Zt350 Series

ZT350
series
OPERATION MANUAL
P/N: 0AZTD-G00101
STERN-
DRIVE
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Disclaimers:
All information, illustrations and specifications in this manual are based on the latest
information available at the time of publishing. The illustrations used in this manual are
intended as representative reference views only. Moreover, because of our continuous
product improvement policy, we may modify information, illustrations and / or specifications
to explain and / or exemplify a product, service or maintenance improvement. We reserve
the right to make any change at any time without notice. Yanmar and are
registered trademarks of Yanmar Co., Ltd. in Japan, the United States and / or other
countries.
All Rights Reserved:
No part of this publication may be reproduced or used in any form by any means - graphic,
electronic, or mechanical, including photocopying, recording, taping, or information storage
and retrieval systems - without the written permission of Yanmar Marine International.
© 2008 Yanmar Marine International
1208
ii ZT350 Operation Manual

TABLE OF
CONTENTS
Page
Introduction......................................................................1
Record of Ownership......................................................2
Safety...............................................................................3
Safety Precautions.........................................................3
General Information ................................................. 4
Before You Operate ................................................. 4
During Operation and Maintenance ............................. 5
Product Overview.............................................................11
Overview....................................................................11
Owner / Operator Responsibilities ............................. 11
New Stern-Drive Break-In: ....................................... 11
Dealer / Distributor Responsibilities ........................... 11
Component Identification...............................................12
Location of Serial Numbers...................................... 13
Corrosion Protection.....................................................14
Galvanic Corrosion ................................................ 14
Corrosion Control .................................................. 14
Shore Power ........................................................ 14
Underwater Drive Coating ....................................... 14
Additional Protection .............................................. 15
Gear Housing Anodic Plates .................................... 16
Ventilation Plate Anode .......................................... 16
Trim Cylinder Anodes ............................................. 16
Propeller Shaft Anode ............................................ 16
Features and Controls...................................................17
Remote Controls ................................................... 17
Power Trim .......................................................... 17
Stern-Drive Trim Angle ........................................... 18
Trim and Tilt / Trailering Switch ................................. 18
Electrical System................................................... 19
ZT350 Operation Manual iii

TABLE OF CONTENTS
Stern-Drive Operation.......................................................21
Propeller Selection.......................................................23
Installing the Propellers..................................................24
Removing the Propeller.................................................26
Daily Checks...............................................................26
Visual Checks....................................................... 26
Check the Stern-Drive Oil Level ................................ 26
Check the Power Trim Pump Fluid............................. 28
Maintenance....................................................................31
Periodic Maintenance....................................................33
The Importance of Periodic Maintenance .................... 33
Performing Periodic Maintenance ............................. 33
The Importance of Daily Checks ............................... 34
Yanmar Replacement Parts ..................................... 34
Tools Required ..................................................... 34
Ask Your Authorized Yanmar Marine Dealer or
Distributor for Help................................................. 34
Tightening Fasteners....................................................34
Torque Charts.............................................................35
Standard Torque Values ......................................... 35
Torque Specifications............................................. 35
Periodic Maintenance Table...........................................36
General Inspection.......................................................38
Power Trim Pump Fluid..................................................38
Periodic Maintenance Procedures....................................39
Weekly................................................................ 39
After Initial 50 Hours of Operation.............................. 40
Every 50 Hours of Operation .................................... 41
Every 100 Hours of Operation .................................. 41
Every 250 Hours of Operation .................................. 46
Every Year ........................................................... 49
Troubleshooting..............................................................51
Long-Term Storage..........................................................53
Cold Weather (Freezing Temperature), Seasonal and
Extended Storage........................................................53
Stern-Drive Lay Up ................................................ 53
Stern-Drive Recommissioning .................................. 54
iv ZT350 Operation Manual

INTRODUCTION
Welcome to the world of Yanmar Marine! • Constant efforts are made to improve the
Yanmar Marine offers engines, stern-drive quality and performance of Yanmar
systems and accessories for all types of products, so some details included in this
vessels, from runabouts to sailboats, and Operation Manual may differ slightly from
from cruisers to mega yachts. In marine your stern-drive. If you have any questions
leisure boating, the worldwide reputation of about these differences, please contact
Yanmar Marine is second to none. your authorized Yanmar Marine dealer or
distributor.
Yanmar stern-drives are designed for a wide
range of applications and are designed to
reduce vibration and make your cruising
more pleasurable.
To help you enjoy your Yanmar Marine
products for many years to come, please
follow these recommendations:
• Read and understand this Operation
Manual before you operate your vessel to
ensure that safe operating practices and
maintenance procedures are followed.
• Keep this Operation Manual in a
convenient place for easy access.
• If this Operation Manual is lost or
damaged, order a new one from your
authorized Yanmar Marine dealer or
distributor.
• Make sure this manual is transferred to
subsequent owners. This manual should
be considered a permanent part of the
vessel and remain with it.
ZT350 Operation Manual 1

INTRODUCTION
RECORD OF OWNERSHIP
Take a few moments to record the information you need when you contact Yanmar for
service, parts or literature.
Stern-Drive Model:
Stern-Drive Transom Assembly Serial No.:
Stern-Drive Unit Serial No.:
Stern-Drive Gear Ratio:
Date Purchased:
Engine Model:
Engine Horsepower:
Propeller Number:
Propeller Pitch:
Propeller Diameter:
Hull Identification Number (HIN):
Boat Manufacturer:
Boat Model:
Dealer:
Dealer Phone:
2 ZT350 Operation Manual

SAFETY
Yanmar considers safety of great SAFETY PRECAUTIONS
importance and recommends that anyone
that comes into close contact with its
products, such as those who install, DANGER
operate, maintain or service Yanmar Indicates a hazardous situation which, if
products, exercise care, common sense not avoided, will result in death or
and comply with the safety information in serious injury.
this manual and on the engine and stern-
drive's safety labels. Keep the labels from
becoming dirty or torn and replace them if WARNING
they are lost or damaged. Also, if you need Indicates a hazardous situation which, if
to replace a part that has a label attached to not avoided, could result in death or
it, make sure you order the new part and serious injury.
label at the same time.
This safety alert symbol appears CAUTION

with most safety statements. It
means attention, become alert, Indicates a hazardous situation which, if
! your safety is involved! Please

read and abide by the message
not avoided, could result in minor or
moderate injury.
that follows the safety alert
symbol. NOTICE
Indicates a situation which can cause
damage to the engine and stern-drive,
personal property and / or the environment
or cause the equipment to operate
improperly.

SAFETY
General Information Before You Operate
There is no substitute for common sense
and careful practices. Improper practices or DANGER
carelessness can cause burns, cuts, The safety messages that follow have
mutilation, asphyxiation, other bodily injury DANGER level hazards. These safety
or death. This information contains general messages describe a hazardous
safety precautions and guidelines that must situation which, if not avoided, will
be followed to reduce risk to personal safety. result in death or serious injury.
Special safety precautions are listed in
specific procedures. Read and understand NEVER permit anyone to
all of the safety precautions before operation install or operate the engine or
or performing repairs or maintenance. stern-drive without proper
training.

Manual before you 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.

SAFETY
During Operation and WARNING
Maintenance
The safety messages that follow have
DANGER WARNING level hazards. These safety
The safety messages that follow have messages describe a hazardous
situation which, if not avoided, could
DANGER level hazards. These safety
result in death or serious injury.
messages describe a hazardous
situation which, if not avoided, will Explosion Hazard
result in death or serious injury. While the engine is running or
Fire Hazard the battery is charging,
hydrogen gas is being
Ensure that appropriate fire
detection and extinguishing produced and can be easily
equipment are installed and ignited. Keep the area around
the battery well-ventilated and keep sparks,
checked periodically for
proper operation. open flame and any other form of ignition out
of the area.
Crush Hazard
Fire Hazard
ALWAYS use lifting
Undersized wiring systems
equipment with sufficient
can cause an electrical fire.
capacity to lift the stern-drive.
NEVER stand under a 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.

SAFETY
WARNING Alcohol and Drug Hazard

NEVER operate the engine
Sever Hazard
while under the influence of
NEVER service the stern- alcohol or drugs or when
drive while under tow or if the feeling ill.
engine is running at idle
speed. The propeller may Exposure Hazard
rotate under these
circumstances. ALWAYS wear personal
protective equipment
If the vessel has more than one engine, including appropriate
NEVER service a stern-drive if either of the clothing, gloves, work
engines are running. In multi-engine shoes, eye and hearing
configurations, the propeller for an engine protection as required by
that is shut down may rotate if any of the the task at hand.
other engines are running.
Entanglement Hazard
Rotating parts can cause severe injury or NEVER leave the key in the
death. NEVER wear jewelry, unbuttoned key switch when servicing the
cuffs, ties or loose-fitting clothing, and engine or stern-drive.
ALWAYS tie long hair back when working Someone may accidentally
near moving / rotating parts such as the start the engine and not
flywheel or PTO shaft. Keep hands, feet and realize you are servicing it.
tools away from all moving parts.
NEVER operate or service the engine while
To prevent accidental equipment wearing a headset to listen to music or the
movement, NEVER start the engine in gear. radio because it will be difficult to hear the
Before starting the engine, ALWAYS make warning signals.
sure that all bystanders are clear of the area. Burn Hazard
Keep children and pets away while the
engine is operating. Some of the engine and stern-
drive surfaces become very
Always remove any tools or shop rags used hot during operation and
during maintenance from the area before shortly after shutdown. Keep
operation. hands and other body parts
away from hot surfaces.
Stop the engine before you begin to service
the stern-drive and secure the propeller so
it will not turn.

SAFETY
WARNING CAUTION
Exhaust Hazard The safety messages that follow have
NEVER block windows, CAUTION level hazards. These safety
vents, or other means of messages describe a hazardous
ventilation if the engine is situation which, if not avoided, could
operating in an enclosed area. result in minor or moderate injury.
All internal combustion NEVER permit anyone to
engines create carbon monoxide gas during install or operate the stern-
operation and special precautions are drive or engine without proper
required to avoid carbon monoxide training. Safety signs and
poisoning. labels are additional
reminders for safe service and
Electrical Shock Hazard maintenance techniques. Read and
ALWAYS turn off the battery understand this Operation Manual before
switch (if equipped) or you operate or service the stern-drive to
disconnect the negative ensure that you follow safe servicing
battery cable before servicing practices and maintenance procedures.
the equipment.
Poor Lighting Hazard
ALWAYS keep the electrical connectors Ensure that the work area is adequately
and terminals clean. Check the electrical illuminated. ALWAYS install wire cages on
harnesses for cracks, abrasions, and portable safety lamps.
damaged or corroded connectors.
Tool Hazard
ALWAYS use tools appropriate for the task
at hand and use the correct size tool for
loosening or tightening machine parts.
Flying Object Hazard
ALWAYS wear eye protection
when servicing the stern-drive
or when using compressed air
or high-pressure water. Dust,
flying debris, compressed air,
pressurized water or steam may injure your
eyes.

SAFETY
CAUTION NOTICE
Slipping and Tripping Hazard The safety messages that follow have
Ensure that adequate floor NOTICE level hazards.
space is set aside for It is important to perform the daily checks as
servicing the stern-drive. The listed in this Operation Manual.
floor space must be flat and Periodic maintenance prevents unexpected
free of holes. downtime, reduces the number of accidents
Keep the floor free of dust, mud, spilled due to poor engine or stern-drive
liquids and parts to help prevent slipping and performance and can help extend the life of
tripping. 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.

SAFETY
NOTICE
NEVER use the stern-drive lifting eye to lift
the engine and stern-drive as an assembly.
Use the engine lifting eyes to lift the engine
and stern-drive. Only use the stern-drive
lifting eye to lift the stern-drive as a separate
component.
The anode of the stern-drive is only

calculated for the stern-drive. Changing the
material of the propeller may require
additional anodes to be installed on the
stern-drive.
Anytime the boat is left in the water and the

engine is not running, the drive must be left
in the fully down position. This will keep the
anodes in the water and will keep the
exhaust pipe engaged with the exhaust port
of the drive.

SAFETY
This Page Intentionally Left Blank

PRODUCT OVERVIEW
OVERVIEW New Stern-Drive Break-In:
• On the initial engine start-up, allow the
Owner / Operator engine to idle for approximately 15
Responsibilities minutes while you check for proper stern-
The operator must, and assumes all drive function and stern-drive oil leaks.
responsibility to: • During the break-in period, carefully
observe stern-drive indicators (if any) for
• Read and understand the operation proper stern-drive function.
manual prior to operating the stern drive; • During the break-in period, check the
• Perform all safety checks as necessary to stern-drive oil levels frequently.
ensure safe operation;
Dealer / Distributor
• Comply with and follow all lubrication and Responsibilities
maintenance instructions and
In general, a dealer's responsibilities to the
recommendations; and
customer include predelivery inspection
• Have an authorized Yanmar Marine and preparation such as:
dealer / distributor perform periodic
checkups. • Ensure that the vessel is properly
Conducting normal maintenance service equipped.
and replacing consumable parts as • Prior to delivery, make certain that the
necessary is the responsibility of the owner / Yanmar stern-drive and other equipment
operator and necessary to provide the best are in proper operating condition.
durability, performance and dependability of • Make all necessary adjustments for
the stern drive while keeping your overall maximum efficiency.
operating expenses to a minimum. • Familiarize the customer with the
Individual operating habits and usage may on-board equipment.
increase the frequency of performing
• Explain and demonstrate the operation of
maintenance service condition. Monitor
the stern-drive and vessel.
conditions frequently to determine if the
maintenance intervals suggested in the
manual are frequent enough for stern drive.
NOTICE: The anode of the stern-drive is

only calculated for the stern-drive. Changing
the material of the propeller may require
stern-drive.

PRODUCT OVERVIEW
COMPONENT IDENTIFICATION
(1) (2)
(3)
(7) (4)
(6)
(5)
0006029
Figure 1
1 – Steering System Location 5 – Trim Cylinder
2 – Transom Assembly 6 – Speedometer Pitot Hole
3 – Drive Unit 7 – Y-CaPS Electrode
4 – Antiventilation Plate

PRODUCT OVERVIEW
Location of Serial Numbers
The serial numbers are the manufacturer's
keys to numerous engineering details which
apply to your Yanmar stern-drive. When
contacting Yanmar about service, always
specify model and serial numbers.
(1) (2)
0006017
Figure 2
1 – Transom Assembly Serial
Number
2 – Drive Unit Serial Number

PRODUCT OVERVIEW
CORROSION PROTECTION • the marina environment such as stray
current in the water, fresh or salt water and
Galvanic Corrosion use and isolation of shore power;
Galvanic corrosion results whenever two or • improper application of marine paint or
more dissimilar metals (like those found on antifouling paint;
the stern-drive) are submerged in a • failure to repaint damaged areas; and
conductive solution, such as saltwater, • how the vessel is bonded.
polluted water or water with a high mineral Please check with the boat builder, dealer or
content because a chemical reaction takes other professional to determine if your
place causing electrical current to flow vessel and/or stern drive is adequately
between the metals. The electrical current protected from galvanic corrosion.
flow causes the metal that is most
chemically active, or anodic, to erode. If not If anodes erode quickly or if signs of
controlled, galvanic corrosion may corrode corrosion are evident, the owner should take
stern-drive components. immediate corrective action. Yanmar
recommends consulting an engineer
NOTICE: The anode of the stern-drive is specializing in marine electricity and
only calculated for the stern-drive. Changing corrosion control to determine the best way
the material of the propeller may require to correct the rapid erosion of the anodes.
stern-drive. Shore Power
Vessels that are connected to shore power
Corrosion Control require additional protection to prevent
It is the boat designer’s responsibility and/or destructive low voltage galvanic currents
the re-powering engineer’s responsibility to from passing through the shore power
design the proper systems and equipment ground wire. Galvanic isolators are available
to control and reduce the possibility of from the aftermarket (not supplied by
galvanic corrosion. Yanmar) to block these currents while still
providing a path to ground for dangerous
To help control the effects of galvanic
shock currents. NOTICE: If the AC shore
corrosion, Yanmar Marine ZT350 stern-
power ground is not isolated from the boat
drives come with several anodes and an
ground, the Y-CaPS and anodes may be
electronic anticorrosion system (Y-CaPS)
unable to neutralize the increased galvanic
that protect the stern-drive in moderate
potential. Corrosion damage that results
corrosive conditions. However, it is
from the improper system design or
essential that the owner/operator frequently
application is not covered by the Yanmar
monitor the anodes for wear, inspect the
limited warranty.
stern drive for corrosion and replace the
anodes often enough to provide a sacrificial Underwater Drive Coating
surface for the electrical current to attack. The lower gear case coating may be
Galvanic isolators are also available from damaged when hit by objects in the water,
the aftermarket (not supplied by Yanmar) to or when having deposits removed from it.
block stray current while still providing a path The underwater coating must be inspected
to ground for dangerous shock currents. at least once per year and when it is believed
The rate of corrosion depends on numerous that an object was hit that may have caused
factors, such as: damage. Repair and repaint damaged
• the number, size and location of anodes areas immediately.
on the stern-drive and vessel;

PRODUCT OVERVIEW
Observe the following precautions when Additional Protection
applying antifouling or marine paint to the In addition to the corrosion protection
transom of the boat hull: devices, take these steps to inhibit
• ALWAYS follow the paint/coating corrosion:
manufacturer's directions for surface
preparation and application. 1. Paint the stern-drive. See Touching-Up
• ALWAYS use a high quality primer and the Stern-Drive Paint and Spray with
topcoat paint specifically designed for Corrosion Guard on page 46.
aluminum outboards or stern-drives. 2. Spray stern-drive components on the
• NEVER paint the anodes installed on the inside of the vessel annually with
stern-drive. Corrosion Guard to protect the finish
from dulling and corrosion. External
• NEVER paint the Y-CaPS reference
stern-drive components may also be
electrode and / or anode.
sprayed.
• NEVER wash the stern-drive with a high
3. Keep all lubrication points, especially
pressure washer. This could damage the
the steering system, shift and throttle
coating on the reference wire.
linkages, well-lubricated.
• NEVER paint the stern-drive with a
4. Flush the coolant system periodically,
material that contains copper or tin.
preferably after each use.
• NEVER paint over drain holes, anodes, Y- NOTICE: Replace anodes if eroded 50
CaPS or other items specified by the percent or more.
anode Manufacturer.
NOTICE: Anytime the boat is left in the
Contact your authorized Yanmar Marine water and the engine is not running, the
dealer or distributor for assistance. drive must be left in the fully down
position. This will keep the anodes in the
NOTICE: Galvanic corrosion damage, water and will keep the exhaust pipe
normal maintenance and consumable parts engaged with the exhaust port of the
are not covered by the Yanmar Limited drive.
Warranty.
(4)
(3)
(2)
(1)
(5)
0005989
Figure 3
1 – Gear Housing Anodic Plates
2 – Ventilation Plate Anode
3 – Y-CaPS Electrode
4 – Trim Cylinder Anodes
5 – Propeller Shaft Anodes

PRODUCT OVERVIEW
Gear Housing Anodic Plates Trim Cylinder Anodes
The gear housing anodic plates are installed The trim cylinder anodes are installed on
on the underside of the antiventilation plate. each trim cylinder.
(1)
(1)
0006016
0006037
Figure 4 Figure 6
1 – Gear Housing Anodic Plates 1 – Trim Cylinder Anodes
Ventilation Plate Anode Propeller Shaft Anode
The ventilation plate anode is installed on The propeller shaft anode is located behind
the front of the drive shaft housing on top of the aft propeller.
the ventilation plate.
(1)
(1)
0006036 0006038
Figure 5 Figure 7
1 – Ventilation Plate Anode 1 – Propeller Shaft Anode

PRODUCT OVERVIEW
FEATURES AND CONTROLS Power Trim
The power trim is used to accelerate the
Remote Controls vessel onto plane, reach the desired engine
The Yanmar ZT350 can be controlled rpm or vessel speed, and improve the
mechanically with push-pull cables or performance of the vessel when there is a
electronically. Please refer to the Yanmar change in water or boating conditions. The
Engine Operation Manual or the Electronic performance of the vessel depends on load
Control System Operation Manual (if so weight and distribution. Distribute the weight
equipped). evenly, from bow to stern and from port to
starboard. Trimming will not improve the
vessel's performance due to an imbalanced
load.
0006019
Figure 8
0006020
Figure 9
0006021
Figure 10

PRODUCT OVERVIEW
Stern-Drive Trim Angle Trim and Tilt / Trailering Switch
Trim angle is the angular relationship Raising and lowering of the stern-drive is
between the stern-drive and the transom of controlled by the combination trim and tilt /
the vessel. Vessel trim while underway trailering switch.
greatly affects vessel performance and
efficiency. For best results, the vessel The trim portion of the switch operates the
should be on plane and trimmed to reduce trim system in either the “bow-up” or “bow-
the wet surface. With less vessel in the down” directions.
water, both speed and fuel economy The tilt portion (or trailering portion) of the
increase. The power trim should be adjusted switch operates the tilt system for trailering,
continuously for best results. beaching, launching and shallow water
If the stern-drive is trimmed in “bow-down” operation (low-speed below 1200 rpm).
(Figure 10) too far (stern-drive is closer to CAUTION! Never raise the stern-drive
the transom), the speed drops, fuel into the tilt / trailering range when the
economy decreases and the vessel may not engine is operating above 1200 rpm.
handle correctly. However, it does provide Damage to the stern-drive may result.
better acceleration from a standstill, and The switch is located on the remote control
because it forces the bow down, visibility is handle or on the vessel's dash panel.
improved.
Single stern-drive applications will have one
If the stern-drive is trimmed out “bow-up” switch.
(Figure 9) too far (stern-drive is away from
the transom), steering torque may increase, Dual stern-drive applications can have
the vessel may be difficult to get on a plane either one integral switch to operate both
and may bounce. stern-drives or may have a separate switch
for each stern-drive. CAUTION! Always
raise and lower dual stern-drives evenly
together. Damage to the tie bar
connecting the two stern-drives
together could result from twisting or
binding if the stern-drives are raised or
lowered separately.

PRODUCT OVERVIEW
Electrical System
The power trim pump's electrical system is
protected by either a 1A in-line fuse
(Figure 11, (1)) or an auto-reset circuit (2)
breaker (Figure 11, (2)) located within the
trim motor. In the event of an electrical
overload, the fuse will blow out or the circuit
breaker will shut off. Correct the cause of the
electrical overload before operating the trim
system. If the electrical overload problem (1)
still exists, contact your authorized Yanmar
Marine dealer or distributor.
0006011
Figure 11
1 – 1A Fuse Holder
2 – Auto-Reset Circuit Breaker

PRODUCT OVERVIEW
Yanmar Cathodic Protection System Test Y-CaPS to ensure adequate output.
The Yanmar Cathodic Protection System The test should be performed where the
(Y-CaPS) has a 20A in-line fuse vessel is moored, using a reference
(Figure 12, (2)) in the wire which connects electrode and test meter. Contact your
to the positive (+) terminal on the controller. authorized Yanmar Marine dealer or
If the fuse blows, the system will not operate distributor for assistance, if necessary.
resulting in a loss of corrosion protection.
(2)
(1)
(3)
0006335
Figure 12
1 – Y-CaPS Controller 3 – Electrode
2 – 20A In-Line Fuse Holder

STERN-DRIVE OPERATION
This section of the Operation Manual
describes the procedures for proper
DANGER
operation of the stern-drive. The safety messages that follow have
Before you operate the ZT350, read the messages describe a hazardous
following safety information and review the situation which, if not avoided, will
Safety on page 3. result in death or serious injury.
NEVER permit anyone to
install or operate the engine or
stern-drive without proper
training.

Manual before you 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.

WARNING CAUTION
The safety messages that follow have The safety messages that follow have
WARNING level hazards. These safety CAUTION level hazards. These safety
messages describe a hazardous messages describe a hazardous
situation which, if not avoided, could situation which, if not avoided, could
result in death or serious injury. result in minor or moderate injury.
Explosion Hazard NEVER permit anyone to
While the engine is running or install or operate the stern-
the battery is charging, drive without proper training.
hydrogen gas is being Safety signs and labels are
produced and can be easily additional reminders for safe
ignited. Keep the area around service and maintenance
the battery well-ventilated and keep sparks, techniques.
open flame and any other form of ignition out Read and understand this Operation
of the area. Manual before you operate or service the
stern-drive to ensure that you follow safe
Sever Hazard servicing practices and maintenance
To prevent accidental equipment procedures.
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.
Alcohol and Drug Hazard
NEVER operate the engine
while under the influence of
alcohol or drugs or when
feeling ill.
Entanglement Hazard
NEVER operate the engine while wearing a
headset to listen to music or the radio
because it will be difficult to hear the warning
signals.

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

INSTALLING THE PROPELLERS
(2) (5) (6)
(4)
(3)
(1)
(7)
(8)
0006015
Figure 1
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

1. Apply a liberal coat of lubricant to the 5. Slide the aft thrust hub onto the propeller
propeller shaft. Recommended shaft, with the tapered side toward the
lubricants are shown in the table below. propeller hub (toward end of shaft).
Description Where Used
6. Align the splines and place the propeller
on the propeller shaft.
Urea Grease Water
Resistant Type, 7. Install and torque the rear propeller nut.
NLGI #2 Propeller Shaft Check the propeller at least every 20
Lithium Grease With hours.
PTFE
Rear Propeller Nut Torque
2. Slide the forward thrust hub onto the
propeller shaft with the tapered side N·m lb-ft
toward the propeller hub (toward end of 80 59
propeller shaft). 8. Install the propeller shaft anode bolt with
3. Align the splines and place the propeller a washer. Torque the bolt.
on the propeller shaft.
Propeller Shaft Anode Bolt Torque
4. Install and torque the front propeller nut.
N·m lb-ft
Check the propeller at least every 20
30 22
hours.
Front Propeller Nut Torque
N·m lb-ft
135 99

REMOVING THE DAILY CHECKS
PROPELLER
All stern-drives have been submitted to a
WARNING! The Remote Control must be test run before shipment.
in NEUTRAL and the starter key
Visual checks for leakage should be made
removed from the switch before
from time to time.
removing and / or installing the
propeller. Before operating the stern-drive, make sure
it is in good operating condition. Make sure
1. Place a wood block between the
you check the following items and have any
propeller blades and the antiventilation
repairs completed before you operate the
plate to prevent rotation.WARNING!
stern-drive.
Place a block of wood between the
antiventilation plate and the NOTICE: Anytime the boat is left in the water
propeller to protect hands from and the engine is not running, the drive must
propeller blades and to prevent the be left in the fully down position. This will
propeller from rotating when keep the anodes in the water and will keep
removing the propeller nut. the exhaust pipe engaged with the exhaust
2. Turn the rear propeller nut port of the drive.
(36 mm [1-7/16 in.]) counterclockwise to
remove the nut. Visual Checks
3. Slide the propeller and the thrust hub off CAUTION! If any problem is noted
the propeller shaft. during the visual check, the necessary
corrective action should be taken before
4. Turn the front propeller nut
you operate the stern-drive.
(70 mm [2-3/4 in.]) counterclockwise to
remove the nut. 1. Check for oil leaks.
5. Slide the propeller and the thrust hub off 2. Check for damaged or missing parts.
the propeller shaft. 3. Check for loose, missing or damaged
fasteners.
4. Check the electrical harnesses for
cracks, abrasions, and damaged or
corroded connectors.
Check the Stern-Drive Oil Level
GL-5 Hypoid Gear Oil Oil Reservoir
Note: The oil level will rise and fall during

operation. Check the oil level before
starting, when the engine is cold.

1. Check the stern-drive oil level Fill the Stern-Drive with Oil
(Figure 2). Keep the oil level at or near See Changing the Stern-Drive Oil on page
the OPERATING RANGE (full) line on 46 when filling the entire stern-drive.
the oil reservoir.
NOTICE: If more than 60 ml (2 fl oz) of gear
2. The oil level is low if it is below the ADD
oil is required to fill the reservoir, a seal may
line on the oil reservoir. Fill as needed
be leaking. Damage to the stern-drive may
with the specified oil. See Fill the Stern-
occur because of lack of lubrication. Contact
Drive with Oil on page 27.
your authorized Yanmar Marine dealer or
(1) distributor.
1. Remove the oil reservoir cap

(Figure 3, (1)).
2. Fill the oil reservoir to the OPERATING
RANGE (Figure 3, (2)) (full) line with
specified fluid. NOTICE: Do not overfill.
(1)
(3)
(2)
(2)
0006336
Figure 2
1 – Oil Reservoir
2 – ADD Line
3 – OPERATING RANGE Line 0006337
Figure 3
NOTICE: If any water is visible at the bottom 1 – Oil Reservoir Cap
of the oil reservoir or appears at the oil fill / 2 – OPERATING RANGE Line
drain plug and / or if oil appears discolored,
contact your authorized Yanmar Marine Description Where Used
dealer or distributor immediately. Both GL-5 Hypoid Gear Oil Oil Reservoir
conditions may indicate a water leak 3. When replacing the cap, ensure that the
somewhere in the stern-drive. rubber gasket is inside the oil reservoir
cap and install the cap. Do not over-
tighten.

Check the Power Trim Pump 3. The oil level is low if it is below the MIN
Fluid line (Figure 4, (1)) on the reservoir. Fill
NOTICE: ALWAYS check the oil level with as necessary with the specified fluid.
stern-drive in the full DOWN / TRIM-IN See Fill the Power Trim Pump Fluid on
position. page 28.
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 4, (2)).
(1)
0006013
Figure 5
1 – MIN Line
(1) Fill the Power Trim Pump Fluid
Note: The power trim fluid does not require
changing unless it becomes contaminated
with water or debris. Contact your
(2) authorized Yanmar Marine dealer or
distributor if the power trim fluid needs to be
changed.
1. Place the stern-drive in the full DOWN /
TRIM-IN position.
2. Unscrew and remove the fill cap
(Figure 6, (1)) assembly from the
reservoir (Figure 6, (3)) with specified
fluid.
Dextron 3 Automatic
Power Trim Pump
Transmission Fluid
0006012
Figure 4
1 – Reservoir
2 – MIN and MAX Lines

3. Add oil to bring the oil level to within the
MIN and MAX lines on the reservoir
(Figure 6, (2)).
(2)
(1)
(3)
0006014
Figure 6
1 – Fill Cap Assembly
2 – MIN and MAX Lines
3 – Reservoir
4. Install the fill cap assembly.

This Page Intentionally Left Blank

MAINTENANCE
This section of the Operation Manual
describes the procedures for proper care
DANGER
and maintenance of the stern-drive. The safety messages that follow have
Before you operate the ZT350, read the messages describe a hazardous
following safety information and review the situation which, if not avoided, will
Safety on page 3. result in death or serious injury.
Crush Hazard
ALWAYS use lifting
equipment with sufficient
capacity to lift the stern-drive.
NEVER stand under a 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.

MAINTENANCE
WARNING CAUTION
The safety messages that follow have The safety messages that follow have
WARNING level hazards. These safety CAUTION level hazards. These safety
messages describe a hazardous messages describe a hazardous
situation which, if not avoided, could situation which, if not avoided, could
result in death or serious injury. result in minor or moderate injury.
Sever Hazard Flying Object Hazard
NEVER service the stern- ALWAYS wear eye protection
drive while under tow or if the when servicing the engine or
engine is running at idle when using compressed air or
speed. The propeller may high-pressure water. Dust,
rotate under these flying debris, compressed air,
circumstances. pressurized water or steam may injure your
eyes.
If the vessel has more than one engine,
NEVER service a stern-drive if either of the
engines are running. In multi-engine
configurations, the propeller for an engine
that is shut down may rotate if any of the
other engines are running.
Rotating parts can cause severe injury or

death. NEVER wear jewelry, unbuttoned
cuffs, ties or loose-fitting clothing, and
ALWAYS tie long hair back when working
near moving / rotating parts such as the
flywheel or PTO shaft. Keep hands, feet and
tools away from all moving parts.
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.
Entanglement Hazard
NEVER leave the key in the
key switch when servicing the
engine or stern-drive.
Someone may accidentally
start the engine and not
realize you are servicing it.

MAINTENANCE
NOTICE PERIODIC MAINTENANCE

The safety messages that follow have CAUTION! Establish a periodic
NOTICE level hazards. maintenance plan according to the
Only use replacement parts specified. Other stern-drive application and make sure to
replacement parts may affect warranty perform the required periodic
coverage. maintenance at the intervals indicated.
Failure to follow these guidelines will
ALWAYS be environmentally impair the stern-drive’s safety and
responsible. performance characteristics, shorten
Follow the guidelines of the the stern-drive’s life and may affect the
EPA or other governmental stern-drive warranty coverage. See your
agencies for the proper authorized Yanmar Marine dealer or
disposal of hazardous materials such as distributor for assistance when
engine oil, diesel fuel and engine coolant. checking items marked with a ●.
Consult the local authorities or reclamation
facility. The Importance of Periodic
Maintenance
NEVER dispose of hazardous materials by Stern-drive deterioration and wear occur in
dumping them into a sewer, on the ground proportion to the length of time the stern-
or into ground water or waterways. drive has been in service and the conditions
it is subjected to during operation. Periodic
maintenance prevents unexpected
downtime, reduces the number of accidents
due to poor performance and helps extend
the life of the stern-drive.
Performing Periodic
Maintenance
WARNING! NEVER block windows,
vents, or other means of ventilation if
the engine is operating in an enclosed
area. All internal combustion engines
create carbon monoxide gas during
operation. Accumulation of this gas
within an enclosure could cause illness
or even death.

MAINTENANCE
The Importance of Daily Checks TIGHTENING FASTENERS
The Periodic Maintenance Schedule
assumes that daily checks are performed on Use the correct amount of torque when
a regular basis. Make a habit of performing tightening fasteners. Applying excessive
daily checks before the start of each torque may damage the fastener or
operating day. component and too little torque may cause
a leak or component failure.
Yanmar Replacement Parts
Yanmar recommends using genuine
Yanmar parts when replacement parts are
necessary. Genuine replacement parts help
ensure long life.
Tools Required
Before starting any periodic maintenance
procedure, make sure to have the tools
needed to perform all of the required tasks
on hand.
Ask Your Authorized Yanmar

Marine Dealer or Distributor for
Help
Our professional service technicians have
the expertise and skills to help with any
maintenance or service related procedures.

MAINTENANCE
TORQUE CHARTS
Standard Torque Values
Nominal Designation of Screw

Standard Tightening Torque
Thread
3.5 ± 0.5 N·m

M5
2.6 ± 0.4 lb-ft
6.0 ± 1.0 N·m
M6
4.4 ± 0.6 lb-ft
15 ± 2.0 N·m
M8
11 ± 1.5 lb-ft
30 ± 2.0 N·m
M10
22 ± 1.5 lb-ft
45 ± 2.0 N·m
M12
33 ± 1.5 lb-ft
Torque Specifications
Item Size Torque
Nut for U-Bolt of Gimbal
M10 x 1.5 50 ± 5 N·m 37 ± 4 lb-ft
Ring
Bolt for Anode of Cylin-
10-32 UNF 3.5 ± 0.5 N·m 2.6 ± 0.4 lb-ft
der Part
Bolt for Rear Cover M8 x 1.25 6.0 ± 1.0 N·m 4.4 ± 0.7 lb-ft
Plug M10 x 1.5 15 ± 2.0 N·m 11 ± 1.5 lb-ft
Bolt for Valve Assembly M12 x 1.25 6.0 ± 1.0 N·m 4.4 ± 0.7 lb-ft
Bolt for Rear of Inner Pro-
1 - 14 UNS 80 ± 5.0 N·m 59 ± 3.7 lb-ft
peller Shaft
Bolt for Rear of Outer
2-1/8 – 16 UNS 135 ± 5.0 N·m 100 ± 3.7 lb-ft
Propeller Shaft

MAINTENANCE
PERIODIC MAINTENANCE TABLE
◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor
Daily
See Daily Every 50 Every 100 Every 250 Every
Weekly
Checks on Hours Hours Hours Year
page 26
Check the Stern-Drive Before Op-

Oil Level (Reservoir), eration
Fill if Necessary ◯
Check the Trim Pump Before Op-

Oil Level, Fill if Neces- eration
sary ◯
Check the Power Before Op-

Steering Fluid, Fill if eration
Necessary ◯
Check the Water Inlets

for Debris or Marine ◯
Growth, Clean if Nec-
essary
Check the Seawater

Inlet Hole, Clean if ◯
Necessary
Inspect the Anodes

and Replace if 50 per- ◯
cent eroded
First Time
Replenish The Oil In
Only
Stern-Drive ◯
Lubricate the Propel-

ler Shaft and Retorque ◯
the Nut*
Touch-Up the Stern-

Drive Paint and Spray ◯ ◯
with Corrosion Guard
First Time
Change the Stern-
Drive Oil
Only ◊** ◊**
◊
Retorque the Gimbal

Ring to Steering Shaft ◯ ◯
Connection
Inspect the Bellows ◯ ◯

and the Clamps

MAINTENANCE
◯: Check or Clean ◊: Replace ●: Contact your authorized Yanmar Marine dealer or distributor
Daily
See Daily Every 50 Every 100 Every 250 Every
Weekly
Checks on Hours Hours Hours Year
page 26
Check the Engine

● ●
Alignment
Lubricate the Unit

Bearing (Gimbal ◯ ◯
Housing)
Lubricate the Engine ◯ ◯ ◯

Coupler***
Check the Circuit for

Loose or Damaged ◯ ◯
Connections
Test the Y-CaPS Out- ◯ ◯

put on ZT350
Check the Steering

System for Loose, ◯ ◯
Missing or Damaged
Parts
Check the Remote
Control for Loose, ◯ ◯
Missing or Damaged
Parts
Lubricate the Cables ◯ ◯

and the Linkages
Retorque the Rear En- ◯ ◯

gine Mounts
* If operating in only freshwater, this maintenance may be extended to every four months.
** Every 250 hours or every year, whichever comes first.
*** Lubricate engine coupler every 50 hours if operated at idle for prolonged periods of time.

MAINTENANCE
GENERAL INSPECTION POWER TRIM PUMP FLUID
Inspect the stern-drive at regular intervals to Power trim fluid does not require changing
help maintain top operating performance unless it becomes contaminated with water
and correct potential problems before they or debris. Contact your authorized Yanmar
occur. Marine dealer or distributor if the power trim
fluid needs to be changed.
Check for loose, damaged or missing parts,
hoses and clamps. Tighten or replace as
needed.
Check the electrical connections and leads

for damage and corrosion.
Remove and inspect the propeller. If it is

badly nicked, bent or cracked, contact your
distributor.
Repair nicks and corrosion damage on

stern-drive exterior finish. NEVER use paint
containing copper or tin. This will damage
the stern-drive and void the warranty. Use a
high quality primer and topcoat paint
specifically designed for aluminum
outboards or stern-drives. Follow the
manufacturer's directions for surface
preparation and application.

MAINTENANCE
PERIODIC MAINTENANCE 3. Install the oil vent plug and gasket.
PROCEDURES Torque the oil vent plug.
Oil Vent Plug Torque
Weekly N·m lb-ft

15 11
Perform the following procedures on a
weekly basis.
• Checking the Water Inlets

• Checking the Seawater Inlet Hole
• Inspecting the Anodes
• Checking the Oil Level
Checking the Water Inlets
Check the water inlets for debris or marine
growth. Clean if necessary.
Checking the Seawater Inlet Hole
Check the seawater inlet hole. Clean if
necessary.
Inspecting the Anodes
Inspect the anodes and replace if 50%
corroded. See Corrosion Protection on
page 14.
Checking the Oil Level
Check the stern-drive oil level within one
week of the first use as follows:
1. Remove the oil vent plug and gasket
(Figure 1, (1)).
(2)
(1)
0006031
Figure 1
1 – Oil Vent Plug
2 – Gasket
2. If necessary, add oil until an air-free
stream of oil flows from the oil vent hole.

MAINTENANCE
After Initial 50 Hours of
Multi-Purpose
Operation Heavy-Duty Type
Coupler
Lithium Grease,
NLGI #2
Perform the following procedures after the
first 50 hours of operation. Note: Lubricate the coupler on the ZT350
model every 50 hours if the vessel is
• Lubricating the Engine Coupler
operated at idle for prolonged periods of
• Changing the Stern-Drive Oil time.
Lubricating the Engine Coupler
Changing the Stern-Drive Oil
Lubricate the engine coupler every 50 hours
if operated at idle for prolonged periods of See Changing the Stern-Drive Oil on page
time. 46.
Note: The stern-drive may be equipped with

a sealed engine coupler. The sealed coupler
and shaft splines can be lubricated without
removing the stern-drive.
Apply approximately 8 to 10 pumps of
grease to the engine coupler grease fitting
(Figure 2, (1)) to lubricate the engine
coupler splines through the grease fittings,
if equipped. Use a typical hand-operated
grease gun to apply the grease.
(1)
0006033
Figure 2
1 – Engine Coupler Grease Fitting

MAINTENANCE
Every 50 Hours of Operation Every 100 Hours of Operation

Perform the following maintenance every 50 Perform the following maintenance every
hours of operation. 100 hours of operation.
• Lubricate the Engine Coupler • Lubricating the Propeller Shaft and

Lubricate the Engine Coupler Retorqueing the Nut
Lubricate the engine coupler every 50 hours • Retorqueing the Gimbal Ring to
if operated at idle for prolonged periods of Steering Shaft Connection
time. See Lubricating the Engine Coupler • Inspecting the Bellows and the Clamps
on page 40. • Checking the Engine Alignment
• Lubricating the Unit Bearing (Gimbal
Housing)
• Checking the Circuit for Loose or
Damaged Connections
• Testing the Y-CaPS Output
• Checking the Steering System for
Loose, Missing or Damaged Parts
• Lubricating the Drive Unit and
Universal-Joint Shaft Spines and O-
Rings
• Torqueing the Rear Engine Mount
Bolts
• Checking the Remote Control for
• Lubricating the Cable and the
Linkages
Lubricating the Propeller Shaft and
Retorqueing the Nut
If operating in only freshwater, this
maintenance may be extended to every four
months. See Installing the Propellers on
page 24.

MAINTENANCE
Retorqueing the Gimbal Ring to
Steering Shaft Connection
Torque the gimbal ring locknuts for the
steering shaft connection.
(2) (1)
(1)
0006032
Figure 4
1 – Unit Bearing (Gimbal Housing)
Grease Fitting
0006035
Figure 3
1 – Gimbal Ring Urea Grease Water
Unit Bearing (Gim-
2 – Locknuts Resistant Type,
bal Housing)
NLGI #2
Gimbal Ring Locknut Torque
N·m lb-ft Lubricating the Engine Coupler
50 37 See Lubricating the Engine Coupler on
page 40.
Inspecting the Bellows and the
Clamps Checking the Circuit for Loose or
See General Inspection on page 38. Damaged Connections
Check the electrical connections and leads
Checking the Engine Alignment for damage and corrosion.
See your authorized Yanmar Marine dealer
or distributor. Testing the Y-CaPS Unit Output
See Yanmar Cathodic Protection System
Lubricating the Unit Bearing (Gimbal on page 20.
Housing)
Apply approximately 8 to 10 pumps of Checking the Steering System for
grease to the unit bearing (gimbal housing) Loose, Missing or Damaged Parts
grease fitting (Figure 4, (1)) to lubricate the Check the steering system and tighten any
unit bearing (gimbal housing). Use a typical loose parts, replace any missing or
hand-operated grease gun to apply the damaged parts.
grease.

MAINTENANCE
Lubricating the Drive Unit and Universal-Joint Shaft Spines and O-Rings
When you remove the stern-drive unit from the transom assembly, your should first remove
the quick connect fitting. This will prevent oil leaks from the reservoir tank.
0006509
Figure 5
Remove the drive unit and lubricate the universal-joint shaft splines (Figure 6, (1)) and the
O-rings (Figure 6, (2)).
(2)
(1)
0006004
Figure 6
1 – Universal-Joint Shaft Splines
2 – Universal-Joint O-Rings
Multi-Purpose
Universal-Joint
Heavy-Duty Type
Shaft Splines and
Lithium Grease,
O-Rings
NLGI #2

MAINTENANCE
Torqueing the Rear Engine Mount Bolts Lubricating the Shift Cable and the
Note: Refer to the Engine Installation Linkages
Manual and / or Operation Manual for front CAUTION! NEVER grease the steering
engine mount information. cable while extended. Hydraulic lock
could occur and cause loss of steering
Torque the rear engine mount bolts. control.
Grease the steering cable grease fitting.
1. Turn the steering wheel until the

steering cable is fully retracted into the
(3) cable housing. Apply approximately
(1) three pumps of grease from a typical
hand-operated grease gun.
(2)
Note: If the steering cable does not have a
grease fitting, the inner wire of the cable
cannot be greased.
0006001
Figure 7 Lithium Grease With
Steering Cable
1 – Rear Engine Mount PTFE
2 – Transom Plate Mount 2. Turn the steering wheel until the
3 – Bolts steering cable is fully extended. Lightly
Engine Rear Mount Bolt Torque lubricate the exposed part of the cable.
N·m lb-ft
45 33
Checking the Remote Control for

See Remote Controls on page 17.
0006000
(1)
Figure 8
1 – Extended Steering Cable
Urea Grease Water
Resistant Type, Steering Cable
NLGI #2

MAINTENANCE
3. Lubricate the steering system clevis pin. Lubricating the Shift Cable (Typical)
Lubricate the shift cable pivot points
(Figure 10, (1)) and the guide contact
(1)
surfaces (Figure 10, (2)).
(1)
(1)
0005991 (1)
Figure 9 (2) 0006010
1 – Steering System Clevis Pin Figure 10
Description Where Used 1 – Shift Cable Pivot Points
Urea Grease Water 2 – Guide Contact Surfaces
Resistant Type, Clevis Pin
NLGI #2 Description Where Used
SAE 30W Engine Shift Cable Pivot
4. On dual engine vessels, lubricate the tie Oil Points
bar clevis pin. Guide Contact Sur-
Lithium Grease
faces and Cable
Description Where Used With PTFE
End
Urea Grease Water
Resistant Type, Clevis Pin
NLGI #2
5. Before starting the engine, turn the
steering wheel several times to
starboard and then port to ensure that
the steering system operates properly
before getting underway.

MAINTENANCE
Every 250 Hours of Operation

Perform the following maintenance every
250 hours of operation.
• Touching-Up the Stern-Drive Paint and (1)

Spray with Corrosion Guard
• Retorqueing the Rear Engine Mounts (2)
• Changing the Stern-Drive Oil
Touching-Up the Stern-Drive Paint
and Spray with Corrosion Guard
Corrosion damage that results from 0006341
improper application of anti-fouling paint will Figure 11

not be covered by the warranty. 1 – Painted Vessel Transom
2 – Minimum 40 mm (1-1/2 in.) of
Painting vessel hull or vessel transom:
unpainted area around transom
Anti-fouling paint may be applied to the
assembly
vessel hull and the vessel transom.
NOTICE: The drive unit and transom
NOTICE: NEVER paint the anodes or Y- assembly can be painted with a good quality
CaPS electrode. Painting these marine paint or an anti-fouling paint that
components will render them ineffective as does not contain copper or any other
galvanic corrosion inhibitors. material that could conduct electrical
current. NEVER paint drain holes, anodes,
NOTICE: Use copper-based paint as anti-
Y-CaPS or items specified by the vessel
fouling protection for the vessel hull or
manufacturer.
vessel transom, as long as it is not prohibited
by law in the area where the vessel will be NOTICE: NEVER wash the stern-drive with
operated. If using copper- or tin-based anti- a power washer because it can damage the
fouling paint, avoid an electrical coating on the reference wire and increase
interconnection between the Yanmar corrosion.
Product, Anodic Blocks, or Y-CaPS and the
paint by allowing a minimum of 40 mm (1-1/2 Retorqueing the Rear Engine
in.) of UNPAINTED area on the transom of Mounts
the vessel and around these items. See Torqueing the Rear Engine Mount Bolts
on page 44.
Note: The Stern-Drive oil must be changed
every 250 hours or every year, whichever
comes first.

MAINTENANCE
NOTICE: ALWAYS be environmentally 6. Drain the oil.
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 (2)
reclamation facility.
(1)
1. Remove the oil reservoir from the
bracket (Figure 12, (4)). 0006030
Figure 13
(1) 1 – Oil Fill / Drain Plug
(2) 2 – Gasket
(3) 7. Remove the oil vent plug and gasket
(Figure 14, (1)). Allow the oil to drain
completely.
(4)
(2)
0006338 (1)
Figure 12
1 – Bracket
2 – Oil Reservoir Cap 0006031
3 – Oil Reservoir Figure 14

1 – Oil Vent Plug
4 – Retaining Strap
2 – Gasket
2. Empty the contents into a container
large enough to hold the drained gear NOTICE: If any water drains from the oil
oil. fill / drain hole, or if it appears milky, the
stern-drive may be leaking and should
3. Install the oil reservoir (Figure 12, (3))
be checked immediately by your
in the bracket.
4. Place the stern-drive in full trim limit distributor.
OUT position.
5. Remove the oil fill / drain plug and
gasket (Figure 13).

MAINTENANCE
8. Remove the case plate cover, filter 13. Fill the oil reservoir so that the oil level is
cover, magnet and filter. Clean or within the operating range.
replace the filter and magnet. NOTICE: NEVER overfill.
Model Capacity Fluid Type
2500 mL GL-5 Hypoid
ZT350
(85 oz) Gear Oil
(5) (6)
(4) (1)
(1)
(2)
(3)
0006441
Figure 15 (2)
1 – Oil Level Sight Glass
2 – Filter Opening
3 – Filter
4 – Magnet
5 – Filter Cover
6 – Case Plate Cover
9. Lower the stern-drive so that the 0006337
propeller shaft is level. Fill the stern- Figure 16

drive through the oil fill / drain hole with 1 – Oil Reservoir Cap
the specified oil until an air-free stream 2 – OPERATING RANGE Line
of oil flows from the filter opening. Install 14. Ensure that the rubber gasket is inside
the filter, magnet, filter cover and case the cap and install the cap. NEVER
plate cover. over-tighten.
10. Continue to fill the stern-drive with oil 15. Remove the pump from the oil fill / drain
through the oil fill / drain hole until an air- hole. Quickly install the gasket and oil
free stream of oil flows from the oil vent fill / drain plug. Torque the oil fill / drain
hole. plug.
11. Install the oil vent plug and gasket. Oil Fill / Drain Plug Torque
Torque the oil vent plug. N·m lb-ft
Oil Vent Plug Torque 15 11
N·m lb-ft 16. Check the oil level in the oil reservoir
15 11 after first use.
12. Continue to pump gear oil into the oil
reservoir circuit until the gear oil
appears in the oil reservoir.

MAINTENANCE
17. Check the stern-drive oil level within one
week of the first use as follows:
Every Year
a. Remove the oil vent plug and Perform the following maintenance every
gasket (Figure 17, (1)). year of operation.
• Retorqueing the Gimbal Ring to

• Inspecting the Bellows and the Clamps
• Checking the Engine Alignment
(2) • Lubricating the Unit Bearing (Gimbal
Housing)
(1)
• Checking the Circuit for Loose or
0006031 Damaged Connections
Figure 17 • Testing the Y-CaPS Unit Output
1 – Oil Vent Plug • Checking the Steering System for
2 – Gasket Loose, Missing or Damaged Parts
b. If necessary, add oil until an air-free • Checking the Remote Control for
stream of oil flows from the oil vent Loose, Missing or Damaged Parts
hole. • Lubricating the Cable and the
c. Install the oil vent plug and gasket. Linkages
Torque the oil vent plug. • Touching-Up the Stern-Drive Paint and
NOTICE: Oil level in the oil reservoir will rise Spray with Corrosion Guard
and fall during stern-drive operation; always • Changing the Stern-Drive Oil
check the level when the stern-drive is cool
• Retorqueing the Rear Engine Mounts
and the engine is shut down.
Retorqueing the Gimbal Ring to
See Retorqueing the Gimbal Ring to
Steering Shaft Connection on page 42.
Inspecting the Bellows and the
Clamps
See General Inspection on page 38.
Checking the Engine Alignment
See Checking the Engine Alignment on
page 42.
Lubricating the Unit Bearing (Gimbal
Housing)
See Lubricating the Unit Bearing (Gimbal
Housing) on page 42.
Lubricating the Engine Coupler
See Lubricating the Engine Coupler on
page 40.

MAINTENANCE
Checking the Circuit for Loose or
Damaged Connections
See Checking the Circuit for Loose or
Damaged Connections on page 42.
Testing the Y-CaPS Unit Output
See Yanmar Cathodic Protection System
on page 20.
Checking the Steering System for
See Checking the Steering System for
Loose, Missing or Damaged Parts on page
42.
Checking the Remote Control for
See Remote Controls on page 17.
Lubricating the Cable and the
Linkages
See Lubricating the Shift Cable (Typical) on
page 45.
Touching-Up the Stern-Drive Paint
and Spray with Corrosion Guard
See Touching-Up the Stern-Drive Paint and
Spray with Corrosion Guard on page 46.
See Changing the Stern-Drive Oil on page
46.
Retorqueing the Rear Engine
Mounts
See Torqueing the Rear Engine Mount Bolts
on page 44.

TROUBLESHOOTING
No. Problem Possible Cause Action Reference Page
1 Remote Control Insufficient lubrication Lubricate. 44
Operates Hard, Binds, on the shift and throttle
Has Excessive Free (if applied) linkage
Play or Makes Unusu- fasteners.
al Sounds
Obstruction in the shift Remove the 44
or throttle (if applied) obstruction.
linkages.
Loose or missing shift Check all throttle link-
and throttle linkages. ages. If any are loose
or missing, see your
authorized Yanmar
Marine dealer or dis-
tributor immediately.
Shift or throttle (if Straighten the cable or 44
equipped) cable is have your authorized
kinked. Yanmar Marine dealer
or distributor replace
the cable if damaged
beyond repair.
2 Steering Wheel Turns Low power steering Check for leaks. Refill —
Hard or Jerky pump fluid level. the system with fluid.
Stern-drive belt is Replace and / or —
loose or in poor adjust.
condition.
Insufficient lubrication Lubricate.
on the steering
components.
Insufficient lubrication Lubricate. 42
on the transom gimbal
housing assembly and
swivel shaft.
Loose or missing Check all parts and 42
steering fasteners or fasteners. If any are
parts. loose or missing, see
your authorized Yan-
mar Marine dealer or
distributor
immediately.
Contaminated power See your authorized —
steering fluid. Yanmar Marine dealer
or distributor.

TROUBLESHOOTING
No. Problem Possible Cause Action Reference Page
3 Power Trim Does Not Blown fuse. Replace the fuse. 19
Operate (Electric
Circuit breaker is Wait until the breaker 19
Motor Does Not Oper-
tripped. cools down and the
ate)
breaker is restored.
Loose or dirty Check all associated 19
electrical connections electrical connections
or damaged wiring. and wires (especially
battery cables). Clean
and tighten faulty
connection. Repair or
replace wiring.
4 Power Trim Does Not Trim pump oil level is Fill pump with oil. 28
Operate (Electric low.
Motor Operates but
Stern-drive binding in Check for obstruction. —
Stern-drive Does Not
gimbal ring. See your authorized
Move)
Yanmar Marine dealer
or distributor.

LONG-TERM STORAGE
COLD WEATHER Stern-Drive Lay Up
(FREEZING 1. Use a piece of wire to check the water
TEMPERATURE), drain passages in the drive unit to
ensure that they are open.
SEASONAL AND EXTENDED
STORAGE
(3)
NOTICE: Yanmar strongly recommends
that this service be performed by an
(2)
(1)
distributor. Damage caused by freezing IS
NOT covered by the Yanmar Warranty.
(4)
0006361
Figure 1
1 – Under Side of Gear Housing
2 – First Anode Cavity Drain
Passage
3 – Second Anode Cavity Drain
Passage
4 – Speedometer Pitot Hole
2. Change the stern-drive oil. See
Changing the Stern-Drive Oil on page
46.
3. Perform all other checks, inspections,
lubrication and fluid changes.

LONG-TERM STORAGE
4. CAUTION! The stern-drive should be
stored in the FULL DOWN / TRIM-IN
position. The universal joint bellows
may develop a set if the unit is
stored in the raised position and
may fail when the stern-drive is
returned to
service. Place the stern-drive in the full
DOWN / TRIM-IN position.
Stern-Drive Recommissioning
1. Carefully inspect the stern-drive for
leaks.
2. Check the steering system, shift and
throttle control for proper operation.


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ii ZT350 Operation Manual

ZT350 Operation Manual iii

iv ZT350 Operation Manual

ZT350 Operation Manual 1

Stern-Drive Transom Assembly Serial No.:

Stern-Drive Unit Serial No.:

Stern-Drive Gear Ratio:

Hull Identification Number (HIN):

2 ZT350 Operation Manual

This safety alert symbol appears CAUTION

! your safety is involved! Please

ZT350 Operation Manual 3

• Read and understand this Operation

4 ZT350 Operation Manual

NEVER stand under a hoisted stern-drive. If

NEVER support the stern-drive with

ZT350 Operation Manual 5

WARNING Alcohol and Drug Hazard

6 ZT350 Operation Manual

ZT350 Operation Manual 7

NEVER dispose of hazardous materials by

Before operating the engine, check stern-

If the stern-drive oil temperature is too high,

Only use replacement parts specified. Other

NEVER attempt to modify the stern-drive’s

8 ZT350 Operation Manual

The anode of the stern-drive is only

Anytime the boat is left in the water and the

ZT350 Operation Manual 9

This Page Intentionally Left Blank

10 ZT350 Operation Manual

NOTICE: The anode of the stern-drive is

ZT350 Operation Manual 11

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ZT350 Operation Manual 15

16 ZT350 Operation Manual

ZT350 Operation Manual 17

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• Read and understand this Operation

ZT350 Operation Manual 21

Before starting the engine, ALWAYS make

22 ZT350 Operation Manual

ZT350 Operation Manual 23

(2) (5) (6)

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ZT350 Operation Manual 25

Note: The oil level will rise and fall during

26 ZT350 Operation Manual

1. Remove the oil reservoir cap

ZT350 Operation Manual 27

1. Place the stern-drive in full DOWN /

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ZT350 Operation Manual 29