Yamaha 90D Owner's Manual
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Yamaha 90D Owner's Manual

Yamaha 90D Owner's Manual

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90D
OWNER'S MANUAL
U.S.A.Edition
LIT-18626-05-86
6H1-28199-14

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  • Page 1 OWNER’S MANUAL U.S.A.Edition LIT-18626-05-86 6H1-28199-14...
  • Page 2 EMU25060 ZMU01690 Read this owner’s manual carefully before operating your outboard motor.

  • Page 3: Important Manual Information

    EMU25110 tain maximum enjoyment from your new Yamaha. If you have any question about the operation or maintenance of your outboard motor, please consult a Yamaha dealer. In this Owner’s Manual particularly important OWNER’S MANUAL...

  • Page 4: Table Of Contents

    Table of contents General information ......1 type) ..........15 Flushing device ....... 16 Identification numbers record..1 Tachometer ........16 Outboard motor serial number ..1 Digital tachometer ......16 Key number........1 Oil level indicators (three Emission control information ... 1 indicators) ........
  • Page 5 ..........44 IMPORTANT WARRANTY Checking fuel system ...... 44 INFORMATION IF YOU USE Inspecting fuel filter ......45 YOUR YAMAHA OUTSIDE Cleaning fuel filter ......45 U.S.A. OR CANADA ....69 Inspecting idling speed ....46 Checking water in engine oil tank ..........

  • Page 6: General Information

    Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Yamaha dealer or for reference in case your outboard motor is sto- len. 1. Key number...

  • Page 7: Safety Information

    General information Before operating the boat, read any own- er’s or operator’s manuals supplied with it and all labels. Be sure you understand EMISSION CONTROL INFORMATION each item before operating. ENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES. REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.

  • Page 8: Important Labels

    General information to a secure place on your clothing, or your 401 N. Michigan Ave. arm or leg while operating. If you acciden- Chicago, Il 60611 tally leave the helm, the cord will pull from Marine Retailers Association of America the switch, stopping the engine.

  • Page 9: Steering And Sailing Rules And Sound Signals

    General information another vessel on the water. Rules and says, Several sets of rules prevail according to “In obeying and construing these rules due geographic location, but are all basically the regard shall be had to all dangers of naviga- same as the International Rules of the Road.

  • Page 10: Other Special Situations

    General information Meeting Overtaking If you are meeting another power vessel If you are passing another vessel, you are head on, and are close enough to run the risk the “Give-Way” vessel. This means that the of collision, neither of you has the right-of- other vessel is expected to maintain its way! Both of you should alter course to avoid course and speed.
  • Page 11 General information the power-driven vessel, the power-driv- en vessel has the right-of-way. Sailing vessels should keep clear of any fishing vessel. In a narrow channel, a sailing vessel should not hamper the safe passage of a power-driven vessel which can navi- gate only in such a channel.

  • Page 12: Fueling Instructions

    General information ZMU01708 EMU25540 away from sparks, flames, or other Fueling instructions sources of ignition. EWM00010 Stop engine before refueling. WARNING Refuel in a well-ventilated area. Refuel GASOLINE AND ITS VAPORS ARE HIGH- portable fuel tanks off the boat. LY FLAMMABLE AND EXPLOSIVE! Take care not to spill gasoline.

  • Page 13: Gasoline

    The performance of your outboard motor will the fuel meets minimum octane ratings. be critically affected by your choice of propel- Yamaha does not recommended gasohol ler, as an incorrect choice could adversely containing methanol because it can cause affect performance and could also seriously fuel system damage or engine performance damage the motor.

  • Page 14: Start-In-Gear Protection

    48. on the engine. EMU25770 Start-in-gear protection Yamaha outboard motors are fitted with pro- Yamaha outboard motors or Yamaha-ap- pellers chosen to perform well over a range proved remote control units are equipped of applications, but there may be uses where with start-in-gear protection device(s).

  • Page 15: Basic Components

    Basic components EMU25795 Main components NOTE: * May not be exactly as shown; also may not be included as standard equipment on all mod- els. ZMU03850 1. Top cowling 15. Tachometer* 2. Top cowling lock lever 16. Trim meter* 3. Anti-cavitation plate 17.

  • Page 16: Fuel Joint

    Basic components licensing or approval authority regula- tions. 1. Power trim and tilt switch ZMU02284 2. Remote control lever 3. Neutral interlock trigger 1. Fuel joint 4. Neutral throttle lever 2. Fuel gauge 5. Main switch / choke switch 3. Fuel tank cap 6.

  • Page 17: Neutral Interlock Trigger

    Basic components 6. Throttle 7. Fully open EMU26201 Neutral interlock trigger To shift out of neutral, first pull the neutral in- terlock trigger up. 1. Fully open 2. Fully closed EMU25970 Throttle friction adjuster A friction device provides adjustable resis- tance to movement of the throttle grip or the remote control lever, and can be set accord- 1.

  • Page 18: Engine Stop Lanyard Switch

    Basic components EMU25990 Engine stop lanyard switch The lock plate must be attached to the en- gine stop switch for the engine to run. The lanyard should be attached to a secure place on the operator’s clothing, or arm or leg. Should the operator fall overboard or leave the helm, the lanyard will pull out the lock plate, stopping ignition to the engine.

  • Page 19: Power Trim And Tilt Switch On Remote Control Or Tiller Handle

    Basic components EMU26141 while the boat is moving could increase Power trim and tilt switch on remote the risk of falling overboard and could control or tiller handle distract the operator, increasing the risk The power trim and tilt system adjusts the of collision with another boat or an obsta- outboard motor angle in relation to the tran- cle.

  • Page 20: Trim Rod (Tilt Pin)

    Basic components protect the engine from electrochemical corrosion. Never paint the trim tab as it will become ineffective as an anode. ZMU03853 EMU26372 Top cowling lock lever(s) (turn type) To remove the engine top cowling, turn the lock lever(s) and lift off the cowling. When in- 1.

  • Page 21: Flushing Device

    Basic components EMU26460 NOTE: Flushing device All segments of the display will light momen- This device is used to clean the cooling wa- tarily after the main switch is turned on and ter passages of the motor using a garden will return to normal thereafter.

  • Page 22: Oil Level Indicator (Digital Type)

    Basic components page 18. ECM00050 CAUTION: Do not continue to run the engine if the overheat warning indicator is on. Serious engine damage will occur. ZMU04580 1. Oil level indicators EMU26550 Oil level indicator (digital type) This indicator shows the engine oil level. If the oil level falls below the lower limit, the ZMU01868 warning indicator will start to blink.

  • Page 23: Hour Meter (Digital Type)

    Warning system ECM00090 CAUTION: Do not continue to operate the engine if a warning device has activated. Consult your Yamaha dealer if the problem can- not be located and corrected. EMU26812 Overheat warning ZMU01869 This engine has an overheat warning device.

  • Page 24: Oil Level Warning And Oil Filter Clogging Warning

    Basic components If the oil level falls below the lower limit, the warning system will activate. Activation of warning device Engine speed will automatically decrease to about 2000 r/min. The oil level warning indicator will light. ZMU04766 The buzzer will sound (if equipped on the tiller handle, remote control box, or main switch panel).
  • Page 25 Basic components NOTE: The warning for oil filter clogging is similar to the warnings for low oil level and overheat- ing. To make troubleshooting easier, check for engine overheating first, then oil level, and finally oil filter clogging. ZMU03828 1. Oil filter...

  • Page 26: Operation

    Operation EMU26901 specific boat and motor combination. Installation EWM00830 ECM00110 WARNING CAUTION: Improper mounting of the outboard mo- Incorrect engine height or obstructions tor could result in hazardous conditions to smooth water flow (such as the design such as poor handling, loss of control, or or condition of the boat, or accessories fire hazards.

  • Page 27: Breaking In Engine

    Be sure to mix gasoline and oil complete- mine the optimum mounting height. Con- ly, otherwise the engine may be dam- sult your Yamaha dealer boat aged. manufacturer for further information on de- EMU30310 termining the proper mounting height.

  • Page 28: Preoperation Checks

    Operation throttle to 3000 r/min or less. are tight (if equipped Yamaha fuel tank or Second hour: boat tank). Accelerate at full throttle onto plane, Be sure the fuel tank is positioned on a se- then reduce engine speed to three-quar- cure, flat surface, and that the fuel line is ter throttle (approximately 4000 r/min).

  • Page 29: Filling Fuel And Engine Oil

    10 minutes of idling, consult or explosion could result. your Yamaha dealer. This engine uses the Yamaha oil injection system, which provides superior lubrication by ensuring the proper oil ratio for all operat- ing conditions. No fuel premixing is needed.
  • Page 30 Operation ZMU03370 Slowly pour the engine oil into the en- gine oil tank. ZMU03371 1. Oil filler access cap 2. Oil tank filler cap After filling, replace the all caps secure-...

  • Page 31: Oil Level Indicator Operation

    Operation EMU27321 Oil level indicator operation The various functions of the oil level system are as follows: EMU27370 Electric start models Oil level Oil level warning warning indicator indicator (analog Engine oil tank Remarks (digital tachometer/ tachometer) bottom cowling) Green more than 1130 No refilling necessary.

  • Page 32: Starting Engine

    Operation from the fuel tank. Squeeze the primer pump with the outlet end up until you feel it become firm. ZMU02295 If there is a fuel joint on the motor, firmly connect the fuel line to the joint. Then ZMU02025 firmly connect the other end of the fuel line to the joint on the fuel tank.

  • Page 33: Warming Up Engine

    Operation to a secure place on your clothing, or turn to “ ” (on). your arm or leg while operating. ECM00191 CAUTION: Do not attach the lanyard to clothing Never turn the main switch to “ ” that could tear loose. Do not route the (start) while the engine is running.

  • Page 34: Shifting

    Consult your Yamaha dealer if the problem cannot be located and cor- rected. EMU27784 Reverse (automatic reverse lock and...

  • Page 35: Stopping Engine

    Operation ZMU02301 EMU27820 Remove the key if the boat will be left Stopping engine unattended. Before stopping the engine, first let it cool off NOTE: for a few minutes at idle or low speed. Stop- The engine can also be stopped by pulling ping the engine immediately after operating the lanyard and removing the lock plate from at high speed is not recommended.

  • Page 36: Adjusting Trim Angle

    Operation Adjust the outboard motor trim angle using the power trim and tilt switch. ZMU03110 1. Power trim and tilt switch ZMU03109 1. Trim operating angle EMU27881 Adjusting trim angle ZMU03871 Power trim and tilt models EWM00750 To raise the bow (trim-out), press the switch WARNING “...

  • Page 37: Tilting Up And Down

    Operation ciency. This is generally when the keel line of through the water, decreasing fuel economy the boat is up about 3 to 5 degrees. With the and making it hard to increase speed. Oper- bow up, the boat may have a greater tenden- ating with excessive trim-in at higher speeds cy to steer to one side or the other.

  • Page 38: Procedure For Tilting Up

    Operation nect the fuel line or close the fuel cock if Press the power trim and tilt switch / the engine will be tilted for more than a power tilt switch “ ” (up) until the out- few minutes. Otherwise fuel may leak. board motor has tilted up completely.

  • Page 39: Procedure For Tilting Down

    Operation motor could fall back down suddenly if oil in the power trim and tilt unit loses pres- sure. Models equipped with trim rods: Once the outboard motor is supported with the tilt support lever, press the power trim and tilt switch “ ”...

  • Page 40: Cruising In Other Conditions

    / tilt For cooling system flushing instructions, see switch. page 37. Cruising in turbid water Yamaha strongly recommends that you use the optional chromium-plated water pump kit if you use the outboard motor in turbid (mud- dy) water conditions.

  • Page 41: Maintenance

    Maintenance EMU28215 Remote control Specifications Starting system: Dimension: Electric Overall length: Starting carburetion system: 726 mm (28.6 in) Prime start Overall width: Min. cold cranking amps (CCA/SAE): 374 mm (14.7 in) 380.0 A Overall height L: Min. marine cranking amps (MCA/ABYC): 1413 mm (55.6 in) 502.0 A Overall height X:...

  • Page 42: Transporting And Storing Outboard Motor

    Maintenance 25.0 Nm (18.4 ft-lb) (2.55 kgf-m) a transom saver bar. Consult your Yamaha Propeller nut: dealer for further details. 35.0 Nm (25.8 ft-lb) (3.57 kgf-m) EMU30272 Storing outboard motor EMU28222 Transporting and storing When storing your Yamaha outboard motor...

  • Page 43: Lubrication (Oil Injection Models)

    Seal replacement should be per- EWM00090 formed by an authorized Yamaha dealer WARNING prior to use. Do not touch or remove electrical parts Grease all grease fittings. For further de-...

  • Page 44: Cleaning And Anticorrosion Measures

    Consult your battery Wax the cowling with a non-abrasive manufacturer’s instructions. wax such as “Yamaha Silicone Wax” Procedure (Part No. ACC-11000-15-02). Disconnect and remove the battery from EMU28430 the boat. Always disconnect the black Battery care negative cable first to prevent the risk of...

  • Page 45: Cleaning The Outboard Motor

    A touch-up paint is avail- ECM00540 CAUTION: able from your Yamaha dealer. Do not leave the garden hose connector loose on the bottom cowling fitting or let the hose hang free during normal opera-...

  • Page 46: Periodic Maintenance

    If you or the owner is not famil- iar with machine servicing, this work should be done by your Yamaha dealer or other qualified mechanic. Maintenance, replacement, or repair of the emission control devices and sys- tems may be performed by any marine engine repair establishment or individual.

  • Page 47: Maintenance Chart

    Refer to the sections in this chapter for explanations of each owner-specific action. The “ ” symbol indicates the check-ups which you may carry out yourself. The “ ” symbol indicates work to be carried out by your Yamaha dealer. Initial Every 50 hours Item...

  • Page 48: Greasing

    Inspection / cleaning Cleaning / adjustment / Spark plug(s) replacement NOTE: When operating in salt water, turbid or muddy water, the engine should be flushed with clean water after each use. EMU28931 Greasing Yamaha marine grease (Water resistant grease) ZMU03879...

  • Page 49: Cleaning And Adjusting Spark Plug

    Wipe off Instead, take the outboard motor to a any dirt from the threads and screw in the Yamaha dealer. You should periodically re- spark plug to the correct torque. move and inspect the spark plug because...

  • Page 50: Inspecting Fuel Filter

    Check the fuel lines for leaks, crack, or mal- There will be fuel in the fuel filter. Keep function. If a problem is found, your Yamaha away from sparks, cigarettes, flames or dealer or other qualified mechanic should re- other sources of ignition.

  • Page 51: Inspecting Idling Speed

    The boat necessary. If any water is found in the could unexpectedly start to move, fuel, the Yamaha portable fuel tank or which could result in an accident. other fuel tanks should be checked and ECM00490 cleaned.

  • Page 52: Checking Wiring And Connectors

    Maintenance neck. If water or foreign matter collects in this EMU29153 Checking power trim and tilt system hose, consult a Yamaha dealer. EWM00430 WARNING Never get under the lower unit while it is tilted, even when the tilt support lever is locked.

  • Page 53: Checking Propeller

    Maintenance Tilt the outboard motor down. Check that the tilt rod and trim rods operate smoothly. NOTE: Consult your Yamaha dealer if any operation is abnormal. EMU29171 Checking propeller EWM00321 ZMU01897 WARNING Checkpoints You could be seriously injured if the en-...

  • Page 54: Removing The Propeller

    Tilt the outboard motor so that the gear Apply Yamaha marine grease or a cor- oil drain screw is at the lowest point pos- rosion resistant grease to the propeller sible.

  • Page 55: Cleaning Fuel Tank

    NOTE: If you have any question about properly For disposal of used oil consult your Yamaha doing this procedure, consult your dealer. Yamaha dealer. Keep away from sparks, cigarettes,...

  • Page 56: Inspecting And Replacing Anode(S)

    Install the cap and shake Inspecting and replacing anode(s) the tank. Drain the solvent completely. Yamaha outboard motors are protected from corrosion by sacrificial anodes. Inspect the external anodes periodically. Remove scales from the surfaces of the anodes. Consult a Yamaha dealer for replacement of external anodes.

  • Page 57: Checking Battery (For Electric Start Models)

    Maintenance equipment, lighted cigarettes, and so on.) DO NOT SMOKE when charging or han- dling batteries. KEEP BATTERIES AND ELECTROLYTIC FLUID OUT OF REACH OF CHILDREN. ECM00360 CAUTION: A poorly maintained battery will quickly ZMU03888 deteriorate. EMU29320 Ordinary tap water contains minerals Checking battery (for electric start harmful to a battery, and should not be models)

  • Page 58: Connecting The Battery

    Maintenance NOTE: Consult a Yamaha dealer when charging or re-charging batteries. EMU29331 Connecting the battery EWM00570 WARNING Mount the battery holder securely in a dry, well-ventilated, vibration-free loca- tion in the boat. Install a fully charged bat- tery in the holder.
  • Page 59 Maintenance marine growth. Do not use anti-fouling paint which includes copper or graphite. These paints can cause more rapid engine corrosion. ZMU01943...

  • Page 60: Trouble Recovery

    Q. Has fuel pump malfunctioned? If your outboard motor requires repair, bring A. Have serviced by a Yamaha dealer. it to your Yamaha dealer. If the engine trouble warning indicator is Q. Are spark plug(s) fouled or of incorrect flashing, consult your Yamaha dealer.
  • Page 61 Q. Is fuel contaminated or stale? A. Fill tank with clean, fresh fuel. Q. Is carburetor clogged? A. Have serviced by a Yamaha dealer. Q. Is fuel filter clogged? A. Clean or replace filter. Q. Is fuel joint connection incorrect? A.
  • Page 62 Trouble Recovery A. Have serviced by a Yamaha dealer. Q. Are weeds or other foreign matter tangled on gear housing? Q. Is load on boat improperly distributed? A. Remove foreign matter and clean lower A. Distribute load to place boat on an even unit.

  • Page 63: Temporary Action In Emergency

    Q. Is steering pivot loose or damaged? EWM00630 A. Tighten or have serviced by a Yamaha WARNING dealer. Be sure to use the specified fuse. An in-...

  • Page 64: Power Trim And Tilt Will Not Operate

    Make sure the remote control lever NOTE: is in neutral. Otherwise the boat could Consult your Yamaha dealer if the new fuse unexpectedly start to move, which immediately blows again. could result in an accident.

  • Page 65: Emergency Starting Engine

    Trouble Recovery starter mechanism or top cowling after the engine is running. Do not touch the ignition coil, spark plug wire, spark plug cap, or other elec- trical components when starting or op- erating the motor. You could get an electrical shock.

  • Page 66: Cold Engine Fails To Start

    Trouble Recovery procedure below. flywheel or other moving parts when the Remove the CDI unit cover or electrical engine is running. cover, if equipped. Adjust the trim angle so that the drive Disconnect the yellow cord (emergency shaft is at right angles to the water sur- circuit) of the CDI unit to return to port.

  • Page 67: Treatment Of Submerged Motor

    If the outboard motor is submerged, immedi- than 5 seconds, the battery will be ately take it to a Yamaha dealer. Otherwise quickly discharged, thus making it im- some corrosion may begin almost immedi- possible to start the engine.
  • Page 68 Drain the fuel from the carburetor, fuel filter, and fuel line. Feed fogging oil or engine oil through the carburetor(s) and spark plug holes while cranking with the manual starter or emergency starter rope. ZMU01911 Take the outboard motor to a Yamaha...

  • Page 69: Consumer Information

    Consumer information EMU29811 Important warranty information for U.S.A. and Canada...
  • Page 70 Consumer information...

  • Page 71: Yamaha Motor Corporation, U.s.a. Outboard Motor Two Year Limited Warranty

    Consumer information EMU29820 YAMAHA MOTOR CORPORATION, U.S.A. OUTBOARD MOTOR TWO YEAR LIMITED WARRANTY...
  • Page 72 Consumer information...
  • Page 73 Consumer information...

  • Page 74: Important Warranty Information If You Use Your Yamaha Outside U.s.a. Or Canada

    Consumer information EMU29840 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR YAMAHA OUTSIDE U.S.A. OR CANADA...
  • Page 75 Printed in Japan March 2004–0.9 × 1 ! Printed on recycled paper...
  • Page 76 (A l’usage du concessionnaire) MODÉLE ET NO. DE SÉRIE DU MOTEUR HORS-BORD (sur l’étiquette d’identification de la presse de fixation) YAMAHA DEALER NUMBER NO. DU CONCESSIONNAIRE YAMAHA DEALER NAME YAMAHA MOTOR CO., LTD. NOM DU MADE IN JAPAN CONCESSIONNAIRE PAYS D'ORIGINE JAPON USAGE...
  • Page 77 PLACE POSTAGE HERE ATTN: WARRANTY DEPARTMENT...

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