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Summary of Contents for Yamaha ME422STI
- Page 1 ME422STI ENGINE SERVICE MANUAL 070026 YAMAHA MOTOR CO., LTD. Printed in Japan N60-28197-ZH-11 Nov. 2005-0.5 × 1 （ME422STI） Printed on recycled paper （E） 300902-...
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Page 2: Specifications
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. -
Page 3: How To Use This Manual
HOW TO USE THIS MANUAL MANUAL FORMAT This manual provides the mechanic with descriptions of the operations of disassembly, repair, assembly and check, 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. -
Page 4: Inportant Information
INPORTANT INFORMATION In this Service Manual particularly important information is distinguished 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 checking or repairing the Stern Drive. -
Page 5: Important Features
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 appears only in the chapter “Periodic check and adjustment”. -
Page 6: Fuel System
K Apply Yamaha gear-case lubricant L Apply water resistant grease (Yamaha marine grease A, Yamaha marine grease) Symbols M and N in an exploded diagram indicate grade of sealing or locking agent, and location of application point: ®... - Page 7 CONTENTS GENERAL INFORMATION INFO SPECIFICATIONS SPEC PERIODIC CHECK AND ADJUSTMENT ENGINE REMOVAL AND INSTALLATION INST ENGINE OVERHAUL OVER FUEL SYSTEM FUEL EXHAUST SYSTEM EXHT COOLING SYSTEM COOL LUBRICATION SYSTEM TURBOCHARGER TURB...
- Page 9 INDEX POWER STEERING SYSTEM STEER – ELECTRICAL SYSTEM ELEC TROUBLESHOOTING TRBL SHTG...
- Page 11 INFO CHAPTER 1 GENERAL INFORMATION ENGINE IDENTIFICATION ...................... 1-1 PROPELLER AND ENGINE ROTATION .................. 1-1 SAFETY WHILE WORKING ....................1-2 Prepare for Emergencies ....................1-2 Handle Fuel Safety ......................1-2 Prevent Battery Explosion ....................1-2 Wear Protective Clothing ....................1-2 Keep Work Area Clean .......................
- Page 12 DO NOT rely on propeller rotation to be in the same direction as engine rotation. Engine rotation is determined by looking at the flywheel end of the engine. The Yamaha engines covered in this manual rotate counterclockwise (to the left) as viewed from the flywheel.
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Page 13: Safety While Working
SAFETY WHILE WORKING INFO SAFETY WHILE WORKING Prepare for Emergencies Be prepared for possible fires. Keep the following items handy: ¡ First Aid Kit ¡ Fire Extinguisher ¡ Emergency Phone Numbers Handle Fuel Safety Use care when handling fuel; it is highly flam- mable. - Page 14 SAFETY WHILE WORKING INFO Keep Work Area Clean Properly ventilate your work area. Keep the shop bench and floor clean and dry. Cover all parts and part opening when they are not being worked on, to prevent foreign materials from entering and damaging the engine.
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Page 15: Pre-Delivery Check
PRE-DELIVERY CHECK INFO PRE-DELIVERY CHECK Perform the following checks to prepare the engine for delivery to the customer. Check Engine Alignment ¡ Use an engine alignment tool to check engine alignment. Make any adjust- ments as necessary. Refer to “Engine Installation”... -
Page 16: Off-Season Storage
PRE-DELIVERY CHECK / OFF-SEASON STORAGE INFO Perform Test Run ¡ Be sure gear shifting and steering is smooth. ¡ Check for leaks in the transom. OFF-SEASON STORAGE If the boat is kept unused for a long period, internal parts of the engine or drive unit might rust through of lack of lubrication and protection. - Page 17 OFF-SEASON STORAGE INFO 3) Tighten the drain bolt to the specified torque, and add the indicated amount of new engine oil. (Refer to “Engine Oil Level Check” on page 3-7.) 4) Start the engine and run it at a speed be- tween 1000 –...
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Page 18: Turbocharger
OFF-SEASON STORAGE INFO Drain Cooling System To protect the cooling system from rust and damage from freezing, drain coolant from the cooling system completely. CAUTION: DO NOT store the engine with water left in the cooling system. NOTE: ¡ When draining coolant, cover all electri- cal parts and accessories with a plastic cover to prevent them from getting wet. -
Page 19: Electrical System
OFF-SEASON STORAGE INFO 3) When all coolant and seawater has been drained, apply a sealant to the drain plugs and tighten them to the specified torque. 4) Check that the hoses are neither cracked nor damaged and re-connect them. Be sure to tighten the hose clamps securely. - Page 20 OFF-SEASON STORAGE / CHECKS BEFORE INFO LAUNCHING AND STARTING THE ENGINE 5) Check all the items listed under “CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE”, and perform any neces- sary maintenance. 6) Test run the engine on land or in the water and make sure there are no prob- lems of any kind.
- Page 21 CHECKS BEFORE LAUNCHING AND STARTING THE ENGINE INFO 4) Check that the engine oil is at the speci- fied level Refer to “Engine Oil Level Check” on page 3-7.) and that there is no water, metal gratings, or anything else irregular in the oil.
- Page 22 INTERNATIONAL SYSTEM OF UNITS [SI] INFO INTERNATIONAL SYSTEM OF UNITS [SI] The unit system currently applied in our daily life is called gravitational system of units. Both gravitational system of units and International System of Units belong to the metric system of measurement, and basically the same units are used in both systems, i.e.
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Page 23: Special Tools
Using special tools will help avoid damage caused by the use of improper tools or incorrect procedures. (These special tools are recommended by Yamaha. The tool numbers indicated below are those of TOYOTA Motor Corporation, except for the tools marked with *.) ILLUSTRATION TOOL No. - Page 24 SPECIAL TOOLS INFO ILLUSTRATION TOOL No. TOOL NAME REMARKS 09213-58013 Flange base To secure crankshaft pulley (Page 5-18, 5-28) 09330-00021 Flange holder To secure crankshaft pulley (Page 5-18, 5-21, 5-26, 5-28) 09950-50013 Puller C set (Page 5-19, 5-21, 6-20) 09951-05010 Hanger 150 To remove crankshaft pulley and injec- tion pump drive gear...
- Page 25 SPECIAL TOOLS INFO ILLUSTRATION TOOL No. TOOL NAME REMARKS 09202-70020 Valve spring compressor To remove and install valve (Page 5-40, 5-57) 09201-10000 Valve guide bush re- (Page 5-43, 5-44) mover and replacer set 09201-01080 Valve guide bush re- To remove and install valve guide bush mover and replacer 8 09950-70010 Handle set...
- Page 26 SPECIAL TOOLS INFO ILLUSTRATION TOOL No. TOOL NAME REMARKS • 95093-10330 Master spring seat To measure injection nozzle (from DENSO) (Page 6-11) • PSG-6TB Power steering fluid To check power steering fluid pressure (from BANZAI) pressure gauge set (Page 11-4) 09820-63010 Alternator wrench To remove and install alternator pul-...
- Page 27 OTHER EQUIPMENT TOOLS INFO OTHER EQUIPMENT TOOLS TOOL NAME REMARKS Vernier caliper Outside micrometer 0 ~ 25 mm, 25 ~ 50 mm, 50 ~ 75 mm, 75 ~ 100 mm V Block Power wrench (4 times) Cylinder gauge 50 ~ 150 mm Battery hydrometer Radiator cap tester Compound (Red lead)
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