Yamaha F90D User manual

F90D
SERVICE MANUAL
6D8-28197-1G-11LIT-18616-02-86
*LIT186160286*

NOTICE
This manual has been prepared by Yamaha primarily for use by Yamaha dealers and their trained
mechanics when performing maintenance procedures and repairs to Yamaha equipment. It has
been written to suit the needs of persons who have a basic understanding of the mechanical and
electrical concepts and procedures inherent in the work, for without such knowledge attempted
repairs or service to the equipment could render it unsafe or unfit for use.
Because Yamaha has a policy of continuously improving its products, models may differ in detail
from the descriptions and illustrations given in this publication. Use only the latest edition of this
manual. Authorized Yamaha dealers are notified periodically of modifications and significant
changes in specifications and procedures, and these are incorporated in successive editions of this
manual.
Important information 1
Particularly important information is distinguished in this manual by the following notations:
The Safety Alert Symbol means ATTENTION! BECOME ALERT! YOUR SAFETY IS
INVOLVED!
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 outboard motor.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the out-
board motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
F90D
SERVICE MANUAL
©2004 by Yamaha Motor Corporation, USA
1st Edition, June 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Corporation, USA
is expressly prohibited.
Printed in USA
LIT-18616-02-86

Contents
General information 1
GEN
INFO
Specifications 2
SPEC
Periodic checks and adjustments 3
CHK
ADJ
Fuel system 4
FUEL
Power unit 5
POWR
Lower unit 6
LOWR
Bracket unit 7
BRKT
Electrical systems 8
ELEC
Troubleshooting 9
TRBL
SHTG
Index
–+

6D81G11
GEN
INFO
1
2
3
4
5
6
7
8
9
General information
How to use this manual.................................................................................1-1
Manual format............................................................................................1-1
Symbols.....................................................................................................1-2
Safety while working......................................................................................1-3
Fire prevention...........................................................................................1-3
Ventilation..................................................................................................1-3
Self-protection ...........................................................................................1-3
Parts, lubricants, and sealants ..................................................................1-3
Good working practices .............................................................................1-4
Disassembly and assembly .......................................................................1-4
Identification...................................................................................................1-5
Applicable model .......................................................................................1-5
Serial number ............................................................................................1-5
Propeller selection.........................................................................................1-5
Propeller size.............................................................................................1-5
Selection....................................................................................................1-6
Predelivery checks ........................................................................................1-6
Checking the fuel system ..........................................................................1-6
Checking the engine oil level.....................................................................1-6
Checking the gear oil level ........................................................................1-7
Checking the battery..................................................................................1-7
Checking the outboard motor mounting height..........................................1-7
Checking the remote control cables ..........................................................1-7
Checking the steering system ...................................................................1-8
Checking the gear shift and throttle operation...........................................1-8
Checking the power trim and tilt system....................................................1-8
Checking the engine start switch and engine stop lanyard switch ............1-8
Checking the cooling water pilot hole ........................................................1-9
Test run .....................................................................................................1-9
Break-in .....................................................................................................1-9
After test run ..............................................................................................1-9

GEN
INFO General information
1-1 6D81G11
How to use this manual 1
Manual format
The format of this manual has been designed to make service procedures clear and easy to under-
stand. Use the information below as a guide for effective and quality service.
1Parts are shown and detailed in an exploded diagram and are listed in the components list.
2Tightening torque specifications are provided in the exploded diagrams and after a numbered
step with tightening instructions.
3Symbols are used to indicate important aspects of a procedure, such as the grade of lubricant
and lubrication point.
4The components list consists of part names and part quantities, as well as bolt and screw dimen-
sions.
5Service points regarding removal, checking, and installation are shown in individual illustrations
to explain the relevant procedure.
NOTE:
For troubleshooting procedures, see Chapter 9, “Troubleshooting.”
LOWR Lower unit
6-5 62Y5A11
Lower unit
No. Part name Q’ty Remarks
1 Lower unit 1
2 Plastic tie 1 Not reusable
3Hose 1
4 Check screw 1
5 Gasket 2 Not reusable
6 Dowel pin 2
7 Bolt 4 M10 40 mm
8 Drain screw 1
9Grommet 1
10 Bolt 1 M10 45 mm
11 Bolt 1 M8 60 mm
12 Thrust washer 1
13 Propeller 1
14 Washer 1
15 Washer 1
16 Cotter pin 1 Not reusable
17 Propeller nut 1
18 Trim tab 1
LOWR Lower unit
6-19 62Y5A11
Removing the drive shaft
1. Remove the drive shaft assembly and
pinion, and then pull out the forward
gear.
Disassembling the drive shaft
1. Install the pinion nut 1, tighten it finger
tight, and then remove the drive shaft
bearing 2using a press.
CAUTION:
•Do not press the drive shaft threads a
directly.
•Do not reuse the bearing, always
replace it with a new one.
Disassembling the forward gear
1. Remove the taper roller bearing from the
forward gear using a press.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
2. Remove the needle bearing from the for-
ward gear.
CAUTION:
Do not reuse the bearing, always replace
it with a new one.
Drive shaft holder 4 1: 90890-06518
Pinion nut holder 2: 90890-06505
Socket adapter 2 3: 90890-06507
Bearing inner race attachment 3:
90890-06639
S62Y6850K
Bearing separator 1: 90890-06534
Stopper guide plate 2: 90890-06501
Stopper guide stand 3:
90890-06538
Bearing puller 4: 90890-06535
Bearing puller claw 1 5:
90890-06536
S62Y6740K
5
4
321

6D81G11 1-2
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8
9
Symbols
The symbols below are designed to indicate the content of a chapter.
General information
Specifications
Periodic checks and adjustments
Fuel system
Power unit
Lower unit
Bracket unit
Electrical systems
Troubleshooting
GEN
INFO
SPEC
CHK
ADJ
FUEL
POWR
LOWR
BRKT
ELEC
TRBL
SHTG
–+
Symbols 1to 6indicate specific data.
1Special tool
2Specified oil or fluid
3Specified engine speed
4Specified tightening torque
5Specified measurement
6Specified electrical value
(resistance, voltage, electric current)
Symbols 7to Cin an exploded diagram indicate the grade of lubricant and the lubrication point.
7Apply Yamaha 4-stroke motor oil
8Apply gear oil
9Apply water resistant grease (Yamaha grease A)
0Apply molybdenum disulfide grease
AApply corrosion resistant grease
(Yamaha grease D)
BApply low temperature resistant grease
(Yamaha grease C)
CApply injector grease
Symbols Dto Hin an exploded diagram indicate the type of sealant or locking agent and the appli-
cation point.
DApply Gasket Maker
EApply LOCTITE 271 (red)
FApply LOCTITE 242 (blue)
GApply LOCTITE 572
HApply silicon sealant
123456
T
R
.
.
7890ABC
E G
A M
D
C I
DEFGH
GM
271
LT
242
LT
572
LT SS
How to use this manual

GEN
INFO General information
1-3 6D81G11
Safety while working 1
To prevent an accident or injury and to
ensure quality service, follow the safety pro-
cedures provided below.
Fire prevention
Gasoline is highly flammable.
Keep gasoline and all flammable products
away from heat, sparks, and open flames.
Ventilation
Gasoline vapor and exhaust gas are heavier
than air and extremely poisonous. If inhaled
in large quantities they may cause loss of
consciousness and death within a short time.
When test running an engine indoors (e.g., in
a water tank) be sure to do so where ade-
quate ventilation can be maintained.
Self-protection
Protect your eyes by wearing safety glasses
or safety goggles during all operations involv-
ing drilling and grinding, or when using an air
compressor.
Protect your hands and feet by wearing pro-
tective gloves and safety shoes when neces-
sary.
Parts, lubricants, and sealants
Use only genuine Yamaha parts, lubricants,
and sealants or those recommended by
Yamaha, when servicing or repairing the out-
board motor.
Under normal conditions, the lubricants men-
tioned in this manual should not harm or be
hazardous to your skin. However, you should
follow these precautions to minimize any risk
when working with lubricants.
1. Maintain good standards of personal and
industrial hygiene.
2. Change and wash clothing as soon as
possible if soiled with lubricants.
3. Avoid contact with skin. Do not, for
example, place a soiled rag in your
pocket.
4. Wash hands and any other part of the
body thoroughly with soap and hot water
after contact with a lubricant or lubricant
soiled clothing has been made.
5. To protect your skin, apply a protective
cream to your hands before working on
the outboard motor.

6D81G11 1-4
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8
9
6. Keep a supply of clean, lint-free cloths for
wiping up spills, etc.
Good working practices
Special service tools
Use the recommended special service tools
to protect parts from damage. Use the right
tool in the right manner—do not improvise.
Tightening torques
Follow the tightening torque specifications
provided throughout the manual. When tight-
ening nuts, bolts, and screws, tighten the
large sizes first, and tighten fasteners starting
in the center and moving outward.
Non-reusable parts
Always use new gaskets, seals, O-rings, cot-
ter pins, circlips, etc., when installing or
assembling parts.
Disassembly and assembly
1. Use compressed air to remove dust and
dirt during disassembly.
2. Apply engine oil to the contact surfaces
of moving parts before assembly.
3. Install bearings with the manufacture
identification mark in the direction indi-
cated in the installation procedure. In
addition, be sure to lubricate the bearings
liberally.
4. Apply a thin coat of water-resistant
grease to the lip and periphery of an oil
seal before installation.
5. Check that moving parts operate nor-
mally after assembly.
Safety while working

GEN
INFO General information
1-5 6D81G11
Identification 1
Applicable model
This manual covers the following model.
Serial number
The outboard motor serial number is
stamped on a label attached to the port
clamp bracket.
1Model name
2Approved model code
3Transom height
4Serial number
Propeller selection 1
The performance of a boat and outboard
motor will be critically affected by the size
and type of propeller you choose. Propellers
greatly affect boat speed, acceleration,
engine life, fuel economy, and even boating
and steering capabilities. An incorrect choice
could adversely affect performance and
could also seriously damage the engine.
Use the following information as a guide for
selecting a propeller that meets the operating
conditions of the boat and the outboard
motor.
Propeller size
The size of the propeller is indicated on the
propeller boss end, on the side of the propel-
ler boss.
aPropeller diameter (in inches)
bPropeller pitch (in inches)
cPropeller type (propeller mark)
Applicable model
F90TR
Model name Approved
model code
Starting
serial No.
F90TR 61P 1007790–
S6D81010
S69J1100
× -
abc
S60C1120
× -
abc

6D81G11 1-6
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9
Selection
When the engine speed is at the full throttle
operating range (5,000–6,000 r/min), the
ideal propeller for the boat is one that pro-
vides maximum performance in relation to
boat speed and fuel consumption.
Predelivery checks 1
To make the delivery process smooth and
efficient, the predelivery checks should be
completed as explained below.
Checking the fuel system
1. Check that the fuel hoses are securely
connected and that the fuel tank is full
with fuel.
CAUTION:
This is a 4-stroke engine. Never use pre-
mixed fuel.
Checking the engine oil level
1. Check the engine oil level.
NOTE:
If the engine oil is below the minimum level
mark b, add sufficient oil until the level is
between aand b.
Propeller size (in) Material
12 5/8 ×21 - K
Aluminum
13 ×19 - K
13 ×23 - K
13 ×25 - K
13 1/4 ×17 - K
13 1/2 ×15 - K
13 5/8 ×13 - K
14 ×11 - K
13 ×17 - K
Stainless
13 ×19 - K
13 ×21 - K
13 ×23 - K
13 ×25 - K
13 1/2 ×14 - K
13 1/2 ×16 - K
Recommended engine oil:
4-stroke motor oil
API: SE, SF, SG, SH, or SJ
SAE: 10W-30 or 10W-40
Engine oil quantity:
Without oil filter replacement:
4.3 L (4.55 US qt, 3.78 Imp qt)
S6D81020
S60C1150
a
b
Identification / Propeller selection / Predelivery checks

GEN
INFO General information
1-7 6D81G11
Checking the gear oil level
1. Check the gear oil level.
Checking the battery
1. Check the capacity, electrolyte level, and
specified gravity of the battery.
2. Check that the positive and negative bat-
tery leads are securely connected.
Checking the outboard motor
mounting height
1. Check that the anti-cavitation plate is
aligned with the bottom of the boat. If the
mounting height is too high, cavitation
will occur and propulsion will be reduced.
Also, the engine speed will increase
abnormally and cause the engine to
overheat. If the mounting height is too
low, water resistance will increase and
reduce engine efficiency.
NOTE:
The optimum mounting height is affected by
the combination of the boat and the outboard
motor. To determine the optimum mounting
height, test run the outboard motor at differ-
ent heights.
2. Check that the clamp brackets are
secured with the clamp bolts.
Checking the remote control cables
1. Set the remote control lever to the neu-
tral position and fully close the throttle
lever.
2. Check that the stopper 1on the throttle
cam contacts the fully closed stopper 2
on the cylinder block.
3. Check that the alignment mark aon the
bushing is aligned with the alignment
mark bon the bracket.
Recommended battery capacity:
CCA/SAE: 380 A
MCA/ABYC: 502 A
RC/SAE: 124 Minute
Electrolyte specified gravity:
1.280 at 20 °C (68 °F)
S60C1140
S6D81030
2
1
S6D81040
a
b

6D81G11 1-8
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WARNING
The shift/throttle cable joint must be
screwed in a minimum of 8.0 mm (0.31 in)
c.
Checking the steering system
1. Check the steering friction for proper
adjustment.
2. Check that the steering operates
smoothly.
3. Check that there is no interference with
wires or hoses when the outboard motor
is steered.
Checking the gear shift and throttle
operation
1. Check that the gear shift operates
smoothly when the remote control lever
is shifted from neutral to forward or
reverse.
2. Check that the throttle operates smoothly
when the remote control lever is shifted
from forward or reverse to the fully open
position a.
Checking the power trim and tilt
system
1. Check that the outboard motor tilts up
and down smoothly when operating the
power trim and tilt unit.
2. Check that there is no abnormal noise
produced when the outboard motor is
tilted up or down.
3. Check that there is no interference with
wires or hoses when the tilted-up out-
board motor is steered.
4. Check that the trim meter points down
when the outboard motor is tilted all the
way down.
Checking the engine start switch and
engine stop lanyard switch
1. Check that the engine starts when the
engine start switch is turned to START.
2. Check that the engine turns off when the
engine start switch is turned to OFF.
S69J3370
c
S60C1200
S69J1210
F
N
R
a
a
S60V1070
Predelivery checks

GEN
INFO General information
1-9 6D81G11
3. Check that the engine turns off when the
engine stop lanyard is pulled from the
engine stop lanyard switch.
Checking the cooling water pilot
hole
1. Check that cooling water is discharged
from the cooling water pilot hole.
Test run
1. Start the engine, and then check that the
gear shift operates smoothly.
2. Check the engine idle speed after the
engine has been warmed up.
3. Operate at trolling speed.
4. Run the outboard motor for 1 hour at
2,000 r/min or at half throttle, then for
another hour at 3,000 r/min or at 3/4
throttle.
5. Check that the outboard motor does not
tilt up when shifting into reverse and that
water does not flow in over the transom.
NOTE:
The test run is part of the break-in operation.
Break-in
During the test run, perform the break-in
operation in the following three stages.
1. One hour aat 2,000 r/min or at approxi-
mately half throttle
2. One hour bat 3,000 r/min or 3/4 throttle
and 1 minute out of every 10 at full throt-
tle
3. Eight hours cat any speed, however,
avoid running at full speed for more than
5 minutes
ÈHour
After test run
1. Check for water in the gear oil.
2. Check for fuel leakage in the cowling.
3. Flush the cooling water passage with
fresh water using the flushing kit and with
the engine running at idle.
S69J1240
01210
È
ab c

6D81G11
SPEC
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9
Specifications
General specifications...................................................................................2-1
Maintenance specification ............................................................................2-3
Power unit..................................................................................................2-3
Lower unit ..................................................................................................2-6
Electrical ....................................................................................................2-6
Dimensions................................................................................................2-9
Tightening torques.......................................................................................2-11
Specified torques.....................................................................................2-11
General torques.......................................................................................2-13

SPEC Specifications
2-1 6D81G11
General specifications 2
Item Unit Model
F90TR
Dimension
Overall length mm (in) 817 (32.2)
Overall width mm (in) 479 (18.9)
Overall height
(L) mm (in) 1,582 (62.3)
(X) mm (in) 1,710 (67.3)
Boat transom height
(L) mm (in) 508 (20.0)
(X) mm (in) 635 (25.0)
Weight
(without propeller)
(L) kg (lb) 168 (370)
(X) kg (lb) 172 (379)
Performance
Maximum output kW (hp) 66.2 (90) at 5,500 r/min
Full throttle operating range r/min 5,000–6,000
Maximum fuel consumption L (US gal,
Imp gal)/hr
33.0 (8.72, 7.26) at 6,000 r/min
Engine idle speed r/min 700 ±50
Power unit
Type In-line, 4-stroke, DOHC, 16 valves
Cylinder quantity 4
Total displacement cm3(cu. in) 1,596 (97.39)
Bore ×stroke mm (in) 79.0 ×81.4 (3.11 ×3.20)
Compression ratio 9.6
Control system Remote control
Starting system Electric
Fuel system Fuel injection
Ignition control system TCI
Advance type Micro computer
Maximum generator output V, A 12, 25
Spark plug LFR5A-11 (NGK)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump

6D81G11 2-2
1
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9
(*1) RON: Research Octane Number
PON: Pump Octane Number =
(RON + Motor Octane Number)/2
(*2) CCA: Cold Cranking Ampere
MCA: Marine Cranking Ampere
ABYC: American Boat and Yacht Council
SAE: Society of Automotive Engineers
RC: Reserve Capacity
Fuel and oil
Fuel type Regular unleaded gasoline
Fuel minimum rating RON(*1)
PON
91
86
Engine oil 4-stroke motor oil
Engine oil grade API
SAE
SE, SF, SG, SH, or SJ
10W-30 or 10W-40
Engine oil quantity
(without oil filter replacement) L (US qt,
Imp qt)
4.3 (4.55, 3.78)
(with oil filter replacement) L (US qt,
Imp qt)
4.5 (4.76, 3.96)
Gear oil type GEAR CASE LUBE
Gear oil grade SAE 90
Gear oil quantity cm3(US oz,
Imp oz)
670 (22.7, 23.6)
Bracket unit
Trim angle
(at 12°boat transom)
Degree –4 to 16
Tilt-up angle Degree 70
Steering angle Degree 35 + 35
Drive unit
Gear shift positions F-N-R
Gear ratio 2.31 (30/13)
Reduction gear type Spiral bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction (rear view) Clockwise
Propeller mark K
Electrical
Battery minimum capacity(*2)
CCA/SAE A 380
MCA/ABYC A 502
RC/SAE Minute 124
Item Unit Model
F90TR
General specifications

SPEC Specifications
2-3 6D81G11
Maintenance specification 2
Power unit
Item Unit Model
F90TR
Power unit
Minimum compression
pressure(*1)
kPa
(kgf/cm2, psi)
860 (8.6, 124.7)
Oil pressure(*2) kPa
(kgf/cm2, psi)
510 (5.1, 74.0) at engine idle speed
Cylinder head
Warpage limit mm (in) 0.1 (0.0039)
(lines indicate straightedge
position)
Camshaft cap inside diameter mm (in) 25.000–25.021 (0.9843–0.9851)
Cylinders
Bore size mm (in) 79.000–79.020 (3.1102–3.1110)
Taper limit mm (in) 0.08 (0.0032)
Out-of-round limit mm (in) 0.05 (0.0020)
Pistons
Piston diameter (D) mm (in) 78.928–78.949 (3.1074–3.1082)
Measuring point (H) mm (in) 13.0 (0.51)
Piston clearance mm (in) 0.070–0.080 (0.0028–0.0031)
Over size piston diameter mm (in) 79.178–79.199 (3.1172–3.1181)
Piston rings
Top ring
Dimension B mm (in) 1.17–1.19 (0.0461–0.0469)
Dimension T mm (in) 2.80–3.00 (0.1102–0.1181)
End gap mm (in) 0.15–0.30 (0.0059–0.0118)
Side clearance mm (in) 0.04–0.08 (0.0016–0.0031)
2nd piston ring
Dimension B mm (in) 1.47–1.49 (0.0579–0.0587)
Dimension T mm (in) 3.00–3.20 (0.1181–0.1260)
End gap mm (in) 0.70–0.90 (0.0276–0.0354)
Side clearance mm (in) 0.03–0.07 (0.0012–0.0028)
(*1) Measuring conditions:
Ambient temperature 20 °C (68 °F), wide open throttle, with spark plugs removed from all cylinders.
The figures are for reference only.
(*2) The figures are for reference only.

6D81G11 2-4
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Oil ring
Dimension B mm (in) 2.38–2.48 (0.0937–0.0976)
Dimension T(*) mm (in) 2.40 (0.0945)
End gap mm (in) 0.20–0.70 (0.0079–0.0276)
Side clearance mm (in) 0.03–0.15 (0.0012–0.0059)
Camshafts
Intake (A) mm (in) 36.48–36.58 (1.4362–1.4402)
Exhaust (A) mm (in) 36.90–37.06 (1.4528–1.4591)
Intake (B) mm (in) 29.95–30.05 (1.1791–1.1831)
Exhaust (B) mm (in) 29.92–30.08 (1.1780–1.1842)
Camshaft journal diameter mm (in) 24.960–24.980 (0.9827–0.9835)
Camshaft runout limit mm (in) 0.03 (0.0012)
Valves
Valve clearance (cold)
Intake mm (in) 0.20 ±0.03 (0.008 ±0.001)
Exhaust mm (in) 0.34 ±0.03 (0.013 ±0.001)
Head diameter (A)
Intake mm (in) 29.0–29.2 (1.14–1.15)
Exhaust mm (in) 24.0–24.2 (0.94–0.95)
Face width (B)
Intake mm (in) 1.99–2.44 (0.0783–0.0961)
Exhaust mm (in) 2.27–2.72 (0.0894–0.1071)
Seat contact width (C)
Intake mm (in) 1.20–1.60 (0.0472–0.0630)
Exhaust mm (in) 1.20–1.60 (0.0472–0.0630)
Margin thickness (D)
Intake mm (in) 0.80–1.20 (0.0315–0.0472)
Exhaust mm (in) 1.00–1.40 (0.0394–0.0551)
Stem diameter
Intake mm (in) 5.975–5.990 (0.2352–0.2358)
Exhaust mm (in) 5.960–5.975 (0.2346–0.2352)
Guide inside diameter
Intake and exhaust mm (in) 6.000–6.018 (0.2362–0.2369)
Stem-to-guide clearance
Intake mm (in) 0.010–0.043 (0.0004–0.0017)
Exhaust mm (in) 0.025–0.058 (0.0010–0.0023)
Stem runout limit mm (in) 0.01 (0.0004)
Valve springs
Free length mm (in) 53.20 (2.0945)
Tilt limit mm (in) 2.6 (0.10)
(*) The figure is for reference only.
Item Unit Model
F90TR
Maintenance specification

SPEC Specifications
2-5 6D81G11
Valve lifters
Valve lifter outside diameter mm (in) 27.965–27.980 (1.1010–1.1016)
Valve lifter-to-cylinder head
clearance
mm (in) 0.020–0.056 (0.0008–0.0022)
Valve shims
Valve shim thickness
(in 0.025 mm increments)
mm (in) 2.0–3.3 (0.08–0.13)
Connecting rods
Big end inside diameter mm (in) 47.025–47.045 (1.8514–1.8522)
Big end side clearance mm (in) 0.14–0.28 (0.0055–0.0110)
Crankpin oil clearance mm (in) 0.024–0.044 (0.0009–0.0017)
Big-end bearing thickness
Yellow mm (in) 1.499–1.506 (0.0590–0.0593)
Green mm (in) 1.506–1.513 (0.0593–0.0596)
Blue mm (in) 1.513–1.520 (0.0596–0.0598)
Red mm (in) 1.520–1.527 (0.0598–0.0601)
Crankshaft
Crankshaft journal diameter mm (in) 47.985–48.000 (1.8892–1.8898)
Crankpin diameter mm (in) 43.982–44.000 (1.7316–1.7323)
Crankpin width mm (in) 21.00–21.07 (0.8268–0.8295)
Runout limit mm (in) 0.03 (0.0012)
Crankcase
Crankshaft journal oil
clearance
mm (in) 0.024–0.044 (0.0009–0.0017)
Upper crankcase main bearing
thickness
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)
Upper crankcase main bearing
#3 thickness
Green mm (in) 2.992–2.999 (0.1178–0.1181)
Blue mm (in) 2.999–3.006 (0.1181–0.1183)
Red mm (in) 3.006–3.013 (0.1183–0.1186)
Lower crankcase main bearing
thickness
Yellow mm (in) 3.010–3.017 (0.1185–0.1188)
Green mm (in) 3.017–3.024 (0.1188–0.1191)
Blue mm (in) 3.024–3.031 (0.1191–0.1193)
Red mm (in) 3.031–3.038 (0.1193–0.1196)
Item Unit Model
F90TR

6D81G11 2-6
1
2
3
4
5
6
7
8
9
Lower unit
Electrical
Oil pump
Discharge
at 97–103 °C (207–217 °F)
with 10W-30 engine oil
L (US gal,
Imp gal)/min
5.9 (1.559, 1.298) at 1,000 r/min
Pressure
at 97–103 °C (207–217 °F)
with 10W-30 engine oil
kPa
(kgf/cm2, psi)
118.0 (1.18, 17.1) at 1,000 r/min
Relief valve opening pressure kPa
(kgf/cm2, psi)
441–539 (4.41–5.39, 63.9–78.2)
Thermostat
Opening temperature °C (°F) 58–62 (136–144)
Fully open temperature °C (°F) 70 (158)
Valve open lower limit mm (in) 4.3 (0.17)
Item Unit Model
F90TR
Gear backlash
Pinion-to-forward gear mm (in) 0.28–0.63 (0.0110–0.0248)
Pinion shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Forward gear shims mm 0.10, 0.12, 0.15, 0.18, 0.30, 0.40, 0.50
Item Unit Model
F90TR
Ignition and ignition control
system
Spark plug gap mm (in) 1.0–1.1 (0.039–0.043)
Ignition coil resistance
at 20 °C (68 °F)
Primary coil (R –B/W) Ω1.53–2.07
Secondary coil kΩ12.495–16.905
Spark plug wire resistance
#1 kΩ4.5–10.7
#2 kΩ3.3–8.0
#3 kΩ3.7–8.9
#4 kΩ4.3–10.2
Item Unit Model
F90TR
Maintenance specification