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Summary of Contents for Parsun F15BM
- Page 1 PARSUN OUTBOARD ENGINE SERVICE MANUAL F15/F9.9BM(F15/F9.9W) SUZHOU PARSUN POWER MACHINE CO., LTD.
- Page 2 Parsun outboard engines, they will help you judge the outboard engine’s status quickly and improve the work efficiency. All rights reserved. This manual cannot be reproduced or transmitted in any form or by any means without the written approval of our company. Suzhou Parsun Power Machine Co., Ltd.
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Page 3: Table Of Contents
INDEX GENERAL INFORMATION················································································································1 IDENTIFICATION··················································································································1 PROPELLER SELECTION···································································································1 EMERGENCY START············································································································1 SAFETY WHILE WORKING································································································2 DISASSEMBLY AND ASSEMBLY························································································3 ONE-TIME USE PARTS·········································································································4 PRE-DELIVERY CHECK······································································································4 SPECIAL TOOLS AND DETECTION DEVICE·································································6 EXPLOSIVE DRAWING AND SYMBOL·············································································8 SPECIFICATIONS································································································································9 OUTBOARD ENGINE SPECIFICATIONS·········································································9 MAINTENANCE INFORMATION·····················································································10 Power unit························································································································10 Lower unit························································································································11 Ignition system·················································································································11 Charge system··················································································································12 TIGHTENING TORQUE······································································································12 Specified torque···············································································································12... - Page 4 Anode································································································································20 Grease points····················································································································20 Cooling water passage·····································································································21 Thermostat·······················································································································22 RECOIL STARTER·····························································································································22 NOTICE··································································································································22 EXPLOSIVE DRAWING······································································································23 DISASSEMBLING·················································································································27 START ROPE REPLACEMENT·························································································27 DISASSEMBLING AND INSPECTION··············································································28 ASSEMBLING·······················································································································29 INSTALLATION····················································································································29 IGNITION SYSTEM···························································································································29 NOTICE··································································································································29 EXPLOSIVE DRAWING······································································································30 WIRING DIAGRAM·············································································································35 SPARK PLUG IGNITION·····································································································35 SPARK PLUG CAP················································································································36 FLYWHEEL MAINTENANCE····························································································36 CDI INSPECTION·················································································································36 IGNITION COIL INSPECTION··························································································36 PULSED COIL INSPECTION·····························································································37 CHARGE COIL INSPECTION····························································································37 FUEL SYSTEM····································································································································38...
- Page 5 DISASSEMBLING POWER UNIT······················································································55 BELT PULLEY AND TIMING BELT··················································································56 DISASSEMBLING AND INSPECTION··············································································57 CYLINDER COVER······································································································57 Disassembling············································································································57 Valve and valve guide bush······················································································58 Valve spring···············································································································58 Valve rocker arm and rocker shaft·········································································58 Camshaft···················································································································58 Oil pump check·········································································································59 Valve guide bush replacement·················································································59 Valve seat inspection·································································································60 Valve seat cutting······································································································61 Valve installation·······································································································61 Assembling cylinder cover·······················································································61 CRANKCASE··················································································································61...
- Page 6 Disassembling and inspection·························································································78 BRACKET······························································································································79 Explosive drawing···········································································································79 Disassembling and inspection·························································································83 UPPER UNIT··························································································································85 Explosive drawing···········································································································85 Disassembling and inspection·························································································86 LOWER UNIT······································································································································87 WATER PUMP ASSEMBLY·································································································87 Explosive drawing···········································································································87 Disassembling and inspection·························································································88 LOWER UNIT························································································································89 Explosive Drawing···········································································································89 Disassembling and inspection·························································································94 Propeller shaft and clutch block··············································································94 Dog clutch installation······························································································95 Lower casing cover···································································································95 Lower casing cover oil seal and bearing installation·············································95 Drive shaft·················································································································96...
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Page 7: General Information
GENERAL INFORMATION IDENTIFICATION 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. -
Page 8: Safety While Working
items far away. Don’t touch flywheel or other moving parts. When starting and operating, don’t touch ignition coil, spark plug cap or other electric parts. The procedure is as follows: 1. Remove the top cowling. 2. Remove the start-in-gear protection device cable. Start-in-gear protection device cable Demount three bolts and remove starter. -
Page 9: Disassembly And Assembly
2. VENTILATION Petroleum vapor and engine exhaust gases are violent in toxicity. They are harmful to breathe and deadly if inhaled in large quantities. When test-running an engine indoors, maintain good ventilation. 3. SELF-PROTECTION Protect your eyes with suitable safety glasses or safety goggles, when drilling, grinding or operating air compressor. -
Page 10: One-Time Use Parts
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. ONE-TIME USE PARTS One-time use parts are gasket, oil seal, O-ring, cotter pin and spring, ring, and etc.. When re-assembling outboard engine, you must change the one-time use parts. - Page 11 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. CHECK SHIFT LEVER AND THROTTLE Check if the shift lever is operated smoothly.
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Page 12: Special Tools And Detection Device
SPECIAL TOOLS AND DETECTION DEVICE When performing maintenance and repair, you need to use all kinds of special tools and detection device. The use of correct tools will improve the work efficiency and avoid of the damage to the people and outboard engines. - Page 13 DETECTION DEVICE Digital tachometer Digital circuit tester Peak voltage adaptor...
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Page 14: Explosive Drawing And Symbol
EXPLOSIVE DRAWING AND SYMBOL EXPLOSIVE DRAWING M8x45 mm 18 Nm 1277 Parts explosive drawing. Screw specification and specified torque. Oil, fluid sealant or locking substance daubing point. Spare parts details. SYMBOL 1277 1243 Daub waterproof Daub screw locking Daub screw locking Daub engine oil Daub fluid sealant grease... -
Page 15: Specifications
SPECIFICATIONS OUTBOARD ENGINE SPECIFICATIONS Item Description Item Description Ignition Overall length 1001mm C.D.I system Starting Overall width 427mm Choke valve enrichment 1080mm Spark plug DPR7HS Overall Exhaust height 1207mm Under water system Lubrication 49kg Pressure lubrication system Unleaded regular 51kg Fuel type gasoline 7.3Kw(9.9hp)@5000r/min... -
Page 16: Maintenance Information
MAINTENANCE INFORMATION Power unit Item Description Item Description Warp limit 0.1mm Intake 0.15~0.25mm Valve Camshaft inside clearance 35.000~35.012mm Exhaust 0.20~0.30mm (cold) diameter Rocker shaft 12.941~12.951mm Intake 1.98~3.11mm outside diameter Face width Rocker inside 13.000~13.018mm Exhaust 1.98~3.11mm diameter Bore 59.00~59.015mm Intake 0.6~0.8mm Seat width Wear limit... -
Page 17: Lower Unit
Intake 27.596~27.696mm Journal diameter 34.997~35.009 mm Crankpin Exhaust 27.616~27.716mm 30.997~31.009 mm diameter Round diameter 23.950~24.050mm Crankpin width 21.00~21.07mm Big end side Journal diameter 34.935~34.955mm 0.05~0.22mm clearance Camshaft round 0.03mm Round limit 0.05mm limit Opening Discharge 5.70L/min 58~62ºC temperature Safety valve Full-opening 388.0~450.0kPa 70ºC... -
Page 18: Charge System
Charge system Item Description Item Description Min. (3000 r/min) 5.5 A Start (load) 14 V Charge Light coil current Max. (5000 r/min) 6.0 A 1500r/min (no-load) 30 V output Rectifier 3000r/min (no-load) 24 V 3500r/min (no-load) 70 V peak 5000r/min (no-load 38 V Light coil resistance 0.33~0.72... -
Page 19: General Torque
Lower unit mounting Bolt 18 Nm Lower unit housing cover Bolt Anode Bolt 8 Nm Water pump housing Bolt 18 Nm Water pump base Bolt 18 Nm Water inlet Bolt 5 Nm Oil drain bolt Bolt 9 Nm Oil filler hole Bolt 9 Nm Pinion... -
Page 20: Periodic Service
PERIODIC SERVICE MAINTENANCE TIME TABLE Initial maintenace General maintenance Items Contents period 10 hours 50 hours 100 hours 200 hours (month (3 months) (6 months) (1 year) Anode Inspection/ replacement Spark plug Cleaning/ adjustment / replacement Grease points Greasing Bolts and nuts Inspection Fuel filter Inspection/ replacement... -
Page 21: Fuel System
FUEL SYSTEM 1. CHECK FUEL TANK, CARBURETOR, FUEL PUMP AND FUEL PIPE Check if fuel tank, carburetor, fuel pump and fuel pipe are damaged or leaked. Replace if necessary. Check if the fuel filter on the tank is dirty. Clean dirt or replace if necessary. 2. -
Page 22: Changing Engine Oil
2. 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 23: Spark Plug
Don’t rotate the flywheel counter clockwise in case the valve system is damaged. NOTE Adjust the valve clearance when the engine is cold Intake valve 0.15~0.25mm Valve clearance (cold position) Exhaust valve 0.20~0.30mm 6. Loose lock nut, rotate adjusting bolt to reach the specified valve clearance. NOTE Rotate adjusting bolt clockwise to reduce the valve clearance. -
Page 24: Idling Speed
throttle cable stop screw Electric start type 1. Turn the gear shift lever to neutral position. 2. Check if the arresting stop on the throttle accelerograph enforce touches the check plate on the bracket. check plate arresting stop 3. Loosen the lock nut and take out the cotter pin, then remove the cable joint. 1. -
Page 25: Start-In-Gear Protection
3. Turn the throttle stop screw clockwise or counter clockwise, until the specified idling speed is attained. NOTE Turn clockwise to increase idling speed. Turn counter clockwise to decrease idling speed. If necessary, turn the idling speed screw on the carburetor clockwise or counter clockwise, until the specified idling speed is attained. -
Page 26: Lower Unit Leakage Check
Remove the drain plug screw, the oil level plug screw, and then drain the gear oil. Oil level plug screw 2. Drain plug screw 4) Add gear oil through the drain plug hole using pressure filling device. 5) When gear oil overflows through the oil level plug hole, install the oil level plug screw. 6) Install the drain plug screw, then clean overflowing gear oil. -
Page 27: Cooling Water Passage
2. Paint anti-corrosion grease on the propeller shaft. Cooling water passage 1. Inspect cooling water passage, if blocked, clean it. 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. -
Page 28: Thermostat
Thermostat 1. Remove the thermostat cover and thermostat. 2. Hang the thermostat in a container with water. 3. Heat the container. 4. Check the valve open height under the specified water temperatures. If out of order, change it. Water temperature Valve open height Under 62 0.1mm... -
Page 29: Explosive Drawing
EXPLOSIVE DRAWING... - Page 32 Electric start type...
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Page 33: Disassembling
DISASSEMBLING Open the top cowling. Screw loosely the adjusting nut of the arrester tightwire. Adjusting nut Remove the tightwire from the arrester. Remove the starter fixing bolts, and remove the starter. STARTER ROPE REPLACEMENT 1. Pull the starter rope out, and insert it in the notch of the start-up wheel. Turn the start-up clockwise until the volute spring is free. -
Page 34: Disassembling And Inspection
6. Insert the start rope in the notch of the start-up wheel and turn the start-up wheel several rounds in counter clockwise direction. 7. Pull the starter handle many times to check if the start-up wheel rotates stably. If necessary, repeat step 6 and step 7. -
Page 35: Assembling
1. Remove the link rod assy of chock valve. 2. Remove the cotter pin and rocker shaft. 3. Remove the rocker. 4. Remove the bush plate, guide bush and chock valve handle. 5. Check if the link rod assy is cranked or deformed. Replace if necessary. 6. -
Page 36: Explosive Drawing
EXPLOSIVE DRAWING... - Page 39 Electric start type...
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Page 41: Wiring Diagram
WIRING DIAGRAM Oil press switch Engine stop switch Spark plug C D I Lighting coil Pulsed coil Grounding wire Charge coil Ignition coil Oil alert light Wire beam color: White Orange Yellow/Red Black Blue Red/White Green Yellow Brown SPARK PLUG IGNITION 1. -
Page 42: Spark Plug Cap
SPARK PLUG CAP 1. Remove the spark plug cap. Check if the spark plug cap is broken. Replace if necessary. 2. Install the spark plug cap. Turn it clockwise until it is tight. FLYWHEEL MAINTENANCE Use flywheel gripper to remove the nut and starter bush; use flywheel puller to remove flywheel. 2. -
Page 43: Pulsed Coil Inspection
PULSED COIL INSPECTION 1. Pulsed coil peak voltage Use the digital circuit tester and peak voltage adaptor to measure the peak voltage. If below the specification, check the pulsed coil resistance. Digital circuit tester Peak voltage adaptor Start (no-load) Start (load) Pulsed coil peak voltage 1500r/min (load) 3500r/min (load) -
Page 44: 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... - Page 49 Electric start type...
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Page 50: Throttle Connecting Rod Adjustment
THROTTLE CONNECTING ROD ADJUSTMENT 1. Turn throttle accelerograph enforce to full opening position. Turn carburetor throttle rod to full opening position. . Throttle accelerograh enforce . Carburetor throttle rod . Lock screw 2. In full opening position, tighten the throttle rod lock screw. FUEL JOINT REMOVAL AND INSPECTION 1. -
Page 51: Filter Inspection
7. Force a prescribed negative pressure and check for leakage. Disassemble the fuel pump to check if necessary. Prescribed pressure: 50kPa 8. Remove four bolts, and separate fuel pump cover from fuel pump seat. 9. Remove the valve screw from fuel pump, and remove the valve plate. 10. -
Page 52: Power Unit
POWER UNIT NOTICE To avoid accidental start of outboard engine during maintenance, please take enough safety measures to disconnect the ignition system. For instance, remove the engine stop lanyard from engine stop switch assembly, and remove spark plug cap from spark plug. EXPLOSIVE DRAWING... - Page 55 14 Nm...
- Page 58 M6x20mm 8 Nm 1243 5 Nm 8 Nm 2 Nm M6x30mm 1st 6 Nm 2nd 12Nm 40 Nm M8x55mm 1st 15 Nm 2nd 30 Nm 18 Nm M6x35mm 1st 6 Nm 2nd 12Nm...
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Page 60: Special Tools
SPECIAL TOOLS Piston slider Flywheel gripper and flywheel puller Valve spring compressor Housing oil seal installer Space gauge Oil cleaner spanner COMPRESSION PRESSURE INSPECTION 1.Start the engine and preheat it for 5 minutes. Then stop it. 2. Remove stopper hang rope. 3. -
Page 61: Oil Pressure Inspection
NOTE: If the cylinder pressure increases continuously, check piston and piston ring for damage. Replace if necessary. If the cylinder pressure doesn’t increase at all, check valve clearance, valve, valve seat, cylinder liner, cylinder cover and cylinder cover gasket. Adjust or replace if necessary. The outboard engine comes with an automatic decompression device, so the pressure data measured may have variance. -
Page 62: Belt Pulley And Timing Belt
6. Remove bolts connecting power unit and upper casing. 7. Lift the engine and remove the pin. 8. Remove oil strainer and safety valve. Check the oil strainer for damage and clog. Replace if necessary. Check the safety valve for damage and crack. Replace if necessary. 9. -
Page 63: Disassembling And Inspection
damaged. 8. Assemble wood ruff key and timing belt pulley. Align the notch mark on the timing belt pulley with the mark “ ” on the cylinder body. 9. Assemble new timing belt. Remember to put the timing belt part number vertical and upward. CAUTION: Please don’t distort, rotate or bend the timing belt. -
Page 64: Valve And Valve Guide Bush
Valve and valve guide bush . Inspect the valve seat width. If not in the prescribed range, repair the valve seat. Valve seat width: 0.6 0.8mm 2. Inspect the valve margin thickness (T). If not as in the prescribed value, replace the valve. The margin thickness of valve: 0.5 0.9mm 3. -
Page 65: Oil Pump Check
Replace if necessary. Intake camshaft 27.596~27.696mm Height Exhaust camshaft 27.616~27.716mm Base circle diameter 23.950~24.050mm 2. Check camshaft run out. Replace if necessary. Roundness limit: 0.03mm 3. Check main journal diameter of camshaft and journal inside diameter of cylinder cover. Replace if necessary. -
Page 66: Valve Seat Inspection
3. Lap the valve on valve seat by valve lapping tool. 4. Measure the valve seat width. The valve face is with bluing dye. If the valve and valve seat do not match, or the valve seat width does not conform to specified value, reface and lap the valve seat. -
Page 67: Valve Installation
CAUTION: Do not overlap the valve. Turn the lapping tool evenly with a downward force of 40~50N. Do not contaminate push rod and valve guide bush with lapping compound. Valve installation 1. Install new valve oil seal and spread engine oil to the valve guide bush. 2. -
Page 68: Piston
2. Remove thermostat cover and gasket. 3. Remove exhaust outer cover, gasket and pin. Clean the anode surface and check the anode. Replace if the corrosion of anode is abnormal. Check the exhaust outer cover for crack, distortion or corrosion. Replace if necessary. 4. -
Page 69: Piston Pin Diameter
Taper limit: 0.08mm (D1-D5, D2-D6) Round limit: 0.05mm (D2-D1, D6-D5) Piston pin outside diameter Measure piston pin outside diameter. If out of specification, replace the piston pin. Piston pin outside diameter: 13.996 14.000mm Piston ring Push the piston ring parallel with the piston into the specified measuring point of the cylinder (10mm from conjunction surface). -
Page 70: Main Journal Oil Clearance
2. Assemble connecting rod to the crankpin. 3. Tighten the connecting rod bolts to the specified torque. Tightening torque: First tightening 10 Nm Second tightening 21 Nm 4. Remove the connecting rod, measure the compressed width of the plastic space gauge. If out of specification, replace the connecting rod. -
Page 71: Piston Ring Installation
Install piston, connecting rod, piston pin and piston pin circlip NOTE: When installing, make sure that the mark on the connecting rod is on the same side as the mark on the piston crown. Piston ring installation 1. Install oil ring, 2nd ring and top ring. NOTE: Make sure that the mark is toward the piston crown when installing the 2nd ring. -
Page 72: Assembling Power Unit
Assembling power unit 1. Install the main bearing to cylinder body. 2. Apply fluid sealant to conjunction surface of the cylinder body, and install dowel pin and cylinder body. Tighten the bolts twice according to the sequences on the right picture. - Page 73 11. Install cover of cylinder cover and tighten bolt according to sequences on right picture. 12. Install throttle cable bracket and accelerograph enforce. 13. For electric start models, install gear shift limitative rod firstly. 14. Install oil pressure switch, ignition coil, C.D.I.
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Page 74: Upper Unit
UPPER UNIT TOP COWLING Explosive drawing... -
Page 75: Disassembling And Inspection
Disassembling and inspection 1. Remove rubber seal. 2. Remove top cowling muffle cover screw and rubber underlay. 3. Remove top cowling muffle cover. 4. Remove locking hook and pothook. 5. Inspect top cowling for crack or damage. Replace if necessary. 6. -
Page 76: Bottom Cowling
BOTTOM COWLING Explosive drawing... -
Page 80: Disassembling And Inspection
Disassembling and inspection 1. Remove rubber plug, wave sheath and throttle cable jacket. 2. Remove bolts fixing bottom cowling cover board, and remove cover board. 3. Remove top cowling locking handle assembly screws, remove top cowling locking handle and top cowling locking block. -
Page 81: Steering Handle
STEERING HANDLE Explosive drawing... -
Page 84: Disassembling And Inspection
Disassembling and inspection 1. Remove shift handle. 2. Remove steering handle cover. 3. Remove handle bush, bush washer and wave washer. 4. Remove cotter pin and friction adjusting bolt. 5. Remove throttle handle. 6. Remove throttle cable. 7. Remove throttle lever stay and throttle lever. 8. -
Page 85: Bracket
BRACKET Explosive drawing... -
Page 89: Disassembling And Inspection
Disassembling and inspection 1. Remove limitative rod and bolt (M6X145). 2. Remove nut and bolt of tilt stopper plate, and remove the tilt stopper plate. - Page 90 3. Remove clamp bracket nut, two hole plate, and double head bolt of clamp bracket. 4. Remove clamp bracket. 5. Remove rotary bracket. 6. Remove lock angle handle and tilt lock rod. Remove tension spring and angle orientation lever. 7. Remove orientation bushing and nylon bush. 8.
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Page 91: Upper Unit
UPPER UNIT Explosive drawing... -
Page 92: Disassembling And Inspection
Disassembling and inspection 1. Remove the oil sump. 2. Remove the oil seal and abnormity seal. 3. Remove the exhaust pipe, oil drain bolt, oil drain jacket and exhaust pipe seal. 4. Remove double hole shock absorber assy, water pipe quadrate seal and water pipe. 5. -
Page 93: Lower Unit
LOWER UNIT WATER PUMP ASSEMBLY Explosive drawing... -
Page 94: Disassembling And Inspection
Disassembling and inspection 1. Remove water pump fixed plate. 2. Remove water pump housing. 3. Remove impeller and water pump inner shell. 4. Remove woodruff key and outer plate. 5. Check water pump housing and outer plate for crack, crank or damage. Replace if necessary. 6. -
Page 95: Lower Unit
LOWER UNIT Explosive drawing... -
Page 100: Disassembling And Inspection
Disassembling and inspection 1. Drain oil, and remove the cotter pin. 2. Put a piece of wood between propeller and anti-swirl baffle. Remove hexagon nut, anode and water inlet. 3. Remove propeller assembly and cushion. 4. Remove anode. 5. Remove the lower casing cover. Remove reverse gear and shim. -
Page 101: Dog Clutch Installation
Dog clutch installation 1. Put clutch spring into the hole at the end of the propeller shaft. Install the dog clutch as shown. Make sure the “F” mark is toward the forward gear. Install clutch pin. 3. Install clutch ring and shift plunger. Lower casing cover 1. -
Page 102: Drive Shaft
3. Install reverse gear and shim. NOTE: Adjust the shim when install the new reverse gear and bearing. Drive shaft 1. Inspect the drive shaft for crank or wear. Replace if necessary. 2. Check the run out of drive shaft. Run out limit: 0.05 mm Shift rod cam Check the shift rod cam for wear or deform. -
Page 103: Lower Unit Installation
4. Install oil seal. it: mm) Bearing block oil seal installer 5. Install nylon bushing, shift rod cam assy, gasket, and drive shaft base. Install forward gear, drive shaft, shim, end thrust bearing and pinion. Forward gear bearing installer CAUTION: Adjust shim when install new drive shaft base or drive shaft. -
Page 104: Shim Selection
3. Connect the columned nut and shift rod cam assy. Change shift, and check if the operation is normal. Adjust the columned nut position if necessary. Tighten the nut thoroughly. 4. Add gear oil using the pressure filling device. Shim selection T1 T2 T3: Shim thickness M1: Reverse gear thickness;... -
Page 105: Common Troubles And Solutions
NOTE Use three measuring points when measuring the thickness. Apply the average. For the optional shim specs, refer to page 11. COMMON TROUBLES AND SOLUTIONS Trouble type Possible reason Recovery action Starter components are faulty Repair or replace Starter will not Shift lever is not in the neutral operate Move to the neutral position... - Page 106 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 angle Motor is mounted at incorrect Adjust motor to proper transom height transom height Boat bottom is fouled with marine Clean boat bottom growth Weeds or other foreign matter are...