Parsun F4BM User manual

PARSUN OUTBOARD ENGINE
SERVICE MANUAL
F4BM (F5BM)
SUZHOU PARSUN POWER MACHINE CO., LTD.
https://www.boat-manuals.com/

NOTICE
This manual includes service instructions for F4, F5, 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.
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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INDEX
GENERAL INFORMATION··········································1
IDENTIFICATION·
············································1
PROPELLER SELECTION·····································1
EMERGENCY START··········································1
SAFETY WHILE WORKING···································3
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
Ignition system·
···········································11
TIGHTENING TORQUE·
·····································11
Specified torque············································11
General torque··········································12
PERIODIC SERVICE·
··············································13
MAINTENANCE TIME TABLE······························13
FUEL SYSTEM··············································13
POWER UNIT·············································14
Engine oil level···········································14
Changing engine oil·
······································15
Valve clearance··········································15
Spark plug·
··············································16
CONTROL SYSTEM·
······································16
Throttle grip·
············································16
Idling speed············································17
Start-in-gear protection·
···································17
LOWER UNIT·············································18
Gear oil·
··················································18
Changing gear oil·
·····································18
Lower unit leakage check·
·································19
GENERAL INSPECTION·
·····································19
Anode·
················································19
Grease points·
···········································19
Cooling water passage·
··································19
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RECOIL STARTER·················································20
NOTICE···················································20
EXPLOSIVE DRAWING·
·····································21
DISASSEMBLING···········································24
START ROPE REPLACEMENT································24
DISASSEMBLING AND INSPECTION·························25
ASSEMBLING···············································26
INSTALLATION············································26
IGNITION SYSTEM·
···············································27
NOTICE·
··················································27
EXPLOSIVEDRAWING······································27
WIRING DIAGRAM··········································28
SPARK PLUG IGNITION·
····································28
SPARK PLUG CAP···········································29
FLYWHEEL MAINTENANCE·
·······························29
IGNITOR ASS’Y COIL INSPECTION···························29
FUEL SYSTEM·
···················································30
NOTICE····················································30
EXPLOSIVE DRAWING······································30
FUEL TANK REMOVAL AND INSPECTION·····················36
OIL SWITCH REMOVAL AND INSPECTION····················37
FUEL JOINT REMOVAL AND INSPECTION·
···················37
FUEL PUMP REMOVAL AND INSPECTION·
···················38
INTAKE SYSTEM REMOVAL AND INSPECTION···············39
POWER UNIT·····················································40
NOTICE···················································40
EXPLOSIVE DRAWING······································40
SPECIAL TOOLS···········································49
DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE···49
DISASSEMBLING AND INSPECTION··························49
CYLINDER COVER·
·····································50
Disassembling·······································50
Push rod············································50
Valve and valve pipe·
··································50
Valve spring··········································51
Valve rocker arm·
····································51
Valve pipe replacement·······························51
Valve seat inspection·
··································51
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Valve seat cutting·····································52
Thermostat··········································53
CRANKCASE·
···········································53
Disassembling·······································53
Breather·············································53
Piston··············································54
Cylinder bore········································54
Piston pin diameter···································54
Piston ring···········································54
Camshaft decompressor································54
Crankshaft········································55
Oil clearance·········································55
Valve lifter··········································55
Oil splash gear········································55
Crankshaft bearing···································55
Oil seal housing·····································56
Crankcase and crankcase cover·························56
FULL INSTALLATION·
··································56
Piston connecting rod installation·
·······················56
Piston ring installation·································56
Piston installation····································56
Oil seal housing installation·····························57
Crankshaft installation································57
Camshaft installation························57
Crankcase cover installation····························58
UPPER UNIT······················································58
TOPCOWLING············································58
Explosive drawing·······································58
Disassembling and inspection·
·····························61
BOTTOM COWLING·
······································61
Explosive drawing·······································61
Disassembling and inspection······························63
STEERING HANDLE·
·······································64
Explosivedrawing·
······································64
Disassembling and inspection·····························66
BRACKET··················································68
Explosive drawing······································68
Disassembling and inspection······························71
UPPER UNIT··
··············································73
Explosive drawing······································73
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Disassembling and inspection······························75
LOWER UNIT····················································76
WATERPUMPASSEMBLY···································76
Explosivedrawing·
······································76
Disassembling and inspection······························78
LOWER UNIT···············································79
ExplosiveDrawing·
·····································79
Disassembling and inspection······························83
Propeller shaft and clutch block·························84
Clutch block installation·
·····························84
Lower casing cover····································84
Lower casing cover oil seal and bearing installation·
········84
Barrel bearing·
······································85
Drive shaft···········································85
Gear················································85
Forward gear bearing·······························85
Lower unit casing·····································85
COMMON TROUBLES AND SOLUTIONS·
··························86
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GENERAL INFORMATION
IDENTIFECATION
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.
1
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
7 1/4×8
7 1/2×7
7 1/4×6 1/2 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
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
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parts.
The procedure is as follows:
1. Remove the top cowling.
2. Remove the start-in-gear protection device cable, and remove the chock lever cable.
1.Start-in-gear protection device cable 2. Chock lever cable
3. Demount three bolts and remove starter.
4. Assemble two bolts to fix the fuel tank.
5. Insert the knot of the cable in the notch of flywheel rotor, and wind the cable around flywheel
several rounds in clockwise direction.
6. Pull the manual starter handle slowly until you feel resistance.
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7. 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.
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.
A summary of the most important precautions is as follows:
○1 To protect the skin, the application of a suitable barrier cream to the hands before working is
recommended.
○2 Clothing which has become contaminated with lubricants should be changed as soon as
practicable, and washed before further use.
○3 Avoid skin contact with lubricants.
○4 Hands 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.
○5 A supply of clean lint-free cloths should be available for wiping run-off lubricants or grease.
5. GOOD WORKING PRACTICES
○1 Follow the tightening torque instruction. When tightening bolts, nuts and screws, tighten
the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.
○2 Use 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:
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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.
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.
2
3
1
4
1. Oil cap 2. Oil rule 3. High position mark 4. 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
1. Oil level plug
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
1
4. CHECK SHIFT LEVER AND THROTTLE
Check if the shift lever is operated smoothly.
Check if the throttle grip is turned smoothly from full closed position to full open position.
5. CHECK ENGINE STOP SWITCH ASSY
Check if the engine stops when pushing the engine stop switch assembly or pulling out the
stopper hang rope.
6. CHECK COOLING WATER CHECKING HOLE
When the engine is running, check if
cooling water overflows at the cooling
water checking hole.
1
1. Cooling water checking hole
7. BREAKING-IN RUNNING
○ 1 Initial 1 hour: operate the engine at 2000 r/min or about a half throttle.
② The second hour: operate the engine at 3000 r/min or about 3/4 throttle.
③ The following 8 hours: operate the engine at full throttle continuously. Each operation
time doesn’t exceed 5 minutes.
8. INSPECTION AFTER BREAKING-IN RUNNING
○
1 Check if gear oil contains water.
②Check if the fuel line leaks.
③After breaking-in running, operate the engine at idling speed. Use cleaning tool to wash
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over the cooling water passage by fresh water.
9. After breaking-in running, inspect idling speed.
① Preheating engine for 5 minutes.
②Using the tachometer to measure idling speed RPM.
If out of specification, adjust it.
Idling speed: 1450~1550 r/min
③Turn the throttle stop screw clockwise or counter clockwise
until the specified idling speed is attained.
④After adjusting idling speed, picking up RPM several times to check the engine’s stability.
SPECIALTOOLS 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.
SPECIALTOOLS:
Pistonslider Flywheelholderandpuller Bearingpuller
Valve spring compressor Housing bearing installer Lower casing cover bearing installer
Oil seal installer tool Housing oil seal installer Space gage
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Barrel bearing with guard board installer tool Lower casing bracket and
barrel bearing without guard board installer tool
Lower casing bracket and drive shaft oil seal installer tool
DETECTION DEVICE:
Digitaltachometer Digitalcircuittester Peakvoltageadaptor
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EXPLOSIVE DRAWINGAND SYMBOL
EXPLOSIVE DRAWING
14
15
L
1277
G
G
1277
L
M6x45 mm
1st 3Nm
2nd 8Nm
M6x25 mm
1st 3Nm
2nd 8Nm
①
②
③
④
1
2
3
4
5
6
7
8
9
10
六角头螺栓M6×45
泵壳固定板
水泵座定位销
水泵壳
泵壳密封垫
水泵内壳
水泵叶轮
外档板
泵壳橡胶管
4
2
1
2
1
1
1
1
1
1
OUT PLATE
PIN ,WATER PUMP
HEXAGON BOLT
F4-03000014
F4-03000015
F4-03060000
F4-03000017
F4-03000018
F4-03000019
F4-03000013
F4-03000021
F4-03000020
DESCRIPTION
PART NO. REMARKS
① Parts explosive drawing
② Oil, fluid sealant or locking substance daubing point
③ Screw specification and specified torque
④ Spare parts details
SYMBOL
O G L
1277
L
1243
Daub engine oil Daub waterproof
grease Daub screw locking substance 1277 Daub screw locking substance 1243
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SPECIFICATIONS
OUTBOARD ENGINE SPECIFICATIONS
Item Description Item Description
Overall length 717mm Starting
enrichment Choke valve
Overall width 361mm Spark plug BPR7HS
S 1029mm Exhaust system Under water
Dimension
Overall
height L 1156mm
Power Unit
Lubrication
system Splash lubrication
S 24.5kg Fuel type
Unleaded regular
gasoline
Weight
L 25.5kg Fuel standard PON86、RON91
2.9Kw(4hp)@4500r/min
Max output 3.6Kw(5hp)@5000r/min Fuel tank
capacity 1.3L
Full throttle
operation 4000～5000r/min Recommended
engine oil
API SE, SF, SE-SF,
SG-CD SAE
10W30, 10W40
Max fuel
consumption 1.6L/h@5000r/min Engine oil
quantity 0.5L
Performance
Idle speed（Neutral）1500±50 r/min Recommended
gear oil Hypoid gear oil SAE﹟90
Type 4 stroke, OHV
Fuel and Oil
Gear oil quantity 100 mm3
Number of cylinders 1 Tilt angle 4o，8o，12 o，
16o，20o
Displacement 112cm³ Tilt-up angle
76o
Bore×Stroke 59mm×41mm Shallow water
cruising angle 30o, 42 o, 54o
Compression ratio 8.4
Bracket
Steering angle 360o
Compression
pressure 660kPa Gear positions F-N-R
Number of
carburetors 1 Gear ratio 2.08
Control system Tiller control Gear type Bevel gear
Starting system Recoil starter Propeller
direction Clockwise
Power Unit
Ignition control
system T.C.I
Drive Unit
Propeller drive
system Spline
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MAINTENANCE INFORMATION
Power Unit
Item Description Item Description
Intake 0.10±0.02mm
Cylinder
Head
Warp limit 0.1mm Valve
clearance
(cold) Exhaust 0.10±0.02mm
Bore 59.00~59.02mm Intake 1.84~2.26mm
Wear limit 59.1mm Face width Exhaust 1.84~2.26mm
Taper limit 0.08mm Intake 0.6~0.8mm
Cylinder
Out of round limit 0.05mm Seat width Exhaust 0.6~0.8mm
Piston diameter 58.950~58.965mm Intake 0.7mm
Measuring point
height
10mm (from the
bottom of piston）
Margin
thickness Exhaust 1.0mm
Piston-to-cylinder
clearance 0.035~0.065mm Intake 23.9~24.1mm
Piston
Pin boss inside
diameter 13.009~13.017mm
Head
diameter Exhaust 21.9~22.1mm
Piston pin outside diameter 12.995~13.000mm Intake 5.475~5.490mm
Thickness 1.5mm
Stem outside
diameter Exhaust 5.460~5.475mm
Breadth 2.6mm Intake
End gap 0.10~0.20mm Guide inside
diameter Exhaust 5.500~5.512mm
Wear limit 0.40mm Intake 0.010~0.037mm
Top ring
Side clearance 0.04~0.08mm
Valve
Stem to
guide
clearance Exhaust 0.025~0.052mm
Thickness 1.5mm Push rod runout limit 0.5mm
Breadth 2.6mm Free length 35.0mm
End gap 0.25~0.40mm Free length limit 34.0mm
Wear limit 0.60mm
Valve
spring
Tilt limit 1.2mm
2nd ring
Side clearance 0.02~0.06mm Small end inside
diameter. 13.006~13.02mm
Thickness 2.5mm
Connecting
rod
Big end oil
clearance 0.016~0.046mm
Breadth 2.6mm Crankshaft width 64.4~64.5mm
End gap 0.20~0.70mm Big end side
clearance 0.2~0.6mm
Piston ring
Oil ring
Wear limit 0.90mm
Crankshaft
Round limit 0.03mm
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Cont’d Item Description Item Description
Intake 26.736~26.836mm Valve opening
temperature 58~62ºC
Height
Exhaust 26.532~26.623mm Full-open
temperature 70ºC
Round diameter 21.950~22.050mm
Thermostat
Valve lift 3mm
Journal diameter 14.966~14.984mm Discharge 8L/h
Camshaft
Camshaft round limit 0.03mm Pressure 50kPa
Valve lifter outside diameter 7.978~7.987mm
Fuel
pump
Plunger stroke 1.8~2.2mm
Ignition system
Item Description Item Description
Ignition timing BTDC28º ~32º Spark plug gap 0.6~0.7mm
T.C.I system output
peak voltage 130V Primary coil 0.7~0.96Ω
T.C.I air gap 0.4~0.6mm
Ignitor
ass’y
resistance Secondary coil 5.8~7.0KΩ
TIGHTENING TORQUE
Specified torque
Part to be tightened Part name Thread size Quantity Torque
Oil drain Bolt M8 1 20Nm
Spark plug —M14 1 25 Nm
Recoil starter Bolt M6 3 8 Nm
Flywheel rotor ass’y Nut M10 1 44 Nm
Carburetor Bolt M6 2 8 Nm
Intake manifold Bolt M6 2 8 Nm
Cylinder head cover Bolt M6 4 11 Nm
1sttightening 15 Nm
2ndtightening Bolt M8 4
30 Nm
1st tightening 6 Nm
Cylinder
head
2ndtightening Bolt M6 1 11 Nm
Rocker arm screw bolt Bolt M6 2 10 Nm
Locknut (rocker arm) Nut M6x0.75 2 10 Nm
Oil seal housing Bolt M8 1 18 Nm
Power unit mounting Bolt M6 7 8 Nm
Thermostat cover Bolt M6 3 8 Nm
Breather cover Bolt M6 3 8 Nm
1st tightening 10 Nm
Power unit
Crankcase 2nd tightening Bolt M8 7
22 Nm
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Cont’dPart to be tightened Part name Thread size Quantity Torque
Connecting rod Bolt M7 2 12 Nm
Power unit
Oil splash gear unit Bolt M6 1 8 Nm
1st tightening 3 NmLower unit
mounting 2nd tightening Bolt M6 2
8 Nm
1st tightening 6Nm
Lower unit
housing
cover 2nd tightening Bolt M6 2
11 Nm
1st tightening 3 Nm
Anode 2nd tightening Bolt M6 1
8 Nm
1st tightening 3 NmWater pump
housing 2nd tightening Bolt M6 4
8 Nm
1st tightening 3 Nm
Lower unit
Water pump
base 2nd tightening Bolt M6 1
8 Nm
Steering handle mounting Bolt M8 1 18 Nm
Shift lever bracket Bolt M6 1 4.5 Nm
1st tightening 3 NmBracket fixed
cover 2nd tightening Bolt M6 2
8 Nm
1st tightening 3 Nm
Tilt lock plate 2nd tightening Nut M6 2
8 Nm
1st tightening 3 NmSwivel
bracket 2nd tightening Nut M6 6
8 Nm
Upper Unit
Clamp bracket Nut M8 1 13 Nm
Ignitor ass’y Bolt M6 2 8Nm
General torque
Nut (a) Bolt (b) Torque
8mm M5 5Nm
10mm M6 8 Nm
12mm M8 18 Nm
14mm M10 36 Nm
17mm M12 43 Nm b
a
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PERIODIC SERVICE
MAINTENANCE TIME TABLE
Initial maintenace General maintenance
period
Items
Contents
10 hours
（1 month）50 hours （3 months）100 hours
（6 months）
200 hours
（1 year）
Anode Inspection/replacement ○○
Spark plug Cleaning/adjustment
/replacement ○○○
Grease points Greasing ○
Bolts and nuts Inspection ○○
Fuel tank and fuel line Inspection ○
Fuel filter Inspection/replacement ○○○
Fuel cock Inspection/replacement ○○
Carburetor Inspection/replacement ○○
Throttle cable Inspection/replacement ○○
Idling speed Inspection/ adjustment ○○
Start-in-gear projection Inspection/ adjustment ○○
Engine oil Replacement ○○
Valve cleanrance Inspection/ adjustment ○○
Ignition timing Inspection ○○
T.C.I air gap Inspection/ adjustment ○○
Thermostat Inspection ○
Cooling water passage Inspection/Cleaning ○○
Gear oil Replacement ○○
Water pump Inspection ○
Propeller Inspection/replacement ○○
CAUTION:
After running the outboard engine in salt water, waste water or mud water, wash
over the engine by fresh water immediately.
If using leaded gasoline frequently, check the valve and components each 100 hours.
FUEL SYSTEM
1. CHECK FUEL TANK, CARBURETOR, FUEL PUMPAND 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 it if necessary.
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2. CHECK FUEL COCK AND FUEL JOINT
Check if fuel cock and fuel joint are cracked, damaged or leaking.
Replace if necessary.
3. CHECK FUEL FILTER
Check if fuel filter is cracked, damaged or has dirt inside.
If so, replace it.
CAUTION:
The arrow mark of the fuel filter must face toward the fuel pump.
Clean the spilled oil.
POWER UNIT
Engine oil level
a) Remove oil level plug, check engine oil level, if between the following marks of the upper and
lower.
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