Yamaha F2 5 Service Manual
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Page 91
69M3E115-30 1 2 3 4 5 6 7 8 9 4. Measure the camshaft runout. Replace if out of specification. Checking the valve lifters 1. Check the valve lifters for bends or wear. Replace if necessary. Checking the oil splasher gear 1. Check the teeth of the oil splasher gear for cracks, damage, or wear. Replace if necessary. Disassembling the cylinder block 1. Check the ball bearing for pitting or rum- bling. Replace if necessary. NOTE: Do not remove the ball bearing if not replac- ing it. 2. Remove the ball...
Page 92
POWRPower unit 5-3169M3E11 Assembling the cylinder block 1. Apply grease to the new oil seal, and then install it into the cylinder block. 2. Install the new ball bearing into the cylin- der block. CAUTION: Do not reuse the bearing, always replace it with a new one. Disassembling the crankcase 1. Remove the bolt and oil seal housing. NOTE: Insert a flat head screwdriver between the tab of the oil seal housing and the tab of the crankcase to pry open the two parts. 2. Remove the O-ring. 3. Remove the oil...
Page 93
69M3E115-32 1 2 3 4 5 6 7 8 9 Checking the oil seal housing 1. Check the oil seal housing for cracks, damage, or corrosion. Replace if neces- sary. Assembling the crankcase 1. Apply grease to the new oil seals, and then install them into the oil seal housing. 2. Apply grease to the new oil seal, and then install it into the oil seal housing.3. Install the new O-ring. 4. Install the oil seal housing 5 to the crankcase 6 . Driver rod L3 1 : 90890-06652 Bushing attachment 2 : 90890-06649 Driver rod L3 3 :...
Page 94
POWRPower unit 5-3369M3E11 Assembling the piston and cylinder block 1. Assemble the piston 1 , connecting rod 2 , piston pin 3 , and new piston pin clips 4 . NOTE: Face the embossed “Y” mark a on the connecting rod in the same direction as the “UP” mark b on the piston. Always use new piston pin clips, and do not allow the piston pin clip end to align with the piston pin slot c . 2. Install the oil ring 5 , second ring 6 , and top ring 7 to the piston with the “N” marks d of the top and second...
Page 95
69M3E115-34 1 2 3 4 5 6 7 8 9 6. Install the connecting rod cap A to the connecting rod, and then tighten the con- necting rod bolts to the specified torques in two stages. NOTE: Apply engine oil to the connecting rod cap and connecting rod bolts before installation. Align the marks e on the connecting rod cap and connecting rod. 7. Install the valve lifters B into the cylinder block.8. Set the camshaft C into the cylinder block as shown. NOTE: Align the crankshaft mark f and the cam- shaft mark...
Page 96
POWRPower unit 5-3569M3E11 11. Install the new gasket and cylinder head, and then tighten the cylinder head bolts H to the specified torques in two stages and in the sequence shown. CAUTION: Do not reuse the cylinder head gasket, always replace it with a new one. NOTE: Apply engine oil to the cylinder head bolts before installation. 12. Install the push rods, rocker arms I , and rocker arm pivots J , and then tighten the rocker arm locknuts. 13. Install the crankcase to the cylinder block, and then...
Page 97
69M3E115-36 1 2 3 4 5 6 7 8 9 Installing the power unit 1. Clean the power unit mating surfaces, and then install the dowels 1 and the new gasket 2 . 2. Install the power unit 3 by installing the bolts 4 , and then tighten them to the specified torque. CAUTION: Do not reuse the power unit gasket, always replace it with a new one. 3. Install bottom cowling 1 5 , bottom cowl- ing 2 6 , and the carrying handle 7 .4. Install the Woodruff key 8 . T R.. Thermostat cover bolt N : 8 N·m (0.8 kgf·m, 5.9 ft·lb)...
Page 98
POWRPower unit 5-3769M3E11 5. Install the flywheel magnet 9 and starter pulley 0 , and then tighten the flywheel magnet nut to the specified torque. CAUTION: Apply force in the direction of the arrows shown, to prevent the flywheel holder from slipping off easily. NOTE: Apply engine oil to the flywheel magnet nut before installation. 6. Install the flywheel magnet cover B and manual starter C . Flywheel holder A : 90890-06522 T R.. Flywheel magnet nut: 44 N·m (4.4 kgf·m, 32.4 ft·lb) S69M5A80 A 0 9
Page 99
69M3E11 LOWR 1 2 3 4 5 6 7 8 9 Lower unit Special service tools ..................................................................................... 6-1 Lower unit ....................................................................................................... 6-2 Removing the lower unit ............................................................................ 6-5 Removing the water pump and shift rod .................................................... 6-5 Checking the water pump and shift...
Page 100
LOWRLower unit 6-169M3E11 Special service tools6 Bushing attachment 90890-06649, 90890-06650 Driver rod L3 90890-06652 Needle bearing attachment 90890-06615, 90890-06617 Bearing puller 90890-06535 Stopper guide plate 90890-06501Stopper guide stand 90890-06538 Bearing puller claw 2 90890-06537 Ball bearing attachment 90890-06637, 90890-06638 Driver rod LS 90890-06606