Yamaha DE-DHT Stern Drive Service Manual

070030

E

STERN 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 equip­ment. 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 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.

STERN DRIVE

SERVICE MANUAL

© 2006 by Yamaha Motor Co., Ltd.

1st Edition, August 2006

All rights reserved. Any reprinting or
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 a ss is t y ou i n fi nd in g yo ur w ay a ro un d t hi s ma nu al , th e se ct io n t it le a nd m aj or h ea di ng i s
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 proce­dure described may relate to several models, though only one is illustrated. (The name of the
model described will be mentioned in the description).

To h e lp y o u i de nt i fy co mp o ne n ts a n d u nd er s ta n d th e c or r ec t pr o ce du re s of d i sa ss e mb l y an d
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 infor­mation 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 proce­dures.

Important procedures including removing, checking, and assembling steps 4 are 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 6 indicates a part name. A circled lower case letter indicates data or an

alignment mark 7.

¡ An arrow 8 indicates 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 assem­bly.

SHIM SELECTION (UPPER UNIT HOUSING)

R-gear Shim (T5) Adjustment

1. Use the guide, bearing pul ler 2 1 and
the bearing puller 2 to remove the bear­ing outer race from the selector valve
housing.

NOTE:

¡ When the bearing and the selector valve

housing are not replaced, DO NOT re­move 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

1

2

E

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. Calc ulate the drive shaft pre-load (mo­tive torque) based on the pre-load (mo­tive torque) A and B.

Formula:
Drive shaft pre-load = pre-load (A) – pre­load (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 INSPEC­TION

1. Inspect:

¡ Shift cable bellows 1
¡ Exhaust bellows 2
¡ Universal joint bellows 3

Cracks/Weathering/Damage → Re­place.
Loose clamps 4 → Tighten.
Refer to “ SWIVEL BRACKET AND
BELLOWS” section (P7-7).

3

12

4

E

INSP

ADJ

BELLOWS AND HOSE INSPECTION

UPPER UNIT HOUSING

3. Af ter inser ting the bearing outer race
with press, install the inner race. Use the
shimming tool, T5/T6a 1 to measure t he
clearance (Measurement B) between the
tool and the bearing with a thickness
gauge.

NOTE:

To ha v e th e c le a ra n ce , m ea su r e t he l i ne be ­tween the point A and B on the bearing.

4. Find the stamped R-valve of the upper
gear case.

Shimming tool, T5/T6a:

6U4-28

A

B

1

B

E

UPPER

UNIT

1

6

8

7

2

3

4

5

⎧
⎪
⎪
⎪
⎨
⎪
⎪
⎪
⎩

SYMBOLS

Symbols 1 to 0 are designed as thumb-tabs
and indicate the content of a chapter.

1 General information
2 Specification
3 Periodic inspection and adjustment
4 Upper unit housing
5 6U41 Lower unit housing
6 6U51 Lower unit housing
7 Intermediate assembly
8 Steering system
9 Power trim system
0 Tr o ub le sh oo ti ng

Symbols A to H indicate specific informa-
tion:

A Special tool
B Recommended fuel
C Lubricant
D Engine speed
E Tightening torque
F Specified value, measure, limit
G Press load
H Resistance (Ω), voltage (V), electric cur-

rent (A)

Symbols I to K in an exploded diagram in­dicate grade of lubricant and location of lu­brication point:

I Apply Yamaha gear-case lubricant
J Apply water resistant grease

(Yamaha marine grease A)

K Apply corrosion resistant grease

(Yamaha marine grease D)

Symbols L and M in an exploded diagram
indicate grade of sealing or locking agent,
and location of application point:

L Apply LOCTITE

®

No. 271, 242, 572,1829

or 1501

M Apply ThreeBond

®

TB-1322, 1324, 1524

or 1501

1

GEN

INFO

2

SPEC

3 4

UPPER

UNIT

5

INT

6

STEER

7

POWR

TRIM

8

90

AB

CD

EF

GH

I

T.R

INSP

ADJ

TRBL

SHTG

J

G

LT

TB

A

K

D

L

M

6U51

LOWER

6U41

LOWER