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Yamaha
Outboard Motor
90A
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204 pages
Manual
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Y
AMAHA MOT
OR CO., L
TD
.
Printed in USA
Feb. 1999 –
?.?
×
1 CR
(50GETO, 60FEHTO, 60FED, 60FEDO, 60FET
, 60FETO, 70BEDO, 70BETO,
75CET
, 75CETO, 75CEHTO, 80AETO, 90AEHD, 90AED, 90AET
, 90AETO)
203
Table of Contents
Main Page
Info Chapter 1 General Information
9
Specifications
2
How to Use this Manual
3
Fuel System
5
Table of Contents
9
Chapter 1
10
Identification
10
Serial Number
10
Starting Serial Numbers
10
Safety While Working
11
Fire Prevention
11
Ventilation
11
Self-Protection
11
Oils, Greases and Sealing Fluids
11
Good Working Practices
12
Disassembly and Assembly
13
Special Tools
14
Measuring
15
Removal and Installation
17
Table of Contents
21
Chapter 2
22
General Specification
22
Maintenance Specifications
26
Engine
26
Electrical
28
Dimension
31
Tightening Torque
33
General Torque Specifications
34
Table of Contents
35
Anode
36
Chapter 3
36
Maintenance Schedule
36
Periodic Service
36
Battery
37
Carburetor
38
Carburetor Link Adjustment
38
Cylinder Head Bolts, Engine Mounting Bolts, and Flywheel Nut
39
Fuel Filter
39
Fuel Tank and Fuel Line
39
Gear Oil
40
Idle-Speed
40
Ignition Timing Adjustment
41
Timing Plate Position Adjustment
41
Throttle Sensor Control Link Adjustment
42
Ignition Timing Adjustment
43
Pick-Up Timing Adjustment
44
Oil Injection Pump
45
Operational Test
45
Checking the Oil Level Warning System
46
Oil Pump Link Adjustment
47
POWER TRIM and TILT FLUID (PTT Model)
47
Propeller
48
Spark Plug
48
Greasing Points
49
Fuel System
51
Chapter 4 Fuel System
52
Exploded Diagram
52
Fuel Line
53
Cleaning and Inspection
54
Fuel Tank
54
Fuel Meter Complete
55
Priming Pump
55
Fuel Filter
55
Fuel Joints
56
Fuel Pump
56
Removal
54
Installation
56
Carburetor
57
EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR)
57
EXPLODED DIAGRAM (for C60ER, C60TR, C75TR)
58
Removal and Disassembly
59
Inspection
60
Carburetor Body
60
Needle Valve
60
Pilot Screw
60
Collar
60
Float
60
Enriching Fuel Pump
61
Electrothermal Valve
61
Assembly
62
Installation
64
OIL-INJECTION SYSTEM (Oil Injection Model)
65
Exploded Diagram
65
Removal
67
Cleaning and Inspection
67
Oil-Tank
67
Oil-Lever Sensor
67
Oil-Hoses
67
Installation
67
Powr Chapter 5 Power Unit
70
Chapter 5
72
Exploded Diagram
72
Preparation for Overhaul
74
Removal
74
Disassembly
76
Inspection
77
Cylinder Head
77
Cleaning
77
Cylinder Block
78
Cleaning
78
Inspection
78
Piston
79
Cleaning
79
Inspection
79
Piston Ring
80
Inspection
80
Piston Pin and Small End Bearing
81
Cleaning
81
Inspection
81
Crankshaft
81
Inspection
82
Reed Valve
82
Inspection
83
Thermostat
83
Cleaning
83
Crank Main Bearing
83
Inspection
84
Drive Gear (Oil Injection Pump Drive)
84
Driven Gear (Oil Injection Pump Drive)
84
Assembly and Adjustment
85
Bearing, Oil Seal and O-Ring
85
Piston and Piston Ring
85
Small End Bearings and Piston Assembly
86
CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 Hp)
87
Oil Seal Housing
88
CRANK CYLINDER ASSEMBLY (50, 60, 70 Hp)
88
CRANK CYLINDER ASSEMBLY (75, 80, 90 Hp)
89
Cylinder Head and Exhaust Cover
90
Drainage Hose
91
Intake Manifold
91
Fuel System and Electrical System
91
Installation
92
Table of Contents
93
Chapter 6 Exploded Diagram
94
Exploded Diagram (for 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)
94
(Except for 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)
95
Disassembly
96
Preparation for Removal
96
Inspection
102
Gear Case
102
Bearing Housing
102
Claw-Washer
102
Ring-Nut
102
Water Pump Housing
103
Impeller
103
OIL-SEAL HOUSING (Water Pump Housing)
103
Gear
103
Bearing
103
Clutch Dog and Components
104
Drive and Propeller Shaft
104
Drive Shaft Sleeve
104
Propeller/Trim Tab/Anode
104
Assembly and Adjustment
105
Propeller-Shaft Housing
105
Gear Case
106
Shim Selection
110
For Usa and Canada
110
Except for Usa and Canada
115
Measuring the Backlash
118
Water Pump Installation
121
Installation
122
Lower Unit Leakage Check
124
Bracket Unit
125
Chapter 7 Bracket Unit
126
Exploded Diagram
126
Manual Handle
126
BRACKET UNIT (Manual Tilt Model)
126
BRACKET (Short Transom)
132
BRACKET (Long Transom)
133
Disassembly
134
Inspection
134
Anode
134
Bracket
134
Trim Sensor
134
Removal
134
Assembly
135
Hydraulic Tilt Unit
136
Inspection
136
Power Trim and Tilt Unit
136
Removal
136
EXPLODED DIAGRAM (Short Transom [6H308])
137
Disassembly
139
Inspection
141
Tilt-Rod and Trim-Rod
141
Assembly
141
EXPLODED DIAGRAM (Long Transom [6H1-15], [62F-02])
145
Disassembly
147
Inspection
149
Tilt-Rod and Trim-Rod
149
Assembly
149
Filling with Hydraulic Fluid and Air-Bleeding
153
Hydraulic Fluid Pressure Test
153
Installation
155
Power Trim and Tilt Motor
156
Disassembly
156
Inspection
156
Armature Coil
156
Brush
157
Base Assembly
157
Circuit Breaker
157
Assembly
158
Table of Contents
160
Chapter 8
162
Electrical Components
162
Electrical Wiring
164
Wiring Diagram
168
Remote Control Box
173
Digital Meter
173
Removal
174
Magneto Base
174
Electrical Analysis
176
Inspection
176
Ignition Spark Gap
177
CDI System Peak Voltage
177
Replacement of Spark-Plug Cap
181
Crank Position Sensor
181
Starter Relay
182
Power Trim and Tilt Relay
182
Trailer Switch
183
Rectifier/Regulator
184
Fuse
184
Thermo Switch
185
Fuel Enrichment Valve
185
OIL INJECTION SYSTEM (Oil Injection Model)
186
Oil-Level Sensor
187
Oil-Level Warning Lamp (L.e.D.)
189
Wiring Harness
189
Bracket
190
Battery
190
Engine Stop Switch
190
Main Switch (P60Th/60Fehto, P75Th/75Cehto, 90Aehd)
191
Neutral Switch
191
Installation
191
Flywheel Magneto
191
Starter Motor
192
Removal
192
Disassembly
192
Inspection
193
Pinion
193
Brush
193
Brush-Holder
193
Armature
194
ASSEMBLY (50, 60, 70 Hp)
195
INSTALLATION (50, 60, 70 Hp)
196
ASSEMBLY (75, 80, 90 Hp)
196
INSTALLATION (75, 80, 90 Hp)
197
Trouble Analysis
200
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