Yamaha F90TR Manuals

Manuals and User Guides for Yamaha F90TR. We have 3 Yamaha F90TR manuals available for free PDF download: Service Manual, Rigging Manual, Owner's Manual

YAMAHA F90TR 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 F90TR Rigging Manual (226 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 7.75 MB

Table of Contents

5
Propellers

59
- Propeller Specifications
  
  60
  - Propeller Types
    60
  - Propeller Identification
    62
- 2009 Propeller Applications
  
  63
- Propeller Selection
  
  63
- Wot Operation Range Table
  
  69
- Remote Controls
  
  71
  - Remote Control Applications
    72
  - Remote Switch Applications
    85
  - Remote Control Cables
    94
  - Remote Control Attachment Kit
    96
  - Steering Hook
    98
  - Steering Guide Attachment Kit
    101
  - Conventional Wire Harness
    103
  - Digital Electronic Control Wire Harness
    105
Tiller Handles

107
- 6X4 Multi-Function Tiller Handle
  
  108
- Steering Friction Contents
  
  117
Conventional Gauge (6Y5 & 6Y7)

119
- Mounting the Meters
  
  122
  - Meter Mounting Procedure
    122
  - Analog Gauge Illumination (6Y7 Type)
    122
- Analog Tachometer
  
  123
  - Analog Tachometer Applications
    123
  - Analog Tachometer Dimensions
    124
  - Pole Number Set up
    124
- Digital Tachometer
  
  125
  - Digital Tachometer Applications
    125
  - Digital Tachometer Dimensions
    125
  - Pole Number Set up
    126
- Speedometer
  
  127
  - Speedometer Applications
    127
  - Speedometer Dimensions
    128
  - Water Pressure Damper (Op)
    128
  - Speedometer Tube Routing
    129
  - Digital Speedometer Set up
    129
- Fuel Management Gauge
  
  130
  - Fuel Management Gauge Applications
    130
  - Fuel Management Gauge Dimensions
    131
  - Fuel Sender Installation
    132
  - Wiring Description
    133
  - Fuel Management Gauge Set up
    135
  - Fuel Mgt Gauge with Speedometer Set up
    135
- Analog Trim Meter
  
  136
  - Analog Trim Meter Applications
    136
  - Analog Trim Meter Dimensions
    136
  - Trim Sender Adjustment
    136
- Coolant Pressure Meter
  
  137
  - Coolant Pressure Meter Applications
    137
  - Coolant Pressure Meter Dimensions
    137
- Coolant Temp. Meter
  
  138
- Hour Meter
  
  144
  - Hour Meter Applications
    144
  - Wiring the Mechanical Hour Meter
    145
  - Wiring the Digital Hour Meter
    145
- Voltage Meter
  
  146
  - Voltage Meter Applications
    146
  - Voltage Meter Dimensions
    146
  - Wiring the Voltage Meter
    146
- Fuel Meter
  
  147
  - Fuel Meter Applications
    147
  - Fuel Meter Dimensions
    147
- Charge Warning Unit
  
  148
  - Charge Warning Unit Applications
    148
- Wire Harnesses
  
  149
  - Remote-Oil Tank Harness
    149
  - Additional Accessory Lead
    149
  - Meter Harness
    150
  - Lamp Switch
    151
  - Combination Trim and Oil Lead 1
    151
  - Combination Trim and Oil Lead 2
    151
  - Trim Meter Lead
    151
  - Pt/T Switch Lead Extension
    152
  - Trim and Oil Lead
    152
  - Fuel Management Gauge Harness
    152
  - Lighting Coil Extension Harness
    152
  - Rectifier Kit
    152
- Wiring Diagrams
  
  153
  - Wire Color Code
    153
  - Digital Meter
    154
  - Analog Meter (6Y7)
    159
  - Interchangeability between Tachometer and Engine
    161
  - Grommet Description
    164
Digital Network Gauge (6Y8)

167
- Digital Network Gauge Compatible Model
  
  168
- Digital Network Gauge Application
  
  168
  - Square Style Gauge Application
    168
- Digital Network Gauge Dimensions
  
  169
  - Round Style Gauge Application
    169
  - Square Style Gauge Dimensions
    169
  - Round Style Gauge Dimensions
    170
- Optional Equipments
  
  171
  - Multi-Sensor Application
    171
  - Fitting Plate
    171
  - Speed Sensor Kit
    172
  - Coolant Pressure Sensor Kit
    172
- Wire Harness
  
  173
  - Main Bus Wire
    173
  - Pigtail Bus Wire
    173
  - Fuel Tank / Gps Wire
    174
  - Hub
    174
- Wiring Diagrams
  
  175
  - FUEL INJECTED F50-F250 [Mechanical RC] & HPDI ENGINES
    175
  - F350/F300/F250 [Digital Electronic Control]
    178
- Initial Gauge Setup
  
  183
- Troubleshooting
  
  184
- Basic Requirements
  
  185
- Nmea0183 Compatible Equipments Connection
  
  185
Battery

187
- Recommended Battery
  
  188
- Battery Cable Length
  
  189
- Battery Wiring
  
  190
Appendix

195
- Model Name Designation
  
  196
  - Us & Canada Model Identification
    197
  - New Us & Canada Model Identification Code
    197
- Fuel System Vacuum Pressure Standard
  
  198
  - Fuel Hose Routing Resistance Measuring Method
    198
  - Lowest Vacuum Pressure Standard
    199
- Portable Fuel Tanks (Typical)
  
  200
- Fuel Pipes (Typical)
  
  200
- Pre-Delivery Inspection (Pdi) Checks
  
  201
- Conventional Rigging Kit Contents
  
  202
  - Digital Tachometer Kit
    202
  - Digital Tachometer and Speedometer Kit
    202
  - Twin-Motor Kit
    203
  - Remote Oil Tank Kit (for 2-Stroke Engine)
    204
- Digital Network Gauge Rigging Kit Contents
  
  205
- 2009 Manufacturing Start Serial Number
  
  219

Yamaha F90TR Owner's Manual (102 pages)

Brand: Yamaha | Category: Outboard Motor | Size: 4.8 MB

Table of Contents
4
Safety Information
7
Outboard Motor Safety
7
Propeller
7
Rotating Parts
7
Hot Parts
7
Electric Shock
7
Power Trim and Tilt
7
Engine Shut-Off Cord (Lanyard)
7
Gasoline
7
Gasoline Exposure and Spills
7
Carbon Monoxide
8
Modifications
8
Boating Safety
8
Alcohol and Drugs
8
Personal Flotation Devices
8
People in the Water
8
Passengers
8
Overloading
8
Avoid Collisions
8
Weather
9
Accident Reporting
9
Boat Education and Training
9
Passenger Training
9
Boating Safety Publications
9
Laws and Regulations
10
Boating Organizations
10
Basic Boating Rules (Rules of the Road)
10
Steering and Sailing Rules and Sound Signals
10
Rules When Encountering Vessels
11
Other Special Situations
12
General Information
15
Identification Numbers Record
15
Outboard Motor Serial Number
15
Key Number
15
Read Manuals and Labels
16
Warning Labels
16
Specifications and Requirements
19
Specifications
19
Installation Requirements
20
Boat Horsepower Rating
20
Mounting Motor
20
Remote Control Requirements
20
Battery Requirements
21
Specifications of Battery
21
Mounting Battery
21
Propeller Selection
21
Start-In-Gear Protection
22
Engine Oil Requirements
22
Fuel Requirements
23
Gasoline
23
Ring Free Fuel Additive
23
Muddy or Acidic Water
23
Anti-Fouling Paint
24
Motor Disposal Requirements
24
Emergency Equipment
24
Emission Control Information
24
North American Models
24
Star Labels
25
Components
27
Components Diagram
27
Remote Control Box
28
Remote Control Lever
29
Neutral Interlock Trigger
29
Neutral Throttle Lever
29
Tiller Handle
29
Gear Shift Lever
30
Throttle Grip
30
Throttle Indicator
30
Throttle Friction Adjuster
30
Engine Shut-Off Cord (Lanyard) and Clip
31
Engine Stop Button
31
Main Switch
32
Steering Friction Adjuster
32
Power Trim and Tilt Switch on Remote Control or Tiller Handle
32
Power Trim and Tilt Switch on Bottom Engine Cowling
33
Variable Trolling RPM Switches
33
Trim Tab with Anode
34
Tilt Support Lever for Power Trim and Tilt Model
34
Top Cowling Lock Lever (Pull up Type)
35
Flushing Device
35
Fuel Filter/Water Separator
35
Alert Indicator
36
Instruments and Indicators
37
Indicators
37
Low Oil Pressure-Alert Indicator
37
Overheat-Alert Indicator
37
Digital Tachometer
37
Tachometer
38
Trim Meter
38
Hour Meter
38
Low Oil Pressure-Alert Indicator
38
Overheat-Alert Indicator
39
Digital Speedometer
39
Speedometer
39
Fuel Gauge
39
Trip Meter / Clock / Voltmeter
40
Fuel Level-Alert Indicator
41
Low Battery Voltage-Alert Indicator
41
Command Link Multifunction Meters
41
Command Link Multifunction Tachometers
41
Start-Up Checks
42
Low Oil Pressure-Alert
42
Overheat Alert
43
Water Separator Alert
43
Engine Trouble Alert
44
Low Battery Voltage-Alert
44
Command Link Multifunction Speed & Fuel Meters
45
Command Link Multifunction Speedometers
46
Command Link Multifunction Fuel Management Meters
46
Engine Control System
48
Alert System
48
Overheat Alert
48
Low Oil Pressure Alert
48
Installation
50
Mounting the Outboard Motor
50
Operation
52
First-Time Operation
52
Fill Engine Oil
52
Breaking in Engine
52
Getting to Know Your Boat
52
Checks before Starting Engine
52
Fuel Level
53
Remove Cowling
53
Fuel System
53
Controls
54
Engine Shut-Off Cord (Lanyard)
54
Engine Oil
54
Engine
55
Flushing Device
55
Install Cowling
55
Power Trim and Tilt System
56
Battery
56
Filling Fuel
56
Operating Engine
57
Feeding Fuel
57
Starting Engine
57
Checks after Starting Engine
60
Cooling Water
60
Warming up Engine
60
Electric Start Models
60
Checks after Engine Warm-Up
61
Shifting
61
Stop Switches
61
Stopping Boat
62
Trolling
62
Adjusting Trolling Speed
62
Stopping Engine
63
Procedure
63
Trimming Outboard Motor
64
Adjusting Trim Angle (Power Trim and Tilt)
64
Adjusting Boat Trim
65
Tilting up and down
66
Procedure for Tilting up (Power Trim and Tilt Models)
66
Procedure for Tilting down (Power Trim and Tilt Models)
68
Shallow Water
68
Power Trim and Tilt Models
68
Cruising in Other Conditions
69
Maintenance
70
Transporting and Storing Outboard Motor
70
Storing Outboard Motor
70
Procedure
71
Lubrication
72
Cleaning and Anticorrosion Measures
72
Flushing Power Unit
72
Cleaning the Outboard Motor
73
Checking Painted Surface of Motor
73
Periodic Maintenance
73
Replacement Parts
74
Maintenance Interval Guidelines
74
Maintenance Chart 1
75
Maintenance Chart 2
77
Greasing
78
Cleaning and Adjusting Spark Plug
79
Changing Engine Oil
79
Checking Wiring and Connectors
81
Checking Propeller
81
Removing Propeller
82
Installing Propeller
82
Changing Gear Oil
83
Inspecting and Replacing Anode(S)
84
Checking Battery (for Electric Start Models)
84
Connecting the Battery
85
Disconnecting the Battery
85
Trouble Recovery
86
Troubleshooting
86
Temporary Action in Emergency
89
Impact Damage
89
Replacing Fuse
89
Power Trim and Tilt will Not Operate
90
Water Separator-Alert Indicator Blinks While Cruising
90
Starter will Not Operate
92
Emergency Starting Engine
93
Treatment of Submerged Motor
94
Consumer Information
95
Important Warranty Information for U.S.A. and Canada
95
Yamaha Motor
97
Four-Stroke Outboard
97
Limited Warranty
97
Important Warranty Information if You Use Your Yamaha Outside the Usa or Canada
99

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Yamaha F90TR Manuals

YAMAHA F90TR 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 F90TR Rigging Manual (226 pages)

Table of Contents

Table of Contents