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Parsun F4BM Service Manual

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PARSUN OUTBOARD ENGINE
SERVICE MANUAL
F4BM (F5BM)
SUZHOU PARSUN POWER MACHINE CO., LTD.
https://www.boat-manuals.com/

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Summary of Contents for Parsun F4BM

  • Page 1 PARSUN OUTBOARD ENGINE SERVICE MANUAL F4BM (F5BM) SUZHOU PARSUN POWER MACHINE CO., LTD. https://www.boat-manuals.com/...
  • Page 2 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.

  • Page 3: Table Of Contents

    INDEX GENERAL INFORMATION· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 1 IDENTIFICATION·...
  • Page 4 RECOIL STARTER· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 20 NOTICE·...
  • Page 5 Valve seat cutting· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 52 Thermostat·...
  • Page 6 Disassembling and inspection· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 75 LOWER UNIT· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 76 WATER PUMP ASSEMBLY·...

  • Page 7: General Information

    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.
  • Page 8 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 2. Chock lever cable 3. Demount three bolts and remove starter. 4. Assemble two bolts to fix the fuel tank. 5.

  • Page 9: Safety While Working

    4. LUBRICANTS AND SEALING FLUIDS When performing maintenance procedures and repair to Parsun outboards, use only products provided or recommended by our Company. Under normal conditions of use, there should be no hazards from the use of the lubricants mentioned in this manual, but safety is all-important, and by adopting good safety practices, any risk is minimized.

  • Page 10: One-Time Use Parts

    1. Use special tools when disassembling and assembling. 2. Clean dirt before disassembling the parts. 3. Oil the contact surfaces of moving parts before assembly. 4. Install bearing with the manufacturer’s markings on the side exposed to view and liberally oil the bearing.
  • Page 11 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. Clamp handle screw 4.

  • Page 12: Special Tools And Detection Device

    over the cooling water passage by fresh water. 9. After breaking-in running, inspect idling speed. ① Preheating engine for 5 minutes. ② Using the tachometer to measure idling speed RPM. If out of specification, adjust it. Idling speed: 1450~1550 r/min ③...
  • Page 13 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 Peak voltage adaptor https://www.boat-manuals.com/...

  • Page 14: Explosive Drawing And Symbol

    EXPLOSIVE DRAWING AND SYMBOL EXPLOSIVE DRAWING ① M6x45 mm 1st 3Nm 2nd 8Nm ② 1277 ③ M6x25 mm 1st 3Nm 2nd 8Nm 1277 ④ PART NO. DESCRIPTION REMARKS 六角头螺栓M6×45 HEXAGON BOLT 泵壳固定板 F4-03000020 泵壳橡胶管 F4-03000021 F4-03000013 水泵座定位销 PIN ,WATER PUMP 水泵壳...

  • Page 15: Specifications

    SPECIFICATIONS OUTBOARD ENGINE SPECIFICATIONS Item Description Item Description Starting Choke valve Overall length 717mm enrichment Overall width 361mm Spark plug BPR7HS 1029mm Exhaust system Under water Overall Lubrication height 1156mm Splash lubrication system Unleaded regular 24.5kg Fuel type gasoline 25.5kg Fuel standard PON86、RON91 2.9Kw(4hp)@4500r/min...

  • Page 16: Maintenance Information

    MAINTENANCE INFORMATION Power Unit Item Description Item Description Valve Intake 0.10±0.02mm Warp limit 0.1mm clearance Exhaust 0.10±0.02mm (cold) 59.00~59.02mm Bore Intake 1.84~2.26mm Face width 59.1mm Wear limit Exhaust 1.84~2.26mm 0.08mm 0.6~0.8mm Taper limit Intake Seat width 0.05mm 0.6~0.8mm Out of round limit Exhaust 0.7mm Piston diameter...

  • Page 17: Ignition System

    Cont’d Item Description Item Description Valve opening 58~62ºC Intake 26.736~26.836mm temperature Full-open 70ºC Exhaust 26.532~26.623mm temperature Round diameter 21.950~22.050mm Valve lift 8L/h Journal diameter 14.966~14.984mm Discharge 50kPa Camshaft round limit 0.03mm Pressure 1.8~2.2mm Valve lifter outside diameter 7.978~7.987mm Plunger stroke Ignition system Item Description...

  • Page 18: General Torque

    Cont’d Part to be tightened Part name Thread size Quantity Torque Connecting rod Bolt 12 Nm Oil splash gear unit Bolt 8 Nm Lower unit 1st tightening 3 Nm Bolt mounting 2nd tightening 8 Nm Lower unit 1st tightening Bolt housing 2nd tightening 11 Nm...

  • Page 19: Periodic Service

    PERIODIC SERVICE MAINTENANCE TIME TABLE Initial maintenace General maintenance Items Contents period 10 hours 50 hours 100 hours 200 hours （1 month） （3 months） （6 months） （1 year） ○ ○ Anode Inspection/replacement Spark plug Cleaning/adjustment ○ ○ ○ /replacement ○ Grease points Greasing ○...

  • Page 20: Power Unit

    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.

  • Page 21: Changing Engine Oil

    1. Oil level plug 2. Oil rule 3. High position mark 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.

  • Page 22: Spark Plug

    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.

  • Page 23: Idling Speed

    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. If out of specification, adjust it. Idling speed: 1450~1550 r/min 3.

  • Page 24: Lower Unit

    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.Oil level plug Changing gear oil 1.

  • Page 25: Lower Unit Leakage Check

    Lower unit leakage check Connecting the leakage tester to the oil level checking hole to check the lower unit leakage. If the pressure drops (pressure: 1kg/cm³), inspect the oil seal and components. GENERAL INSPECTION Anode Inspect lower unit anode and engine anode (on the thermostat cover). Clean the greasy dirt and scales.

  • Page 26: Recoil Starter

    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.

  • Page 27: Explosive Drawing

    EXPLOSIVE DRAWING M6x20 mm M6x35 mm 6.5Nm PART NO. DESCRIPTION REMARKS STARTER ASSY F4-04130000 起动器组件 CASE,STARTER F4-04130001 起动器外壳 F4-04130012 GUIDE,ROPE 起动绳导向器 起动减震块 F4-04130018 SEAL,RUBBER F4-04130101 HANDLE,STARTER 起动手柄 COVER F4-04130102 起动手柄盖 MEATUS,START ROPE F4-04130013 起动绳导管 F4-04130011 WIRE,STARTER 起动绳 F4-04130004 SPRING,DRIVE 卡瓣弹簧 PAWL,DRIVE F4-04130003 卡瓣...
  • Page 28 M6x20 mm M6x35 mm 6.5Nm PART NO. DESCRIPTION REMARKS F4-04130008 BOLT,STARTER 起动压板螺钉 F4-04130006 起动压板 PLATE,PRELL F4-04130007 起动压板夹簧 SPRING,PLATE 起动轮 DRULL,SHEAVE F4-04130019 F4-04130005 涡形弹簧 SPRING,VOLUTE F4-04130014 起动轮减磨片 WASHER,THRUST F4-04130002 起动器外壳衬管 F4-04130010 制动器扭簧 DETENT F4-04130009 制动器 WASHER,THRUST GB/T97.1-85 平垫圈 6 https://www.boat-manuals.com/...
  • Page 29 M6x20 mm M6x35 mm 6.5Nm PART NO. DESCRIPTION REMARKS BOLT,HEXAGON 六角头螺栓 M6x35 BOLT,HEXAGON 六角头螺栓 M6x20 F4-04000005 钢索固定架 F4-02000013 制动器钢索组件 https://www.boat-manuals.com/...

  • Page 30: Disassembling

    DISASSEMBLING 1. Open the top cowling 2. Screw loosely the adjusting nut of the dent tightwire. 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. Turn the sheave drum clockwise until the volute spring is free.

  • Page 31: Disassembling And Inspection

    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.

  • Page 32: Assembling

    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 with the triangle marking of the starter case.

  • Page 33: Ignition System

    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.

  • Page 34: Wiring Diagram

    WIRING DIAGRAM ○ Flywheel ○ Ignition coil ○ Engine stop switch ○ Grounding ○ 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.

  • Page 35: Spark Plug Cap

    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.

  • Page 36: Fuel System

    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.
  • Page 37 PART NO. DESCRIPTION REMARKS https://www.boat-manuals.com/...
  • Page 38 M6x30 mm PART NO. DESCRIPTION REMARKS 十字槽小盘头螺钉M4×25 GB/T823-88 F4-04090003 燃油泵盖 COVER,FUEL PUMP DIAPHRAGM ,TOP F4-04090004 上隔膜 阀片螺钉M3×5 SCRRW ,VALVE F4-04090011 F4-04090005 单向阀片 PLATE F4-04090002 FUEL PUMP SHELL 燃油泵壳 隔膜组件 DIAPHRAGM ASSY F4-04090100 ROLLER NEEDLE GB/T309-2000 滚针φ3x12 F4-04090008 隔膜弹簧 燃油泵座 F4-04090001 SEAT ,FUEL PUMP https://www.boat-manuals.com/...
  • Page 39 11 12 M6x30 mm 29 30 PART NO. DESCRIPTION REMARKS F4-04090007 柱塞弹簧 SPRING ,PLUNGER F4-04090006 柱塞 PLUNGER GB/T6170-2000 螺母 M4 燃油泵组件 FUEL PUMP ASSY F4-04090000 燃油泵座O形圈 F4-04090009 O-RING CLIP ,NYLON "B" F4-04000031-2 尼龙管夹 F4-04000028 燃油管E PIPE ,FUEL "E" F4-04000030 SPRING,FUEL PIPE "B" 油管夹簧...
  • Page 40 11 12 M6x30 mm 29 30 PART NO. DESCRIPTION REMARKS 六角头螺栓 M6×30 HEXAGON BOLT GB/T5783-2000 燃油管D F4-05000008 PIPE ,FUEL "D" 燃油过滤器组件 FUEL FILTER ASSY F4-05000300 燃油管C F4-05000007 PIPE ,FUEL "C" 三通 F15-05000011 THREE THROUGH F4-05000300 燃油管接头组件 燃油管B F4-05000006 PIPE ,FUEL "B" F4-05000100 油开关...
  • Page 41 M6x90 mm M6x25 mm PART NO. DESCRIPTION REMARKS HEXAGON BOLT GB/T5284-86 六角头螺栓M6x90 平垫圈6 WASHER ,PLATE GB/T97.1-85 F4-04110000 进气消音器组件 O-RING O形密封圈2-24-031 JASO F404-96 化油器密封垫 F4-04000024 化油器垫块 F4-04000025 GASKET ,CARBURETOR F4-04110006 齿形尼龙卡箍 回气管 F4-04000035 PIPE , RETURN GAS 尼龙管卡（A） F4-04000031-1 CLAMP ,NYLON "A" F4-05000400 阻风门拉柄组件...

  • Page 42: Fuel Tank Removal And Inspection

    M6x90 mm M6x25 mm PART NO. DESCRIPTION REMARKS F4-04000022 进气弯管密封垫 进气岐管 F4-04000025 MANIFOLD ,INTAKE 六角头螺栓 M6x25 GB/T97.1-85 HEXAGON BOLT 化油器 F4-04000025 CARBURETOR 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.

  • Page 43: Oil Switch Removal And Inspection

    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.

  • Page 44: Fuel Pump Removal And Inspection

    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.

  • Page 45: Intake System Removal And Inspection

    INTAKE SYSTEM REMOVAL AND INSPECTION １. Loose throttle cable stop screw, and remove throttle cable. 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.

  • Page 46: Power Unit

    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 M6x20 mm 23 22...
  • Page 47 M6x20 mm 1st 15Nm 2nd 30Nm 25Nm M6x45 mm 1st 8Nm 2nd 12Nm PART NO. DESCRIPTION REMARKS F4-04000034 气缸头螺栓B BOLT 六角头螺栓M8×14 BOLT ,HEXAGON GB/T97.1-85 平垫圈8 WASHER ,PLATE 节温器 F4-04000036 THERMOSTAT GB/T97.1-85 平垫圈6 WASHER ,PLATE 六角头螺栓M6×20 BOLT ,HEXAGON F4-04000012 回水管 PIPE ,RETURN SPILE WATER 水咀...
  • Page 48 M6x20 mm 1st 15Nm 2nd 30Nm 25Nm M6x45 mm 1st 8Nm 2nd 12Nm PART NO. DESCRIPTION REMARKS F4-04000011 节温器盖密封垫 节温器盖阳极 F4-04070003 ANODE GB/T818-85 十字槽盘头螺钉M5×25 https://www.boat-manuals.com/...
  • Page 49 10Nm 1277 1277 PART NO. DESCRIPTION REMARKS 气门挺柱 PS2700.03.02 LIFTER,VALVE F4-04000015 气门推杆 ROD,VALVE PUSH 导向板 PLATE,PUSH ROD F4-04080009 PS2700.04.12 摇臂螺杆 BOLT,ROCKER ARM 气门摇臂 PS2700.04.12 ARM,VALVE ROCKER PS2700.04.13 摇臂球座 PIVOT,ROCKER ARM 六角螺母M6x0.75 PS2700.04.18 BOLT F4-04080005 进气门 DOOR,INTAKE 排气门 DOOR,EXHAUST F4-04080006 F4-04080007 气门弹簧垫圈...
  • Page 50 10Nm 1277 1277 PART NO. DESCRIPTION REMARKS 气门油封 SEAT,VALVE STEM PS2700.04.03 F4-04080008 气门弹簧 气门弹簧座 F4-04080010 F4-04080011 气门锁片 CLAMP,VALVE https://www.boat-manuals.com/...
  • Page 51 M6x12mm M8x50mm 1st10Nm 2nd 22Nm M8x20mm 1277 18Nm PART NO. DESCRIPTION REMARKS 曲轴箱体 CRANK CASE F4-04010100 气嘴 F4-04010002 PIPE,JOINT 曲轴油封A25x40x5 F4-04010003 OIL SEAL GB/T276-94 深沟球轴承6205C3 BEARING F4-04000009 呼吸器密封垫 BREATHER GASKET 呼吸器盖板 F4-04000010 COVER 六角头螺栓M6x14 HEXAGON ,BOLT 平垫圈6 GB/T97.1-85 WASHER 十字槽盘头螺钉M4x6 SCREW,PAN HEAD GB/T818-85 F4-04010003...
  • Page 52 M6x12mm M8x50mm 1st10Nm 2nd 22Nm M8x20mm 1277 18Nm PART NO. DESCRIPTION REMARKS F4-04000003 HOLLOW PIN 空心定位销φ10x8.4x14 F4-04050001 曲轴箱盖 COVER,CRANK CASE 曲轴箱体复合垫 F4-04000002 六角法兰面螺栓M8x50 BOLT,HEXAGON OIL,SEAL F4-04060003 曲轴油封20x30x7(B) F4-04060004 OIL,SEAL O-RING F4-04060002 油封壳体0型圈 油封壳体 F4-04060001 SHELL,OIL SEAL 油封壳体组件 F4-04060000 GB/T97.1-85 平垫圈8 WASHER,PLATE https://www.boat-manuals.com/...
  • Page 53 M6x12mm M8x50mm 1st10Nm 2nd 22Nm M8x20mm 1277 18Nm PART NO. DESCRIPTION REMARKS HEXAGON ,BOLT 六角头螺栓M8x20 放油螺栓密封垫 F4-04000006 WASHER 甩油轮组件 GEAR UNIT ASSY F4-04050000 六角头螺栓M6x12 BOLT,HEXAGON 机油盖阻油圈 F4-04000008 O-RING 带尺机油盖 F4-04000007 放油螺栓 F4-04000001 凸轮减压组件 F4-04040000 CAMSHAFT ASSY https://www.boat-manuals.com/...
  • Page 54 M7x35mm 12Nm PART NO. DESCRIPTION REMARKS 气环1 F4-04020002 PISTON RING 1 F4-04020003 PISTON RING 2 气环2 F4-04020004 组合油环 COMBINED OIL RING F4-04020006 活塞销卡簧 CIRCLIP 活塞销 F4-04020005 PIN ,PISTON F4-04020001 活塞 PISTON 连杆组件 F4-04020100 ROD ,CONNECTING 连杆螺栓 BOLT,ROD CLEVEL F4-04020103 F4-04030000 曲轴组件...

  • Page 55: Special Tools

    SPECIAL TOOLS Piston slider Bearing puller Valve spring compressor Housing bearing installer Oil seal installer tool 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.

  • Page 56: Cylinder Cover

    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.

  • Page 57: Valve Spring

    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.

  • Page 58: Valve Seat Cutting

    The valve seat width: 0.6～0.8mm The maximum valve seat width: 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. 2. If the valve seat is centered on the valve face but it’s too wide, to reduce the valve seat width, use cutter to adjust the top edge of the seat, and use 60 cutter to adjust the bottom edge of the seat.

  • Page 59: Thermostat

    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.

  • Page 60: Piston

    3. Inspect breather return pipe. If cracked/leaked/damaged, replace. Piston Measure piston outside diameter at the specified measuring point. If out of specification, replace. Piston diameter: 58.950～58.965mm Measuring point○ a : 10mm Cylinder bore 1. 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.

  • Page 61: Crankshaft

    If weight is unsmoothly moving, replace. 2. Measure camshaft lobe diameter○ a and height ○ b . If out of specification, replace it. ○ a Intake camshaft: 21.950～22.050mm Exhaust camshaft: 21.950～22.050mm ○ b Intake camshaft: 26.736～26.836mm Exhaust camshaft: 26.532～26.623mm 3. Measure camshaft diameter. If out of specification, replace the camshaft. Camshaft journal wear limit: 14.934mm Crankshaft Measure crankshaft runout.

  • Page 62: Oil Seal Housing

    NOTE: Don’t remove bearing unless you replace it. Oil seal housing 1. Inspect oil seal housing for crack/damage. Replace if necessary. 2. Inspect O-ring for crack/damage. Replace if necessary. Crankcase and crankcase cover 1. Inspect crankcase cover. If cracked/damaged, replace. 2.

  • Page 63: Oil Seal Housing Installation

    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...

  • Page 64: Crankcase Cover Installation

    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. UPPER UNIT TOP COWLING EXPLOSIVE DRAWING...
  • Page 65 PART NO. DESCRIPTION REMARKS F4-06000000 GB/T8.8-2000 F4-06000005 F4-06000002 GB/T845-85 F4-06000003 F15-08000004 F4-06000001 GB/T818-2000 https://www.boat-manuals.com/...
  • Page 66 PART NO. DESCRIPTION REMARKS F4-06000006 F4-06000004 https://www.boat-manuals.com/...

  • Page 67: Disassembling And Inspection

    Disassembling and inspection Remove airproof rubber bar. Remove top cowling muffling cover bolt and rubber underlay. Remove top cowling muffling cover. Remove lock hook and pothook. Inspect if top cowling is cracked or damaged. Replace it if necessary. Inspect if airproof rubber bar is cracked or damaged. Replace it if necessary. Inspect if top cowling muffling cover is cracked or damaged.
  • Page 68 PART NO. DESCRIPTION REMARKS F4-05000001 GB/T818-2000 F4-05000016 GB/T818-2000 GB/T5783-86 F15-05030000 F15-05000022 F15-05000023 F15-05000036 F4-05000012 https://www.boat-manuals.com/...

  • Page 69: Disassembling And Inspection

    PART NO. DESCRIPTION REMARKS F4-05000013-2 GB/T6170-86 GB/T5783-2000 GB/T97.1-85 GB/T5783-2000 Disassembling and inspection Remove rubber cover B. Remove handle bolt and handle. Remove top cowling clamp lever bolt and clamp lever. https://www.boat-manuals.com/...

  • Page 70: Steering Handle

    Remove top cowling clamp lever bush A and clamp lever bush B. Remove wave washer. Inspect if bottom cowling is cracked or damaged. Replace if necessary. Inspect if clamp lever handle is cracked or damaged. Replace if necessary. Inspect if clamp lever is cracked or damaged. Replace if necessary. Inspect if wave washer and clamp lever bush are cracked or damaged.
  • Page 71 1243 M8x25mm 18Nm 1243 PART NO. DESCRIPTION REMARKS F4-01090200 阻力调整旋钮组件 衬套 BUSH F4-01090006 F4-01090007 压缩弹簧 WASHER,PLATE GB/T848-85 小垫圈10 F4-01090303 油门标志牌 操舵手柄塑胶套 F4-01090301 F4-01090302 操舵手柄橡胶套 RUBBER,HANDLE 十字槽半沉头螺钉M5x24 SCREW GB/T820-85 标牌铆钉2x5 GB/T827-86 RINET F4-01090300 油门握把组件 https://www.boat-manuals.com/...

  • Page 72: Disassembling And Inspection

    1243 M8x25mm 18Nm 1243 PART NO. DESCRIPTION REMARKS F4-01090003 操舵手柄握把摩擦块 FRICTION 节气门杆组件 LEVER,THROTLLE F4-01090100 十字槽盘头螺钉M5x12 SCREW,PAN HEAD GB/T818-85 F4-01090002 STAY 节气门杆固定板 油门钢索组件 F4-01090008 引擎停止安全索 F4-01090401 急停开关组件 F4-01090400 Disassembling and inspection 1. Remove steering handle cover. 2. Remove handle bush, bush washer and wave washer. 3.
  • Page 73 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．...

  • Page 74: Bracket

    BRACKET Explosive drawing M6x35mm 1st 3Nm 2nd 8Nm 13Nm M6x10mm 1st 3Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS F4-02000008 减震圈衬管 F4-02000007 上减震圈 F4-02020000 水上装置锁紧圈组件 SPRING ,CONICAL F4-01050002 锥形弹簧 F4-01050000 TILT ROD ASSY 角度调整杆组件 非金属嵌件六角锁紧螺母M8 F4-01000002 双孔固定板 PLATE 旋转支架座 F4-01030001 BRACKET ,SWIVEL 六角螺母M6 HEXAGON NUT GB/T6170-86...
  • Page 75 M6x35mm 1st 3Nm 2nd 8Nm 13Nm M6x10mm 1st 3Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS F4-01000003 WASHER ,NYLON 尼龙垫圈 F4-01030003 支撑架扭簧（左） 支撑架尼龙衬套 F4-01030002 BUSHING ,NYLON 六角头螺栓M6×20 HEXAGON ,BOLT 支撑架固定盖 F4-01030005 SHEATH HANDLE 手柄套 F4-01030103 支撑架扭簧（右） F4-01030004 F4-01030100 角度定位支撑架组件 锁紧钩扭簧（左） F4-01000006 SPRING F4-01000007 SPRING...
  • Page 76 M6x35mm 1st 3Nm 2nd 8Nm 13Nm M6x10mm 1st 3Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS 六角头螺栓M6×12 HEXAGON BOLT 起翘锁紧钩组件 F4-01070000 下减震圈 F4-02000009 BUSHER ,BOLT F4-01000004 螺栓垫管 F4-01010005 艉板夹紧手柄铆钉 艉板夹紧手柄 F4-01010004 F4-01010002 艉板夹紧螺杆 CLAMP BOLT F4-01010003 艉板夹紧圆盘 CLAMP PLATE 六角螺栓M6×120 HEXAGON BOLT 六角螺栓M8×135 HEXAGON BOLT https://www.boat-manuals.com/...

  • Page 77: Disassembling And Inspection

    M6x35mm 1st 3Nm 2nd 8Nm 13Nm M6x10mm 1st 3Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS F4-01010001 夹紧托架（右） F4-01000005 旋转支架座盖 HEXAGON BOLT GB/T5782-86 六角头螺栓M6x35 F4-01060002 锁紧手柄 CLAMP HANDLE RIVET 扁平头半空心铆钉φ4x11 GB/T875-86 LOCKED SCREW 锁紧螺杆 F4-01060001 大垫圈 GB/T96-1985 BIG WASHER F4-01020000 夹紧托架（左）组件 Disassembling and inspection 1.
  • Page 78 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. Replace if necessary. 8. Inspect the bush and shock absorption for damage or crack. Replace if necessary. 9.

  • Page 79: Upper Unit

    UPPER UNIT Explosive drawing M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION REMARKS F4-00000007 变档手柄 HANDLE,GEAR SHIFT F4-02010000 SHAFT,CHANGE 变档拨叉组件 JISB2401 O-RING "O"形密封圈P9 水上装置壳体铜套 F4-02000002 BUSHING,SHIFT ROD LEVER SCREW,OVAL HEAD 十字半沉头螺钉M5x20 GB/T820-2000 SPRING,GEAR F4-02000003 变档弹簧 钢珠8 BALL 8 GB308-84 六角螺栓M5x25 BOLT GB/T5783-2000 PIN,COTTER 开口销1.6x12...
  • Page 80 M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION REMARKS F4-02000006 变档连杆支架 LEVER,SHIFT ROD ROD,SHIFT F4-02000004 变档连杆 F4-00000003 CONNECTOR,SHIFT ROD A 变档连杆连接器A CONNECTOR,SHIFT ROD B F4-00000004 变档连杆连接器B F4-00000005 大垫圈 BIG,WASHER BOLT GB/T5284-86 六角头螺栓M6x20 Type S：2 F4-00000001 空心定位销 PIN ,HOLLOW 直通式压注油杯M6 GREASE CUP 平垫圈6 WASHER GB/T97.1-85...

  • Page 81: Disassembling And Inspection

    M6x25mm 4.5Nm M6x20mm 10Nm PART NO. DESCRIPTION REMARKS 变档轴密封圈 F4-02000011 水上装置壳体 F4-02000001 CASING ,UPPER 水上装置橡胶堵头 F4-02000012 F4-02040002 工形橡胶圈 F4-02040000 进水管 F4-02030001 接长体 EXTENSION CIRCLIP 孔用弹性挡圈22 RUBBER BUSHING F4-02030003 驱动轴橡胶衬套 驱动轴衬套 F4-02030002 F4-00000006 发动机密封垫 GASKET ,ENGINE Disassembling and inspection 1. Remove the water tube. 2.

  • Page 82: Lower Unit

    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. LOWER UNIT WATER PUMP ASSEMBLY https://www.boat-manuals.com/...

  • Page 83: Explosive Drawing

    Explosive drawing M6x45 mm 1st 3Nm 2nd 8Nm M6x25 mm 1st 3Nm 2nd 8Nm 1277 PART NO. DESCRIPTION REMARKS HEXAGON BOLT 六角头螺栓M6×45 泵壳固定板 F4-03000020 泵壳橡胶管 F4-03000021 F4-03000013 水泵座定位销 PIN ,WATER PUMP 水泵壳 F4-03000019 泵壳密封垫 F4-03000018 水泵内壳 F4-03000017 水泵叶轮 F4-03060000 F4-03000015 外档板...

  • Page 84: Disassembling And Inspection

    M6x45 mm 1st 3Nm 2nd 8Nm M6x25 mm 1st 3Nm 2nd 8Nm 1277 PART NO. DESCRIPTION REMARKS 六角头螺栓M6×25 HEXAGON BOLT 平垫圈6 WASHER ,PLATE GB/T97.1-85 水泵座 BASE ,WATER PUMP F4-03000012 HERMETIC GASKET 水泵座密封垫 F4-03000011 Disassembling and inspection 1. Remove water pump fixed plate. 2.

  • Page 85: Lower Unit

    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. Replace if necessary. 7. Check water pump base for crack, crank, scratch or damage. Replace if necessary. LOWER UNIT Explosive drawing https://www.boat-manuals.com/...
  • Page 86 M6x16mm 1277 1277 22 26 1277 M6x16mm 1st 3Nm 1st 3Nm 2nd 8Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS 开口销2.5×30 PIN ,COTTER GB/T91-86 NUT ASSY F4-03080000 螺母组件 F4-03000026 WASHER 不锈钢垫片 F4-03070000 PROPELLER ASSY 螺旋桨组件 F4-03000025 SPACER 不锈钢垫块 F4-03000022 阳极 ANODE GB/T97.1-85 平垫圈6 WASHER ,PLATE...
  • Page 87 M6x16mm 17 16 1277 1277 22 21 1277 M6x16mm 1st 3Nm 1st 3Nm 2nd 8Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS F4-03000027 油封 10.8×21×7 OIL SEAL F4-03000009 倒档齿轮垫圈 倒档齿轮组件 F4-03040000 深沟球轴承6004C2 GB/T276-94 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...
  • Page 88 M6x16mm 1277 1277 22 26 1277 M6x16mm 1st 3Nm 1st 3Nm 2nd 8Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS F4-03000023 注油孔螺塞 PLUG ,OIL HOLE F4-03000024 注油孔螺塞垫圈 GASKET 水下装置壳体 LOWER CASING F4-03000001 GB/T-896-86 CIRCLIP 开口档圈6 主动齿轮 F4-03000007 INITIATIVE GEAR F4-03000006 主动齿轮垫圈 BEARING F4-03000002 带档边筒形轴承...

  • Page 89: Disassembling And Inspection

    M6x16mm 1277 1277 22 26 1277 M6x16mm 1st 3Nm 1st 3Nm 2nd 8Nm 2nd 8Nm PART NO. DESCRIPTION REMARKS 离合器块压簧 F4-03000003 F4-03030001 螺旋桨轴 SHAFT ,PROPELLER 驱动轴 F4-03000004 SHAFT ,DRIVE F4-03000004S SHAFT ,DRIVE F4-03000016 叶轮定位销 轴用钢丝档圈 CLIP F4-03000005 六角头长螺栓M6×167 HEXAGON BOLT HEXAGON BOLT 六角头长螺栓M6×40 变档凸轮组件...

  • Page 90: Propeller Shaft And Clutch Block

    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.

  • Page 91: Barrel Bearing

    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.

  • Page 92: Common Troubles And Solutions

    COMMON TROUBLES AND SOLUTIONS Trouble type Possible reason Recovery action Starter will not Starter components are faulty Repair or replace operate Shift level is not in neutral Shift to neutral Fuel tank is empty Fill tank with clean, fresh fuel Fuel is contaminated or stale Fuel filter clogged Replace fuel filter...
  • Page 93 Cont’d Trouble type Possible reason Recovery action Propeller is damaged Repair or replace propeller Adjust trim angle to achieve most efficient Trim angle is incorrect operation Motor is mounted at incorrect transom Adjust motor to proper transom height height Boat bottom is fouled with marine growth Clean boat bottom Weeds or other foreign matter are tangled Remove foreign matter and clean lower unit...

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