Parsun F15/F9.9BM User manual

PARSUN OUTBOARD ENGINE
SERVICE MANUAL
F15/F9.9BM(F15/F9.9W)
SUZHOU PARSUN POWER MACHINE CO., LTD.

NOTICE
This manual includes service instructions for F9.9, F15 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. If you use other service procedure and tools, please follow guidance from experienced
maintenance people, to avoid damage to people and outboard engines.
The manual is based on the sample machines that are produced at the time of printing, so the model
being actual purchased may differ a little from the descriptions and illustrations given in this manual.
If necessary, our company will distribute the manual revision to dealers.
In this Service Manual, particularly important information is distinguished in the following ways,
please ready the manual carefully, and perform the instructions correctly and carefully.
WARNING:
Failure to follow WARNING instructions could result in severe injury or death to the machine operator
and bystander.
CAUTION:
A CAUTION indicates special precautions that must be taken to avoid damage to the outboard motor.
NOTE:
A NOTE provides key information to make procedures easier or clearer.
The common troubles and solutions are given in the end of the manual, please ready carefully. When
performing maintenance and repair to Parsun outboard engines, they will help you judge the outboard
engine’s status quickly and improve the work efficiency.
Allrightsreserved.
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.

INDEX
GENERALINFORMATION················································································································1
IDENTIFICATION··················································································································1
PROPELLERSELECTION···································································································1
EMERGENCYSTART············································································································1
SAFETYWHILEWORKING································································································2
DISASSEMBLYANDASSEMBLY························································································3
ONE-TIMEUSEPARTS·········································································································4
PRE-DELIVERYCHECK······································································································4
SPECIALTOOLSAND DETECTION DEVICE·································································6
EXPLOSIVEDRAWINGANDSYMBOL·············································································8
SPECIFICATIONS································································································································9
OUTBOARD ENGINE SPECIFICATIONS·········································································9
MAINTENANCEINFORMATION·····················································································10
Powerunit························································································································10
Lowerunit························································································································11
Ignitionsystem·················································································································11
Chargesystem··················································································································12
TIGHTENINGTORQUE······································································································12
Specifiedtorque···············································································································12
Generaltorque·················································································································13
PERIODICSERVICE·························································································································14
MAINTENANCETIMETABLE··························································································14
FUELSYSTEM······················································································································15
POWERUNIT························································································································15
Engineoillevel·················································································································15
Changingengineoil·········································································································16
Valve clearance················································································································16
Sparkplug························································································································17
CONTROLSYSTEM············································································································17
Throttlegrip·····················································································································17
Idlingspeed······················································································································18
Start-in-gearprotection···································································································19
LOWERUNIT························································································································19
Gearoil·····························································································································19
Changinggearoil·············································································································19
Lowerunitleakage check·······························································································20
GENERALINSPECTION·····································································································20

Anode································································································································20
Greasepoints····················································································································20
Coolingwaterpassage·····································································································21
Thermostat·······················································································································22
RECOILSTARTER·····························································································································22
NOTICE··································································································································22
EXPLOSIVEDRAWING······································································································23
DISASSEMBLING·················································································································27
STARTROPEREPLACEMENT·························································································27
DISASSEMBLINGANDINSPECTION··············································································28
ASSEMBLING·······················································································································29
INSTALLATION····················································································································29
IGNITIONSYSTEM···························································································································29
NOTICE··································································································································29
EXPLOSIVEDRAWING······································································································30
WIRINGDIAGRAM·············································································································35
SPARKPLUGIGNITION·····································································································35
SPARKPLUGCAP················································································································36
FLYWHEELMAINTENANCE····························································································36
CDIINSPECTION·················································································································36
IGNITIONCOILINSPECTION··························································································36
PULSEDCOILINSPECTION·····························································································37
CHARGECOILINSPECTION····························································································37
FUELSYSTEM····································································································································38
NOTICE··································································································································38
EXPLOSIVEDRAWING······································································································38
THROTTLE CONNECTINGRODADJUSTMENT·························································44
FUELJOINT REMOVALAND INSPECTION··································································44
FUELPUMPREMOVALANDINSPECTION···································································44
FILTER INSPECTION··········································································································45
POWERUNIT······································································································································46
NOTICE··································································································································46
EXPLOSIVEDRAWING······································································································46
SPECIALTOOLS··················································································································54
COMPRESSION PRESSURE INSPECTION····································································54
OILPRESSUREINSPECTION···························································································55
OILPRESSURE SWITCH INSPECTION··········································································55

DISASSEMBLINGPOWERUNIT······················································································55
BELTPULLEYANDTIMINGBELT··················································································56
DISASSEMBLINGAND INSPECTION··············································································57
CYLINDERCOVER······································································································57
Disassembling············································································································57
Valve and valve guide bush······················································································58
Valve spring···············································································································58
Valve rockerarm and rocker shaft·········································································58
Camshaft···················································································································58
Oilpumpcheck·········································································································59
Valve guide bush replacement·················································································59
Valve seat inspection·································································································60
Valve seat cutting······································································································61
Valve installation·······································································································61
Assemblingcylindercover·······················································································61
CRANKCASE··················································································································61
Disassembling············································································································61
Piston·························································································································62
Cylinderbore············································································································62
Pistonpindiameter···································································································63
Pistonring·················································································································63
Crankshaft·················································································································63
Crankpinoilclearance·····························································································63
Mainjournaloilclearance·······················································································64
Cylinderbody and crankcase··················································································64
FULLINSTALLATION··································································································64
Pistonconnectingrod installation···········································································64
Pistonringinstallation·····························································································65
Pistoninstallation·····································································································65
Crankshaftinstallation····························································································65
Assemblingpowerunit·····························································································66
UPPERUNIT········································································································································68
TOPCOWLING·····················································································································68
Explosivedrawing···········································································································68
Disassemblingandinspection·························································································69
BOTTOMCOWLING···········································································································70
Explosivedrawing···········································································································70
Disassemblingandinspection·························································································74
STEERINGHANDLE···········································································································75
Explosivedrawing···········································································································75

Disassemblingandinspection·························································································78
BRACKET······························································································································79
Explosivedrawing···········································································································79
Disassemblingandinspection·························································································83
UPPERUNIT··························································································································85
Explosivedrawing···········································································································85
Disassemblingandinspection·························································································86
LOWERUNIT······································································································································87
WATERPUMPASSEMBLY·································································································87
Explosivedrawing···········································································································87
Disassemblingandinspection·························································································88
LOWERUNIT························································································································89
ExplosiveDrawing···········································································································89
Disassemblingandinspection·························································································94
Propellershaft and clutch block··············································································94
Dogclutchinstallation······························································································95
Lowercasingcover···································································································95
Lower casing cover oil seal and bearing installation·············································95
Driveshaft·················································································································96
Shiftrodcam·············································································································96
Gear···························································································································96
Forwardgearbearing······························································································96
Lowercasinginspection···························································································96
Assemblinglowercasing··························································································96
Lowerunitinstallation·····························································································97
Shimselection············································································································98
COMMON TROUBLESAND SOLUTIONS····················································································99

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.
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1. Outboard motor serial number location
Serial number as follows:
SN
MOTOR BATCH SEQUENCE NUMBER
PRODUCTION CODE
PROPELLER SELECTION
The performance of your outboard motor will be critically affected by your choice of propeller, as an
incorrect choice could adversely affect performance.
For a greater boat load and a low engine speed, a smaller-pitch propeller is more suitable. Conversely,
a large-pitch propeller is more suitable for a smaller operating load as it enables the correct engine speed
to be maintained.
When the engine is running at full throttle position, the suitable propeller should be used according to
the engine’s RPM and the fuel capability. So the outboard engine can supply the best performance.
Propeller sizes Material
9 1/4×8
9 1/4×11 Aluminum alloy
EMERGENCY START
If the starting device is not working, the engine can be started by emergency start cable.
WARNING：
 The start program can only be used in emergency and to return to harbor for repairing.
 When you start the engine by emergency start cable, the start-in-gear protection device is not
working. So please ensure the shift rod is in NEUTRAL position.
 Please ensure nobody standing behind you in case the cable is pulled out to hurt people.
 After the engine starts up, don’t fit the start device or top cowling. Put clothing or other
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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.
1. Start-in-gear protection device cable
3. Demount three bolts and remove starter.
4. Insert the knot of the cable in the notch of flywheel rotor, and wind the cable around flywheel
several rounds in clockwise direction..
5. Pull the manual starter handle slowly until you feel resistance.
6. 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.
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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. Protect hands and feet by wearing protective work clothes, safety
gloves and shoes if necessary.
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.
○
1To protect the skin, the application of a suitable barrier cream to the hands before working is
recommended.
○
2Clothing which has become contaminated with lubricants should be changed as soon as
practicable, and washed before further use.
○
3Avoid skin contact with lubricants.
○
4Hands and any other part of the body which have been in contact with lubricants or
lubricant-contaminated clothing, should be thoroughly washed with hot water and soap as
soon as practicable.
○
5A supply of clean lint-free cloths should be available for wiping run-off lubricants or grease.
5. GOOD WORKING PRACTICES
○
1Follow the tightening torque instruction. When tightening bolts, nuts and screws, tighten
the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.
○
2Use the recommended special tools to protect parts from damage. Use the right tool in the
right manner.
DISASSEMBLYAND ASSEMBLY
When disassembly and assembly, please follow the following principles：
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.
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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.
PRE-DELIVERY CHECK
To ensure the using, please inspect the following before delivery.
1. CHECKING FUEL SYSTEM
Check if the fuel pipe is connected firmly, and if the fuel tank is filled with fuel.
CAUTION:
Do not use pre-mixed fuel for this 4-stoke outboard engine.
2. CHECKING OIL LEVEL
○ 1 Check the engine oil level
Remove oil cap, check engine oil level..
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2
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1. Oil cap 2. High position mark 3. Low position mark
Ensure the oil level between the marks of upper and lower. If above upper level, drain engine
oil; if below lower mark, add engine oil up to upper level.
○ 2 Check the gear oil level
Remove the oil level plug. Check if the gear oil overflows at the oil level checking hole. If
so, install the oil level plug and tighten it according to specified torque. Otherwise please add
gear oil.
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1. Oil level plug
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