Yamaha DE-DHT Manuale utente

070030

ESTERN DRIVE

SERVICE MANUAL

DE-DHT

6U5-28197-ZJ-11

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 equip-

ment. It has been written to suit the needs of persons who have a 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 edi-

tion of this manual. Authorized Yamaha dealers are notified periodically of modifications and

significant changes in specifications and procedures, and these are incorporated in succes-

sive editions of this manual.

STERN DRIVE

SERVICE MANUAL

1st Edition, August 2006

unauthorized use without the written

permission of Yamaha Motor Co., Ltd.

is expressly prohibited.

Printed in Japan.

HOW TO USE THIS MANUAL

MANUAL FORMAT

This manual provides the mechanic with descriptions of the operations of disassembly, repair,

assembly and inspection, each of which is presented in a sequential, step-by-step procedure.

To assist you in finding your way around this manual, the section title and major heading is

given at the head of each page.

A table of contents is provided on the first page of each section.

ILLUSTRATIONS

Some illustrations in this manual may differ from the model you have. This is because a proce-

dure described may relate to several models, though only one is illustrated. (The name of the

model described will be mentioned in the description).

To help you identify components and understand the correct procedures of disassembly and

assembly, exploded diagrams are provided. Steps in the procedure are numbered: 1), 2), 3).

Parts shown in the illustrations are identified as: 1, 2, 3.

REFERENCES

These have been kept to a minimum. References to other sections of the manual include the

relevant page number.

WARNINGS, CAUTIONS AND NOTES

Attention is drawn to the various warnings, cautions and notes that distinguish important

information in this manual in the following ways.

⁄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 marine

vehicle operator, a bystander, or a person inspecting or repairing the Stern Drive.

CAUTION:

A CAUTION indicates special precautions that must be taken to avoid damage to the Stern

Drive.

NOTE:

A NOTE provides key information to make procedures easier or clearer.

CONSTRUCTION OF THIS MANUAL

This manual consists of chapters for the main categories of subjects. (See “Symbols” on the

next page.)

1st title 1: This is a chapter with its symbol on the upper right of each page.

2nd title 2: This title appears on the top of the each page, to the left of the chapter symbol.

3rd title 3: This title precedes the paragraphs describing the working procedure.

All the procedures in this manual are organized in a sequential, step-by-step order. The infor-

mation has been compiled to provide the mechanic with an easy-to-read, handy reference that

contains comprehensive explanations of all disassembly, check, repair, and assembly proce-

dures.

Important procedures including removing, checking, and assembling steps 4are explained in

detail.

IMPORTANT FEATURES

¡Important engine data and information about special tools framed in a box together with

an illustrative symbol 5.

¡A circled numeral 6indicates a part name. A circled lower case letter indicates data or an

alignment mark 7.

¡An arrow 8indicates the course of action required to remedy the started condition of a

component.

EXPLODED DIAGRAM

Each chapter begins with exploded diagrams which facilitate correct disassembly and assem-

bly.

SHIM SELECTION (UPPER UNIT HOUSING)

R-gear Shim (T5) Adjustment

1. Use the guide, bearing puller 2 1and

the bearing puller 2to remove the bear-

ing outer race from the selector valve

housing.

NOTE:

¡When the bearing and the selector valve

housing are not replaced, DO NOT re-

move the bearing outer race.

¡When replacing the bearing, replace the

total inner and outer set.

¡Make sure that the bearing puller is set at

the position specified in the illustration.

Guide, bearing puller 2:

6U4-30-3

Bearing puller:

6U4-35

UPPER

UNIT

Drive shaft motive torque (A):

0.4 – 1.5 N·m

3. Loosen the front bearing housing bolts

to 1/2 rotation and measure pre-load B

(motive torque) of the drive shaft.

NOTE:

Measure resistance of the clutch disk section

as the pre-load B (motive torque).

4. Calculate the drive shaft pre-load (mo-

tive torque) based on the pre-load (mo-

tive torque) A and B.

Formula:

Drive shaft pre-load = pre-load (A) –pre-

load (B)

NOTE:

If the drive shaft pre-load (motive torque) is

greater than the specification, reduce the

shim T6b. If the drive shaft pre-load (motive

torque) is less than the specification, increase

the shim T6b.

4-27

T.R

Clamp screw:

3 N·m

BELLOWS AND HOSE INSPEC-

TION

1. Inspect:

¡Shift cable bellows 1

¡Exhaust bellows 2

¡Universal joint bellows 3

Cracks/Weathering/Damage →Re-

place.

Loose clamps 4→Tighten.

Refer to “SWIVEL BRACKET AND

BELLOWS”section (P7-7).

INSP

ADJ BELLOWS AND HOSE INSPECTION

UPPER UNIT HOUSING

3. After inserting the bearing outer race

with press, install the inner race. Use the

shimming tool, T5/T6a 1to measure the

clearance (Measurement B) between the

tool and the bearing with a thickness

gauge.

NOTE:

To have the clearance, measure the line be-

tween the point Aand Bon the bearing.

4. Find the stamped R-valve of the upper

gear case.

Shimming tool, T5/T6a:

6U4-28

UPPER

UNIT

⎧

⎪

⎨

⎪

⎩

SYMBOLS

Symbols 1to 0are designed as thumb-tabs

and indicate the content of a chapter.

1General information

2Specification

3Periodic inspection and adjustment

4Upper unit housing

56U41 Lower unit housing

66U51 Lower unit housing

7Intermediate assembly

8Steering system

9Power trim system

0Tr o ub le sh oo ti ng

Symbols Ato Hindicate specific informa-

tion:

ASpecial tool

BRecommended fuel

CLubricant

DEngine speed

ETightening torque

FSpecified value, measure, limit

GPress load

HResistance (Ω), voltage (V), electric cur-

rent (A)

Symbols Ito Kin an exploded diagram in-

dicate grade of lubricant and location of lu-

brication point:

IApply Yamaha gear-case lubricant

JApply water resistant grease

(Yamaha marine grease A)

KApply corrosion resistant grease

(Yamaha marine grease D)

Symbols Land Min an exploded diagram

indicate grade of sealing or locking agent,

and location of application point:

LApply LOCTITE®No. 271, 242, 572,1829

or 1501

MApply ThreeBond®TB-1322, 1324, 1524

or 1501

GEN

INFO

SPEC

3 4

UPPER

UNIT

INT

STEER

POWR

TRIM

T.R

INSP

ADJ

TRBL

SHTG

6U51

LOWER

6U41

LOWER

INDEX

GENERAL INFORMATION 1

GEN

INFO

SPECIFICATIONS 2

UPPER UNIT HOUSING 4

UPPER

UNIT

6U41 LOWER UNIT HOUSING 5

6U41

LOWER

6U51 LOWER UNIT HOUSING 6

6U51

LOWER

INTERMEDIATE ASSEMBLY 7

STEERING SYSTEM 8

POWER TRIM SYSTEM 9

POWR

TRIM

TROUBLESHOOTING

TRBL

SHTG

INT

STEER

INSP

ADJ

PERIODIC INSPECTION

AND ADJUSTMENT

SPEC

GEN

INFO

CHAPTER 1

GENERAL INFORMATION

OUTDRIVE IDENTIFICATION ................................................................................................. 1-1

Intermediate Assembly ..................................................................................................... 1-1

Drive Unit ........................................................................................................................... 1-1

Engine and Propeller Rotation .......................................................................................... 1-1

SAFETY PRECAUTIONS ......................................................................................................... 1-2

Prepare for Emergencies ................................................................................................... 1-2

Handle Fuel Safely ............................................................................................................. 1-2

Prevent Battery Explosion ................................................................................................. 1-2

Wear Protective Clothing .................................................................................................. 1-2

Keep Work Area Clean ....................................................................................................... 1-3

Operate Stern Drive Safely ............................................................................................... 1-3

PRE-DELIVERY INSPECTION ................................................................................................. 1-3

Check Engine Alignment ................................................................................................... 1-3

Inspect Drive Belts .............................................................................................................1-3

Check Gear Oil ................................................................................................................... 1-3

Inspect Outdrive Exterior .................................................................................................. 1-3

Check Power Trim System ................................................................................................ 1-3

Inspect Battery and Electrical Connections ..................................................................... 1-4

Check Remote Control Operation ..................................................................................... 1-4

Perform Test Run ............................................................................................................... 1-4

Drive Unit Break-in ............................................................................................................ 1-4

PROPELLERS ........................................................................................................................... 1-5

Propellers ........................................................................................................................... 1-5

Propeller Selection ............................................................................................................ 1-5

GEN

INFO E

OUTDRIVE IDENTIFICATION

Intermediate Assembly

The model and serial number plate 1is lo-

cated on the bottom surface of the interme-

diate housing.

OUTDRIVE IDENTIFICATION

1Intermediate Assembly

2Drive Unit

*Code Explanation:

DP–With Power Steering

DL–Without Power Steering, for Twin Installation

D–1.68:1 Gear Ratio

C–1.78:1 Gear Ratio

Engine and Propeller Rotation

Engine rotation is determined by looking at

the flywheel end of the engine. The Yamaha

engines covered in this manual rotate coun-

terclockwise to the left as viewed from the

flywheel.

As for the propeller rotation, the front pro-

peller rotates counterclockwise, and the rear

propeller rotates clockwise.

NOTE:

INT-HDP 6U0 DP *******

INT-HDL 6U0 DL *******

MODEL PREFIX

VARIATION* SERIAL NO.

ABC D

INT-HDP 6U00 DP 1

INT-HDL 6U00 DL *******

DE-DHT 6U41 C 2

6U51 D *******

Drive Unit

The model and serial number plate 1is lo-

cated on the upper case of the drive unit.

The different models can be identified by

checking the model and serial number plate

and using the following plate.

YAMAHA MOTOR CO.,LTD.

MADE IN JAPAN

PAYS D'ORIGINE JAPON

B C D

1-1

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