Yamaha F2 5 Service Manual

							69M3E113-6
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2
3
4
5
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7
8
9
3. Clean the electrodes 2
 with a spark plug
cleaner or wire brush. Replace the spark
plug if necessary.
4. Check the electrodes for erosion and
excessive carbon or other deposits, and
the gasket for damage. Replace the
spark plug if necessary.
5. Check the spark plug gap a
. Adjust if out
of specification.
6. Install the spark plug, tighten it finger
tight b
, then to the specified torque with
a spark plug wrench c
.
Checking the thermostat
1. Remove the fuel tank 1
, manual starter
2
, flywheel magnet cover 3
, thermostat
cover 4
, and thermostat 5
.
 WARNING
Before removing the fuel tank, fuel hose,
and carburetor, let the fuel drain com-
pletely.
2. Suspend the thermostat in a container of
water.
3. Place a thermometer in the water and
slowly heat the water.
Specified spark plug: BR6HS (NGK)
Spark plug gap a
:
0.6–0.7 mm (0.024–0.028 in)
T R..
Spark plug:
25 N·m (2.5 kgf·m, 18.4 ft·lb)
S69J5E40
Power unit 
						

							CHK 
ADJ
Periodic checks and adjustments
3-769M3E11
4. Check the thermostat valve opening at
the specified water temperatures.
Replace if out of specification.
5. Install the thermostat, new gasket, ther-
mostat cover, flywheel magnet cover,
manual starter, and fuel tank.
Checking the cooling water passage
1. Check the cooling water inlet 1
 for
clogs. Clean if necessary.
2. Place the lower unit in water, and then
start the engine.
3. Check for water flow at the cooling water
pilot hole. If there is no water flow, check
the cooling water passage inside the out-
board motor.
Control system3
Checking the engine idle speed
1. Start the engine and warm it up for 5 min-
utes.
2. Attach the special service tool to the
spark plug wire 1
, and then check the
engine idle speed. Adjust if out of specifi-
cation.Water 
temperatureValve lift a
 
48–52 °C 
(118–126 °F)0 mm (0 in)
(valve begins to lift)
above 
60 °C (140 °F)more than 
3 mm (0.12 in)
Digital tachometer: 90890-06760
Engine idle speed:
1,800–2,000 r/min 
						

							69M3E113-8
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2
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4
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8
9
3. Turn the throttle stop screw 2
 in direc-
tion a
 or b
 until the specified engine
idle speed is obtained.
NOTE:
To increase the idle speed, turn the throttle
stop screw in direction a
.
To decrease the idle speed, turn the throttle
stop screw in direction b
.
When turning the throttle stop screw in
direction b
, check that the throttle link con-
tacts the screw. If the throttle link does not
contact the throttle stop screw, follow steps
4–6.
4. Check that the throttle grip is in the fully
closed position.
5. Loosen the throttle cable stop screw 3
,
and then adjust the engine idle speed.
6. After adjusting the engine idle speed,
adjust the throttle cable.
NOTE:
For adjusting procedures, see Chapter 4,
“Installing the throttle cable.”7. After adjusting the idle speed, rev the
engine a few times and let it idle for at
least 15 seconds to check the stability of
the engine.
Checking the ignition timing
1. Start the engine.
2. Attach the special service tool to the
spark plug wire 1
.
3. Check that the flywheel magnet indent a
is visible through the timing mark b
check window. If not visible, adjust the
TCI unit air gap.
S69M3400
3
Timing light: 90890-03141
S69M3390
a
b
Power unit / Control system 
						

							CHK 
ADJ
Periodic checks and adjustments
3-969M3E11
Checking the TCI unit air gap
1. Remove the fuel tank 1
, manual starter
2
, and flywheel magnet cover 3
.
2. Measure the gap a
 between both pro-
jections b
 and flywheel magnet using a
thickness gauge. Adjust if out of specifi-
cation.
3. Loosen the bolts 4
 and adjust the TCI
unit air gap position.4. Tighten the bolts, and then check the TCI
unit air gap. Adjust if necessary.
Lower unit3
Checking the gear oil level
1. Fully tilt the outboard motor down.
2. Remove the check screw 1
, and then
check the gear oil level in the lower case.
NOTE:
If the oil is at the correct level, the oil should
overflow out of the check hole when the
check screw is removed.
3. If necessary, add sufficient gear oil of the
recommended type until it overflows out
of the check hole.
4. Install the check screw.
TCI unit air gap:
0.4–0.6 mm (0.016–0.024 in)
Recommended gear oil:
Hypoid gear oil
SAE: 90
S69M3220
1 
						

							69M3E113-10
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Changing the gear oil
1. Fully tilt the outboard up, and then sup-
port it with the tilt stop lever 1
.
2. Slide the trim rod 2
 and position it to the
upper trim rod position a
.
3. Release the tilt stop lever and tilt the out-
board down until it contacts the mount
housing.
4. Place a drain pan under the drain screw
3
, remove the drain screw, then the
check screw 4
 to drain the oil.5. Check the oil for metal, discoloration, and
viscosity. Check the internal parts of the
lower case if necessary.
6. Insert the gear oil tube or gear oil pump
into the drain hole and slowly fill the gear
oil until oil flows out of the check hole and
no air bubbles are visible.
7. Install the check screw, quickly install the
drain screw, and then tighten them.
Recommended gear oil:
Hypoid gear oil
SAE: 90
Oil quantity:
75 cm
3 (2.5 US oz, 2.6 Imp oz)
S69M3260
Control system / Lower unit 
						

							CHK 
ADJ
Periodic checks and adjustments
3-1169M3E11
Checking the lower unit for air 
leakage
1. Remove the check screw 1
, and then
install the special service tool.
2. Apply the specified pressure to check
that the pressure is maintained in the
lower unit for at least 10 seconds.
CAUTION:
Do not over pressurize the lower unit, oth-
erwise the oil seals may be damaged.
NOTE:
Cover the check hole with a rag when remov-
ing the pressure/vacuum tester from the
lower unit.
3. If pressure drops below specification,
check the drive shaft and propeller shaft
oil seals for damage.
Checking the propeller
1. Check the propeller blades and splines
for cracks, damage, or wear. Replace if
necessary.
General3
Checking the anodes
1. Check the anodes for scales, grease, or
oil. Clean if necessary.
CAUTION:
Do not oil, grease, or paint the anodes,
otherwise they will be ineffective.
2. Replace the anodes if excessively
eroded.
Leakage tester: 90890-06840
Lower unit holding pressure:
100 kPa (1.0 kgf/cm
2, 14 psi) 
						

							69M3E113-12
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Lubricating the outboard motor
1. Apply water resistant grease to the areas
shown.
NOTE:
Apply grease to the grease nipple until it
flows from the bushings a
.
2. Apply corrosion resistant grease to the
area shown.
Lower unit / General 
						

							CHK 
ADJ
Periodic checks and adjustments
3-1369M3E11
— MEMO — 
						

							69M3E11
FUEL
1
2
3
4
5
6
7
8
9
Fuel system
Special service tools ..................................................................................... 4-1
Hose routing ................................................................................................... 4-2
Fuel and blowby hoses .............................................................................. 4-2
Fuel tank ......................................................................................................... 4-3
Carburetor and intake silencer ..................................................................... 4-4
Carburetor....................................................................................................... 4-5
Draining the fuel ........................................................................................ 4-7
Checking the fuel tank and fuel filler cap ................................................... 4-7
Checking the fuel filter ............................................................................... 4-7
Checking the fuel cock .............................................................................. 4-7
Checking the carburetor ............................................................................ 4-7
Assembling the carburetor......................................................................... 4-9
Installing the carburetor ............................................................................. 4-9
Installing the throttle cable ....................................................................... 4-10
Adjusting the pilot screw .......................................................................... 4-10 
						

							FUELFuel system
4-169M3E11
Special service tools4
Digital tachometer
90890-06760
Pilot screw wrench
90890-03154