assistance.
NOTICE: Galvanic corrosion damage,
normal maintenance and consumable
parts are not covered by the Yanmar
Limited Warranty.
Additional Protection
In addition to the corrosion protection
devices, take these steps to inhibit
corrosion:
1. Paint the stern-drive. See Touching-Up
the Stern-Drive Paint and Spray with
Corrosion Guard on page 43.
2. Spray stern-drive components on the
inside of the vessel annually with
Corrosion Guard to protect the finish
from dulling and corrosion. External
stern-drive components may also be
sprayed.
3. Keep all lubrication points, especially
the steering system, shift and throttle
linkages, well-lubricated.
4. Flush the coolant system periodically,
preferably after each use.
(4)
(3) (2)
(5)
(1)
0005989
Figure 3
1 – Gear Housing Anodic Plates
2 – Ventilation Plate Anode
3 – Y-CaPS Electrode
4 – Trim Cylinder Anodes
5 – Propeller Shaft Anodes
NOTICE: Replace anodes if eroded 50
percent or more.
PRODUCT OVERVIEW
ZT350 Operation Manual 15
© 2008 Yanmar Marine International

Gear Housing Anodic Plates
The gear housing anodic plates are installed
on the underside of the antiventilation plate.
0006016
(1)
Figure 4
1 – Gear Housing Anodic Plates
Ventilation Plate Anode
The ventilation plate anode is installed on
the front of the drive shaft housing on top of
the ventilation plate.
0006036
(1)
Figure 5
1 – Ventilation Plate Anode
Trim Cylinder Anodes
The trim cylinder anodes are installed on
each trim cylinder.
0006037
(1)
Figure 6
1 – Trim Cylinder Anodes
Propeller Shaft Anode
The propeller shaft anode is located behind
the aft propeller.
0006038
(1)
Figure 7
1 – Propeller Shaft Anode
PRODUCT OVERVIEW
16 ZT350 Operation Manual
© 2008 Yanmar Marine International