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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 
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