Imv3 Rev4 Master Book 29dec08

Marine
INSTALLATION MANUAL
Volume 3
BY, BY2, LH, LP, LY, CX, SY Series and ZT350
Marine Installation Manual - Volume 3
P/N 0FMPE-U00304
MARINE
INSTALLATION
MANUAL
6BY2
Page
Engine Specifications .....................................................................2
Engine Room Space for Service ....................................................3
Marine Gear / Stern Drive Specifications .......................................4
Flywheel Housing Dimensions (Borg Warner Flange)....................7
Flywheel Housing Dimensions (Stern Drive) ..................................8
Fuel System Specifications ............................................................9
Piping Diagram .............................................................................10
Cooling System Specifications .....................................................11
Air Intake and Exhaust Specifications ..........................................13
Mixing Elbow ................................................................................14
Alarm System Specifications ........................................................15
Remote Control System ...............................................................15
Electrical System ..........................................................................16
Standard Alternator Data..............................................................17
Performance Curves.....................................................................20
Engine Mount ...............................................................................22
Installation Specifications .............................................................23
Cold Starting Aids.........................................................................23
Water Heater Tank Connection ....................................................24
Heat Insulation Requirements ......................................................24
Optional Accessories....................................................................24
Marine Installation Manual - Volume 3 SEPT 2008 (Rev. 4) 6BY2 - 1

6BY2 6BY2
6BY2 Parameter Data

Please refer to the Safety section at the beginning 6BY2-220 6BY2-260
of this manual. Low Idling Speed
670 rpm*
(at 88°C [190°F])
Engine Specifications
Firing Order 1 - 5 - 3 - 6 - 2 - 4 - 1**
Parameter Data Engine
6BY2-220 6BY2-260 Lubrication Enclosed, Forced
System
Configuration 4-cycle Diesel, 15° Inclined,
Dual Overhead Camshaft Engine Oil
11.0 L2
Capacity
Crankshaft (11.62 qt)***
(0° incline)
Rotation
Counterclockwise (Dry Weight
(Viewed from
Flywheel) without For Stern Drive: 338 kg
Gear/Drive or For Marine Gear: 319 kg
Combustion Mixing Elbow)
Direct Injection
System
Total Air Flow 2750 m3/h
Aspiration Turbocharger with Charge Air Requirements (97115 ft3/h)
Cooler
Number of * 1080 rpm at startup for alternator excitation.
In-line 6
Cylinders
** No. 1 cylinder is at the coolant pump end of the
Bore x Stroke 84 mm x 90 mm engine.
(3.307 in. x 3.543 in.)
*** The engine oil capacity includes oil in the oil pan,
Displacement 2.993 L
channels, coolers, and filter.
(182.6 cu in.)
Continuous Note: Rating condition, ISO 8665
Rating Output at 124 kW 153 kW Fuel temperature: 40°C (104°F)
Crankshaft (166 hp) (208 hp)
1 hp metric = 0.7355 kW
(at 3600 rpm)
Maximum Output
162 kW 191 kW
at Crankshaft
(220 hp) (260 hp)
(at 4000 rpm)
Piston Speed
10.8 m/sec 11 m/sec
(Continuous
(35.4 ft/sec) (36.1 ft/sec)
Rating Output)
Piston Speed
12.0 m/sec
(Maximum
(39.4 ft/sec)
Output)
Brake Mean
Effective
1.62 MPa 1.92 MPa
Pressure
(234.96 psi) (260 hp)
(Maximum
Output)
Maximum 500 N·m 550 N·m
Torque (369 ft-lb) (407 ft-lb)
High Idling
4600 rpm
Speed
6BY2 - 2 SEPT 2008 (Rev. 4) Marine Installation Manual - Volume 3

6BY2
12/05
6BY2
Engine Room Space for Service
537 mm 391 mm
(21.15 in.) (15.4 in.)
70 mm
(2.8 in.)
(21.65 in.)
550 mm
239.8 mm
(9.45 in.)
159.8 mm
(6.3 in.)
267 mm
(14.5 in.)
0006581
Figure - 1
The installer is responsible for ensuring that there is sufficient engine room space to access the engine for
service and repair.
Superstructures and connected components should be installed so that the engine can be removed, fitted
and serviced without time being lost to any obstructions.
The following components must be easy to access:
• Fuel filter(s) • Coolant pump
• Fuel system components for bleeding the fuel • Heat exchanger
system
• Complete seawater pump assembly (to access
• Air filter impeller and filter)
• Engine oil filter(s) • Zinc anodes
• Oil fill port and dipstick • Batteries
• Engine oil drain plug • Starter motor
• Marine Gear or Sail-Drive oil fill port / dipstick • Alternator
• Coolant tank fill port • Turbocharger
• Coolant drain cock(s)

6BY2 6BY2
Marine Gear / Stern Drive

Specifications
Use the KMH50 marine gear or ZT350 or
Mercruiser Bravo 1, 2 or 3 stern drive with the
6BY2 series engine.
Note: See the marine gear / stern drive
manufacturers literature for additional
information.

6BY2
12/05
6BY2
Borg Warner
S
1064 (41.89)
1001 (39.41)
145 (5.71)
279 (10.98)
287 (11.3)
716 (28.19)
847.45 (33.36)
709 (27.91)
700 (27.56)
240 (9.45) 460 (18.11)

332 (13.07)
A
A
716.48 (28.21)
203 (7.99)
(C16)
VIEW
Ansicht S
(G6)
SECTION A-A
Schnitt A-A
548.5 (21.59)
(1.81)
46
15.5 (.61)
SAE 20/40-26
0006541
Unit: mm (in.)
Figure - 2

6BY2 6BY2
Stern Drive
614.5 (24.19)
1001 (39.41)
145 (5.71)
279 (10.98)
287 (11.3)
716 (28.19)
709 (27.91)
700 (27.56)
240 (9.45) 460 (18.11)
373 (14.69)
802 (31.57)
761 (29.96)
203.99 (8.03)
429 (16.89)
894 (35.2)
(5.87)
149.1 (2.8)
(3.71)
94.21
71.1
0006495
Unit: mm (in.)
Figure - 3

6BY2
12/05
6BY2
Flywheel Housing Dimensions (Borg Warner Flange)
119 (4.69)
235 (9.25)
0006489
Figure - 4
Unit: mm (in.)

6BY2 6BY2
Flywheel Housing Dimensions (Stern Drive)
220 (8.66)
241.3 (9.5)
10.3 (.406)
0006490
Figure - 5
Unit: mm (in.)

6BY2
12/05
6BY2
Fuel System Specifications
Parameter Data
6BY2-220 6BY2-260
Maximum Fuel Feed 1.0 m
Pump Suction Head (39.37 in.)
Maximum Fuel Feed
200.0 L/hr minimum
Pump Discharge
(52.8 gal/hr minimum)
Volume
Maximum Fuel Feed
5 bar
Pump Discharge
(72.5 psi)
Pressure
Fuel Inlet Pipe
3/8 NPT
Connector Thread
Maximum Fuel Inlet
70°C (158°F)
Temperature
Fuel Consumption at 44.5 L/hr
53 L/hr
Rated Output (11.7
(14 gal/hr)
gal/hr)
Hose acc. DIN ISO 7840
A1 (fire resistance hose)
is requested. Max length
Fuel Line
of hose between prefilter
(minimum size)
and engine depends on
suction height of
complete suction line.
Inner diameter for
8 mm (0.32 in.)
inlet
Inner diameter for
12 mm (0.47 in.)
outlet
Note: Yanmar supplies a water separating pre-

filter for mounting by the installer. The
engine is also equipped with an on-
engine fine filter.

6BY2 6BY2
Piping Diagram
Fuel Flow
(9)
(8)
(15)
(10)
(7)
(11) (2)
(3)
(14)
(6)
(12)
(1)
(13)
(4)
(16)
0006510
(5)
1. Fuel Inlet from Tank 10. Fuel Injector Return Hose
2. Fuel Filter (10 micron) 11. Common Rail Return Line
3. Fuel Feed Pump 12. Return Fuel Tee with Back Pressure Valve
4. Inlet Fuel Temperature Sensor 13. Return Fuel to Fuel Tank with Over Pressure
5. High-Pressure Fuel Pump Valve
6. High-Pressure Fuel Supply Line 14. Fuel Pressure Sensor
7. High-Pressure Fuel Common Rail 15. Fuel Pressure Regulator (ECU-Controlled)
8. Fuel Injection Line 16. Fuel Measuring Unit (ECU-Controlled)
9. Fuel Injector
Figure - 6

6BY2
12/05
6BY2
Cooling System Specifications
Parameter Data
6BY2-220 6BY2-260
Cooling System Closed Cooling with Heat
Exchanger
Coolant Capacity 13.0 L
(Approximately) (13.7 qt)
Coolant Capacity 1.0 L
(Recovery Tank) (1.0 qt)
Maximum Seawater
165 L/min.
Pump Flow Rate at
(174 qt/min)
Maximum Rating
Maximum Seawater 0.5 m
Pump Suction Head (19.69 in.)
Seawater Inlet Pipe 38.1 mm
Connector Outer (1.5 in.)
Diameter
Thermostat
96°C
Operating
(205°F)
Temperature
(Full Open)
Thermostat
88°C
Operating
(190.4°F)
Temperature
(Opening)
Maximum Overflow
1.0 m
Pipe Length
(39.37 in.)
(Coolant Recovery
Tank to Filler Cap)
Overflow Pipe Inner
6 mm
Diameter
(0.250 in.)
(Coolant Recovery
Tank to Filler Cap)
Water Heater Tank /
10 mm
Cabin Heater Pipe
(0.394 in.)*
Inside Diameter
* Must have a minimum pressure rating of 1.5 bar

(22 psi).

6BY2 6BY2
Cooling Flow
(2) (3)
(1)
(6)
(4)
(7)
(5)
(12)
(9)
(13)
(8)
(11)
(10)
0006511
Note: Typicak 4BY2 engine shown. 6BY2 is similar.
1. Seawater Supply 8. Engine Coolant Pump

2. Seawater Pump 9. Thermostat
3. Hydraulic Oil Cooler 10. Engine Oil Cooler
4. Charge Oil Cooler 11. Engine Coolant Passages
5. Engine Heat Exchanger 12. Coolant Recovery Tank
6. Exhaust / Seawater Mixing Elbow 13. Water Cooled Exhaust Manifold
7. Exhaust / Seawater Exit
Figure - 7

6BY2
12/05
6BY2
Air Intake and Exhaust Specifications
Check for leaks at initial start.
Parameter Data
6BY2-220 6BY2-260
Exhaust Pipe
Outer 102 mm
Diameter (4.0 in.)
Connection
Air Volume
Necessary for 950 m3/h
Combustion at (33549 ft3/h)
WOT
Maximum Air 4.0 kPa
Inlet 408 mmAq
Depression (16.06 in.Aq)
Maximum 45 kPa
Back Pressure 4589 mmAq
(180.67 in.Aq)
EPA Exhaust Location: Mixing Elbow
Test Port G 1/4 - 19 BSPP
Sizes or
G 3/8 - 19 BSPP4*
600°C 650°C
Maximum (1112°F) (1202°F)
Output at rated speed at rated speed
Exhaust
Temperature 700°C 700°C
Before (1292°F) (1292°F)
Turbocharger at full load at full load
2000 rpm 2000 rpm
Maximum
1950 / 2150
Turbocharger 2000 / 2200
mbar
Boost mbar
(28.3 / 31.2
Pressure (29.0 / 31.9 psi)
psi)
(min/max)
Maximum
Engine Room 60°C
Ambient (140°F)
Temperature
* NOTE: Back pressure measured from EPA test

port located on the mixing elbow. CAUTION! Test
ports are British Standard Pipe Parallel (BSPP)
not National Pipe Thread (NPT). BSPP and NPT
threads are not compatible due to the thread
pitch. Mixing can cause thread damage.

6BY2 6BY2
Mixing Elbow
410.5 (16.16)
351 (13.82) 3)
.7
(4
0
12
404.5 (15.93)
ø1 .02
(ø
02 )
336 (13.23)
4
(10.83)
275.1
436.1 (17.17)
ø1 .0
(ø
02 2)
4
700.4 (27.57)
615.5 (24.23)
464.5 (18.29)
223.3
(8.79)
(ø 4. 02
ø1 02
328 (12.91)
559.4 (22.02)
486.9 (19.17)
)
(ø 4 .0
ø102 )
2
574.2 (22.61)
506.9 (19,92)
775.3 (30.52)
732.8 (28.85)
0006602
Unit = mm (in.)

6BY2
12/05
6BY2
Alarm System Specifications Remote Control System
Parameter Data Panel

6BY2-220 6BY2-260 The 6BY2 series utilizes Yanmar Marine Electronic
control technology, incorporating an LCD
Coolant Overheat
108°C multi-function display panel. Refer to the
Alarm Operating
(226°F) appropriate Yanmar Electronic Control System
Temperature
Installation Manual for detailed component
Below 1500 rpm: specifications and options.
Lube Oil Low < 0.5 bar (7.25 psi) for
Pressure Alarm more than one second Yanmar Digital Display
(Alarm not available Above 1500 rpm: (1)
on Classic controls) < 2.0 bar (29 psi) for (2)
more than one second
Overspeed
Protection (fuel 4600 rpm
cutoff)
2 3 0 100
84 PSi
1 4 (3)
0 2615
X1000 RPM
100 250
11 4 Fah
0003327
1. Tachometer
2. Engine Oil Pressure Meter
3. Multi-function Meter (Coolant Temperature,
Lube Oil Temperature, Fuel Temperature,
Boost Pressure, Voltage, Load Factor,
Throttle Valve, Fuel Consumption Rate and
Gear Shift Position)
Figure - 8

6BY2 6BY2
Electrical System Starter Specifications

Check all electrical connections per the wiring Parameter Data
diagrams and ensure the bolts are tightened to the
correct torque specifications. 6BY2-220 6BY2-260
Yanmar Code 165000-70110
Battery Specifications Starter Model DENSO
Parameter Data Voltage 12 V
6BY2-220 6BY2-260 Output 2.0 kW (2.7 hp)
Battery Size 12 V, 85 Ah, 680 CCA Direction of
(Minimum)* (cold cranking amps) Rotation (Viewed Clockwise
Nominal Output 12 V / 150 A from Pinion Side)
Earth Polarity Negative Ground Weight 3.5 kg (7.7 lb)
Number of Pinion
* Note: No other device can be connected to the 11
Teeth
starting battery.
No-load Terminal
12 V
Battery Cable Requirements Voltage
Battery Cable Battery Cable No-load Current 50 A or less

AWG
Length Area
1.0-2.5 m 50 mm2
1
(3.3-8.2 ft) (0.08 in.2)
2.0-4.0 m 70 mm2
2/0
(6.6-13.1 ft) (0.11 in.2)
2.5-5.0 m 95 mm2
3/0
(8.2-16.4 ft) (0.15 in.2)
3.25-6.5 m 120 mm2
4/0
(10.7-21.3 ft) (0.19 in.2)2

6BY2
12/05
6BY2
Starter Performance Curve
SPEED OUTPUT TORQUE VOLTS
(rpm) (kW) (N•m) (V)
kW
N•m
rpm
CURRENT (A) 0004044
Figure - 9
Standard Alternator Data

Parameter Data
6BY2-220 6BY2-260
Yanmar Code 120640-00030
Alternator
Valeo
Model
Alternator 12 V, 150 A
IC Regulator
7 788 823.1
Model
Battery Voltage 12 V
Nominal Output 12 V / 150 A
Earth Polarity Negative Ground
Rotation
(Viewed from Clockwise
Pulley End)
Weight 6.9 kg (15.2 lb)

6BY2 6BY2
Wiring Diagram
B+
(3) (4) (5) (8) (9) (10)
(7)
F2 F1 F6 (6) F4 F3 F5
X1/C
KL50 KL15 KL87

(49)
201 203 205
X1/B
(211, 224)
182
207
234
(12) (11)
157
K1
ϑ 132
(48)
X1/R
(44) ϑ (1)
p
X1/G (43) 154
232 (13)
(47) (42) K2
X1/D
(46) 107
(15)
106 220 (14)
180
(45) K3
139
(16) 187
(2) (16)
(41) 115
162 (53)
124 X1/H
(40) 114
X1/L
243
245 X1/F
(18)
X1/W X1/V (37) X1/N 252
256
BOSCH
X1/O
(36) EDC16 172

(19)
p X1/K 239
DDE 5 DRV
X1/P 229
X1/M
171
(20)
(39) (38) 230
ZME
183
(35) 130
ϑ (34)
149
(21)
p
156
(50) 173
151 (22)
111
175
178
103
(23)
F7 211
127
KL87
(33)
150
(24)
F8 251
(51) 174
(32) 102 (25)

238
126
X1/J
250
101
(26)
(30) 125
X1/E 208
(31) 202 204 206 233 246
KL31
X1/Q
X1/A X1/U (53)
(52) (27)
(28) X1/S X1/T
0003303
(29)
Figure - 10

6BY2
12/05
6BY2
1. Engine Control Unit (ECU) 28. CAN Signal - High
2. Internal ECU Sensors (operating voltage and 29. Panel, ECU, and CAN Ground
ambient air pressure) 30. K-Line
3. Fuse (F2) 10 A1 - Ignition 31. Neutral Start Switch (NC in neutral)
4. Fuse (F1) 3 A - CAN Switched Power 32. Jumper Fuse (F8) 3 A - CAN / Analog Throttle
5. Fuse (F6) 10 A - Auxiliary Power Selection, default is analog (fuse out). Insert
6. Start Signal from Key Switch 3 A fuse to configure for CAN.
7. Fuse (F4) 30 A - ECU Switched Power 33. Jumper Fuse (F7) 3 A - Single / Port Selection,
8. Fuse (F3) 15 A - Fuel Supply Pump default is single / port (fuse in). Remove fuse for
9. Fuse (F5) 20 A - Fuel Pressure Regulator, starboard configuration.
Water-in-Fuel, Camshaft Sensor, and Fuel 34. Fuel Rail Pressure Sensor
Volume Regulator 35. Fuel Temperature Sensor
10. Circuit Breaker (Boatbuilder Installed) 36. Subthrottle Sensor 2
11. Power to Starter Solenoid Primary Terminal 37. Subthrottle Sensor 1
12. Starter Relay K1 38. Oil Pressure Sensor
13. Main Power Relay K2 39. Water-in-Fuel Sensor
14. Fuel Supply Pump Relay K3 40. Camshaft Speed Sensor
15. Power to Fuel Supply Pump 41. Crankshaft Speed Sensor
16. B+ to Water-in-Fuel Sensor 42. Charge Air Pressure Sensor
17. Not Used 43. Charge Air Temperature Sensor
18. Check Engine Indicator Output 44. Engine Coolant Temperature Sensor
19. Fuel Rail Pressure Control Valve 45. Ignition Power Input from Key Switch (terminal
20. Fuel Volume Control (high-pressure pump) X1-D)
21. Fuel Injector No. 4 (4BY2) or No. 6 (6BY2) 46. Auxiliary Power Output (terminal X1-G)
22. Fuel Injector No. 2 (4BY2) or No. 2 (6BY2) 47. NMEA + Power Supply (X7-R)
23. Fuel Injector No. 3 (4BY2) or No. 5 (6BY2) 48. Battery Power to Key Switch (terminal X1-B)
24. Fuel Injector No. 1 (4BY2) or No. 3 (6BY2) 49. CAN Signal Blocking Diode
25. Fuel Injector No. 1 (6BY2) 50. High Bench 1
26. Fuel Injector No. 4 (6BY2) 51. High Bench 2
27. CAN Signal - Low 52. Oil Pressure Switch (X1-Q)
53. NMEA Ground Supply
54. Power Resistor for the Generator
1
NEVER connect any additional devices to F2. F6
may be used however, it is not switched.

6BY2 6BY2
Performance Curves
6BY2-220
600 200
525 175
450 150
375 125
torque
torque [Nm]
power [kW]
300 100
power
225 75
150 50
75 25
0 0
0 1000 2000 3000 4000
engine speed [rpm]
0006528
Figure - 11
6BY2-260
600 200
525 175
450 150
torque
375 125
torque [Nm]
power
power [kW]
300 100
225 75
150 50
75 25
0 0
0 1000 2000 3000 4000
engine speed [rpm]
0006527
Figure - 12

6BY2
12/05
6BY2
Fuel Consumption
6BY2-220
specific fuel consumption
270
265
260
255
specific fuel consumption [g/kWh]
250
245
240
235
230
225
220
215
210
205
200
500 1000 1500 2000 2500 3000 3500 4000 4500
engine speed [rpm]
0006579
Figure - 13
6BY2-260
specific fuel consumption
270
265
260
255
specific fuel consumption [g/kWh]
250
245
240
235
230
225
220
215
210
205
200
500 1000 1500 2000 2500 3000 3500 4000 4500
engine speed [rpm]
0006580
Figure - 14
6BY2 6BY2
Engine Mount
10
(.39)
T IG H T E N T O 1 1 0 N m
( 8 1 L b - F t) O N
A S S E M B LY
T I GHT EN TO 50 N m
(3 7 L b -Ft ) O N
ASSE MBLY 157
(6.18)
49
(1 .9 3 ) 4
(.1 6 )
140 (5. 51)
183 (7. 20)
2 0 (. 79)
75
(2 .9 5 ) 13 30
(.5 1 ) (1.18)
13
(.51)
0006604
Unit: mm (in.)

6BY2
12/05
6BY2
Type of Mount: Flexible

Installation Specifications
Part Numer 120650-08400 Inclination Angle Specifications
Trelleborg
Mount ID Movex Number 10-03964-01
Compound 16 x 45
Quantity 4
Optional Rear Engine Mounts
Type of Mount: Flexible

Part Numer 120650-08401
Trelleborg
Mount ID Movex Number 10-04418-01
Compound 16 x 55
Quantity 4
0000303B
Figure - 15
Inclination Angle
Static Running Peak
Unit = degree
β 0-8 max 20 25
λ 0 -5 -10
α 0 20 30
Cold Starting Aids

The 6BY2 series engine is equipped with a glow
plug cold starting aid.

6BY2 6BY2
Water Heater Tank Connection

The 6BY2 series engine supports water heating
tank connections for onboard head and galley
operation.
0004144
1. Water from Tank

2. Water to Tank
Figure - 16
Heat Insulation Requirements

Temperature proof from -30 to +90°C.
Must fulfill the requirements of ISO 4589 for noise
and temperature.
Optional Accessories
The following is a list of the 6BY2 series optional
accessories.
• Yanmar digital display
• Yanmar rocker switch panel (1st station)
• Yanmar interface module, HARNESS
• Yanmar control head
• Yanmar NMEA, terminal and T-connector,
CABLE

ZT350
Page
Safety .................................................................................................. 4
Notice to Vessel OEM & Equipment Installer ...................................... 9
Sales and Technical Assistance.................................................... 9
Lubricants / Sealants / Adhesives ............................................... 10
Special Tools ............................................................................... 11
Trim-In Limiter ............................................................................. 11
Steering Tie Bar Considerations ....................................................... 12
Internal Tie Bar Only.................................................................... 12
Internal and External Tie Bar....................................................... 12
External Power Steering with an External Tie Bar....................... 12
Corrosion Control .............................................................................. 12
Shore Power................................................................................ 12
Antifouling Paint........................................................................... 13
Painting the Transom and Stern-Drive ........................................ 13
Vessel Design Considerations .......................................................... 14
Transom Thickness ..................................................................... 14
Laying Out the Transom Cutout .................................................. 14
Vessel Engine Mount Position..................................................... 14
Selecting an Engine Exhaust System.......................................... 15
Positioning the Drive Unit .................................................................. 16
Locating the Crankshaft Vertical Centerline -
Single Engine Installation ............................................................ 16
Locating the Crankshaft Vertical Centerline -
Dual Engine Installation............................................................... 16
Finding the Crankshaft Horizontal Centerline (X-Dimension)...... 17
Cutting the Vessel Transom ........................................................ 19
Checking the Transom Thickness ............................................... 20
Marine Installation Manual - Volume 3 JUNE 2008 (Rev. 4) ZT350 - 1

INSTALLATION INFORMATION ZT350
Installing the Transom Assembly ...................................................... 21
Connecting the Speedometer Pickup.......................................... 23
Drive Unit Seawater Pickup......................................................... 23
Alternate Seawater Pickup .......................................................... 24
Connecting the Inlet Water Hose ................................................ 25
Connecting the Oil Reservoir Hose ............................................. 26
Installing the Oil Reservoir .......................................................... 27
Installing the Shift Plate............................................................... 28
Installing the Steering System..................................................... 28
Connecting the Steering Cables.................................................. 30
Installing the Power Trim Pump .................................................. 32
Exhaust Options ................................................................................ 33
Through-the-Propeller Exhaust ................................................... 33
Alternate Exhaust System ........................................................... 33
Installing the Engine .......................................................................... 34
Aligning the Engine ..................................................................... 35
Electrical Connections....................................................................... 37
Engine Bonding Wire Connection ............................................... 37
Trim Position Sender Connection................................................ 37
Y-CaPS Controller Connection.................................................... 37
Hydraulic Connections ...................................................................... 39
Oil Reservoir................................................................................ 39
Power Steering Hoses................................................................. 40
Installing the Drive Unit ..................................................................... 40
Speedometer Connection............................................................ 48
Power Trim System / Steering Helm and Cable................................ 49
Control System............................................................................ 49
Pump Location ............................................................................ 49
Steering Helm and Cable ............................................................ 49
Steering Cable Specifications ..................................................... 50
Installation of Steering Cable ...................................................... 51
Throttle and Shift Cables................................................................... 52
Shift and Throttle Cable Travel.................................................... 52
Verify Propeller Rotation with Mechanical Shift System.............. 52
Shift Cable Installation and Adjustment............................................. 53
Setting the Cable Length:............................................................ 54
Install the Drive Unit Shift Cable.................................................. 54
Troubleshooting Shift Problems .................................................. 57
Pre-Delivery Preparation ................................................................... 58
Power Steering Fluid ................................................................... 58
Battery Connections .................................................................... 58
Check the Power Trim Pump Fluid.............................................. 59
Fill the Power Trim Pump Fluid ................................................... 60
Check the Stern-Drive Oil Level .................................................. 60
Fill the Stern-Drive with Oil.......................................................... 61
Propeller Selection ...................................................................... 62
General Propeller Installations .................................................... 63
ZT350 - 2 JUNE 2008 (Rev. 4) Marine Installation Manual - Volume 3

ZT350
12/05
INSTALLATION INFORMATION
Installing the Propellers ............................................................... 64

Removing the Propeller ............................................................... 65
Test Preparations ........................................................................ 66
Engine Operation Tests............................................................... 66
Out-of-Water Testing ................................................................... 66
In-Water Testing .......................................................................... 67
Drive Unit Operational Tests ....................................................... 67
Cold Weather (Freezing Temperature), Seasonal and
Extended Storage........................................................................ 69

SAFETY
Yanmar considers safety of great importance and Indicates a hazardous situation which, if not
recommends that anyone that comes into close avoided, will result in death or serious injury.
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 Indicates a hazardous situation which, if not
and stern-drive's safety labels. Keep the labels avoided, could result in death or serious injury.
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 Indicates a hazardous situation which, if not
order the new part and label at the same time. avoided, could result in minor or moderate
injury.
This safety alert symbol appears
with most safety statements. It
A means attention, become alert, your

safety is involved! Please read and
abide by the message that follows
Indicates a situation which can cause damage to
the engine and stern-drive, personal property
the safety alert symbol. and / or the environment or cause the equipment to
operate improperly.
ZT350 - 4 DEC 2007 (Rev. 3) Marine Installation Manual - Volume 3

ZT350
12/05
General Information
There is no substitute for common sense and
The safety messages that follow have DANGER
careful practices. Improper practices or
level hazards. These safety messages describe
carelessness can cause burns, cuts, mutilation,
a hazardous situation which, if not avoided, will
asphyxiation, other bodily injury or death. This
result in death or serious injury.
information contains general safety precautions
and guidelines that must be followed to reduce risk NEVER permit anyone to install or
to personal safety. Special safety precautions are operate the engine or stern-drive
listed in specific procedures. Read and understand without proper training.
all of the safety precautions before operation or
performing repairs or maintenance.
• Read and understand the Operation Manual
information before you install, operate or service
the engine or stern-drive to ensure that you follow
safe operating practices and maintenance
procedures.
• Safety signs and labels are additional reminders
for safe operating and maintenance techniques.
• See your authorized Yanmar marine dealer or
distributor for additional training.
Crush Hazard
ALWAYS use lifting equipment with
sufficient capacity to lift the stern-drive.
NEVER stand under hoisted stern-drive. If the hoist

mechanism fails, the stern-drive will fall on you,
causing serious injury or death.
NEVER support the stern-drive with equipment not

designed to support the weight of the stern-drive
such as wooden pieces, blocks or by only using a
jack.
Marine Installation Manual - Volume 3 DEC 2007 (Rev. 3) ZT350 - 5

Sever Hazard
NEVER service the stern-drive while
The safety messages that follow have under tow or if the engine is running at
WARNING level hazards. These safety idle speed. The propeller may rotate
messages describe a hazardous situation under these circumstances.
which, if not avoided, could result in death or
serious injury.
If the vessel has more than one engine, NEVER
Explosion Hazard service a stern-drive if either of the engines are
While the engine is running or the running. In multi-engine configurations, the
battery is charging, hydrogen gas is propeller for an engine that is shut down may rotate
being produced and can be easily if any of the other engines are running.
ignited. Keep the area around the
battery well-ventilated and keep sparks, Rotating parts can cause severe injury or death.
open flame and any other form of ignition out of the NEVER wear jewelry, unbuttoned cuffs, ties or
area. loose-fitting clothing, and ALWAYS tie long hair
back when working near moving / rotating parts
Fire Hazard such as the flywheel, propeller or PTO shaft. Keep
hands, feet and tools away from all moving parts.
Undersized wiring systems can cause
an electrical fire.
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.

ZT350
12/05
Entanglement Hazard The safety messages that follow have CAUTION

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

ZT350 INSTALLATION INFORMATION
NEVER use the stern-drive lifting eye to lift the

engine and stern-drive as an assembly. Use the
The safety messages that follow have NOTICE engine lifting eyes to lift the engine and stern-drive.
level hazards. Only use the stern-drive lifting eye to lift the stern-
drive as a separate component.
It is important to perform the daily checks as listed
in this Operation Manual. Periodic maintenance
prevents unexpected downtime, reduces the The anode of the ZT350 is only calculated for the
number of accidents due to poor engine or stern- ZT350. Changing the material of the propeller may
drive performance and can help extend the life of require additional anodes to be installed.
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.
ZT350 - 8 NOV 2008 (Rev. 4) Marine Installation Manual - Volume 3

ZT350
12/05
NOTICE TO VESSEL OEM & We could not possibly know of and advise the
marine trade of all conceivable procedures or
EQUIPMENT INSTALLER methods by which a service might be performed, or
This Installation Manual contains safety information of every possible hazard and / or results of each
designed to: procedure or method. We have not undertaken any
such wide evaluation. Therefore, anyone who uses
• Make you aware of the hazards associated with a procedure or method not described by the
the installation of the ZT350 stern-drive. manufacturer must first satisfy himself that neither
his safety, nor the safety of the product, will be
• Inform you of the risk of injury associated with
endangered by the installation or servicing
those hazards.
procedure selected.
• Tell you how to avoid or reduce the risk of injury.
All information, illustrations and specifications
• Prior to work, read and understand the section(s) contained in this manual are based on the latest
of this manual that pertain to the job. production information available at the time of
publication. However, Yanmar Marine International
• Read and follow all safety warnings. reserves the right to change, alter or otherwise
NOTICE: Indicates critical information or improve the product at any time without obligation
instructions that are necessary for proper or prior notice.
installation and / or operation.
Sales and Technical Assistance
Note: See the appropriate Yanmar Technical The Yanmar dealer / distributor network is trained
Manual for application to assist with any sales or technical issues. This
recommendations. includes application engineering and service
This Installation Manual has been written and information.
published by Yanmar Marine International to assist
If you have an issue with the application of our
boat manufacturer's and service personnel when
product that cannot be resolved, contact your
installing the products described herein.
Yanmar Distributor Service Engineer. All requests
It is assumed that these personnel are familiar with for assistance should be directed to your local
the installation procedures for these products, or Yanmar distributor. The distributor for your area
like or similar products, manufactured by Yanmar can be found by using the service locator on the
Marine International. It is also assumed that they Yanmar website (www.yanmarmarine.com) or by
have been trained in the recommended installation contacting Yanmar Marine International.
procedures for these products, which includes the
use of mechanics hand tools and any special tools
that might be required.

Tightening Torques for Standard Bolts and Nuts
Note: Securely tighten all of the fasteners not listed below.
Description N·m lb-in. lb-ft

Transom Plate Bolt 45 — 33
Connector Bolt (Seawater) 6 53 —
Plate Bolt (Seawater Inlet) 6 53 —
Exhaust Block-Off Plate Bolt 30 — 22
Steering System Upper and Lower
35 — 26
Pivot Bolt
Steering Cable Coupler Nut 45 — 33
Rear Engine Mount Bolt 45 — 33
Stern Drive Unit Fastener 60 — 44
Front 135 — 99
Propeller Locknut
Rear 80 — 59
Propeller Shaft Anode Screw 30 — 22
Lubricants / Sealants / Adhesives

Description Where Used Part Number
Power Steering Bushings
Upper and Lower Pivot Bolts
UREA Grease Clevis Pin
Water Resistant Type NLGI #2
Ex) Rykon Premium Grease EP Steering Cable End
Propeller Shaft Splines
Steering Cable and Clevis
Liquid Type Neoprene or Electrical Connections
Silicon Sealant Y-CaPS Connections
Multipurpose Heavy-Duty Type Lithium Drive Unit Pilot
Grease Universal Joint Shaft O-Rings
NLGI #2
Ex) Valvoline Multipurpose Drive Shaft Splines
Grease / GM Coupler Splines Obtain Locally
SAE 30W Engine Oil Shift Cable Pivot Points
GL5 Hypoid Gear Oil Oil Reservoir
Bell Housing Studs
Lithium Grease O-Ring Seals
with PTFE
Ex) Cortec Co. Lithium EP Grease with PTFE Anchor Pin Threads
Shift Cable
UREA Grease
Water Resistant
Unit Bearing (Gimbal Housing)
Type NLGI #2
Ex) Rykon Premium Grease EP
Dexron III Power Steering Pump
Automatic Transmission Fluid Power Trim Pump

ZT350
12/05
Special Tools
Use to determine where to cut and drill

Transom Cutout and Drill Fixture
the boat’s transom for the stern-drive
(196350-92020)
installation.
0006039
Remove and install the hose insert into

Hose Insert Tool
the water inlet hose.
0006498
Alignment Shaft Aligns the engine and the drive unit

(196350-92010) during installation.
0006040
Trim-In Limiter This condition is primarily a result of vessel design

and can only be reduced with thorough
WARNING! Only qualified personnel should performance testing by the manufacturer (OEM) of
install and evaluate the effectiveness of the the vessel. However, shifting hull weight to the
Trim-In limiter. The vessel is required to be stern may be helpful in controlling this tendency.
tested at trim-in range and several different
speed settings. 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 stern-
trimmed in at higher speeds, the trim-in range drive, as a service part.
should be adjusted by using a Trim-in limiter.
Wider trim-in ranges and higher speeds may The Trim-In limiter reduces stern-lift by preventing
cause handling problems on some vessels that the stern-drive unit from reaching the last few
could result in personal injury. degrees of full trim under. While this device should
reduce the rolling tendency, it may not eliminate the
The stern-lift will cause certain vessels tendency entirely. The use of a Trim-In limiter, and
(predominantly heavy, deep-V hulls) to list towards the evaluation of its effectiveness, can only be
the port or starboard side during full power speeds determined by trial and error adjustments and is
with the stern-drive set to full Trim-In. The vessel ultimately the responsibility of the boat
will not roll over completely, but the list can often be manufacturer.
significant enough to unseat the operator and / or
passengers. This creates an unsafe situation.

ZT350 INSTALLATION INFORMATION
STEERING TIE BAR CORROSION CONTROL

CONSIDERATIONS It is the boat designer's responsibility and/or the re-
powering engineer's responsibility to design the
NOTICE: The use of multiple stern-drives requires
proper systems and equipment to control and
a careful consideration of the type of steering
reduce the possibility of galvanic corrosion.
system that should be used.
To help control the effects of galvanic corrosion,
CAUTION! Failure to observe the recommended
Yanmar Marine ZT350 stern-drives come with
tie bar arrangements could result in serious
several anodes and an electronic anticorrosion
damage to the steering and / or power trim
system (Y-CaPS) that protect the stern-drive in
system components. This damage could
moderate corrosive conditions. However, it is
adversely affect boat control.
essential that the owner/operator frequently
Internal Tie Bar Only monitor the anodes for wear, inspect the stern drive
for corrosion and replace the anodes often enough
This system is recommended for vessels that to provide a sacrificial surface for the electrical
operate at speeds up to 50 knots (58 mph). current to attack. Galvanic isolators are also
It is a direct connection between the slave stern- available from the aftermarket (not supplied by
drive and the stern-drive that is directly connected Yanmar) to block stray current while still providing a
to the factory power steering output. This internal path to ground for dangerous shock currents.
tie bar is available in a variety of lengths from NOTICE: The anode of the ZT350 is only
Yanmar. Contact your Yanmar dealer or distributor. calculated for the ZT350. Changing the material of
the propeller may require additional anodes to be
Internal and External Tie Bar installed.
This system is recommended for vessels that
operate at speeds from 50 to 60 knots (60 to 70 Shore Power
mph) or for the benefit of reduced steering Vessels that are connected to shore power require
backlash. additional protection to prevent destructive low
Usually, external tie bars are attached at the aft voltage galvanic currents from passing through the
power trim cylinder bosses, but if one drive is shore power ground wire. A galvanic isolator is
trimmed differently than the other, undue stress on available to block these currents while still
the system is introduced. For this reason, dual trim providing a path to ground for dangerous shock
control equipment should be installed to limit the tilt currents.
differential between the two drives to 20°. NOTICE: If AC shore power is not isolated from the
NOTICE: When using an internal power steering boat ground, the Y-CaPS and anodes may be
system, Yanmar does not recommend the use of an unable to neutralize the increased galvanic
external tie bar by itself. This can cause excessive potential.
loads on the steering components and may result in
an increase of the play in boat steering.
External Power Steering with an

External Tie Bar
This system is recommended for vessels that
operate at speeds of 70 knots (80 mph) or greater
or for the ultimate in reduced steering backlash.
This system does not use an internal tie bar, but
requires dual trim control equipment. See Internal
and External Tie Bar on page ZT350-12.
ZT350 - 12 NOV 2008 (Rev. 4) Marine Installation Manual - Volume 3

ZT350
12/05
Antifouling Paint
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
antifouling or marine paint to the transom of the (1)
boat hull. (2)
• NEVER paint the anodes of installed on the stern-
drive.
• NEVER paint the Y-CaPS reference electrode 0006341
and / or anode.
• NEVER wash the stern-drive with a high pressure Figure - 1
washer. This could damage the coating on the 1 – Painted Vessel Transom
reference wire. 2 – Minimum 40 mm (1-1/2 in.) of unpainted area
around transom assembly.
• NEVER paint the stern-drive with a material that
contains copper or tin. NOTICE: The drive unit and transom assembly can
be painted with a good quality marine paint or an
• NEVER paint over drain holes, anodes, Y-CaPS anti-fouling paint that does not contain copper or
or other items specified by the anode any other material that could conduct electrical
manufacturer. current. NEVER paint drain holes, anodes, Y-CaPS
or items specified by the vessel manufacturer.
Painting the Transom and Stern-
NOTICE: NEVER wash the stern-drive with a
Drive power washer because it can damage the coating
Corrosion damage that results from improper on the reference wire and increase corrosion.
application of anti-fouling paint will not be covered
by the warranty.
Anti-fouling paint may be applied to the vessel hull
and the vessel transom.
NOTICE: NEVER paint the anodes or Y-CaPS
electrode. Painting these components will render
them ineffective as galvanic corrosion inhibitors.
NOTICE: Use copper-based paint as anti-fouling
protection for the vessel hull or vessel transom, as
long as it is not prohibited by law in the area where
the vessel will be operated. If using copper- or tin-
based anti-fouling paint, avoid an electrical
interconnection between the Yanmar product,
anodic blocks, or Y-CaPS and the paint by allowing
a minimum of 40 mm (1-1/2 in.) of UNPAINTED
area on the transom of the vessel and around these
items.

VESSEL DESIGN
CONSIDERATIONS (3) (3)
(1)
(2)
ALWAYS adhere to all applicable marine
regulations such as the United States Coast (4)
Guard (USCG), European Union-Recreational
Craft Directive (EU-RCD), and so on and the (5) 0006042
standards they reference such as the American
Boat and Yacht Council (ABYC), Society of Figure - 2
Automotive Engineers (SAE), International
Standards Organization (ISO), and so on, when 1 – Transom Thickness
2 – Transom Angle
designing and constructing the boat and the
3 – Transom plate coverage 203 mm (8.0 in.)
boat components, such as the engine from the center.
compartment, fuel delivery system and exhaust 4 – Inner Surface
system. 5 – Outer Surface
When choosing a vessel that will potentially be
Transom Thickness
modified for the installation of the ZT350 stern-
drive, ensure that the vessel transom meets the See Checking the Transom Thickness on
following criteria: page ZT350-20.
• Transom thickness should be between 51 and 57 Laying Out the Transom Cutout
mm (2 - 2.25 in.).
See Positioning the Drive Unit on page ZT350-16.
• The inner and outer surface of the transom
should be parallel to within 3 mm (0.125 in.). Vessel Engine Mount Position
• The inner surface of the transom is flat to within 3 The engine mount position should allow for a
mm (0.125 in.). minimum of 6 mm (0.25 in.) of vertical adjustment
on the front mounts of the engine.
• The outer surface of the transom is flat to within 2
mm (0.075 in.). Note: The mounting hardware that is
incorporated with the engine usually
• The transom angle is between 10 and 16° (13° is allows for some adjustment. However, it
ideal). is good practice to ensure that the
engine mount points that hold the engine
• Ensure that there is enough flat surface area on
in the vessel are all in parallel planes.
the transom to apply the transom plate. This
would be 203 mm (8 in.) on either side of the • Tie a string from the front right mount position
center line of the transom. and the left rear mount position.
• Tie a string from the left front mount position
and the right rear mount position.
• The strings should touch at the point of
intersection.

ZT350
12/05
Selecting an Engine Exhaust System

It is important to know what type of engine exhaust
system will be used with the ZT350 Stern-Drive.
The following chart describes the parts required for
each system.
Engine Exhaust Transom Transom Exhaust

System Exhaust Bellows or Tube
Through-the-Transom
Exhaust Exhaust
Through-the-Hull Cover Plate
Exhaust Tube
Exhaust
Through-the-Propeller Engine
Exhaust Exhaust Pipe
See Exhaust Options on page ZT350-33.

POSITIONING THE DRIVE UNIT Locating the Crankshaft Vertical
Centerline - Dual Engine Installation
Locating the Crankshaft Vertical
Locate and mark the transom vertical centerline
Centerline - Single Engine
(See Locating the Crankshaft Vertical Centerline -
Installation Single Engine Installation on page ZT350-16).
If the crankshaft vertical centerline is not already NOTICE: The minimum distance between the
marked by the vessel manufacturer, locate and crankshaft vertical centerlines for dual side-by-side
mark the vertical centerline on the transom in applications is 838 mm (33 in.).
accordance with the following steps and methods:
1. Make a set of marks equal to 1/2 the minimum
Use a large compass to locate the vertical distance 419 mm (16.5 in.) on both sides of the
centerline. transom vertical centerline.
1. Mark identical locations on each side of the 2. Draw the two crankshaft vertical centerlines
boat 305 mm (12 in.) from the bottom of the through the intersection of the marks.
hull.
2. Position the fixed end of a compass at the (1) (1)
marks and draw arcs on the transom.
3. Draw the crankshaft vertical centerline through
the intersection points of the two arcs.
(5)
(1) (2) (2)
(4)
(2)
(1)
(3)
(1)
(5)
(3) 0006044
0006043 Figure - 4
Figure - 3 1 – 1/2 minimum distance between the
1 – 305 mm (12 in.) crankshaft centerlines.
2 – Identical Side Marks 2 – Transom Vertical Centerline
3 – Compass Arc 3 – Dual Engine Crankshaft Vertical Centerlines
4 – Arc Intersection Points
5 – Crankshaft Vertical Centerline

ZT350
12/05
Finding the Crankshaft Horizontal The 90° Tool Method

Centerline (X-Dimension) Construct the 90° tool as shown in Figure - 5.
There are two general methods available for
locating the horizontal centerline of the engine (1) 90˚
crankshaft. They are the “90° Tool Method” and the
“Tape Measure Method”. Regardless of the method
used, several vessel design considerations need to
be examined before an optimum determination can
be made. The following suggestions are offered as (2)
a general guideline. The actual “X-Dimension”
should be the result of thorough design testing by Figure - 5
the hull manufacturer.
1 – 345 mm (13-9/16 in.)
2 – 1.2 m (4 ft)
Vessel Characteristics
Speeds Below 22 Knots Subtract 13 mm (0.5 in.)
NOTICE: The 345 mm (13-9/16 in.) dimension
(25 mph) from X-Dimension should only be raised or lowered after proper
Subtract 25 mm (1.0 in.)
testing (See Finding the Crankshaft Horizontal
Heavy Duty Applications Centerline (X-Dimension) on page ZT350-17).
from X-Dimension
Speeds Between 22 Knots Use the X-Dimension • To lower the drive unit - subtract from the 345 mm
(25 mph) and 43 Knots given in the 90° Tool
(13 9/16 in.) dimension (Figure - 5, (1)).
(50 mph) Method
Speeds Above 43 Knots Increase the X-Dimension • To raise the drive unit - add to 345 mm
(50 mph) to improve performance. (13 9/16 in.) dimension (Figure - 5, (1)).
NOTICE: When the X-dimension is increased, the Use the 90° tool as follows:
pulling power for skiing is decreased. During 1. Place the 90° tool along the boat bottom at the
testing, increase the X-dimension in 13 mm (1/2 in.) vertical centerline.
increments until preferred performance is achieved.
2. Locate the point at which the top of the 90° tool
Never increase the X-dimension by more than: contacts the transom on the vertical centerline.
3. This is the crankshaft horizontal centerline or X-
Maximum Increase in X-Dimension
dimension.
ZT350 25 mm (1 in.)
Observe the following details during the testing

process:
• Ensure that the water supply does not become
aerated when the drive unit is raised.
• 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.

4. Draw a line perpendicular to the vertical
centerline at the intersection of the crankshaft X-Dimension (measuring
Transom Angle
horizontal centerline. up from the keel)
16° 364 mm (14-5/16 in.)
15° 362 mm (14-1/4 in.)
(2)
14° 360 mm (14-3/16 in.)
13° 359 mm (14-1/8 in.)
12° 357 mm (14-1/16 in.)
11° 356 mm (14 in.)
10° 354 mm (13-15/16 in.)
(3) 1. On the vertical crankshaft centerline, measure

up from the bottom of the vessel transom to the
(1) X-dimension selected from the chart.
0006046A
2. This point is the crankshaft horizontal centerline
Figure - 6 at the X-dimension.
3. Draw a line perpendicular to the vertical
(2)
centerline at the crankshaft horizontal
centerline.
(1)
(3)
(1) 0006046B
Figure - 7
(2)
1 – 90° tool along the boat bottom at the vertical (3)
centerline. 0006047A
2 – Contact Point Figure - 8

3 – Crankshaft Horizontal Centerline
(1)
The Tape Measure Method
NOTICE: These dimensions should only be raised
or lowered after proper testing (See Finding the
Crankshaft Horizontal Centerline (X-Dimension) on
page ZT350-17).
Use the following chart to determine the X- (3)
dimension. (2)
0006047B
Figure - 9
1 – Vertical Centerline
2 – X-Dimension that corresponds to the
transom angle selected from the chart.
3 – Crankshaft Horizontal Centerline

ZT350
12/05
Cutting the Vessel Transom Transom Cutout and Drill Fixture

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.
2. Ensure that the centerlines of the template or
the drilling fixture align with the marks
determined previously. See Positioning the
Drive Unit on page ZT350-16.
Template
0006039
Figure - 11
1. Drill two 6 mm (1/4 in.) pilot holes at a 60° angle
for the hole saw guides.
2. Use a hole saw to cut the two 51 mm (2 in.)
holes for the steering lever cutout.
NOTICE: If the hole saw cutout is made incorrectly,
stern-drive steering lever may come in contact with
the transom causing limited steering travel.
(1)
(2)
0006048
Figure - 10 (2)
0006049
Figure - 12
1 – 51 mm (2 in.) Steering Lever Cutout
2 – 60° from the surface of the transom

1. Cut the transom on the cut line at a 90° angle.
Use caution when making the transom cutout.
An incorrect cut could cause the gimbal
housing or exhaust system to come in contact
with the boat transom, making it difficult to
mount the drive unit.
2. Seal the inside edge of the transom cutout
opening with a sealant to prevent water
absorption and deterioration of the transom.
(3)
0006052
Figure - 15
(1)
1 – Measuring Transom Flatness
2 – Measuring Transom Thickness
(2)
3 – Suitable tool to check for uniform transom
thickness.
(4)
Transom Specifications
(3) Thickness Between 51-57 mm

0006050 (2-2-1/4 in.).
Figure - 13 Parallelism1 Inner and outer surfaces
must be parallel within 3
1 – 90° from the surface of the transom. mm (1/8 in.).
2 – Cut Line Surface Plane1 Transom surfaces in an
3 – Exhaust Pipe Area area where transom
4 – Mounting holes perpendicular (90°) to the assembly will be mounted
transom surface (8 ea.). (Includes vertical as well
as horizontal dimensions):
Checking the Transom Thickness Inner Surface - flat within 3
mm (1/8 in.)
Ensure that the transom thickness and surface Outer Surface - flat within
dimensions conform to specifications listed 2 mm (1/16 in.)
previously and to the chart below. See Vessel Angle 10°-16° (13° Ideal)
Design Considerations on page ZT350-14.
1
Measured in transom assembly mounting area.
(2)
(1)
0006051
Figure - 14

ZT350
12/05
INSTALLING THE TRANSOM 3. Secure the transom assembly with hardware as

shown in Figure - 16.
ASSEMBLY 4. Torque the transom plate bolt.
1. Insert wires, hoses and shift cable through the
corresponding openings in the inner transom Transom Plate Bolt Torque
plate. N·m lb-ft
2. Position the gimbal housing on the transom and 45 33

hold it in place.
5. Attach the bonding wires.
NOTICE: Tighten the transom assembly
fasteners using an X-pattern torque sequence. NOTICE: The steering lever bonding wire must be
Tighten in small increments and go around the positioned as shown in Figure - 16 to avoid
pattern several times until the proper torque is stressing the wire when the steering lever moves.
achieved.

(1) (4)
(2)
(3)
(1) (1)
5 7
(5)
3 2
1 4
8 6
0006053
Figure - 16
1 – Locknuts and Flat Washers (8 ea.) 4 – Transom Plate Bonding Wire
2 – Steering Lever Bonding Wire 5 – Torque Sequence
3 – Bolt

ZT350
12/05
Connecting the Speedometer Pickup Drive Unit Seawater Pickup

CAUTION! Excess water in the bilge can Seawater for engine cooling may be supplied
damage the engine or cause the boat to sink. through the drive unit or through an alternative
NEVER remove the plug from the speedometer method. When using the drive unit for engine
pickup tube fitting unless the connection is to cooling seawater, a quick connect seawater hose
be used. fitting is included in the engine loose parts.
1. Remove the protective cap from the male quick
(2)
connect.
2. Connect a 4 mm (5/32 in.) hose (not provided)
from the speedometer to the barb fitting.
3. Secure the hose to the fitting with a cable tie.
(1)
(1) (2)
(3) 0006055
Figure - 18
1 – Seawater Hose Fitting
2 – Connector (Seawater)
1. Install the fitting gasket (connector).
2. Install the connector (seawater).
(3) (4)
(5) 3. Install J-clip if oil reservoir hose assembly will
be routed to the port side.
4. Install the lock washers and connector
(2) (seawater) bolts.
0006054 5. Torque the bolts.
Figure - 17 Seawater Inlet Fitting Bolt Torque
1 – Male Quick Connect N·m lb-in.
2 – Female Quick Connect 6 53
3 – Barbed Fitting
4 – Tie Strap
5 – Hose (2)
4. Secure the hose to the transom with the hose
clip and screw.
(1)
5. Ensure that the hose NEVER contacts the (3)
steering system components, the engine
coupler or the drive shaft. CAUTION! Avoid
water leaking into the boat. The
speedometer hose is filled with water,
especially during boat operation. Hose
(4)
contact with moving or rotating engine parts 0006056
could cause damage to the hose resulting in Figure - 19

water leaking into boat. NEVER let the
speedometer hose come in contact with the 1 – Connector (Seawater)
steering system components, the engine 2 – J-Clip
coupler or the drive shaft. 3 – Gasket (Connector)
4 – Bolt and Lock Washer

Alternate Seawater Pickup 2. Install the plate (seawater inlet) with a new
gasket.
Seawater for engine cooling can be supplied
through an alternate (separate) seawater pickup, 3. Install the lock washers and plate bolts.
not through the drive unit. When using a separate 4. Torque the bolts.
seawater pickup, it is necessary to cover the drive
unit seawater passage and to cut the water line in Plate (Seawater Inlet) Bolt Torque
order to circulate seawater through the drive unit N·m lb-in.
for cooling. 6 53
NOTICE: Installation of a water inlet cover plate will

make it necessary to provide an alternate seawater
pickup and related hardware. Depending upon
application and boat configuration a through-the-
hull or through-the-transom seawater pickup must
be used.
CAUTION! Avoid overheating the drive unit. The
drive unit water inlet holes must be allowed to
flow water without being obstructed, or
overheating damage to drive unit may result.
NEVER dead-end the water hose from the bell
housing. The hose must be cut as
recommended. (3)
(2)
1. Use the hose insert tool to remove the insert in (1)
the gimbal housing.
(2) (3) (4)
0006058
Figure - 21
1 – Bolts
2 – Lock Washer
3 – Plate (Seawater Inlet)
(3) 4 – Gasket
(2)
(1)
0006499
Figure - 20
1 – Hose Insert Tool
2 – Insert
3 – Gimbal Housing

ZT350
12/05
Connecting the Inlet Water Hose

(1)
(2)
(2)
(4) (3)
(4)
(3)
0006059
Figure - 22
(1)
1 – Gimbal Housing
2 – Speedometer Hose
3 – Water Hose
4 – Trim Sender Limit Switch Wires (5)
WARNING! Avoid water leaking into the boat. 0006060
Damage to U-joint bellows could result from
water entering the boat. Do not damage the U- Figure - 23
joint bellows when removing the section of the 1 – Water Hose
water hose attached between the gimbal 2 – Speedometer Hose
housing and bell housing. 3 – Clip
4 – Trim Sender Limit Switch Wires
Note: Move the trim sender limit switch wires 5 – Measurement: 127 mm (5 in.)
and speedometer hose to avoid
damaging them when cutting the inlet
drive shaft water hose. The existing tie
strap and clip can be reused if they are
moved and repositioned after the hose is
cut.
1. Cut completely through the inlet water hose 127
mm (5 in.) in front of the aft end of the hose
where it is fitted into the bell housing. Do not
damage the U-joint bellows.
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.

Connecting the Oil Reservoir Hose (3)
1. Connect the quick connector 90° of the gimbal
housing hose assembly to the gimbal housing
(1)
fitting.
(2)
(1)
(4)
(5)
(2)
(3) 0006062
Figure - 25
(3) 0006061
1 – Plate (Seawater Inlet)
Figure - 24 2 – ACCEPTABLE Positions
3 – Quick Release Button
1 – Gimbal Housing Hose Assembly 4 – NOT ACCEPTABLE Position
2 – Quick Connector 90° 5 – Quick Connector 90°
3 – Gimbal Housing Fitting
NOTICE: NEVER let the hose come in contact
CAUTION! Avoid drive unit damage. The with the steering system components, the engine
quick release button on oil reservoir 90° hose coupler or the drive shaft.
fitting may not lock on gimbal housing if
touching or depressed by connector 3. The oil reservoir hose assembly can be routed
(seawater), or plate (seawater inlet) if toward the port side of the engine.
equipped. Ensure that the quick release 4. Secure the hose assembly at the top side of the
button NEVER contacts the plate, or connector (seawater), or plate (seawater inlet),
connector if equipped. Failure to do so may using the hose J-clip.
result in a loose 90° fitting, a loss of gear lube
and / or damage to the drive unit. (1)
2. Position the quick release button on the 90°

hose fitting away from the connector
(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 - 26
1 – Oil Reservoir Hose
2 – Hose J-Clip

ZT350
12/05
5. Secure the oil reservoir gimbal housing hose

assembly with J-clips on the transom plate. (1)
(2)
(3)
(4)
(1)
0006064
Figure - 27
1 – J-Clips 0006065
6. Temporarily position the hose out of the way Figure - 28

until connection is completed after engine 1 – Bracket (Oil Reservoir)
installation. 2 – Oil Reservoir and Cap
3 – Strap (Oil Reservoir)
Installing the Oil Reservoir 4 – Lag Screw and Flat Washer (obtain locally)
NOTICE: A bracket is included to allow oil reservoir
to be located on the transom. The mounting
location specified must be above the steering lever
on the transom assembly. The hose must be
positioned away from moving parts such as the
steering system and engine coupler.
1. Install the oil reservoir bracket in the specified
location and secure with lag screws and flat
washers.
2. Install the oil reservoir in the bracket. Secure
the reservoir with the retaining strap.

Installing the Shift Plate (1)
NOTICE: The shift plate and bracket are only for
the mechanical shift type. They are not necessary
for the electric shift type.
NOTICE: The shift plate and bracket assembly
must be installed within the reach of the drive unit
shift cable.
Install the shift plate to the inside of the transom.
• Never mount the assembly near moving
components.
• Avoid causing sharp bends and kinks in the
control cable. 0006067
Figure - 30
• Use fasteners that are appropriate for the
mounting surface to install the mounting bracket. 1 – Power Steering Bushings
UREA Grease Water Resistant Type NLGI #2

(1) Where Used Part Number
Power Steering Bushings Obtain Locally
3. Remove the upper and lower pivot bolts and

lubricate the threads liberally.
(2)
(1) (2)
0006066
Figure - 29
1 – Mounting Bolt Location
2 – Shift Plate
Installing the Steering System 0006068
Note: For dual installations the power steering Figure - 31

unit can be mounted on the port or
starboard transom assembly. Measure 1 – Lock Tab Washers
the exact distance between stern-drive 2 – Upper and Lower Pivot Bolt
centerlines. Use a proper tie bar (See UREA Grease Water Resistant Type NLGI #2
Internal and External Tie Bar on Where Used Part Number
page ZT350-12).
Upper and Lower Pivot Bolts Obtain Locally
1. Inspect the bushings for debris.
2. Lubricate the power steering bushings. 4. Position the steering assembly so that the pivot
bolts will fit in the bushings in the power
steering cylinder.

ZT350
12/05
5. Install the upper and lower pivot bolts along (1) (2)
with the lock tab washers. Ensure that the lock
tab washer tangs straddle the ridge on the inner
transom plate.
Upper Pivot Bolt and Tab Washer Shown (Lower
Similar).
(1) (1) (2)

0006070
Figure - 33
(2)
1 – Bent Tab
2 – Pivot Bolt
9. Wear eye protection while moving the spool
barrel cable guide tube in the directions shown
in Figure - 34. It will be less difficult to pull it out
or push it in during the following installation
steps. CAUTION! Moving the spool barrel
cable guide tube with the hoses
disconnected will leak fluid from the ports.
0006069
Wear eye protection to avoid injury.
Figure - 32
(1) (2)
1 – Locking Washer Tang
2 – Ridge
6. Turn the pivot bolts all the way in by hand.
Ensure that the steering assembly pivots freely.
7. Torque the pivot bolts.
Upper and Lower Pivot Bolt Torque
N·m lb-ft
35 26 (1)
(2)
8. Bend the locking washer tabs against the
corresponding flats on the bolt heads.
Note: It may be necessary to tighten the pivot
bolts a little more to align the flats on bolt
head with the tabs on the washer.
0006071
Figure - 34
1 – Port
2 – Spool Barrel Cable Guide Tube

10. Connect the clevis to the steering lever. Connecting the Steering Cables
11. Lubricate the clevis pin. Spread both ends of 1. Coat the steering cable end with a liberal
the clevis pin. amount of lubricant.
Note: Insert the clevis pin from the top and 2. Install the steering cable and secure with
rotate the pin to ensure that the cotter pin hardware as shown in Figure - 35.
hole is as shown in Figure - 35.
NOTICE: The flat surfaces of the spool barrel
(2) cable guide tube must be positioned horizontally
to prevent feedback in the steering system.
(1) 3. Use a wrench to hold the flat surfaces of the

spool barrel cable guide tube horizontally.
4. Torque the coupler nut. Ensure that the flat
surfaces are still aligned horizontally after
torque is applied to the coupler nut.
Where Used
Steering Cable End
(3)
Cable Coupler Nut Torque

(4) 0006072
N·m lb-ft
Figure - 35
45 33
1 – Clevis
2 – Steering Lever
3 – Cotter Pin
4 – Clevis Pin

Where Used
Clevis Pin
CAUTION! The steering cable and outer casing

must move freely for the steering system to
function properly. Never fasten any items to the
steering cable and / or the outer casing.
(1)
0006073
Figure - 36
1 – Steering Cable and Outer Casing

ZT350
12/05
(1)
(2)
(6) (5)
(7)
(4) (3) (2)
0006074
Figure - 37
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

Installing the Power Trim Pump Note: An adapter harness may be needed to
connect the remote control trim pump
The mounting location for the trim pump should be: harness to the pump. Acquire an adapter
• Within length limits of the hydraulic hoses coming harness that has a “PACKARD METRI-
from gimbal housing assembly. PACK 150” series 3-pin connector.
• Close to the battery so that the trim pump battery 2. Connect the power trim pump control harness
leads can be connected. to the trim pump connector.
• Easily accessible to trim pump oil fill and vent (1)

locations.
• In an area where the pump will not be exposed to
water.
• Prevent the power assist steering cylinder from
coming in contact with the trim pump when the
steering wheel is turned to the limit in either
direction. (2)
Mount the pump in the selected position.

Note: Make hydraulic connections as quickly
as possible to prevent oil from leaking
out of the system.
1. Connect the hydraulic hoses to the trim pump.
Ensure that the quick connect fittings
0006076
completely seat when connecting the hoses.
Figure - 39
1 – Power Trim Pump Control Harness
2 – Trim Pump Connector
(2)
3. Connect the trim limit switch wires and secure
with a wire retainer and tie strap.
(1)
(1)
(2) 0006077
(3) Figure - 40
0006075
1 – Trim Limit Switch Wires
Figure - 38 2 – Wire Retainer and Tie Strap (obtain locally)
1 – Hydraulic Hose (UP hose)

2 – Quick Connect Fittings
3 – Hydraulic Hose (DOWN hose)

ZT350
12/05
EXHAUST OPTIONS Alternate Exhaust System

1. Install the exhaust block-off plate as shown in
Through-the-Propeller Exhaust Figure - 43, using the four bolts and lock
NOTICE: To prevent water and / or exhaust from washers.
entering the boat, the exhaust tube and the gimbal 2. Torque the cover plate bolts.
housing mating surfaces must be clean, free of
nicks and scratches, and the O-ring must be (1)
properly seated in the groove.
(2)
(1)
(2)
0006080
Figure - 43
1 – Bolts and Lock Washers
0006078
2 – Exhaust Block-Off Plate
Figure - 41
Exhaust Block-Off Plate Bolt Torque
1 – Gimbal Housing Exhaust Tube Mating
N·m lb-ft
Surface
2 – O-Ring 30 22
Install the engine exhaust tube as shown in

Figure - 42.
(1)
0006079
Figure - 42
1 – Engine Exhaust Tube
Please refer to the relevant manual for the correct
tightening torque.

INSTALLING THE ENGINE

CAUTION! Avoid product damage caused by (1)
improper engine alignment. Improper engine
alignment can be caused by mismatched (7)
flywheel housing mounts and inner transom (2)
plate mounting hardware. Ensure that the (6)
flywheel housing mounts and the inner transom
plate mounting hardware, port and starboard,
are the correct parts and match before (5) (3)
installing the engine.
NOTICE: Use hard rubber washers on the inner
transom plate engine mounts. (4)
1. Attach a sling to the lifting eyes on the engine

and adjust so that the engine is level when
suspended.
2. Lift the engine into position in the boat using an 0006086
overhead hoist. WARNING! Only use a hoist
with adequate lifting capacity of the engine. Figure - 45
CAUTION! When lowering the engine into 1 – Bolt

position, NEVER set the engine on the shift 2 – Spacer
cable. The shift cable outer casing can be 3 – Steel Washer (obtain locally)
crushed causing difficult or improper 4 – Inner Transom Plate Mount
5 – Hard Rubber Washer
shifting.
6 – Rear Engine Mount
3. Align the rear engine mounts with the inner 7 – Washer
transom plate mounts. 5. Adjust the front engine mounts until they rest on
4. Set the engine on the front engine mounts and the boat stringers.
inner transom plate mounts. Do not relieve the 6. Set the engine on the stringers.
hoist tension at this time. 7. Relieve the hoist tension.
NOTICE: Engine attaching hardware must be 8. Disconnect the sling from the engine lifting
installed in the sequence illustrated. Install and eyes.
torque rear engine mounting bolts with hardware
as illustrated. NOTICE: The finished boat stringer must position
the front engine mount so that a minimum of 6 mm
(1/4 in.) up or down adjustment exists after the
(1) (2) mount is adjusted to contact the stringer. This
allows for future engine alignment or adjustments.
(3) Make proper alterations to the boat stringer
(structure) height to obtain the 6 mm (1/4 in.)
dimension.
0006085
Figure - 44
1 – Steel Washer (obtain locally)
2 – Corrected Engine Mount
3 – Hard Rubber Washer

ZT350
12/05
Aligning the Engine

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. If necessary, hit the (3)
sides of the Alignment Tool with a soft mallet at
90° increments to help align the gimbal
bearings to the coupler.
(3) (2) (4)

0006083
Figure - 47
1 – Insert this end of the alignment tool through
the gimbal housing assembly.
2 – Alignment Shaft
3 – 90° Increments
Aligns the engine

Alignment Shaft and the stern-
(196350-92010) drive during
installation.
(1) (2) 2. If the Alignment Tool does not fit, remove it and
carefully adjust engine mounts as necessary.
NOTICE: Turn both front engine mount
adjustment nuts an equal amount in the direction
required to align the engine.
To Adjust the Engine Up or Down:
(a) Loosen locknuts on mounts.
(b) Turn adjusting nuts as necessary.
(c) Temporarily tighten locknuts.
To Move the Engine to the Left or Right:
0006082
(a) The locknuts on mounts should be loose.
(b) Move the engine in the slotted mount holes
Figure - 46
as necessary, if equipped.
1 – The end of the alignment shaft is inserted 3. Attempt to insert the solid end of the Alignment
through the gimbal housing assembly. Tool through the gimbal bearing and into the
2 – Alignment Shaft
engine coupler splines again.
3 – Unit Bearing (Gimbal Housing)
4 – Engine Coupler

4. On models where the front engine mounts 7. Torque the rear engine mount bolts.
cannot be lowered enough to allow for proper
engine alignment: Rear Engine Mount Bolts
N·m lb-ft
(a) Attach a sling and lifting arm to the engine
lifting eyes and adjust so that the engine is 45 33
level when suspended.
8. Fasten the front mount assemblies to the boat
(b) Remove the rear engine mounting bolts and stringers using appropriate hardware (as per
hardware. manufacturer's design specifications).
(c) Use an overhead hoist to lift the engine (a) Torque both front mount locking nuts.
enough to install the stainless steel washer
inside the inner diameter of both fiber (b) Recheck alignment with the Alignment Tool.
washers. NOTICE: The Alignment Tool must enter the
Note: This will position the washer between the coupler splines freely. If not, remove the
new engine mount and the transom Alignment Tool and readjust the alignment.
mounting support, which should raise the (c) Remove the Alignment Tool when alignment
engine slightly, resulting in additional is complete.
front mount adjustment.
9. If operating in a saltwater environment, apply
5. Install both rear engine mounting bolts with sealant to the threads and nuts of the engine
hardware as illustrated. mounting hardware to help protect against
(a) Set the engine on the stringers. corrosion. This will allow for easier loosening in
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. assembly during shipment if the boat will
(d) Insert the solid end of the Alignment Tool be shipped without the drive unit
through the gimbal bearing and into the installed. On boats that will be shipped
engine coupler splines. with the drive unit installed, fold the bell
6. Repeat this process until the Alignment Tool housing dust cover flap back into place
installs easily (slides freely with two fingers) all and tape shut.
the way into and out of engine coupler splines. 10. Ensure that all hardware is properly installed.
Never twist the alignment tool into position.

ZT350
12/05
ELECTRICAL CONNECTIONS Y-CaPS Controller Connection

(Cathodic Protection System)
Engine Bonding Wire Connection
1. Connect the wires to the Y-CaPS controller
NOTICE: When routing all wire harnesses and
assembly.
hoses, ensure that they are routed and secured
away from hot spots on the engine and away from NOTICE: The opposite end of the RED wire and
any moving parts. BLACK wire must be connected directly to the
battery terminals. NEVER connect them to a
1. Connect the engine bonding wire, supplied with switched circuit. The Y-CaPS system must
engine package, from the engine to the function continuously to provide proper corrosion
transom assembly. protection.
2. Tighten the inner transom plate screw securely.
NOTICE: NEVER attach any accessory ground (-)
wires to the transom plate ground point. Accessory
ground wires can only be attached to the ground
stud on the engine.
(2)
(1)
(1) (2) (3) (4)
0006089
(3)
Figure - 50
1 – BROWN Wire - From the electrode on the
0006087
transom assembly.
Figure - 48 2 – BLACK Wire - From the engine harness, if
equipped, or to the negative (-) battery
1 – Engine Ground Stud terminal.
2 – Inner Transom Plate Grounding Screw 3 – RED Wire - Connect (other end) to the
3 – Engine Bonding Wire positive (+) battery terminal.
4 – YELLOW Wire - From the anode on the
Trim Position Sender Connection transom assembly.
Connect the trim position sender leads from the 2. Connect wires the to Y-CaPS electrode.
gimbal housing to the leads from the engine 3. Apply a thin coat of sealant to all wire
harness. connections.
Signal to Gauge
RED Liquid Type Neoprene or Silicon Sealant
(1) (2)
GND BLK Where Used Part Number
0006088 Electrical Connections Obtain Locally
Figure - 49
1 – From the engine harness. (Refer to the
appropriate Engine and Control System
Installation Manual.)
2 – From the gimbal housing.

(1) (2)
(5) (3)
(4)
0006090
Figure - 51
1 – BLACK Wire - From the engine harness, if 3 – YELLOW Lead - From the anode on the
equipped, or to the negative (-) battery transom assembly.
terminal. 4 – Y-CaPS Electrode Connector
2 – RED Wire - To the positive (+) battery 5 – BROWN Wire - From the electrode on the
terminal. transom assembly.

ZT350
12/05
HYDRAULIC CONNECTIONS (5)

(4)
Oil Reservoir (3)
(2)
CAUTION! If the oil reservoir hose is kinked, the
(1)
reservoir will not function properly and damage
to the drive unit will occur. Ensure the oil
reservoir hose is not kinked when connected.
NOTICE: Avoid using excessive hose when routing
to the oil reservoir. The hose should be routed
directly, in as straight of a line as possible, to avoid
low spots (traps) in the system.
1. Locate the white oil reservoir quick connect at 0006092
the rear of the engine. Figure - 53

2. Ensure the oil reservoir hose is mounted in the
1 – Quick Connect (if equipped)
J-clip on the transom plate.
2 – Oil Reservoir Hose
(3) 3 – Clamp
4 – Fitting
(2)
5 – Oil Reservoir
(1) 4. Route the oil reservoir hose, assemblies if

equipped with quick connect, to the oil
reservoir.
5. If necessary, cut the oil reservoir hose to the
0006091 correct length at the oil reservoir.
Figure - 52 6. Connect and securely clamp the oil reservoir
hose to the oil reservoir fitting.
1 – Oil Reservoir hose assembly
2 – Quick connect fitting (Male and female NOTICE: NEVER let the oil reservoir hose come
quick connect fittings have check valve) in contact with the steering system components,
3 – Gimbal housing hose assembly the engine coupler or the drive shaft.
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.

Power Steering Hoses INSTALLING THE DRIVE UNIT
CAUTION! To avoid injury or property damage 1. Apply lubricant to the threads of the bell
route the hydraulic hoses to avoid extreme housing studs.
heat, stress on the hose fittings and / or hose
kinks or a loss of steering control may occur.
Route the hoses away from extreme heat, without
any kinks in the hoses and without stress on the
hose fittings.
1. Attach both hydraulic hose fittings to the
steering control valve.
2. Ensure that the quick connect fittings are
securely engaged.
3. Position the hoses as illustrated.
(1)
(2)
(1)
0006094
Figure - 55
1 – Studs (6 ea.)
Lithium Grease with PTFE

Where Used Part Number
Bell Housing Studs Obtain Locally
NOTICE: Yanmar recommends applying

multipurpose, heavy-duty type grease to the
drive unit pilot to help prevent corrosion.
0006093
Figure - 54
1 – Return Hose
2 – Pressure Hose
NOTICE: NEVER let the hose come in contact with
the steering system components, the engine
coupler, the U-joint shaft or the drive shaft. Secure
the hoses to avoid contact with hot or moving
components.

ZT350
12/05
2. Lubricate the drive unit pilot, U-joint shaft O- Lithium Grease with PTFE
rings, and drive shaft splines.
(1) O-Ring Seals Obtain Locally
4. Lift the drive unit by using the eye-bolt mounted

on the top cover.
(2) (1)
(2)
(3)
0006095
Figure - 56
1 – Drive Unit Pilot
2 – O-Rings
3 – Splines
Multipurpose Heavy-Duty Type Grease NLGI #2

Where Used Part Number 0006097
Drive Unit Pilot
Figure - 58
U-Joint Shaft O-Rings Obtain Locally
Drive Shaft Splines 1 – Eye-Bolt M10 (Obtain Locally)
2 – Plug-Bolt and Gasket (Remove)
3. Ensure that the drive shaft U-joint bellows are NOTICE: As the drive unit is inserted into the bell
clean and free of debris. Apply lubricant to housing, the shift cable must be connected to the
O-ring seals. jaws of the shift linkage assembly in the drive unit.
(1)
(2)
(2)
0006096
Figure - 57
1 – U-Joint Bellows (Clean)
2 – O-Ring Seals (Lubricate)

5. Mechanical Shift Type 6. Mechanical Shift Type
Pull the shift cable out as far as it moves by Pull the slider (shift linkage) out as far as it goes
hand. with a piece of wire.
(1)
(2)
(1)
0006099
Figure - 61
1 – Slider (Shift Linkage)
0006098 2 – Wire (obtain locally)
Figure - 59 Electric Shift Type
Don’t pull the connector wire from the driveshaft
1 – Shift Cable housing end by 20 mm or more.
Electric Shift Type
Don’t pull the shift cable, it doesn’t expand and
contract.
(1)
0006501
(1)
Figure - 62
1 – 20 mm Max
0006500
Figure - 60
1 – Shift Cable

ZT350
12/05
7. Mechanical Shift Type

Follow steps 1, 2 and 3 in Figure - 63 to
connect the cable to the slider (shift linkage).
(2)
(1)
(3) 0006100
Figure - 63
Electric Shift Type
Connect the wires that are the same color.
(3) (4) (5) (3) (4) (5)
(1) (2)
0006502
Figure - 64
1. Drive Unit Side 4. White Wire
2. Transom Assembly Side 5. Orange Wire
3. Black Wire

8. Mechanical Shift Type CAUTION! Make sure the cable is not caught in
After the cable is connected, push it into the the transom assembly and the drive unit.
inside of the housing.
(1) (2)
(3)
0006504
0006101
Figure - 67
Figure - 65
1 – Drive Unit
Electric Shift Type 2 – Transom Assembly
After the cable is connected, push it into the 3 – Wire
housing. Figure - 68 shows where to store the connectors
(Figure - 68, (1)) after the drive unit has been
installed.
0006503
Figure - 66 (1)
0006505
Figure - 68

ZT350
12/05
9. Place the drive unit in position on the bell (d) Slide the drive unit all-the-way into the bell
housing and install as follows: housing.
(a) Position the trim cylinders so that they point (e) Secure the drive unit to the bell housing with
straight back. 5 flat washers and 6 locknuts.
(b) Position the drive unit so that the U-joint
shaft aligns with the bell housing bore.
(c) Guide the U-joint shaft through the bearing
in the gimbal housing and into the engine (1)
coupler. Make sure that the slider engages
the bell housing shift cable assembly. (2)
(1)
CAUTION! DO NOT allow the edge of the bell (1)
housing (Figure - 69, (1)) and the edge of the
drive shaft housing (Figure - 69, (2)) on the
stern-drive to contact when installing the stern-
drive. 0006102
Figure - 70
1 – Locknut and Flat Washer
2 – Locknut Only
(f) Torque the drive unit locknuts.
Drive Unit Locknut Torque
N·m lb-ft
60 44
10. Remove the eye-bolt from the top cover and

replace the plug and washer to prevent
corrosion.
(1) 11. Apply lubricant to all of the components (except
plastic caps) during installation.
12. Install the trim cylinders on the aft end of the
(2) drive unit with the hardware as illustrated.
13. Tighten the locknuts until the washer and nut
contact the shoulder on the anchor pin.
0006506
Figure - 69

14. Install the plastic caps and hand-tighten. 15. Open the oil valve screw in the drive shaft
housing before the engine is operated the first
(1) (2) (1) (3) time.
(1)
0006103A
Figure - 71
1 – Rubber Bushing (4 ea.)
2 – Large Inner Diameter Flat Washer (2 ea.) 0006363A
3 – Aft Anchor Pin Figure - 73

(2) (3) 1 – Oil Valve Screw
(1)
(2)
(1) (4)
0006103B
Figure - 72
1 – Rubber Bushing (4 ea.)
2 – Small Inner Diameter Flat Washer (2 ea.)
3 – Locknut (2 ea.) 0006363B
4 – Plastic Cap (2 ea.) Figure - 74

Lithium Grease with PTFE 1 – 9 mm Wrench (hold the nut)
Where Used Part Number 2 – Screwdriver (turn left one rotation)
Anchor Pin Threads Obtain Locally 16. Hold the nut with the wrench and turn the
valve screw one turn counterclockwise.

ZT350
12/05
17. Remove the oil reservoir cap and fill the 18. Fill the reservoir to the “OPERATING RANGE”
reservoir with lubricant (GL5 Hypoid Gear Oil). (Full) line.
(1) 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.
0006364
Figure - 75
1 – Oil Reservoir Cap
GL5 Hypoid Gear Oil

Oil Reservoir Obtain Locally

Speedometer Connection
Figure - 76 shows the speedometer hose piping.
(7)
(1)
(2)
(8)
(4)
(3)
(3) (5) (6)
0006507
Figure - 76
1 – Speedometer Hose 5 – Cable Band A*
2 – Trim Sender Wire 6 – Cable Band B**
3 – Engine Cooling Hose 7 – Straight Area
4 – Bell Housing 8 – Exhaust Opening
*This cable band attaches the Speedometer Hose (1) and the Trim Sender Wire (2) to the Engine Cooling Hose (3). The
fixed place is the Straight Area (7) of the Engine Cooling Hose (3). The Speedometer Hose (1) passes the port side of the
Engine Cooling Hose (3), and it passes the port side of the Exhaust Opening (8).
**This cable band attaches the Speedometer Hose (1) to the Bell Housing (4).

ZT350
12/05
1. Raise the drive unit to gain access to the area POWER TRIM SYSTEM /
between the gimbal housing and the drive unit,
immediately on top of the transom end of the STEERING HELM AND CABLE
antiventilation plate.
2. Insert the speedometer tube fitting into the
Control System
opening on the topside of the ventilation plate in Use the appropriate control panel or in-handle trim
position as illustrated. control arrangement (for instance Teleflex controls)
with the power trim system. Install the trim control
according to the instructions included with the
power trim system.
Pump Location
(1)
Select a mounting location for the trim pump that
meets the following requirements:
• Within a comfortable reach of the hydraulic hoses
(coming from the gimbal housing assembly).
• Close enough to the battery so trim pump battery
(2) leads can be connected.
0006365
• Allows easy access to the trim pump oil fill and
Figure - 77 vent locations.
1 – Speedometer Tube Fitting • In an area where the pump will not be exposed to
2 – Opening water.
3. With the fitting fully seated, turn the handle to
• Mount the trim pump so that when the steering
the left to a tightly seated position.
wheel is turned either to the right or left the power
assist steering cylinder does not come in contact
with trim pump.
Steering Helm and Cable

The stern drive is shipped with the steering cable
guide preset for cables with end dimensions that
comply with ABYC standards, as outlined in the
NMMA certification handbook. Yanmar
recommends using the steering cable with a
coupler nut. There must also be a means of locking
it to the guide tube as specified in the ABYC
(1) requirements.
0006366 WARNING! Failure to use a steering cable
Figure - 78 locking device could cause a loss of steering.
1 – Handle 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.

Steering Cable Specifications Ensure that the steering cable is the correct length,
particularly when installed in larger boats.
WARNING! Power steering units only - If the
steering cable is installed with improper Route the cable so it does not go around any sharp
dimensions, it may cause severe damage to the bends. Remove and avoid any kinks or loops when
transom assembly and / or steering system. mounting the cable.
NEVER attempt to adjust the cable guide tube
on the power steering unit, as the guide tube Use the following illustration to determine the cable
and locknut have been torqued (with Loctite®) end dimension when the power steering cable is
at the factory, and an attempt to loosen nut or fully-extended.
tube may result in damage to tube. NOTICE: Power steering pump lugging (squealing)
in a hard right turn (against the lock) may mean that
the steering cable has been installed using
incorrect dimensions.
(3)
(2)
(1) (4)
(5) (7)
(6)
(11) (10) (8)
(12)
(9)
0006388
Figure - 79
1 – Coupler / Nut - 7/8 UNF - 28 Thread 10 – 1-3/8 in. (34.9 mm) Maximum
2 – 298 mm (11-3/4 in.) Minimum 11 – 15.9 mm (5/8 in.) Diameter Tube
3 – Interface Point 12 – Cable Travel:
4 – 12.7 mm (1/2 in.) Maximum Mid-Travel Position - 429 mm (16-7/8 in.)
5 – 10.7 mm (27/64 in.) Minimum Flat Total travel to be 203 mm (8 in.) minimum to
6 – 3.1 mm (7/64 in.) Minimum Radius 228 mm (9 in.) maximum.
7 – 15.9 mm (5/8 in.) Maximum Diameter End 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
12/05
Installation of Steering Cable

When installing the steering cable (Figure - 80, (6)) between the rotary or rack helm (Figure - 80, (1)) and
the steering lever of the stern-drive (Figure - 80, (5)), follow the following specifications:
• NEVER exceed a 20 cm (8 in.) radius bend in the cable (Figure - 80, (2))
• Keep plus or minus 25 mm (1 in.) free motion of cable and power steering valve (Figure - 80, (3)) and be
sure to prevent any interferences with other objects.
• NEVER tie down or clamp the steering cable within 90 cm (3 ft) of the power steering cylinder
(Figure - 80, (4)).
(5)
(1)
(7) (4)
(2)
(3) (6)
0006437
Figure - 80
1 – Rotary or rack helm 5 – Steering lever
2 – Minimum 20 cm (8 in.) bend radius 6 – Steering Cable
3 – Plus or minus 25 mm (1 in.) free motion of 7 – Power Steering Cylinder
cable housing and power steering valve
4 – NEVER tie down or clamp within 90 cm (3 ft)
of the power steering cylinder.
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.

THROTTLE AND SHIFT CABLES Verify Propeller Rotation with

Mechanical Shift System
Shift and Throttle Cable Travel
NOTICE: Use this method to verify the correct
Yanmar recommends using a Teleflex remote propeller rotation (RH or LH) for this drive unit.
control and cables to ensure proper shift and
throttle operation. If a control other than Yanmar - The front propeller on the drive unit is always LH
Teleflex is used, a shift control cable must be (at Rotation and the rear propeller is always RH
the shift plate end) 70 mm (2-3/4 in.) to 77 mm Rotation. The shift cable end guide must move in
(3-1/32 in.) with a 50 to 70 N (11 to 16 lb.) load direction 1 shown in Figure - 81, when the control
applied to the cable end. lever is placed in the FORWARD gear position.
0006367
Figure - 81
NOTICE: Route the cable away from sharp bends
and moving parts. NEVER fasten items to the shift
cables.

ZT350
12/05
SHIFT CABLE INSTALLATION AND ADJUSTMENT

Shift Cable Installation for Electric Shift Type
1. Connect the shift cable to the control system and the engine. Please refer to the manual of the control
system and the engine.
(5) (3)
(6)
(1)
(2)
(7)
(4) (3)
(3) (3)
(5) (4)
(5) (4)
(3) (3)
(6) (7)
(4)
(5)
(3)
0006508
Figure - 82
1 – FORWARD connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P
2 – REVERSE connector (female): DEUTSCH DT04-2P-CE03 1060-16-0622 W2P
3 – Black: for earth signal (negative)
4 – White: for REVERSE signal
5 – Orange: for FORWARD signal
6 – Name tag: FORWARD
7 – Name tag: REVERSE

Shift Cable Installation for Install the Drive Unit Shift Cable.
Mechanical Shift Type 1. Insert the cotter pins from the top. Spread the
1. Install the shift cable into the remote control. ends of the cotter pins fully.
Refer to the appropriate instructions that come
with the system you are using.
2. Loosen the stud and move it to the dimension
as shown in the illustration below. Tighten the
stud.
(2)
(2) (1)
(1)
0006368
Figure - 83
1 – Stud
2 – 76 mm (3 in.) - Center of the pivot bolt to the
center of the stud.
Setting the Cable Length:

Find the NEUTRAL position at the shift cable for (3)
the drive unit. Measure the distance between the (4)
control cable barrel center and the center of the 0006370
attachment hole of the cable end. Adjust it at the Figure - 85
screw of the attachment if necessary, and then lock
the nut. This distance should be 180.6 mm (7-7/64 1 – Short Cotter Pin
in). 2 – Washers (2 ea.)
3 – Long Cotter Pin
(1) 4 – Drive Unit Shift Cable
(2)
0006369
Figure - 84
1 – Lock Nut
2 – 180.6 mm (7-7/64 in) - The control cable
barrel center and the center of the
attachment hole.

ZT350
12/05
2. Locate the center of the remote control and

control cable play (backlash):
(a) Shift the remote control to NEUTRAL.
(b) Push in on the control cable end with
enough pressure to remove play, and mark
position 2 on tube.
(c) Pull out on the control cable end with
enough pressure to remove play and mark
position 3 on tube.
(d) Measure the distance between marks 2 and (1)
(2)
3 and mark position 1 half-way between (3) (4)
(5)
marks 2 and 3. 0006372
Figure - 87
(1)
1 – Stud
2 – Control Cable Barrel
3 – Backlash Center
4 – Control Cable End Guide
5 – Clevis Pin
4. Install the shift control cable.
5. Install the washer and cotter pin to secure the
(2) (3) barrel. Spread the ends of the cotter pin.
0006371 6. Install the clevis pin.
7. Install the cotter pin into the clevis pin. Spread
Figure - 86
the ends of the cotter pin.
NOTICE: Keep center mark 1 aligned with sleeve
(2) (3)
end face when making the following adjustment. (4)
Adjust the Shift Control Cable

1. Temporarily install the shift control cable end
guide into the shift lever and insert the clevis
pin.
2. Adjust the shift control cable barrel so that the (1)
hole in the barrel centers with the vertical 0006373
centerline of the stud. Ensure that the backlash
center mark is aligned with the edge of the Figure - 88
control cable end guide. CAUTION! NEVER
attempt to install or remove the shift control 1 – Washers - (on both sides of barrel)
cable barrel from the stud without first 2 – Cotter Pin
3 – Cotter Pin (partially shown)
removing the end guide clevis pin from the
4 – Clevis Pin
shift lever and removing the cable.
Attempting to bend the shift control cable to 8. Shift the remote control lever into the
install or remove the barrel will put undue FORWARD position.
stress on the cable end guide and shift 9. Measure the distance between the shift control
lever. Damage to both could occur. cable barrel center and the shift lever stud
3. Remove the shift control cable end guide from center. This distance should be
the shift lever by removing the clevis pin. 155.6 ± 1.5 mm (6-1/8 ± 1/16 in).

10. If the distance does not satisfy the dimension, (2)
loosen the shift lever stud and slide the stud up
or down until the distance is within the stated
the dimension. When the adjustment is correct,
tighten the stud.
(2)
(1)
(3)
0006375
Figure - 90
1 – Barrel Retainer Cotter Pin
(1)
2 – 205.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control
(3) cable barrel center and the shift lever stud
0006374 center.
Figure - 89 3 – Shift Lever Stud
15. Ensure that all of the cotter pins are secure and
1 – Barrel Retainer Cotter Pin
2 – 155.6 ± 1.5 mm (6-1/8 ± 1/16 in) - The control that the ends of the cotter pins are spread
cable barrel center and the shift lever stud completely.
center. 16. Lubricate the shift cable pivot points.
3 – Shift Lever Stud
SAE 30W Engine Oil
11. Shift the remote control into REVERSE.
12. Measure the distance between the control
Shift Cable Pivot Points Obtain Locally
cable barrel center and the shift lever stud
center. This distance should be 205.6 ± 1.5 mm
(8-3/32 ± 1/16 in).
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
12/05
Troubleshooting Shift Problems 4. Never strap or clamp the control cables to any
other cables or rigid structure within 1000 mm
Note: Use the following information to (3 ft) of the control box. Make sure there are no
troubleshoot hard shifting or chucking / kinks in the cable.
roughing when shifting into forward gear.
5. Ensure that there is enough clearance for cable
1. When installing the control box into the side movement when the control box is installed in
panel of the boat, ensure that the cables have the side panel. The cables must have room to
enough clearance to operate (Figure - 91). This move up and down when the control handle is
is necessary because the cables move up and shifted into either FORWARD or REVERSE.
down when the shift handle is moved. If the
6. Ensure that the engine was not set down on the
control box is mounted too far back toward any
intermediate shift cable during installation; this
fiberglass structure, the cables will be interfered
will crush the inner cable tubing and cause
with. This will cause very hard shifting.
improper and / or stiff shifting.
7. NEVER fasten the shift cable with straps or
clamps to any other cable within 1500 mm (5
ft.) of the shift plate.
8. Avoid over-tightening the shift cable to the
transom with any type of plastic clips or
fasteners within 1500 mm (5 ft.) of the shift
plate.
0006376
9. Do not over-tighten the throttle or shift cable
Figure - 91 attaching nuts at the engine end. Barrel and
cable end must be free to rotate on the
2. Route the shift cable from the control box mounting stud.
through the side gunnel of the hull without
inducing any extremely sharp bends Note: Lubricate attaching points with engine oil.
(Figure - 91) to prevent stiff shifting.
SAE 30W Engine Oil
3. Before installing the shift cable into the
control box, extend the stainless rod eye
Shift Cable Pivot Points Obtain Locally
end of the cable and coat it with lubricant
(Figure - 92, (1)). Move it back and forth to
10. The drive unit shift cable must be routed to
allow even distribution of the lubricant.
allow sufficient length for connection to shift
(1) plate.
Note: Make a final check of the adjustments
with the boat in the water and with the
engine running. If this cannot be done, or
is not done at the manufacturing facility,
make arrangements with the dealer to do
this as part of the pre-delivery inspection.
(1) 0006377
Figure - 92
1 – Lubrication Point
Lithium Grease with PTFE

Shift Cable End Obtain Locally

PRE-DELIVERY PREPARATION
NOTICE: Before starting pre-delivery read the
General Information and Installation Requirements
completely.
When the drive unit installation is complete,
complete these final steps to prepare the package
for delivery to the customer. It is the boat
manufacturer's responsibility to perform these
steps, or to make arrangement with the dealer to
have these procedures completed. (1)
(2)
Power Steering Fluid
NOTICE: Use only Dexron III automatic
transmission fluid (ATF), in a power steering
system.
CAUTION! NEVER operate the engine and
power steering without fluid or the pump will be
0006378
damaged.
Figure - 93
Dexron III Automatic Transmission Fluid
1 – Positive Battery Lead (RED)
Where Used Part Number 2 – Negative Battery Lead (BLACK)
Power Steering Pump Obtain Locally
6. Ensure that all battery terminal connections are
tight.
Battery Connections
7. Spray the battery terminal connections with a
NOTICE: The engine electrical system is negative sealant to help retard corrosion.
(-) ground.
1. Position the battery as close to the engine as
possible.
2. Connect the engine positive (+) battery cable
(usually RED) to the positive (+) battery
terminal.
3. Connect the engine negative (-) battery cable
(usually Black) to the negative (-) battery
terminal.
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
12/05
Check the Power Trim Pump Fluid 3. The oil level is low if it is below the MIN line
(Figure - 95, (1)) on the reservoir. Fill as
NOTICE: ALWAYS check the oil level with stern- necessary with the specified fluid. See Fill the
drive in the full DOWN / TRIM-IN position. Power Trim Pump Fluid on page ZT350-60.
1. Place the stern-drive in full Down / TRIM-IN
position.
2. Observe the oil level in the reservoir. The oil
level should be maintained within the MIN and
MAX lines on the reservoir (Figure - 94, (2)).
(1)
0006013
Figure - 95
(1) 1 – MIN Line
(2)
0006012
Figure - 94
1 – Reservoir
2 – MIN and MAX Lines

Fill the Power Trim Pump Fluid Check the Stern-Drive Oil Level
Note: The power trim fluid does not require GL-5 Hypoid Gear Oil
changing unless it becomes
Where Used
contaminated with water or debris.
Contact your authorized Yanmar Marine Oil Reservoir
dealer or distributor if the power trim fluid
needs to be changed. Note: The oil level will rise and fall during
operation. Check the oil level before
1. Place the stern-drive in the full DOWN / TRIM- starting, when the engine is cold.
IN position.
1. Check the stern-drive lube oil level
2. Unscrew and remove the fill cap (Figure - 97). Keep the oil level at or near the
(Figure - 96, (1)) assembly from the reservoir OPERATING RANGE (full) line on the oil
(Figure - 96, (3)) with specified fluid. reservoir.
Dexron 3 Automatic Transmission Fluid 2. The oil level is low if it is below the ADD line on
Where Used the oil reservoir. Fill as needed with the
Power Trim Pump
specified oil. See Fill the Stern-Drive with Oil on
page ZT350-61.
3. Add lubricant to bring the oil level to within the
MIN and MAX lines on the reservoir (1)
(Figure - 96, (2)).
(3)
(2)
(2)
(1)
0006336
Figure - 97
(3)
1 – Oil Reservoir
2 – ADD Line
3 – OPERATING RANGE Line
NOTICE: If any water is visible at the bottom
of the oil reservoir or appears at the oil fill /
000
drain plug and / or if oil appears discolored,
Figure - 96 contact your authorized Yanmar Marine
dealer or distributor immediately. Both
1 – Fill Cap Assembly
conditions may indicate a water leak
2 – MIN and MAX Lines
3 – Reservoir
somewhere in the stern-drive.
4. Install the fill cap assembly.

ZT350
12/05
Fill the Stern-Drive with Oil

GL-5 Hypoid Gear Oil
NOTICE: If more than 60 ml (2 fl oz) of gear oil is Where Used
required to fill the reservoir, a seal may be leaking.
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.
gasket is inside the oil reservoir cap and install
1. Remove the oil reservoir cap the cap. Do not over-tighten.
(Figure - 98, (1)).
2. Fill the oil reservoir to the OPERATING RANGE
(Figure - 98, (2)) (full) line with specified fluid.
NOTICE: Do not overfill.
(1)
(2)
0006337
Figure - 98
1 – Oil Reservoir Cap
2 – OPERATING RANGE Line

Propeller Selection Keep these guidelines in mind when selecting a
propeller:
The propeller converts the engine’s power into the
thrust needed to propel the vessel. Careful • NOTICE: NEVER attempt to change propellers
selection of your propeller is very important to until after determining the average load and
proper vessel operation. Propellers are identified individual requirements. Your Yanmar dealer or
by two numbers, such as 15.75 x 20 left-hand and distributor is most qualified to help you select a
stainless steel propeller. In the number sequence, propeller.
the first number is the diameter of the propeller and
the second is the pitch. Left-hand is • Engine rpm must be within the recommended
counterclockwise rotation for front propeller. Right- operating range. Refer to the Engine Operator’s
hand is clockwise rotation for rear propeller. Manual.
Pitch is the angle of the blades expressed in the WARNING! To prevent accidental start-up,
theoretical distance a propeller travels in each complete the following before installing or
revolution. If for example the pitch is 20, each removing the propeller:
revolution of the propeller pushes the vessel 20 in. ◆ Put the remote control to the NEUTRAL
through the water. A 28 pitch is considered “higher” position.
pitched and a 20 pitch propeller is considered ◆ Put the main switch to OFF position and
“lower” pitched. A smaller pitch propeller should be remove the key.
selected for water skiing or for heavy loads. WARNING! NEVER use your hand to hold the
propeller when loosening the nut. Put a wood
block between the antiventilation plate and the
propeller blade to prevent the propeller from
turning.
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
12/05
General Propeller Installations

WARNING! A rotating propeller, especially
when driven by an operating engine, can cause
severe injury. Prior to installing or removing the
propeller, ensure that the remote control is in
the NEUTRAL position, the lanyard switch, if
equipped, is in the OFF position, and the
ignition switch is in the OFF position with the
key removed from the switch.
WARNING! A rotating propeller can cause
severe injury. Place a block of wood between
the anti-ventilation plate and the propeller to
protect hands from the propeller blades and to
prevent the propeller from turning when
removing and tightening the propeller nut.
NOTICE: Installation is correct when at least 2 0006382
threads of the propeller shaft are exposed through
Figure - 99
the propeller locknut after applying torque to the
locknut. Place a block of wood between the anti- To aid in the future removal of the propeller,
ventilation plate and the propeller when tightening liberally apply lubricant on the propeller shaft
the propeller nut. splines.

Propeller Shaft Splines Obtain Locally

Installing the Propellers
(2) (5) (6)
(4)
(3)
(1)
(7)
(8)
0006015
Figure - 100
1 – Rear Propeller Nut 5 – Front Propeller
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
12/05
1. Apply a liberal coat of lubricant to the propeller Removing the Propeller

shaft. Recommended lubricants are shown in
the table below. WARNING! The Remote Control must be in
NEUTRAL and the starter key removed from the
Description Where Used switch before removing and / or installing the
Urea Grease Water propeller.
Resistant Type, NLGI #2
Propeller Shaft 1. Place a wood block between the propeller
Lithium Grease With
blades and the antiventilation plate to prevent
PTFE
rotation. WARNING! Place a block of wood
2. Slide the forward thrust hub onto the propeller between the antiventilation plate and the
shaft with the tapered side toward the propeller propeller to protect hands from propeller
hub (toward end of propeller shaft). blades and to prevent the propeller from
rotating when removing the propeller nut.
3. Align the splines and place the propeller on the
propeller shaft. 2. Turn the rear propeller nut (36 mm [1-7/16 in.])
counterclockwise to remove the nut.
4. Install and torque the front propeller nut. Check
the propeller at least every 20 hours. 3. Slide the propeller and the thrust hub off the
propeller shaft.
Front Propeller Nut Torque 4. Turn the front propeller nut (70 mm [2-3/4 in.])
N·m lb-ft counterclockwise to remove the nut.
135 99 5. Slide the propeller and the thrust hub off the
propeller shaft.
5. Slide the aft thrust hub onto the propeller shaft,
with the tapered side toward the propeller hub
(toward end of shaft).
6. Align the splines and place the propeller on the
propeller shaft.
7. Install and torque the rear propeller nut. Check
the propeller at least every 20 hours.
Rear Propeller Nut Torque
N·m lb-ft
80 59
8. Install the propeller shaft anode bolt with a

washer. Torque the bolt.
Propeller Shaft Anode Bolt Torque
N·m lb-ft
30 22

Test Preparations Engine Operation Tests
WARNING! NEVER leave the helm unattended WARNING! If engine is to be tested with the
when performing tests with the boat in the boat out of the water, the propeller must be
water. removed to avoid injury.
NOTICE: During operation ensure that the engine CAUTION! Overheating from insufficient
seawater pump suction does not collapse the hose coolant will cause engine and drive unit
to the water source, causing the engine water damage. Ensure that there is sufficient water
supply to stop. available at the water inlet holes during
operation.
1. Ensure that there is a sufficient supply of
coolant to the drive unit seawater inlet holes 1. Ensure that the coolant system drain plugs and
and / or the through-hull-seawater inlet holes. petcocks are installed and tight.
2. Use the correct flushing attachment for the 2. Ensure that the coolant system hoses are
seawater pickup found on the drive unit. installed and clamped securely.
CAUTION! If using a flush test device
(attachment), install over the seawater intake
Out-of-Water Testing
holes and connect a water hose. NEVER use The following information is for engine operation
full water tap pressure. Also, avoid operating tests with the boat out of the water:
the engine above 1500 rpm, because the
suction created could cause the water hose NOTICE: On vessels with the drive unit seawater
to collapse causing the water supply to be cut inlet blocked off at the gimbal housing and using a
off. through-the-hull seawater inlet, a constant supply
of coolant must be available for both the drive unit
3. Check all engine-related items as specified by and the engine during operation.
the engine manufacturer. See the engine
manufacturer's instructions. 1. Install a flushing attachment over the drive unit
and / or the alternate seawater inlet pickup
Note: See the Operation Manual provided with holes.
your engine / vessel for operating
specifications and fluid capacities. 2. Connect a hose between the flushing
attachments and a water source.
4. NOTICE: The drive unit oil level in the oil NOTICE: If using a flushing attachment
reservoir will rise and fall during the drive unit (sometimes referred to as a flush test device)
operation. Always check the oil level in the over the seawater inlet holes and a water hose as
reservoir when the drive unit is cool and when shown, NEVER use full water source pressure.
the engine is shut down. Open the water source about 1/2 maximum.
5. Check the drive unit oil level in the oil reservoir. NEVER use full water pressure.
6. Test the audio warning system, if equipped.
(1)
(2)
0006384
Figure - 101
1 – Typical Flushing Attachment (Obtain
Locally)
2 – Water Hose

ZT350
12/05
3. See Test Preparations on page ZT350-66 for Drive Unit Operational Tests
other checks.
WARNING! NEVER leave the helm unattended
In-Water Testing when performing tests with the boat in the
water.
The following information is for engine operation
tests with the boat in the water. CAUTION! Instruments can warn of engine
problems. Watch the temperature gauge on the
WARNING! NEVER leave the helm unattended dash to ensure that the engine does not
when testing the vessel in the water. overheat to avoid engine damage.
NOTICE: The water level must be above the 1. Refer to the Engine Operation Manual and start
seawater inlet holes on the drive unit or the the engine.
through-the-hull pickup.
2. Operate the engine at IDLE rpm until it reaches
1. On engines with a drive unit seawater inlet: The normal operating temperature.
water level must be above the seawater inlet 3. Turn the steering wheel to starboard, then to
holes on the drive unit. port, and ensure that the drive unit turns the
correct way.
4. Check the power steering system for a lugging
(1) condition (engine rpm drops and / or the power
steering pump tone changes).
(2) 5. Turn the steering wheel to the LEFT (Port) until
it stops and then continue to apply pressure. If
0006385 the pump lugs, check the following:
Figure - 102 (a) Check for an obstruction between the gimbal
ring and the gimbal housing, and all moving
1 – Minimum Water Level steering components.
2 – Water Inlet Holes
(b) Ensure that the steering lever is not
2. On engines with a through-the-hull seawater contacting the cutout in the transom. Modify
inlet: Ensure that the water level is above the the cutout if there is contact between the
seawater inlet holes on the through-the-hull transom and the cutout.
seawater inlet.
6. Turn the steering wheel to the RIGHT
Wide Open Throttle Test (starboard) until it stops and then continue to
apply pressure. If the pump lugs, check the
NOTICE: Follow the Engine Operation Manual to
following:
operate the engine at full throttle before the break-
in period is complete. (a) Check for an obstruction between gimbal
ring and gimbal housing, and all moving
1. To test if the correct propeller has been steering components.
installed, operate the boat with a full load
(b) Ensure that the steering lever is not
onboard at wide open throttle (WOT) and check
contacting the cutout in the transom. Modify
the rpm with an accurate tachometer. Engine
the cutout if there is contact between the
rpm should be near top of the specified range
transom and the cutout.
so that engine speed will not fall below
specifications under a heavy load. If the engine 7. Check steering cable end dimension with the
speed is too high, replace the propeller with a cable FULLY EXTENDED. See Steering Helm
higher pitch propeller. and Cable on page ZT350-49 for proper
steering cable dimensions.
2. See Test Preparations on page ZT350-66 for
other checks. 8. Turn the engine off.

9. Lubricate the steering cable and clevis. 11. Ensure that there is nothing attached to
NOTICE: Ensure that the cable end that enters steering cable casing. The cable must be free
the clevis is heavily lubricated. to move when actuated.
12. Check the power steering pump fluid level.
13. Position the drive unit so it is straight back.
(1)
14. Turn the engine off.
15. Check the power steering fluid level and add as
necessary.
CAUTION! If the power package will not be used
for an extended period of time, or will be
(4) (2) exposed to freezing temperatures, drain the
water from the drive unit. ALWAYS drain water
to prevent corrosion and freeze damage to the
engine and / or the drive unit.
(3) 0006386 If the power package will not be used for an
Figure - 103 extended period of time, or will be exposed to
freezing temperatures, drain the water from the
1 – Clevis drive unit. See Cold Weather (Freezing
2 – Steering Lever
Temperature), Seasonal and Extended Storage on
3 – Clevis Pins and Cotter Pins
page ZT350-69.
4 – Steering Cable End
CAUTION! The drive unit should be stored in
the FULL DOWN / IN position. The U-joint
bellows may develop a set if the drive unit is
Steering Cable End Obtain Locally stored in the raised position and may fail when
the drive unit is returned to service.
10. Restart the engine and observe the drive unit.If
drive unit creeps, an external tension may exist
on steering cable.

ZT350
12/05
Cold Weather (Freezing CAUTION! The drive unit should be stored in

the FULL DOWN / IN position. The U-joint
Temperature), Seasonal and bellows may develop a set if the unit is stored in
Extended Storage the raised position and may fail when the unit is
NOTICE: Yanmar strongly recommends that this returned to service.
service should be performed by an authorized 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.
(1)
(2)
(3)
(4)
0006387
Figure - 104
1 – Underside of Anticavitation Plate
2 – First Anode Cavity Drain Passage
3 – Second Anode Cavity Drain Passage
4 – Speedometer Pitot Hole

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