YAMAHA Marine 90AETO Manuals

Manuals and User Guides for YAMAHA Marine 90AETO. We have 1 YAMAHA Marine 90AETO manual available for free PDF download: Service Manual

YAMAHA Marine 90AETO Service Manual

YAMAHA Marine 90AETO Service Manual (204 pages)

Brand: YAMAHA Marine | Category: Outboard Motor | Size: 7.43 MB

Table of Contents

Info Chapter 1 General Information

9
- Table of Contents
  9
- Identification
  10
- Serial Number
  10
- Starting Serial Numbers
  10
- Safety While Working
  11
- Fire Prevention
  11
- Ventilation
  11
- Self-Protection
  11
- Oils, Greases and Sealing Fluids
  11
- Good Working Practices
  12
- Disassembly and Assembly
  13
- Special Tools
  14
- Measuring
  15
- Removal and Installation
  17
Table of Contents

21
- General Specification
  22
- Engine
  26
- Maintenance Specifications
  26
- Electrical
  28
- Dimension
  31
- Tightening Torque
  33
Table of Contents

35
- Anode
  36
- Maintenance Schedule
  36
- Periodic Service
  36
- Battery
  37
- Carburetor
  38
- Carburetor Link Adjustment
  38
- Cylinder Head Bolts, Engine Mounting Bolts, and Flywheel Nut
  39
- Fuel Filter
  39
- Fuel Tank and Fuel Line
  39
- Gear Oil
  40
- Idle-Speed
  40
- Ignition Timing Adjustment
  41
- Timing Plate Position Adjustment
  41
- Throttle Sensor Control Link Adjustment
  42
- Ignition Timing Adjustment
  43
- Pick-Up Timing Adjustment
  44
- Oil Injection Pump
  45
- Operational Test
  45
- Checking the Oil Level Warning System
  46
- Oil Pump Link Adjustment
  47
- POWER TRIM and TILT FLUID (PTT Model)
  47
- Propeller
  48
- Spark Plug
  48
- Greasing Points
  49
Carburetor/Oil-Injection System (Oil Injection Model)

51
- Exploded Diagram
  52
- Fuel System
  52
- Fuel Line
  53
- Cleaning and Inspection
  54
- Fuel Tank
  54
- Removal
  54
- Fuel Filter
  55
- Fuel Meter Complete
  55
- Priming Pump
  55
- Fuel Joints
  56
- Fuel Pump
  56
- Installation
  56
- Carburetor
  57
- EXPLODED DIAGRAM (Except for C60ER, C60TR, C75TR)
  57
- EXPLODED DIAGRAM (for C60ER, C60TR, C75TR)
  58
- Removal and Disassembly
  59
- Carburetor Body
  60
- Collar
  60
- Float
  60
- Inspection
  60
- Needle Valve
  60
- Pilot Screw
  60
- Electrothermal Valve
  61
- Enriching Fuel Pump
  61
- Assembly
  62
- Installation
  64
- Exploded Diagram
  65
- OIL-INJECTION SYSTEM (Oil Injection Model)
  65
- Cleaning and Inspection
  67
- Installation
  67
- Oil-Hoses
  67
- Oil-Lever Sensor
  67
- Oil-Tank
  67
- Removal
  67
Table of Contents

70
- Exploded Diagram
  72
- Preparation for Overhaul
  74
- Removal
  74
- Disassembly
  76
- Cleaning
  77
- Cylinder Head
  77
- Inspection
  77
- Cleaning
  78
- Cylinder Block
  78
- Inspection
  78
- Cleaning
  79
- Inspection
  79
- Piston
  79
- Inspection
  80
- Piston Ring
  80
- Cleaning
  81
- Crankshaft
  81
- Inspection
  81
- Piston Pin and Small End Bearing
  81
- Inspection
  82
- Reed Valve
  82
- Cleaning
  83
- Crank Main Bearing
  83
- Inspection
  83
- Thermostat
  83
- Drive Gear (Oil Injection Pump Drive)
  84
- Driven Gear (Oil Injection Pump Drive)
  84
- Inspection
  84
- Assembly and Adjustment
  85
- Bearing, Oil Seal and O-Ring
  85
- Piston and Piston Ring
  85
- Small End Bearings and Piston Assembly
  86
- CONNECTING ROD BIG END BEARING ASSEMBLY (75, 80, 90 Hp)
  87
- CRANK CYLINDER ASSEMBLY (50, 60, 70 Hp)
  88
- Oil Seal Housing
  88
- CRANK CYLINDER ASSEMBLY (75, 80, 90 Hp)
  89
- Cylinder Head and Exhaust Cover
  90
- Drainage Hose
  91
- Fuel System and Electrical System
  91
- Intake Manifold
  91
- Installation
  92
Table of Contents

93
- Exploded Diagram
  94
- Exploded Diagram (for 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)
  94
- (Except for 50Geto, C60Er, C60Tr/60Fet (Oceania), C75Tr, 90Aehd, 90Aed, C90Tr/90Aet)
  95
- Disassembly
  96
- Preparation for Removal
  96
- Bearing Housing
  102
- Claw-Washer
  102
- Gear Case
  102
- Inspection
  102
- Ring-Nut
  102
- Bearing
  103
- Gear
  103
- Impeller
  103
- OIL-SEAL HOUSING (Water Pump Housing)
  103
- Water Pump Housing
  103
- Clutch Dog and Components
  104
- Drive and Propeller Shaft
  104
- Drive Shaft Sleeve
  104
- Propeller/Trim Tab/Anode
  104
- Assembly and Adjustment
  105
- Propeller-Shaft Housing
  105
- Gear Case
  106
- For Usa and Canada
  110
- Shim Selection
  110
- Except for Usa and Canada
  115
- Measuring the Backlash
  118
- Water Pump Installation
  121
- Installation
  122
- Lower Unit Leakage Check
  124
Table of Contents

125
- Bracket Unit
  126
- BRACKET UNIT (Manual Tilt Model)
  126
- Exploded Diagram
  126
- Manual Handle
  126
- BRACKET (Short Transom)
  132
- BRACKET (Long Transom)
  133
- Anode
  134
- Bracket
  134
- Disassembly
  134
- Inspection
  134
- Removal
  134
- Trim Sensor
  134
- Assembly
  135
- Hydraulic Tilt Unit
  136
- Inspection
  136
- Power Trim and Tilt Unit
  136
- Removal
  136
- EXPLODED DIAGRAM (Short Transom [6H308])
  137
- Disassembly
  139
- Assembly
  141
- Inspection
  141
- Tilt-Rod and Trim-Rod
  141
- EXPLODED DIAGRAM (Long Transom [6H1-15], [62F-02])
  145
- Disassembly
  147
- Assembly
  149
- Inspection
  149
- Tilt-Rod and Trim-Rod
  149
- Filling with Hydraulic Fluid and Air-Bleeding
  153
- Hydraulic Fluid Pressure Test
  153
- Installation
  155
- Armature Coil
  156
- Disassembly
  156
- Inspection
  156
- Power Trim and Tilt Motor
  156
- Base Assembly
  157
- Brush
  157
- Circuit Breaker
  157
- Assembly
  158
Table of Contents

160
- Electrical Components
  162
- Electrical Wiring
  164
- Wiring Diagram
  168
- Digital Meter
  173
- Remote Control Box
  173
- Magneto Base
  174
- Removal
  174
- Electrical Analysis
  176
- Inspection
  176
- CDI System Peak Voltage
  177
- Ignition Spark Gap
  177
- Crank Position Sensor
  181
- Replacement of Spark-Plug Cap
  181
- Power Trim and Tilt Relay
  182
- Starter Relay
  182
- Trailer Switch
  183
- Fuse
  184
- Rectifier/Regulator
  184
- Fuel Enrichment Valve
  185
- Thermo Switch
  185
- OIL INJECTION SYSTEM (Oil Injection Model)
  186
- Oil-Level Sensor
  187
- Oil-Level Warning Lamp (L.e.D.)
  189
- Wiring Harness
  189
- Battery
  190
- Bracket
  190
- Engine Stop Switch
  190
- Flywheel Magneto
  191
- Installation
  191
- Main Switch (P60Th/60Fehto, P75Th/75Cehto, 90Aehd)
  191
- Neutral Switch
  191
- Disassembly
  192
- Removal
  192
- Starter Motor
  192
- Brush
  193
- Brush-Holder
  193
- Inspection
  193
- Pinion
  193
- Armature
  194
- ASSEMBLY (50, 60, 70 Hp)
  195
- ASSEMBLY (75, 80, 90 Hp)
  196
- INSTALLATION (50, 60, 70 Hp)
  196
- INSTALLATION (75, 80, 90 Hp)
  197

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