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Yamaha Z300A Supplementary Service Manual

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

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Summary of Contents for Yamaha Z300A

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

  • Page 2: Important Information

    • Do not use gasoline mixed with oil during the break-in period or anytime thereafter. YAMALUBE 2-STROKE OUTBOARD OIL IS RECOMMENDED. 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.

  • Page 3: Table Of Contents

    Contents General information INFO Specifications SPEC Periodic checks and adjustments Fuel system FUEL Power unit POWR Lower unit LOWR Bracket unit BRKT – Electrical systems ELEC Troubleshooting TRBL SHTG Index...

  • Page 4: General Information

    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 ....................

  • Page 5: Specifications

    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 ..................

  • Page 6: Power Unit

    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) ...............

  • Page 7: Electrical Systems

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

  • Page 8: Gen Info

    INFO General information How to use this manual 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.

  • Page 9: Spec

    7 Apply 2-stroke outboard motor oil A Apply corrosion resistant grease 8 Apply gear oil (Yamaha grease D) 9 Apply water resistant grease (Yamaha grease A) B Apply low temperature resistant grease 0 Apply molybdenum disulfide grease (Yamaha grease C)

  • Page 10: Identification

    INFO General information Identification Applicable models This manual covers the following models. Applicable models Z300AETO, LZ300AETO Serial number outboard motor serial number stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Approved Starting...

  • Page 11: Features And Benefits

    Identification / Features and benefits Features and benefits Crankcase and cylinders The following modifications have been adopted to increase the output as compared to the Z250 power unit. (*1) • The material of the crankshaft has been changed to a high-grade clean steel to increase dura- bility against stress.
  • Page 12 INFO General information • Newly-forged lightweight pistons with a hard anodic coating on the piston pin boss have been adopted to increase durability and reduce the inertia mass of the pistons. • The top piston rings are made of steel and are ion-plated to increase durability. •...

  • Page 13: Intake System

    Features and benefits • The anti-corrosion anodes in the cooling water passages of the cylinder block are larger to increase reliability and performance. 1 Anodes Intake system The openings in the throttle bodies were enlarged to a 46 mm (1.81 in) diameter to increase power output.
  • Page 14 INFO General information An oil groove has been added to each reed valve seat. Oil in the groove helps to reduce impact when the reed valve contacts the reed valve seat. The dimensions of the reed valve assembly are the same as those for the Z250. 1 Oil groove 2 Identification mark: 6D0 The oil pump has been newly designed to obtain optimal oil supply.

  • Page 15: Upper Case

    Features and benefits Upper case Water jackets have been incorporated to both sides of the lower part of the upper case. This struc- ture reduces the heat transfer to the upper case from the exhaust gas. The cooling water discharged from the water pump is supplied to the upper case around the muffler from the pipe connected to the exhaust guide, flows down into the water jacket, and then drains to the lower case.

  • Page 16: Lower Case

    INFO General information Lower case The propeller shaft housing and the ring are newly designed to reduce the exhaust back-pressure and cool the propeller damper. Cooling water is taken in from the front of the trim tab, flows through the pipe in the lower case and propeller shaft housing, and then is supplied directly to the propeller boss.

  • Page 17: Ecm (Electronic Control Module)

    VZ225 (Z250H) 60Y-01 VZ250 (Z250F) 60X-01 60V-01 Z250 (Z250D) Ë 60V-21 Z300 (Z300A) 6D0-00 S6D01100 È Model Ê Note É ECM identification Ë For Brazil Wiring harness connector holder A wiring harness connector holder has been added to the side of bottom cowling to secure the 10- pin main harness, remote oil tank harness, warning indicator harness, and trim meter harness.

  • Page 18: Propeller Selection

    INFO General information Propeller selection Selection When the engine speed is at the full throttle The performance of a boat and outboard operating range (4,500–5,500 r/min), the motor will be critically affected by the size ideal propeller for the boat is one that pro- and type of propeller you choose.

  • Page 19: Predelivery Checks

    Propeller selection / Predelivery checks Predelivery checks Checking the gear oil level 1. Check the gear oil level. To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel.

  • Page 20: Checking The Outboard Motor Mounting Height

    INFO General information Checking the outboard motor mounting height 1. Check that the anti-cavitation plate is aligned with the bottom of the boat. If the mounting height is too high, cavitation will occur and propulsion will be reduced. Also, the engine speed will increase abnormally and cause the engine to overheat.

  • Page 21: Checking The Steering System

    Predelivery checks Checking the steering system Checking the power trim and tilt 1. Check the steering friction for proper system adjustment. 1. Check that the outboard motor tilts up and down smoothly when operating the 2. Check that steering operates power trim and tilt unit.

  • Page 22: Checking The Cooling Water Pilot Hole

    INFO General information Checking the cooling water pilot hole 1. Check that cooling water is discharged from the cooling water pilot hole. È S60V1120 È Hour After test run 1. Check for water in the gear oil. S60V3140 2. Check for fuel leakage in the cowling. Test run 1.

  • Page 23: General Specifications

    Predelivery checks / General specifications General specifications Model Item Unit Z300AETO LZ300AETO Dimension Overall length mm (in) 868 (34.2) Overall width mm (in) 568 (22.4) Overall height mm (in) 1,830 (72.0) mm (in) 1,957 (77.0) — Boat transom height mm (in) 635 (25.0) mm (in) 762 (30.0)
  • Page 24 SPEC Specifications Model Item Unit Z300AETO LZ300AETO Fuel and oil Fuel type Regular unleaded gasoline (*1) Fuel minimum rating (*2) Engine oil YAMALUBE 2-stroke outboard motor oil Engine oil tank capacity Oil tank L (US gal, 1.2 (0.32, 0.26) lmp gal) Remote oil tank L (US gal, 10.5 (2.77, 2.31)

  • Page 25: Maintenance Specifications

    General specifications / Maintenance specifications Maintenance specifications Power unit Model Item Unit Z300AETO LZ300AETO Power unit Minimum compression 580 (5.8, 84) pressure* (kgf/cm , psi) Cylinder heads Warpage limit mm (in) 0.1 (0.004) (lines indicate straightedge position) Cylinders Bore size mm (in) 93.000–93.020 (3.6614–3.6622) Bore size limit...
  • Page 26 SPEC Specifications Model Item Unit Z300AETO LZ300AETO Piston rings Top ring Dimension B mm (in) 2.05 (0.0807) Dimension T mm (in) 3.00–3.20 (0.118–0.126) End gap mm (in) 0.30–0.50 (0.0118–0.0197) Side clearance mm (in) 0.02–0.06 (0.0008–0.0024) 2nd piston ring Dimension B mm (in) 2.05 (0.0807) Dimension T...

  • Page 27: Lower Unit

    Maintenance specifications Lower unit Model Item Unit Z300AETO LZ300AETO Gear backlash Pinion-to-forward gear mm (in) 0.12–0.44 0.30–0.62 (0.0047–0.0173) (0.0118–0.0244) Pinion-to-reverse gear mm (in) 0.61–0.90 (0.0240–0.0354) Pinion shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Forward gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Reverse gear shims 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50 Propeller shaft shims...
  • Page 28 SPEC Specifications Model Item Unit Z300AETO LZ300AETO Ω (*1) Pulser coil resistance 294–398 (W/R, W/B, W/Y, W/G, W/L, W/Br – B) Throttle position sensor Input voltage (O – R) Output voltage (P – O) 0.58–0.62 at engine idle speed (0.48–0.52 at throttle valve full closed) Crank position sensor output peak voltage (G/L –...
  • Page 29 Maintenance specifications Model Item Unit Z300AETO LZ300AETO Starter motor Type Sliding gear Output Cranking time limit Second Brushes Standard length mm (in) 15.5 (0.61) Wear limit mm (in) 9.5 (0.37) Commutator Standard diameter mm (in) 29.0 (1.14) Wear limit mm (in) 28.0 (1.10) Mica Standard undercut...

  • Page 30: Dimensions

    SPEC Specifications Dimensions Exterior mm (in) X: 1,152 (45.4) 628 (24.7) U: 1,270 (50.0) 211 (8.3) 645 (25.4) 75 (3.0) 245 (9.6) X: 48 (1.9) U: 55 (2.2) 677 (26.7) S60V2010 6D03F1X...
  • Page 31 Maintenance specifications Clamp bracket mm (in) 180 (7.1) 180 (7.1) 163.5 (6.4) 163.5 (6.4) 79 (3.1) 13 (0.5) 13 (0.5) 125.4 (4.9) 125.4 (4.9) S60V2020 6D03F1X...

  • Page 32: Tightening Torques

    SPEC Specifications Tightening torques Specified torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Fuel system Fuel pump screw Emergency switch — High pressure fuel pump bolt 17.0 Power unit Negative battery terminal nut (M8) Drive belt tensioner bolt 28.8 Starter motor bolt 21.4...
  • Page 33 Tightening torques Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Shift cut switch mounting screw Spark plug 18.4 Positive battery terminal nut (M8) Thermostat cover bolt Throttle body mounting bolt and nut Power unit mounting bolt 23.6 Lower unit (regular rotation model) Exhaust guide bolt 23.6...

  • Page 34: General Torques

    SPEC Specifications Tightening torques Part to be tightened Thread size N·m kgf·m ft·lb Power trim and tilt unit Blind plug — Gear pump housing mounting screw Gear pump housing bolt Trim down spring screw Main valve — Manual valve — PTT motor unit mounting bolt 14.0 Oil pipe...

  • Page 35: Special Service Tools

    Tightening torques / Special service tools Special service tools Leakage tester Shift rod push arm 90890-06840 90890-06052 Flywheel holder Bearing housing puller claw L 90890-06522 90890-06502 Pinion height gauge Stopper guide plate 90890-06710 90890-06501 Fixing plate Center bolt 90890-06711 90890-06504 Digital caliper Backlash indicator 90890-06704...
  • Page 36 Periodic checks and adjustments Magnet base plate Ball bearing attachment 90890-07003 90890-06657 Dial gauge set Driver rod LL 90890-01252 90890-06605 Magnet base B Bearing outer race attachment 90890-06844 90890-06628 Needle bearing attachment Bearing outer race puller assembly 90890-06653, 90890-06654 90890-06523 Driver rod L3 Driver rod SS 90890-06652...
  • Page 37 Special service tools PTT oil pressure gauge assembly 90890-06580 PTT oil pressure gauge adapter 90890-06581 Diagnostic flash indicator B 90890-06865 6D03F1X...

  • Page 38: Maintenance Interval Chart

    Periodic checks and adjustments Maintenance interval chart Use the following chart as a guideline for general maintenance. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Initial Every Item Remarks 10 hours 50 hours 100 hours 200 hours (1 month) (3 months)

  • Page 39: Oil Injection System

    Maintenance interval chart / Oil injection system / Lower unit Oil injection system Lower unit Adjusting the oil pump link rod Checking the lower unit for air 1. Loosen the locknut 1 and then discon- leakage nect the oil pump link rod 2. 1.

  • Page 40: General

    Periodic checks and adjustments General Lubricating the outboard motor 1. Apply water resistant grease to the areas shown. S60V3430 6D03F1X...
  • Page 41 General S6D03010 NOTE: Apply grease to the grease nipple until it flows from the bushings a. 2. Apply low temperature resistant grease to the areas shown. S60V3440 3. Apply corrosion resistant grease to the areas shown. 4. Apply injector grease to the areas shown. 6D03F1X...

  • Page 42: Fuel Filter

    FUEL Fuel system Fuel filter · · · m (0.8 kgf m, 5.9 ft S6D04010 Part name Q’ty Remarks M6 × 16 mm Bolt Washer Holder M6 × 14 mm Bolt Collar Grommet Bracket M6 × 25 mm Bolt Fuel hose Fuel hose O-ring Not reusable...

  • Page 43: Power Unit

    Fuel filter / Power unit Power unit · · · 32 N m (3.2 kgf m, 23.6 ft S6D05010 Part name Q’ty Remarks Apron M6 × 16 mm Bolt Screw grommet ø4 × 16 mm Screw Hose Hose Plastic tie Not reusable Joint Joint...

  • Page 44: Removing The Power Unit

    POWR Power unit Removing the power unit NOTE: It is recommended to loosen the flywheel magnet nut before removing the power unit to improve working efficiency. 1. Disconnect the battery leads 1. 6. Remove the bracket 8 and disconnect the trim sensor coupler (or connector) 9. 2.
  • Page 45 Power unit 9. Remove the apron B and the hose joint assembly C. 10. Remove the bolts D, then the power unit. 11. Remove the shift rod assembly E and gasket F. S6D05070 6D03F1X...

  • Page 46: Crankcase

    POWR Power unit Crankcase · · · 11 N m (1.1 kgf m, 8.1 ft · · · 11 N m (1.1 kgf m, 8.1 ft · · · 11 N m (1.1 kgf m, 8.1 ft 10 14 S6D05080 Part name Q’ty Remarks...

  • Page 47: Removing The Crankcase Covers

    Crankcase Removing the crankcase covers Installing the power unit 1. Disconnect the hoses from the crank- 1. Clean the power unit mating surface, and then install new dowels 1, a new gasket case covers. 2, and the shift rod assembly 3. 2.
  • Page 48 POWR Power unit 3. Install the hose joint assembly 6 and the apron 7. PTT motor lead bolt: 4 N·m (0.4 kgf·m, 3.0 ft·lb) 8. Install the bracket B and connect the trim sensor coupler (or connector) C. 4. Connect the PTT switch coupler and the shift lever 8.
  • Page 49 Crankcase 11. Connect the shift cable F and throttle cable G, and then adjust their lengths. NOTE: Align the marks a on the pointer H, which you made during disassembly. 12. Install the Woodruff key and flywheel magnet. 15. Install all removed parts. 13.

  • Page 50: Propeller Shaft Housing (Regular Rotation Model)

    LOWR Lower unit Propeller shaft housing (regular rotation model) Part name Q’ty Remarks Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Propeller shaft Washer Reverse gear Reverse gear shim — Ball bearing Not reusable O-ring...
  • Page 51 Propeller shaft housing (regular rotation model) Part name Q’ty Remarks Dowel Grease nipple Rubber seal O-ring Not reusable Needle bearing Oil seal Not reusable Ring M8 × 20 mm Bolt M8 × 33 mm Bolt Cooling water inlet cover Screw 6D03F1X...

  • Page 52: Shimming (Regular Rotation Model)

    LOWR Lower unit Shimming (regular rotation model) 65.0 B1 39.4 41.0 S6D06020 6D03F1X...

  • Page 53: Selecting The Pinion Shims

    Shimming (regular rotation model) Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown.

  • Page 54: Backlash (Regular Rotation Model)

    LOWR Lower unit 5. Calculate the pinion shim thickness (T3) Example: as shown in the examples below. If “T3” is 0.68 mm, then the pinion shim is 0.65 mm. If “T3” is 0.70 mm, then the pinion shim is 0.68 mm. Backlash (regular rotation model) Measuring the forward and reverse...
  • Page 55 Shimming (regular rotation model) / Backlash (regular rotation model) Bearing housing puller claw L 1: Forward gear Shim thickness backlash 90890-06502 Stopper guide plate 2: 90890-06501 Less than To be decreased by Center bolt 3: 90890-06504 (0.28 – M) × 0.81 0.12 mm (0.0047 in) More than To be increased by...
  • Page 56 LOWR Lower unit 10. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction. Reverse gear backlash: 0.61–0.90 mm (0.0240–0.0354 in) 11. Add or remove shim(s) if out of specifica- tion.

  • Page 57: Propeller Shaft Housing (Counter Rotation Model)

    Backlash (regular rotation model) / Propeller shaft housing (counter rotation model) Propeller shaft housing (counter rotation model) Part name Q’ty Remarks Water pipe Rubber seal Rubber seal Shift rod joint Ball Slider Shift plunger Dog clutch Cross pin Spring Forward gear Forward gear shim —...
  • Page 58 LOWR Lower unit Part name Q’ty Remarks Propeller shaft shim — O-ring Not reusable Propeller shaft housing Dowel Grease nipple Rubber seal O-ring Not reusable Needle bearing Oil seal Not reusable Ring M8 × 20 mm Bolt M8 × 33 mm Bolt Cooling water inlet cover Screw...

  • Page 59: Drive Shaft And Lower Case (Counter Rotation Model)

    Propeller shaft housing (counter rotation model) / Drive shaft and lower case (counter rotation model) Drive shaft and lower case (counter rotation model) Part name Q’ty Remarks Drive shaft Cover Oil seal Not reusable M8 × 25 mm Bolt Drive shaft housing Needle bearing O-ring Not reusable...
  • Page 60 LOWR Lower unit Part name Q’ty Remarks Thrust bearing Needle bearing Not reusable Reverse gear 6D03F1X...

  • Page 61: Disassembling The Reverse Gear

    Drive shaft and lower case (counter rotation model) Disassembling the reverse gear CAUTION: 1. Remove the needle bearing from the Add or remove shim(s), if necessary, if reverse gear using a chisel. replacing the forward gear or lower case. Ball bearing attachment 3: 90890-06657 Driver rod LL 4: 90890-06605 3.
  • Page 62 LOWR Lower unit 5. Install the new needle bearing into the reverse gear to the specified depth. Needle bearing attachment 7: 90890-06653 Driver rod SS 8: 90890-06604 Depth b: 6.75–7.25 mm (0.266–0.285 in) 6. Install the thrust bearing and reverse gear into the lower case.

  • Page 63: Shimming (Counter Rotation Model)

    Drive shaft and lower case (counter rotation model) / Shimming (counter rotation model) Shimming (counter rotation model) 65.0 B1 38.4 47.5 T´4 S6D06150 6D03F1X...

  • Page 64: Selecting The Pinion Shims

    LOWR Lower unit Selecting the pinion shims 1. Install the special service tools onto the drive shaft 1. Digital caliper 4: 90890-06704 4. Turn the thrust bearing 5 two or three times to seat the drive shaft housing 6, and then measure the housing height (M3) as shown.

  • Page 65: Backlash (Counter Rotation Model)

    Shimming (counter rotation model) / Backlash (counter rotation model) Backlash NOTE: (counter rotation model) “P” is the deviation of the lower case dimen- Measuring the forward and reverse sion from standard. The “P” mark a is gear backlash stamped on the trim tab mounting surface of the lower case in 0.01 mm units.
  • Page 66 LOWR Lower unit 5. Set the lower unit upside down. 8. Remove the special service tools from the propeller shaft. NOTE: Install the dial gauge so that the plunger a 9. Turn the shift rod to the reverse position contacts the mark b on the backlash indica- c with the shift rod push arm.
  • Page 67 Backlash (counter rotation model) 13. Turn the shift rod to the reverse position c with the shift rod push arm. 14. Slowly turn the drive shaft clockwise and counterclockwise and measure the back- lash when the drive shaft stops in each direction.

  • Page 68: Bottom Cowling

    BRKT Bracket unit Bottom cowling 15 14 11 10 S6D07010 Part name Q’ty Remarks Bottom cowling Rubber seal Grommet M6 × 16 mm Bolt Bracket Cowling lock lever Bushing Plate M6 × 30 mm Bolt Wave washer Lever Washer M6 × 16 mm Bolt Spring Hook...
  • Page 69 Bottom cowling 15 14 11 10 S6D07010 Part name Q’ty Remarks Holder Grommet Holder M6 × 25 mm Bolt Retaining plate M6 × 25 mm Bolt M6 × 16 mm Bolt Cable holder Grommet Power trim and tilt switch M6 × 20 mm Bolt Bracket Bracket...
  • Page 70 BRKT Bracket unit 15 14 11 10 S6D07010 Part name Q’ty Remarks Gasket Not reusable Cover M6 × 20 mm Bolt Cover Ground lead Rubber trim 6D03F1X...

  • Page 71: Upper Case, Steering Arm, Swivel Bracket, And Clamp Brackets

    Bottom cowling / Upper case, steering arm, swivel bracket, and clamp brackets Upper case, steering arm, swivel bracket, and clamp brackets Part name Q’ty Remarks Upper case assembly Cover Ground lead M6 × 10 mm Bolt M6 × 25 mm Bolt Adapter Dowel...
  • Page 72 BRKT Bracket unit Part name Q’ty Remarks Bushing Steering arm Washer Washer Grommet 6D03F1X...
  • Page 73 Upper case, steering arm, swivel bracket, and clamp brackets Part name Q’ty Remarks Upper case Dowel Upper mount Washer Washer Washer M14 × 190 mm Bolt Bracket Muffler assembly Gasket Not reusable Mount housing Ground lead Washer Washer Lower mount M10 ×...
  • Page 74 BRKT Bracket unit Part name Q’ty Remarks M8 × 30 mm Bolt Gasket U-transom model Not reusable Muffler U-transom model M6 × 35 mm / U-transom model Bolt M10 × 45 mm Bolt M14 × 205 mm Bolt Circlip Bushing 6D03F1X...
  • Page 75 Upper case, steering arm, swivel bracket, and clamp brackets Part name Q’ty Remarks Muffler Exhaust manifold Gasket Not reusable Lower exhaust guide Gasket Not reusable Upper exhaust guide Flushing hose Plastic tie Not reusable Joint Hose Rubber seal Pipe Rubber seal M8 ×...

  • Page 76: Power Trim And Tilt Unit

    BRKT Bracket unit Power trim and tilt unit Battery Checking the hydraulic pressure PTT motor lead terminal 1. Check the hydraulic pressure. Check the Light green (Lg) internal parts if out of specification. Down Sky blue (Sb) 2. Fully extend the power trim and tilt rams. Hydraulic pressure (down): 3.
  • Page 77 Power trim and tilt unit NOTE: 14. Remove the oil pressure gauge 2. Wrap the removed pipe joint b in a rag. 15. Install the pipe joint b, and then tighten the pipe joints to the specified torque. PTT oil pressure gauge assembly: 90890-06580 Pipe joint 3: 15 N·m (1.5 kgf·m, 11.1 ft·lb)
  • Page 78 BRKT Bracket unit 18. If necessary, add fluid of the recom- mended type to the correct level. NOTE: If the fluid is at the correct level, the fluid should overflow out of the filler hole when the cap is removed. Recommended power trim and tilt fluid: ATF Dexron II...

  • Page 79: Electrical Components

    Power trim and tilt unit / Electrical components Electrical components Port view S6D08010 1 Throttle position sensor 9 Electric fuel pump 2 Emergency switch 3 Pulser coil 4 Oil level sensor 5 Stator coil 6 Water detection switch 7 Atmospheric pressure sensor 8 Electric oil pump 6D03F1X...

  • Page 80: Top View

    – ELEC Electrical systems Top view S6D08020 1 Ignition coil A Engine temperature sensor 2 Fuel injector 3 Spark plug 4 Oil level sensor 5 Emergency switch 6 Throttle position sensor 7 Power trim and tilt switch 8 Shift position switch 9 Shift cut switch 0 Crank position sensor 6D03F1X...

  • Page 81: Self-Diagnosis

    Electrical components / Self-diagnosis Self-diagnosis Diagnosing the electronic control system 1. Connect the special service tool to the outboard motor as shown. • Trouble code indication Example: The illustration indicates code number 23. a: Light on, 0.33 second b: Light off, 4.95 seconds c: Light off, 0.33 second d: Light off, 1.65 seconds NOTE:...
  • Page 82 TRBL SHTG Troubleshooting 4. If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. NOTE: When more than one problem is detected, the light of the diagnostic flash indicator flashes in the pattern of the lowest numbered problem.

  • Page 83: Checking The Power Trim And Tilt System

    Index Adjusting the oil pump link rod ..... 32 General............33 After test run ..........15 General specifications ......... 16 Applicable models.......... 3 General torques........... 27 Assembling the lower case ......54 How to use this manual ......... 1 Backlash (counter rotation model) ....58 Backlash (regular rotation model) ....
  • Page 84 Index Selecting the pinion shims .....46 Selection ............11 Self-diagnosis ..........74 Serial number..........3 Shimming (counter rotation model)....56 Shimming (regular rotation model)....45 Special service tools ........28 Specified torques ......... 25 Symbols ............2 Test run............15 Tightening torques ........
  • Page 85 Index — MEMO — 6D03F1X...
  • Page 86 Wiring diagram Z300AETO, LZ300AETO 1 Electric fuel pump Color code 2 Electric oil pump : Black 3 Oil level sensor : Brown 4 Water detection switch : Green 5 Throttle position sensor : Gray 6 Emergency switch : Blue 7 Atmospheric pressure sensor : Light green 8 Thermoswitch : Orange...
  • Page 88 YAMAHA MOTOR CO., LTD. Printed in the Netherlands Jul. 2003 – 0.5 × 1 CR...
  • Page 89 Z300AETO, LZ300AETO W/B W/Y B W/Br W/Br W/Br B B B (*1) (*2) Pu/R Pu/B 7GH 56A 1 2 3 4 Ì EDCBAHG Pu/Y Pu/G 5678 Br/W Pu/L Pu/W Ì È B/Br B B B B B B B B ±...
  • Page 90 Pu/Y Pu/B — — Pu/W Pu/B Pu/L Pu/L Pu/R Pu/W Pu/R — — Pu/L Pu/Y Pu/B Pu/Y Pu/R Pu/G Pu/W Pu/G Pu/G Pu/R Pu/W Pu/L Pu/Y Pu/B Pu/G — — — W/Br Pu/Y — Pu/L Pu/R W/Br B/Br — Pu/G B/Br Pu/W Pu/B...

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Lz300a

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