F2.

5A

SERVICE GUIDE

294157 90894-62941-57
 NOTICE
This Service Guide has been prepared to provide Yamaha dealers with information for the product
concept, technical, features, benefit, technical tips and new servicing points, regarding to a new
model.

The information contained in this guide is essential to the service staffs of Yamaha dealers for daily
service to customers.
It is our hope that you will use this guide to train your dealer service staffs about new model and that
it will help answer the questions about this model.

NOTE:
• The descriptions herein are based on the information officially announced by Yamaha Motor Co.,
Ltd. as of the end of March 2002.
• For further detail information, refer to the appropriate service manual.

The specifications, features, tips and servicing points are subject to change without notice.

OTHER INFORMATION;
If this outboard motor is used with an inflatable boat, remove the warning label from the tag (part
number 61H-2819R-31) attached to the motor crated, and then stick the label securely to the inner
boat.

NOTE:
• Clean the surface before the label sticking.
• Do not stick the label to a rubber flotation portion. Otherwise, the label can be removed when the
flotation is deflated for transporting.

F2.5A
SERVICE GUIDE
©2002 by Yamaha Motor Co., Ltd.
1st Edition, April 2002
All rights reserved.
Any reprinting or unauthorized use
without the written permission of
Yamaha Motor Co., Ltd.
is expressly prohibited.
Printed in Japan
 CONTENTS
OUTLINE OF FEATURES ........................................................................................1

FEATURES AND BENEFITS ....................................................................................2

1. STORING BASE .................................................................................................2
2. CARRYING HANDLE ..........................................................................................3
3. IGNITION SYSTEM .............................................................................................4
4. AUTOMATIC DECOMPRESSION DEVICE ...........................................................5
5. BLOW-BY GAS RE-BURNING SYSTEM...............................................................6
6. OIL CHECK WINDOW .........................................................................................7
7. IDLE SILENCER .................................................................................................8
8. SPLASH LUBRICATION DEVICE .........................................................................9
9. FUEL TANK COOLING SYSTEM .......................................................................10
10. AUTOMATIC TILT SUPPORT AND STEERING PIVOT
IMMOBILIZATION SYSTEM ..................................................................................11
11. LOW VIBRATION TILLER HANDLE..................................................................12
12. TILT PIN WITH RUBBER DAMPER ..................................................................13
13. MAINTENANCE GROMMET ............................................................................14

TECHNICAL TIPS ...................................................................................................15

1. TCI SYSTEM ....................................................................................................15
1) BEFORE IGNITING ......................................................................................15
2) JUST IGNITING ...........................................................................................15
2. AUTOMATIC DECOMPRESSION DEVICE .........................................................16
1) WHILE THE ENGINE IS STOPPED ...............................................................16
2) WHEN THE ENGINE IS CRANKING..............................................................16
3) AFTER THE ENGINE HAS STARTED ...........................................................17
3. FUEL TANK COOLING SYSTEM .......................................................................18
4. AUTOMATIC TILT SUPPORT AND STEERING PIVOT
IMMOBILIZATION SYSTEM ..................................................................................19
5. COOLING WATER FLOW CHART .....................................................................20

SERVICE INFORMATION.......................................................................................21
1. GENERAL SPECIFICATIONS ............................................................................21
2. DIMENSIONS ...................................................................................................23
1) EXTERIOR...................................................................................................23
2) BRACKET ....................................................................................................24
3. TIGHTENING TORQUES...................................................................................25
1) SPECIFIED TORQUES .................................................................................25
2) GENERAL TORQUES ..................................................................................26
4. IDLE SPEED .....................................................................................................27
1) READJUSTING THE IDLE SPEED ................................................................27

WIRING DIAGRAM..................................................................................................28
 OUTLINE OF FEATURES
The outboard motor F2.5 has the following features:
• Newly designed light weight and compact 4-stroke engine, consisting of the single cylinder, OHV, splash
lubrication and TCI (Transistor Controlled Ignition).
(Displacement: 72 cm3, Dry weight: 17.0 kg (37.5 lb) for S/17.5 kg (38.6 lb) for L)
• Utility structure for carrying, storing, operating and servicing.
• Low noise, low emission and low fuel consumption.

ELECTRICAL
• Simple ignition system by TCI
(Transistor Controlled Ignition)
POWER UNIT
• Automatic decompression device for
easier starting engine.
• Splash lubrication system to obtain
a light weight and compact cylinder block.
• Storing base on the bottom cowl to
stabilize the motor for storage.
• Compact ignition system by TCI.
• Pilot hole for easier checking cooling
water.
• Blow-by-gases re-burning system for low
emission.
• Oil check window for easier oil level
checking.
• New air intake system to cool fuel tank.
• Maintenance grommets for easier
servicing of the spark plug and exhaust
probe takeout.

BRACKET UNIT/UPPER CASE

• Big carrying handle for easier carrying.
• Automatic tilt support device for easier
operation.
• Steering lock system after tilting up for
holding power unit.
• Low vibration tiller handle with throttle
LOWER UNIT grip, engine stop switch and throttle
• F-N shift for easier operation. friction for easier operation.
• Maintenance grommets for easier • Idling silencer for low noise.
service to the shift rod joint. • Tilt pin with rubber damper to reduce
engine vibration and tilt-down shock.

Fig. 1

1
 FEATURES AND BENEFITS
1. STORING BASE
When storing the outboard motor for a long term, the exclusive bases are incorporated to the bottom
cowling to make the motor stable on the base in the laid down position so that the oil or the cooling
water does not flow backward.

Fig. 2

2
2. CARRYING HANDLE
A big carrying handle is designed to equilibrate the center of gravity on the outboard motor.
Therefore, the outboard motor can be lifted easier and carried by one hand for maintaining the
proper balance.

Fig. 3

3
3. IGNITION SYSTEM
A simple and compact ignition system, which induces the high voltage to the secondary coil by shut-
ting off the electrical current produced by the primary coil due to the rotation of the permanent mag-
net incorporated in the flywheel by the transistor, is adopted.
This TCI (Transistor Controlled Ignition) system greatly contributes to a compact and lightweight
engine.

1 TCI unit
2 Permanent magnet
3 Flywheel
a Air gap: 0.5 mm (0.02 in)
Fig. 4

7 4

8
6

1 5
2 3

1 Flywheel 6 Spark plug

2 Permanent magnet 7 Transistor 1
3 Core 8 Transistor 2
4 Primary coil 9 Engine stop switch
5 Secondary coil
Fig. 5

4
4. AUTOMATIC DECOMPRESSION DEVICE
The automatic decompression device is adopted to reduce the force needed for pulling the manual
starter because the timing to “close” the exhaust valve is retarded to reduce the compression pres-
sure while the engine is cranking.
This device operates automatically by the centrifugal force. Therefore, easier starting of the engine
can be obtained.

Fig. 6

5
5. BLOW-BY GAS RE-BURNING SYSTEM
A lot of the oil particles are included in the blow-by gases because of a splash lubrication system.
Therefore, a reburning system is incorporated to separate the oil from the blow-by gases in two
stages: once in the cylinder head and again in the intake silencer.
The blow-by gases are first separated to oil and gases by the labyrinth structure in the cylinder
head. The oil is drained into the cylinder head and the gases are discharged to the intake silencer.
The gases enter the intake silencer from the cylinder head. They are separated to oil and gases
again by the labyrinth structure in the intake silencer. The oil is drained into the oil pan through the
hose from the bottom of the silencer, and the gases are finally drawn into the carburetor to reburn in
the engine.
A

:Blow-by gas
Cylinder head
:Oil

C
Intake silencer

A To intake silencer
B From cylinder head
C To oil pan
Fig. 7

6
6. OIL CHECK WINDOW
The oil check window is adopted for easier oil level checking.
The metal plate of the oil check window shows the proper oil level when the outboard motor is in the
vertical position.
The end of the plate means the lowest oil level. Therefore, the oil has to be filled until the plate is
submerged in the oil.

1 Oil checking plate

a Full oil level
b Low oil level
Fig. 8

7
7. IDLE SILENCER
The silencer is mounted to the exhaust idle port of the upper casing to reduce the exhaust noise.
Also, stains around the exhaust idle port due to the exhaust gases will be reduced.
The exhaust gases are discharged into the silencer from two upper idle ports of the upper casing,
and flow with eddying inside the silencer, and then discharged to atmosphere from the lower hole of
the silencer.
The cooling water accumulated in the silencer is drained into the upper casing from the lower hole.

:Exhaust gas
:Cooling water

Fig. 9

8
8. SPLASH LUBRICATION DEVICE
The splash lubrication system for a simple design is adopted.
The splasher is driven by the gear on the camshaft and splashes the oil accumulated to the oil pan
to the components in the crankcase.

Fig. 10

9
9. FUEL TANK COOLING SYSTEM
The compartment board is located between the engine unit and the fuel tank to prevent the temper-
ature of fuel from rising up.
Also, the fresh intake air for combustion passes through and around the fuel tank before reaching
the carburetor. Thereby, this design makes the fuel in the tank cool down.

Fig. 11

10
10. AUTOMATIC TILT SUPPORT AND STEERING PIVOT
IMMOBILIZATION SYSTEM
This outboard motor is equipped with new functions, the tilt support lever automatically supports the
motor on the clamp bracket and prevents the motor from swiveling at the same time, when the
motor is tilted up completely with the steering turned forward.

Fig. 12

11
11. LOW VIBRATION TILLER HANDLE
The tiller handle is mounted to the near center of the motor to allow low vibration.
Also, the rubber damper is adopted to the mounting portion of the handle to help reduce the vibra-
tion transferring to the handle.
The throttle grip with indicator, the engine stop switch with emergency stop function and the throttle
friction adjuster are incorporated into the tiller handle, which allows for easier operation.

2
3

4
5

1 Rubber damper
2 Big throttle grip
3 Throttle indicator
4 Engine stop lanyard switch
5 Throttle friction adjuster
Fig. 13

12
12. TILT PIN WITH RUBBER DAMPER
The rubber damper is incorporated in the tilt pin to help reduce vibration from the engine to the boat.
Also, this reduces an impact when the outboard motor is tilted down.

Fig. 14

13
13. MAINTENANCE GROMMET
The maintenance grommets have been provided to access the spark plug, exhaust gas probe, car-
buretor drain screw and shift rod joint.

1 For spark plug

2 For exhaust probe
3 For shift rod joint
4 For carburetor drain screw
Fig. 15

14
 TECHNICAL TIPS
1. TCI SYSTEM
The working logic of the TCI system is as below.

1) BEFORE IGNITING
By the rotation of the flywheel, the primary coil generates a voltage, and an electric current A flows.
This electric current opens transistor Q1, therefore the electric current B flows to the primary coil.

A
B
Q1

Q2

Fig. 16

2) JUST IGNITING
As the flywheel continues to rotate, the voltage generated by the primary coil becomes higher.
When this voltage has reached the operation voltage of the transistor Q2, the electrical current C
flows to the transistor Q2 and opens it, and thereby the electrical current D flows.
This instant is the ignition timing.
When the electrical current B flowing to the primary coil through the transistor Q1 has been shut off
in this instant, the secondary coil generates high voltage by an electrical induction and the spark
plug is ignited.

C B
Q1
D
Q2

Fig. 17

15
2. AUTOMATIC DECOMPRESSION DEVICE
Operation of the automatic decompression device.
The automatic decompression device incorporated into the camshaft consists of the weight arm,
spring and pin.
The principle of the operation is as below.

1) WHILE THE ENGINE IS STOPPED

The pin is pushed by the weight arm due to the force of the spring, and protrudes 1.1 mm (0.043 in)
from the surface of the exhaust cam.

1 Spring
2 Pin
3 Weight arm
4 Camshaft
5 Exhaust valve lifter
Fig. 18

2) WHEN THE ENGINE IS CRANKING

When the engine begins cranking by pulling the manual starter, the valve lifter contacts the pin, and
is lifted up.
Therefore, the exhaust valve remains longer open, and retards the timing to close.
As a result, the engine continues cranking with the reduced compression pressure.

16
3) AFTER THE ENGINE HAS STARTED
When the engine speed rises to approximately 600 r/min or more after the initial combustion occurs,
the centrifugal force effected to the weight arm exceeds the spring force.
Therefore, the weight arm moves to outward with the fulcrum in the center until the stopper of the
arm comes to contact with the camshaft.
As a result, the pin becomes free.
The pin has lost the force to lift the exhaust valve lifter, and normal compression is obtained.
As a result, the outboard motor can be operated normally.

Fig. 19

17
3. FUEL TANK COOLING SYSTEM
The fresh atmosphere air is ducked by rotating the fan on the flywheel.
Fresh air enters from the rear of the top cowling and passes the fuel tank compartment formed by a
partition to cool the tank, and then flows into the engine compartment.

Fig. 20

18
4. AUTOMATIC TILT SUPPORT AND STEERING PIVOT IMMOBILIZATION
SYSTEM
The tilt support lever is constantly pushed against the clamp bracket by the force of a spring.
When the outboard motor is tilted up completely with the steering turned forward, the stopper linked
to the tilt support lever is put into the cutout of the swivel. At the same time, the tilt support lever
automatically supports the motor on the clamp bracket.
If the outboard motor is tilted up with the steering in either direction, the tilt support lever linked to
the stopper will stop working as the stopper will not be put into the cutout of the swivel, therefore the
motor cannot be supported.
The stopper, which is fitted on the swivel, prevents the outboard motor from swiveling.

3 4

1
2

1 Spring
2 Tilt support lever
3 Stopper
4 Recess of swivel
Fig. 21

19
5. COOLING WATER FLOW CHART

Crankcase Cylinder Cylinder

body head

Upper case
Pilot outlet (Top starboard Upper case Thermostat
side) (Inside)

Lower case
Atmosphere Water pump
exhaust port

Cold water Cooling water

Atmosphere
inlet

Hot water

Exhaust gas
and water

Fig. 22

20
 SERVICE INFORMATION
1. GENERAL SPECIFICATIONS
Model
USA F2.5MH
Item Unit
Canada F2.5MH
Worldwide F2.5AMH
Model code 69M
Starting serial number 1000101
Dimension
Overall length mm (in) 623 (24.5)
Overall width mm (in) 345 (13.6)
Overall height
(S) mm (in) 1,021 (40.2)
(L) mm (in) 1,148 (45.2)
Transom height
(S) mm (in) 432 (17.0)
(L) mm (in) 559 (22.0)
Weight (*1)
(S) kg (lb) 17.0 (37.5)
(L) kg (lb) 17.5 (38.6)
Performance
Maximum output kW (hp) 1.8 (2.5) @ 5,500 r/min
Full throttle operating range r/min 5,250–5,750
Maximum fuel consumption L (US gal, 1.1 (0.29, 0.24) @ 5,500 r/min
lmp gal)/hr
Idle speed (*2) r/min 1,900
Power unit
Type 4-stroke, single, OHV
3
Total displacement cm (cu. in) 72 (4.4)
Bore × stroke mm (in) 54.0 (2.13) × 31.5 (1.24)
Compression ratio 9.0
Compression pressure (*3) kPa 700 (7.0, 100)
(minimum) (kgf/cm2, psi)
Control system Tiller control
Starting system Manual starter
Enrichment system Choke valve
Ignition control system TCI
Ignition timing Degree BTDC 30
Spark plug (NGK) BR6HS
Cooling system Water
Exhaust system Under water
Lubrication system Oil splash
(*1)
Includes an aluminum propeller and excludes oil and fuel.
(*2)
Readjust the idle speed after the breaking-in period is finished.
(*3)
At sea level and 20 °C (68 °F)

21
 Model
USA F2.5MH
Item Unit
Canada F2.5MH
Worldwide F2.5AMH
Fuel and oil
Fuel type Regular unleaded gasoline
(*4)
Fuel rating PON 86
(minimum) RON(*4) 91
Fuel tank capacity L (US gal, 0.9 (0.24, 0.20)
lmp gal)
Engine oil type 4-stroke motor oil
Engine oil grade API SE, SF, SG, SH, or SJ
SAE 10W-30 or 10W-40
Engine oil quantity L 0.35 (0.09, 0.08)
(US qt, lmp qt)
Gear oil type Hypoid gear oil
Gear oil grade API GL-4
SAE 90
3
Gear oil quantity cm (US oz, 75 (2.5, 2.6)
lmp oz)
Bracket
Trim angle Degree 0, 4, 8, 12
(@ 12 degree boat transom)
Tilt-up angle Degree 80
Steering angle Degree 360
Drive unit
Gearshift positions F-N
Gear ratio 2.08 (27/13)
Reduction gear type Straight bevel gear
Clutch type Dog clutch
Propeller shaft type Spline
Propeller direction Clockwise
(rear view)
Propeller identification mark BS
(*4)
PON: Pump Octane Number = (Research Octane Number + Motor Octane Number)/2
RON: Research Octane Number

22
 S: 645 (25.4)
L: 772 (30.4) 406 (16.0)

S: 432 (17.0)
103 (4.1) L: 559 (22.0) 376 (14.8)
1) EXTERIOR

264 (10.4)
32 (1.3) 205 (8.1) 140 (5.5)
2. DIMENSIONS

15 (0.6)

1 2˚
57 (2
366 (14.4)

.2)
93 (3.7)
309 (12.2)

167 (6.6)

23
57 (2.2)

215 (8.5)
315 (12.4)
L: 761 (30.0)
S: 636 (25.0)

139 (5.5) 135 (5.3)

8
0˚

S: 642 (25.3)
L: 746 (29.4) 470 (18.5)
mm (in)

S69M2010
2) BRACKET

mm (in)

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)

S69M2020

24
3. TIGHTENING TORQUES
1) SPECIFIED TORQUES
Tightening torques
Part to be tightened Thread size
N·m kgf·m ft·lb
Power unit
Anode mount screw M5 2.0 0.2 1.5
Choke knob nut — 3.5 0.4 2.6
1st 5.0 0.5 3.7
Connecting rod cap M6
2nd 9.0 0.9 6.6
1st 5.0 0.5 3.7
Crankcase bolt M6
2nd 11 1.1 8.1
1st 14 1.4 10
Cylinder head M8
2nd 30 3.0 22
1st 5.0 0.5 3.7
Cylinder head cover M6
2nd 12 1.2 8.9
Drive shaft oil seal housing bolt M8 18 1.8 13
Exhaust probe plug M8 20 2.0 15
Flywheel magnet nut — 44 4.4 32
Fuel cock mount screw M5 0.7 0.1 0.5
Rocker arm lock nut M6 10 1.0 7.4
Rocker arm pivot stud M6 10 1.0 7.4
Oil drain bolt M8 18 1.8 13
Power unit mount bolt M6 11 1.1 8.3
Spark plug — 25 2.5 18
Splasher mount bolt M6 13 1.3 10
Thermostat cover 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 plug — 8.5 0.9 6.3
Idle silencer M6 2.5 0.3 1.8
Shift rod arm bolt M5 4.5 0.5 3.3
Shift rod connecting bolt M6 10 1.0 7.2
Bracket unit
Apron M6 2.5 0.3 1.8
Bottom cowling M5 2.0 0.2 1.5
Tiller handle mount bolt M8 26 2.6 19
Carrying handle protector screw M4 1.0 0.1 0.7
Engine stop switch nut — 1.8 0.2 1.3
Grease nipple — 3.0 0.3 2.2
Swivel bracket cover bolt M6 12 1.2 8.5
Throttle grip screw M5 3.5 0.4 2.6
Through bolt inner nut — 5.0 0.5 3.7
Through bolt outer nut — 16 1.6 11
Throttle grip shaft cap bolt M5 3.0 0.3 2.2
Tilt pin nut — 4.5 0.5 3.3

25
2) GENERAL TORQUES
This chart specifies tightening torques for
standard fasteners with a standard ISO
thread pitch. To avoid a warpage of the com-
ponents, tighten the fasteners with a criss-
cross pattern and progressive stages until
the specified tightening torque is obtained.
Unless otherwise specified, the tightening
torque specifications require clean and dry
threads.
The components should be at room tempera-
ture.

Specifications
Nut (A) Bolt (B)
N·m kgf·m ft·lb
8 mm M5 5 0.5 3.6
10 mm M6 8 0.8 5.8
12 mm M8 18 1.8 13
14 mm M10 36 3.6 25
17 mm M12 43 4.3 31

26
4. IDLE SPEED 4. Turn the throttle stop screw 2 until the
The idle speed has to be readjusted after the specified idle speed is obtained.
breaking-in period has been finished.
With the smallest engine and lowest output, Clockwise a: Idle speed is increased.
the idle speed tends to rise by the reduction Counterclockwise b: Idle speed is
of the engine internal friction due to the decreased.
breaking-in.

1) READJUSTING THE IDLE SPEED

1. Warm the engine up for 5 minutes and
stop it.

2. Set the special tachometer to the spark

plug cord 1.

5. Rev the engine a few times, and then run

it at the idle speed for 15 seconds and
over to check its stability.
Repeat the steps if necessary.

3. Start the engine and check the idle

speed. Follow the step 4 if the idle speed
is out of the specification.

Digital tachometer:
90890-06760

Idle speed:
1,900 ± 100 r/min

27
 WIRING DIAGRAM
F2.5MH
F2.5AMH

1 Flywheel magnet Color code

2 TCI unit B : Black
3 Engine shut-off switch W : White
4 Ground
5 Spark plug

28
 YAMAHA MOTOR CO., LTD.

Printed in Japan
Apr. 2002 – 0.2 × 1 CR
(E)