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204 CHAPTER TEN Intermediate shaft 1. Remove and discard the O-ring (Figure 14) at the end of the shaft. 2. Remove the thrust washer, gear and roller bearings. 3. Inspect the bearings, shaft and reverse idler gear inside diameter for excessive wear, grooves, metal transfer and discoloration from overheating. If necessary, replace the shaft, gear and bearings. 4. Check the idler gear teeth for excessive wear, corrosion or rust and mechanical damage. Check the teeth for galling, chips, cracks, missing pieces, distortion or discoloration from overheating. If necessary, replace the gear. 5. Reassemble the intermediate shaft. Install a new O-ring on the shaft. Output shaft Refer to Figure 15. 1. Using a suitable puller (Figure 16), remove the bearing, spacer and reverse gear from the output shaft. 2. The retaining nut at the end of the shaft is staked. Use a chisel to cut away the staked portion so the nut will rotate. To hold the output shaft, position the coupling flange in a vise, then set the output shaft into the splines in the flange as shown in Figure 17. NOTE The retaining nut has left-hand threads. 3. Unscrew the retaining nut by rotating the nut clockwise (left-hand threads). 4. Using a suitable puller, pull the bearing, spacer and forward gear off the output shaft. 5. Remove the pin from the shaft. NOTE Mark the clutch cone in Step 6 according to forward or reverse end so it can be reinstalled in its original position. 6. While holding the clutch cone, tap the end of the shaft with a soft-faced hammer to remove the inner roller bearing race, spacer and cone clutch. A suitable puller or press may also be used. Remove the remaining inner bearing race and spacer. 7. Check the forward and reverse gear teeth for excessive wear, corrosion and mechanical damage. Check the teeth for galling, chips, cracks, missing pieces, distortion or discoloration from overheating. If necessary, replace the gears. Intermediate shaft / Reverse idler aear Roller / bearings O-ring 8. Inspect the forward and reverse gear inside diameters for excessive wear, grooves, metal transfer and discoloration from overheating. If necessary, replace the gears. 9. Install the cone clutch on the output shaft and check movement of the clutch on the output shaft. If the clutch does not move smoothly, inspect the splines on the clutch and shaft for burrs, scoring, galling or other signs of damage. If dressing will not correct the damaged splines, replace the clutch and/or shaft. 10. Inspect the tapered surface of the forward and reverse gears for galling, scoring or other damage that will prevent smooth cone clutch engagement. If necessary, replace the gears. 11. Install the cone clutch into the forward and reverse gears. Measure clutch depth as shown in Figure 18. Compare the measurement with the specification in Table 3. Replace the part, in necessary. 12. Measure the width of the shifter groove in the cone clutch (Figure 19) and compare with the specification in Table 4. 13. Inspect the roller bearings and inner bearing races for excessive wear, grooves, metal transfer and discoloration from overheating. If necessary, replace the bearings and inner races. 14. Measure the wear surface of the thrust washers. If wear exceeds 0.20 mm (0.008 in.) on the thin thrust washer, replace the washer. If wear exceeds 0.05 mm (0.002 in.) on the thick thrust washer, replace the washer. 15. On KM2P and KM3P transmissions-Measure the width of the spring cups and compare them with the specifications in Table 5. 16. On KM2P and KM3P transmissions-Measure the width of the spring cup retainers and compare them with the specifications in Table 5. If any surface wear on the retainer exceeds 0.10 mm (0.004 in.), replace the retainer. 17. Assemble the output shaft by reversing the disassembly procedure while noting the following:
TRANSMISSION-KM SERIES 205 OUTPUT SHAFT 4 1. Shims 2. Nut (LH) 3. Washer 4. Roller bearing 5. Thrust washer 6. Retainer (KM2P and KM3P) 7. Spring cup (KM2P and KM3P) 8. Forward gear 9. Needle bearing 10. Inner bearing race 11. Thrust washer 12. Pin 13. Output shaft 14. Clutch cone 15. Reverse gear
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YANMAR DIESEL INBOARD SHOP MANUAL O
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Contents QUICKREFERENCEDATA .......
Page 5:
CHAPTER EIGHT COOLINGSYIZM ........
Page 14 and 15:
GENERAL INFORMATION 7 Common nut Se
Page 28 and 29:
GENERAL INFORMATION 21 Bearing Bloc
Page 30 and 31:
GENERAL INFORMATION 23 b. Remove th
Page 32 and 33:
Chapter Two Troubleshooting Every i
Page 34 and 35:
2 8 CHAPTER TWO Ohmmeter Ohmmeter (
Page 36 and 37:
30 CHAPTER TWO CHARGING SYSTEM (TYP
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32 CHAPTER TWO VOLTAGE OUTPUT TEST
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TROUBLESHOOTING 35 1. Loose pump dr
Page 43 and 44:
TROUBLESHOOTING 37 LUBRICATION SYST
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TROUBLESHOOTING 39 LUBRICATION SYST
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Chapter Three Operation, Lubricatio
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OPERATION, LUBRICATION, MAINTENANCE
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50 CHAPTER THREE I Intake port Alte
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54 CHAPTER THREE Freshwater (Closed
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56 CHAPTER THREE flush it down a dr
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OPERATION, LUBRICATION, MAINTENANCE
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CHAPTER THREE Table 4 FRESHWATER (C
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66 CHAPTER FOUR able containers and
Page 74 and 75:
Chapter Five Single-Cylinder Engine
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70 CHAPTER FIVE Fuel injector Open
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78 CHAPTER FIVE 5. Remove the valve
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80 CHAPTER FIVE 3. Remove the cylin
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82 CHAPTER FIVE Cylinder block 7 su
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98 CHAPTER FIVE Camshaft Valve lobe
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100 CHAPTER SIX Have the engine mod
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102 CHAPTER SIX VALVE COVER 3HM AND
Page 110 and 111:
104 CHAPTER SIX EXHAUST MANIFOLD WI
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106 CHAPTER SIX
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MULTICYLINDER ENGINES 109 CYLINDER
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MULTICYLINDER ENGINES 111 Valve Rem
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MULTICYLINDER ENGINES 113 OIL PICKU
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MULTICYLINDER ENGINES 115 Cyllnder
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MULTICYLINDER ENGINES 121 3. Thorou
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126 CHAPTER SIX d. Install a dial i
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132 CHAPTER SIX Bore 2GM 2GM20 Stro
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134 CHAPTER SIX Cylinder block warp
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136 CHAPTER SIX Piston ring side cl
Page 144 and 145:
Chapter Seven Fuel Injection and Go
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140 CHAPTER SEVEN Individual pumpin
Page 159 and 160: FUEL INJECTION AND GOVERNOR SYSTEMS
Page 166 and 167: 160 CHAPTER EIGHT SEAWATER COOLING
Page 168 and 169: 162 CHAPTER EIGHT SEAWATER COOLING
Page 170 and 171: 164 CHAPTER EIGHT CLOSED COOLING SY
Page 173: COOLING SYSTEM 167 1 Testing (Out o
Page 179 and 180: COOLING SYSTEM 173 SEAWATER PUMP (1
Page 181 and 182: COOLING SYSTEM 175 SEAWATER PUMP (2
Page 183: COOLING SYSTEM 177 ant or water may
Page 186 and 187: 180 CHAPTER EIGHT FRESHWATER EXHAUS
Page 188 and 189: 182 CHAPTER EIGHT Table 1 TIGHTENIN
Page 191 and 192: ELECTRICAL SYSTEM 185 making or bre
Page 193 and 194: ELECTRICAL SYSTEM 187 NEEDS FULLY D
Page 195: ELECTRICAL SYSTEM 189 CHARGING SYST
Page 199 and 200: ELECTRICAL SYSTEM 193 STARTER MOTOR
Page 203: ELECTRICAL SYSTEM 197 3. To determi
Page 207: TRANSMISSION-KM SERIES 201 0 SHIFTE
Page 213 and 214: TRANSMISSION-KM SERIES 207 Neutral
Page 215 and 216: TRANSMISSION-KM SERIES 209 SHIFTER
Page 217 and 218: TRANSMISSION-KM SERIES 211 Output s
Page 220 and 221: 214 CHAPTER TEN 1 Model Transmissio
Page 222 and 223: Chapter Eleven Transmission-KBW Ser
Page 224 and 225: 218 CHAPTER ELEVEN
Page 226 and 227: 220 CHAPTER ELEVEN Input shaft 1. C
Page 228 and 229: 222 CHAPTER ELEVEN 16. Measure the
Page 230: 224 CHAPTER ELEVEN 3. Push in the d
Page 233 and 234: Index A ................. Alarm buz
Page 236 and 237: 230 INDEX Tune-up cover battery ...
Page 238 and 239: 232 WIRING DIAGRAMS EARLY MODELS WI
Page 240: 234 WIRING DIAGRAMS LATE MODELS WIT
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YANMAR

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