Parsun F40 EFI User manual

1
Maintenance Manual for Outboard Motor
F40/30 EFI
Suzhou Parsun Power Machine Co., Ltd.

Preface
This Manual is a maintenance instruction for F30/40, 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:
Means that preventive measures must be taken to avoid damage to the outboard motor.
Note:
Key information are provided here 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.
After-sales service hotline: [phone]
0512-66212797

Contents
Overview .....................................................................................................................................................................1
Identification Mark......................................................................................................................................................1
Selection of propeller...................................................................................................................................................1
Protection at work........................................................................................................................................................1
Disassembly and assembly..........................................................................................................................................2
Disposable parts...........................................................................................................................................................2
Pre-delivery inspection................................................................................................................................................2
Special tools and testing equipment.............................................................................................................................4
Disassembly schematic diagram and symbol description............................................................................................5
Specification................................................................................................................................................................7
Outboard motor parameters.........................................................................................................................................7
Maintenance information.............................................................................................................................................8
Engine..................................................................................................................................................................8
Underwater unit...................................................................................................................................................9
Electrical system..........................................................................................................................................................9
Ignition and ignition control system....................................................................................................................9
Charging system ................................................................................................................................................10
Seating torque............................................................................................................................................................10
Specified torque.................................................................................................................................................10
Average torque...................................................................................................................................................11
Dimensions................................................................................................................................................................11
Overall dimensions............................................................................................................................................11
Mounting dimensions of clamp bracket.............................................................................................................16
Basic maintenance.....................................................................................................................................................17
Fuel system................................................................................................................................................................17
Engine........................................................................................................................................................................18
Engine oil level..................................................................................................................................................18
Change engine oil..............................................................................................................................................18
Valve clearance..................................................................................................................................................19
Spark plug..........................................................................................................................................................19
Control system...........................................................................................................................................................20
Throttle push-pull cable.....................................................................................................................................20
Shift operation ...................................................................................................................................................21
Underwater unit.........................................................................................................................................................21
Gear oil..............................................................................................................................................................21
Replace gear oil .................................................................................................................................................21
Air tightness inspection of underwater unit.......................................................................................................21
General maintenance .................................................................................................................................................21
Anode.................................................................................................................................................................21
Lubricating point ...............................................................................................................................................22
Cooling water channel.......................................................................................................................................22
Thermostat.........................................................................................................................................................23
Propeller.............................................................................................................................................................23

Electrical system........................................................................................................................................................24
Precautions.................................................................................................................................................................24
Disassembly schematic diagram................................................................................................................................25
Wiring diagram..........................................................................................................................................................32
Spark plug ignition ....................................................................................................................................................35
Spark plug cap...........................................................................................................................................................35
Flywheel maintenance...............................................................................................................................................35
Check engine startsup switch.....................................................................................................................................35
Check engine stop switch ..........................................................................................................................................35
Detection of starting relay .........................................................................................................................................35
Detection of magneto coil..........................................................................................................................................36
Detection of rectifier regulator ..................................................................................................................................36
Use fault diagnosis tester...........................................................................................................................................36
Fault code table..................................................................................................................................................36
Fuel system................................................................................................................................................................38
Precautions.................................................................................................................................................................38
Disassembly schematic diagram................................................................................................................................39
Release the fuel pressure in the fuel line ...................................................................................................................44
Removal and inspection of fuel joint.........................................................................................................................44
Removal and inspection of fuel pump.......................................................................................................................45
Filter inspection.........................................................................................................................................................45
Disassembly and inspection of electric fuel pump ....................................................................................................46
Inspection of fuel pipe and fuel filter.........................................................................................................................47
Check the fuel common rail.......................................................................................................................................47
Engine........................................................................................................................................................................47
Precautions.................................................................................................................................................................47
Disassembly schematic diagram................................................................................................................................48
Special tool................................................................................................................................................................60
Check the compression pressure................................................................................................................................60
Check oil pressure......................................................................................................................................................60
Remove the engine ....................................................................................................................................................61
Pulley and timing belt................................................................................................................................................61
Disassembly and inspection.......................................................................................................................................62
Cylinder cover ...................................................................................................................................................62
Crankcase...........................................................................................................................................................66
Reinstallation.............................................................................................................................................................70
Assemble piston connecting rod........................................................................................................................70
Installing the piston rings...................................................................................................................................70
Installing piston .................................................................................................................................................70
Installing crankshaft...........................................................................................................................................70
Assemble the engine..........................................................................................................................................71
About water ...............................................................................................................................................................72
Top cover...................................................................................................................................................................72
Disassembly schematic diagram........................................................................................................................72
Disassembly and inspection...............................................................................................................................74
Bottom cover .............................................................................................................................................................74
Disassembly schematic diagram........................................................................................................................74
Disassembly and inspection...............................................................................................................................82
Steering handle..........................................................................................................................................................83
Disassembly schematic diagram........................................................................................................................83

Disassembly and inspection...............................................................................................................................84
Water unit and bracket...............................................................................................................................................85
Disassembly schematic diagram................................................................................................................................86
Disassembly and inspection of bracket......................................................................................................................95
Disassembly and inspection of water unit .................................................................................................................95
Hydraulic warping device..........................................................................................................................................96
Disassembly schematic diagram........................................................................................................................96
Disassemble.......................................................................................................................................................97
Manual warping device..............................................................................................................................................98
Disassembly schematic diagram........................................................................................................................98
Disassemble.......................................................................................................................................................99
Check the oil level.............................................................................................................................................99
Exhaust the air in the oil line of the hydraulic warping device..........................................................................99
Underwater part.......................................................................................................................................................101
Disassembly schematic diagram..............................................................................................................................101
Disassembly and inspection.....................................................................................................................................106
Propeller shaft and clutch block.......................................................................................................................106
Install the claw clutch......................................................................................................................................107
Housing cover of underwater unit ...................................................................................................................107
Install the oil seal and bearing of the housing cover........................................................................................107
Drive shaft .......................................................................................................................................................108
Shift cam..........................................................................................................................................................108
Gear .................................................................................................................................................................108
Forward gear bearing.......................................................................................................................................108
Check the housing of the underwater unit .......................................................................................................108
Check the water pipe .......................................................................................................................................108
Assemble the housing of the underwater unit..................................................................................................108
Install the underwater unit ...............................................................................................................................109
Selection of shim.....................................................................................................................................................109
Deviation value mark.......................................................................................................................................110
Pinion shim...................................................................................................................................................... 111
Forward gear shim........................................................................................................................................... 111
Reverse gear shim............................................................................................................................................111
Common faults and solutions ..................................................................................................................................112

1
Overview
Identification Mark
The serial number is printed on a label which is fixed to 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 SN indicates the following:
排量
发动机顺序号
年代号
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 at maximum load, if the throttle is half or more of the full throttle range,
the selected propeller is appropriate.
Propeller dimensions
Material
3-11
"
8
3
×12"
Aluminum alloy
3-11
"
8
1
×13"
Aluminum alloy
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 protective
gloves and safety shoes when necessary.
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Outboard motor series number
Made Year Code
Engine displacement

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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.
①Apply protective cream on both hands before overhauling the outboard motor;
②Replace and clean the clothes as soon as possible after they are contaminated by the
lubricant;
③Avoid skin contact;
④Wash your hands and skin carefully with soap and hot water after contact with the
lubricant;
⑤Wipe the spilled grease with a clean, lint-free rag.
5. Develop good work habits
①Tighten nuts, bolts and screws according to the specified torque from large size to
small size, from the center to the outside.
②Use 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.
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.
①Check engine oil level.
Pull out the oil dipstick and observe the oil level through the dipstick.

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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.
②Check gear oil level
Unscrew the oil level plug and observe whether the gear 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 with gear oil.
1. Oil level plug
3. Check the steering system.
Check whether the steering is smooth;
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.
Check the cooling water while the motor 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.
1
1
1
1
2
1
3

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③After running-in operation, run the engine at idle speed and use the washing tool to
flush the cooling water channel with fresh water.
9. After running-in operation, check the idle speed of the engine.
①Preheat the engine for 5 minutes.
②Measure the idle speed using tachometer.
If the specified value is not met, adjust it. Idle speed value: 900~1000rpm.
③After idle adjustment, accelerate the speed several times to check the engine stability.
Note:
Idle adjustment needs to be done by qualified maintenance personnel with
professional equipment; Adjusting at will may cause startup difficulty, weakness, jitter and
other faults of the engine.
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 Flywheel gripper and flywheel puller
Oil filter spanner Bearing puller Valve spring compressor kit
Underwater unit housing cover
bearing installation tool
Underwater unit housing cover
oil seal installation tool
Underwater unit housing cover
needle bearing installation tool
Underwater unit housing cover
assembly installation tool
Underwater unit needle bearing
installation tool
Drive shaft bearing jacket
installation tool

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Drive shaft bearing
installation tool
Drive shaft seal oil seal
installation kit
Forward gear bearing
casing installation kit
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