Yamaha F2 5 Service Manual

							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 bearing.
3. Remove the oil seal 5
.Camshaft runout limit:
0.03 mm (0.0012 in)
S69M5730
S69M5740
S69M5750
Stopper guide plate 1
: 90890-06501
Stopper guide stand 2
:
90890-06538
Bearing puller 3
: 90890-06535
Bearing puller claw 1 4
:
90890-06536
S69M5755
S69M5770
3
42 1
S69M5780
5
Cylinder block 
						

							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 seals.
Driver rod L3 1
: 90890-06652
Needle bearing attachment 2
:
90890-06613
Driver rod LS 3
: 90890-06606
Bearing outer race attachment 4
:
90890-06624
S69M5800
1
2
AA
S69M5820
3
4
E
S69M5830
S69M5840
S69M5850 
						

							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
: 90890-06652
Needle bearing attachment 4
:
90890-06613
S69M5860
S69M5880
1
2
AA
S69M5900
3
4
AA
S69M5910
AA
Cylinder block 
						

							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 ring fac-
ing upward.
3. Offset the piston ring end gaps as
shown.
CAUTION:
Do not scratch the piston or break the pis-
ton rings.
NOTE:
After installing the piston rings, check them
for smooth operation.
4. Install the crankshaft 8
 into the cylinder
block 9
.
5. Install the piston with the “UP” mark on
the piston crown facing towards the fly-
wheel magnet.
NOTE:
Apply engine oil to the piston and piston rings
before installation.
S69M5940
UP
N
N
5
6
7
d d
#1,#4#2
#5 #3
45˚45˚
#1 #2 #5
#4
#3
E
Piston slider 0: 90890-06843
S69M5950
89
S69M5970
UP
0 
						

							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 g
.
9. Install the oil splasher gear D
, and then
tighten the bolt to the specified torque.
10. Install the dowel E
, new gasket F
, and
the washer G
.
CAUTION:
Do not reuse the crankcase gasket,
always replace it with a new one.
T R..
Connecting rod bolt:
1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
2nd: 9 N·m (0.9 kgf·m, 6.6 ft·lb)
S69M5980
A
e
S69M5990
E
B
T R..
Oil splasher gear bolt:
13 N·m (1.3 kgf·m, 9.6 ft·lb)
S69M5A00
C
g
f
S69M5A10ED
F
E
G
Cylinder block 
						

							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 tighten the crankcase
bolts to the specified torques in two stage
and in the sequence shown.14. Install the new gasket and cylinder head
cover, and then tighten the bolts to the
specified torques in two stages and in the
sequence shown.
15. Install the thermostat K
, new gasket L
,
and thermostat cover M
, and then
tighten the thermostat cover bolts N
 to
the specified torque.
T R..
Cylinder head bolt H
:
1st: 14 N·m (1.4 kgf·m, 10.3 ft·lb)
2nd: 30 N·m (3.0 kgf·m, 22.1 ft·lb)
S69M5C10
2
43
1
E
H
S69M5480
JI
T R..
Crankcase bolt:
1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
2nd: 11 N·m (1.1 kgf·m, 8.1 ft·lb)
T R..
Cylinder head cover bolt:
1st: 5 N·m (0.5 kgf·m, 3.7 ft·lb)
2nd: 12 N·m (1.2 kgf·m, 8.9 ft·lb)
S69M5A20
6
1
5
4
32 8
7
9
0
E
S69M5500
1
4
326 5 
						

							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)
T R..
Power unit bolt 4
:
11 N·m (1.1 kgf·m, 8.1 ft·lb)
Cylinder block 
						

							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 
						

							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 rod ..................................................... 6-6
Propeller shaft housing ................................................................................. 6-7
Removing the propeller shaft housing assembly ....................................... 6-8
Disassembling the propeller shaft assembly ............................................. 6-8
Disassembling the propeller shaft housing ................................................ 6-8
Checking the propeller shaft housing ........................................................ 6-8
Checking the propeller shaft ...................................................................... 6-9
Assembling the propeller shaft assembly .................................................. 6-9
Assembling the propeller shaft housing..................................................... 6-9
Drive shaft and lower case .......................................................................... 6-10
Removing the drive shaft ......................................................................... 6-11
Disassembling the lower case ................................................................. 6-11
Checking the pinion and forward gear ..................................................... 6-12
Checking the drive shaft .......................................................................... 6-12
Checking the lower case ......................................................................... 6-12
Assembling the lower case ...................................................................... 6-12
Installing the drive shaft ........................................................................... 6-13
Installing the propeller shaft housing ....................................................... 6-14
Installing the water pump and shift rod .................................................... 6-14
Installing the lower unit ............................................................................ 6-15 
						

							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