YAMAHA F90D Manuals

Manuals and User Guides for YAMAHA F90D. We have 2 YAMAHA F90D manuals available for free PDF download: Service Manual, Ower's Manual

YAMAHA F90D Service Manual (241 pages)

Outboard Motor F90D

Brand: YAMAHA | Category: Outboard Motor | Size: 12.69 MB

Gen Info General Information

4
- 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
Spec Specifications

14
- 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
- Control System
  
  36
- Bracket Unit
  
  39
  - Checking the Power Trim and Tilt Operation
    39
  - Checking the Power Trim and Tilt Fluid Level
    39
- Lower Unit
  
  40
- 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
- Intake Manifold
  
  52
- Vapor Separator
  
  57
- Canister
  
  63
  - Checking the Canister
    64
Powr Power Unit

65
- Special Service Tools
  
  67
- Power Unit
  
  67
- Power Unit
  
  69
- 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
- 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
- Propeller Shaft Housing
  
  129
- 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
- Gear Pump
  
  180
  - Disassembling the Gear Pump
    183
  - Checking the Gear Pump
    183
  - Assembling the Gear Pump
    183
- Tilt Cylinder and Trim Cylinder
  
  185
- 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
- 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

YAMAHA F90D Ower's Manual (75 pages)

Outboard Motor F75D; F90D

Brand: YAMAHA | Category: Outboard Motor | Size: 4.24 MB

Important Manual Information
3
Table of Contents
4
General Information

6
- Identification Numbers Record
  6
  - Outboard Motor Serial Number
    6
  - Key Number
    6
- Emission Control Information
  6
  - North American Models
    6
  - Star Labels
    7
- Safety Information
  8
- Important Labels
  9
  - Warning Labels
    9
- Basic Boating Rules (Rules of the Road)
  9
- Fueling Instructions
  13
  - Gasoline
    14
  - Engine Oil
    14
- Battery Requirement
  14
  - Battery Specifications
    15
- Propeller Selection
  15
- Start-In-Gear Protection
  16
Basic Components

17
- Main Components
  17
  - Remote Control
    17
  - Remote Control Lever
    18
  - Neutral Interlock Trigger
    18
  - Neutral Throttle Lever
    18
  - Throttle Friction Adjuster
    18
  - Engine Stop Lanyard Switch
    19
  - Main Switch
    19
  - Power Trim and Tilt Switch on Remote Control or Tiller Handle
    20
  - Power Trim and Tilt Switch on Bottom Engine Cowling
    20
  - Trim Tab with Anode
    20
  - Tilt Support Lever for Power Trim and Tilt or Hydro Tilt Model
    21
  - Top Cowling Lock Lever (Pull up Type)
    21
  - Flushing Device
    22
  - Digital Tachometer
    22
  - Low Oil Pressure Warning Indicator
    22
  - Overheat Warning Indicator (Digital Type)
    23
  - Speedometer (Digital Type)
    23
  - Trim Meter (Digital Type)
    24
  - Hour Meter (Digital Type)
    24
  - Trip Meter
    24
  - Clock
    25
  - Fuel Gauge
    25
  - Fuel Warning Indicator
    25
  - Low Battery Voltage Warning Indicator
    25
- Warning System
  26
  - Overheat Warning
    26
  - Low Oil Pressure Warning
    26
Operation

28
- Installation
  28
  - Mounting the Outboard Motor
    28
- Breaking in Engine
  29
  - Procedure for 4-Stroke Models
    29
- Preoperation Checks
  29
  - Fuel
    29
  - Controls
    30
  - Engine
    30
  - Checking the Engine Oil Level
    30
- Filling Fuel
  30
  - Ring Free Fuel Additive
    31
- Operating Engine
  31
  - Feeding Fuel
    31
  - Starting Engine
    31
- Warming up Engine
  33
  - Manual Start and Electric Start Models
    33
- Shifting
  33
  - Forward (Tiller Handle and Remote Control Models)
    33
  - Reverse (Automatic Reverse Lock and Power Trim and Tilt Models)
    34
- Stopping Engine
  34
  - Procedure
    34
- Trimming Outboard Motor
  34
  - Adjusting Trim Angle
    35
  - Adjusting Boat Trim
    36
- Tilting up and down
  37
  - Procedure for Tilting up
    37
  - Procedure for Tilting down
    38
- Cruising in Shallow Water
  39
  - Power Trim and Tilt Models / Power Tilt Models
    39
- Cruising in Other Conditions
  39
Maintenance

41
- Specifications
  41
- Transporting and Storing Outboard Motor
  42
  - Storing Outboard Motor
    42
  - Procedure
    43
  - Lubrication (Except Oil Injection Models)
    44
  - Cleaning and Anticorrosion Measures
    44
  - Battery Care
    44
  - Flushing Power Unit
    45
  - Cleaning the Outboard Motor
    45
  - Checking Painted Surface of Motor
    46
- Periodic Maintenance
  46
  - Replacement Parts
    46
  - Maintenance Chart
    47
  - Maintenance Chart (Additional)
    48
  - Greasing
    49
  - Cleaning and Adjusting Spark Plug
    49
  - Checking Fuel System
    50
  - Inspecting Fuel Filter
    50
  - Cleaning Fuel Filter
    51
  - Inspecting Idling Speed
    51
  - Changing Engine Oil
    52
  - Checking Wiring and Connectors
    54
  - Exhaust Leakage
    54
  - Water Leakage
    54
  - Engine Oil Leakage
    54
  - Checking Power Trim and Tilt System
    54
  - Checking Propeller
    55
  - Removing the Propeller
    56
  - Installing the Propeller
    56
  - Changing Gear Oil
    56
  - Inspecting and Replacing Anode(S)
    57
  - Checking Battery (for Electric Start Models)
    58
  - Connecting the Battery
    59
  - Disconnecting the Battery
    59
  - Checking Top Cowling
    59
  - Coating the Boat Bottom
    59
Trouble Recovery

61
- Troubleshooting
  61
- Temporary Action in Emergency
  64
  - Impact Damage
    64
  - Replacing Fuse
    64
  - Power Trim and Tilt will Not Operate
    65
  - Starter will Not Operate
    65
  - Emergency Starting Engine
    66
- Treatment of Submerged Motor
  67
  - Procedure
    67
Consumer Information

68

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YAMAHA F90D Manuals

YAMAHA F90D Service Manual (241 pages)

Table of Contents

Gen Info General Information

General Information

How to Use this Manual

Safety While Working

Identification

Propeller Selection

Predelivery Checks

Spec Specifications

General Specifications

Maintenance Specification

Specifications

Tightening Torques

Chk Adj/Chk Adj

Chk Adj

Special Service Tools

Periodic Checks and Adjustments

Maintenance Interval Chart

Top Cowling

Fuel System

Power Unit

Control System

Bracket Unit

Lower Unit

General

Fuel Fuel System

Special Service Tools

Fuel System

Hose Routing

Fuel Filter and Fuel Pump

Intake Manifold

Vapor Separator

Canister

Powr Power Unit

Special Service Tools

Power Unit

Power Unit

Throttle Link

Ecm

Junction Box

Cylinder Head

Exhaust Cover

Cylinder Block

Lowr Lower Unit

Lower Unit

Special Service Tools

Lower Unit

Propeller Shaft Housing

Drive Shaft and Lower Case

Shimming

Backlash

Brkt Bracket Unit

Bracket Unit

Special Service Tools

Shift Rod

Bottom Cowling

Upper Case

Steering Arm

Clamp Brackets and Swivel Bracket

Power Trim and Tilt Unit

Power Trim and Tilt Motor

Gear Pump

Tilt Cylinder and Trim Cylinder

Power Trim and Tilt Electrical System

Elec Electrical Systems

Electrical Systems

Special Service Tools

Checking the Electrical Components

Electrical Components

Ignition and Ignition Control System

Fuel Control System

Starting System

Starter Motor

Charging System

Trbl Shtg Troubleshooting

YAMAHA F90D Ower's Manual (75 pages)

Table of Contents

General Information