Yamaha Marine F90D Outboards Repair Service Manual

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This Yamaha Outboard Engine Workshop Service Repair Manual PDF download for the F90D Yamaha Marine Outboards has been prepared as an aid to improve the quality of repairs by giving the serviceman an accurate understanding of the product and by showing him the correct way to perform repairs and make judgements. Make sure you understand the contents of this manual and use it to fully at every opportunity.


Yamaha F90TR 61P 1007790–


Chapter 1 General Information
Chapter 2 Specifications
Chapter 3 Periodic Checks and Adjustments
Chapter 4 Fuel System
Chapter 5 Power Unit
Chapter 6 Lower Unit
Chapter 7 Bracket Unit
Chapter 8 Electrical Systems
Chapter 9 Troubleshooting

Wiring Diagram


File Format : PDF
Language : English
Printable : Yes
Searchable : Yes
Bookmarked : Yes
P/N : LIT-18616-02-86 / 6D8-28197-1G-11
Total Pages : 247

All of the procedures in this manual are organized in a sequential, step-by-step format. The information has been compiled to provide the mechanic with an easy to read, handy reference that contains comprehensive explanations of all disassembly, repair, assembly, and inspection operations.

This Service / Repair / Workshop Manual PDF Download contains specs, diagrams, actual real photo illustrations, and schemes. In addition to space savings, nice thing about having completly searcheble PDF files instead of a hard-printed manual is that you can use the Search feature in your PDF reader software (Adobe Acrobat) to find just what your looking for and just print out the exact pages you need or all manual easily. This is the same manual your local dealer will use when doing a repair. This is a must for the Do-It-Yourselfer! Saving Yourself $$$$$$ In Service Repair And Maintenance Costs !!!!

Instant Download means there is NO shipping costs or waiting for a CD or paper manual to arrive in the mail! You will receive this manual TODAY via Instant Download on completion of payment via our secure payment processor. We accept ALL major credit/debit cards/paypal.

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F90D Service Manual
Table of Contents
Chapter 1 General Information
How to use this Manual
Safety While Working
Identification Applicable Model
Propeller Selection
Predelivery Checks
Checking the gear oil / the battery / the remote control cables
Checking the steering system / the gear shift and throttle operation / the power trim and tilt system
Chapter 2 Specifications
Power Unit
Lower Unit / Electrical
Tightening Torques
General Torques
Chapter 3 Periodic Checks and Adjustments
Special Service Tools
Maintenance Interval Chart
Top Cowling / Fuel System
Power Unit
Control System
Bracket Unit
Lower Unit
Chapter 4 Fuel System
Special Service Tools
Hose Routing
Fuel and Blowby Hoses
Fuel Filter and Fuel Pump
Checking the Fuel Pump / Disassembling the Fuel Pump
Checking the Diaphragm and Valves / Assembling the Fuel Pump
Intake Manifold
Checking the Throttle Position
Vapor Separator
Reducing the Fuel Pressure / Disconnecting the Quick Connector
Measuring the Fuel Pressure
Checking the Pressure Regulator
Draining the Fuel / Removing the Fuel Hose Clamp
Checking the Vapor Separator / Assembling the Vapor Separator
Checking the Canister
Chapter 5 Power Unit
Special Service Tools
Power Unit
Checking the Compression Pressure
Checking the Valve Clearance
Replacing the Timing Belt
Removing the Timing Belt and Sprockets
Checking the Timing Belt and Sprockets
Throttle Link
Junction Box
Cylinder Head
Removing the Cylinder Head
Checking the Valve Lifters and the Valve Springs and Valves
Checking the Valve Guides
Checking the Valve Seat
Replacing the Valve Seat
Checking the Camshafts
Checking the Cylinder Head
Installing the Valves
Installing the Cylinder Head
Exhaust Cover
Removing the Exhaust Cover
Installing the Exhaust Cover
Cylinder Block
Disassembling the Cylinder Block / Checking the Piston Diameter
Checking the Cylinder Bore / Checking the Piston Clearance / Checking the Piston Rings
Checking the Piston Ring Grooves / Checking the Piston Ring Side Clearance
Checking the Connecting Rod Big End Side Clearance
Checking the Crankshaft / the Crankpin Oil Clearance
Selecting the Connecting Rod Bearing
Checking the Crankshaft Journal Oil Clearance
Selecting the Main Bearing
Assembling the Power Unit
Installing the Power Unit
Chapter 6 Lower Unit
Special Service Tools
Lower Unit
Removing the Lower Unit
Removing the Water Pump and Shift Rod / Disassembling the Oil Seal Housing
Checking the Water Pump and Shift Rod
Propeller Shaft Housing
Removing the Propeller Shaft Housing Assembly
Disassembling the Propeller Shaft Assembly / the Propeller Shaft Housing
Checking the Propeller Shaft Housing
Assembling the Propeller Shaft Housing
Drive Shaft and Lower Case
Removing the Drive Shaft / Disassembling the Drive Shaft and Forward Gear
Checking the Pinion and Forward Gear / Checking the Bearings and Drive Shaft
Installing the Water Pump and Shift Rod
Selecting the Pinion Shims
Selecting the Forward Gear Shims
Measuring the Forward Gear Backlash
Chapter 7 Bracket Unit
Special Service Tools
Shift Rod
Bottom Cowling
Upper Case
Removing the Upper Case / Disassembling the Oil Pump / Checking the Oil Pump / Assembling the Oil Pump
Disassembling the Upper Case and Oil Pan
Assembling the Oil Pan
Assembling the Upper Case / Installing the Upper Case
Steering Arm
Removing the Steering Arm / Installing the Steering Arm
Clamp Brackets and Swivel Bracket
Removing the Clamp Brackets / Installing the Clamp Brackets / Adjusting the Trim Sensor
Power Trim and Tilt
Removing the Power Trim and Tilt Unit
Power Trim and Tilt Motor
Disassembling the Power Trim and Tilt Motor / Checking the Power Trim and Tilt Motor
Assembling the Power Trim and Tilt Motor
Gear Pump
Disassembling the Gear Pump / Checking the Gear Pump
Assembling the Gear Pump
Tilt Cylinder and Trim Cylinder
Disassembling the Trim Cylinder and Tilt Cylinder
Checking the Tilt Cylinder and Trim Cylinder / Checking the Valves
Assembling the Tilt Cylinder
Assembling the Power Trim and Tilt Unit
Bleeding the Power Trim and Tilt Unit
Installing the Power Trim and Tilt Unit
Power Trim and Tilt Electrical System
Checking the Fuse
Checking the Power Trim and Tilt Relay
Checking the Power Trim and Tilt Switch / Checking the Trim Sensor
Chapter 8 Electrical Systems
Special Service Tools
Checking the Electrical Components
Electrical Components
Ignition and Ignition Control System
Checking the Ignition Spark / spark plug wires
Checking the ECM / the Pulser Coils / the Sensor Assembly
Checking the Cooling Water Temperature Sensor / the Oil Pressure Switch
Fuel Control System
Checking the Injectors
Checking the Main and Fuel Pump Relay
Starting System
Checking the Fuses / the Starter Relay
Starter Motor
Disassembling the Starter Motor / Checking the Starter Motor Pinion and Armature
Checking the Brushes / Magnet Switch
Charging System
Checking the Stator Coil
Checking the Rectifier Regulator
Chapter 9 Troubleshooting
Special Service Tools
Yamaha Diagnostic System
Power Unit
Bracket Unit
Electrical System
Wiring Diagram


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