90D Owner's Manual - Yamaha Motor Company

1 Printed in JapanMarch 2004 1 !Printed on recycled paper90 DOWNER S 3/10/04 10:40 AM Page 1 EMU25060 ZMU01690 Read this owner s Manual carefully before operating your outboard 3/10/04 10:40 AM Page 2 Important Manual information EMU25100 To the owner Thank you for choosing a Yamaha outboardmotor. This owner s Manual contains infor-mation needed for proper operation, mainte-nance and care. A thorough understandingof these simple instructions will help you ob-tain maximum enjoyment from your newYamaha. If you have any question about theoperation or maintenance of your outboardmotor, please consult a Yamaha this owner s Manual particularly importantinformation is distinguished in the followingways. The Safety Alert Symbol meansATTENTION! BECOME ALERT! YOURSAFETY IS INVOLVED!WARNING EWM00780 Failure to follow WARNING instructionscould result in severe injury or death tothe machine operator, a bystander, or aperson inspecting or repairing the out- board : ECM00700 A CAUTION indicates special precautionsthat must be taken to avoid damage to the outboard : A NOTE provides key information to make procedures easier or continually seeks advancements inproduct design and quality.

2 Therefore, whilethis Manual contains the most current prod-uct information available at the time of print-ing, there may be minor discrepanciesbetween your machine and this Manual . Ifthere is any question concerning this manu-al, please consult your Yamaha : The 90TR and the standard accessories areused as a base for the explanations and illus-trations in this Manual . Therefore some items may not apply to every model. EMU25110 90 DOWNER S Manual 2004 by Yamaha Motor Corporation, USA1st edition, March 2004 All rights reprinting or unauthorized usewithout the written permission ofYamaha Motor Corporation, USAis expressly in JapanP/N LIT-18626-05-86 Table of contents General information .. 1 Identification numbers record .. 1 Outboard Motor serial number .. 1 Key 1 Emission control information .. 1 North American 1 Safety information .. 2 Important 3 Warning labels .. 3 Basic boating rules (Rules of the road).

3 3 Steering and sailing rules and sound signals .. 4 Rules when encountering vessels .. 4 Other special 5 Fueling instructions .. 7 Gasoline .. 8 Engine oil .. 8 Battery 8 Battery specifications .. 8 Propeller 8 Start-in-gear protection .. 9 Basic components .. 10 Main components .. 10 Fuel tank .. 10 Fuel joint .. 11 Fuel gauge .. 11 Fuel tank cap .. 11 Air vent screw .. 11 Remote 11 Remote control lever .. 11 Neutral interlock trigger .. 12 Neutral throttle 12 Throttle friction 12 Engine stop lanyard switch .. 13 Main switch .. 13 Power trim and tilt switch on remote control or tiller handle .. 14 Power trim and tilt switch on bottom engine cowling .. 14 Trim tab with anode .. 14 Trim rod (tilt pin) .. 15 Tilt support lever for power trim and tilt or hydro tilt 15 Top cowling lock lever(s) (turn type) .. 15 Flushing device .. 16 Tachometer .. 16 Digital tachometer .. 16 Oil level indicators (three indicators).

4 16 Oil level indicator (digital type) .. 17 Overheat warning indicator (digital type) .. 17 Trim meter .. 17 Trim meter (digital type) .. 17 Hour meter (digital type).. 18 Warning system .. 18 Overheat warning .. 18 Oil level warning and oil filter clogging warning .. 19 Operation .. 21 21 Mounting the outboard Motor .. 21 Breaking in engine .. 22 Gasoline and engine oil mixing chart (50:1).. 22 Procedure for oil injection models .. 22 Preoperation checks .. 23 Fuel .. 23 Oil .. 23 Controls .. 23 Engine .. 23 Operation after a long period of storage .. 23 Filling fuel and engine oil .. 24 Filling fuel for portable tank .. 24 Filling oil for electric start models .. 24 Oil level indicator operation .. 26 Operating engine .. 26 Feeding fuel (portable tank) .. 26 Starting engine .. 27 Warming up 28 Electric start and prime start models .. 28 Shifting .. 29 Forward (tiller handle and remote control models).

5 29 Table of contents Reverse (automatic reverse lock and power trim and tilt models).. 29 Stopping engine .. 30 Procedure .. 30 Trimming outboard Motor .. 30 Adjusting trim angle .. 31 Adjusting boat trim .. 31 Tilting up and down .. 32 Procedure for tilting up .. 33 Procedure for tilting down .. 34 Cruising in shallow water .. 34 Power trim and tilt models / power tilt 34 Cruising in other conditions .. 35 36 Specifications .. 36 Transporting and storing outboard Motor .. 37 Storing outboard Motor .. 37 Procedure .. 37 Lubrication (oil injection models).. 38 Cleaning and anticorrosion measures .. 39 Battery 39 Flushing power unit .. 39 Cleaning the outboard Motor .. 40 Checking painted surface of 40 Periodic 41 Replacement parts .. 41 Maintenance chart .. 42 Greasing .. 43 Cleaning and adjusting spark plug .. 44 Checking fuel system .. 44 Inspecting fuel filter .. 45 Cleaning fuel filter.

6 45 Inspecting idling speed .. 46 Checking water in engine oil tank .. 46 Checking wiring and connectors .. 47 Exhaust leakage .. 47 Water leakage .. 47 Checking power trim and tilt system .. 47 Checking propeller .. 48 Removing the propeller .. 49 Installing the propeller .. 49 Changing gear oil .. 49 Cleaning fuel tank .. 50 Inspecting and replacing anode(s) .. 51 Checking battery (for electric start models) .. 52 Connecting the battery .. 53 Disconnecting the 53 Checking top cowling .. 53 Coating the boat bottom .. 53 Trouble 55 Troubleshooting .. 55 Temporary action in emergency .. 58 Impact damage .. 58 Replacing fuse .. 58 Power trim and tilt will not operate .. 59 Starter will not operate .. 59 Emergency starting engine .. 60 Engine fails to operate .. 60 Ignition system malfunction .. 60 Cold engine fails to 61 Treatment of submerged Motor .. 62 62 Consumer information .. 64 Important warranty information for and Canada.

7 64 Yamaha Motor CORPORATION, OUTBOARD Motor TWO YEAR LIMITED WARRANTY .. 66 IMPORTANT WARRANTY INFORMATION IF YOU USE YOUR Yamaha OUTSIDE OR CANADA .. 69 1 General information EMU25170 Identification numbers record EMU25182 Outboard Motor serial number The outboard Motor serial number isstamped on the label attached to the portside of the clamp bracket or the upper part ofthe swivel your outboard Motor serial number inthe spaces provided to assist you in orderingspare parts from your Yamaha dealer or forreference in case your outboard Motor is sto-len. EMU25190 Key number If a main key switch is equipped with the mo-tor, the key identification number is stampedon your key as shown in the this number in the space provided forreference in case you need a new key. EMU25220 Emission control information EMU25230 North American models This engine conforms to EnvironmentalProtection Agency (EPA) regulations for ma-rine SI engines.

8 See the label affixed to yourengine for details. EMU30390 Approval label of emission control certif-icate This label is attached to the bottom Technology; N/A 1. Outboard Motor serial number location1 ZMU02931 1. Key numberZMU04695 General information 2 EMU25261 Manufactured date label This label is attached to the clamp bracket orthe swivel bracket. EMU25361 Safety information Before mounting or operating the outboardmotor, read this entire Manual . Reading itshould give you an understanding of themotor and its operation. Before operating the boat, read any own-er s or operator s manuals supplied with itand all labels. Be sure you understandeach item before operating. Do not overpower the boat with this out-board Motor . Overpowering the boat couldresult in loss of control. The rated power ofthe outboard should be equal to or lessthan the rated horsepower capacity of theboat. If the rated horsepower capacity ofthe boat is unknown, consult the dealer orboat manufacturer.

9 Do not modify the outboard. Modificationscould make the Motor unfit or unsafe touse. 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. Itis a good idea to wear a PFD wheneverboating. At a minimum, children and non-swimmers should always wear PFDs, andeveryone should wear PFDs when thereare potentially hazardous boating condi-tions. Gasoline is highly flammable, and its va-pors are flammable and explosive. Handleand store gasoline carefully. Make surethere are no gas fumes or leaking fuel be-fore starting the engine. This product emits exhaust gases whichcontain carbon monoxide, a colorless,odorless gas which may cause brain dam-age or death when inhaled. Symptoms in-clude nausea, dizziness, and cockpit and cabin areas well ventilat-ed.

10 Avoid blocking exhaust outlets. Check throttle, shift, and steering for prop-er operation before starting the engine. Attach the engine stop switch lanyard cordEMISSION CONTROL INFORMATIONENGINE FAMILY : THIS ENGINE CONFORMS TO 2001 EPA REGULATIONS FOR MARINE SI TO THE OWNERS Manual FOR MAINTENANCE SPECIFICATIONS AND :SPARK PLUG :DISPLACEMENT :ADVERTISED POWER :IDLE SPEED :SPARK PLUG GAP (mm) :FUEL : GASOLINEVALVE LASH (mm) :INEX cmkwg/kw-hrrpm IN NEUTRAL3 ZMU04304 ZMU04696 General information 3 to a secure place on your clothing, or yourarm or leg while operating. If you acciden-tally leave the helm, the cord will pull fromthe switch, stopping the engine. Know the marine laws and regulationswhere you will be boating and obeythem. For basic boating rules, see Rulesof the road on page 3. Stay informed about the weather. Checkweather forecasts before boating. Avoidboating in hazardous weather.