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Outboard Motor
F90D
Yamaha F90D User Manual
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6D81G11
7-2
1
2
3
4
5
6
7
8
9
Shift rod
7
No.
Part name
Q
’
ty
Remarks
1B
o
l
t
1
2S
p
r
i
n
g
1
3B
a
l
l
1
4
Washer
1
5
Bushing
2
6B
o
l
t
2
M
6
×
25 mm
7B
r
a
c
k
e
t
1
8
Shift rod
1
9S
c
r
e
w
2
ø
4
×
16 mm
10
Plate
1
11
Shift position switch
1
12
Bolt
2
M6
×
50 mm
13
Bushing
1
14
Bracket
1
15
Cotter pin
1
Not reusable
16
Bushing
1
17
Lever
1
S6D87010
9
14
15
1
2
3
4
5
8
7
12
10
11
6
13
5
17
16
T
R
.
.
18 N
·
m (1.8 kgf
·
m, 13.3 ft
·
Ib)
T
R
.
.
1 N
·
m (0.1 kgf
·
m, 0.7 ft
·
Ib)
A
A
A
A
A
A
A
A
LT
572
LT
Special service tools / Shift rod
151
153
Table of Contents
Gen Info General Information
4
Default Chapter
2
Important Information
2
Table of Contents
4
General Information
5
Specifications
5
Manual Format
5
Periodic Checks and Adjustments
6
Fuel System
6
Power Unit
6
Lower Unit
6
Bracket Unit
6
Symbols
6
How to Use this Manual
5
Safety While Working
7
Fire Prevention
7
Ventilation
7
Self-Protection
7
Parts, Lubricants, and Sealants
7
Good Working Practices
8
Disassembly and Assembly
8
Identification
9
Applicable Model
9
Serial Number
9
Propeller Selection
9
Propeller Size
9
Selection
10
Predelivery Checks
10
Checking the Fuel System
10
Checking the Engine Oil Level
10
Checking the Gear Oil Level
11
Checking the Battery
11
Checking the Outboard Motor Mounting Height
11
Checking the Remote Control Cables
11
Checking the Steering System
12
Checking the Gear Shift and Throttle Operation
12
Checking the Power Trim and Tilt System
12
Checking the Engine Start Switch and Engine Stop Lanyard Switch
12
Checking the Cooling Water Pilot Hole
13
Test Run
13
Break-In
13
After Test Run
13
Spec Specifications
14
Default Chapter
15
General Specifications
15
General Specifications
17
Maintenance Specification
17
Power Unit
17
Lower Unit
20
Electrical
20
Dimensions
23
Specifications
17
Tightening Torques
25
Specified Torques
25
General Torques
27
Chk Adj/Chk Adj
28
Chk Adj
29
Special Service Tools
29
Periodic Checks and Adjustments
29
Maintenance Interval Chart
30
Top Cowling
31
Checking the Top Cowling
31
Fuel System
31
Checking the Fuel Joint and Fuel Hoses (Fuel Joint-To-Fuel Injector)
31
Checking the Fuel Filter
31
Power Unit
32
Checking the Engine Oil
32
Changing the Engine Oil Using an Oil Changer
32
Changing the Engine Oil by Draining It
32
Replacing the Oil Filter
33
Checking the Timing Belt
34
Checking the Spark Plugs
34
Checking the Thermostat
35
Checking the Cooling Water Passage
36
Control System
36
Checking the Engine Idle Speed
36
Adjusting the Throttle Link and Throttle Cable
36
Checking the Gear Shift Operation
38
Bracket Unit
39
Checking the Power Trim and Tilt Operation
39
Checking the Power Trim and Tilt Fluid Level
39
Lower Unit
40
Checking the Gear Oil Level
40
Changing the Gear Oil
40
Checking the Lower Unit for Air Leakage
41
Checking the Propeller
41
General
42
Checking the Anodes
42
Checking the Battery
42
Lubricating the Outboard Motor
43
Fuel Fuel System
45
Special Service Tools
46
Fuel System
46
Hose Routing
47
Fuel and Blowby Hoses
47
Fuel Filter and Fuel Pump
48
Checking the Fuel Pump
50
Disassembling the Fuel Pump
50
Checking the Diaphragm and Valves
51
Assembling the Fuel Pump
51
Intake Manifold
52
Checking the Throttle Position Sensor
54
Installing the Throttle Position Sensor
54
Checking the Idle Speed Control
54
Vapor Separator
57
Reducing the Fuel Pressure
58
Disconnecting the Quick Connector
58
Measuring the Fuel Pressure
58
Checking the Pressure Regulator
59
Draining the Fuel
60
Removing the Fuel Hose Clamp
60
Installing the Fuel Hose Clamp
60
Disassembling the Vapor Separator
60
Checking the Vapor Separator
61
Assembling the Vapor Separator
61
Adjusting the Float
62
Canister
63
Checking the Canister
64
Powr Power Unit
65
Special Service Tools
67
Power Unit
67
Power Unit
69
Checking the Compression Pressure
69
Checking the Oil Pressure
69
Checking the Valve Clearance
76
Replacing the Timing Belt
79
Removing the Power Unit
82
Removing the Timing Belt and Sprockets
83
Checking the Timing Belt and Sprockets
84
Installing the Sprockets and Timing Belt
84
Throttle Link
86
Ecm
87
Junction Box
88
Cylinder Head
90
Removing the Cylinder Head
92
Checking the Valve Lifters
93
Checking the Valve Springs
93
Checking the Valves
93
Checking the Valve Guides
94
Replacing the Valve Guides
94
Checking the Valve Seat
95
Refacing the Valve Seat
96
Checking the Camshafts
97
Checking the Cylinder Head
98
Installing the Valves
99
Installing the Cylinder Head
99
Exhaust Cover
102
Removing the Exhaust Cover
104
Checking the Pressure Control Valve
104
Installing the Pressure Control Valve
104
Installing the Exhaust Cover
104
Cylinder Block
105
Disassembling the Cylinder Block
106
Checking the Piston Diameter
106
Checking the Cylinder Bore
107
Checking the Piston Clearance
107
Checking the Piston Rings
107
Checking the Piston Ring Grooves
108
Checking the Piston Ring Side Clearance
108
Checking the Connecting Rod Big End Side Clearance
109
Checking the Crankshaft
109
Checking the Crankpin Oil Clearance
109
Selecting the Connecting Rod Bearing
111
Checking the Crankshaft Journal Oil Clearance
112
Selecting the Main Bearing
113
Assembling the Power Unit
115
Installing the Power Unit
117
Lowr Lower Unit
119
Lower Unit
120
Special Service Tools
120
Lower Unit
122
Removing the Lower Unit
127
Removing the Water Pump and Shift Rod
128
Disassembling the Oil Seal Housing
128
Checking the Water Pump and Shift Rod
128
Propeller Shaft Housing
129
Removing the Propeller Shaft Housing Assembly
130
Disassembling the Propeller Shaft Assembly
130
Disassembling the Propeller Shaft Housing
130
Checking the Propeller Shaft Housing
131
Checking the Propeller Shaft
131
Assembling the Propeller Shaft Assembly
131
Assembling the Propeller Shaft Housing
132
Drive Shaft and Lower Case
134
Removing the Drive Shaft
136
Disassembling the Drive Shaft
136
Disassembling the Forward Gear
136
Disassembling the Lower Case
136
Checking the Pinion and Forward Gear
137
Checking the Bearings
137
Checking the Drive Shaft
137
Checking the Lower Case
137
Assembling the Lower Case
138
Assembling the Forward Gear
138
Assembling the Drive Shaft
139
Installing the Drive Shaft
139
Installing the Propeller Shaft Housing
139
Installing the Water Pump and Shift Rod
140
Installing the Lower Unit
141
Shimming
144
Selecting the Pinion Shims
145
Selecting the Forward Gear Shims
146
Backlash
147
Measuring the Forward Gear Backlash
147
Brkt Bracket Unit
149
Bracket Unit
151
Special Service Tools
151
Shift Rod
152
Bottom Cowling
153
Upper Case
156
Removing the Upper Case
162
Disassembling the Oil Pump
162
Checking the Oil Pump
162
Assembling the Oil Pump
162
Disassembling the Upper Case
163
Checking the Drive Shaft Bushing
163
Disassembling the Oil Pan
163
Checking the Oil Strainer
164
Assembling the Oil Pan
164
Assembling the Upper Case
165
Installing the Upper Case
165
Steering Arm
167
Removing the Steering Arm
168
Installing the Steering Arm
168
Clamp Brackets and Swivel Bracket
169
Removing the Clamp Brackets
171
Installing the Clamp Brackets
171
Adjusting the Trim Sensor
171
Power Trim and Tilt Unit
173
Removing the Power Trim and Tilt Unit
174
Power Trim and Tilt Motor
175
Disassembling the Power Trim and Tilt Motor
177
Checking the Power Trim and Tilt Motor
177
Assembling the Power Trim and Tilt Motor
179
Gear Pump
180
Disassembling the Gear Pump
183
Checking the Gear Pump
183
Assembling the Gear Pump
183
Tilt Cylinder and Trim Cylinder
185
Disassembling the Trim Cylinder
188
Disassembling the Tilt Cylinder
188
Checking the Tilt Cylinder and Trim Cylinder
189
Checking the Valves
189
Assembling the Tilt Cylinder
189
Assembling the Power Trim and Tilt Unit
191
Bleeding the Power Trim and Tilt Unit
193
Installing the Power Trim and Tilt Unit
194
Bleeding the Power Trim and Tilt Unit (Built-In)
194
Power Trim and Tilt Electrical System
195
Checking the Fuse
195
Checking the Power Trim and Tilt Relay
195
Checking the Power Trim and Tilt Switch
196
Checking the Trim Sensor
196
Elec Electrical Systems
197
Electrical Systems
198
Special Service Tools
198
Checking the Electrical Components
199
Measuring the Peak Voltage
199
Measuring the Lower Resistance
199
Electrical Components
200
Port View
200
Starboard View
201
Bow View
202
Top View
203
Ignition and Ignition Control System
204
Checking the Ignition Spark
204
Checking the Spark Plug Wires
204
Checking the Ignition Coils
204
Checking the ECM
205
Checking the Pulser Coils
205
Checking the Sensor Assembly
205
Checking the Cooling Water Temperature Sensor
206
Checking the Oil Pressure Switch
206
Checking the Shift Position Switch
206
Checking the Main and Fuel Pump Relay (Main Control)
207
Fuel Control System
207
Checking the Injectors
207
Checking the Electric Fuel Pump
207
Checking the Main and Fuel Pump Relay (Fuel Control)
208
Starting System
208
Checking the Fuses
208
Checking the Starter Relay
208
Starter Motor
210
Disassembling the Starter Motor
212
Checking the Starter Motor Pinion
212
Checking the Armature
212
Checking the Brushes
213
Checking the Magnet Switch
213
Checking the Starter Motor Operation
213
Charging System
213
Checking the Stator Coil
213
Checking the Rectifier Regulator
214
Trbl Shtg Troubleshooting
215
Special Service Tools
216
Trbl Shtg
216
Troubleshooting
216
Yamaha Diagnostic System
216
Power Unit
220
Bracket Unit
228
Electrical Systems
232
Diagnosing the Electronic Control System
233
Self-Diagnosis
233
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Yamaha F90D Specifications
General
Brand
Yamaha
Model
F90D
Category
Outboard Motor
Language
English
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