1986 Evinrude 90 Manual

The 1986 Evinrude 90 is a 90 horsepower outboard motor featuring V4 configuration, loop-charged combustion system, 89.7 cubic inch displacement, thermostatically controlled cooling, CD ignition system, built-in fuel pump, 12-volt electric starting, power trim and tilt, single-lever remote control, and corrosion-resistant construction. Below are key sections for safety, features, installation, operation, maintenance, and troubleshooting.

1. Features at a Glance 2. Installation 3. First-Time Setup 4. Specifications 5. Controls and Operation 6. Fuel System 7. Maintenance Schedule 8. Winterization 9. Storage & Care 10. Regulatory Information 11. Troubleshooting

Features at a Glance

Key components: V4 powerhead, CD ignition system, thermostatic cooling, power trim/tilt, single-lever remote control, built-in fuel pump.

Feature	Description
Powerhead	90° V4 configuration, 89.7 cu in displacement
Ignition System	CD capacitor discharge with electronic timing
Cooling System	Thermostatically controlled water pump
Fuel System	Built-in mechanical fuel pump
Starting System	12-volt electric start with alternator
Trim/Tilt System	Power trim and tilt with hydraulic cylinders
Gearcase	Shear-proof propeller hub, 2.00:1 gear ratio
Control System	Single-lever remote control with safety lanyard
Exhaust System	Through-propeller hub exhaust
Corrosion Protection	Aluminum alloy with corrosion-resistant coatings

Installation

Mount motor on transom following manufacturer specifications.

Select proper transom height: Match motor mounting bracket to boat transom.
Install mounting bolts: Use stainless steel bolts, nuts, and washers.
Connect steering system: Attach steering cable or hydraulic lines.
Connect control cables: Install throttle and shift cables to motor.
Connect battery: Use marine-grade cables with proper polarity.
Connect fuel system: Install fuel line with quick-connect fittings.

WARNING! Motor is heavy; use proper lifting equipment. Ensure all connections are secure before operation.

First-Time Setup

Prepare motor for initial startup and break-in period.

Fuel mixture: Use 50:1 gasoline to TC-W3 outboard oil ratio.
Priming: Squeeze fuel line bulb until firm.
Starting procedure: Set neutral, advance throttle slightly, turn key.
Break-in period: Vary RPM for first 10 hours, avoid prolonged idle.
Initial adjustments: Set idle speed to 650-750 RPM in neutral.
Check systems: Verify cooling water discharge, oil injection (if equipped).

CAUTION! Follow break-in procedures carefully to ensure proper engine longevity.

Specifications

Horsepower: 90 HP at 5000 RPM
Cylinders: 4 (V4 configuration)
Displacement: 89.7 cubic inches (1470 cc)
Bore x Stroke: 3.50 x 2.30 inches
Ignition: CD capacitor discharge
Starting: 12-volt electric with 35-amp alternator
Gear Ratio: 2.00:1
Full Throttle RPM: 4500-5500 RPM
Weight: Approximately 295 lbs
Fuel/Oil Ratio: 50:1 (TC-W3 outboard oil)

Controls and Operation

Single-lever remote control: Push forward for forward gear and throttle, pull back for reverse gear and throttle.

Control Functions: Key switch (off/on/start), choke button, trim/tilt switches, neutral safety switch, emergency stop lanyard.

Starting Procedure: Ensure in neutral, advance throttle slightly, turn key to start. Warm up at 1000-1500 RPM. Shifting: Pause in neutral when changing directions. Trim Operation: Use trim switches to adjust motor angle for optimal performance.

Fuel System

Built-in mechanical fuel pump with pulse operation. Fuel recommendations: 87 octane minimum, ethanol-blended fuels acceptable with proper additives.

Fuel mixture: 50:1 ratio of gasoline to TC-W3 certified outboard oil.
Fuel filter: Replace annually or every 100 hours.
Fuel lines: Inspect for cracks, replace if deteriorated.
Fuel tank: Use approved marine fuel tanks with proper ventilation.

Tip: Always use fresh fuel and proper oil mixture to prevent engine damage.

Maintenance Schedule

Regular maintenance ensures optimal performance and longevity.

Every 100 hours: Replace spark plugs, check compression.
Annual: Change gearcase lube, inspect water pump impeller.
Every 200 hours: Clean carburetors, check timing.
Seasonal: Grease fittings, check propeller for damage.
Monthly: Check battery charge, inspect electrical connections.
Before each use: Check fuel system, verify cooling water flow.

WARNING! Disconnect battery before performing electrical maintenance.

Winterization

Proper winter storage prevents corrosion and fuel system damage.

Fuel stabilization: Add fuel stabilizer and run engine for 10 minutes.
Fogging: Spray fogging oil into carburetors while running.
Gearcase: Check and change gearcase lubricant.
Cooling system: Flush with fresh water, drain completely.
Battery: Remove and store fully charged.
Storage: Store upright in dry, covered location.

Care & Cleaning

Rinse with fresh water after each use in saltwater. Use mild soap and soft brush for cleaning. Lubricate pivot points with marine-grade grease.

CAUTION! Do not use high-pressure spray near seals or electrical components. Avoid abrasive cleaners on painted surfaces.

Regulatory Information

US Coast Guard approved for marine use. EPA emissions compliant for 1986 model year. Manufactured by Outboard Marine Corporation. For technical support and parts, contact authorized Evinrude dealers or visit www.evinrude.com. Serial number located on mounting bracket.

Troubleshooting

Symptom	Possible Cause	Corrective Action
Engine won't start	Fuel, spark, or compression	Check fuel supply, spark plugs, compression test.
Overheating	Water pump, thermostat	Inspect water pump impeller, check thermostat operation.
Poor performance	Fuel system, ignition	Clean carburetors, check spark advance, verify timing.
No spark	Ignition components	Test stator, power pack, trigger, and coils.
Vibration	Propeller, alignment	Inspect propeller for damage, check engine alignment.

Service: Contact authorized Evinrude dealer for major repairs. Keep records of all maintenance.

Parts: Use genuine Evinrude parts for optimal performance and warranty coverage.