Yanmar ZT350 Series Installation Manual
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Yanmar ZT350 Series Installation Manual

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

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Summary of Contents for Yanmar ZT350 Series

  • Page 1 ZT350 series INSTALLATION MANUAL ZT350 Installation Manual P/N: 0FZTD-G00100 STERN-DRIVE...
  • Page 2 / 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:...

  • Page 3: Table Of Contents

    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 ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 4 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 ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 5 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 ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 6 This Page Intentionally Left Blank ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 7: Safety

    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, Indicates a hazardous situation which, if not operate, maintain or service Yanmar products, avoided, will result in death or serious injury.
  • Page 8 • 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.
  • Page 9 Exposure Hazard ALWAYS wear personal protective equipment including appropriate clothing, gloves, work shoes, eye and hearing protection as required by the task at hand. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 10 ALWAYS keep the electrical connectors and terminals clean. Check the electrical harnesses for cracks, abrasions, and damaged or corroded connectors. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 11 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. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 12 SAFETY This Page Intentionally Left Blank ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 13: General Information

    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 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 14: Notice To Vessel Oem & Equipment Installer

    Sales and Technical Assistance • Read and follow all safety warnings. The Yanmar dealer / distributor network is trained to NOTICE: Indicates critical information or assist with any sales or technical issues. This...

  • Page 15: Tightening Torques For Standard Bolts And Nuts

    Ex) Cortec Co. Lithium EP Grease with PTFE Shift Cable UREA Grease Water Resistant Unit Bearing (Gimbal Housing) Type NLGI #2 Ex) Rykon Premium Grease EP Power Steering Pump Dexron III Automatic Transmission Fluid Power Trim Pump ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 16: Special Tools

    If an undesirable handling To help reduce the effect of stern-lift, a Trim-In characteristic occurs when the drive unit is limiter is available for the Yanmar ZT350 trimmed in at higher speeds, the trim-in range stern-drive, as a service part.

  • Page 17: Steering Tie Bar Considerations

    Galvanic isolators are also available from the aftermarket (not supplied by It is a direct connection between the slave Yanmar) to block stray current while still providing a stern-drive and the stern-drive that is directly path to ground for dangerous shock currents.

  • Page 18: Antifouling Paint

    Figure 2-1 NOTICE: Corrosion damage that results from the improper application of marine paint or antifouling paint is not covered by the Yanmar limited warranty. Observe the following precautions when applying ( 1 ) antifouling or marine paint to the transom of the boat hull.

  • Page 19: Vessel Design

    Section 3 VESSEL DESIGN Page 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 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 20: Vessel Design Considerations

    203 mm (8 in.) on either side of the center line of the transom. • The strings should touch at the point of intersection. ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 21: Selecting An Engine Exhaust System

    Engine Exhaust Transom Transom Exhaust System Exhaust Bellows or Tube Through-the-Transom Exhaust Exhaust Cover Plate Through-the-Hull Exhaust Tube Exhaust Through-the-Propeller Engine Exhaust Exhaust Pipe See Exhaust Options on page 4-21. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 22 VESSEL DESIGN Vessel Design Considerations This Page Intentionally Left Blank ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 23: Installing Engine And Drive Unit

    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 ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 24 INSTALLING ENGINE AND DRIVE UNIT Hydraulic Connections ..............4-27 Oil Reservoir................4-27 Power Steering Hoses.............. 4-28 Installing the Drive Unit ..............4-29 Speedometer Connection............4-33 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 25: Positioning The Drive Unit

    3 – Dual Engine Crankshaft Vertical Centerlines 0006043 Figure 4-1 1 – 305 mm (12 in.) 2 – Identical Side Marks 3 – Compass Arc 4 – Arc Intersection Points 5 – Crankshaft Vertical Centerline ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 26: Finding The Crankshaft Horizontal Centerline (X-Dimension)

    • Use a clear water inlet hose to monitor incoming water while watching the engine temperature gauge to prevent the engine from overheating. NOTICE: Damage to Yanmar products caused by a crankshaft horizontal centerline that is too high, will not be covered by Yanmar warranty.
  • Page 27 ( 3 ) ( 2 ) X-dimension. 0006047B Figure 4-7 1 – Vertical Centerline 2 – X-Dimension that corresponds to the transom angle selected from the chart. 3 – Crankshaft Horizontal Centerline ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 28: Cutting The Vessel Transom

    Figure 4-9 Use the template or the Transom Cutout and Drill Fixture to drill and cut the vessel transom. These items are available separately from Yanmar Marine International. 1. Follow the instructions that are indicated on the template or provided with the drilling fixture.

  • Page 29: Checking The Transom Thickness

    See Vessel Angle 10°-16° (13° Ideal) Design Considerations on page 3-2. Measured in transom assembly mounting area. Figure 4-12 ( 2 ) ( 1 ) 0006051 Figure 4-12 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 30: Installing The Transom Assembly

    Figure 4-14 to avoid Tighten in small increments and go around the stressing the wire when the steering lever moves. pattern several times until the proper torque is achieved. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 31 ( 5 ) 0006053 Figure 4-14 1 – Locknuts and Flat Washers (8 ea.) 4 – Transom Plate Bonding Wire 2 – Steering Lever Bonding Wire 5 – Torque Sequence 3 – Bolt ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 32: Connecting The Speedometer Pickup

    1 – Connector (Seawater) speedometer hose come in contact with the 2 – J-Clip steering system components, the engine 3 – Gasket (Connector) coupler or the drive shaft. 4 – Bolt and Lock Washer ZT350 Installation Manual 4-10 © 2007 Yanmar Marine International...

  • Page 33: Alternate Seawater Pickup

    1 – Bolts (1) (2) 2 – Lock Washer 3 – Plate (Seawater Inlet) 4 – Gasket 0006057 Figure 4-18 1 – Pliers 2 – Ring 3 – Insert 4 – Gimbal Housing ZT350 Installation Manual 4-11 © 2007 Yanmar Marine International...

  • Page 34: Connecting The Inlet Water Hose

    2. Discard the loose hose piece. 3. Secure the trim sender limit switch wires and speedometer hose to the remaining section of water hose using the existing tie strap and clip. ZT350 Installation Manual 4-12 © 2007 Yanmar Marine International...

  • Page 35: Connecting The Oil Reservoir Hose

    (seawater), or plate (seawater inlet) if equipped. The release button must not contact the connector (seawater), or plate (seawater inlet), if equipped. ( 2 ) 0006063 Figure 4-24 1 – Oil Reservoir Hose 2 – Hose J-Clip ZT350 Installation Manual 4-13 © 2007 Yanmar Marine International...

  • Page 36: Installing The Oil Reservoir

    • Use fasteners that are appropriate for the mounting surface to install the mounting bracket. Figure 4-27 ( 1 ) ( 2 ) 0006066 Figure 4-27 1 – Mounting Bolt Location 2 – Shift Plate ZT350 Installation Manual 4-14 © 2007 Yanmar Marine International...

  • Page 37: Installing The Steering System

    7. Torque the pivot bolts. ( 2 ) ( 1 ) Upper and Lower Pivot Bolt Torque N·m lb-ft 0006068 Figure 4-29 1 – Lock Tab Washers 2 – Upper and Lower Pivot Bolt ZT350 Installation Manual 4-15 © 2007 Yanmar Marine International...
  • Page 38 Figure 4-33 ( 2 ) ( 1 ) ( 3 ) ( 4 ) 0006072 Figure 4-33 1 – Clevis 2 – Steering Lever 3 – Cotter Pin 4 – Clevis Pin ZT350 Installation Manual 4-16 © 2007 Yanmar Marine International...
  • Page 39 Never fasten any items to the steering cable and / or the outer casing. Figure 4-34 ( 1 ) 0006073 Figure 4-34 1 – Steering Cable and Outer Casing ZT350 Installation Manual 4-17 © 2007 Yanmar Marine International...

  • Page 40: Connecting The Steering Cables

    UREA Grease Water Resistant Type NLGI #2 Where Used Steering Cable End Cable Coupler Nut Torque N·m lb-ft ZT350 Installation Manual 4-18 © 2007 Yanmar Marine International...
  • Page 41 1 – Clevis Pin 5 – Cotter Pin 2 – Spool Barrel Cable Guide Tube 6 – Clevis 3 – Cable Coupler Nut 7 – Steering Cable End 4 – Steering Cable ZT350 Installation Manual 4-19 © 2007 Yanmar Marine International...

  • Page 42: Installing The Power Trim Pump

    1 – Trim Limit Switch Wires Figure 4-36 2 – Wire Retainer and Tie Strap (obtain locally) 1 – Hydraulic Hose (UP hose) 2 – Quick Connect Fittings 3 – Hydraulic Hose (DOWN hose) ZT350 Installation Manual 4-20 © 2007 Yanmar Marine International...

  • Page 43: Exhaust Options

    1 – Gimbal Housing Exhaust Tube Mating N·m lb-ft Surface 2 – O-Ring Install the engine exhaust tube as shown in Figure 4-40. Figure 4-39 ( 1 ) 0006079 Figure 4-40 1 – Engine Exhaust Tube ZT350 Installation Manual 4-21 © 2007 Yanmar Marine International...

  • Page 44: Installing The Engine

    Make proper alterations to the boat stringer (structure) height to obtain the 6 mm (1/4 in.) dimension. 0006085 Figure 4-42 1 – Steel Washer (obtain locally) 2 – Corrected Engine Mount 3 – Hard Rubber Washer ZT350 Installation Manual 4-22 © 2007 Yanmar Marine International...

  • Page 45: Aligning The Engine

    Figure 4-44 CAUTION! Avoid drive unit damage. Use the Yanmar Alignment Tool ONLY. Alignment tools ( 1 ) other than the Yanmar Alignment Tool may ( 2 ) cause damage to the gimbal bearing, the engine coupler, or both. 1. Attempt to insert the solid end of the Alignment Tool through the gimbal bearing and into the engine coupler splines.
  • Page 46 This will allow for easier loosening in (a) Set the engine on the stringers. the future. (b) Relieve the hoist tension. Note: Yanmar recommends that the shipping (c) Disconnect the sling from the engine lifting hardware remain on the transom eyes.

  • Page 47: Electrical Connections

    Part Number Electrical Connections Obtain Locally 0006088 Figure 4-47 1 – From the engine harness. (Refer to the appropriate Engine and Control System Installation Manual.) 2 – From the gimbal housing. ZT350 Installation Manual 4-25 © 2007 Yanmar Marine International...
  • Page 48 4 – Y-CaPS Electrode Connector 2 – RED Wire - To the positive (+) battery 5 – BROWN Wire - From the electrode on the terminal. transom assembly. ZT350 Installation Manual 4-26 © 2007 Yanmar Marine International...

  • Page 49: Hydraulic Connections

    3 – Gimbal housing hose assembly 3. Fasten the quick connect fitting between gimbal 7. Secure the oil reservoir hose with cable ties. housing hose assembly and the oil reservoir hose assembly. ZT350 Installation Manual 4-27 © 2007 Yanmar Marine International...

  • Page 50: Power Steering Hoses

    2. Ensure that the quick connect fittings are securely engaged. 3. Position the hoses as illustrated. Figure 4-51 0006093 Figure 4-52 1 – Return Hose 2 – Pressure Hose ZT350 Installation Manual 4-28 © 2007 Yanmar Marine International...

  • Page 51: Installing The Drive Unit

    2. Lubricate the drive unit pilot, U-joint shaft O-rings, and drive shaft splines. 0006096 Figure 4-55 1 – U-Joint Bellows 2 – O-Ring Seals Lithium Grease with PTFE Where Used Part Number O-Ring Seals Obtain Locally ZT350 Installation Manual 4-29 © 2007 Yanmar Marine International...
  • Page 52 5. Pull the shift cable out as far as it moves by hand. Figure 4-55 0006100 Figure 4-59 0006098 Figure 4-57 1 – Shift Cable ZT350 Installation Manual 4-30 © 2007 Yanmar Marine International...
  • Page 53 (e) Secure the drive unit to the bell housing with 5 flat washers and 6 locknuts. 0006103A Figure 4-62 1 – Rubber Bushing (4 ea.) 2 – Large Inner Diameter Flat Washer (2 ea.) 3 – Aft Anchor Pin ZT350 Installation Manual 4-31 © 2007 Yanmar Marine International...
  • Page 54 Obtain Locally 15. Open the oil valve screw in the drive shaft housing before the engine is operated the first time. Figure 4-62 0006363A Figure 4-64 1 – Oil Valve Screw ZT350 Installation Manual 4-32 © 2007 Yanmar Marine International...

  • Page 55: Speedometer Connection

    19. Install the oil reservoir cap. Ensure that the rubber gasket is inside the reservoir cap. Do not over-tighten the cap. 20. Recheck the oil level after the first use. 0006366 Figure 4-68 1 – Handle ZT350 Installation Manual 4-33 © 2007 Yanmar Marine International...
  • Page 56 INSTALLING ENGINE AND DRIVE UNIT Installing the Drive Unit This Page Intentionally Left Blank ZT350 Installation Manual 4-34 © 2007 Yanmar Marine International...
  • Page 57 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 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 58: Remote Controls

    WARNING! Failure to use a steering cable locking device could cause a loss of steering. Yanmar recommends using the steering cable with a self-locking coupler nut. Use an external locking device if using a steering cable that does not have a self-locking coupler nut.
  • Page 59 Travel each side of mid-travel position - 102 Fitting mm (4 in.) minimum, 114 mm (4-1/2 in.) 8 – 9.5 mm (3/8 in.) maximum. 9 – 9.8 mm (3/8 in.) Diameter Through Hole (chamfered each side) ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 60: Installation Of Steering Cable

    CAUTION! Be sure the steering cable is correctly installed. Verify that all cable bends, free motion of cable housing and restraints of the cable are within specifications. Incorrect installation of the steering cable could result in erratic or loss of steering. ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 61: Throttle And Shift Cables

    The front propeller on the drive unit is always LH throttle operation. If a control other than Yanmar - Rotation and the rear propeller is always RH Teleflex is used, a shift control cable must be (at the Rotation.

  • Page 62: Shift Cable Installation And Adjustment

    4 – Drive Unit Shift Cable Figure 5-5 0006369 Figure 5-5 1 – Lock Nut 2 – 180.6 mm (7-7/64 in) - The control cable barrel center and the center of the attachment hole. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 63 This distance should be 3. Remove the shift control cable end guide from 155.6 ± 1.5 mm (6-1/8 ± 1/16 in). the shift lever by removing the clevis pin. ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 64 13. If the distance does not satisfy the dimension, loosen the shift lever stud and slide the stud up or down, until the distance is within the stated dimension. 14. When the adjustment is correct, tighten the stud. ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 65: Troubleshooting Shift Problems

    0006377 Figure 5-13 1 – Lubrication Point Lithium Grease with PTFE Where Used Part Number Shift Cable End Obtain Locally ZT350 Installation Manual © 2007 Yanmar Marine International...
  • Page 66 REMOTE CONTROLS Shift Cable Installation and Adjustment This Page Intentionally Left Blank ZT350 Installation Manual 5-10 © 2007 Yanmar Marine International...
  • Page 67 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 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 68: Pre-Delivery Preparation

    4. Connect the Power Trim pump RED (+) battery cable to the positive (+) battery terminal. 5. Connect the Power Trim pump BLACK (-) battery cable to the negative (-) battery terminal. ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 69: Check The Power Trim Pump Fluid

    MIN and MAX lines on the reservoir (Figure 6-2, (2)). Figure 6-2 0006013 Figure 6-3 1 – MIN Line 0006012 Figure 6-2 1 – Reservoir 2 – MIN and MAX Lines ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 70: Fill The Power Trim Pump Fluid

    Where Used contaminated with water or debris. Oil Reservoir Contact your authorized Yanmar Marine dealer or distributor if the power trim fluid Note: The oil level will rise and fall during needs to be changed. operation. Check the oil level before 1.

  • Page 71: Fill The Stern-Drive With Oil

    Oil Reservoir Damage to the stern-drive may occur because of lack of lubrication. Contact your authorized Yanmar 3. When replacing the cap, ensure that the rubber Marine dealer or distributor.

  • Page 72: Propeller Selection

    Problems associated with propellers include ventilation, cavitation and blow-out. These problems have similar symptoms and are best diagnosed by an expert. If a propeller related problem develops, see your Yanmar Marine dealer or distributor. ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 73: General Propeller Installations

    UREA Grease Water Resistant Type NLGI #2 Where Used Part Number Propeller Shaft Splines Obtain Locally ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 74: Installing The Propellers

    2 – Rear Propeller 6 – Front Propeller Thrust Hub 3 – Rear Propeller Thrust Hub 7 – Propeller Shaft Anode 4 – Front Propeller Nut 8 – Propeller Shaft Anode Bolt and Washer ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 75: Removing The Propeller

    20 hours. Rear Propeller Nut Torque N·m lb-ft 8. Install the propeller shaft anode bolt with a washer. Torque the bolt. Propeller Shaft Anode Bolt Torque N·m lb-ft ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 76: Test Preparations

    6. Test the audio warning system, if equipped. Figure 6-9 0006384 Figure 6-9 1 – Typical Flushing Attachment (Obtain Locally) 2 – Water Hose 3. See Test Preparations on page 6-10 for other checks. ZT350 Installation Manual 6-10 © 2007 Yanmar Marine International...

  • Page 77: In-Water Testing

    2. See Test Preparations on page 6-10 for other cable FULLY EXTENDED. See Steering Helm checks. and Cable on page 5-2 for proper steering cable dimensions. 8. Turn the engine off. ZT350 Installation Manual 6-11 © 2007 Yanmar Marine International...
  • Page 78 10. Restart the engine and observe the drive unit.If drive unit creeps, an external tension may exist on steering cable. 6-12 ZT350 Installation Manual © 2007 Yanmar Marine International...

  • Page 79: Cold Weather (Freezing Temperature), Seasonal And Extended Storage

    Store the drive unit in the full DOWN (IN) position. Yanmar dealer / distributor. Damage caused by freezing is not covered by the Yanmar Warranty. Use a piece of wire to check the water drain passages in the drive unit to ensure that they are open.
  • Page 80 PRE-DELIVERY Pre-Delivery Preparation This Page Intentionally Left Blank ZT350 Installation Manual 6-14 © 2007 Yanmar Marine International...

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