Yamaha F350 B Lf 350B repair Manual

F350B LF350B

SERVICE MANUAL

LIT-18616-03-42

6BJ-28197-1R-12

Preface This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has been written to suit the needs of persons who have the Bronze Technical Certificate of the YTA (Yamaha Technical Academy) marine or the equivalent basic understanding of the mechanical and electrical concepts and procedures inherent in the work, for without such knowledge attempted repairs or service to the equipment could render it unsafe or unfit for use.

Because Yamaha has a policy of continuously improving its products, models may differ in detail from the descriptions and illustrations given in this publication. Use only the latest edition of this manual. Authorized Yamaha dealers are notified periodically of modifications and significant changes in specifications and procedures, and these are incorporated in successive editions of this manual. Also, up-to-date parts information is available on YDS (Yamaha Dealer System). Additional information and up-to-date information on Yamaha products and services are available on YDS (Yamaha Dealer System).

Important information Particularly important information is distinguished in this manual by the following notations:  The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS INVOLVED!

A WARNING indicates a hazardous situation which, if not avoided, could result in death or serious injury.

A NOTICE indicates special precautions that must be taken to avoid damages to the outboard motor or other property.

TIP: A TIP provides key information to make procedures easier or clearer.

F350B, LF350B SERVICE MANUAL Š2012 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2012 All rights reserved.

Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited.

LIT-18616-03-42

Contents General information

0

Specification

1

Technical feature and description

2

Rigging information

3

Troubleshooting

4

Electrical system

5

Fuel system

6

Power unit

7

Lower unit

8

Bracket unit

9

Maintenance

10

Index Appendix

A

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General information Safety while working .................................................... 0-1 Rotating part .............................................................................. 0-1 Hot part ...................................................................................... 0-1 Electric shock ............................................................................ 0-1 Propeller .................................................................................... 0-1 Handling of gasoline .................................................................. 0-1 Ventilation .................................................................................. 0-1 Self-protection ........................................................................... 0-2 Working with crane .................................................................... 0-2 Handling of gas torch ................................................................ 0-2 Part, lubricant, and sealant ........................................................ 0-2 Handling of sealant .................................................................... 0-3 Special service tool ................................................................... 0-3 Tightening torque ...................................................................... 0-3 Non-reusable part ...................................................................... 0-3 Disassembly and assembly ....................................................... 0-3

How to use this manual .................................................... 0-4 Manual format ........................................................................... 0-4 Abbreviation .............................................................................. 0-5

Lubricant, sealant, and thread locking agent ................. 0-6

0

0 1 2 3 4 5 6

Symbol ...................................................................................... 0-6

Special service tool ........................................................... 0-8

7 8 9 10

A

Safety while working

Safety while working

Handling of gasoline

To prevent an accident or injury and to provide quality service, observe the following safety procedures.

• Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames.

• Gasoline is poisonous and can cause injury or death. Handle gasoline with care. Never siphon gasoline by mouth. If you swallow some gasoline, inhale a lot of gasoline vapor, or get some gasoline in your eyes, see your doctor immediately. If gasoline spills on your skin, wash with soap and water. If gasoline spills on your clothing, change your clothes.

Rotating part • Hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, can become entangled with internal rotating parts of the engine, resulting in serious injury or death.

• Keep the top cowling installed whenever possible. Do not remove or install the top cowling when the engine is running.

• Only operate the engine with the top cowling removed according to the specific instructions in the manual. Keep hands, feet, hair, jewelry, clothing, personal flotation device straps, and so on, away from any exposed moving parts.

Hot part During and after operation, engine parts are hot enough to cause burns. Do not touch any parts under the top cowling until the engine has cooled.

Ventilation • Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If gasoline vapor or exhaust gas is inhaled in large quantities, it may cause loss of consciousness and death within a short time.

• When test running an engine indoors (for example, in a water tank) make sure to do so where adequate ventilation can be maintained.

Electric shock Do not touch any electrical parts while starting or operating the engine. Otherwise, shock or electrocution could result.

Propeller Do not hold the propeller with your hands when loosening or tightening the propeller nut.

0-1

Safety while working

Self-protection

Handling of gas torch

• Protect your eyes by wearing safety glasses or safety goggles during all operations involving drilling and grinding, or when using an air compressor.

• Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

• Improper handling of a gas torch may result in burns. For information on the proper handling of the gas torch, see the operation manual issued by the manufacturer.

• When using a gas torch, keep it away from the gasoline and oil, to prevent a fire.

• Components become hot enough to cause burns. Do not touch any hot components directly.

0 1 2 3 4

Working with crane • Outboard motors weighing 18.0 kg (39.7 lb) and over must be carried by a crane.

• Use the wire ropes of adequate strength to lift up the outboard motor in a stable manner.

• Suspend the outboard motor in a stable manner using the designated lifting eye or the like.

Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants, or those recommended by Yamaha, when servicing or repairing the outboard motor.

5 6 7 8 9 10

A 0-2

Safety while working

Handling of sealant

Non-reusable part

• Wear protective gloves to protect your skin, when using the sealants.

• See the material safety data sheet issued by the manufacturer. Some of the sealants may be harmful to human health.

Always use new gaskets, seals, O-rings, cotter pins, and so on, when installing or assembling parts.

Disassembly and assembly • Use compressed air to remove dust and dirt during disassembly.

• Apply engine oil to the contact surfaces of moving parts before assembly.

Special service tool Use the recommended special service tools to work safely, and to protect parts from damage.

• Install bearings so that the bearing identification mark is facing in the direction indicated in the installation procedure. In addition, make sure to lubricate the bearings liberally.

• Apply a thin coat of water resistant grease to the lip and periphery of an oil seal before installation.

• Check that moving parts operate normally after assembly.

Tightening torque When tightening nuts, bolts, and screws, follow the tightening instructions provided throughout the manual. If the tightening order is not specified, tighten the large sizes first, and then tighten the small sizes, starting from the center and moving outward.

0-3

How to use this manual

How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to understand. Use the following information as a guide for effective and quality service.

• Parts are shown and detailed in an exploded diagram and are listed in the component list (see “1” in the following figure for an example page).

• The component list consists of part names and quantities, as well as bolt and screw dimensions (see “2” in the following figure).

• Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and the lubrication points (see “3” in the following figure).

• Tightening torque specifications are provided in the exploded diagrams (see “4” in the following figure), and in the related detailed instructions. Some torque specifications are listed in stages as torque figures or angles in degrees.

• Separate procedures and illustrations are used to explain the details of removal, checking, and installation where necessary (see “5” in the following figure for an example page).

TIP:

1 2 3 4

For troubleshooting procedures, See Chapter 4, “Troubleshooting”.

3

0

5

4 1

Lower unit (regular rotation model, U-transom model)

Lower unit (regular rotation model, U-transom model) 15 13

6

54 N·m (5.4 kgf·m, 39.8 ft·lb)

12 16 23

14 21 22

12

20 17

12

Drive shaft and lower case (regular rotation model)

24

2. While holding the special service tool “1”, strike the tool to check that the roller bearing is installed properly.

11 2 10

9 7

a

12

8

3

9 N·m (0.9 kgf·m, 6.6 ft·lb)

5

47 N·m (4.7 kgf·m, 34.7 ft·lb)

26

31 32 30 33

3 1

9 N·m (0.9 kgf·m, 6.6 ft·lb) 2 N·m (0.2 kgf·m, 1.5 ft·lb)

Par t name Water inlet cover (PORT) Nu t Gasket Drain screw B o lt Water inlet cover (STBD) Check screw B o lt Washer Cover Gasket Dowel Stud bolt Rubber seal Rubber seal Extension Lower unit

2

28

• Use heat-resistant gloves. Otherwise, burns could result.

• To prevent fires, remove any flammable substances, such as gasoline and oil, from around the working area.

• Keep good ventilation while working.

29 42 N·m (4.2 kgf·m, 31.0 ft·lb)

47 N·m (4.7 kgf·m, 34.7 ft·lb)

Q’ty 1 1 2 1 1 1 1 4 4 1 1 4 6 1 1 1 1

8

Assembling the lower case

27 4

1

2

1

2

9

R ema r k s

1. Heat the installation area of the roller bearing in the lower case using a gas torch, and then install a new roller bearing “1”.

Not reusable

Driver rod LL “1”: 90890-06605 Needle bearing attachment “2”: 90890-06839

M5 × 42 mm

3. Install a new needle bearing “1”.

When heating the lower case, heat the entire installation area evenly. Otherwise, the paint on the lower case could be burned.

M6 × 20 mm

7

If a high-pitched metallic sound is produced when the special service tool is struck, the outer race is installed properly.

19

18

25 25 26

6

No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17

TIP:

1

TIP: • The needle bearing contains 18 rollers.

• Face the bearing identification mark “a” on the needle bearing toward the pinion side.

Not reusable

TIP: Face the bearing identification mark “a” on the roller bearing “1” down.

10

3 1

1

4 1

8-6 2

a

2 a

2 5

8-25

0-4

A

How to use this manual

Abbreviation The following abbreviations are used in this service manual.

Abbreviation

Description

ABYC

American Boat and Yacht Council

API

American Petroleum Institute

ATF

Automatic Transmission Fluid

AWG

American Wire Gauge

CAN

Controller Area Network

CARB

California Air Resources Board

CCA

Cold Cranking Ampere

CL

Command Link

DN

Down side

DOHC

Double Overhead Camshaft

ECM

Electronic Control Module

EPA

Environmental Protection Agency

EX

Exhaust

F

Forward

ID

Identification

IN

Intake

ISO

International Organization for Standardization

LPS

Lever Position Sensor

MCA

Marine Cranking Ampere

N

Neutral

OCV

Oil Control Valve

PCV

Pressure Control Valve

PON

Pump Octane Number

PORT

Port side

PTT

Power Trim and Tilt

R

Reverse

RC

Reserve Capacity

SAE

Society of Automotive Engineers

STBD

Starboard side

TCI

Transistor-Controlled Ignition

TDC

Top Dead Center

TPS

Throttle Position Sensor

UP

Up side

VCT

Variable Camshaft Timing

Y-COP

Yamaha Customer Outboard Protection

YDIS

Yamaha Diagnostic System

0-5

Lubricant, sealant, and thread locking agent

Lubricant, sealant, and thread locking agent Symbol Symbols in an exploded diagram or illustration indicate the grade of lubricant and the lubrication points.

Symbol

Name

Application

0

YAMALUBE 4-M FC-W oil or Yamaha 4-stroke motor oil

Lubricant

1

Yamalube Marine Lower Unit Gearcase Lube or hypoid gear oil

Lubricant

2

Water resistant grease (Yamalube Marine Grease)

Lubricant

Low temperature resistant grease (Yamalube Molybdenum Disulfide grease)

3

Lubricant

Corrosion resistant grease (Yamalube Marine Grease)

Lubricant

Molybdenum disulfide grease (Yamalube Molybdenum Disulfide grease)

Lubricant

WR-No.2 grease

Lubricant

4 5 6

Symbols in an exploded diagram or illustration indicate the type of sealant or thread locking agent and the application points.

Symbol

Name

Application

Gasket Maker

Sealant

ThreeBond 1280B (Yamabond 4 Marine)

Sealant

ThreeBond 1303

Thread locking agent

ThreeBond 1322

Thread locking agent

ThreeBond 1377B

Thread locking agent

ThreeBond 1386B

Sealant

0-6

7 8 9 10

A

Lubricant, sealant, and thread locking agent Symbol

Name

Application

ThreeBond 1530D

Sealant

LOCTITE 271 (red)

Thread locking agent

LOCTITE 242 (blue)

Thread locking agent

LOCTITE 572 (white)

Sealant

Silicone sealant

Sealant

0-7

Special service tool

Special service tool For U.S.A. and Canada.

Special service tools numbered “YB/YM/YS/YU-*****� are distributed by K & L. Special service tool with part number 90890-06883 is distributed by the Marine Service Division.

Engine lifting eye YB-06820

0

Test harness (3 pins) YB-06869

1 2 Pressure/vacuum tester YB-35956-B

Drilling plate YB-34465-A

3 4

YDIS 2 starter kit 90890-06883

Test harness (3 pins) YB-06870

5 6

***

****** ******

7 Spark checker YM-34487

Digital multimeter YU-34899-A

8 9

Peak volt adapter YU-39991

Test harness (2 pins) YB-06867

10

A 0-8

Special service tool Test harness (3 pins) YB-06791

Flywheel magnet holder YB-06139

Fuel pressure gauge adapter YB-06946

Flywheel stopper YB-06598

Fuel pressure gauge YU-03153M

Primary sheave holder YS-01880-A

Compression gauge YU-33223

Valve spring compressor YM-04019

Balance hanger YB-06822

Valve attachment YB-06320

0-9

Special service tool Valve guide remover YB-06801

Driver handle (large) YB-06071

0 1 Valve guide reamer YM-01196

Driveshaft needle bearing installer and remover YB-06196

2 3

Valve lapping tool YM-A8998

Driveshaft bearing installer YB-06246

4 5 6

Neway valve seat kit YB-91044

Piston ring compressor YM-08037

7 8

Oil filter wrench YB-06830

Shift rod socket YB-06681

9 10

A 0-10

Special service tool Oil seal installer YB-06168

Bearing puller legs YB-06523

Ring nut wrench extension YB-06784

Needle bearing installer YB-06111

Ring nut wrench YB-06823

Oil seal installer YB-06085

Slide hammer YB-06096

Forward gear outer race installer YB-06199-A

Propeller shaft remover YB-06335

and

bearing

housing

Forward gear bearing installer YB-41446

0-11

Special service tool Drive shaft ring nut wrench YB-06833

Driver rod LL YB-06605

0 1 Drive shaft holder YB-06832

Needle bearing attachment YB-06665

2 3 Pinion nut holder YB-06715

Bearing inner race attachment YB-06640

4 5

Socket adapter YB-06831

Needle bearing attachment YB-06839

6 7 8

Holder guide YB-06834

Driveshaft bearing installer YB-06664

9 10

A 0-12

Special service tool Stopper guide plate YB-06667

Backlash adjustment plate YB-07003

Universal puller YB-06117

Magnetic base stand YU-A8438

Bearing housing puller YB-06207

Ring nut extension YB-06666

Backlash indicator YB-06836

Pinion shimming gauge YB-06835

Dial indicator gauge YU-03097

Forward gear bearing cap installer YB-06277-A

0-13

Special service tool Bearing cup installer YB-06167

Oil filter tray YB-06845

0 1 Up-relief fitting YB-06838

2 3 Hydraulic pressure gauge YB-06800

4 5 6

Down-relief fitting YB-06774

7 8 Cylinder-end screw wrench YB-06837

9 10

A 0-14

Specification Model feature ..................................................................... 1-1 General feature ......................................................................... 1-1 Model designation ..................................................................... 1-2 Serial number ............................................................................ 1-2

Model data ......................................................................... 1-3 Dimension and weight ............................................................... 1-3 Performance .............................................................................. 1-3 Power unit ................................................................................. 1-3 Lower unit .................................................................................. 1-4 Bracket unit ............................................................................... 1-4 Fuel and oil requirement ............................................................ 1-4 Battery requirement ................................................................... 1-4 PTT fluid requirement ................................................................ 1-4

Electrical system technical data ...................................... 1-5 Ignition timing control system .................................................... 1-5 Fuel injection control system ..................................................... 1-5 Engine speed control system .................................................... 1-6 VCT system ............................................................................... 1-6 Shift actuator ............................................................................. 1-6 PTT system ............................................................................... 1-7 Charging system ....................................................................... 1-7 Starting system .......................................................................... 1-7 Y-COP (optional) ....................................................................... 1-7 Gauge/sensor ............................................................................ 1-8

Fuel system technical data .............................................. 1-9 Fuel system ............................................................................... 1-9

Power unit technical data ............................................... 1-10 Power unit ............................................................................... 1-10 Cylinder head assembly .......................................................... 1-10 Crankcase assembly ............................................................... 1-11

Lower unit technical data ............................................... 1-13 Lower unit assembly (regular rotation model) ......................... 1-13 Lower unit assembly (counter rotation model) ........................ 1-13

Bracket unit technical data ............................................ 1-14 PTT system ............................................................................. 1-14

1

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