Remove the connecting rod cap and 3. Connect the special service tool to the outboard motor as shown. Install new oil seals into the oil seal hous- ing. This is a complete Yamaha Marine F90D 2004-2007 Service and Repair Manual! Tighten the crankcase bolts to the speci- fied torques in two stages and in the sequence shown. Even with diligent routine maintenance, outboard motors may require periodic repairs.
If a flash pattern listed in the diagnostic code chart is displayed, check the mal- functioning part according to the flash pattern. Because of their reliable design, relatively simple construction, and ease of repair; outboard motors are the ideal machine for maintenance and repair at home. Check the ignition coils resis- tance. Check the anodes and trim tab for motor to check an anode, refer to the applica- scales, grease, or oil. . Calculate the valve stem-to-valve guide 0. Connect the negative battery lead to the starter motor body.
Initial Every Refer to Item Remarks 10 hours 50 hours 100 hours 200 hours. Remove the oil dipstick, wipe it clean, and then insert it back into the dipstick hole. Check the fuel sys- the relay terminals 2 and 3 after dis- tem if there is no sound. Adjust the maintenance intervals according to the operating conditions of the outboard motor. Install a new timing belt 8 onto the drive 13.
Replace the armature if below specifica- tion. Replace the connecting Crankpin diameter b: rod or crankshaft or both if out of specifi- 43. Another asset that makes outboard motor repair easier, is access to quality service manuals and parts catalogues. Install the relief valve seat caps F by installing bolts G and H, then tightening S6C17620 them to the specified torques. Straighten the claw washer tabs a, and the cross pin 2, dog clutch 3, slider and then remove the ring nut and claw washer.
Crankshaft journal oil clearance: 0. It prolongs the life of your outboard motor. Fully tilt the outboard motor up, and then support it with the tilt stop lever 1. S6C17600 Checking the gear pump 1. It contains all the information and details you need to help you not only fix your vehicle problems, but also maintain your vehicle good functioning for future use! Check that the outboard motor tilts up and down smoothly when operating the power trim and tilt unit. Routine outboard motor maintenance starts right after using the motor. Symptom: Engine can run, but engine speed will not increase.
Compress the valve spring, and then install the valve cotters 8 using a thin 1. Check the dog clutch and slider for ing. Measure the stator coil output peak volt- age. Failure in starting operation clearance. Assembling the power trim and tilt unit 1. Having a quality service manual specific to your outboard motor will help you identify the parts of your motor and assist you during routine maintenance. At specified Add fluid to the correct level.
Be sure to turn the cutter evenly downward at a pres- Valve seat contact width a: sure of 40—50 N 4—5 kgf, 8. Assembling the tilt cylinder 1. Throttle position sensor output voltage at engine idle speed: 0. Remove the circlips 6, then the lower Removing the power trim and tilt unit mounting shaft 7. Apply water resistant grease to the areas specification. Also, check the fuel filter 1, 1. Apply engine oil to the contact surfaces Use the recommended special service tools of moving parts before assembly.
The optimum mounting height is affected by the combination of the boat and the outboard motor. Check the fuel system using the Within Yamaha Diagnostic System. Hold the power trim and tilt unit 1 in a vise using aluminum plates a on both sides. Valve spring tilt limit b: 2. Check the operation of the shift rod. Install the balls C, valves D, and springs E into the trim piston, and then install the washer F and trim piston to the tilt cylin- der G. Install the mount covers 8.