Parsun F115 BEX-T User manual

Service Manual
F115/FL115
Suzhou Parsun Power Machine Co., Ltd.

Preface
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.
If you choose other maintenance procedures and tools, please follow the instructions of
experienced maintenance personnel to avoid injuries to personnel and the outboard motor.
The materials, drawings and technical parameters used in this Manual are based on the
prototype at the time of publication, so there may be some small differences between the actual motor
you purchased and that described in the Manual; If necessary, our Company will distribute the revised
part to the dealers in various places.
When the following characters appear in this Manual, please read the Manual carefully
and execute the relevant instructions and descriptions correctly and carefully.
Warning:
Failure to comply with the warnings may lead to injury to maintenance personnel and
bystanders, and severe cases may result in death.
Note:
“Note” means that preventive measures must be taken to avoid damage to the outboard
motor.
Note:
Key information are provided to make your operation steps simpler and clearer.
The last part of this Manual describes the common faults and troubleshooting methods of
the outboard motor. Please read it carefully; When overhauling the outboard motor, it can help
you quickly judge the status of the motor and improve working efficiency.
It is forbidden to copy and disseminate this Manual without written authorization
Suzhou Parsun Power Machine Co., Ltd.

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 .............................................................................. 7
Symbol description ......................................................................................................................... 7
Specification ........................................................................................................................................... 8
Outboard motor parameters ............................................................................................................ 8
Maintenance information ........................................................................................................................ 9
Engine ............................................................................................................................................. 9
Underwater unit ............................................................................................................................ 10
Electrical system ........................................................................................................................... 11
Seating torque ....................................................................................................................................... 12
Specified torque ............................................................................................................................ 12
Average torque .............................................................................................................................. 13
Overall dimensions ............................................................................................................................... 14
Basic maintenance ................................................................................................................................ 19
Maintenance Interval Chart ................................................................................................................... 19
Fuel system ........................................................................................................................................... 20
Engine ................................................................................................................................................... 20
Engine oil level ............................................................................................................................. 20
Change engine oil ......................................................................................................................... 21
Spark plug ..................................................................................................................................... 21
Control system ...................................................................................................................................... 22
Throttle push-pull cable ................................................................................................................ 22
Shift operation ............................................................................................................................... 22
Underwater unit .................................................................................................................................... 23
Gear oil .......................................................................................................................................... 23
Replace gear oil ............................................................................................................................. 23
Air tightness inspection of underwater unit .................................................................................. 23
General maintenance ............................................................................................................................. 24
Anode ............................................................................................................................................ 24
Lubricating point ........................................................................................................................... 24
Cooling water channel .................................................................................................................. 24
Thermostat .................................................................................................................................... 25
Propeller ........................................................................................................................................ 25
Check the main switch/stop switch ............................................................................................... 25
Change the oil filter ...................................................................................................................... 26
Check the top cover ...................................................................................................................... 26
Check valve clearance ................................................................................................................... 27
Electrical system ................................................................................................................................... 28
Matters needing attention ...................................................................................................................... 28
Disassembly schematic diagram ........................................................................................................... 29

Wiring diagram ..................................................................................................................................... 35
Spark plug ignition ................................................................................................................................ 37
Spark plug cap ....................................................................................................................................... 37
Flywheel maintenance .......................................................................................................................... 37
Ignition coil detection ........................................................................................................................... 37
Trigger coil detection ............................................................................................................................ 37
Check engine startup switch ................................................................................................................. 38
Check engine stop switch ...................................................................................................................... 38
Detection of starting relay ..................................................................................................................... 38
Detection of magneto coil ..................................................................................................................... 38
Detection of rectifier regulator .............................................................................................................. 38
Use fault diagnosis tester ...................................................................................................................... 39
Fault code table ............................................................................................................................. 39
Fuel system ........................................................................................................................................... 41
Matters needing attention ...................................................................................................................... 41
Disassembly schematic diagram ........................................................................................................... 42
Reduce fuel pressure ............................................................................................................................. 50
Check the oil filter cup .......................................................................................................................... 50
Removal and inspection of fuel pump .................................................................................................. 50
Check the fuel filter .............................................................................................................................. 51
Remove and check the fuel injector ...................................................................................................... 51
Check throttle body ............................................................................................................................... 52
Check the intake manifold .................................................................................................................... 52
Disassemble and check the carbon canister and carbon canister solenoid valve .................................. 52
Disassemble and check the electric fuel pump ..................................................................................... 53
Engine ................................................................................................................................................... 54
Matters needing attention ...................................................................................................................... 54
Disassembly schematic diagram ........................................................................................................... 55
Special tool ............................................................................................................................................ 67
Check the compression pressure ........................................................................................................... 67
Check oil pressure ................................................................................................................................. 67
Check valve clearance ........................................................................................................................... 68
Adjust valve clearance .......................................................................................................................... 71
Remove the engine ................................................................................................................................ 72
Pulley and timing belt ........................................................................................................................... 73
Disassembly and inspection .................................................................................................................. 73
Cylinder cover ............................................................................................................................... 73
Check the valve tappet .................................................................................................................. 73
Check the driven pulley ................................................................................................................ 74
Check the cylinder head bolts ....................................................................................................... 74
Valve and valve guide ................................................................................................................... 74
Valve spring .................................................................................................................................. 74
Replace valve guide ...................................................................................................................... 75
Check valve seat ring .................................................................................................................... 75
Trim the valve seat ring ................................................................................................................ 75
Assemble and mount the cylinder head ........................................................................................ 76
Crankcase .............................................................................................................................................. 77
Disassembly .................................................................................................................................. 77
Piston ............................................................................................................................................. 78
Cylinder bore ................................................................................................................................ 78

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 ..................................................................................... 80
Main journal oil clearance ............................................................................................................ 81
Selection of crankshaft bearing bush ............................................................................................ 81
Body and engine base ................................................................................................................... 82
Check the oil pump ....................................................................................................................... 82
Check and mount exhaust pipe ..................................................................................................... 82
Reinstallation ........................................................................................................................................ 83
Assemble piston connecting rod ................................................................................................... 83
Installing the piston rings .............................................................................................................. 83
Installing piston ............................................................................................................................. 83
About water ........................................................................................................................................... 85
Top cover............................................................................................................................................... 85
Disassembly schematic diagram ................................................................................................... 85
Disassembly and inspection .......................................................................................................... 87
Bottom cover ......................................................................................................................................... 88
Disassembly schematic diagram ................................................................................................... 88
Disassembly and inspection .......................................................................................................... 92
Water unit and bracket .......................................................................................................................... 93
Disassembly schematic diagram ................................................................................................... 93
Disassembly and inspection of bracket ......................................................................................... 99
Disassembly and inspection of water unit .................................................................................... 99
Hydraulic warping device ................................................................................................................... 100
Check the oil level. ..................................................................................................................... 100
Underwater part .................................................................................................................................. 102
Disassembly schematic diagram ......................................................................................................... 102
Disassembly and inspection ................................................................................................................ 113
Propeller shaft and clutch block .................................................................................................. 114
Install the claw clutch ................................................................................................................. 114
Housing cover of underwater unit ............................................................................................... 114
Install the oil seal and bearing of the housing cover ................................................................... 114
Drive shaft ................................................................................................................................... 115
Shift cam ..................................................................................................................................... 115
Gear ............................................................................................................................................. 115
Forward gear bearing .................................................................................................................. 115
Check the housing of the underwater unit .................................................................................. 115
Check the water pipe ................................................................................................................... 115
Assemble underwater unit ................................................................................................................... 115
Install the underwater unit .................................................................................................................. 117
Selection of shim ................................................................................................................................. 118
Deviation value mark .................................................................................................................. 119
Pinion shim ................................................................................................................................. 120
Forward gear shim ...................................................................................................................... 120
Reverse gear shim ....................................................................................................................... 121

Backward-rotating pinion shim ................................................................................................... 122
Propeller shaft shim .................................................................................................................... 122
Reverse gear shim ....................................................................................................................... 123
Forward gear shim ...................................................................................................................... 123
Common faults and solutions .............................................................................................................. 124

1
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.
1. Position of the serial number
The numbers are expressed as follows:
发动机顺序号
SN
生产代号
Selection of propeller
The performance of the outboard motor is seriously affected by the propeller. Improper
selection will have adverse effects on the motor. When the ship runs in full load, the motor will
operate at low speed for a long time. At this time, the propeller with smaller pitch should be selected,
whereas the propeller with larger pitch should be selected to maintain the normal operation of the
engine.
When the engine is running at full throttle, the most suitable propeller for the ship is to refer
to the engine speed and fuel performance, which can provide the highest performance.
Propeller dimensions Material
3-14"×11" Aluminum alloy
3-13 "
8
5×13" Aluminum alloy
3-13 "
8
5×14" Aluminum alloy
3-13 "
2
1×15" Aluminum alloy
3-13 "
4
1×17" Aluminum alloy
3-13"×19" Aluminum alloy
3-12 "
8
5×21" Aluminum alloy
3-13"×23" Aluminum alloy
3-13"×25" Aluminum alloy
3-13 "
2
1×14" Stainless steel
1

2
Continued:
Propeller dimensions Material
3-13 "
2
1×16" Stainless steel
3-13"×17" Stainless steel
3-13"×19" Stainless steel
3-13"×21" Stainless steel
3-13"×23" Stainless steel
3-13"×25" Stainless steel
3-13 "
2
1×17" Stainless steel
3-13 "
2
1×19" Stainless steel
3-13 "
2
1×21" Stainless steel
3-12 "
2
1×23" Stainless steel
3-13"×17" Stainless steel
3-13"×17" Stainless steel
Backward-rotating propeller:
Propeller dimensions Material
3-13"×17" Stainless steel
3-13"×19" Stainless steel
3-13"×21" Stainless steel
Note:
Backward-rotating outboard motor must use backward-rotating propeller,
otherwise the vessel will not advance in the desired direction, which is likely to cause accidents!
Protection at work
In order to prevent danger or accident during maintenance and improve work quality, please
observe the following safety regulations.
1. Fire prevention
Gasoline and various lubricating oils and greases are easy to burn; Keep away from heat
sources, sparks and open flames during operation.
2. Ventilation
Gasoline vapor and engine exhaust gas are highly toxic. Massive inhalation of such
substances can cause shock and even death. When testing the engine indoors, please keep
good ventilation conditions.
3. Self-protection
Wear protective glasses when drilling, grinding or using air compressors. Wear

3
protective gloves and safety shoes when necessary.
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. However, please take protective measures before use to reduce risks.
○
1 Apply protective cream on both hands before overhauling the outboard motor;
○
2 Replace and clean the clothes as soon as possible after they are contaminated by the
lubricant;
○
3 Avoid skin contact;
○
4 Wash your hands and skin carefully with soap and hot water after contact with the
lubricant;
○
5 Wipe the spilled grease with a clean, lint-free rag.
5. Develop good work habits
○
1 Tighten nuts, bolts and screws according to the specified torque from large size to
small size, from the center to the outside.
○
2 Use recommended special tools to avoid damage to parts. Use the right tools in the
proper way.
Disassembly and assembly
When disassembling and assembling the outboard motor, please follow the following
principles:
1. Please use special tools when disassembling and assembling the parts of the outboard
motor;
2. Remove dust and dirt before decomposing the parts;
3. Apply engine oil on the contact surface of moving parts before assembly;
4. When installing the bearing, place the manufacturer's mark in the specified direction and
fully lubricate it;
5. Before installation, coat a thin layer of waterproof lubricating oil on the protruding part
and periphery of the oil seal;
6. After assembly, check whether the moving parts work normally.
7.
Disposable parts
Parts such as gasket, oil seal, O-ring, cotter pin and spring ring are disposable parts, and they
must be replaced before reinstalling the outboard motor.
Pre-delivery inspection
To ensure the normal use by customers, please carry out the following inspection before
delivery. 1. Check the fuel system.
Check whether the fuel hose is securely connected and whether the fuel tank is full.
Note:
As it is a four-stroke engine, premixed fuel cannot be used.
2. Check the oil level.
3.
○
1 Check engine oil level.
Pull out the oil dipstick and observe the oil level through the dipstick.

4
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.
○
2 Check gear oil level
Unscrew the oil level plug and observe whether the oil overflows in the oil level plug.
If yes, install the oil level plug and tighten it according to the specified torque; If not, fill
it with oil.
1. Oil level plug
3. Check the steering system.
Check whether the steering is smooth;
Check whether the steering friction is adjusted correctly.
Turn the locking bolt clockwise to increase the resistance.
Turn the locking bolt counterclockwise to reduce the resistance.
4. Check shift and throttle operation.
Check whether the shift operation is smooth; Check whether the throttle grip operates
smoothly from the full-close position to the full-open position.
5. Check the emergency stop switch assembly.
Check whether the engine stops when the emergency stop switch assembly is pressed
and hold or the engine stop safety line is pulled out.
6. Check the cooling water peep door.
When the engine is running, check whether the cooling water flows out of the cooling
water observation hole.
1. Cooling water observation hole
7. Running-in operation.
○
11st hour: The engine runs at 2000 rpm or about half of the throttle.
②2nd hour: Run the engine at 3000 rpm or about 3/4 of the throttle.
③The next 8 hours: Avoid running at full throttle for 5 minutes continuously.
8. Inspection after running-in operation
○
1Check the gear oil for water.
②Check the fuel line for leaks.
③After running-in operation, run the engine at idle speed and use the washing tool to
flush the cooling water channel with fresh water.
1
1
1
2
2
2
3