Yamaha F90D (90HP) Outboard OEM Service & Repair Manual

F90D SERVICE MANUAL 6D8-28197-1G-11 LIT-18616-02-86 *LIT186160286*

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 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. 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 1 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 out- board motor. NOTE: A NOTE provides key information to make procedures easier or clearer. F90D SERVICE MANUAL ©2004 by Yamaha Motor Corporation, USA 1st Edition, June 2004 All rights reserved. Any reprinting or unauthorized use without the written permission of Yamaha Motor Corporation, USA is expressly prohibited. Printed in USA LIT-18616-02-86

Contents General information 1 GEN INFO Specifications 2 SPEC Periodic checks and adjustments 3 CHK ADJ Fuel system 4 FUEL Power unit 5 POWR Lower unit 6 LOWR Bracket unit 7 BRKT Electrical systems 8 ELEC Troubleshooting 9 TRBL SHTG Index – +

6D81G11 GEN INFO 1 2 3 4 5 6 7 8 9 General information How to use this manual ................................................................................. 1-1 Manual format............................................................................................ 1-1 Symbols ..................................................................................................... 1-2 Safety while working...................................................................................... 1-3 Fire prevention........................................................................................... 1-3 Ventilation .................................................................................................. 1-3 Self-protection ........................................................................................... 1-3 Parts, lubricants, and sealants .................................................................. 1-3 Good working practices ............................................................................. 1-4 Disassembly and assembly ....................................................................... 1-4 Identification ................................................................................................... 1-5 Applicable model ....................................................................................... 1-5 Serial number ............................................................................................ 1-5 Propeller selection ......................................................................................... 1-5 Propeller size ............................................................................................. 1-5 Selection .................................................................................................... 1-6 Predelivery checks ........................................................................................ 1-6 Checking the fuel system .......................................................................... 1-6 Checking the engine oil level ..................................................................... 1-6 Checking the gear oil level ........................................................................ 1-7 Checking the battery.................................................................................. 1-7 Checking the outboard motor mounting height .......................................... 1-7 Checking the remote control cables .......................................................... 1-7 Checking the steering system ................................................................... 1-8 Checking the gear shift and throttle operation ........................................... 1-8 Checking the power trim and tilt system .................................................... 1-8 Checking the engine start switch and engine stop lanyard switch ............ 1-8 Checking the cooling water pilot hole ........................................................ 1-9 Test run ..................................................................................................... 1-9 Break-in ..................................................................................................... 1-9 After test run .............................................................................................. 1-9

GEN INFO General information 1-1 6D81G11 How to use this manual 1 Manual format The format of this manual has been designed to make service procedures clear and easy to under- stand. Use the information below as a guide for effective and quality service. 1 Parts are shown and detailed in an exploded diagram and are listed in the components list. 2 Tightening torque specifications are provided in the exploded diagrams and after a numbered step with tightening instructions. 3 Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant and lubrication point. 4 The components list consists of part names and part quantities, as well as bolt and screw dimen- sions. 5 Service points regarding removal, checking, and installation are shown in individual illustrations to explain the relevant procedure. NOTE: For troubleshooting procedures, see Chapter 9, “Troubleshooting.” LOWR Lower unit 6-5 62Y5A11 Lower unit No. Part name Q’ty Remarks 1 Lower unit 1 2 Plastic tie 1 Not reusable 3 Hose 1 4 Check screw 1 5 Gasket 2 Not reusable 6 Dowel pin 2 7 Bolt 4 M10 40 mm 8 Drain screw 1 9 Grommet 1 10 Bolt 1 M 10 45 mm 11 Bolt 1 M8 60 mm 12 Thrust washer 1 13 Propeller 1 14 Washer 1 15 Washer 1 16 Cotter pin 1 Not reusable 17 Propeller nut 1 18 Trim tab 1 LOWR Lower unit 6-19 62Y5A11 Removing the drive shaft 1. Remove the drive shaft assembly and pinion, and then pull out the forward gear. Disassembling the drive shaft 1. Install the pinion nut 1, tighten it finger tight, and then remove the drive shaft bearing 2 using a press. CAUTION: • Do not press the drive shaft threads a directly. • Do not reuse the bearing, always replace it with a new one. Disassembling the forward gear 1. Remove the taper roller bearing from the forward gear using a press. CAUTION: Do not reuse the bearing, always replace it with a new one. 2. Remove the needle bearing from the for- ward gear. CAUTION: Do not reuse the bearing, always replace it with a new one. Drive shaft holder 4 1: 90890-06518 Pinion nut holder 2: 90890-06505 Socket adapter 2 3: 90890-06507 Bearing inner race attachment 3: 90890-06639 S62Y6850K Bearing separator 1: 90890-06534 Stopper guide plate 2: 90890-06501 Stopper guide stand 3: 90890-06538 Bearing puller 4: 90890-06535 Bearing puller claw 1 5: 90890-06536 S62Y6740K 5 4 3 2 1

6D81G11 1-2 1 2 3 4 5 6 7 8 9 Symbols The symbols below are designed to indicate the content of a chapter. General information Specifications Periodic checks and adjustments Fuel system Power unit Lower unit Bracket unit Electrical systems Troubleshooting GEN INFO SPEC CHK ADJ FUEL POWR LOWR BRKT ELEC TRBL SHTG – + Symbols 1 to 6 indicate specific data. 1 Special tool 2 Specified oil or fluid 3 Specified engine speed 4 Specified tightening torque 5 Specified measurement 6 Specified electrical value (resistance, voltage, electric current) Symbols 7 to C in an exploded diagram indicate the grade of lubricant and the lubrication point. 7 Apply Yamaha 4-stroke motor oil 8 Apply gear oil 9 Apply water resistant grease (Yamaha grease A) 0 Apply molybdenum disulfide grease A Apply corrosion resistant grease (Yamaha grease D) B Apply low temperature resistant grease (Yamaha grease C) C Apply injector grease Symbols D to H in an exploded diagram indicate the type of sealant or locking agent and the appli- cation point. D Apply Gasket Maker E Apply LOCTITE 271 (red) F Apply LOCTITE 242 (blue) G Apply LOCTITE 572 H Apply silicon sealant 1 2 3 4 5 6 T R . . 7 8 9 0 A B C E G A M D C I D E F G H GM 271 LT 242 LT 572 LT SS How to use this manual

GEN INFO General information 1-3 6D81G11 Safety while working 1 To prevent an accident or injury and to ensure quality service, follow the safety pro- cedures provided below. Fire prevention Gasoline is highly flammable. Keep gasoline and all flammable products away from heat, sparks, and open flames. 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 ade- quate ventilation can be maintained. Self-protection Protect your eyes by wearing safety glasses or safety goggles during all operations involv- ing drilling and grinding, or when using an air compressor. Protect your hands and feet by wearing pro- tective gloves and safety shoes when neces- sary. Parts, lubricants, and sealants Use only genuine Yamaha parts, lubricants, and sealants or those recommended by Yamaha, when servicing or repairing the out- board motor. Under normal conditions, the lubricants men- tioned 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. 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.

6D81G11 1-4 1 2 3 4 5 6 7 8 9 6. Keep a supply of clean, lint-free cloths for wiping up spills, etc. Good working practices Special service tools Use the recommended special service tools to protect parts from damage. Use the right tool in the right manner—do not improvise. Tightening torques Follow the tightening torque specifications provided throughout the manual. When tight- ening nuts, bolts, and screws, tighten the large sizes first, and tighten fasteners starting in the center and moving outward. Non-reusable parts Always use new gaskets, seals, O-rings, cot- ter pins, circlips, etc., when installing or assembling parts. Disassembly and assembly 1. Use compressed air to remove dust and dirt during disassembly. 2. Apply engine oil to the contact surfaces of moving parts before assembly. 3. Install bearings with the manufacture identification mark in the direction indi- cated in the installation procedure. In addition, be sure to lubricate the bearings liberally. 4. Apply a thin coat of water-resistant grease to the lip and periphery of an oil seal before installation. 5. Check that moving parts operate nor- mally after assembly. Safety while working

GEN INFO General information 1-5 6D81G11 Identification 1 Applicable model This manual covers the following model. Serial number The outboard motor serial number is stamped on a label attached to the port clamp bracket. 1 Model name 2 Approved model code 3 Transom height 4 Serial number Propeller selection 1 The performance of a boat and outboard motor will be critically affected by the size and type of propeller you choose. Propellers greatly affect boat speed, acceleration, engine life, fuel economy, and even boating and steering capabilities. An incorrect choice could adversely affect performance and could also seriously damage the engine. Use the following information as a guide for selecting a propeller that meets the operating conditions of the boat and the outboard motor. Propeller size The size of the propeller is indicated on the propeller boss end, on the side of the propel- ler boss. a Propeller diameter (in inches) b Propeller pitch (in inches) c Propeller type (propeller mark) Applicable model F90TR Model name Approved model code Starting serial No. F90TR 61P 1007790– S6D81010 S69J1100 × - a b c S60C1120 × - a bc

6D81G11 1-6 1 2 3 4 5 6 7 8 9 Selection When the engine speed is at the full throttle operating range (5,000–6,000 r/min), the ideal propeller for the boat is one that pro- vides maximum performance in relation to boat speed and fuel consumption. Predelivery checks 1 To make the delivery process smooth and efficient, the predelivery checks should be completed as explained below. Checking the fuel system 1. Check that the fuel hoses are securely connected and that the fuel tank is full with fuel. CAUTION: This is a 4-stroke engine. Never use pre- mixed fuel. Checking the engine oil level 1. Check the engine oil level. NOTE: If the engine oil is below the minimum level mark b, add sufficient oil until the level is between a and b. Propeller size (in) Material 12 5/8 × 21 - K Aluminum 13 × 19 - K 13 × 23 - K 13 × 25 - K 13 1/4 × 17 - K 13 1/2 × 15 - K 13 5/8 × 13 - K 14 × 11 - K 13 × 17 - K Stainless 13 × 19 - K 13 × 21 - K 13 × 23 - K 13 × 25 - K 13 1/2 × 14 - K 13 1/2 × 16 - K Recommended engine oil: 4-stroke motor oil API: SE, SF, SG, SH, or SJ SAE: 10W-30 or 10W-40 Engine oil quantity: Without oil filter replacement: 4.3 L (4.55 US qt, 3.78 Imp qt) S6D81020 S60C1150 a b Identification / Propeller selection / Predelivery checks