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2008 Yamaha LF300TR Outboard Service Repair Manual SN1000001 and up .pdf



Original filename: 2008 Yamaha LF300TR Outboard Service Repair Manual SN1000001 and up.pdf

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F300
LF300
F350
LF350

SERVICE MANUAL
LIT-18616-03-08

6BJ-28197-1K-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 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

Contents
General information
Specification
Technical features and description
Rigging information
Troubleshooting
Electrical system
Fuel system
Power unit
Lower unit
Bracket unit

GEN
INFO

SPEC

TECH
FEA

RIG
GING

TRBL
SHTG

ELEC

FUEL

POWR

LOWR

BRKT

0
1
2
3
4
5
6
7
8
9

Contents
Maintenance
Index
Appendix

MNT

10

GEN
INFO

General information
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

6BJ1K11

0

0
2
3
4
5
6
7
8
9

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.

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

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 adequate ventilation can be maintained.

Under normal conditions, the lubricants mentioned 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.

Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involving drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing protective gloves and safety shoes when necessary.

0-1

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

Safety while working
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.

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

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.

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

3. Install bearings with the manufacture
identification mark in the direction indicated in the installation procedure. In
addition, be sure to lubricate the bearings liberally.

Non-reusable part

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

Always use new gaskets, seals, O-rings, cotter pins, circlips, etc., when installing or
assembling parts.

5. Check that moving parts operate normally after assembly.

6BJ1K11

0-2

0
2
3
4
5
6
7
8
9

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 understand. 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.”

a

d

FUEL

Fuel system

Throttle body
T.

T.

R.

R.

13 N m (1.3 kgf m, 9.6 ft Ib)

c

13 N m (1.3 kgf m, 9.6 ft Ib)

T.

R.

5 N m (0.5 kgf m, 3.7 ft Ib)
T.

R.

13 N m (1.3 kgf m, 9.6 ft Ib)

7

1

8
2

11

9

10

3
LT

5

LT

242

4

5. Drain the fuel from the vapor separator
drain hose by pressing the pressure
check valve using a thin screwdriver.

12
6

14

19

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.

13

23
17

Vapor separator

242

10

b

24

5. Install the needle valve and float to the
vapor separator cover.

18

a
25
20

6. Place the vapor separator cover assembly in the position shown in the illustration, and then measure the float height
a.

16
26

22
21

a
15
Q’ty
1
1
4
2
1
1
1
1
1
4
1
1
1
3
6
1
1

Remarks
S6AW05023
S6AW05024

WARNING
Not reusable
M6 20 mm

Reduce the fuel pressure before loosening the vapor separator drain screw, or
pressurized fuel will spray out and may
result in serious injury.

M8

6. Tighten the drain screw.

18 mm

Not reusable
M6 20 mm
M8 35 mm

R.

Part name
Plastic tie
Joint
Nut
Washer
Electronic throttle valve assembly
Gasket
Bolt
Washer
Intake air pressure sensor
Bolt
Crip
Plate
Gasket
Bolt
Bolt
Surge tank
Clamp

T.

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

S6AW05038

NOTE:
To measure the height of the float, it should
be resting on the needle valve. Do not press
the float.
Float height a:
60.5±3.0 mm (2.38±0.12 in)

Vapor separator drain screw:
2 N·m (0.2 kgf·m, 1.5 ft·lb)

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.

5-11

6AW3K11

b

1
2
3
4
5
5
7
8
9

S6AL4350

e
6AW3K11

0-3

5-30

6BJ1K11

How to use this manual

Symbol
The symbols below are designed to indicate the content of a chapter.
General information

Troubleshooting

Lower unit

TRBL
SHTG

GEN
INFO
Specification

LOWR

Electrical system

Bracket unit

ELEC

SPEC
Technical features and
description

BRKT

Fuel system

Maintenance

FUEL

TECH
FEA
Rigging information

MNT

Power unit

RIG
GING

POWR

Symbols a to f indicate specific data.
a

b

c

d

e

f

T.

R.

a Special service tool
b Specified oil or fluid
c Specified engine speed
d Specified tightening torque

e Specified measurement
f Specified electrical value
(resistance, voltage, electric current)

Symbols g to m in an exploded diagram and text indicate the grade of lubricant and the lubrication
point.
g

h

i

j
A

E

k
M

l
C

D

G

m
1208B
WR-No.2

g Apply Yamaha 4-stroke motor oil
h Apply gear oil
i Apply water resistant grease
(Yamaha grease A)

j Apply molybdenum disulfide grease

6BJ1K11

k Apply low temperature resistant grease
(Yamaha grease C)

l Apply corrosion resistant grease
(Yamaha grease D)

m Apply WR-No.2 grease

0-4

0
2
3
4
5
6
7
8
9

GEN
INFO

General information

Symbols n to w in an exploded diagram and text indicate the type of sealant or locking agent and
the application point.
n

o
1208B

p
1207D

q
1322

r
1386B

s
1104J

LT

518

t

u

v

w

LT

LT

LT

271

242

572

n Apply ThreeBond 1208B
o Apply ThreeBond 1207D
p Apply ThreeBond 1322
q Apply ThreeBond 1386B
r Apply ThreeBond 1104J

SS

s Apply LOCTITE 518 (red)
t Apply LOCTITE 271 (red)
u Apply LOCTITE 242 (blue)
v Apply LOCTITE 572 (white)
w Apply silicon sealant

Abbreviation
The following abbreviations are used in this service manual.
Abbreviation
ABYC
AFT
API
AWG
BOW
CA
CCA
C/E
DN
ECM
ENG
ETV
EX
EXH
ID
IDM
IN
INT
ION
ISC
LPS
M.E.S.
OCV
PCV
PON
PORT
PTT

0-5

Description
American Boat and Yacht Council
Aft end
American Petroleum Institute
American Wire Gauge
Bow end
Crank Angle
Cold Cranking Ampere
Check Engine
Down side
Electronic Control Module
Engine
Electronic Throttle Valve
Exhaust
Exhaust
Identification
Ionic current Detection Module
Intake
Intake
Ionic Current
Idle Speed Control
Lever Position Sensor
Multi Engine System
Oil Control Valve
Pressure Control Valve
Pump Octane Number = (RON + Motor Octane Number)/2
Port side
Power Trim and Tilt
6BJ1K11

How to use this manual
Abbreviation
RON
R.C.
SAE
SM
SPS
STBD
STERN
TDC
TPS
UP
VCT
W/F
YDIS

6BJ1K11

Description
Research Octane Number
Remote Control (Digital Electronic Control)
Society of Automotive Engineers
Service Manual
Shift Position Sensor
Starboard side
Stern side
Top Dead Center
Throttle Position Sensor
Upside
Variable Camshaft Timing
Water in Fuel
Yamaha Diagnostic System

0
2
3
4
5
6
7
8
9
0-6

GEN
INFO

General information

Model features
General feature
F300/LF300 and F350/LF350 OVERALL FEATURES;
• Electronic fuel injection, 60° V8, DOHC, 32-valves, VCT, 5,330 cm3 (325.2 cu. in) engine
• Use of common components between F150 and F350
• Electro deposition treatment for durability
• Easy startability and drivability
• Low noise and vibration
• Low emission in compliance with EPA 2008, CARB 3 STARS and EU1 regulations
• Digital Electronic Control system and Command Link Multifunction Meters for easy rigging and
precision control
A Power unit
• VCT (for intake valve)
• Flywheel installed with 6 bolts
• Crankshaft with drive sprocket
• Forged piston with molybdenum coating
• Crankcase cooler, fuel cooler
• Vapor gas treatment system
• Modularized fuel system components
• Dual exhaust passages and divided
exhaust manifold
• One piece top cowl with large water separator and roller locks
• Exclusive engine lifting eye
• Simple rigging grommet
B Electrical
• Electronic Fuel Injection (Multi-point and
Sequential injection)
• Digital Electronic Control and gauge system
• New YDIS 1.30 version
• Tilt-up limiter settings by YDIS 1.30
• Sequential direct ignition
• Ionic current detection module for knock
control
• Water-cooled Rectifier Regulator and isolator
• Water detection alert system
• Multi-engine system for alert mode and
auto engine speed synchronization
• Adjusting trolling speed function

E Lower unit
• Dual water inlets and large water pump
• Flat key for water pump impeller. Big drive
unit
• Large exclusive propeller (Saltwater series
XL)
• Reliable thrust receiver structure
• Drive shaft free play reduction structure
• Exhaust pressure reduction and prop
damper cooling system (same as F250)

A
B

D

C

E

C Bracket unit
• Large clamp bracket with 6 mounting holes.
• New PTT unit to deal with additional power
• Selectable 3 full tilt-up positions
D Upper case
• Dual idle silencers
• Oil pan capacity 8.0 L (8.45 US qt, 7.04 lmp
qt)
• Water-wall cooling system around muffler

0-7

6BJ1K11

Model features

Model designation

F 350 T U R
b

c d

c

a

Model Description

F : 4-stroke regular rotation
LF: 4-stroke counter rotation

b

Prop Shaft Horsepower

300: 300 HP
350: 350 HP

c

Functions

T: Power trim and tilt
R: Remote control

d

Transom Height

X: UL (25 in)
U: SUL (30 in)

Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.

c
b

Model name
F300TR
LF300TR
F350TR
LF350TR

Approved
model code
6BJ
6BK
6AW
6AX

Starting
serial No.
1000001–
1000001–
1000001–
1000001–

a
d

a Model name
b Approved model code
c Transom height
d Serial number

6BJ1K11

0-8

0
2
3
4
5
6
7
8
9

GEN
INFO

General information

Special service tool

Engine lifting eye
90890-06820

Peak volt adapter
YU-39991

Drilling plate
90890-06783

Test harness (6 pins)
YB-06872

YDIS (CD-ROM, Ver. 1.30)
60V-WS853-04

Pressure/vacuum tester
YB-35956-A

YDIS (KIT)
60V-85300-04

Test harness (3 pins)
YB-06869

Digital multimeter
YU-34899-A

Test harness (3 pins)
YB-06870

0-9

6BJ1K11

Special service tool

Spark checker
YM-34487

Compression gauge extension
YB-06563

Test harness (4 pins)
YB-06878

Flywheel holder
YB-06139

Fuel pressure gauge adapter
YB-06842

Balance hangar
90890-06822

Fuel pressure gauge
YB-06766

Primary sheave holder
YS-01880-A

Compression gauge
YU-33223

Valve guide remover
YB-06801

6BJ1K11

0
2
3
4
5
6
7
8
9
0-10

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