2008-2010 Yamaha Marine F300 / LF300 / F350 / LF350 Service & Repair Manual

SERVICE MANUAL LIT-18616-03-08 6BJ-28197-1K-11 F300 LF300 F350 LF350

NOTICE 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 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. 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! WARNING Failure to follow WARNING instructions could result in severe injury or death to the machine operator, a bystander, or a person inspecting or repairing the outboard motor. CAUTION: A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor. NOTE: A NOTE provides key information to make procedures easier or clearer. F300, LF300, F350, LF350 SERVICE MANUAL ©2007 by Yamaha Motor Corporation, U.S.A. 1st Edition, February 2008 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, U.S.A. is expressly prohibited. Printed in U.S.A. LIT-18616-03-08

0 1 2 3 4 5 General information Specification Technical features and description Rigging information Troubleshooting Electrical system 6 7 8 9 Fuel system Power unit Lower unit Bracket unit GEN INFO SPEC TECH FEA RIG GING ELEC FUEL POWR LOWR BRKT TRBL SHTG Contents

10 Maintenance Index Appendix MNT Contents

GEN INFO 6BJ1K11 0 2 3 4 5 6 7 8 9 General information 0 Safety while working ..................................................................................... 0-1 Fire prevention .......................................................................................... 0-1 Ventilation ................................................................................................. 0-1 Self-protection .......................................................................................... 0-1 Part, lubricant, and sealant ....................................................................... 0-1 Special service tool ................................................................................... 0-2 Tightening torque ...................................................................................... 0-2 Non-reusable part ..................................................................................... 0-2 Disassembly and assembly ...................................................................... 0-2 How to use this manual ................................................................................ 0-3 Manual format ........................................................................................... 0-3 Symbol ...................................................................................................... 0-4 Abbreviation .............................................................................................. 0-5 Model features ............................................................................................... 0-7 General feature ......................................................................................... 0-7 Model designation .................................................................................... 0-8 Serial number ........................................................................................... 0-8 Special service tool ...................................................................................... 0-9

0-1 6BJ1K11 GEN INFO General information Safety while working To prevent an accident or injury and to ensure quality service, follow the safety procedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. Ventilation Gasoline vapor and exhaust gas are heavier than air and extremely poisonous. If inhaled in large quantities they may cause loss of consciousness and death within a short time. When test running an engine indoors (e.g., in a water tank) be sure to do so where ade- quate ventilation can be maintained. Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv- ing drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing protective gloves and safety shoes when necessary. Part, lubricant, and sealant Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the outboard motor. Under normal conditions, the lubricants men- tioned in this manual should not harm or be hazardous to your skin. However, you should follow these precautions to minimize any risk when working with lubricants. 1. Maintain good standards of personal and industrial hygiene. 2. Change and wash clothing as soon as possible if soiled with lubricants. 3. Avoid contact with skin. Do not, for example, place a soiled rag in your pocket. 4. Wash hands and any other part of the body thoroughly with soap and hot water after contact with a lubricant or lubricant soiled clothing has been made. 5. To protect your skin, apply a protective cream to your hands before working on the outboard motor.

6BJ1K11 0-2 Safety while working 0 2 3 4 5 6 7 8 9 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Special service tool Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torque Follow the tightening torque specifications provided throughout the manual. When tightening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable part Always use new gaskets, seals, O-rings, cot- ter pins, circlips, etc., when installing or assembling parts. Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts before assembly. 3. Install bearings with the manufacture identification mark in the direction indi- cated in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate nor- mally after assembly.

0-3 6BJ1K11 GEN INFO General information How to use this manual Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below 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 a in the figure below for an example page). • The component list consists of part names and quantities, as well as bolt and screw dimensions (see b in the figure below). • Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point (see c in the figure below). • Tightening torque specifications are provided in the exploded diagrams (see d in the figure below for an example), 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 e in the figure below for an example page). NOTE: For troubleshooting procedures, see Chapter 4, “Troubleshooting.” 5-11 6AW3K11 FUEL Fuel system Throttle body No. Part name Q’ty Remarks 1 Plastic tie 1 2 Joint 1 3 Nut 4 4 Washer 2 5 Electronic throttle valve assembly 1 6 Gasket 1 Not reusable 7 Bolt 1 M6 20 mm 8 Washer 1 9 Intake air pressure sensor 1 10 Bolt 4 M8 18 mm 11 Crip 1 12 Plate 1 13 Gasket 1 Not reusable 14 Bolt 3 M6 20 mm 15 Bolt 6 M8 35 mm 16 Surge tank 1 17 Clamp 1 1 2 3 4 6 7 8 9 10 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 5 13 N m (1.3 kgf m, 9.6 ft Ib) 13 N m (1.3 kgf m, 9.6 ft Ib) 13 N m (1.3 kgf m, 9.6 ft Ib) 5 N m (0.5 kgf m, 3.7 ft Ib) LT 242 LT 242 S6AW05038 6AW3K11 5-30 Vapor separator 1 2 3 4 5 5 7 8 9 5. Drain the fuel from the vapor separator drain hose by pressing the pressure check valve using a thin screwdriver. WARNING Reduce the fuel pressure before loosen- ing the vapor separator drain screw, or pressurized fuel will spray out and may result in serious injury. 6. Tighten the drain screw. Checking the vapor separator 1. Reduce the fuel pressure. See Chapter 5, “Reducing the fuel pressure.” 2. Check the needle valve. Replace needle valve assembly if bent or worn. 3. Check the float. Replace the float if there is deterioration. 4. Check the high-pressure fuel pump filter. Clean the filter if there is dirt or residue. 5. Install the needle valve and float to the vapor separator cover. 6. Place the vapor separator cover assembly in the position shown in the illustra- tion, and then measure the float height a. NOTE: To measure the height of the float, it should be resting on the needle valve. Do not press the float. T R . . Vapor separator drain screw: 2 N·m (0.2 kgf·m, 1.5 ft·lb) a b S6AW05023 S6AL4350 Float height a: 60.5±3.0 mm (2.38±0.12 in) a S6AW05024 a b c d e

2008-2010 Yamaha Marine F300 / LF300 / F350 / LF350 Service & Repair Manual

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