F75B

F80B
F90B

SERVICE GUIDE

038001
 NOTICE
This service guide has been prepared to provide Yamaha dealers with information for the product
concept, technical features, benefit, technical tips and new servicing points, regarding to a new
model.

The information contained in this guide is essential to the service staffs of Yamaha dealers for daily
service to customers.
It is our hope that you will use this guide to train your dealer service staffs about new model and that
it will help answer the questions about this model.

NOTE:
• The descriptions herein are based on the information officially announced by Yamaha motor Co.,
Ltd. as of the end of April 2004.
• For further information, refer to the appropriate service manual.

Specifications, features, descriptions, and information are subject to change without notice.

F75B, F80B, F90B

SERVICE GUIDE
(c) 2004 by Yamaha Motor Co., Ltd.
1st Edition, May 2004
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Produced in Japan
 CONTENTS
OUTLINE OF FEATURES ................................................................................................ 1

TECHNICAL FEATURES AND DESCRIPTIONS .......................................................... 2

1. FUEL SYSTEM .......................................................................................................... 2
1) FUEL INJECTION SYSTEM .................................................................................. 3
2) FUEL FILTER ........................................................................................................ 4
3) VAPOR GAS CANISTER....................................................................................... 5
2. EXHAUST SYSTEM................................................................................................... 6
1) IDLE SILENCER .................................................................................................... 6
3. ELECTRICAL SYSTEM ............................................................................................. 7
1) IGNITION SYSTEM ............................................................................................... 7
2) ELECTRIC CHARGING SYSTEM ......................................................................... 7
4. INTAKE SYSTEM....................................................................................................... 8
5. BRACKET .................................................................................................................. 9
1) TILT SUPPORT ..................................................................................................... 9
2) SINGLE ROD PT/T .............................................................................................. 10
6. ELECTRONIC CONTROL SYSTEM........................................................................ 11
1) ECU ..................................................................................................................... 12
2) TPS ...................................................................................................................... 13
3) FAIL-SAFE CONTROL ........................................................................................ 13
4) WARNING CONTROL ......................................................................................... 14
5) OVER-REVOLUTION CONTROL........................................................................ 15
6) VARIABLE TROLLING RPM SWITCH (OPTIONAL)........................................... 15
7) FUEL PUMP CONTROL ...................................................................................... 16
7. SELF-DIAGNOSIS SYSTEM ................................................................................... 16
8. DIAGNOSIS BY A PERSONAL COMPUTER .......................................................... 17
1) ENGINE PARAMETER ........................................................................................ 17
2) DIAGNOSIS AND TROUBLE RECORD .............................................................. 17
3) OPERATION HOURS .......................................................................................... 18
4) DATA LOGGER ................................................................................................... 18
5) STATIC AND DYNAMIC TEST ............................................................................ 18
6) ECU INFORMATION ........................................................................................... 18
9. COOLING SYSTEM ................................................................................................. 19
10. LUBRICATION SYSTEM ......................................................................................... 20
RIGGING INFORMATION .............................................................................................. 21
1. DIMENSIONS........................................................................................................... 21
1) EXTERIOR........................................................................................................... 21
2) BRACKET ............................................................................................................ 22
2. UNCRATING PROCEDURE .................................................................................... 23
3. MOUNTING OUTBOARD MOTOR .......................................................................... 24
4. CONNECTING REMOTE CONTROLS AND GAUGES........................................... 25
1) CONNECTING BATTERY CABLES .................................................................... 25
2) CONNECTING REMOTE CONTROL CABLES................................................... 26
3) CONNECTING WIRE-HARNESS ........................................................................ 28
4) INSTALLING WATER PRESSURE OR TEMPERATURE GAUGE..................... 28
5) INSTALLING VARIABLE TROLLING RPM SWITCH
(FOR TILLER HANDLE MODEL) ........................................................................ 29
5. PROPELLER SELECTION ...................................................................................... 31
1) WOT SPEED RANGE.......................................................................................... 31
2) PROPELLER APPLICATIONS ............................................................................ 32

SERVICE INFORMATION .............................................................................................. 33

1. GENERAL SPECIFICATIONS ................................................................................. 33
2. SERVICE DATA (EXTRACTED).............................................................................. 35
3. CRANKSHAFT OIL CLEARANCE ........................................................................... 35
4. TIGHTENING TORQUES ........................................................................................ 38
1) SPECIFIED TORQUES (EXTRACTED) .............................................................. 38
2) GENERAL TORQUES ......................................................................................... 39
 OUTLINE OF FEATURES
New electronic fuel injected F75B, F80B, F90B outboard motor has mainly redesigned the
fuel and intake system based on the carbureted F75A, F80A, F90A outboard motor, and
has the following features;
• Newly designed light weight and compact electronic fuel injection and intake system.
• Total displacement : 1596 cm3 (97.4 cu in)
• Bore × Stroke = 79.0 mm × 81.4 mm (3.11 in × 3.20 in)
• Dry weight : 170 – 174 kg (375 – 384 lb) with an aluminum prop.
• Serviceability and safety function
• Usability function
• Low emission conformed to 2008 CARB regulation
• Low noise, low fuel consumption

POWER UNIT
• Intake silencer with porous duct
• Single throttle body, single throttle valve
• Multi-point injection system, group injection
(#1/#4 and #2/#3)
• Group ignition system (#1/#4 and #2/#3)
• Plastic large intake manifold
• Plastic compact fuel rail
• Modularized intake system components
• Fuel pressure regulator built-in vapor separator tank
• Vapor gas canister
• Fuel cooler

ELECTRICAL
• Compact electronic fuel injection system
• Self-diagnosis system and YDIS
• Fail safe system
• Variable trolling RPM switch
(optional for tiller handle model)
• TPS with learning function (adjustment free)
• Low RPM charging system
• Compact injector
• Fuel filter with water separator

CLAMP BRACKET/UPPER CASING

• Double tilt support levers
• Plastic PTT motor housing
• Modularized gear pump
• Big capacity water wall structure around muffler
• Idle exhaust labyrinth structure

LOWER UNIT
• Same lower drive unit as carbureted F90 model

Fig. 1 Outboard motor outline

1
 TECHNICAL FEATURES AND DESCRIPTIONS
1. FUEL SYSTEM
A fuel pressure regulator is built-into the exit of the fuel injection pump to obtain compact and simple
fuel delivery structure.
A plastic fuel rail is used to prevent it from corrosion, and for light weight.
Fuel discharged from the pressure regulator returns to the vapor separator after cooling down
through the fuel cooler.
The fuel joint is used on the high pressure fuel hose to remove and/or install the intake unit easily.

Fuel filter (Optional) Fuel tank

Primer bulb

Fuel filter with water separator

Fuel feed pump (Mechanical)

Fuel filter

Vapor separator tank (VST) Fuel cooler

Fuel injection pump Fuel pressure regulator

Fuel rail

Injector Injector Injector Injector

1 2 3 4

Fig. 2 Fuel flow chart

2
1) FUEL INJECTION SYSTEM
The multi-point- and group-injection systems are used for simple fuel injection control programs.
The smallest injector is used for compact structure.
The very small 10 holes are used on the injector tip to discharge the minute particle of fuel, resulting
of much more fuel and air mixture.

Body color: Red

Fig. 3 Injector

Initial injection timing

BTDC10
▼ ▼ ▼ ▼
#1 cylinder Compression Combustion Exhaust Intake

#3 cylinder Intake Compression Combustion Exhaust

#4 cylinder Exhaust Intake Compression Combustion

#2 cylinder Combustion Exhaust Intake Compression

Fig. 4 Injection order

3
2) FUEL FILTER
A middle size fuel filter with water separator has been adopted.
This can protect the fuel system from mixing water into fuel lines.
Also, the other fuel filters have been located to the entrances of VST, fuel injection pump and injec-
tors, which can increase reliability of the fuel system.
On the entrance of fuel injection pump, a fine gauze and large filter is used for better percolation and
deterrent effect for clogging.

Fig. 5 Fuel filter with water separator

4
3) VAPOR GAS CANISTER
Just after the engine is stopped, the cooling-water supply is also stopped and the heat is conducted
to the VST from the engine, causing birth of many fuel vapor gases.
The vapor gases are led into the intake silencer to reburn them.
However, many vapor gases are sucked into the combustion chambers, causing rich air fuel mix-
ture, which is difficult to restart the engine.
So the canister has been used as a damper for returning the vapor gases into the intake silencer,
which can obtain to easy restart the engine while it is warm.
Many vapor gases are accumulated into the canister, and discharged gradually into atmosphere.
After the engine restarts, the vapor gases in canister are sucked into the intake manifold from ISC.

Canister
Filter
Atmosphere

Fuel pressure regulator

To ISC

Return fuel pipe Fuel

Vapor gas
Fuel
Cooler
Injector

VST
Fuel filter

Fuel feed pump

Fuel Tank
Fuel Filter Fuel injection pump

Fig. 6 Fuel system

5
2. EXHAUST SYSTEM
1) IDLE SILENCER
The exhaust gases leak from the small hole on the exhaust manifold, and flow into the labyrinth
structure of the upper casing.
The gases detour in the labyrinth and expand, and finally are discharged from the idle hole.
This could reduce the exhaust noise at idle RPM.

: Exhaust gas
: Water

Fig. 7 Exhaust system

6
3. ELECTRICAL SYSTEM
1) IGNITION SYSTEM
The same timing ignition system for #1/#4-cylinder and #2/#3-cylinder is used for simple design
because of two ignition coils.
Two pulser coils are used to detect the crank position, and determined the ignition timing.
If one pulser coil malfunctioned, another coil can recover to run the engine.

2) ELECTRIC CHARGING SYSTEM

Compared with carbureted F90 model, the height of magnet in the flywheel is 5 mm (0.2 in) higher
and the stator coil becomes bigger, which can obtain the battery charging capability from 500 rpm.
The current of 20 amperes is generated at 1,000 rpm.
Also, the maximum electrical current output is 25 amperes.
This can maintain the electronic fuel injection system and obtains reliability.

NOTE:
The rectifier and regulator is the same as F115.

Magnet height:
Carbureted F90: 44 mm (1.73 in)
Fuel injected F90: 49 mm (1.93 in)

Fig. 8 Flywheel magneto

30

25
Output current (A)

20

15

10

0 1 2 3 4 5 6
Rotation speed × 10 (rpm)
3

Fig. 9 Generator chart

7
4. INTAKE SYSTEM
The single throttle body with single throttle valve is used for compact engine design.
Also, compared with multi-throttle body, this is obtained to reduce the load of throttle operation.

The large plastic intake manifold is used for light weight and corrosion prevention, and obtained
engine stability at low speed.
The intake system components are modularized to obtain serviceability for removal and installation.
Intake manifold, fuel rail, injectors, throttle body, ISC, TPS, and intake air temperature/pressure
sensor are made one unit.
Porous duct is attached to the entrance of intake silencer to reduce intake air noise.
This duct is usually used on car engines for the same purpose.

Injector Air temperature/pressure sensor

ISC

Fuel rail
TPS

Surge tank Throttle body Intake manifold

Fig. 10 Intake unit module

Fig. 11 Porous duct

8
5. BRACKET
1) TILT SUPPORT
Double tilt support lever is used to increase durability and reliability.

Double support lever

Fig. 12 Tilt support lever

9
2) SINGLE ROD PT/T
Specifications have been changed as shown Fig. 13 based on that of carbureted F90.
A plastic is used to PTT motor housing to increase corrosion-resistance.
The gear pump is modularized for more serviceability.
General specifications are the same as previous model.

Tilt & trim cylinder

Open valve Open valve

pressure pressure
31 MPa 9.5 MPa
Manual valve
21 MPa
Main valve

Up relief Down relief

valve valve Modularized gear pump unit
18 MPa 2 MPa
Hydraulic pump

Fig. 13 Gear pump unit

Specifications Carbureted F90 (61P) Fuel injected F90 (6D8) Remarks

Stamped on the
ID mark 67F-03 6D8-00
bracket of motor
UP relief pressure 18.0 MPa 18.0 MPa
DN relief pressure 2.0 MPa 2.0 MPa
Absorber valve Tilt piston: 31.0 MPa Tilt piston: 31.0 MPa
opening pressure Trim piston: 9.5 MPa Trim piston: 9.5 MPa
Absorber valve seat Tilt piston: 2.0 mm, 0.08 in
Tilt piston: 2.0 mm, 0.08 in Tilt piston: 2-hole
diameter Trim piston: 2.7 mm, 0.11 in
Trim piston: 2.7 mm, 0.11 in Trim piston: 5-hole
Tilt piston diameter 35 mm, 1.38 in 35 mm, 1.38 in
Trim piston diameter 65 mm 65 mm
Tilt stroke 110 mm, 4.33 in 110 mm, 4.33 in
Trim stroke 45 mm 45 mm
Dexron-2 or upper
Oil grade ATF ATF
grade
310 cm3, 10.5 US_oz, 10.9 310 cm3, 10.5 US_oz, 10.9
Oil capacity
Imp_oz Imp_oz

Service data
Brush length 10.0 mm (0.39 in)
Wear limit 3.5 mm (0.14 in)
Commutator diameter 22.0 mm (0.87 in)
Commutator diameter limit 21.0 mm (0.83 in)
Commutator under cut 1.5 mm (0.06 in)
Commutator under cut limit 1.0 mm (0.04 in)

10
6. ELECTRONIC CONTROL SYSTEM
The electric control system is built up by the sensors and the ECU (Electric Control Unit).
The ECU receives signals from the sensors, and determines Air and Fuel mixture (A/F), and ignition
timing.
Under various condition, the ECU gives the best-suitable engine operation.
In addition, the warning control, fail-safe control, self-diagnosis function, etc. are equipped to
increase reliability.

Cooling water
temperature sensor

ECU

Intake air pressure & Crank position sensor

temperature sensors (Pulser coil) Oil pressure switch

Throttle position sensor

Fig. 14 Electric sensor location

11
1) ECU
This engine is controlled by the ECU (Electric Control Unit) to obtain precision combustion under
various operations, and can realize high power output, low fuel consumption and low emission.
The ECU controls the ignition timing, the fuel injection timing and the fuel injection volume, and
ensures that an optimum ignition timing and air/fuel ratio can be achieved in all operating conditions
such as engine start, normal operation and quick acceleration.
The ignition timing and air/fuel ratio are controlled by signals from the sensors shown in Fig. 14.

The self-diagnostic function is incorporated into the ECU, and can be easily found a malfunction point by
a personal computer with the optional software installed. (Refer to the self-diagnostic with PC section)

INPUT OUTPUT

40 3
Pulser coil Injector #1, 4
49 (Crank position sensor)
4
16 Injector #2, 3
Power source for sensors
36
Throttle position
sensor (TPS)
18
17 Ignition coil #1, 4
Intake air pressure
sensor
1
Ignition coil #2, 3
23
Idle speed controller (ISC)(S1)
6
Idle speed controller (ISC)(S2)
46 20
Cooling-water Idle speed controller (ISC)(S3)
pressure sensor 21
Idle speed controller (ISC)(S4)

Main relay
31 7
Ground for sensors Tachometer T
38
Intake air temperature sensor
26
48 Oil indicator
Cooling-water temperature sensor
8
Overheat indicator
25
Check engine indicator
9
Buzzer/DES switch BZ

DES switch

34 P
Neutral switch
24
Fuel injection pump relay
Relay

27
Stop switch
10
Oil pressure switch
28
Idle RPM switch (UP)
29 45
Idle RPM switch Power for diagnosis lamp
(DOWN)
Self-diagnosis

13
14 Diagnosis
Ground for ECU
5
Ground
15
Battery (+)

Flywheel
Rectifire/Regulator
magneto

Main relay

– +
Battery Engine key switch

Fig. 15 ECU diagram

12
 ECU ID Description
6D6-00 F75
6D7-00 F80
6D8-00 F90

Fig. 16 ECU identification

2) TPS
This TPS has a learning function, which obtains no initial position adjustment.

After the main switch is turned on, the idle position setting (throttle fully closed position) is carried
out due to the detection of TPS voltage output.
If the actual TPS output voltage is over 1.4 V, the fully closed throttle position voltage recorded in
the ECU is used as the initial value.
If the output voltage is below 1.4 V, it is used for the initial value.
The throttle valve angle is computed from the amount of change of voltage on the basis of initial set-
ting.

3) FAIL-SAFE CONTROL
If the electrical components malfunction, the ECU controls the ignition and fuel injection as shown in
the table.
Malfunction components Criterion Ignition control Fuel control
Pulser coil
No output Fixed BTDC 10 Fixed BTDC 10
(Crank position sensor)
Throttle position sensor Output voltage is below Controlled by Controlled by
(TPS) 0.30 V, or over 4.70 V. intake air pressure intake air pressure
Output voltage is below
Intake air pressure sensor Normal control Normal control
0.20 V, or over 4.50 V.
Cooling-water temperature Output voltage is below
Normal control Normal control
sensor 0.10 V, or over 4.52V.
Intake air temperature Output voltage is below
Normal control Normal control
sensor 0.10, or over 4.61 V.
Neutral switch Switch is off when starting. Normal control Normal control

13
4) WARNING CONTROL
This outboard motor is equipped with warning control functions to avoid serious engine damage.
If the engine overheats or the oil pressure is down, when the engine is operated over 2,000 RPM,
the cylinders misfire and stop injection, and the engine RPM is limited.
When the sensor detects the specified value or the switch activates, the engine is controlled as
shown in the table.
Cooling-water Oil pressure DES Engine RPM
temperature sensor switch signal Over 2,200 Below 2,150 Below 1,600
Engine temperature is
Increases
detected above 90 °C Switch is on, Comebacks
misfire and Comebacks
(194 °F), when engine is after 3 sec- fire and injec-
shut-off injec- fire and injec-
running at over 2,000 rpm onds after On tion in 0.2
tion in 2.5 tion immedi-
passing 24 seconds and starting seconds
seconds ately
time is passing 74 seconds engine (*1) interval
interval
after starting engine.
Oil indicator NOTE:
Buzzer
lights and • Warning indicators light for 3 seconds after
Overheat indicator lights sounds.
buzzer ignition key switch is turned to ON.
and buzzer sounds. All engine
sounds. • Buzzer sounds when the engine shut-off
Engine RPM is limited. RPM is
Engine RPM switch lanyard is removed while starting
limited.
is limited. engine.
(*1) If the engine RPM is quickly decelerated to the idle from over 2,000, the warning mode is not
activated for 630 seconds.

Cylinders #1, #4, and #3 or #2 misfire in order in 2.5 second intervals when the engine is running at
2,200 r/min or more.
When the throttle opening angle becomes 30 degrees or below, the #3 or #2 cylinder will start to
ignite again.
If the throttle opening angle becomes 7 degrees or below, all cylinders will be ignited.
Cylinder #2 or #3 is always ignited.
When the engine speed drops to 2,150 r/min, the cylinders #3, #4, and #1 will ignite in order in 0.2
seconds interval.
If the engine RPM falls in below 1,600, the ignition and injection for all cylinders is immediately
comeback.

NOTE:
The oil warning indicator is cleared when the engine stops.

14
5) OVER-REVOLUTION CONTROL
This outboard motor is equipped with an over-revolution control system to protect the engine.
If the engine speed exceeds 6,200 r/min, the fuel injections are shut off in order #1, #4, #3 cylinder.

This fuel shut-off system can stop useless fuel consumption.

Engine RPM Activated cylinder
Below 6,199 #1, #2, #3, #4
6,200 to 6,250 #2, #3, and #1 or #4
6,251 to 6,300 #2, #3
6,301 to 6,351 #2 or #3
Above 6,352 N/A

6) VARIABLE TROLLING RPM SWITCH (OPTIONAL)

This device is an optional equipment for tiller handle model.
The idling and/or trolling RPM can be controlled in the range of 550 through 1,000 rpm with 50 rpm
interval.
Pushing and holding the switch changes RPM continuously at 50 rpm interval.
If engine RPM reaches to the ends of specified range, the RPM is no longer changed.

CAUTION:
Do not modify the variable trolling RPM switch.
Modification such as wire extension, disassembly, etc. can malfunction for the system and/
or damage the electrical components.

NOTE:
Variable trolling RPM switch kit P/N: 6C5-W8186-00

Variable trolling RPM switch

(optional)

Fig. 17 Variable trolling RPM switch

15
7) FUEL PUMP CONTROL
The fuel injection pump operates for 3 seconds after the ignition key switch is turned on, and it
always operates while the engine is running.
The pump stops 1 second later after the engine stopped.

NOTE:
After the main key switch is turned on, all injectors are driven to prevent from sticking before the fuel
injection pump is driven.

7. SELF-DIAGNOSIS SYSTEM
This outboard motor is equipped with the self-diagnosis system for easier servicing.
The diagnosis signals are output from the check engine warning lead (Blue/ White) after main key
switch is turned on.
If numerous signals are detected, the diagnostic flash indicator flashes in the lowest code pattern.
The output code signals are flashed as shown the table.
Code Faulty components or symptom Example:
01 Normal (No fault) Code 01: Normal condition
The lamp flashes every 5 seconds.
13 Pulser coil (Crank position sensor)
15 Cooling-water temperature sensor Flash
18 Throttle position sensor (TPS)
Off
19 Battery 5 seconds
23 Intake air temperature sensor
28 Shift position switch
29 Intake air pressure sensor Code 23: Intake air sensor malfunction
37 ISC air passage The lamp flashes 2, then 3 times continuously.
44 Engine shut-off switch Flash
49 Thermostat
59 ECU memory Off
2 seconds 5 seconds

NOTE:
The diagnosis signal code and its applicable component are the same as other models.

16
8. DIAGNOSIS BY A PERSONAL COMPUTER
The YDIS as known on big model can be used.
The diagnosis function is the same as big models.
For further details, see the instruction packed in the software.

The following functions are enclosed to find a trouble point easier.

1) ENGINE PARAMETER
Shows the engine condition.
Engine RPM
Intake air pressure
Atmosphere pressure ECU
Ignition timing
Battery voltage
TPS voltage, Throttle valve angle
ISC valve angle
Fuel injection range
Cooling-water temperature
Intake air temperature
Emergency stop switch
Neutral switch
Oil pressure switch
DES switch Fig. 18 YDIS system

2) DIAGNOSIS AND TROUBLE RECORD

Shows below items.
Pulser coil (Crank position sensor)
Cooling-water temperature sensor
TPS
Battery voltage
Intake air temperature sensor
Neutral switch
Intake air pressure sensor
Intake air passage
Thermostat (over cooling)
Memory data

17
3) OPERATION HOURS
Shows operation hours as follows.
Total operation hours
Below 999 rpm operation hours
1,000 to 1,999 rpm operation hours
2,000 to 2,999 rpm operation hours
3,000 to 3,999 rpm operation hours
4,000 to 4,999 rpm operation hours
5,000 to 5,999 rpm operation hours
Over 6,000 rpm operation hours

4) DATA LOGGER
Records the data for 13 minutes with 1 minute interval before stopping the engine.
Engine RPM
Battery voltage
TPS voltage
Cooling-water temperature
Intake air pressure
Oil pressure switch

5) STATIC AND DYNAMIC TEST

Tests the following components.
Igniting #1 and #4 spark plugs
Igniting #2 and #3 spark plugs
Driving #1 and #4 injectors
Driving #2 and #3 injectors
Driving fuel injection pump
Driving ISC valve
Fixing ISC valve angle

6) ECU INFORMATION
Indicates ECU serial number.

18
9. COOLING SYSTEM
The cooling water flow diagram is as follows.

Thermostat Cylinder head

Cylinder body Water temperature sensor

Flushing device Fuel cooler Pilot hole

Exhaust outer cover PCV

Exhaust guide

Oil pan EX pipe Upper case

Lower case
Water pump
Trim tab

Cooling water inlets Propeller boss

Sea/ River/ Lake

Fig. 19 Cooling water flow chart

19
10.LUBRICATION SYSTEM
The lubrication oil flow diagram is as follows.

Connecting-rod big end (Crank pin)

Crankshaft main journal Camshaft main journal Valve and related parts

Main galley Oil pressure switch

Oil filter

Oil pump with releaf valve

Strainer

Oil sump

Fig. 20 Lubrication oil flow chart

20
 L: 24 (0.9) L: 917 (36.1)
X: 25 (1.0) X: 1044 (41.1) 857 (33.7)

L: 536 (21.1)
1) EXTERIOR
191 (7.5) X: 663 (26.1) 666 (26.2)
1. DIMENSIONS

366 (14.4)

27 (1.1) 49 (1.9)

240 (9.4) 405 (15.9)

35˚

171 (6.7)

164 (6.5)

12˚
63 (2.
527 (20.7)

5)

28 (1.1)

21
62 (2.4)

4˚

574 (22.6)
651 (25.6)
RIGGING INFORMATION

L: 998 (39.3)
X: 1115 (43.9)

L: 766 (30.2)
X: 842 (33.1)
66
˚
mm (in)
2) BRACKET
mm (in)

180 (7.1) 180 (7.1)

163.5 (6.4) 163.5 (6.4)

(0.73) (0.73) (0.73) (2.0)

18.5 18.5 18.5 50.8
80 (3.1)

254 (10.0)
367 (14.4)

13
(0.51)

(2.2)
55.5
19 (0.75)

13 (0.51)
101.5 (4.0) 101.5 (4.0)

125.4 (4.9) 125.4 (4.9)

22
2. UNCRATING PROCEDURE 5) Lift the top frame (4) strait up.

1) Inspect the crate for shipping damage. If a (4)

damage is found, apply the shipping dam-
age claim.
2) Cut the straps (1).
(1)

6) Remove the wrapping (5), and inspect the

motor for concealed damage. If any dam-
age is found, apply the crate damage
claim.

3) Lift the top cover (2) straight up to remove.

(2)

(5)

7) Remove the top cowling.

8) Remove the flywheel cover.
9) Attach the lifting harness to the lifting
4) Remove the bottom bolts (3).
points (6).

(6)

(3)

23
 10) Carefully lift up the motor with bottom 3. MOUNTING OUTBOARD
crate. Have help someone with holding the
MOTOR
frame to avoid injury.
CAUTION:
Be sure to mount the outboard motor with
supplied hardware.

1) Drill the mounting holes with the transom

template if needed.

NOTE:
Remove the steering retainer, and install a
hydraulic steering cylinder following the manu-
facturer’s recommendation before mounting the
motor.
Consult available literature for proper mounting
height.

2) Apply a proper waterproof sealer to the

mounting holes (1) on the transom.
CAUTION:
Do not interfere the lifting hardware to the
other components.

11) Remove the skeg holder (7).

(1)
(7)
3) Mount the motor on the pre-drilled tran-
12) Remove the clamp bracket bolts (8). som.
4) Insert the small washer (2) first, and then
the large washer (3) to the mounting bolt
(4).

(3) (2)

(4)

(8)

24
 5) Apply a proper waterproof sealer to the 2) Remove the bolt (3), and retainer (4).
bolts, and install the bolts with washers
from inside transom to outside.
6) Install the nut (5) double, and tighten them
to the specified torque.
(3)

(4)

10-P main harness

(5) Water temp. lead
Water press. tube Throttle cable
Speed pitot tube Shift cable
Battery cable

Nut torque:
43 Nm, 4.3 kgf•m, 31 ft•lb
Fuel hose
7) Remove the lifting harness.
8) Reinstall the flywheel cover. Fig. 21 Grommet description

1) CONNECTING BATTERY CABLES

4. CONNECTING REMOTE 1) Install the (+) cable terminal (1) using the
nut.
CONTROLS AND GAUGES
Nut torque:
WARNING
9 Nm, 0.9 kgf•m, 6 ft•lb
Make sure the electrical leads never inter-
fere with any moving parts.

1) Remove the bolts (1), and then fitting plate

(2).

(1)
(1)

(2) 2) Coat the terminal with marine grease, and

cover the rubber cap (2) onto the terminal.

(2)

25
3) Install the (–) cable terminal using the bolt 2) CONNECTING REMOTE CONTROL
(3). CABLES
Coat the terminal with marine grease. 1) Prepare the clips and cable ends from
small parts box.
2) Fully screw in the cable end to the shift and
throttle cables.

(3)

4) Loosen the bolt (4), and secure the cable

with the plate (5) and retighten the bolt.

3) Set the remote control lever in the neutral

Bolt torque:
and idling position.
10 Nm, 1.0 kgf•m, 7.2 lb•ft
4) Remove the bolt (1), and the cable holder
(2).

(2) (1)

(5)

(4)

5) Insert the shift control cable to the desig-

5) Insert the battery cable so that the white nated position of grommet, and secure the
line mark is up and the white tape (6) is po- cable using the holder and bolt.
sitioned at the inner end of grommet.
6) Reinstall the retainer using bolt (7) to firm Bolt torque:
the cables. 10 Nm, 1.0 kgf•m, 7.2 lb•ft

Bolt torque:
10 Nm, 1.0 kgf•m, 7.2 lb•ft

(7)

Shift cable
(6)

26
6) Align the center mark (3) of set pin of shifter 9) Turn the throttle arm (7) to clockwise to
with the mark (4) on the shift bracket. contact the arm to the stopper on the cylin-
der body.

(3) (7)

(4)

7) Adjust the shift cable end position to the

pin, and secure it with the clip (5) and lock
nut (6).
10) Adjust the throttle cable end position to the
Lock nut: pin of arm, and secure it with the clip and
5 Nm, 0.5 kgf•m, 3.6 ft•lb lock nut.

Lock nut:
(6)
5 Nm, 0.5 kgf•m, 3.6 ft•lb

(5)

8) Insert the throttle control cable to the des-

ignated position of grommet, and fit the ca-
ble into the holder.
11) Check the shift and throttle cables for
smooth operation, readjust if necessary.
Throttle cable
WARNING
The remote control cable end must be
screwed in a minimum of 8 mm (0.31 in).

Shift cable

27
3) CONNECTING WIRE-HARNESS 5) Pass the wire-harnesses through the des-
1) Loosen the band (1) to free the couplers. ignated position of grommet.
6) Reinstall the fitting plate.

Bolt torque:
10 Nm, 1.0 kgf•m, 7.2 lb•ft

(1)

2) Connect the 4-P coupler to the matched

coupler, and secure it with holder.

4) INSTALLING WATER PRESSURE OR

TEMPERATURE GAUGE
Either the water temperature gauge or the
water pressure gauge can be installed.

3) Connect the 10-P coupler, and secure it 10-P main harness

with the band. Water temp. lead
Water press. tube Throttle cable
Speed pitot tube Shift cable
Battery cable

Fuel hose

Fig. 22 Grommet description

4) Secure the wire-harnesses with the bolt (2) 1) Remove the plug (1).
and plate.
(1)
Bolt torque:
10 Nm, 1.0 kgf•m, 7.2 lb•ft

(2)

2) Remove the (–) battery terminal and the oil

dipstick.
Put a rag on the oil stick hole to prevent the
parts from entering them into the oil sump.

28
 3) Install the sender (2) with gasket. 5) INSTALLING VARIABLE TROLLING
RPM SWITCH (FOR TILLER HANDLE
Sender torque: MODEL)
20 Nm, 2.0 kgf•m, 15 lb•ft 1) Remove the screws as shown by allow (1),
and then the cover.
(2) Water temp. (1)
sender

2) Install the variable trolling RPM switch (2)

with the supplied hardware.
(2) Water press.
sender

4) Secure the wire or tube using the bolt and

plate (3).
(2)

3) Reinstall the cover, and secure the lead

with the clamps (3).

(3)
(3)

5) Pass the wire or tube through the designat-

ed position of grommet.

NOTE:
For connecting to the gauge, see the instruc-
tion packed with gauge. Bend this clamp so wire is
over screw head.

29
 10-P main harness
Variable RPM
switch

Fig. 23 Grommet description

4) Pass the lead through the designated posi-

tion of grommet.

(4)

5) Remove the cap (4), and connect the

switch coupler (5).

(5)

NOTE:
The variable trolling RPM switch is accommo-
dated with the tiller handle for 2005 model.

30
5. PROPELLER SELECTION
Yamaha outboard motors are fitted with propellers chosen to perform well over a range of applica-
tions, but there may be uses where a propeller with a different pitch would be more appropriate.
For a greater operating load, a smaller pitch propeller is more suitable as enables the correct engine
speed at WOT (Wide-Open-Throttle) to be maintained.
Conversely, a larger pitch propeller is more suitable for a smaller operating load.

1) WOT SPEED RANGE

With WOT operation and under a maximum boat load, the engine should be within the upper half of
the WOT speed range.
Select a propeller which fulfills this requirement.

WOT speed range:

5,000 – 6,000 r/min

CAUTION:
Do not run the engine which exceeds the WOT speed range.
Otherwise, an overheat or engine damage could occur.

If the engine exceeds the WOT speed range, replace the propeller to a larger pitch.
Conversely if not reached to the specified range, a smaller pitch propeller is suitable.

NOTE:
• The engine speed at WOT makes a change of approximately 200 – 300 rpm if the propeller pitch is
changed one inch.
• The maximum engine speed can increase when the outboard motor is maintained in trimmed up
position.

31
2) PROPELLER APPLICATIONS
Diameter Pitch
Model Mark Material Part No. Remarks
(inch) (inch)
F75B 14 11 K Aluminum 6E5-45954-00-EL
F80B 14 11 K Aluminum 68S-45941-00 Dual thrust
F90B 13 5/8 13 K Aluminum 6E5-45949-00-EL
13 1/2 14 K SST 688-45932-60-98
13 1/2 15 K Aluminum 6E5-45947-00-EL
13 1/2 16 K SST 688-45978-60-98
13 17 K SST 688-45930-02-98
13 1/4 17 K Aluminum 6E5-45945-01-EL
13 19 K SST 688-45970-03-98
13 19 K Aluminum 6E5-45941-00-EL
12 5/8 21 K Aluminum 6E5-45943-00-EL
13 21 K SST 688-45972-02-98
13 23 K SST 688-45974-02-98
13 23 K Aluminum 6E5-45952-00-EL
13 25 K SST 688-45976-01-98
13 25 K Aluminum 6E5-45956-00-EL

32
 SERVICE INFORMATION
1. GENERAL SPECIFICATIONS
Model
Item Unit
F75BET F80BET F90BET
Model prefix ID code 62P 6D7 61P
Starting serial number 1003813 1000001 1007790
Dimensions
Overall length mm (in) 817 (32.2)
Overall width mm (in) 479 (18.9)
L mm (in) 1,582 (62.3)
Overall height
X mm (in) 1,709 (67.3)
L mm (in) 536 (21.1)
Transom height
X mm (in) 663 (26.1)
Dry weight
L kg (lb) (*1) 170 (375)
X kg (lb) (*1) 174 (384)
Performance
55.2 (75) 58.8 (80) 66.2 (90)
Maximum output kW (HP)
@5,500 rpm @5,500 rpm @5,500 rpm
Full throttle operating range r/min 5,000 – 6,000
L (US gal, 33 (8.7, 7.3)
Maximum fuel consumption N/A
Imp gal)/hr @6,000 rpm
Idle speed r/min 700
Power unit
Engine type 4-stroke, Inline-4, DOHC, 4-valve/cyl.
Total displacement cm3 (cu.in) 1,596 (97.4)
Bore × Stroke mm (in) 79.0 × 81.4 (3.11 × 3.20)
Compression ratio 9.60
Control system Remote control
Starting system Electric starter (magnetic shift clutch)
Enrichment system Electronic fuel injection
Ignition control system TCI (Transistor Controlled Ignition)
Ignition timing Degree BTDC17-TDC BTDC18-TDC
Volts-
Maximum generator output 12-25 (20 Amps @1,000rpm)
Amps
Spark plug / Gap / mm (in) NGK LFR5A-11 / 1.1 (0.043)
Cooling system Water
Exhaust system Propeller boss
Lubrication system Wet sump
Fuel and oil
Fuel type Regular unleaded gasoline
RON /
Fuel minimum rating 91 / 86
PON (*2)
Engine oil type 4-stroke motor oil
API SE, SF, SG, SH, SJ
Engine oil grade (*3)
SAE 10W-30, 10W-40

33
 Model
Item Unit
F75BET F80BET F90BET
Without oil L (US qt,
4.3 (4.5, 3.8)
Engine oil replacement filter Imp qt)
quantity With oil L (US qt,
4.5 (4.8, 4.0)
filter Imp qt)
Gear oil type Hypoid gear oil
API GL-4
Gear oil grade (*3)
SAE 90
cm3 (US
Gear oil quantity 670 (23.6, 22.7)
oz, Imp oz)
Clamp bracket unit
Trim angle (*4) 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 rotation direction Rear view Clockwise
Propeller ID mark K
Electrical
CCA/SAE Amps 380
MCA/ABYC Amps 502
Battery minimum RC/SAE Mins 124
capacity (*5) CCA/EN Amps 430
20HR/IEC Ah 70
JIS 65D31-95E41
Grommet
Battery cable length m (ft) 2.83 (9.3)
to terminal
(*1) With an aluminum propeller (Approx. 2 kg, 4 lb)
(*2) RON; Research Octane Number PON; Pump Octane Number = (RON + Motor Octane Number)/2
(*3) Meeting both API and SAE requirements.
(*4) At 12-degree boat transom
(*5) CCA: Cold Cranking Amperage
SAE: Society of Automotive Engineering
MCA: Marine Cold Cranking
ABYC: American Boat and Yacht Counsel
RC: Reserve Capacity
EN: European Norm (European standard)
IEC: International Electro-technical Commission
JIS: Japanese Industry Standard

34
2. SERVICE DATA (EXTRACTED)
Item Unit Data
Fuel injection pressure range
kpa (kgf/cm2, psi) 210 – 284 (2.1 – 2.9, 30 – 41)
(while running engine)
Fuel regulator control pressure kpa (kgf/cm2, psi) 284 (2.9, 41)
TPS output voltage (at idling) V 0.8 – 1.3
Intake air pressure sensor output voltage
V Approx. 4
(at sea level)
Minimum compression pressure at sea
kpa (kgf/cm2, psi) 860 (8.8, 125)
level and room temp. (for reference)
Oil pressure at idling (for reference) kpa (kgf/cm2, psi) 410 (4.2, 60)
Valve clearance IN (cold engine) mm (in) 0.17 – 0.23 (0.007 – 0.009)
Valve clearance EX (cold engine) mm (in) 0.31 – 0.37 (0.012 – 0.015)

3. CRANKSHAFT OIL CLEARANCE

The adjusting oil clearance for crankshaft main journal and crank-pin can be performed to select the
plane bearings due to indications and calculation.

Plane bearing selection

Main journal bearing selection (20 °C, 68 °F)
Difference of diameter
Body cylinder plane Crankcase plane
between crank journal
bearing color bearing color
and case journal
6.023-6.026 Green Yellow
6.027-6.034 Blue Green
6.035-6.042 Blue Blue
6.043-6.049 Red Blue
6.050-6.058 Red Red

Crankshaft pin bearing selection (20 °C, 68 °F)

Difference of diameter
Connecting rod upper Connecting rod cap
between crank-pin
plane bearing color plane bearing color
and big end
3.025-3.027 Yellow Yellow
3.028-3.034 Yellow Green
3.035-3.041 Green Green
3.042-3.049 Green Blue
3.050-3.057 Blue Blue
3.058-3.063 Blue Red

35
Mark location on the crankshaft

Crank-pin #1 #2 #3 #4

Journal #1 #2 #3 #4 #5

Fig. 24 Journal and pin mark location on crankshaft

Example:
If the journal #1 is stamped 96, the actual diameter is 47.996 mm.
If the crank-pin #1 is stamped 89, the actual diameter is 43.989 mm.

Mark location on the cylinder body

Journal #1 #2 #3 #4 #5

Fig. 25 Crank journal mark location on cylinder body

Example:
If journal #1 is stamped 28, the actual diameter is 54.028 mm.

36
Connecting rod big end measurement

Diameter measurement

Up mark

Fig. 26 Connecting rod big end

Connecting rod big end diameter measurement,

1) Install the cap using the exclusive bolts with specified torque.
2) Measure several diameter points using a cylinder gauge.
3) Average the measurements.

NOTE:
The diameter measurement should be in 47.025 to 47.045 mm.

CAUTION:
Do not reuse the connecting rod cap bolt.

37
4. TIGHTENING TORQUES
1) SPECIFIED TORQUES (EXTRACTED)
Tightening torques
Part to be tightened Thread size
N•m kgf•m ft•lb
POWER UNIT
Belt tensioner bolt M10 39 4 29
1st M7 8 0.8 6
Camcap bolt
2nd M7 17 1.7 12
1st M8 8 0.8 6
Connecting rod cap bolt
2nd M8 Turn 90
1st M10 19 1.9 14
2nd M10 Turn 60
Crankcase bolt
1st M8 14 1.4 10
2nd M8 28 2.8 20
1st M10 15 1.5 11
2nd M10 30 3.0 22
Cylinder head bolt 3rd M10 Turn 90
1st M8 14 1.4 10
2nd M8 28 2.8 20
Cylinder head cover bolt M6 8 0.8 6
Drive sprocket nut (M40) 265 27 195
Driven sprocket bolt M10 60 6 44
1st M6 6 0.6 4
Exhaust outer cover bolt
2nd M6 12 1.2 9
Flywheel nut (M24) 215 22 159
Oil filter 18 1.8 13
Oil filter mount plug (M20) 49 5 36
Plug for optional water sender M14 23 2.3 17
Spark plug M14 25 2.5 18
DRIVE UNIT
Engine mount bolt M10 42 4.2 31
Gear oil plug M8 9 0.9 6
Lower casing/ Extension mount bolt M10 39 4 29
Oil drain plug 27 2.7 20
Pinion nut (M16) 93 9.3 69
Propeller nut (M16) 93 9.3 69
Ring nut (M101.5) 103 10 76
BRACKET UNIT
Grease nipple (M6) 3 0.3 2
Steering hook / Tiller handle mount nut (M10) 37 3.7 27
Through tube nut (M22) 15 1.5 11
Lower rubber mount nut (M12) 51 5 38
Upper mount cap bolt (M8) 28 2.8 21
Upper rubber mount nut (M12) 51 5 38

38
 Tightening torques
Part to be tightened Thread size
N•m kgf•m ft•lb
PT/T UNIT
Inner cylinder end cap 80 8 59
Outer cylinder end cap 90 9 66
Tilt rod bolt 85 8.5 63

2) GENERAL TORQUES
General torques
This chart specifies tightening torques for stan- Nut (A) Bolt (B)
dard fasteners with a standard ISO thread N•m kgf•m ft•lb
pitch. To avoid warpage of the components, 8 mm M5 5 0.5 4
tighten the fasteners with a criss-cross pattern 10 mm M6 8 0.8 6
and progressive stages until the specified tight- 12 mm M8 18 1.8 13
ening torque is obtained. 14 mm M10 36 3.6 27
Unless otherwise specified, the tightening
17 mm M12 43 4.3 32
torque specifications require clean and dry
threads.
The components should be at room tempera-
ture.

39
 YAMAHA MOTOR CO., LTD.
Produced in Japan
May 2004 –1P
(E)