Yamaha F90D Bedienungsanleitung

F90D

SERVICE MANUAL

6D8-28197-1G-11LIT-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

1st Edition, June 2004

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

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.

1Parts are shown and detailed in an exploded diagram and are listed in the components list.

2Tightening torque specifications are provided in the exploded diagrams and after a numbered

step with tightening instructions.

3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant

and lubrication point.

4The components list consists of part names and part quantities, as well as bolt and screw dimen-

sions.

5Service 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

3Hose 1

4 Check screw 1

5 Gasket 2 Not reusable

6 Dowel pin 2

7 Bolt 4 M10 40 mm

8 Drain screw 1

9Grommet 1

10 Bolt 1 M10 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 2using 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

321

6D81G11 1-2

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 1to 6indicate specific data.

1Special tool

2Specified oil or fluid

3Specified engine speed

4Specified tightening torque

5Specified measurement

6Specified electrical value

(resistance, voltage, electric current)

Symbols 7to Cin an exploded diagram indicate the grade of lubricant and the lubrication point.

7Apply Yamaha 4-stroke motor oil

8Apply gear oil

9Apply water resistant grease (Yamaha grease A)

0Apply molybdenum disulfide grease

AApply corrosion resistant grease

(Yamaha grease D)

BApply low temperature resistant grease

(Yamaha grease C)

CApply injector grease

Symbols Dto Hin an exploded diagram indicate the type of sealant or locking agent and the appli-

cation point.

DApply Gasket Maker

EApply LOCTITE 271 (red)

FApply LOCTITE 242 (blue)

GApply LOCTITE 572

HApply silicon sealant

123456

7890ABC

E G

A M

C I

DEFGH

271

242

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

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.

1Model name

2Approved model code

3Transom height

4Serial 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.

aPropeller diameter (in inches)

bPropeller pitch (in inches)

cPropeller type (propeller mark)

Applicable model

F90TR

Model name Approved

model code

Starting

serial No.

F90TR 61P 1007790–

S6D81010

S69J1100

× -

abc

S60C1120

× -

abc

6D81G11 1-6

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 aand 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

Identification / Propeller selection / Predelivery checks

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