PARSUN OUTBOARD ENGINE SERVICE MANUAL F4BM (F5BM) SUZHOU PARSUN POWER MACHINE CO., LTD.
NOTICE This manual includes service instructions for F4, F5, and has been prepared by Parsun Power primarily for use by the dealers when performing maintenance and repair to Parsun outboard engines. Before performing maintenance, please read the manual carefully. When performing maintenance and repair to Parsun outboard engines, please use the service procedure and tools recommended by the manual.
INDEX GENERAL INFORMATION··········································1 IDENTIFICATION·············································1 PROPELLER SELECTION·····································1 EMERGENCY START··········································1 SAFETY WHILE WORKING···································3 DISASSEMBLY AND ASSEMBLY································3 ONE-TIME USE PARTS·········································4 PRE-DELIVERY CHECK······································4 SPECIAL TOOLS AND DETECTION DEV
RECOIL STARTER·················································20 NOTICE···················································20 EXPLOSIVE DRAWING······································21 DISASSEMBLING···········································24 START ROPE REPLACEMENT································24 DISASSEMBLING AND INSPECTION·························25 ASSEMBLING···············································26 INSTALLATION············································26 IGNITION SYSTEM······················
Valve seat cutting·····································52 Thermostat··········································53 CRANKCASE············································53 Disassembling·······································53 Breather·············································53 Piston··············································54 Cylinder bore········································54 Piston pin diameter···································54 Piston ring···········································54 Camshaf
Disassembling and inspection······························75 LOWER UNIT····················································76 WATER PUMP ASSEMBLY···································76 Explosive drawing·······································76 Disassembling and inspection······························78 LOWER UNIT···············································79 Explosive Drawing······································79 Disassembling and inspection······························83 Propeller shaft and clutch blo
GENERAL INFORMATION IDENTIFECATION The outboard motor serial number is marked on the label. The label can be found on the bracket left assembly or on the upper part of the bracket swivel. Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Parsun dealer or for reference in case your outboard motor is stolen. 1 1.
parts. The procedure is as follows: 1. Remove the top cowling. 2. Remove the start-in-gear protection device cable, and remove the chock lever cable. 1.Start-in-gear protection device cable 3. Demount three bolts and remove starter. 4. Assemble two bolts to fix the fuel tank. 2. Chock lever cable 5. Insert the knot of the cable in the notch of flywheel rotor, and wind the cable around flywheel several rounds in clockwise direction. 6. Pull the manual starter handle slowly until you feel resistance.
7. Give a strong pull to start the engine. Repeat if necessary. SAFETY WHILE WORKING To prevent the danger or accidents when performing maintenance and repair, and improve the work efficiency, please obey the following safety procedures. 1. FIRE PREVENTION Gasoline (petrol), lubricant and grease are highly flammable. While working, keep away from heat, sparks and open flames. 2. VENTILATION Petroleum vapor and engine exhaust gases are violent in toxicity.
1. 2. 3. 4. Use special tools when disassembling and assembling. Clean dirt before disassembling the parts. Oil the contact surfaces of moving parts before assembly. Install bearing with the manufacturer’s markings on the side exposed to view and liberally oil the bearing. 5. When installing oil seals, apply a light coating of water-resistant grease to the ledge and outside diameter. 6. After assembly, check if the moving parts operate normally.
1 1. Oil level plug 3. CHECK STEERING SYSTEM Check if steering is stable. Check if steering friction is adjusted correctly. Turn clamp handle screw clockwise to increase resistance. Turn clamp handle screw counter clockwise to lower resistance. 1 1. Clamp handle screw 4. CHECK SHIFT LEVER AND THROTTLE Check if the shift lever is operated smoothly. Check if the throttle grip is turned smoothly from full closed position to full open position. 5.
over the cooling water passage by fresh water. 9. After breaking-in running, inspect idling speed. ① ② ③ ④ Preheating engine for 5 minutes. Using the tachometer to measure idling speed RPM. If out of specification, adjust it. Idling speed: 1450~1550 r/min Turn the throttle stop screw clockwise or counter clockwise until the specified idling speed is attained. After adjusting idling speed, picking up RPM several times to check the engine’s stability.
Barrel bearing with guard board installer tool Lower casing bracket and barrel bearing without guard board installer tool Lower casing bracket and drive shaft oil seal installer tool DETECTION DEVICE: Digital tachometer Digital circuit tester 7 Peak voltage adaptor
EXPLOSIVE DRAWING AND SYMBOL EXPLOSIVE DRAWING ① M6x45 mm 1st 3Nm 2nd 8Nm ② L 1277 ③ G M6x25 mm 1st 3Nm 2nd 8Nm G L 1277 14 15 PART NO.
SPECIFICATIONS OUTBOARD ENGINE SPECIFICATIONS Description Item Description Choke valve Spark plug BPR7HS Exhaust system Under water 1156mm Lubrication system Splash lubrication S 24.5kg Fuel type Unleaded regular gasoline L 25.5kg Fuel standard PON86、RON91 Max output 2.9Kw(4hp)@4500r/min 3.6Kw(5hp)@5000r/min Fuel tank capacity 1.3L Full throttle operation 4000～5000r/min Recommended engine oil API SE, SF, SE-SF, SG-CD SAE 10W30, 10W40 Max fuel consumption 1.
MAINTENANCE INFORMATION Power Unit Wear limit Taper limit 0.08mm Out of round limit 0.05mm Piston diameter 58.950~58.965mm Measuring point height 10mm (from the bottom of piston） Piston-to-cylinder clearance 0.035~0.065mm Pin boss inside diameter 13.009~13.017mm Cylinder Piston Piston pin outside diameter End gap Wear limit 0.40mm Side clearance 0.04~0.08mm Thickness 1.5mm Breadth 2.6mm End gap 0.25~0.
Cont’d Item Item Description Valve opening temperature 58~62ºC Full-open temperature 70ºC 26.736~26.836mm Exhaust 26.532~26.623mm Round diameter 21.950~22.050mm Valve lift Journal diameter 14.966~14.984mm Discharge Camshaft round limit 0.03mm Fuel pump Valve lifter outside diameter Thermostat Intake Height Camshaft Description 7.978~7.987mm Pressure Plunger stroke 3mm 8L/h 50kPa 1.8~2.2mm Ignition system Item Description Item Ignition timing BTDC28º ~32º T.C.
Cont’d Power unit Part to be tightened Part name Thread size Quantity Torque Connecting rod Bolt M7 2 12 Nm Oil splash gear unit Bolt M6 1 8 Nm Bolt M6 2 Bolt M6 2 Lower unit Lower unit mounting Lower unit housing cover 2nd tightening 1st tightening 8 Nm 6Nm 2nd tightening 1st tightening 3 Nm 11 Nm 3 Nm Bolt M6 1 Bolt M6 4 Bolt M6 1 Steering handle mounting Bolt M8 1 18 Nm Shift lever bracket Bolt M6 1 4.
PERIODIC SERVICE MAINTENANCE TIME TABLE Initial maintenace Items Contents 10 hours （1 month） Anode Spark plug Inspection/replacement Grease points Bolts and nuts Fuel tank and fuel line Fuel filter Fuel cock Carburetor Throttle cable Idling speed Greasing Start-in-gear projection Inspection/ adjustment Cleaning/adjustment /replacement ○ General maintenance period 50 hours 100 hours （3 months） （6 months） ○ ○ ○ ○ 200 hours （1 year） ○ ○ Inspection Inspection ○ ○ ○ ○ ○ ○ ○ ○ ○ ○ Inspection/r
2. CHECK FUEL COCK AND FUEL JOINT Check if fuel cock and fuel joint are cracked, damaged or leaking. Replace if necessary. 3. CHECK FUEL FILTER Check if fuel filter is cracked, damaged or has dirt inside. If so, replace it. CAUTION: The arrow mark of the fuel filter must face toward the fuel pump. Clean the spilled oil. POWER UNIT Engine oil level a) Remove oil level plug, check engine oil level, if between the following marks of the upper and lower.
2 1 1. Oil level plug 2. Oil rule 3 3. High position mark 4 4. Low position mark b) If above the upper mark, drain the engine oil; if below lower mark, add engine oil up to upper mark. CAUTION: Run the engine and then turn it off, wait for several minutes, and check the engine oil level by the oil rule again. If the engine oil still not within the proper level, add/drain as needed. Changing engine oil 1. Remove oil level plug, drain plug with washer and gasket; drain off the engine oil. 2.
2. Remove cylinder head cover 3. Use feeler gauge to measure the clearance between rocker arm and valve rod top: if out of specification, adjust. Valve clearance (cold position): Inlet valve: 0.10±0.02mm Outlet valve: 0.10±0.02mm Spark plug 1. Remove spark plug cap and spark plug. 2. Clean off carbon build-up on the electrodes. 3. Check if the electrodes are corroded or have deposit, or if the washer is damaged. If necessary, change the spark plug. Spark plug type: BPR7HS 4.
1 1.throttle cable stop screw Idling speed Check idling speed, and adjust it if necessary. 1. Preheat engine for 5 minutes. 2. Attach the tachometer to the spark plug wire to measure idling speed RPM. specification, adjust it. Idling speed: 1450~1550 r/min If out of 3. Turn the throttle stop screw clockwise or counter clockwise, until the specified idling speed is attained. NOTE: Turning clockwise to increase idling speed. Turning counter clockwise to decrease idling speed.
LOWER UNIT Gear oil Check gear oil level: Remove the oil level plug. If the gear oil overflows at the oil level checking hole, the oil volume added is correct; otherwise please add gear oil. 1 1.Oil level plug Changing gear oil 1. Hold the outboard engine in an upright position. 2. Place a container under the drain plug. 3. Remove the drain plug, the oil level plug, and then drain the gear oil. 1 2 1. Oil level plug 2. Drain plug 4. Add gear oil through the drain plug using pressure filling device. 5.
Lower unit leakage check Connecting the leakage tester to the oil level checking hole to check the lower unit leakage. pressure drops (pressure: 1kg/cm³), inspect the oil seal and components. If the GENERAL INSPECTION Anode Inspect lower unit anode and engine anode (on the thermostat cover). Clean the greasy dirt and scales. If wear or damage is above 1/2, replace the anode. CAUTION: Cannot grease or paint the anode, or it will not operate properly. Grease points 1.
1 Cooling water passage inlet 2. Place the outboard engine in the water and ensure the water level is above the anti-vortex plate, then start the engine. 3. Check if water overflows at the cooling water checking hole. If there is no flow or intermittent flow, check the cooling water passage. 1 2 1. Cooling water inlet 2. Cooling water checking hole RECOIL STARTER NOTICE When you service, please wear safety glasses and gloves.
EXPLOSIVE DRAWING M6x20 mm 8Nm M6x35 mm 8Nm G G G G 6.5Nm PART NO.
M6x20 mm 8Nm M6x35 mm 8Nm G G G G 6.5Nm PART NO. 11 12 13 14 15 16 17 18 19 20 F4-04130008 F4-04130006 F4-04130007 F4-04130019 F4-04130005 F4-04130014 F4-04130002 F4-04130010 F4-04130009 GB/T97.
M6x20 mm 8Nm M6x35 mm 8Nm G G G G 6.5Nm PART NO.
DISASSEMBLING 1. Open the top cowling 2. Screw loosely the adjusting nut of the dent tightwire. 1 1. Adjusting nut 3. Remove the tightwire from the detent. 4. Remove the starter fixing bolt, and remove the starter. STARTER ROPE REPLACEMENT 1. Pull the starter rope out, and insert it in the notch of the sheave drum. clockwise until the volute spring is free. Turn the sheave drum 2. Pull the starter rope completely. 3.
6. Insert the start rope in the notch of the sheave drum and turn the sheave drum several rounds in counter clockwise direction. 7. Pull the starter handle many times to check if the sheave drum rotates stably. If necessary, repeat step 6 and step 7. DISASSEMBLING AND INSPECTION 1. Remove the start rope. 2. Remove starter bolt, and remove press plate. 3. Remove the sheave drum WARNING Uninstall the sheave drum carefully, to ensure that the volute spring does not pop out to hurt people. 4.
ASSEMBLING Reverse the steps of disassembling. INSTALLATION 1. Put starter onto the power unit. 2. Screw the hexagon bolt, and tighten it according to the specified torque. 3. Install the detent tightwire. 4. Adjust the adjusting nut on the tightwire of the dent, and align the triangle marking of the dent 2 with the triangle marking of the starter case. 1 2 3 1. Triangle mark 2. Adjusting nut 3.
IGNITION SYSTEM NOTICE When checking and repairing the ignition system, keep your hand, clothes, hair or personal belongings away from the rotating flywheel. Check ignition coil on insulated working table, to prevent electricity leak and electroshock. Don’t touch the ignition coil or spark plug when the engine is running, to avoid electroshock. Keep the wires away from the rotating flywheel, to prevent the wire from being cut, or the insulating layer of the wire from being worn.
WIRING DIAGRAM 5 W B W B 1 Flywheel ○ 2 Ignition coil ○ 3 Engine stop switch ○ 4 Grounding ○ 5 Spark plug ○ Wire beam color: W White B Black SPARK PLUG IGNITION 1. Remove spark plug cap from spark plug. . 2. Connect the ignition tester to the spark plug cap. 3. Start the engine, and observe the sparks through the discharge window of the tester. WARNING Do not touch any joint part of the lead wire of the tester.
SPARK PLUG CAP 1. Remove the spark plug. Check if the spark plug cap is broken. Replace if necessary. 2. Measure the resistance. If it’s out of specification, replace. Spark plug cap resistance: 4.0～6.0kΩ 3. Install the spark plug cap Turn it clockwise until it is tight. FLYWHEEL MAINTENANCE 1. Use flywheel holder to remove the nut and starter pulley; use flywheel puller to remove flywheel. 2. Check if the flywheel is damaged or the permanent magnet part is firm. Replace if necessary.
FUEL SYSTEM NOTICE Gasoline is inflammable and highly volatile liquid. Its leakage can cause fire and explosion. Don’t start the engine before all joints of the fuel system are connected or installed. When completing all maintenance steps, force short-time pressure to the fuel system to check for leakage. EXPLOSIVE DRAWING PART NO.
PART NO.
1 2 34 5 6 13 5 4 78 9 M6x30 mm 8Nm 16 17 10 12 11 18 21 19 18 20 14 PART NO.
1 2 34 5 6 13 5 4 78 9 M6x30 mm 8Nm 16 17 10 12 11 18 21 19 18 20 14 PART NO. 15 18 18 24 18 25 18 DESCRIPTION 24 18 26 REMARKS SPRING,FUEL PIPE "B" 1 1 4 1 1 1 1 9 WASHER ,SPRING WASHER ,PLATE 2 2 F4-04090007 柱塞弹簧 F4-04090006 柱塞 SPRING ,PLUNGER PLUNGER GB/T6170-2000 螺母 M4 NUT FUEL PUMP ASSY F4-04090000 燃油泵组件 F4-04090009 燃油泵座O形圈 O-RING CLIP ,NYLON "B" F4-04000031-2 尼龙管夹 F4-04000028 燃油管E PIPE ,FUEL "E" F4-04000030 油管夹簧 GB/T93-1987 弹簧垫圈 6 GB/T97.
1 2 34 5 6 13 5 4 78 9 M6x30 mm 8Nm 16 17 10 12 11 18 21 19 18 20 14 PART NO.
M6x90 mm 8Nm 1 2 3 4 14 7 5 6 5 8 11 9 12 10 PART NO. DESCRIPTION GB/T5284-86 六角头螺栓M6x90 GB/T97.
M6x90 mm 8Nm 1 2 3 4 14 7 5 6 5 8 11 9 10 PART NO. 12 DESCRIPTION F4-04000022 进气弯管密封垫 F4-04000025 进气岐管 GB/T97.1-85 六角头螺栓 M6x25 F4-04000025 化油器 2 13 M6x25 mm 8Nm REMARKS MANIFOLD ,INTAKE HEXAGON BOLT CARBURETOR 1 1 2 1 FUEL TANK REMOVAL AND INSPECTION 1. Open the top cowling. 2. Remove three bolts fixing the starter. 3. Remove the starter. Pull the fuel tank out. 4. Remove the fuel pipe from fuel tank.
5. Inspect the fuel tank and fuel tank cover for crack, leakage or damage. Replace if necessary. 6. Inspect the tank strainer for dirt or clog. Clean or replace if necessary. OIL SWITCH REMOVAL AND INSPECTION 1. Remove the fuel tank. 2. Remove the bolts fixing the thumb wheel of the oil switch, and remove the thumb wheel. 1 2 3 4 1. Oil switch 2. Thumb wheel 3. Plus pan head screw M4X12 4. Thumb wheel block 3. Remove the bolts fixing the oil switch, and remove oil switch. 1. Screw 2. Gasket 3.
3. Inspect the fuel joint for crack or damage. 4. Connect the fuel joint exit with a vacuum pressure gauge. 5. Check whether the negative pressure can be maintained for over 10 minutes under the prescribed pressure. Replace if necessary. Prescribed pressure: 50kPa. FUEL PUMP REMOVAL AND INSPECTION 1. Remove the bolts fixing the fuel pump. 2. Remove the fuel pump. 3. Connect the fuel pump intake with a vacuum pressure gauge. 4.
INTAKE SYSTEM REMOVAL AND INSPECTION １. Loose throttle cable stop screw, and remove throttle cable. 1 1. Throttle cable stop screw ２. Remove choke cable from carburetor. Remove choke cable. ３. Remove the bolt fixing air filter. ４. Remove air filter and carburetor. ５. Remove intake manifold from engine. ６. Check if air filter and intake manifold are cracked or damaged. 39 Replace it if necessary.
POWER UNIT NOTICE To prevent the engine from accidental starting, you should adopt adequate safeguard measures to cut off the ignition system. For example: remove the hang rope stopper from stop switch assembly, and remove spark plug cap from spark plug. EXPLOSIVE DRAWING 14 23 22 20 15 16 21 19 18 1 2 3 5 17 7 M6x20 mm 8Nm 15 4 1st 15Nm 2nd 30Nm 6 11 9 10 6 13 12 25Nm PART NO.
14 23 22 20 15 16 21 19 18 1 2 3 5 17 7 M6x20 mm 8Nm 15 4 1st 15Nm 2nd 30Nm 6 11 9 10 6 13 12 25Nm PART NO. DESCRIPTION REMARKS BOLT F4-04000034 气缸头螺栓B 六角头螺栓M8×14 BOLT ,HEXAGON GB/T97.1-85 平垫圈8 WASHER ,PLATE F4-04000036 节温器 THERMOSTAT GB/T97.
14 23 22 20 15 16 21 19 18 1 2 3 5 17 7 M6x20 mm 8Nm 15 4 1st 15Nm 2nd 30Nm 6 11 9 10 6 13 12 25Nm PART NO.
13 11 10 O 14 6 12 7 10Nm 5 O 4 8 3 L 1277 6 2 5 O O 1 4 L 1277 2 1 13 O 11 10 14 12 9 PART NO. DESCRIPTION REMARKS PS2700.03.02 气门挺柱 F4-04000015 气门推杆 LIFTER,VALVE ROD,VALVE PUSH PLATE,PUSH ROD F4-04080009 导向板 PS2700.04.12 摇臂螺杆 BOLT,ROCKER ARM PS2700.04.12 气门摇臂 ARM,VALVE ROCKER PS2700.04.13 摇臂球座 PIVOT,ROCKER ARM PS2700.04.18 六角螺母M6x0.
13 11 10 O 14 6 12 7 10Nm 5 O 4 8 3 L 1277 6 2 5 O O 1 4 L 1277 2 1 13 O 11 10 14 12 9 PART NO. DESCRIPTION PS2700.04.
7 8 6 5 3 M6x12mm 8Nm 9 10 O 28 2 1 O 26 13 25 4 O 11 24 12 23 2 O 15 19 14 M8x50mm 1st10Nm 2nd 22Nm O 17 22 L 1277 1 2 3 4 5 6 7 8 9 10 18 20 27 PART NO. 16 19 M8x20mm 18Nm 21 DESCRIPTION F4-04010100 曲轴箱体 F4-04010002 气嘴 F4-04010003 曲轴油封A25x40x5 GB/T276-94 深沟球轴承6205C3 F4-04000009 呼吸器密封垫 F4-04000010 呼吸器盖板 REMARKS CRANK CASE PIPE,JOINT OIL SEAL BEARING BREATHER GASKET COVER 六角头螺栓M6x14 HEXAGON ,BOLT GB/T97.
7 8 6 5 3 M6x12mm 8Nm 9 10 28 O 2 1 O 26 13 25 4 O 11 24 12 23 2 O 15 19 14 M8x50mm 1st10Nm 2nd 22Nm O 16 17 22 27 L 1277 PART NO. 11 12 13 14 15 16 17 18 19 20 18 20 19 M8x20mm 18Nm 21 DESCRIPTION F4-04000003 空心定位销φ10x8.4x14 F4-04050001 曲轴箱盖 F4-04000002 曲轴箱体复合垫 REMARKS HOLLOW PIN COVER,CRANK CASE 六角法兰面螺栓M8x50 BOLT,HEXAGON F4-04060003 曲轴油封20x30x7(B) OIL,SEAL F4-04060004 OIL,SEAL O-RING F4-04060002 油封壳体0型圈 SHELL,OIL SEAL F4-04060001 油封壳体 F4-04060000 油封壳体组件 GB/T97.
7 8 6 5 3 M6x12mm 8Nm 9 10 28 O 2 1 O 26 13 25 4 O 11 24 12 23 2 O 15 19 14 M8x50mm 1st10Nm 2nd 22Nm O 16 17 22 27 L 1277 PART NO.
4 5 6 1 23 9 4 O 7 M7x35mm 12Nm 8 O 10 PART NO.
SPECIAL TOOLS Piston slider Bearing puller Housing bearing installer Oil seal installer tool Valve spring compressor Housing oil seal installer Space gauge DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE 1. Open the top cowling. 2. Remove the starter and fuel pump. 3. Remove choke cable and throttle cable. 4. Remove air filter and carburetor. 5. Remove bolts connecting the engine and upper casing. 6. Carry the power unit and put it onto the working table.
CYLINDER COVER Disassembling 1. Remove the bolts of cylinder head cover. 2. Remove the bolts of the cylinder cover according to the reverse numbering sequence of the cylinder cover. 3. Remove the crankcase cover. Remove the valve push rod. 4. Remove the rocker arm pivot, rocker arm, rocker arm shaft and push rod plate. 5. Use the valve spring compressor to remove intake door and exhaust door. Push rod Inspect valve push rod runout. Replace if exceeding the specified value. Valve push rod runout limit: 0.
4. Measure the valve stem runout. If exceeding the limit, replace the valve. Valve stem runout limit: 0.03mm 5. Measure the inner diameter of the valve pipe. The inner diameter of the valve pipe: 5.500～5.512mm CAUTION: When replacing the valve, please use the new valve pipe and valve oil seal. Valve spring 1. Measure the free length of valve spring. If less than prescribed value, replace. The minimum free length: 34mm 2. Measure the valve spring tilt. If exceeding the prescribed limit, replace.
The valve seat width: The maximum valve seat width: 0.6～0.8mm 1.1mm Valve seat cutting 1. Use 45 cutter to adjust the valve seat width. Turn the cutter clockwise until the valve seat face is smooth. o 2. If the valve seat is centered on the valve face but it’s too wide, to reduce the valve seat width, use 30 o cutter to adjust the top edge of the seat, and use 60o cutter to adjust the bottom edge of the seat. 3.
Do not overlap the valve. Turn the lapping tool evenly with a downward force of 40~50N. Do not contaminate push rod and valve pipe with lapping compound. Thermostat 1. Remove thermostat cover and thermostat. 2. Suspend thermostat in the container with water. 3. Heat the container. 4. Inspect valve lift situation in the prescribed water temperature. If out of specification, replace. Water temperature The lift height 58～62℃ 0.05mm valve lift Over 70℃ Over 3mm 5. Install thermostat and thermostat cover.
3. Inspect breather return pipe. If cracked/leaked/damaged, replace. Piston Measure piston outside diameter at the specified measuring point. Piston diameter: 58.950～58.965mm a : 10mm Measuring point○ If out of specification, replace. a D Cylinder bore Measure cylinder bore separately at measuring point ○ 1, ○ 2, ○ 3 . At each point, measure the cylinder bore at places D1, D3, D5 parallel to the crankcase and at places D2, D4, D6 vertical to the crankshaft. ① 1. 2.
If weight is unsmoothly moving, replace. a and height ○ b . If out of specification, replace it. 2. Measure camshaft lobe diameter○ a ○ Intake camshaft: 21.950～22.050mm Exhaust camshaft: 21.950～22.050mm b b ○ Intake camshaft: 26.736～26.836mm Exhaust camshaft: 26.532～26.623mm a 3. Measure camshaft diameter. If out of specification, replace the camshaft. Camshaft journal wear limit: 14.934mm Measure crankshaft runout. Crankshaft If out of specification, replace. Crankshaft runout limit: 0.
NOTE: Don’t remove bearing unless you replace it. 1. Oil seal housing Inspect oil seal housing for crack/damage. Replace if necessary. 2. Inspect O-ring for crack/damage. 1. Crankcase and crankcase cover Inspect crankcase cover. If cracked/damaged, replace. 2. Inspect cooling water passage for dirt or clog. Replace if necessary. Clean if necessary. FULL INSTALLATION Piston connecting rod installation Install piston, connecting rod, piston pin and piston pin circlip.
NOTE: Apply motor oil to the piston and piston ring side when installing. Oil seal housing installation. 1. Install oil seals 10.8x21x7 (2 pieces) by oil seal installer tool. 2. Install oil seals B20×30×7 by oil seal installer tool. NOTE: ① Apply grease onto new seal before installation. ② Make sure the oil seal direction as shown. 1. Crankshaft installation Install the crankshaft bearing to crankcase by special tools (if change bearing).
Crankcase cover installation 1. Install oil seal housing. 2. Install oil splasher gear assembly. 3. Install crankcase cover, and tighten the bolts twice as shown. Tightening torque: 1st 10 Nm 2nd 22 Nm NOTE: Apply motor oil to moving parts before installing.
5Nm 5Nm PART NO. DESCRIPTION REMARKS F4-06000000 GB/T8.
5Nm 5Nm PART NO.
Disassembling and inspection 1. Remove airproof rubber bar. 2. Remove top cowling muffling cover bolt and rubber underlay. 3. Remove top cowling muffling cover. 4. Remove lock hook and pothook. 5. Inspect if top cowling is cracked or damaged. 6. Inspect if airproof rubber bar is cracked or damaged. 7. Inspect if top cowling muffling cover is cracked or damaged. 8. Inspect if lock hook and pothook is cracked, deformed or damaged. Replace it if necessary. Replace it if necessary.
PART NO.
PART NO. DESCRIPTION REMARKS F4-05000013-2 GB/T6170-86 GB/T5783-2000 GB/T97.1-85 GB/T5783-2000 Disassembling and inspection 1. Remove rubber cover B. 2. Remove handle bolt and handle. 3. Remove top cowling clamp lever bolt and clamp lever.
4. Remove top cowling clamp lever bush A and clamp lever bush B. 5. Remove wave washer. 6. Inspect if bottom cowling is cracked or damaged. 7. Inspect if clamp lever handle is cracked or damaged. 8. Inspect if clamp lever is cracked or damaged. 9. Inspect if wave washer and clamp lever bush are cracked or damaged. necessary. Replace if necessary. Replace if necessary. Replace if necessary. STEERING HANDLE Explosive drawing L 1243 M8x25mm 18Nm G G G L 1243 PART NO.
L 1243 M8x25mm 18Nm G G G L 1243 PART NO.
L 1243 M8x25mm 18Nm G G G L 1243 PART NO. 21 22 23 24 25 26 27 G DESCRIPTION REMARKS F4-01090003 操舵手柄握把摩擦块 FRICTION LEVER,THROTLLE F4-01090100 节气门杆组件 GB/T818-85 十字槽盘头螺钉M5x12 SCREW,PAN HEAD F4-01090002 节气门杆固定板 STAY F4-01090008 油门钢索组件 F4-01090401 引擎停止安全索 F4-01090400 急停开关组件 1 1 2 1 1 1 1 1. Disassembling and inspection Remove steering handle cover. 2. Remove handle bush, bush washer and wave washer. 3. Remove steering handle shocker damper.
4． Remove cotter pin and friction adjusting bolt. 5． Remove steering handle. 6． Remove throttle cable. 7． Remove throttle lever stay and throttle lever. 8． Remove engine stop switch. 9． Inspect if steering handle is cracked or damaged. Replace if necessary. 10． Inspect if bush, bush washer and wave washer are cracked or damaged. necessary. 11. Inspect if steering handle shock damper is cracked or damaged. 12. Inspect if throttle cable is cracked or damaged. 13.
BRACKET Explosive drawing G M6x35mm 1st 3Nm 2nd 8Nm G 13Nm G M6x10mm 1st 3Nm 2nd 8Nm G PART NO. 1 2 3 4 5 6 7 8 DESCRIPTION REMARKS HEXAGON NUT 4 1 1 1 1 1 2 1 1 WASHER 11 F4-02000008 减震圈衬管 F4-02000007 上减震圈 F4-02020000 水上装置锁紧圈组件 F4-01050002 锥形弹簧 F4-01050000 角度调整杆组件 SPRING ,CONICAL TILT ROD ASSY 非金属嵌件六角锁紧螺母M8 F4-01000002 双孔固定板 F4-01030001 旋转支架座 9 GB/T6170-86 六角螺母M6 10 GB/T97.
G M6x35mm 1st 3Nm 2nd 8Nm G 13Nm G M6x10mm 1st 3Nm 2nd 8Nm G PART NO.
G M6x35mm 1st 3Nm 2nd 8Nm G 13Nm G M6x10mm 1st 3Nm 2nd 8Nm G PART NO.
G M6x35mm 1st 3Nm 2nd 8Nm G 13Nm G M6x10mm 1st 3Nm 2nd 8Nm G PART NO. 31 32 33 34 35 36 37 38 DESCRIPTION REMARKS F4-01010001 夹紧托架（右） F4-01000005 旋转支架座盖 GB/T5782-86 六角头螺栓M6x35 HEXAGON BOLT F4-01060002 锁紧手柄 CLAMP HANDLE RIVET GB/T875-86 扁平头半空心铆钉φ4x11 LOCKED SCREW F4-01060001 锁紧螺杆 GB/T96-1985 大垫圈 BIG WASHER F4-01020000 夹紧托架（左）组件 1 1 6 1 1 1 2 1 Disassembling and inspection 1. Remove tilt locked clasp. 2. Remove swivel bracket cover. 3.
4. Remove clamp bracket 5. .Remove swivel bracket. 6. Remove bracket fixed cover, and the tilt lock bracket. 7. Inspect the the swivel bracket and clamp bracket for damage or crack. 8. Inspect the bush and shock absorption for damage or crack. Replace if necessary. Replace if necessary. 9. Inspect: whether the tilt lock bracket and tilt locked clasp were distorted, replace if needed.
UPPER UNIT Explosive drawing G M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION 1 2 F4-00000007 变档手柄 F4-02010000 变档拨叉组件 3 4 5 6 JISB2401 "O"形密封圈P9 F4-02000002 水上装置壳体铜套 7 REMARKS HANDLE,GEAR SHIFT SPRING,GEAR BALL 8 1 1 2 1 1 1 1 BOLT PIN,COTTER WASHER,PLATE 5 1 1 2 SHAFT,CHANGE O-RING BUSHING,SHIFT ROD LEVER GB/T820-2000 十字半沉头螺钉M5x20 SCREW,OVAL HEAD F4-02000003 变档弹簧 钢珠8 GB308-84 8 GB/T5783-2000 六角螺栓M5x25 9 GB/T308-84 开口销1.6x12 平垫圈5 10 GB/T97.
G M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION 11 F4-02000006 变档连杆支架 12 13 14 15 16 17 F4-02000004 F4-00000003 F4-00000004 F4-00000005 GB/T5284-86 F4-00000001 REMARKS LEVER,SHIFT ROD 1 ROD,SHIFT 1 变档连杆 变档连杆连接器A CONNECTOR,SHIFT ROD1 A 变档连杆连接器B CONNECTOR,SHIFT ROD1 B 大垫圈 BIG,WASHER 1 六角头螺栓M6x20 BOLT 1 PIN ,HOLLOW 空心定位销 直通式压注油杯M6 GREASE CUP 18 WASHER 19 GB/T97.
G M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION REMARKS 21 F4-02000011 变档轴密封圈 22 F4-02000001 水上装置壳体 CASING ,UPPER 23 F4-02000012 水上装置橡胶堵头 24 F4-02040002 工形橡胶圈 25 F4-02040000 进水管 26 F4-02030001 接长体 EXTENSION 27 孔用弹性挡圈22 CIRCLIP 28 F4-02030003 驱动轴橡胶衬套 RUBBER BUSHING 29 F4-02030002 驱动轴衬套 GASKET ,ENGINE 30 F4-00000006 发动机密封垫 1 1 2 1 1 1 Disassembling and inspection 1. Remove the water tube. 2. Remove the gear shift handle and change shaft. 3. Remove the shift rod and shift rod lever.
4. Check upper casing and extension for crack or wear. Replace if necessary. 5. Check gear shift handle and change shaft for crack or wear. Peplace if necessary.
Explosive drawing M6x45 mm 1st 3Nm 2nd 8Nm G M6x25 mm 1st 3Nm 2nd 8Nm G L 1277 14 15 PART NO.
M6x45 mm 1st 3Nm 2nd 8Nm G M6x25 mm 1st 3Nm 2nd 8Nm G PART NO. L 1277 DESCRIPTION 六角头螺栓M6×25 11 12 GB/T97.1-85 平垫圈6 13 F4-03000012 水泵座 14 F4-03000011 水泵座密封垫 REMARKS HEXAGON BOLT WASHER ,PLATE BASE ,WATER PUMP HERMETIC GASKET 1 5 1 1 Disassembling and inspection 1. Remove water pump fixed plate. 2. Remove water pump housing. 3. Remove water pump impeller and inner water pump cover. 4. Remove water pump base.
5. Check water pump housing and out plate for crack, crank or damage. Replace if necessary. 6. Check inner water pump cover and impeller for crack, deform, burn or damage. necessary. 7. Check water pump base for crack, crank, scratch or damage. LOWER UNIT Explosive drawing 79 Replace if necessary.
G 33 1 M6x16mm 8Nm 37 19 2 3 4 34 G 18 17 16 35 5 14 L 1277 15 13 12 11 20 32 G 31 30 10 29 14 28 27 6 7 8 9 M6x16mm 1st 3Nm 2nd 8Nm PART NO. L 1277 23 22 21 22 26 25 21 24 M6 1st 3Nm 2nd 8Nm DESCRIPTION 开口销2.5×30 螺母组件 不锈钢垫片 螺旋桨组件 不锈钢垫块 F4-03000022 阳极 GB/T97.1-85 平垫圈6 GB/T861.
G 33 1 M6x16mm 8Nm 37 19 2 3 4 34 G 18 17 16 35 5 14 L 1277 15 20 32 G 31 30 10 29 14 28 27 6 7 8 9 L 1277 M6x16mm 1st 3Nm 2nd 8Nm PART NO. 11 12 13 14 15 16 17 18 19 20 13 12 11 22 26 25 21 24 M6 1st 3Nm 2nd 8Nm DESCRIPTION REMARKS F4-03000027 油封 10.8×21×7 OIL SEAL F4-03000009 倒档齿轮垫圈 F4-03040000 倒档齿轮组件 GB/T276-94 深沟球轴承6004C2 BEARING OIL SEAL F4-03050002 油封13×22×7 JISB2401 P48 水下装置壳体盖O形圈 O-RING F4-03050001 水下装置壳体盖 GB/T97.
G 33 1 M6x16mm 8Nm 37 19 2 3 4 34 G 18 17 16 35 5 14 13 12 11 L 1277 15 20 32 G 31 30 10 29 14 28 27 6 7 8 9 L 1277 M6x16mm 1st 3Nm 2nd 8Nm PART NO.
G 33 1 M6x16mm 8Nm 37 19 2 3 4 34 G 18 17 16 5 35 14 13 12 11 L 1277 15 20 32 G 31 30 10 29 14 28 27 6 7 8 9 L 1277 M6x16mm 1st 3Nm 2nd 8Nm PART NO.
4. Remove the reverse gear assy, drive shaft, positive gear assy, and shift pluger. 5. Remove shift rod cam assy and drive shaft. 6. Remove barrel bearing with guard board (F4-03000002). 7. Remove barrel bearing without guard board (F4-03000003) by using barrel bearing installer tool. 8. Remove the clutch block from the propeller shaft. Propeller shaft and clutch block 1. Check clutch block for wear or damage. 2. Check propeller shaft for wear or damage. Replace if necessary. Replace if necessary.
Note: Please use special tool to install oil seal and bearing. Pay attention to the oil seal installation direction and installation depth. Make sure the manufacturer mark faces toward the reverse gear. Barrel bearing Inspect barrel bearing with guard board and barrel bearing without guard board for wear, crack or damage. Replace if necessary. Inspect the drive shaft for crank or wear. Drive shaft Replace if necessary. Gear Inspect the forward gear, reverse gear and mini gear for wear or damage.
COMMON TROUBLES AND SOLUTIONS Trouble type Starter will not operate Possible reason Recovery action Starter components are faulty Repair or replace Shift level is not in neutral Shift to neutral Fuel tank is empty Fill tank with clean, fresh fuel Fuel is contaminated or stale Engine will not start (starter operates) Engine idles irregularly or stalls Fuel filter clogged Replace fuel filter Fuel pump has malfunctioned Repair or replace Air vent screw not loosened Loosen air vent screw Spar
Cont’d Trouble type Possible reason Recovery action Propeller is damaged Repair or replace propeller Trim angle is incorrect Adjust trim angle to achieve most efficient operation Motor is mounted at incorrect transom height Adjust motor to proper transom height Boat bottom is fouled with marine growth Clean boat bottom Weeds or other foreign matter are tangled on gear housing Remove foreign matter and clean lower unit Spark plug(s) are fouled or incorrect type Inspect spark plug(s).
