Yamaha FL350B Manuals

Manuals and User Guides for Yamaha FL350B. We have 1 Yamaha FL350B manual available for free PDF download: Service Manual

Yamaha FL350B Service Manual

Yamaha FL350B Service Manual (508 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 33 MB

Table of Contents

Table of Contents

3
- General Information
  4
- Model Information
  5
- Applicable Model
  5
- Model Name Designation
  5
- General Feature
  7
- Important Safety and Service Information
  8
- Rotating Parts
  8
- Hot Parts
  8
- Electric Shock
  8
- Propeller
  8
- Handling of Gasoline
  8
- Ventilation
  8
- Self-Protection
  8
- Parts, Lubricants, and Sealants
  9
- Handling of Lubricants and Sealants
  9
- Handling of Gas Torch
  9
- Lifting Outboard Motors
  9
- Special Service Tools
  10
- Tightening Torque
  10
- Non-Reusable Parts
  10
- Disassembly and Assembly
  10
- Disposal of Used Components and Chemicals
  10
- How to Use this Manual
  11
- Manual Format
  11
- Conditions When Testing and Adjusting
  12
- Abbreviation
  12
- Color Code
  13
- Specified Tightening Torque
  13
- General Tightening Torque
  13
- Lubricant, Sealant, and Thread Locking Agent Symbol
  14
- Specification Symbol
  14
- Symbol
  14
- Special Service Tool
  16
- Specification
  23
  - Specification Data
    24
  - External Dimensions
    24
  - Clamp Bracket Dimensions
    26
Technical Feature and Description

27
- Electronic Control System
  29
- Electrical Components
  32
- Electronic Fuel Injection Control
  35
- Ignition Timing Control
  36
- Knock Control
  37
- VCT Control
  37
- Engine Speed Control
  38
- ETV Control
  39
- Electronic Shift Control System
  40
- Water Detection Warning
  41
- Fail-Safe
  42
- Charging System
  44
- Y-Cop
  45
- Outline
  46
- Power Unit
  46
- Oil Dipstick
  48
- Heat Exhaust Fan and Heat Vent
  49
- Bracket Unit
  50
- SBW (Steer by Wire) System
  50
- System Diagram
  51
- Structure
  53
- Operation
  54
- Outboard Motor Manual Steering Method
  55
- Clamp Bracket
  56
- PTT Sensor
  57
- PTT Totaltilt
  58
- Bushing of the Drive Shaft
  61
- Upper Case
  61
- Lower Unit
  62
- Split-Type Drive Shaft
  63
- Reverse Thrust
  64
- Engine ECM
  65
- PTT Protection Control
  65
- Fuel System
  66
- High-Pressure Fuel Pump Control
  66
- Low-Pressure Fuel Pump Control
  66
- Fuel Diagram
  67
- Lubrication Diagram
  69
- Lubrication System
  69
- Cooling Diagram
  71
- Cooling System
  71
- Intake and Exhaust Diagram
  73
- Intake and Exhaust System
  73
- Fuel Hose and Blowby Hose
  74
- Hose Routing
  74
- Pressure Regulator Hose and Vapor Gas Hose
  75
- Cooling Water Hose
  76
Rigging Information

77
- Important Reminder on Rigging
  79
- Outboard Motor Mounting Instructions
  79
- Crate Handling
  80
- Crate Top Cover Symbol Description
  80
- Uncrating
  81
- Uncrating Procedure
  81
- Outboard Motor Mounting
  82
- Securing the Outboard Motor
  82
- Installing the Battery Cable
  83
- Installing the Main Wire Harness
  83
- Rigging Grommet Description
  83
- Rigging Grommet Mounting
  83
- Installing the Isolator Lead
  84
- Installing the Rigging Grommet
  84
- Installing the SCU Communication Lead
  84
- Optional Equipment
  84
- Battery Installation
  85
- Single Outboard Motor Application (Single Station)
  86
- System Diagram
  86
- Twin Outboard Motor Application (Single Station)
  89
- Triple Outboard Motor Application (Single Station)
  92
- Quad Outboard Motor Application (Single Station)
  95
- Single Outboard Motor Application (Dual Station)
  98
- Twin Outboard Motor Application (Dual Station)
  101
- Triple Outboard Motor Application (Dual Station)
  104
- Quad Outboard Motor Application (Dual Station)
  108
- Digital Electronic Control
  112
- Digital Electronic Control System Reset
  112
- Setting the Tilt Limiter
  113
- Tilt Limiter
  113
- Clearing the Tilt Limiter
  114
- Calibration (6X9 Digital Electronic Control)
  115
- CL5 Display Calibration
  115
- Configuring the Number of Outboard Motors
  115
- Deactivating the Tilt Limiter
  115
- Accessing the Calibration Menu
  116
- Steer Sensor
  117
- Toe Adjust
  119
- Lock to Lock
  121
- Friction Set
  123
- Battery Cable Length
  124
- Rigging Recommendation
  124
- Propeller Selection
  125
Troubleshooting

127
- Ydis
  128
- Connecting the Communication Cable
  129
- ECM Reprogramming
  131
- Outboard Motor Troubleshooting
  132
- Troubleshooting Procedure
  132
- Troubleshooting the Power Unit Using the YDIS
  132
- Trouble Code and Checking Step
  135
- Troubleshooting Procedure (Trouble Code Not Detected)
  150
- Troubleshooting the Power Unit
  150
- Troubleshooting the PTT Unit
  156
- Troubleshooting the Lower Unit
  157
Electrical System

158
- Electrical System
  159
- Electrical Component and Wire Harness Routing
  161
- Port
  161
- Starboard
  163
- Fuse Holder
  165
- Rear
  166
- Front
  168
- Top
  169
- Bottom Cowling
  171
- Bracket
  173
- ECM Circuit Diagram
  175
- ECM Coupler Layout
  178
- Checking the Electrical Component
  180
- Measuring the Peak Voltage
  180
- Using the YDIS
  180
- Checking the Main Relay
  181
- Engine Control Unit and Component
  181
- Using the Digital Tester
  181
- Checking the Engine ECM Circuit
  182
- Checking the ETV and TPS
  183
- Checking the ETV Motor Relay
  184
- Checking the Shift Actuator Relay
  185
- Checking the SPS
  185
- Checking the Cam Position Sensor
  186
- Checking the Shift Actuator
  186
- Checking the OCV
  188
- Checking the Oil Pressure Sensor
  189
- Checking the Water Detection Switch
  190
- Fuel Control Unit and Component
  190
- Checking the Fuel Injector
  191
- Checking the Low-Pressure Fuel Pump and High-Pressure Fuel Pump
  192
- Checking the High-Pressure Fuel Pump Relay
  193
- Checking the Low-Pressure Fuel Pump Relay
  193
- Checking the Vapor Shut-Off Valve
  194
- Charging Unit and Component
  195
- Checking the Lighting Coil (Stator Assembly)
  195
- Checking the Rectifier/Regulator/Isolator
  196
- Checking the Ignition Coil
  197
- Checking the Ignition Spark
  197
- Checking the Pulser Coil
  197
- Ignition Unit and Component
  197
- Checking the Intake Air Temperature Sensor
  198
- Checking the Engine Temperature Sensor
  199
- Checking the Intake Air Pressure Sensor
  199
- Checking the Thermo Sensor
  200
- Checking the Engine Shut-Off Switch
  201
- Checking the Knock Sensor
  201
- Checking the Power Switch
  202
- Checking the Starter Relay
  202
- Starting Unit and Component
  202
- Checking the Engine Start/Stop Switch
  203
- Starter Motor
  205
- Checking the Armature (Starter Motor)
  206
- Checking the Starter Motor Pinion
  206
- Disassembling the Starter Motor
  206
- Removing the Starter Motor
  206
- Checking the Brush Holder
  207
- Assembling the Starter Motor
  208
- Installing the Starter Motor
  209
- 6X9 Digital Electronic Control Circuit
  210
- Checking the Extension Wire Harness
  210
- Checking the LPS
  210
- Outboard Motor and Digital Electronic Control Connection
  210
- Checking the LPS Continuity
  211
- Checking the PTT Relay
  212
- PTT System
  212
- Checking the PTT Switch (on Bottom Cowling)
  213
- Checking the PTT Buzzer
  214
- Checking the PTT Sensor
  214
Fuel System

215
- Disconnecting the Quick Connector
  217
- Reducing the Fuel Pressure
  217
- Measuring the Fuel Pressure
  218
- Checking the Pressure Regulator
  219
- Fuel Filter Assembly
  222
- Checking the Fuel Cup Assembly
  223
- Checking the Fuel Filter Assembly
  223
- Checking the Fuel Filter Element
  223
- Removing the Fuel Filter Assembly
  223
- Assembling the Fuel Filter
  224
- Checking the Primer Pump
  224
- Installing the Fuel Filter
  224
- Intake Manifold
  226
- Checking the Intake Manifold
  227
- Installing the Intake Manifold
  227
- Installing the Intake Silencer
  228
- Etv
  229
- Checking the ETV
  230
- Checking the Intake Air Pressure/Temperature Sensor
  230
- Installing the ETV and Surge Tank
  230
- Canister
  232
- Checking the Canister
  233
- Checking the Canister Check Valve
  233
- Installing the Canister
  233
- Low-Pressure Fuel Pump
  235
- Installing the Low-Pressure Fuel Pump
  236
- Vapor Separator and Vapor Shut-Off Valve
  237
- Checking the Vapor Shut-Off Valve
  238
- Draining the Fuel
  238
- Installing the Vapor Separator
  238
- Vapor Separator and High-Pressure Fuel Pump
  240
- Checking the Check Valve
  242
- Checking the High-Pressure Fuel Pump
  242
- Checking the Vapor Separator
  242
- Fuel Injector
  244
- Checking the Fuel Rail
  245
- Installing the Fuel Injector
  245
Power Unit

246
- Power Unit
  247
- Checking the Compression Pressure
  249
- Checking the Oil Pressure
  249
- Power Unit (Check and Adjustment)
  249
- Checking the Pulser Coil Air Gap
  250
- Checking the Valve Clearance
  250
- Adjusting the Valve Clearance
  253
- Power Unit Assembly
  255
- Removing the Power Unit
  256
- Installing the Power Unit
  258
- Flywheel Magneto
  262
- Removing the Flywheel Magneto
  263
- Installing the Flywheel Magneto
  264
- Wire Harness
  266
- Installing the Wire Harness
  267
- Fuse Box
  270
- Junction Box
  271
- Installing the Junction Box
  272
- Installing the Rectifier/Regulator/Isolator
  272
- Installing the Starter Motor
  275
- Starter Motor
  275
- Engine ECM
  276
- Ignition Coil and Spark Plug
  277
- Checking the Spark Plug
  278
- Shift Actuator
  279
- Assembling the Shift Actuator Assembly
  280
- Installing the Shift Actuator Assembly
  280
- Timing Belt
  281
- Removing the Timing Belt
  282
- Checking the Timing Belt
  283
- Installing the Timing Belt
  283
- Camshaft
  286
- Removing the Camshaft, VCT Assembly, and Driven Sprocket
  287
- Checking the Sprocket
  288
- Checking the Valve Lifter
  288
- Checking the Camshaft
  289
- Checking the Camshaft Journal Oil Clearance
  289
- Checking the Camshaft Journal Outside Diameter and Camshaft Journal Inside Diameter
  291
- Installing the Camshaft, VCT Assembly, and Driven Sprocket
  291
- Cylinder Head
  296
- Disassembling the Cylinder Head
  297
- Removing the Cylinder Head
  297
- Checking the Cylinder Head
  298
- Checking the Cylinder Head Bolt
  298
- Checking the Valve Spring
  298
- Checking the Valve
  299
- Checking the Valve Guide
  300
- Replacing the Valve Guide
  300
- Checking the Valve Seat
  301
- Refacing the Valve Seat
  302
- Assembling the Cylinder Head
  305
- Checking the Cylinder Head Anode
  305
- Installing the Cylinder Head
  307
- Oil Cooler and Oil Pump Assembly
  308
- Checking the Oil Cooler
  309
- Checking the Oil Pump
  309
- Removing the Oil Filter
  309
- Assembling the Oil Pump
  310
- Checking the Oil Cooler Anode
  310
- Installing the Oil Cooler
  311
- Installing the Oil Pump Assembly
  311
- Installing the Oil Filter
  312
- Cylinder Block Sensor and Switch
  315
- Checking the Cooling Water Cover Anode
  316
- Checking the Thermostat
  316
- Installing the Thermostat
  316
- Installing the Cooling Water Cover
  317
- Installing the Knock Sensor
  318
- Installing the Pulley Bracket
  318
- Cylinder Block
  319
- Disassembling the Cylinder Block
  320
- Checking the Cylinder Bore
  321
- Checking the Piston Diameter
  321
- Checking the Piston Clearance
  322
- Checking the Piston Ring
  322
- Checking the Piston Ring End Gap
  322
- Checking the Piston Ring Groove
  323
- Checking the Piston Ring Side Clearance
  323
- Checking the Connecting Rod Small End Inside Diameter and Big End Inside Diameter
  324
- Checking the Piston Pin Boss Inside Diameter
  324
- Checking the Piston Pin Diameter
  324
- Checking the Connecting Rod Big End Side Clearance
  325
- Checking the Crankshaft
  325
- Checking the Big End Oil Clearance
  326
- Checking the Crankcase Bolt
  326
- Selecting the Crankshaft Pin Bearing
  328
- Crankshaft Pin Bearing Selection Table
  330
- Checking the Journal Oil Clearance
  331
- Selecting the Crankshaft Journal Bearing
  332
- Crankshaft Journal Bearing Selection Table
  334
- Assembling the Cylinder Block
  336
- Checking the Cylinder Block Anode
  336
Lower Unit

340
- Lower Unit
  341
- Checking the Propeller
  344
- Disassembling the Propeller (Shift Dampener System [SDS] Propeller)
  344
- Propeller
  344
- Removing the Propeller
  344
- Assembling the Propeller (Shift Dampener System [SDS] Propeller)
  345
- Installing the Propeller
  345
- Lower Unit
  347
- Removing the Lower Unit
  348
- Checking the Lower Unit Anode
  349
- Checking the Lower Unit for Leakage
  349
- Installing the Lower Unit
  349
- Extension (Except for X-Transom Model)
  351
- Assembling the Extension
  352
- Checking the Extension
  352
- Installing the Extension
  352
- Water Pump and Shift Rod
  353
- Checking the Shift Rod
  354
- Checking the Water Pump
  354
- Removing the Water Pump and Shift Rod
  354
- Assembling the Water Pump Housing
  355
- Checking the Intermediate Drive Shaft
  355
- Installing the Shift Rod
  356
- Installing the Water Pump
  357
- Propeller Shaft Housing (Regular Rotation Model)
  358
- Removing the Propeller Shaft Housing Assembly
  360
- Disassembling the Propeller Shaft Assembly
  361
- Disassembling the Propeller Shaft Housing Assembly
  361
- Disassembling the Reverse Gear
  361
- Checking the Dog Clutch
  362
- Checking the Propeller Shaft
  362
- Checking the Propeller Shaft Housing
  362
- Checking the Reverse Gear
  362
- Assembling the Propeller Shaft Assembly
  363
- Assembling the Propeller Shaft Housing Assembly
  363
- Assembling the Reverse Gear
  363
- Installing the Propeller Shaft Housing Assembly
  366
- Drive Shaft and Lower Case (Regular Rotation Model)
  368
- Disassembling the Drive Shaft
  369
- Disassembling the Oil Seal Housing
  369
- Removing the Drive Shaft
  369
- Removing the Forward Gear
  369
- Disassembling the Forward Gear
  370
- Checking the Forward Gear
  371
- Checking the Pinion
  371
- Disassembling the Lower Case
  371
- Assembling the Drive Shaft
  372
- Checking the Drive Shaft
  372
- Checking the Lower Case
  372
- Assembling the Forward Gear
  374
- Assembling the Lower Case
  374
- Assembling the Oil Seal Housing
  375
- Installing the Drive Shaft
  376
- Installing the Forward Gear
  376
- Shimming (Regular Rotation Model)
  378
- Shimming Workflow
  378
- Shimming Check Sheet
  379
- Shimming Procedure
  380
- Shim Location
  381
- Selecting the Forward Gear Shim (T1) and Reverse Gear Shim (T2)
  382
- Selecting the Pinion Shim (T3)
  382
- Measuring the Forward Gear Backlash and Reverse Gear Backlash
  384
- Selecting the Propeller Shaft Shim (T4)
  388
- Propeller Shaft Housing (Counter Rotation Model)
  390
- Disassembling the Propeller Shaft Housing Assembly
  392
- Removing the Propeller Shaft Housing Assembly
  392
- Assembling the Propeller Shaft Housing and Forward Gear
  393
- Checking the Dog Clutch
  393
- Checking the Forward Gear
  393
- Checking the Propeller Shaft
  393
- Checking the Propeller Shaft Housing
  393
- Disassembling the Forward Gear
  393
- Installing the Propeller Shaft Housing Assembly
  395
  - Drive Shaft and Lower Case (Counter Rotation Model)
    396
Bracket Unit

409
- Molding
  411
- Shift Rod and SPS
  412
- Installing the Shift Rod and SPS
  413
- PTT Switch and Cowling Lock Lever
  414
- Installing the Flushing Hose
  416
- Installing the PTT Sensor Lead
  416
- Installing the SBW Harness
  416
- Upper Case and Mounts
  418
- Installing the Upper Case
  419
  - Upper Case
    422
- Removing the Upper Case
  419
- Disassembling the Upper Case
  423
- Assembling the Upper Case
  424
- Checking the Drive Shaft Bushing
  424
- Checking the Exhaust Guide Anode
  424
- Oil Pan and Exhaust Manifold
  426
- Assembling the Oil Pan and Exhaust Manifold
  427
- Checking the Oil Pan and Exhaust Manifold
  427
- Checking the Oil Strainer
  427
- Steering Actuator and Steering Arm
  429
- Removing the Power Steering Unit
  430
- Checking the Steering Arm and Steering Arm Joint
  431
- Installing the Steering Arm
  431
- Removing the Steering Arm
  431
- Installing the Steering Actuator
  432
- Clamp Bracket and Swivel Bracket
  435
- Assembling the Swivel Bracket
  436
- Checking the Clamp Bracket Anode
  436
- Removing the Clamp Bracket
  436
- Installing the Clamp Bracket
  437
- Removing the PTT Unit
  439
- Checking the Hydraulic Pressure
  440
- Bleeding the PTT Unit
  442
- Installing the PTT Unit
  443
  - PTT Motor
    447
- Checking the PTT Motor
  448
- Disassembling the PTT Motor
  448
- Removing the Reservoir
  448
- Assembling the PTT Motor
  449
- Checking the Brush
  449
- Checking the Filter
  449
- Checking the Reservoir
  449
- Installing the PTT Motor
  450
- Installing the Reservoir
  450
- PTT Gear Pump
  452
- Assembling the Gear Pump Assembly
  454
- Checking the Filter
  454
- Checking the Gear Pump
  454
- Checking the Gear Pump Housing
  454
- Disassembling the Gear Pump Assembly
  454
- Installing the Gear Pump Assembly
  456
- PTT Cylinder
  457
- Removing the Tilt Ram
  458
- Removing the Trim Ram
  458
- Assembling the Tilt Ram
  459
- Checking the Absorber Valve
  459
- Checking the Tilt Cylinder and Trim Cylinder
  459
- Disassembling the Tilt Ram
  459
- Assembling the Trim Ram
  461
- Installing the Tilt Cylinder
  461
- Installing the Tilt Ram
  462
- Installing the Trim Ram
  462
- Maintenance
  464
  - Maintenance Interval Chart
    465
  - Predelivery Check
    468
  - Checking the Engine Oil Level
    471
  - Checking the Battery
    471
  - Checking the Cooling Water Pilot Hole
    472
  - Checking the Gear Oil Level
    472
  - Checking the Outboard Motor Mounting Height
    473
  - General Periodic Maintenance
    474
  - Checking the Engine Idle Speed
    477
  - Replacing the Oil Filter
    480
  - Changing the Gear Oil
    481
  - Greasing Points
    483
  - Checking the PTT Fluid Level
    484
  - Wiring Diagram
    495

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