Home > Yamaha > Outboards > Yamaha F2 5 Service Manual

Yamaha F2 5 Service Manual

    Download as PDF Print this page Share this page

    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+.

    							69M3E112-6
    1
    2
    3
    4
    5
    6
    7
    8
    9
    Dimensions
    Exterior
    S69M2010
    140 (5.5) 205 (8.1)
    135 (5.3) 139 (5.5)
    366 (14.4)S: 636 (25.0)
    L: 761 (30.0)
    309 (12.2)
    93 (3.7)
    57 (2.2)315 (12.4)
    S: 645 (25.4)
    L: 772 (30.4)
    S: 432 (17.0)
    L: 559 (22.0)406 (16.0)
    376 (14.8)
    264 (10.4)
    32 (1.3)
    15 (0.6) 103 (4.1)
    57 (2.2)
    167 (6.6)
    12˚
    80˚
    S: 642 (25.3)
    L: 746 (29.4)
    215 (8.5)
    470 (18.5)
    mm (in)
    Maintenance specifications 
    						
    							SPECSpecifications
    2-769M3E11
    Clamp bracket
    S69M2020
    69 (2.7) 69 (2.7)
    56 (2.2) 56 (2.2)
    40 (0.2)
    143.7 (5.7)
    21.8 (0.9)
    58 (2.3)mm (in) 
    						
    							69M3E112-8
    1
    2
    3
    4
    5
    6
    7
    8
    9
    Tightening torques2
    Specified torques
    Part to be tightened Thread sizeTightening torques
    N·mkgf·mft·lb
    Power unit
    Anode screw M5 2.0 0.2 1.5
    Choke knob nut—3.5 0.4 2.6
    Connecting rod cap1st 
    M65.0 0.5 3.7
    2nd 9.0 0.9 6.6
    Crankcase bolt1st
    M65.0 0.5 3.7
    2nd 11 1.1 8.1
    Cylinder head bolt1st
    M814 1.4 10.3
    2nd 30 3.0 22.1
    Cylinder head cover bolt1st
    M65.0 0.5 3.7
    2nd 12 1.2 8.9
    Drive shaft oil seal housing bolt M8 18 1.8 13
    Exhaust probe bolt M8 20 2.0 14.8
    Flywheel magnet nut—44 4.4 32.4
    Fuel cock lever screw M5 0.7 0.1 0.5
    Rocker arm locknut M6 10 1.0 7.4
    Rocker arm stud bolt M6 10 1.0 7.4
    Engine oil drain bolt M8 18 1.8 13.3
    Power unit bolt M6 11 1.1 8.1
    Spark plug—25 2.5 18.4
    Oil splasher gear bolt M6 13 1.3 9.6
    Thermostat cover bolt M6 8.0 0.8 5.9
    Throttle cable lock screw—0.4 0.04 0.3
    Top cowling lock lever screw M3 0.4 0.04 0.3
    Drive unit
    Gear oil screw—8.5 0.9 6.3
    Idle silencer screw M6 2.5 0.3 1.8
    Shift rod arm bolt M5 5.0 0.5 3.7
    Shift rod connecting bolt M6 10 1.0 7.4
    Bracket unit
    Apron screw M6 2.5 0.3 1.8
    Bottom cowling screw M5 2.0 0.2 1.5
    Tiller handle bolt M8 26 2.6 19.2
    Carrying handle screw M4 1.0 0.1 0.7
    Engine shut-off switch nut—1.8 0.2 1.3
    Grease nipple—3.0 0.3 2.2
    Swivel bracket bolt M6 12 1.2 8.9
    Throttle grip screw M5 3.5 0.4 2.6
    Clamp bracket inner nut—5.0 0.5 3.7
    Clamp bracket outer nut—16 1.6 11.8
    Throttle grip shaft cap bolt M5 3.0 0.3 2.2
    Trim rod nut—5.0 0.5 3.7
    Maintenance specifications / Tightening torques 
    						
    							SPECSpecifications
    2-969M3E11
    General torques
    This chart specifies tightening torques for
    standard fasteners with a standard ISO
    thread pitch. Tightening torque specifications
    for special components or assemblies are
    provided in applicable sections of this man-
    ual. To avoid warpage, tighten multi-fastener
    assemblies in a crisscross fashion and pro-
    gressive stages until the specified torque is
    reached. Unless otherwise specified, torque
    specifications require clean, dry threads. 
    Components should be at room temperature.
    Nut (A) Bolt (B)General torque 
    specifications
    N·mkgf·mft·lb
    8 mm M5 5 0.5 3.6
    10 mm M6 8 0.8 5.8
    12 mm M8 18 1.8 13 
    						
    							69M3E11
    CHK 
    ADJ
    1
    2
    3
    4
    5
    6
    7
    8
    9
    Periodic checks and adjustments
    Special service tools ..................................................................................... 3-1
    Maintenance interval chart ............................................................................ 3-2
    Fuel system .................................................................................................... 3-3
    Checking the fuel line ................................................................................ 3-3
    Checking the fuel filter ............................................................................... 3-3
    Power unit ....................................................................................................... 3-3
    Checking the engine oil ............................................................................. 3-3
    Changing the engine oil ............................................................................. 3-4
    Checking the valve clearance.................................................................... 3-4
    Checking the spark plug ............................................................................ 3-5
    Checking the thermostat............................................................................ 3-6
    Checking the cooling water passage ......................................................... 3-7
    Control system ............................................................................................... 3-7
    Checking the engine idle speed ................................................................ 3-7
    Checking the ignition timing....................................................................... 3-8
    Checking the TCI unit air gap .................................................................... 3-9
    Lower unit ....................................................................................................... 3-9
    Checking the gear oil level ........................................................................ 3-9
    Changing the gear oil .............................................................................. 3-10
    Checking the lower unit for air leakage ................................................... 3-11
    Checking the propeller............................................................................. 3-11
    General .......................................................................................................... 3-11
    Checking the anodes ............................................................................... 3-11
    Lubricating the outboard motor................................................................ 3-12 
    						
    							CHK 
    ADJ
    Periodic checks and adjustments
    3-169M3E11
    Special service tools3
    Digital tachometer
    90890-06760
    Timing light
    90890-03141
    Leakage tester
    90890-06840 
    						
    							69M3E113-2
    1
    2
    3
    4
    5
    6
    7
    8
    9
    Maintenance interval chart3
    Use the following chart as a guideline for general maintenance.
    Adjust the maintenance intervals according to the operating conditions of the outboard motor.
    NOTE:
    The engine should be flushed with fresh water after operating in salt, turbid, or muddy water.
    If leaded gasoline is used regularly, check the engine valves and related parts every 100 hours of
    operation in addition to the items in the maintenance interval chart.Item RemarksInitial Every
    Refer to 
    page
    10 hours 
    (Break-in)50 hours 
    (3 months)100 hours 
    (6 months)200 hours 
    (1 year)
    Fuel system
    Fuel line Check 3-3
    Fuel filter Check/replace 3-3
    Power unit
    Engine oil Change 3-4
    Valve clearance Check/adjust 3-4
    Spark plug Clean/adjust/replace 3-5
    Thermostat Check 3-6
    Outboard motor 
    exteriorCheck—
    Cooling water passage Clean 3-7
    Control system
    Carburetor Check 4-7
    Engine idle speed Adjust 3-7
    Ignition timing Check 3-8
    TCI unit air gap Check/adjust 3-9
    Lower unit
    Gear oil Change 3-10
    Propeller Check 3-11
    General
    Anodes Check/replace 3-11
    Bolts and nuts Tighten—
    Lubrication points Lubricate 3-12
    Special service tools / Maintenance interval chart 
    						
    							CHK 
    ADJ
    Periodic checks and adjustments
    3-369M3E11
    Fuel system3
    Checking the fuel line
    1. Check the fuel tank 1
     for leaks. Replace
    if necessary. Also, check the fuel hose 2
    for leaks and deterioration, and the car-
    buretor 3
     and fuel cock for leaks.
    Replace if necessary.
    Checking the fuel filter
    1. Check the fuel filter for dirt or residue.
    Clean with straight gasoline and replace
    the filter if necessary.
    Power unit3
    Checking the engine oil
    1. Place the outboard motor in an upright
    position.
    2. Check the oil level through the oil level
    window 1
    .
    NOTE:
    Change the oil if it appears milky or dirty.
    If the engine oil is above the maximum level
    a
    , drain sufficient oil until the level is
    between a
     and b
    .
    If the engine oil is below the minimum level
    b
    , add sufficient oil until the level is
    between a
     and b
    .
    S69M3040
    aa
    bb 
    						
    							69M3E113-4
    1
    2
    3
    4
    5
    6
    7
    8
    9
    Changing the engine oil
    1. Remove the oil filler cap 1
    .
    2. Place a drain pan under the drain hole,
    and then remove the drain bolt 2
     and let
    the oil drain completely.
    NOTE:
    Be sure to clean up any oil spills.
    3. Install the drain bolt 2
    , and then tighten
    it to the specified torque.
    4. Pour the specified amount of the recom-
    mended engine oil into the oil filler hole.5. Install the oil filler cap, and then start the
    engine and warm it up for 5 minutes.
    6. Turn the engine off, and then check the
    oil level and correct it if necessary.
    Checking the valve clearance
    1. Remove the engine shut-off cord from
    the engine shut-off switch on the tiller
    handle.
    2. Remove the carrying handle 1
    , fuel cock
    lever 2
    , bottom cowling 2 3
    , spark plug
    4
    , fuel tank bolts 5
    , and cylinder head
    cover 6
    .
    T R..
    Engine oil drain bolt 2
    :
    18 N·m (1.8 kgf·m, 13.3 ft·lb)
    Recommended engine oil:
    4-stroke motor oil
    API: SE, SF, SG, SH, or SJ
    SAE: 10W-30 or 10W-40
    Oil quantity:
    0.35 L (0.09 US gal, 0.08 Imp gal)
    Fuel system / Power unit 
    						
    							CHK 
    ADJ
    Periodic checks and adjustments
    3-569M3E11
    3. Slowly pull the starter rope to set the pis-
    ton position to TDC of the compression
    stroke.
    NOTE:
    Make sure that the rocker arms 7
     are not
    pushing the intake valve 8
     and exhaust
    valve 9
    .
    Check the position of the piston from the
    spark plug installation hole 0
    .
    Do not turn the flywheel magnet counter-
    clockwise.
    4. Check the valve clearance. Adjust if out
    of specification.
    NOTE:
    Check the valve clearance when the engine
    is cold.
    Note the measurement.5. Loosen the rocker arm locknuts A
    , and
    then turn the rocker arm pivot B
     until the
    specified valve clearance is obtained.
    NOTE:
    To decrease the valve clearance, turn the
    rocker arm pivot in direction c
    .
    To increase the valve clearance, turn the
    rocker arm pivot in direction d
    .
    6. Tighten the rocker arm locknuts to the
    specified torque, and then check the
    valve clearances. Adjust if necessary.
    7. Install the cylinder head cover, fuel tank
    bolts, spark plug, bottom cowling 2, fuel
    cock lever, and carrying handle.
    Checking the spark plug
    1. Remove the grommet 1
    .
    2. Disconnect the spark plug cap from the
    spark plug, and then remove the spark
    plug.
    Valve clearance:
    Intake a
    :
    0.08–0.12 mm 
    (0.0031–0.0047 in)
    Exhaust b
    :
    0.08–0.12 mm 
    (0.0031–0.0047 in)
    T R..
    Rocker arm locknut A
    :
    10 N·m (1.0 kgf·m, 7.4 ft·lb) 
    						
    All Yamaha manuals Comments (0)

    Related Manuals for Yamaha F2 5 Service Manual