Professional Documents
Culture Documents
90D
OWNER’S MANUAL
U.S.A.Edition
Printed in Japan LIT-18626-05-86
March 2004–0.9 × 1 ! Printed on recycled paper
6H1-28199-14
6H1-28199-14_Hyoshi 3/10/04 10:40 AM Page 2
EMU25060
ZMU01690
Read this owner’s manual carefully before operating your outboard motor.
Important manual information
EMU25100
al, please consult your Yamaha dealer.
To the owner NOTE:
Thank you for choosing a Yamaha outboard The 90TR and the standard accessories are
motor. This Owner’s Manual contains infor- used as a base for the explanations and illus-
mation needed for proper operation, mainte- trations in this manual. Therefore some
nance and care. A thorough understanding items may not apply to every model.
of these simple instructions will help you ob-
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. 90D
In this Owner’s Manual particularly important OWNER’S MANUAL
information is distinguished in the following ©2004 by Yamaha Motor Corporation, USA
1st edition, March 2004
ways.
All rights reserved.
Any reprinting or unauthorized use
The Safety Alert Symbol means without the written permission of
ATTENTION! BECOME ALERT! YOUR Yamaha Motor Corporation, USA
SAFETY IS INVOLVED! is expressly prohibited.
EWM00780 Printed in Japan
P/N LIT-18626-05-86
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 out-
board motor.
ECM00700
CAUTION:
A CAUTION indicates special precautions
that must be taken to avoid damage to the
outboard motor.
NOTE:
A NOTE provides key information to make
procedures easier or clearer.
1. Key number
EMU25220
EMU25190
Key number
If a main key switch is equipped with the mo-
ZMU04695
tor, the key identification number is stamped
on your key as shown in the illustration.
Record this number in the space provided for
1
General information
● Before operating the boat, read any own-
er’s or operator’s manuals supplied with it
EMISSION CONTROL INFORMATION
and all labels. Be sure you understand
ENGINE FAMILY :
THIS ENGINE CONFORMS TO 2001 U.S. EPA REGULATIONS FOR MARINE SI ENGINES.
each item before operating.
REFER TO THE OWNERS MANUAL FOR MAINTENANCE SPECIFICATIONS AND ADJUSTMENTS.
FELs : g/kw-hr IDLE SPEED : rpm IN NEUTRAL ● Do not overpower the boat with this out-
SPARK PLUG : SPARK PLUG GAP (mm) :
DISPLACEMENT : cm 3 FUEL : GASOLINE board motor. Overpowering the boat could
ADVERTISED POWER : kw VALVE LASH (mm) : IN EX
result in loss of control. The rated power of
the outboard should be equal to or less
than the rated horsepower capacity of the
ZMU04304
boat. If the rated horsepower capacity of
EMU25261 the boat is unknown, consult the dealer or
Manufactured date label boat manufacturer.
This label is attached to the clamp bracket or ● Do not modify the outboard. Modifications
the swivel bracket. could make the motor unfit or unsafe to
use.
● Never operate after drinking alcohol or tak-
ing drugs. About 50% of all boating fatali-
ties involve intoxication.
● Have an approved personal flotation de-
vice (PFD) on board for every occupant. It
is a good idea to wear a PFD whenever
boating. At a minimum, children and non-
swimmers should always wear PFDs, and
ZMU04696
everyone should wear PFDs when there
are potentially hazardous boating condi-
tions.
● Gasoline is highly flammable, and its va-
pors are flammable and explosive. Handle
and store gasoline carefully. Make sure
there are no gas fumes or leaking fuel be-
fore starting the engine.
● This product emits exhaust gases which
contain carbon monoxide, a colorless,
odorless gas which may cause brain dam-
EMU25361 age or death when inhaled. Symptoms in-
clude nausea, dizziness, and drowsiness.
Safety information Keep cockpit and cabin areas well ventilat-
● Before mounting or operating the outboard ed. Avoid blocking exhaust outlets.
motor, read this entire manual. Reading it ● Check throttle, shift, and steering for prop-
should give you an understanding of the er operation before starting the engine.
motor and its operation. ● Attach the engine stop switch lanyard cord
2
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. 155 N. Michigan Ave.
● Know the marine laws and regulations Chicago, Il 60601
where you will be boating—and obey EMU25380
3
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. tion and collision, and to any special circum-
The rules presented here in your Owner’s stances, which may render a departure from
Manual are condensed, and have been pro- the above rules necessary in order to avoid
vided for your convenience only. Consult immediate danger.”
your local U.S. Coast Guard Auxiliary or De- In other words, follow the standard rules ex-
partment of Motor Vehicles for a complete cept when a collision will occur unless both
set of rules governing the waters in which vessels try to avoid each other. If that is the
you will be using your boat. case, both vessels become “Give-Way” ves-
EMU25510
sels.
Steering and sailing rules and sound EMU25520
4
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. You must stay out of its
an accident. You should keep the other ves- way until you are clear of it. Likewise, if an-
sel on your port (left) side. This rule doesn’t other vessel is passing you, you should
apply if both of you will clear one another if maintain your speed and direction so that the
you continue on your set course and speed. other vessel can steer itself around you.
EMU25530
5
General information
the power-driven vessel, the power-driv-
en vessel has the right-of-way.
2. Sailing vessels should keep clear of any
fishing vessel.
3. 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.
Reading buoys and other markers
The waters of the United states are marked
for safe navigation by the lateral system of
buoyage. Simply put, buoys and markers
have an arrangement of shapes, colors,
numbers and lights to show which side of the
buoy a boater should pass on when navigat-
ing in a particular direction. The markings on
these buoys are oriented from the perspec-
tive of being entered from seaward (the boat-
er is going towards the port). This means that
red buoys are passed on the starboard
(right) side when proceeding from open wa-
ter into port, and black buoys are to port (left)
side. When navigating out of port, your posi-
tion with respect to the buoys should be re-
versed; red buoys should be to port and
black buoys to starboard.
Many bodies of water used by boaters are
entirely within the boundaries of a particular
state. The Uniform State Waterway Marking
System has been devised for these waters.
This system uses buoys and signs with dis-
tinctive shapes and colors to show regulato-
ry or advisory information. These markers
are white with black letters and orange
boarders. They signify speed zones, restrict-
ed areas, danger areas, and general infor-
mation.
Remember, markings may vary by geo-
graphic location. Always consult local boat-
ing authorities before driving your boat in
unfamiliar waters.
6
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. If gaso-
● Do not smoke when refueling, and keep line spills, wipe it up immediately with
7
General information
dry rags. EMU25650
8
General information
speed is too high or too low for good engine For instructions on propeller removal and in-
performance, this will have an adverse effect stallation, see page 48.
on the engine. EMU25770
x -
1 2 3
ZMU04606
NOTE:
Select a propeller which will allow the engine
to reach the middle or upper half of the oper-
ating range at full throttle with the maximum
boat load. If operating conditions such as
light boat loads then allow the engine r/min to
rise above the maximum recommended
range, reduce the throttle setting to maintain
the engine in the proper operating range.
9
Basic components
EMU25795
Main components
NOTE:
* May not be exactly as shown; also may not be included as standard equipment on all mod-
els.
90D
13 14
1
12
11 2
10
15 16
9
8
17
7
6 3
4
5
ZMU03850
10
Basic components
licensing or approval authority regula-
tions.
4
3 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. Engine stop lanyard switch
4. Air vent screw 7. Throttle friction adjuster
EMU25830
EMU26190
Fuel joint Remote control lever
This joint is used to connect the fuel line. Moving the lever forward from the neutral po-
EMU25841
sition engages forward gear. Pulling the le-
Fuel gauge
ver back from neutral engages reverse. The
This gauge is located on either the fuel tank
engine will continue to run at idle until the le-
cap or on the fuel joint base. It shows the ap-
ver is moved about 35° (a detent can be felt).
proximate amount of fuel remaining in the
Moving the lever farther opens the throttle,
tank.
EMU25850
and the engine will begin to accelerate.
Fuel tank cap
This cap seals the fuel tank. When removed,
the tank can be filled with fuel. To remove the
cap, turn it counterclockwise.
EMU25860
Remote control
The remote control lever actuates both the
1. Neutral “ ”
shifter and the throttle. The electrical switch-
2. Forward “ ”
es are mounted on the remote control box.
3. Reverse “ ”
4. Shift
5. Fully closed
11
Basic components
6. Throttle
7. Fully open
EMU26201
1. Fully open
2. Fully closed
EMU25970
12
Basic components
EMU25990
13
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.
som. Pressing the switch “ ” (up) trims the
outboard motor up, then tilts it up. Pressing
the switch “ ” (down) tilts the outboard mo-
tor down and trims it down. When the switch
is released, the outboard motor will stop in its
current position.
NOTE:
For instructions on using the power trim and
tilt switch, see pages 30 and 32.
ZMU03851
NOTE:
For instructions on using the power trim and
tilt switch, see page 32.
EMU26240
14
Basic components
protect the engine from electrochemical
corrosion. Never paint the trim tab as it
will become ineffective as an anode.
ZMU03853
EMU26372
ZMU03854
ZMU03852
EMU26340
15
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.
hose and tap water.
NOTE:
For details on usage, see page 39.
1
2
3
1
5 4
6 7 ZMU01891
1. Tachometer
ZMU03857 2. Trim meter
3. Hour meter
1. Flushing device 4. Oil level indicator
5. Overheat warning indicator
EMU26470
6. Set button
Tachometer 7. Mode button
This gauge shows the engine speed and has
the following functions. EMU26540
CAUTION:
Do not operate the engine without oil. Se-
2 rious engine damage will occur.
ZMU04577
1. Tachometer
2. Oil level indicator
EMU26490
Digital tachometer
The tachometer shows the engine speed
and has the following functions.
16
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.
1
ZMU04580
EMU26550 1
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. For fur-
ther information, see page 19. 1. Overheat warning indicator
ECM00030
EMU26610
CAUTION:
Trim meter
Do not operate the engine without oil. Se- This gauge shows the trim angle of your out-
rious engine damage will occur. board motor.
1 ZMU04581
ZMU01867
17
Basic components
board motor. ● Total hours→Trip hours→Display off
NOTE: ● Resetting the trip hours
● Memorize the trim angles that work best ● Simultaneously pressing the “ ” (set)
for your boat under different conditions. and “ ” (mode) buttons for more than
Adjust the trim angle to the desired using 1 second while the trip hours are displayed
the power trim and tilt switch. resets the trip counter to 0 (zero).
● If the trim angle of your motor exceeds the NOTE:
trim operating range, the top segment on The total number of hours the engine has
the trim meter display will blink. been run cannot be reset.
EMU26801
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
ZMU01869 Overheat warning
EMU26650 This engine has an overheat warning device.
Hour meter (digital type) If the engine temperature rises too high, the
This meter shows the number of hours the warning device will activate.
engine has been run. It can be set to show Activation of warning device
the total number of hours or the number of ● The engine speed will automatically de-
hours for the current trip. The display can crease to about 2000 r/min.
also be turned on and off. ● The overheat warning indicator will light (if
ZMU01870
18
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
ZMU04766
ZMU03942
ZMU03858
ZMU03025
EMU26843
Oil level warning and oil filter If the warning system has been activated,
clogging warning stop the engine and check for the cause.
Oil injection models
This engine has an oil level warning system.
19
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
20
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. Observe the following:
such as transom ladders or depth finder
● For permanently mounted models, your
transducers) can create airborne water
dealer or other person experienced in
spray while the boat is cruising. Severe
proper rigging should mount the motor.
engine damage may result if the motor is
If you are mounting the motor yourself,
operated continuously in the presence of
you should be trained by an experi-
airborne water spray.
enced person.
NOTE: ● For portable models, your dealer or oth-
During water testing check the buoyancy of er person experienced in proper out-
the boat, at rest, with its maximum load. board motor mounting should show
Check that the static water level on the ex- you how to mount your motor.
haust housing is low enough to prevent wa-
Mount the outboard motor on the center line
ter entry into the powerhead, when water
(keel line) of the boat, and ensure that the
rises due to waves when the outboard is not
boat itself is well balanced. Otherwise the
running.
boat will be hard to steer. For boats without
EMU26910 a keel or which are asymmetrical, consult
Mounting the outboard motor your dealer.
EWM00820
WARNING
● Overpowering a boat could cause se-
vere instability. Do not install an out-
board motor with more horsepower
than the maximum rating on the capac-
ity plate of the boat. If the boat does not
have a capacity plate, consult the boat
manufacturer.
● The information presented in this sec- 1 ZMU01760
21
Operation
motor greatly affects the water resistance. If life.
the mounting height is too high, cavitation ECM00140
ZMU01762
1. : Gasoline
NOTE: 2. : Engine oil
● The optimum mounting height of the out-
board motor is affected by the boat/motor ECM00150
22
Operation
throttle to 3000 r/min or less. are tight (if equipped Yamaha fuel tank or
3. 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). not twisted or flattened, or likely to contact
Vary engine speed occasionally. Run at sharp objects (if equipped Yamaha fuel
full throttle for one minute, then allow tank or boat tank).
about 10 minutes of operation at three- EMU27120
23
Operation
3. Watch for oil flowing through the oil feed EMU27311
pipes. After any air in the oil lines has Filling oil for electric start models
EWM00530
been expelled, the oil injection system
WARNING
should supply oil normally. If no oil is
flowing after 10 minutes of idling, consult Do not add gasoline into the oil tank. Fire
your Yamaha dealer. or explosion could result.
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.
Simply pour gasoline into the fuel tank and
oil into the oil tank. Convenient indicator seg-
ments indicate the status of the oil supply.
For details on reading the indicator seg-
ments, see page 26.
ZMU03367
To fill the engine oil tank, proceed as follows:
ECM00130
WARNING
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other ZMU03369
sources of ignition.
2. Open the oil tank filler cap by pulling the
1. Remove the fuel tank cap. tab on the cap.
2. Fill the fuel tank carefully.
3. Close the cap securely after refueling.
Wipe up any spilled fuel.
24
Operation
ZMU03370
2
1
ZMU03371
25
Operation
EMU27321
26
Operation
from the fuel tank.
ZMU02295
Starting engine
EMU27662
ZMU03869
NOTE:
The start-in-gear protection device prevents
the engine from starting except when in neu-
tral.
ZMU02024
2. Attach the engine stop switch lanyard to
a secure place on your clothing, or your
3. If a steering friction adjuster is provided arm or leg. Then install the lock plate on
on your outboard motor, securely attach the other end of the lanyard into the en-
the fuel line to the fuel line clamp. gine stop switch.
EWM00120
NOTE:
During engine operation place the tank hori- WARNING
zontally, otherwise fuel cannot be drawn ● Attach the engine stop switch lanyard
27
Operation
to a secure place on your clothing, or turn to “ ” (on).
your arm or leg while operating. ECM00191
NOTE:
● When the engine is cold, it needs to be
warmed up. For further information, see
page 28.
● If the engine is warm and fails to start,
open the throttle slightly and try to start the
engine again. If the engine still fails to
3. Turn the main switch to “ ” (on). start, see page 55.
4. Turn the main switch to “ ” (start), EMU27670
and hold it for a maximum of 5 seconds. Warming up engine
EMU27701
CAUTION:
A flow of water from the hole on the ex-
5. Immediately after the engine starts, re- haust cover shows that the water pump is
lease the main switch and allow it to re- pumping water through the cooling pas-
sages. If water is not flowing out of the
hole at all times while the engine is run-
28
Operation
ning, overheating and serious damage equipped) and move the remote control
could occur. Stop the engine and check lever quickly and firmly from neutral to
whether the cooling water inlet on the forward.
lower case or the cooling water pilot hole
is blocked. Consult your Yamaha dealer if
the problem cannot be located and cor-
rected.
EMU27784
29
Operation
ZMU02301
EMU27820
4. 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. the engine stop switch, then turning the main
EMU27844
switch to “ ” (off).
Procedure
1. Push and hold the engine stop button or EMU27861
WARNING
Excessive trim for the operating condi-
ZMU03870
tions (either trim up or trim down) can
3. Tighten the air vent screw on the fuel cause boat instability and can make
tank cap (if equipped). steering the boat more difficult. This in-
creases the possibility of an accident. If
the boat begins to feel unstable or is hard
to steer, slow down and/or readjust the
trim angle.
30
Operation
Adjust the outboard motor trim angle using
the power trim and tilt switch.
UP
DN
1
ZMU03110
1
ZMU03109 UP
DN
1. Trim operating angle
EMU27881
31
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. Compen- also makes the boat unstable. Resistance at
sate for this as you steer. The trim tab can the bow is greatly increased, heightening the
also be adjusted to help offset this effect. danger of “bow steering” and making opera-
When the bow of the boat is down, it is easier tion difficult and dangerous.
to accelerate from a standing start onto
plane.
NOTE:
Depending on the type of boat, the outboard
Bow Up motor trim angle may have little effect on the
Too much trim-out puts the bow of the boat trim of the boat when operating.
too high in the water. Performance and econ-
EMU27931
omy are decreased because the hull of the
boat is pushing the water and there is more
Tilting up and down
air drag. Excessive trim-out can also cause If the engine will be stopped for some time or
the propeller to ventilate, which reduces per- if the boat is moored in shallows, the out-
formance further, and the boat may “por- board motor should be tilted up to protect the
poise” (hop in the water), which could throw propeller and casing from damage by colli-
the operator and passengers overboard. sion with obstructions, and also to reduce
salt corrosion.
EWM00220
WARNING
Be sure all people are clear of the out-
board motor when tilting up and down,
also be careful not to pinch any body
parts between the drive unit and engine
bracket.
EWM00250
WARNING
Bow Down Leaking fuel is a fire hazard. If there is a
Too much trim-in causes the boat to “plow” fuel joint on the outboard motor, discon-
32
Operation
nect the fuel line or close the fuel cock if 3. 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.
ECM00241
CAUTION:
● Before tilting the outboard motor, stop
the engine by following the procedure
on page 30. Never tilt the outboard mo-
tor while the engine is running. Severe
damage from overheating can result.
● Do not tilt up the engine by pushing the
tiller handle (if equipped) because this
could break the handle.
EMU28004
ZMU03872
ZMU03196
ZMU03115
EWM00260
WARNING
After tilting the outboard motor, be sure
ZMU03873 to support it with the tilt support knob or
tilt support lever. Otherwise the outboard
33
Operation
motor could fall back down suddenly if oil
in the power trim and tilt unit loses pres-
sure.
5. Models equipped with trim rods: Once
the outboard motor is supported with the
tilt support lever, press the power trim
and tilt switch “ ” (down) to retract the
trim rods.
ECM00250
ZMU03875
CAUTION:
Be sure to retract the trim rods complete- 3. Push the power tilt / power trim and tilt
ly during mooring. This protects the rods switch “ ” (down) to lower the outboard
from marine growth and corrosion which motor to the desired position.
could damage the power trim and tilt
mechanism.
UP
DN
DN
ZMU01936
ZMU03874
EMU28052
34
Operation
to allow operation in shallow water.
EWM00660
WARNING
UP UP
● Place the gear shift in neutral before DN
35
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: Min. reserve capacity (RC/SAE):
1540 mm (60.6 in) 124 minutes
Transom height L: Alternator output for battery DC:
520 mm (20.5 in) 10.0 A
Transom height X: Drive unit:
647 mm (25.5 in) Gear positions:
Weight (without propeller) L: Forward-neutral-reverse
119.0 kg (262 lb) Gear ratio:
Performance: 2.00 (26/13)
Full throttle operating range: Trim and tilt system:
4500–5500 r/min Power trim and tilt
Maximum output: Propeller mark:
66.2 kW@5000 r/min (90 HP@5000 K
r/min) Fuel and oil:
Idling speed (in neutral): Recommended fuel:
800 ±50 r/min Regular unleaded gasoline
Engine: Min. pump octane:
Type: 86
2-stroke L Recommended engine oil:
Displacement: YAMALUBE 2-stroke outboard motor
1140.0 cm3 (69.56 cu.in) oil
Bore × stroke: Lubrication:
82.0 × 72.0 mm (3.23 × 2.83 in) Oil injection
Ignition system: Engine oil tank capacity:
CDI (micro computer) 3.3 L (3.49 US qt) (2.90 Imp.qt)
Spark plug (NGK): Recommended gear oil:
B8HS-10 Hypoid gear oil SAE#90
Spark plug with resistor (NGK): Gear oil quantity:
BR8HS-10 610.0 cm3 (20.62 US oz) (21.51
Spark plug gap: Imp.oz)
0.9–1.0 mm (0.035–0.039 in) Tightening torque for engine:
Control system: Spark plug:
36
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
37
Maintenance
cover/cap. Remove the propeller. when starting or during operation.
4. Install the flushing attachment over the ● Keep hands, hair, and clothes away
cooling water inlet. from the flywheel and other rotating
ECM00300
parts while the engine is running.
CAUTION:
6. Run the engine at a fast idle for 10–15
Do not run the engine without supplying
minutes in neutral position while supply-
it with cooling water. Either the engine
ing fresh water.
water pump will be damaged or the en-
7. Just prior to turning off the engine, quick-
gine will be damaged from overheating.
ly spray “Yamaha Stor-Rite Engine
Before starting the engine, be sure to
Fogging Oil” (Part No. LUB-STRRT-12-
supply water to the cooling water passag-
00) alternately into each carburetor/
es.
each intake manifold. When properly
ECM00310
done, the engine will smoke excessively
CAUTION: and almost stall.
Avoid running the outboard motor at high 8. Remove the flushing attachment and
speed while on the flushing attachment, wipe off any excess water.
otherwise overheating could occur. 9. Install the silencer cover/cap and top
cowling. Install the propeller.
NOTE:
A flushing attachment is available from your
Yamaha dealer.
EMU28410
38
Maintenance
EMU28421
equipment, lighted cigarettes, and so
Cleaning and anticorrosion on.)
measures ● DO NOT SMOKE when charging or han-
1. Wash down the exterior of the outboard dling batteries.
motor with fresh water and dry off com- KEEP BATTERIES AND ELECTROLYTIC
pletely. FLUID OUT OF REACH OF CHILDREN.
2. Spray the outboard motor exterior with
Batteries vary among manufacturers. There-
“Yamaha Silicone Protectant” (Part No.
fore the following procedures may not al-
LUB-SILCNE-13-00).
ways apply. Consult your battery
3. Wax the cowling with a non-abrasive
manufacturer’s instructions.
wax such as “Yamaha Silicone Wax”
Procedure
(Part No. ACC-11000-15-02).
EMU28430 1. Disconnect and remove the battery from
Battery care the boat. Always disconnect the black
EWM00330 negative cable first to prevent the risk of
WARNING shorting.
Battery electrolytic fluid is dangerous; it 2. Clean the battery casing and terminals.
contains sulfuric acid and therefore is Fill each cell to the upper level with dis-
poisonous and highly caustic. tilled water.
Always follow these preventive mea- 3. Store the battery on a level surface in a
sures: cool, dry, well-ventilated place out of di-
● Avoid bodily contact with electrolytic rect sunlight.
fluid as it can cause severe burns or 4. Once a month, check the specific gravity
permanent eye injury. of the electrolyte and recharge as re-
● Wear protective eye gear when han- quired to prolong battery life.
EMU28440
dling or working near batteries.
Antidote (EXTERNAL): Flushing power unit
● SKIN - Flush with water.
Perform this procedure right after operation
● EYES - Flush with water for 15 minutes
for the most thorough flushing.
and get immediate medical attention. 1. After shutting off the engine, unscrew
Antidote (INTERNAL): the garden hose connector from the fit-
● Drink large quantities of water or milk
ting on the bottom cowling.
followed by milk of magnesia, beaten
egg, or vegetable oil. Get immediate
medical attention.
Batteries also generate explosive hydro-
gen gas; therefore, you should always
follow these preventive measures:
● Charge batteries in a well-ventilated ar-
ea.
● Keep batteries away from fire, sparks,
or open flames (for example: welding
39
Maintenance
instead of cooling the engine, which can
1 cause serious overheating. Be sure the
connector is tightened securely on the fit-
ting after flushing the engine.
NOTE:
● When flushing the engine with the boat in
3 2 the water, tilting up the outboard motor un-
til it is completely out of the water will
achieve better results.
● For cooling system flushing instructions,
see page 37.
EMU28450
ZMU04697
1. Fitting
2. Garden hose connector
3. Garden hose
40
Maintenance
EMU28483
Periodic maintenance
EWM01070
WARNING
Be sure to turn off the engine when you
perform maintenance unless otherwise
specified. 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.
All warranty repairs, however, including
those to the emission control system,
must be performed by an authorized
Yamaha marine dealership.
A service manual is available for purchase
through your Yamaha dealer for owners who
have the mechanical skills, tools, and other
equipment necessary to perform mainte-
nance not covered by this owner’s manual.
EMU28510
Replacement parts
If replacement parts are necessary, use only
genuine Yamaha parts or parts of the same
type and of equivalent strength and materi-
als. Any part of inferior quality may malfunc-
tion, and the resulting loss of control could
endanger the operator and passengers.
Yamaha genuine parts and accessories are
available from your Yamaha dealer.
41
Maintenance
EMU28521
Maintenance chart
Frequency of maintenance operations may be adjusted according to the operating condi-
tions, but the following table gives general guidelines. 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
42
Maintenance
Initial Every
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)
90D
ZMU03879
43
Maintenance
EMU28951
WARNING
When removing or installing a spark plug,
be careful not to damage the insulator. A
damaged insulator could allow external
sparks, which could lead to explosion or
fire.
The spark plug is an important engine com-
ponent and is easy to inspect. The condition 1. Spark plug gap
of the spark plug can indicate something 2. Spark plug I.D. mark (NGK)
about the condition of the engine. For exam-
ple, if the center electrode porcelain is very Spark plug gap:
white, this could indicate an intake air leak or 0.9–1.0 mm (0.035–0.039 in)
carburetion problem in that cylinder. Do not
attempt to diagnose any problems yourself. When fitting the plug, always clean the gas-
Instead, take the outboard motor to a ket surface and use a new gasket. Wipe off
Yamaha dealer. You should periodically re- any dirt from the threads and screw in the
move and inspect the spark plug because spark plug to the correct torque.
heat and deposits will cause the spark plug
Spark plug torque:
to slowly break down and erode. If electrode
25.0 Nm (18.4 ft-lb) (2.55 kgf-m)
erosion becomes excessive, or if carbon and
other deposits are excessive, you should re-
NOTE:
place the spark plug with another of the cor-
If a torque-wrench is not available when you
rect type.
are fitting a spark plug, a good estimate of
Standard spark plug: the correct torque is 1/4 to 1/2 a turn past fin-
B8HS-10 ger-tight. Have the spark plug adjusted to the
BR8HS-10 correct torque as soon as possible with a
torque-wrench.
Before fitting the spark plug, measure the EMU28962
electrode gap with a wire thickness gauge; Checking fuel system
adjust the gap to specification if necessary. EWM00060
WARNING
Gasoline and its vapors are highly flam-
mable and explosive. Keep away from
sparks, cigarettes, flames, or other
44
Maintenance
sources of ignition. EMU28980
dealer or other qualified mechanic should re- away from sparks, cigarettes, flames or
pair it immediately. other sources of ignition.
● This procedure will allow some fuel to
spill. Catch fuel in a rag. Wipe up any
spilled fuel immediately.
● The fuel filter must be reassembled
carefully with the O-ring, filter cup, and
hoses in place. Improper assembly or
replacement could result in a fuel leak,
which could result in a fire or explosion
hazard.
EMU29001
ZMU03126
Checkpoints
● Fuel system parts leakage
45
Maintenance
spilled fuel in a rag. parts while the engine is running.
3. Remove the filter element, and wash it in ● 2-hp models: The propeller rotates
solvent. Allow it to dry. Inspect the filter whenever the engine is running. Do not
element and O-ring to make sure they move the throttle control lever from the
are in good condition. Replace them if start position during warm-up. 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. CAUTION:
This procedure must be performed while
the outboard motor is in the water. A
flushing attachment or test tank can be
2 used.
3
A diagnostic tachometer should be used for
4
this procedure. Results may vary depending
on whether testing is conducted with the
1
flushing attachment, in a test tank, or with the
ZMU02079
outboard motor in the water.
1. Start the engine and allow it to warm up
1. Filter cup
fully in neutral until it is running smooth-
2. Filter element
3. Filter housing
ly.
4. O-ring 2-hp model: Warm the engine with the
throttle in the start position or less. If the
4. Reinstall the filter element in the cup. outboard is mounted on a boat, be sure
Make sure the O-ring is in position in the the boat is tightly moored.
cup. Firmly screw the cup onto the filter NOTE:
housing. Correct idling speed inspection is only possi-
5. Attach the filter assembly to the bracket ble if the engine is fully warmed up. If not
so that the fuel hoses are attached to the warmed up fully, the idle speed will measure
filter assembly. higher than normal. If you have difficulty ver-
6. Run the engine and check the filter and ifying the idle speed, or the idle speed re-
lines for leaks. quires adjustment, consult a Yamaha dealer
EMU29040
or other qualified mechanic.
Inspecting idling speed
EWM00450 2. Verify whether the idle speed is set to
WARNING specification. For idle speed specifica-
● Do not touch or remove electrical parts tions, see page 36.
EMU29061
when starting or during operation.
Checking water in engine oil tank
● Keep hands, hair, and clothes away
A translucent water drain hose is connected
from the flywheel and other rotating
from the bottom of the oil tank to the filler
46
Maintenance
neck. If water or foreign matter collects in this EMU29153
hose, consult a Yamaha dealer. Checking power trim and tilt system
EWM00430
WARNING
2 ● Never get under the lower unit while it
is tilted, even when the tilt support lever
is locked. Severe injury could occur if
the outboard motor accidentally falls.
1 ● Make sure no one is under the outboard
motor before performing this test.
1. Check the power trim and tilt unit for any
ZMU03881
sign of oil leaks.
1. Drain hose 2. Operate each of the power trim and tilt
2. Filler neck side switches on the remote control and en-
gine bottom cowling (if equipped) to
EMU29111
check that all switches work.
Checking wiring and connectors 3. Tilt the outboard motor up and check
● Check that each grounding wire is properly that the tilt rod and trim rods are extend-
secured. ed completely.
● Check that each connector is engaged se-
curely.
ZMU03883
47
Maintenance
8. 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
You could be seriously injured if the en- Checkpoints
gine accidentally starts when you are ● Check each of the propeller blades for
near the propeller. wear, erosion from cavitation or ventila-
● Before inspecting, removing, or install- tion, or other damage.
ing the propeller, remove the spark ● Check the propeller shaft for damage.
plug caps from the spark plugs. Also, ● Check the splines / shear pin for wear or
48
Maintenance
EMU29193
shaft.
Removing the propeller 3. Install the spacer (if equipped) and the
1. Straighten the cotter pin and pull it out washer. Tighten the propeller nut to the
using a pair of pliers. specified torque.
2. Remove the propeller nut, washer, and 4. Align the propeller nut with the propeller
spacer (if equipped). shaft hole. Insert a new cotter pin in the
hole and bend the cotter pin ends.
1
3
6
2
4
5 ZMU03886
ZMU02063
1. Cotter pin
2. Propeller nut
NOTE:
3. Washer
If the propeller nut does not align with the
4. Spacer
propeller shaft hole after tightening to the
5. Propeller
6. Thrust washer
specified torque, tighten the nut further to
align it with the hole.
3. Remove the propeller and thrust wash- EMU29280
49
Maintenance
3. Remove the gear oil drain screw. the gear oil drain screw hole.
1
ZMU03133
NOTE:
If the magnetic gear oil drain screw
equipped: remove all metal particles from ZMU03887
50
Maintenance
plosion hazard. 4. Clean the filter (located on the end of the
● Dispose of old gasoline according to lo- suction pipe) in a suitable cleaning sol-
cal regulations. vent. Allow the filter to dry.
5. Replace the gasket with a new one. Re-
1. Empty the fuel tank into an approved
install the fuel joint assembly and tighten
container.
the screws firmly.
2. Pour a small amount of suitable solvent EMU29312
into the tank. 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.
ECM00720
CAUTION:
Do not paint anodes, as this would render
them ineffective.
NOTE:
Inspect ground leads attached to external
anodes on equipped models. Consult a
Yamaha dealer for inspection and replace-
ment of internal anodes attached to the pow-
er unit.
ZMU03231
ZMU01901
ZMU02324
51
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:
ZMU03888 ● A poorly maintained battery will quickly
deteriorate.
EMU29320
● Ordinary tap water contains minerals
Checking battery (for electric start
harmful to a battery, and should not be
models) used for topping up.
EWM00330
52
Maintenance
NOTE:
Consult a Yamaha dealer when charging or
re-charging batteries.
EMU29331
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. 1. Red cable
2. Black cable
ECM01121
3. Battery
CAUTION:
● Make sure the main switch (on applica- EMU29370
EMU29400
53
Maintenance
marine growth.
Do not use anti-fouling paint which includes
copper or graphite. These paints can cause
more rapid engine corrosion.
ZMU01943
54
Trouble Recovery
EMU29422
A. Fill tank with clean, fresh fuel.
Troubleshooting
A problem in the fuel, compression, or igni- Q. Is fuel filter clogged?
tion systems can cause poor starting, loss of A. Clean or replace filter.
power, or other problems. This section de-
scribes basic checks and possible remedies, Q. Is starting procedure incorrect?
and covers all Yamaha outboard motors. A. See page 27.
Therefore some items may not apply to your
model. 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. type?
A. Inspect spark plug(s). Clean or replace
Starter will not operate. with recommended type.
Q. Is battery capacity weak or low?
A. Check battery condition. Use battery of Q. Are spark plug cap(s) fitted incorrectly?
recommended capacity. A. Check and re-fit cap(s).
Q. Are battery connections loose or corrod- Q. Is ignition wiring damaged or poorly con-
ed? nected?
A. Tighten battery cables and clean battery A. Check wires for wear or breaks. Tighten
terminals. all loose connections. Replace worn or bro-
ken wires.
Q. Is fuse for electric start relay or electric cir-
cuit blown? Q. Are ignition parts faulty?
A. Check for cause of electric overload and A. Have serviced by a Yamaha dealer.
repair. Replace fuse with one of correct am-
perage. Q. Is engine stop switch lanyard not at-
tached?
Q. Are starter components faulty? A. Attach lanyard.
A. Have serviced by a Yamaha dealer.
Q. Are engine inner parts damaged?
Q. Is shift lever in gear? A. Have serviced by a Yamaha dealer.
A. Shift to neutral.
Engine idles irregularly or stalls.
Engine will not start (starter operates). Q. Are spark plug(s) fouled or of incorrect
Q. Is fuel tank empty? type?
A. Fill tank with clean, fresh fuel. A. Inspect spark plug(s). Clean or replace
with recommended type.
Q. Is fuel contaminated or stale?
55
Trouble Recovery
Q. Is fuel system obstructed? A. Return to home position.
A. Check for pinched or kinked fuel line or
other obstructions in fuel system. Q. Is motor angle too high?
A. Return to normal operating position.
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. Connect correctly.
Q. Have ignition parts failed?
A. Have serviced by a Yamaha dealer. Q. Is throttle valve adjustment incorrect?
A. Have serviced by a Yamaha dealer.
Q. Has warning system activated?
A. Find and correct cause of warning. Q. Is battery cable disconnected?
A. Connect securely.
Q. Is spark plug gap incorrect?
A. Inspect and adjust as specified. Warning buzzer sounds or indicator
lights.
Q. Is ignition wiring damaged or poorly con- Q. Is cooling system clogged?
nected? A. Check water intake for restriction.
A. Check wires for wear or breaks. Tighten
all loose connections. Replace worn or bro- Q. Is engine oil level low?
ken wires. A. Fill oil tank with specified engine oil.
Q. Is specified engine oil not being used? Q. Is heat range of spark plug incorrect?
A. Check and replace oil as specified. A. Inspect spark plug and replace it with rec-
ommended type.
Q. Is thermostat faulty or clogged?
A. Have serviced by a Yamaha dealer. Q. Is specified engine oil not being used?
A. Check and replace oil with specified type.
Q. Are carburetor adjustments incorrect?
A. Have serviced by a Yamaha dealer. Q. Is engine oil contaminated or deteriorat-
ed?
Q. Is fuel pump damaged? A. Replace oil with fresh, specified type.
A. Have serviced by a Yamaha dealer.
Q. Is oil filter clogged?
Q. Is air vent screw on fuel tank closed? A. Have serviced by a Yamaha dealer.
A. Open air vent screw.
Q. Has oil feed/injection pump malfunc-
Q. Is choke knob pulled out? tioned?
56
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.
plane.
Q. Is fuel system obstructed?
Q. Is water pump or thermostat faulty? A. Check for pinched or kinked fuel line or
A. Have serviced by a Yamaha dealer. other obstructions in fuel system.
Q. Is boat bottom fouled with marine growth? Q. Is air vent screw closed?
A. Clean boat bottom. A. Open the air vent screw.
57
Trouble Recovery
board motor unsafe to operate.
Q. Is heat range of spark plug incorrect?
If the outboard motor hits an object in the wa-
A. Inspect spark plug and replace it with rec-
ter, follow the procedure below.
ommended type.
Replacing fuse
Q. Is motor mounting bolt loose? If the fuse has blown on an electric start
A. Tighten bolt. model, open the fuse holder and replace the
fuse with a new one of the proper amperage.
Q. Is steering pivot loose or damaged? EWM00630
Impact damage
EWM00870
WARNING
The outboard motor can be seriously
damaged by a collision while operating or
trailering. Damage could make the out-
58
Trouble Recovery
EMU29531
59
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.
EMU29572
ZMU03891
OFF ON START
Engine fails to operate
EMU29691
60
Trouble Recovery
procedure below. flywheel or other moving parts when the
1. Remove the CDI unit cover or electrical engine is running.
cover, if equipped.
1. Adjust the trim angle so that the drive
2. Disconnect the yellow cord (emergency
shaft is at right angles to the water sur-
circuit) of the CDI unit to return to port.
EWM00350
face or is trimmed in.
2. On models equipped with an emergency
WARNING
starter valve, open it. The valve is locat-
When the yellow cord is disconnected,
ed behind the silencer cover on the front
the idle and low speeds are slightly high-
of the engine.
er than normal. Use care when starting off
or stopping.
ECM00380
CAUTION:
Follow this procedure only in an emer- OPEN
gency and just long enough to return to
port for repairs. CLOSE
1 ZMU03894
ZMU03893
2
1. CDI unit
2. Yellow cord
EMU29703
ZMU03142
Cold engine fails to start
If the engine fails to start when it is cold, use 4. Open the throttle slightly without shifting
the following procedure. using the throttle grip, neutral throttle le-
EWM00410
ver or free accelerator. It is necessary to
WARNING change the throttle opening slightly de-
When starting or operating the engine, do pending on the engine temperature. Af-
not touch the ignition coil, spark plug ter the engine starts, return the throttle to
wire, spark plug cap, or other electrical its original position.
parts carrying high voltage. Keep loose
clothing and other objects away from the
engine when starting it. Do not touch the
61
Trouble Recovery
N
ON
OFF START
ZMU03845 ZMU03335
5. Turn the main switch to (on). 7. After the engine starts, close the emer-
gency starter valve (if used), then return
the throttle to its original position.
OFF ON START
OPEN
CLOSE
ZMU03144
CAUTION: NOTE:
● Never turn the main switch to “ ” When the starter mechanism malfunctions,
(start) while the engine is running. see page 59.
● Do not keep the starter motor turning
EMU29760
for more than 5 seconds. If the starter
motor is turned continuously for more
Treatment of submerged motor
than 5 seconds, the battery will be If the outboard motor is submerged, immedi-
quickly discharged, thus making it im- ately take it to a Yamaha dealer. Otherwise
possible to start the engine. The starter some corrosion may begin almost immedi-
can also be damaged. If the engine will ately.
not start after 5 seconds of cranking, If you cannot immediately take the outboard
return the main switch to “ ” (on), wait motor to a Yamaha dealer, follow the proce-
10 seconds, then crank the engine dure below in order to minimize engine dam-
again. age.
EMU29771
Procedure
1. Thoroughly wash away mud, salt, sea-
weed, and so on, with fresh water.
62
Trouble Recovery
dealer as soon as possible.
ECM00400
CAUTION:
Do not attempt to run the outboard motor
until it has been completely inspected.
ZMU01909
ZMU01910
ZMU01911
63
Consumer information
EMU29811
64
Consumer information
65
Consumer information
EMU29820
66
Consumer information
67
Consumer information
68
Consumer information
EMU29840
69
6H1-28199-14_Hyoshi 3/10/04 10:40 AM Page 1
90D
OWNER’S MANUAL
U.S.A.Edition
Printed in Japan LIT-18626-05-86
March 2004–0.9 × 1 ! Printed on recycled paper
6H1-28199-14
Warranty card 2/27/02 11:47 AM Page 1
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DATE SOLD (Check One) LOISIR
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MONTH DAY YEAR
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