Page 1
Service Manual F115/FL115 Suzhou Parsun Power Machine Co., Ltd.
Page 2
This Manual includes the maintenance instruction for F115 and FL115 outboard motors, which is provided by Parsun to dealers for use in maintaining and repairing Parsun outboard motors. Please read this Manual carefully before maintaining and servicing the outboard motors. When repairing and maintaining the outboard motors, please use the maintenance procedures and tools recommended in the Manual.
Contents Overview ..............................1 Identification mark ..........................1 Selection of propeller ..........................1 Protection at work ........................... 2 Disassembly and assembly ........................3 Disposable parts ............................3 Pre-delivery inspection ........................... 3 Special tools and testing equipment ......................5 Disassembly schematic diagram and symbol description ............... 7 Description of disassembly schematic diagram ................
Page 5
Outside diameter of piston pin ...................... 78 Piston ring ............................. 78 Inner diameter of connecting rod small end ................. 79 Inner diameter of connecting rod large end .................. 79 Connecting rod large end backlash ....................79 Crankshaft ............................. 79 Crank pin oil clearance ......................... 80 Selection of connecting rod bearing bush ..................
Overview Identification mark The serial number is printed on a label which is pasted on the port side of the clamp bracket or the upper part of the rotary bracket. The serial number is recorded in the blank of the label to help you order spare parts from dealers or for your reference in case the engine is stolen.
4. Use of lubricants and sealants Only products provided or recommended by Parsun can be used when maintaining and repairing the outboard motor. Under normal circumstances, the lubricant mentioned in this Manual will not damage your skin.
Page 10
1. Oil dipstick 2. High mark 3. Low mark Make sure the oil level is between the high mark and the low mark; Drain oil when the oil level is above the high mark and add oil when the oil level is below the low mark. ○...
Special tools and testing equipment Various special tools and testing equipment will be used when repairing and maintaining the outboard motor. Using these tools and equipment expertly and correctly can improve your work efficiency and effectively avoid injuries to personnel and the outboard motor. Special tools: Clearance gauge Piston slideway...
Page 12
Drive shaft spline sleeve pinion nut spanner Testing equipment: Digital tachometer Digital multimeter Peak voltage adapter...
Disassembly schematic diagram and symbol description Description of disassembly schematic diagram ① ② ③ 18 Nm 49 Nm M10x1.5x105 mm 1st 16 Nm 2nd 42 Nm ④ M8x55 mm 1st 14 Nm 2nd 28 Nm ①Exploded view of parts. ②Thread specification and specified torque. ③Points where oil, sealant or locking agent are applied ④Parts list.
Specification Outboard motor parameters Item Data Item Data Ignition Full length 833 mm system Overall width 517 mm Spark plug LKR6E L-type 1672 mm Engine Overall Overall Exhaust height dimensions X-type 1799 mm Through the propeller hub system Lubrication Stem L-type 510 mm Purging-type oil mist lubrication...
Basic maintenance Maintenance Interval Chart The outboard motor should be maintained regularly, operated in normal environment and maintained correctly, which can effectively prolong the service life of the outboard motor. The following table gives the general principles of the maintenance intervals, which can be adjusted according to the operating conditions.
1. Oil dipstick 2. High mark 3. Low mark 2. If the oil level is above the high mark, discharge the engine oil; If the oil level is below the low mark, add engine oil. Note: Run and then turn off the engine, and let it stand for several minutes; Check the oil level with the oil dipstick again.
Control system Throttle push-pull cable 1. Please put the shift lever to the neutral position for the front operating model. 2. Check the contact between the throttle actuator driving pulley and the box. If there is no contact between the throttle actuator and the box, adjust the screw-in length of the control cable joint.
4. If the shift slider is not aligned with the mark on the microswitch, adjust the screw-in depth of the push-pull cable joint. (Refer to the adjustment mode of throttle push-pull cable joint) Underwater unit Gear oil Check the amount of gear oil: Remove the oil level plug screw, if there is gear oil overflow, the oil amount is correct;...
General maintenance Anode Check the anode of underwater unit and the anode of the engine (mounted on the thermostat cover); Remove oil stains and scale; If damage or corrosion exceeds 1/2, replace the anode. Note: Do not oil or paint the anode to avoid anode failure. Lubricating point 1.
outboard motor. 1. Cooling water observation hole Thermostat 1. Remove thermostat cover and then remove thermostat. 1. Thermostat cover 2. Thermostat 2. Hang the thermostat in a container containing water. 3. Heat the container. 4. Check the opening of thermostat valve at the specified water temperature; If it does not meet the specifications, replace it.
3. When the engine stop safety line is removed from the emergency stop switch, check if the engine stops. If the engine does not stop, please check the emergency stop switch. Change the oil filter 1. Drain the engine oil, see "Change engine oil". 2.
Move it up in the direction of "a" to loosen the locking device; Move it down in the direction of “b" to tighten the locking device; 4. Tighten the lock nut "2". 5. Re-check if the top cover is locked tightly. If the tightness cannot be adjusted, please replace the top cover sealing strip.
Electrical system Matters needing attention When monitoring and repairing the ignition system, be careful not to put your hands, clothes, hair or accessories close to the running flywheel. Check the ignition coil on the insulated workbench to prevent electric leakage and electric shock.
Spark plug ignition 1. Remove the spark plug cap from the spark plug. 1. Spark plug cap; 2. Spark plug 2. Connect the ignition detector to the spark plug cap. 3. Start the engine and observe the spark through the discharge window of the detector. Warning: Do not touch any connection part of the detector lead.
negative pole with black wire) Note: The data are for reference only. Check engine startup switch Check the conductivity of the engine startup switch. If it is not conductive, replace it. Note: See wiring diagram for startup switch status, Check engine stop switch Check the conductivity of the engine stop switch.
Use fault diagnosis tester When the engine is running, if the fault indicator or service indicator on the handle or multifunction tester is always on/buzzer is always on, it indicates that there is a fault in the engine. At this time, connect the fault diagnosis tester with the corresponding detection port on the engine, and display the running parameters and fault codes of the engine on the mobile phone through the APP.
Page 46
Excessive idle speed fault Idle fault Low idle speed fault Low system voltage System voltage fault High system voltage Continued: Fault type Fault item Code Fault indicator fault Fault indicator Short circuit to ground of oil pressure sensor line Oil pressure fault Short circuit to high level of oil pressure sensor Carbon canister...
Fuel system Matters needing attention Fuel oil is a highly flammable and volatile liquid, and fuel oil leakage can cause fire and explosion. Do not attempt to start the engine until the fuel system components are connected or installed. After completing all maintenance steps, apply pressure to the fuel system for a short time to check for leakage.
Reduce fuel pressure Warning: Make sure to reduce the fuel pressure in the fuel line before maintaining the fuel line or high-pressure fuel pump. Otherwise, high-pressure fuel will be sprayed out, causing injury or accident. 1. Disconnect the joint of oil pump power supply connection line. 2.
2. Remove the fuel pump. 3. Connect a vacuum manometer to the fuel pump inlet. 4. Plug the outlet of the oil pump and apply the specified positive pressure. Check for air leakage. Specified pressure: 50kPa 5. Apply a specified negative pressure. Check for air leakage. Specified pressure: 30kPa 6.
5. Remove the fuel injector and the common rail. 6. Check the fuel common rail. If there is crack or deformation, please replace it. 7. Check the electrical characteristics of the fuel injector. 8. Re-mount the common rail and fuel injector. Check throttle body 1.
9. Check the exterior of the carbon canister solenoid valve. If there is crack, please replace it. 10. Check the functional characteristics of the carbon canister solenoid valve. 11. Assemble the carbon canister and carbon canister solenoid valve in reverse order according to the disassembly sequence.
16. Check the screen filter on the rubber pad of the oil pump. If there is fuel colloid or other residues, please clean them. 17. Mount the float and invert the electric fuel pump body, and measure the float height. Note: When measuring the height of the float, the float should be placed on the needle valve.
Special tool Piston slideway Flywheel gripper and flywheel puller Clearance gauge Oil filter spanner Check the compression pressure 1.Start the outboard motor, warm it up at idle speed for 5 minutes, and then turn it off. 2.Remove the spark plug and connect the pressure gauge to the spark plug hole. Note: Before removing the spark plug, clean the pit where the spark plug is installed with compressed air to prevent dust or other sundries from entering the cylinder.
Check valve clearance Please measure the valve clearance when the engine is cold. Note: Don't turn the flywheel counterclockwise. Otherwise, the valve mechanism will be damaged. 1. Remove the spark plug. 2. Turn the flywheel clockwise until the mark on the flywheel is aligned with the indicator mounted on the box, making sure that the "...
Page 75
6. Remove the bolts that hold the driven pulley with the flywheel gripper and remove the driven pulley. 7. Remove cylinder head cover. 8. Mount the driven pulley and fasten the pulley bolts with the flywheel gripper. 9. Screw the timing belt in the order of crankshaft end, driven pulley B ("EX”) and driven pulley A ("IN"...
Page 76
√: Measurable valve clearance 18. Turn the flywheel clockwise until the mark on the flywheel is aligned with the indicator mounted on the box, making sure that the “EX" and “IN” marks on the two driven pulleys are opposite. 19. Measure and record the clearance between the specified cylinder cam and the valve tappet with a clearance gauge.
29. Turn the timing belt tensioner gradually counterclockwise until the timing belt is in tightened position. 30. Tighten the bolts of the tensioner at specified torque. Specified torque: 39 Nm 31. Adjust the timing belt height so that it is located in the middle of the pulley. 32.
5. Calculate the required thickness of the replaced valve tappet based on the formula. Formula: Required thickness of the valve tappet = a + measured valve clearance -specified valve clearance 6. Load the selected valve tappet into the cylinder head, then mount the camshaft and camshaft cap.
Flywheel gripper and flywheel puller 9. Remove relevant parts according to the exploded view of the two sections Electrical System and Fuel System. 10. Disconnect the control system with reference to the exploded view on page P85. Pulley and timing belt 1.
Check the driven pulley Check whether the driven pulley is deformed, cracked and worn; If yes, replace it. Check the cylinder head bolts Measure D1 and D2 at specified measuring points. Calculate the value of D2 minus D1. If it is greater than 0.17mm, replace it.
2. Check the inclination of the valve spring; Replace it if it is beyond the limit. Inclination limit: 1.8 mm Camshaft 1. Check the cam dimensions. Replace the camshaft if necessary. Intake cam 41.011~41.111 mm height Exhaust cam 41.260~41.360 mm height 2.
1. Trim the valve with a 45° valve seat ring cutter and adjust the width of the sealing surface. Turn the cutter clockwise until the surface of the seat ring is smooth. 2. If the valve sealing surface is too wide and in the middle of the valve surface, trim the top edge of the seat ring with a 30°...
4. Tap the valve spring seat with a plastic or rubber hammer to secure the retainer. 5. Install the valve tappet. 6. Install the camshaft and tighten the camshaft cover bolts at the specified torque and in sequence. Specified torque: First time 6 Nm 13 Nm for the second time Tightening sequence: Cylinder No.1 position -Cylinder No.3 position-Cylinder No.4 position-Cylinder No.2 position-Driven pulley end position...
5. Remove the connecting rod bolts and connecting rod cover, remove the crankshaft, and then remove the connecting rod and piston assembly. 6. Remove piston pin clamp spring with pliers, then remove the piston pin and piston. 7. Remove the oil seal, locating pin and bearing bush. Piston 1.
the specified value, replace it. End face clearance (during installation): Top ring 0.15~0.30 mm Second ring 0.70~0.90 mm Oil ring 0.20~0.70 mm 3. Install the piston ring on the piston, and measure the clearance between the piston ring and the piston ring groove with a clearance gauge; If it does not meet the specified value, replace it.
Crankshaft runout limit: 0.04mm Crank pin oil clearance 1. Place a plastic clearance gauge on the crank pin and make it parallel to the crankshaft. 2. Fit the connecting rod and bearing bush on the crank pin. 3. Tighten the connecting rod bolts according to the specified torque. Seating torque: 13 Nm for the first time 35 Nm for the second time 4.
Main journal oil clearance 1. Clean the bearing bush, main journal, and the mounting surface of the engine body and engine base. 2. Install the bearing bush and crankshaft to the engine body. 3. Place a plastic clearance gauge on the main journal and parallel it to the crankshaft Note: Do not place the plastic clearance gauge on the oil hole of the main journal.
主轴颈分组标识(5位) Crankshaft bearing bushes are divided into three groups according to their thickness. From thin to thick, blue, green and red marks are painted on the side of the bushes to distinguish them. Examples of pairing: If the group numbers of the corresponding positions of the engine body and the crankshaft are the same, then 1 select the blue-marked bearing bush, 2 select the green-marked bearing bush, 3 select the red-marked bearing bush, If the group numbers of the corresponding positions of the engine body and the...
4. Re-mount the exhaust pipe assembly. Alternately tighten the bolts (M6x30mm) to mount the exhaust pipe A&B and control the clearance shown in the figure to the specified value. Specified clearance: 9.5 mm Note: Use a new O-ring. 5. Remove the bolts (M6x30mm). 6.
Page 90
When installing, apply oil to the sides of the piston and piston ring. Installing crankshaft 1. Install crankshaft bearing bushes on the body separately. 2.Install the crankshaft to the engine body and install the oil seal. Note: Apply oil on the inside of the oil seal before installation. 3.
Note: Before installation, inject oil into the oil channel. 6. Install the anode, exhaust cover plate, thermostat and thermostat cover plate. 7. Install the exhaust pipe. Seating torque: 13 Nm for the first time 35 Nm for the second time 8.
Remove the sealing rubber strips. Remove the top cover screws. Remove the top cover. Remove the locking pulley retaining plate screws and remove the front and rear locking pulley assemblies. Check the top cover for cracks or damage. Replace it if necessary. Check the sealing rubber strip for cracks or damage.
Disassembly and inspection of bracket 1. Remove the left and right absorber covers, and remove the left and right absorbers and double-hole absorber fixing nuts. Remove the left and right absorbers 2. Remove the water unit, oil pan and exhaust manifold seat as a whole from the bracket. 3.
8. Check the exhaust rubber pipe and exhaust rubber elbow for aging and cracking. Replace it if necessary. Hydraulic warping device Check the oil level. 1. Position the hydraulic warping device vertically and fix it. 2. Connect the lead of the warping motor of the hydraulic warping device to the battery. 3.
Page 107
If the hydraulic warping device is installed on the outboard motor and exhausting is required, please follow the following steps. 1. Turn the manual valve counterclockwise until it cannot turn. 1. Manual valve. 2. Tilt the outboard motor completely upward, and then lower it downward by its own gravity;...
Replace it if necessary. 13. Remove the housing cover of the underwater unit. F115: Remove the reverse gear and the cushion block of reverse gear, remove the deep groove ball bearing, needle roller bearing and oil seal. FL115 rotates backward: Remove the forward gear and the cushion block of the forward gear, and remove the plane thrust bearing, propeller shaft shim and needle roller bearing;...
18. Remove the needle bearing from the underwater unit. 19. Remove the oil seal and plane thrust bearing of the drive shaft seat, and remove the drive shaft shim and needle roller bearing. Propeller shaft and clutch block 1. Check the claw clutch; If broken or damaged, replace it. 2.
Needle roller 24.75~25.25 mm bearing Depth 4.75~5.25 mm seal Depth 11.75~12.25 mm Underwater unit housing cover Underwater unit housing cover Underwater unit housing cover bearing installation tool oil seal installation tool needle bearing installation tool 3. Install reverse gear and shim. Note: Shim adjustment is required when installing new reverse gears and bearings.
Page 122
0.25~0.75 mm seal Depth 7.25~7.75 mm 4. F115 forward-rotating model: Install forward gear, long nylon sleeve, drive shaft, plane thrust bearing, shim, install drive shaft seat, pinion and shift cam. F115 backward-rotating model: Install shift cam, drive shaft, shim, install reverse gear, drive shaft seat, long nylon sleeve, plane thrust bearing and pinion.
8. Tighten the housing cover nut and pry up a tongue piece on the locking washer. Specified torque: 103 Nm Cover nut installation tool 9. Check whether the gear shift is working properly. 10. Install the water pump assembly. 11. Install the anode and water inlet. Install the propeller and slotted hexagon nut, place a piece of wood between the anti-swirl baffle and the propeller, and tighten the nut at the specified torque.
The installation surface of the anode/heading tab of the underwater unit is engraved with deviation value marks, which are F, R and P respectively; they represent the difference between the actual size and the theoretical size on the housing of the underwater unit. For example, the mark P is followed by +3, which means that the actual size is 0.03 mm more than the theoretical size;...
1. Use standard block to calibrate the special tooling, ensure a compression of 0.5-0.8 mm, push the standard block several times, and clear zero position. 2. Turn tapered roller bearing 25580/25520 outer ring two or three times so that the rollers fall completely into the bearing outer ring.
Backward-rotating pinion shim 1. Attach the drive shaft to the special tool. Install the pinion and lock the pinion nut according to the specified torque. Specified torque: 94 Nm Special tooling for pinion shim (201.35) 2. Measure the clearance M3 between the special tooling and the pinion with a filler gauge.
0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm Reverse gear shim 1. Check the F size marked on the housing of the underwater unit. 2. Formula: T1=58.7-20-4.5-33.3+(F/100)=0.9+(F/100) 3. The shim can be reduced by 0~0.05mm compared with T1 (try to choose the most similar size as possible) 4.
Common faults and solutions Fault type Fault cause Solution There is no fuel in the fuel tank Fill the fuel tank with clean new fuel Contaminated or obsolete fuel oil Fuel filter blocked Replace the fuel filter Fuel pump failure Overhaul or replace it Vent screw of fuel tank cap not Loosen the vent screw...
Page 131
Continued: Fault type Fault cause Solution The bottom of the ship is polluted Clean the bottom of the ship by underwater organisms Gear box twined by aquatic plants Remove the foreign matters and clean it or foreign matters The spark plug is contaminated or Clean it or replace with the correct spark plug the model is incorrect Check the fuel line for extrusion, entanglement or...
Need help?
Do you have a question about the F115 and is the answer not in the manual?
Questions and answers
Как отрегулировать переключение передач на моторе
Trimmanzeige funktioniert ****