Yamaha F2 5 Service Manual
Have a look at the manual Yamaha F2 5 Service Manual online for free. It’s possible to download the document as PDF or print. UserManuals.tech offer 255 Yamaha manuals and user’s guides for free. Share the user manual or guide on Facebook, Twitter or Google+.
69M3E118-4 1 2 3 4 5 6 7 8 9 Ignition system8 Checking the ignition spark gap 1. Disconnect the spark plug cap 1 from the spark plug. 2. Connect the special service tool to the spark plug cap and to the ground bolt. 3. Set the spark gap length on the adjusting knob. 4. Crank the engine and observe the spark through the discharge window of the spark gap tester. Check the TCI unit or spark plug cap if out of specification. WARNING •Do not touch any of the connections of the spark gap tester leads. •Keep flammable gas or liquids away, since this test can produce sparks. Checking the spark plug cap 1. Remove the spark plug cap from the spark plug wire by turning the cap coun- terclockwise. 2. Measure the spark plug cap resistance. Replace if out of specification.Ignition tester: 90890-06754 Ignition spark gap: 7 mm (0.28 in) S69M8040 1 Spark plug cap resistance: 4.0–6.0 kΩ OK S69M8060 Ω × 1K S69M8080 Electrical components / Ignition system
ELECElectrical systems –+ 8-569M3E11 Checking the TCI unit 1. Remove the spark plug cap from the spark plug wire by turning the cap coun- terclockwise. 2. Measure the TCI unit resistance. Replace if out of specification. Checking the engine shut-off switch 1. Check the engine shut-off switch for con- tinuity. Replace if there is no continuity. TCI unit resistance: Primary coil: White (W) – Black (B) 0.56–0.84 Ω Secondary coil: White (W) – Spark plug wire 11.6–17.4 kΩ Lead color White (W) Black (B) Clip removed a Clip installed b Engine stop button pushed c
69M3E11 TRBL SHTG 1 2 3 4 5 6 7 8 9 Troubleshooting Power unit ....................................................................................................... 9-1
TRBL SHTG Troubleshooting 9-169M3E11 NOTE: To diagnose a mechanical malfunction, use the troubleshooting charts pertaining to the trouble located in this chapter. Also, when checking and maintaining the outboard motor, see Chapters 4– 8 for safe maintenance procedures. Check that all electrical connections are tight and free from corrosion. Power unit9 Symptom: Engine does not start (manual starter is operating normally). Check the ignition system. Check the fuel system. Check the compression pressure of the power unit. Check the engine shut-off switch for continuity (with clip installed). Replace the engine shut-off switch.Is there continuity?No Check the ignition spark gap using the spark gap tester. Continued on next page. WARNING •Do not touch any of the connections of the spark gap tester leads. •Keep flammable gas or liquids away, since this test can produce sparks. No Yes Check the condition of the spark plug. Check the TCI unit or spark plug cap.Out of specifica- tion? Yes
69M3E119-2 1 2 3 4 5 6 7 8 9 NoClean, adjust or replace the spark plug.Good condition? Check the compression pres- sure of the combustion chamber. Out of specification? Yes NoCheck the fuel system. Out of specification? No Check the cylinder head, cylin- der body, and piston assembly. Check the valve clearance. YesAdjust the valve clearance. Power unit
TRBL SHTG Troubleshooting 9-369M3E11 Symptom: Engine can be started, but does not remain on. Check the fuel system. Check the ignition system. Check the compression pressure of the power unit. Fuel system Ignition system Is the vent screw open? Residue? Kinks or fuel leakage? Check for residue in the fuel filter. Open the air vent screw. Check the fuel hose for kinks or fuel leakage. No Yes Yes No Check that the air vent screw of the fuel tank is open. YesReplace the respective parts. Check the carburetor. No Clean the fuel tank. Out of specification? Yes No Check the ignition spark gap using the spark gap tester. Check the spark plug. Check the TCI unit or spark plug cap.
69M3E119-4 1 2 3 4 5 6 7 8 9 Compression pressure Symptom: The engine idle speed is not steady, but increases or decreases. Check the intake manifold. Check the air intake system. Check the ignition system. Is there air intake?Replace the respective seals. Check the compression pres- sure of the combustion chamber. No Yes Check that there is no secondary air intake on the contact surfaces of the carburetor. Out of specification? Check the ignition timing. Yes No Check the operation of the throttle cable and throttle link. Yes NoAdjust the throttle cable and throttle link.Good operat- ing condition? Check the TCI unit air gap. Check the secondary air intake on the O-ring and the gaskets.Power unit
TRBL SHTG Troubleshooting 9-569M3E11 Symptom: Engine does not accelerate when the throttle is opened quickly. The engine turns off when the throttle is opened quickly. Acceleration is tardy and the engine is likely to stop at any moment. Check the carburetors. Check the ignition system. Check the compression pressure of the power unit. Check the throttle cable operation. Do the car- buretor throt- tle valves close simul- taneously? Yes Yes No Disassemble the carburetor and check the internal parts for clogs, debris, or wear. Clean the carburetor or replace the respective parts. Adjust the throttle cable. Clogs, debris, or wear?Check the ignition system and the compression pressure of the power unit. No
69M3E119-6 1 2 3 4 5 6 7 8 9 Symptom: Shift mechanism of the forward gear does not operate properly. Check the operation of the shift lever. Replace the shift rod. Check the bracket, spring, and ball.Good operat- ing condition? Connected properly? Yes Yes No No Disassemble the lower case, and then check the operation of the dog clutch. Yes NoReplace the respective parts.Good operat- ing condition? Check the condition of the shift rod connection. Check the forward gear.Power unit
Index i-169M3E11 A. Adjusting the engine idle speed ................ 1-18 Adjusting the pilot screw ........................... 4-10 After test run ............................................. 1-18 Applicable model......................................... 1-5 Assembling the carburetor .......................... 4-9 Assembling the clamp brackets .................. 7-9 Assembling the crankcase ........................ 5-32 Assembling the cylinder block................... 5-31 Assembling the lower case ....................... 6-12 Assembling the manual starter ................... 5-8 Assembling the piston and cylinder block .......................................... 5-33 Assembling the propeller shaft assembly ................................................... 6-9 Assembling the propeller shaft housing ...... 6-9 Assembling the swivel bracket .................... 7-8 Assembling the tiller handle ........................ 7-3 Automatic tilt support and steering pivot immobilization system ............................. 1-13 B. Blowby gas reburning system ..................... 1-7 Break-in..................................................... 1-18 C. Carburetor ................................................... 4-5 Carburetor and intake silencer .................... 4-4 Changing the engine oil .............................. 3-4 Changing the gear oil ................................ 3-10 Checking the anodes ................................ 3-11 Checking the camshaft ............................. 5-29 Checking the carburetor.............................. 4-7 Checking the compression pressure........... 5-7 Checking the connecting rod big end side clearance ......................................... 5-27 Checking the connecting rod small end inside diameter........................................ 5-27 Checking the cooling water passage .......... 3-7 Checking the cooling water pilot hole ....... 1-17 Checking the crankpin oil clearance ......... 5-28 Checking the crankshaft ........................... 5-27 Checking the cylinder bore ....................... 5-25 Checking the cylinder head....................... 5-20 Checking the drive shaft ........................... 6-12 Checking the engine idle speed .................. 3-7 Checking the engine oil..................... 1-16 , 3-3 Checking the engine shut-off switch .............................................. 1-17 , 8-5 Checking the fuel cock ................................ 4-7 Checking the fuel filter ........................ 3-3 , 4-7 Checking the fuel line.................................. 3-3Checking the fuel system ......................... 1-15 Checking the fuel tank and fuel filler cap ............................................. 4-7 Checking the gear oil ................................ 1-15 Checking the gear oil level ......................... 3-9 Checking the gear shift and throttle operation..................................... 1-17 Checking the ignition spark gap ................. 8-4 Checking the ignition timing........................ 3-8 Checking the lower case .......................... 6-12 Checking the lower unit for air leakage .... 3-11 Checking the oil seal housing ................... 5-32 Checking the oil splasher gear ................. 5-30 Checking the outboard motor mounting height ...................................... 1-16 Checking the pinion and forward gear ...... 6-12 Checking the piston clearance ................. 5-25 Checking the piston diameter ................... 5-24 Checking the piston pin ............................ 5-27 Checking the piston pin boss bore ........... 5-26 Checking the piston ring grooves ............. 5-26 Checking the piston ring side clearance ... 5-26 Checking the piston rings ......................... 5-25 Checking the propeller.............................. 3-11 Checking the propeller shaft ....................... 6-9 Checking the propeller shaft housing ......... 6-8 Checking the push rod guide .................... 5-15 Checking the push rods ............................ 5-15 Checking the rocker arms......................... 5-15 Checking the spark plug ............................. 3-5 Checking the spark plug cap ...................... 8-4 Checking the spiral spring .......................... 5-8 Checking the steering system .................. 1-16 Checking the TCI unit ................................. 8-5 Checking the TCI unit air gap ..................... 3-9 Checking the thermostat............................. 3-6 Checking the valve clearance..................... 3-4 Checking the valve guides........................ 5-16 Checking the valve lifters.......................... 5-30 Checking the valve seat ........................... 5-18 Checking the valve springs....................... 5-15 Checking the valves ................................. 5-16 Checking the water pump and shift rod ...... 6-6 Control system............................................ 3-7 Cooling water flow chart ........................... 1-14 Cylinder block ........................................... 5-22 Cylinder head ........................................... 5-12