User manual YAMAHA F90HP-2005

[. . . ] F90D SERVICE MANUAL *LIT186160286* LIT-18616-02-86 6D8-28197-1G-11 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. [. . . ] 6-28 Measuring the forward gear backlash . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-28 1 2 3 4 5 6 7 8 9 6D81G11 LOWR Lower unit 3 Special service tools Gland nut wrench YB-34447 Bearing housing needle bearing remover YB-06112, YB-06153 Bearing housing puller YB-06207 Driver handle (large) YB-06071 Universal puller YB-06117 Propeller shaft oil seal installer YB-06269 Slide hammer YB-06096 Drive shaft needle bearing depth stop YB-34473 Bearing puller legs YB-06523 Bearing outer race attachment YB-06109 6-1 6D81G11 Special service tools Drive shaft holder YB-06151 Shift rod push arm YB-06052 Drive shaft needle bearing remover and installer YB-06155 Pinion shim selecting tool YB-34432-9, YB-34432-10A, YB-34432-11A, YB-34432-17 Drive shaft seal installer YB-06244 Forward gear shim selecting tool YB-34446-1, YB-34446-3, YB-34446-5, YB-34446-7 Forward gear bearing cup installer YB-06276-B Backlash indicator rod YB-06265 Forward gear outer race installer YB-06085 1 2 3 4 5 6 7 8 9 6-2 Backlash adjustment plate YB-07003 6D81G11 LOWR Lower unit Dial indicator gauge YU-03097 Magnetic base stand YU-A8438 6-3 6D81G11 Special service tools / Lower unit Lower unit 6 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Lower unit Hose Check screw Gasket Dowel Bolt Drain screw Grommet Bolt Bolt Spacer Propeller Washer Washer Cotter pin Nut Trim tab Q'ty 1 1 1 2 2 4 1 1 1 1 1 1 1 1 1 1 1 Remarks Not reusable M10 × 40 mm/L-transom model M10 × 45 mm M8 × 60 mm/L-transom model 1 2 3 4 5 6 7 8 9 6-4 Not reusable 6D81G11 LOWR Lower unit 6 No. 18 19 20 21 22 23 24 Part name Dowel Extension Stud bolt Washer Spring washer Nut Bolt Q'ty 2 1 4 4 4 4 1 Remarks X-transom model X-transom model M10 × 180 mm/X-transom model X-transom model X-transom model X-transom model M8 × 190 mm/X-transom model 6-5 6D81G11 Lower unit 6 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Bolt O-ring Oil seal Oil seal housing O-ring Circlip Shift rod Woodruff key Screw Bolt Cover Bolt Seal Water pump housing Insert cartridge Impeller Dowel Q'ty 2 1 1 1 1 1 1 1 2 2 1 2 1 1 1 1 2 Remarks M6 × 16 mm Not reusable Not reusable Not reusable ø4 × 12 mm M8 × 75 mm M8 × 50 mm 1 2 3 4 5 6 7 8 9 6-6 6D81G11 LOWR Lower unit 6 No. 18 19 20 21 22 23 24 Part name Gasket Outer plate cartridge Gasket Oil seal housing O-ring Gasket Oil seal Q'ty 1 1 1 1 1 1 2 Remarks Not reusable Not reusable Not reusable Not reusable Not reusable 6-7 6D81G11 Lower unit Removing the lower unit 1. Set the gear shift to the neutral position, and place a block of wood between the anti-cavitation plate and propeller to keep the propeller from turning, and then remove the propeller nut and propeller. S6D86020 5. Loosen the bolts (nuts), and then remove the lower unit from the upper case. WARNING · Do not hold the propeller with your hands when loosening or tightening it. · Be sure to disconnect the battery leads from the battery and the clip from the engine stop lanyard switch. · Put a block of wood between the anticavitation plate and propeller to keep the propeller from turning. Mark the trim tab 2 at the area shown, and then remove it. È X-transom model 1 2 3 4 5 6 7 8 9 6D81G11 6-8 LOWR Lower unit Removing the water pump and shift rod 1. Remove the water pump housing and impeller. Remove the outer plate cartridge and oil seal housing. Remove the shift rod assembly 1. Checking the water pump and shift rod 1. Check the water pump housing for deformation. Check the impeller and insert cartridge for cracks or wear. Check the Woodruff key 1 and the groove a on the drive shaft for wear. Replace if necessary. a 1 1 S6D86050 4. Replace if necessary. b a 2 S60C6405 NOTE: Pull up the shift rod assembly a little a to disconnect it from the shift slider 2, turn it clockwise 90° b, and then remove it. Disassembling the oil seal housing 1. Remove the oil seals using a flat head screw driver. 6-9 6D81G11 Lower unit / Propeller shaft housing Propeller shaft housing 6 No. 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 Part name Slider Shift plunger Dog clutch Spring Propeller shaft Shim Washer Reverse gear Thrust washer Ball bearing O-ring Propeller shaft housing Straight key Needle bearing Oil seal Claw washer Ring nut Q'ty 1 1 1 1 1 1 1 1 1 1 1 1 1 1 2 1 1 Remarks 0. 3 mm Not reusable Not reusable 1 2 3 4 5 6 7 8 9 6-10 Not reusable 6D81G11 LOWR Lower unit Removing the propeller shaft housing assembly 1. Straighten the claw washer tabs a, and then remove the ring nut and claw washer. Disassembling the propeller shaft assembly 1. Remove the spring 1, and then remove the cross pin 2, dog clutch 3, slider and shift plunger. Gland nut wrench 1: YB-34447 2. [. . . ] 5-28 J. Junction box. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22 S. Safety while working. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3 Selecting the connecting rod bearing . . . . . . . 5-45 Selecting the forward gear shims . . . . . . . . . . . . . 6-27 Selecting the main bearing . . . . . . . . . . . . . . . . . . . . . . . [. . . ]