ge5255472241733080100
4
Andrew Norton1 Jun 2005
REVIEW

90 to 100hp four-strokes and direct-injection two-strokes

In the next of his popular series of guides to choosing the right low-pollution outboard for your boat, Andrew Norton compares 90 to 100hp four-strokes and direct-injection two-strokes

FOUR-STROKES

HONDA BF90
Up-rated from its 75hp counterpart, the BF90 is based on the 1.6lt Honda Civic car engine. It has electrically-operated manual chokes for simplicity with a manual override for hand-starting should the battery be flat, and unlike the Johnson/Suzuki DF90, a battery isn't needed to run the engine - which is just as well given the alternator charging capacity is low nowadays for a 90.

Mounted on a 5m Horizon aluminium centre console spinning a 19in alloy prop and pushing a total of 900kg including four adults, the demo BF90 performed well on this hull despite being over-propped. It started easily hot or cold, warmed quickly from cold and didn't blow any visible oil smoke.

The trolling average was 4.6kmh on 800 revs using 1.1lt/h. At 4000rpm the averages were 45.0kmh and 9.0lt/h. Through tight figure-eight turns at these revs no prop ventilation occurred.

The WOT average was 62.0kmh on 5300 revs using 26lt/h and for a carbie four-stroke noise and vibration levels were pleasantly low.

Although the BF90 is still a "first generation" four-stroke it scores by being a simple engine to work on and has an impressive reliability record. Powerhead access is very good and the dipstick and oil filter are easily reached, while the toothed camshaft timing belt should last around 800 hours before it needs replacing.

JOHNSON/SUZUKI DF90
De-rated from its 115hp counterpart and based on the Suzuki Vitara 4WD engine, the DF90 is the only four-stroke in this power range to have EFI, which enables it to operate as efficiently on high altitude alpine lakes as it does at sea level and equally well on hot humid summer days or cool dry winter ones.

Another advantage is the two-stage gear reduction, achieved by offsetting the driveshaft from the crankshaft with a reduction in between these and an additional reduction in the gearcase where drive changes from vertical to horizontal. This system enables coarse-pitch props to be swung without increasing gearcase diameter and subsequent hydrodynamic drag. Both sets of reductions are chaindrive, as is the camshaft drive, and Suzuki says the chains are designed to last the life of the engine.

The alternator produces 24 amps more than the BF90's alternator and twice that of the F90's system, but some of that current is used to power the computer-controlled EFI.

The drawback of the DF90 is its weight. The DF90 is best suited to mounting on aluminium hulls that have full-width transom pods and are over 5m in length.

On a 5.3m Clark Abalone Centre Console the demo DF90 proved almost as quick as a DF115 on a Clark 570 Abalone. The DF90 started instantly hot or cold, never blew any visible oil smoke and was so quiet when trolling it could barely be heard from the helm, while vibration levels across the entire rev range were very low. Slightly under-propped spinning a 19in-pitch alloy Suzuki prop and pushing a total of 950kg including three adults, the Suzy trolled at 4.8kmh on 650 revs using 1.1lt/h and averaged 38.2kmh on 4000 revs using 12.5lt/h.

Through tight figure-eight turns at 4000 revs there was no prop ventilation.

The WOT average was 57.9kmh on 5600 revs using 30.5lt/h. Powerhead access is good and the engine oil dipstick and oil filter are easily reached.

The large oil sump has sufficient capacity to effectively reduce oil sludging between oil/filter changes when used for extended trolling periods.

MERCURY/MARINER F90
A joint venture between Mercury Marine and Yamaha Marine, the F90 is up-rated from its F75 counterpart and uses the powerhead from the European Ford Sierra car, but with four carbies instead of EFI. The DOHC powerhead is more throttle-responsive than Honda's BF75 and also quieter despite the additional valves and associated complication.

The F90 has an automatic choke system and an Electronic Control Module that advances the ignition timing for cold starting as well as normal operation. The ECM also reduces engine revs should the engine overheat or suffer low oil pressure.

Mounted on a 5.05m fibreglass Signature 520R Runabout and spinning a 14in Quicksilver Vengeance stainless-steel prop the demo F90 provided a good blend of performance and fuel efficiency. It started easily hot or cold, warmed quickly from cold and didn't blow any visible oil smoke.

Pushing a total of 920kg including two adults the F90 trolled us a 3.8kmh on 750 revs using 1.1lt/h and averaged 45.5kmh on 4000rpm using 10.5lt/h. Through tight figure-eight turns at 4000 revs there was no prop ventilation. However for some reason the rev limiter was set at 5300 revs where we averaged 66.0kmh using 28lt/h.

With its DOHC powerhead, access is not as good as the BF75 but at least the dipstick and oil filter are easily reached. Unlike the Honda there's no provision for operating the chokes manually, so a "healthy" battery is a must.

YAMAHA F100A
Up-rated from its F80A counterpart, the F100A was Yamaha's next "big" four-stroke after the release of the F50 in the mid-90s and remains the lightest four-stroke outboard in this power range. The alternator output is acceptable for a 100hp outboard and 12 amps are produced at a low 1000 revs, useful for fast trolling.

On a 5.8m fibreglass Southern Star longboat, the demo F100A was little affected by widely varying loads and provided significantly better performance than its F80A counterpart. Spinning a 19in stainless-steel Yamaha prop and pushing a total of 850kg including two adults it cruised at 39.9kmh on 4000 revs using 13.0lt/h and through tight figure-eight turns at these revs no prop ventilation occurred. The WOT average was 65.7kmh on 6000rpm using 31lt/h and with pleasantly low noise levels.

Although trolling trials were not conducted, the fuel consumption should be very similar to the F90.

Powerhead access is good with the dipstick and oil filter easily reached although the carbie balancing linkages appeared more fiddly to adjust than the F90. Again, the toothed timing belt should last about 800 hours but as the F100A probably has an "interference" engine (should the belt break the valves could contact the piston crowns) the belt should be checked for any damage every 100 hours. The first service is at 10 hours.

 TWO-STROKES


EVINRUDE E-TEC 90
Up-rated from its 75hp counterpart, the E-Tec 90 is essentially an Evinrude/Johnson V6 cut in half and has a big bore.

The lightest low-pollution 90 on the Aussie market, the 90 also has the only self-contained DFI system that doesn't need a battery to function. Should the battery be flat the engine can be manually started, if your arms are strong enough!

Other features include a massive-output variable voltage alternator and Speed Adjusting Failsafe Electronics (SAFE) which reduce engine revs should the oil level in the under-cowl tank drop below a preset level or the engine overheat.

On Bombardier XD50 oil the fuel/oil ratios vary from 360:1 at trolling speed to about 60:1 at WOT.

On a fibreglass Seafarer 5.0 Venus half cabin and pushing a total of 950kg including two adults, the demo 90 provided similar performance to a V4 FICHT 90 tested on this hull, despite having only 75 per cent of the piston displacement.

Spinning a 17in-pitch stainless-steel SST prop the Evinrude E-Tec 90 trolled us at 4.7kmh on 650 revs using an estimated 0.8lt/h and averaged 44.5kmh on 4000 revs using an estimated 18.7lt/h.

Through tight figure-eight turns at these revs there was no prop ventilation.

The WOT average was 64.5kmh on 5400 revs using about 30.2lt/h, whereas spinning a 17in prop and pushing 970kg the FICHT 90 averaged 69.9kmh on 5300 revs. The demo E-Tec 90 started instantly hot or cold and didn't blow any visible oil smoke, nor was there an oil smell.

To ensure gearcase oil longevity the lower unit is straight from the Evinrude/Johnson V4 range and although Bombardier says changing the gear oil is not needed for three years, I would recommend changing it anyway once a year to check for water contamination. Better safe than sorry!

E-Tec dealers I've spoken to also recommend lubricating the throttle and gearshift linkages and cables at least once a year.

MERCURY/MARINER 90 OPTIMAX
The 90 is the middle of a trio of OptiMax engines from 75 to 115, all utilising the 3.0lt powerhead from the V6 OptiMax 200 and 250 but essentially cut in half to provide the 1.5lt powerhead.

The 90 uses the Orbital Engine Corporation's OCP which mixes fuel pressurised to 80psi with air at 90psi which is then injected directly into the combustion chambers, providing an atomised spray of around five microns per droplet. A mix of stratified combustion where the air/fuel ratio is about 40:1 is used below around 1500 revs and homogenous (25:1) above for power out of the hole. The engine oil is injected electrically where needed and the fuel/oil ratios vary between 400:1 when trolling and 44:1 at WOT.

The OptiMax 90 has automatic additional engine oiling for the first five hours and is SmartCraft-compatable, giving operators fuel-flow and range to empty info and providing full engine protection features such as automatic revs reduction should the engine overheat or suffer low oil pressure/level.

The engine can be fitted with Troll Control to reduce engine revs to only 400rpm for slow-speed trolling.

So far I've not been able to test the 90, but with its large piston displacement for its output and it should outperform the E-Tec 90 while returning excellent mid-range fuel efficiency.

The OptiMax needs a battery for the ECU so a capacity of at least 110A/h is required to prevent low-speed engine misfiring.

TOHATSU TLDI 90
The second generation of Tohatsu's direct fuel injection two-strokes, the 90hp TLDI (Tohatsu Low-Pressure Direct Injection) utilises the Orbital Engine Corporation's combustion process which Tohatsu has modified in-house.

The stratified combustion system below about 3000 revs gives an air/fuel ratio of about 40:1, richening to 25:1 when the engine operates on homogenous combustion. The fuel/oil ratios vary from 450:1 to 50:1.

Standard are warning systems for engine over-rev (6000 revs), low oil, engine overheat and low battery voltage.

Should any of these problems occur, the electronic control unit (engine management system) will reduce the revs in stages down to 900rpm.

By depressing the ignition key for a second at a time the trolling revs can be adjusted in increments of 100 revs from 700 to 900rpm.

Mounted on a fibreglass 5.05m Signature 520C half cabin to compare as closely as possible to the Mariner/Mercury F90 tested a year earlier on this hull, the demo TLDI 90 was not as fast as the F90 but was more throttle-responsive. It started instantly hot or cold and didn't blow any visible oil smoke although there was a slight oil smell on cold starting. Vibration and noise levels were lower than any carbie two-stroke 90 available but vibration levels were higher than Tohatsu's TLDI 50, to my mind.

Spinning a 15in stainless-steel Power Tech prop and pushing a total of 920kg including two adults, the 90 trolled us along at 4.1kmh on 700 revs using 0.7lt/h and cruised quietly at 40.9kmh on 4000 revs using 12.8lt/h. Through tight figure-eight turns at 4000 revs there was some prop ventilation.

The WOT average was 58.9kmh on 5600 revs using 27.6lt/h with slightly higher noise levels than the E-Tec 90.

Powerhead access is good and the air compressor drive belt, fuel pump, vapour separator, injector block and throttle body assembly are easily reached.

The first service is at 10 hours but a battery of around 120A/h capacity should be used as the management computer and electric oil pump draw a fair amount of current and the voltage must be maintained above 10.8V.

BACKUP & WARRANTY
All the engines listed comply with US EPA 2006 exhaust emission regulations but in addition the Honda BF90, Johnson/Suzuki DF90, Evinrude E-Tec 90 and Mariner/Mercury OptiMax 90 meet California Air Resources Board (CARB) 2008 requirements. The DF90 also meets EU2005 requirements and the E-Tec 90 meets EU2006, which take into account noise emissions.

Standard are two-year warranties for recreational usage, while the Suzuki DF90 and E-Tec 90 have three years and in addition the Mariner/Mercury F90 and OptiMax 90 have three years against corrosion perforation and four for selected ignition components.

Recommended servicing requirements for the four-strokes are every 50 hours (100 for the BF90) with water pump impeller replacement every 100 hours. Apart from the Yamaha F100A, the first service is at 20 hours when the valve clearances should be checked. All the four-strokes have canister-type oil filters.

The Tohatsu TLDI 90 and OptiMax 90 require servicing every 100 hours while the E-Tec 90 doesn't require any servicing for the first 300 operating hours or three years.

AND THE WINNER IS...
Having not yet tested the Mercury/Mariner OptiMax 90 I can't comment on how well this engine compares with direct four-stroke and DFI two-stroke competition.

Of the other engines it's a toss-up between the DF90 and the E-Tec 90, which are the cleanest-running engines in the 90–100hp power range. While the DF90 has tons of torque, it's a real heavyweight, so while the E-Tec 90 is too new to judge its reliability, for performance, power-to-weight and clean running it's my choice of engines in this power range.
























































































































































90-100hp Four-Strokes
Engine Honda 90 Johnson/Suzuki 90 Mercury Mariner 90 Yamaha 100
Engine type Crossflow four-cylinder
Valves 12 16 16 16
Valve actuations SOHC DOHC DOHC DOHC
Drive Belt Chain Belt Belt
Prop HP @ rpm Carburetted 88.7/5500 -- 89.8/5500 98.7/5500
EFI -- 88.7/5000 -- --
WOT rev range Carburetted 5000–6000 -- 5000–6000 5000–6000
EFI -- 4500–5500 -- --
Piston displ. (cc) 1590 1950 1596 1596
Bore x stroke (mm) 75x90 84x88 79x81.4 79x81.4
Ignition system Carburetted All CD with electronic timing advance
EFI All electronic engine management
Charging circuit (amps) Carburetted 16 reg -- 20 reg 20 reg
EFI -- 40 reg -- --
Break-in period (hrs) 10 10 10 10
Fuel delivery Carburetted Four -- Four Four
EFI All sequential multipoint
Oil type (SAE) 10W30/40 10W30/40 10W30/40 10W40
Oil capacity (lt) 4.5 5.5 4.5 4.5
Gear ratios 2.3:1 2.59:1 2.33:1 2.31:1
Standard Transom heights (in) 20/25 20/25 20/25 20/25
Weights (kg) Longshaft 169* 189* 175* 174*
Weights (kg) Extra-long 174* 194* 180* 178*
Rec. retail Longshaft $13,240* $12,646* $14,204* $14,781*
Rec. retail Extralong $13,720* $12,778* $14,553* $15,097*
* Weights electric start remote control versions with power trim. Prices accurate at press time



































































































90-100hp Two-Strokes
Engine E-Tec 90 OptiMax 90 TLDI 90
Engine type Three-cylinder DFI two-stroke
Prop HP @ rpm 89.8/5500 89.8/5375 88.7/5500
WOT rev range 4500–5500 5000–6000 5000–6000
Piston displ. (cc) 1295 1524 1267
Bore x stroke (mm) 91x66 92x76 86x72.7
Ignition system All electronic engine management
Charging circuit (amps) 75 reg 60 reg 23 reg
Break-in period (hrs) 5 5 10
Fuel/air scavenging Loopcharged L/C L/C
Fuel delivery High pressure single stage Low pressure Dual stage
Oil type Bombardier XD50 or XD100 Quicksilver Premium TC-W3 Valvoline Premium
Oil capacity (lt) 2.8 -- 4.0
Gear ratios 2:1 2.33:1 2:1
Transom heights (in) 20/25 20/25 20/25
Weights (kg) Longshaft 138* 164* 143*
Weights (kg) Extra-long 141* 169* 147*
Rec. retail Longshaft $12,080* $14,490* $10,036*
Rec. retail Extralong $13,000* $14,825* $10,278*
* Weights are electric start versions with power trim and tilt. Prices correct at press time



Share this article
Written byAndrew Norton
See all articles
Stay up to dateBecome a boatsales member and get the latest news, reviews and advice straight to your inbox.
Subscribe today
Love every move.
Buy it. Sell it.Love it.
®
Download the boatsales app
    AppStoreDownloadGooglePlayDownload
    App Store and the Apple logo are trademarks of Apple Inc. Google Play and the Google Play logo are trademarks of Google LLC.
    © carsales.com.au Pty Ltd 1999-2026
    In the spirit of reconciliation we acknowledge the Traditional Custodians of Country throughout Australia and their connections to land, sea and community. We pay our respect to their Elders past and present and extend that respect to all Aboriginal and Torres Strait Islander peoples today.