Yamaha F2 5 Service Manual

							69M3E116-12
1
2
3
4
5
6
7
8
9
5. Use a bolt a
 with the specified measure-
ments, two nuts, and a plate as shown in
the illustration.
6. Hold the bolt a
 and turn the nut b
 coun-
terclockwise to pull bushing 2 out.
Checking the pinion and forward 
gear
1. Check the teeth of the pinion, and the
teeth and dogs of the forward gear for
cracks or wear. Replace if necessary.
Checking the drive shaft
1. Check the drive shaft for bends or wear.
Replace if necessary.
Checking the lower case
1. Check the skeg and torpedo for cracks or
damage. Replace if necessary.
Assembling the lower case
1. Use a bolt a
 with the specified measure-
ments, two nuts, and a plate as shown in
the illustration.
2. Hold the bolt a
 and turn the nut b
 coun-
terclockwise to install bushing 1.
Specified bolt a
: M6 ×
 120 mm
S69M6490
a
b
S69M6290
S69M6300
Specified bolt a
: M6 ×
 120 mm
S69M6310
S69M6500
a
b
Drive shaft and lower case 
						

							LOWRLower unit
6-1369M3E11
3. Install bushing 2 into the lower case to
the specified depth.
NOTE:
Apply engine oil to bushing 1, 2 before instal-
lation.
4. Apply grease to the new oil seal, and
then install it into the lower case to the
specified depth.
5. Install the new ball bearing into the lower
case.CAUTION:
Do not reuse the bearing, always replace
it with a new one.
NOTE:
Install the ball bearing with the manufacture
identification mark e
 facing toward the for-
ward gear.
Apply engine oil to the ball bearing before
installation.
Installing the drive shaft
1. Install the forward gear into the lower
case.
2. Install the drive shaft into the lower case,
and then install the washer 1
, pinion,
and circlip 2
 onto the drive shaft.
Bushing attachment 1
:
90890-06649
Driver rod L3 2
: 90890-06652
Depth c
: 0.9–1.0 mm (0.03–0.04 in)
Ball bearing attachment 3
:
90890-06638
Driver rod LS 4
: 90890-06606
Depth d
: 1.5–2.0 mm (0.06–0.08 in)
S69M6320
2
1
cc
E
S69M6330
dd
AA
4
3
Ball bearing attachment 5:
90890-06637
Driver rod LS 6: 90890-06606
S69M6350
e
6
5
E
S69M6360
2
1 
						

							69M3E116-14
1
2
3
4
5
6
7
8
9
NOTE:
If replacing the washer 1
, be sure to replace
it with a new one of the same thickness.
Installing the propeller shaft housing
1. Install the washer 1
 and propeller shaft
assembly 2
 into the propeller shaft
housing assembly 3
. 
2. Apply grease to the new O-rings.
3. Install the propeller shaft housing assem-
bly into the lower case.
Installing the water pump and shift 
rod
1. Install the shift rod 1
, new gasket 2
,
and plate 3
.
2. Install the dowels 4
, new O-ring 5
, and
outer plate cartridge 6
.
NOTE:
Apply Yamabond No. 4 to both sides of sec-
tion a
 of the gasket 2
.
3. Install the dowel 7
 into the drive shaft.
4. Align the groove on the impeller 8
 with
the dowel, and then install the impeller
onto the drive shaft.
NOTE:
Check the dowel 7
 for wear. Replace if nec-
essary.
Available washer thicknesses:
2.0, 2.1, 2.2, and 2.3 mm
S69M6370
21 3AA
S69M6380
2
1
4
6
5
3
AA4
a
Drive shaft and lower case 
						

							LOWRLower unit
6-1569M3E11
5. Install the new O-ring 9
 and insert car-
tridge 0
 into the water pump housing A
.
NOTE:
Align the insert cartridge projection b
 with
the hole c
 in the water pump housing.
6. Install the water pump housing assembly
B
 to the lower case.
NOTE:
When installing the water pump housing,
apply grease to the inside of the housing, and
then turn the drive shaft clockwise while
pushing the water pump housing down.
Installing the lower unit
1. Set the gear shift to the neutral position
at the lower unit.2. Install the lower unit to the upper case.
ÈL-transom model
NOTE:
Align the rubber seal projection a
 with the
hole b
 in the water pump housing.
S69M6400
AA
AA
A
9cb
0
S69M6430
F
N 
						

							69M3E116-16
1
2
3
4
5
6
7
8
9
3. Install the shift rod 1
 to the joint 2
, and
then tighten the bolt 3
 to the specified
torque.
4. Install the propeller and propeller nut 4
.
Place a block of wood between the anti-
cavitation plate and propeller to keep the
propeller from turning, and then tighten
the nut. If the holes in the propeller nut 4
do not align with the cotter pin hole,
loosen the nut until the holes are aligned.
 WARNING
•Do not hold the propeller with your
hands when loosening or tightening it. 
•Be sure to disconnect the spark plug
cap from the spark plug and the clip
from the engine shut-off switch.
•Put a block of wood between the anti-
cavitation plate and propeller to keep
the propeller from turning.
T R..
Joint bolt 3
:
10 N·m (1.0 kgf·m, 7.4 ft·lb)
S69M6470
Drive shaft and lower case 
						

							LOWRLower unit
6-1769M3E11
— MEMO — 
						

							69M3E11
BRKT
1
2
3
4
5
6
7
8
9
Bracket unit
Tiller handle .................................................................................................... 7-1
Assembling the tiller handle....................................................................... 7-3
Installing the tiller handle ........................................................................... 7-3
Upper case, swivel bracket, and clamp brackets........................................ 7-4
Assembling the swivel bracket .................................................................. 7-8
Assembling the clamp brackets ................................................................. 7-9
Installing the upper case............................................................................ 7-9 
						

							BRKTBracket unit
7-169M3E11
Tiller handle7
No. Part name Q’ty Remarks
1 Tiller handle 1
2 Throttle grip 1
3Screw 1ø5 
× 21 mm
4 Throttle friction adjuster 1
5 Engine shut-off switch 1
6Nut 1
7 Engine shut-off cord 1
8 Throttle lever 1
9 Bushing 1
10 Spring 1
11 Washer 1
12 Plate 1
13 Screw 2ø5 
× 12 mm
14 Bushing 1
15 Washer 2
16 Wave washer 1
17 Friction piece 1
S69M7010
AA
AA
AA
4
1
8
12
13199101115 16 15 14
17
18 7 6
5 3
2
22
23
24
2521
20
AA
T R..26 N · 
m (2.6 kgf · 
m, 19.2 ft · Ib)
AA 
						

							69M3E117-2
1
2
3
4
5
6
7
8
9
7
No. Part name Q’ty Remarks
18 Bushing 1
19 Screw 1ø5 
× 7 mm
20 Cover 1
21 Throttle cable 1
22 Washer 1
23 Bushing 1
24 Cover 1
25 Bolt 1 M8 
× 25 mm
S69M7010
AA
AA
AA
4
1
8
12
13199101115 16 15 14
17
18 7 6
5 3
2
22
23
24
2521
20
AA
T R..26 N · 
m (2.6 kgf · 
m, 19.2 ft · Ib)
AA
Tiller handle 
						

							BRKTBracket unit
7-369M3E11
Assembling the tiller handle
1. Install the throttle cable 1
 to the throttle
lever 2
.
NOTE:
Make sure that the throttle grip is fully closed
when installing the throttle cable.
Installing the tiller handle
1. Install the bushing 1
 into the upper case
2
.
NOTE:
Align the mark a
 on the bushing with the
mark b
 on the upper case.
2. Route the engine shut-off switch lead as
shown so that it does not interfere with
the throttle lever.3. Install the tiller handle assembly to the
upper case, and then tighten the bolt 3
to the specified torque.
NOTE:
Route the engine shut-off switch lead 4
 and
throttle cable 5
 as shown.
S69M7020
1
2AA
S69M7030
2
1 ab
S69M7140
T R..
Tiller handle bolt 3
:
26 N·m (2.6 kgf·m, 19.2 ft·lb)
S69M7040
43
5543