Parsun F60 BEL-D User manual

PARSUN OUTBOARD MOTOR
SERVICE MANUAL
F60/50
Suzhou Parsun Power Machine Co., Ltd.

Introduction
This Manual is a repair instruction for F50/60 and is provided by Parsun to the dealers when
maintaining or repairing Parsun outboard motors. Please read this Manual carefully before
maintaining and servicing the outboard motor. Please use the repair procedures and tools
recommended in this
Manual when repairing and maintaining the outboard motor. If other maintenance procedures and
tools are selected, please follow the instructions of experienced maintenance personnel to avoid
injury to personnel and outboard motor.
The information, drawings and technical parameters used in this Manual are subject to the prototype
at the time of publication, so there can be slight differences between the actual motor you purchased
and that described in the Manual. If necessary, the Company will distribute the revised part to the
dealers.
When the following characters appear in the Manual, please read the Manual carefully and follow
the relevant instructions and descriptions correctly and carefully.
Warning:
Failure to obey the warning may cause injuries to maintenance personnel and bystanders, and in
serious cases, this may lead to death.
Attention:
Preventive measures must be taken to prevent outboard motor from being damaged.
Note:
Provide you with key information to make your operation steps simpler and clearer.
The last part of this Manual provides the common faults and troubleshooting methods of outboard
motors, so please read them carefully, and it can help you quickly judge the status of the outboard
motor and improve your working efficiency when overhauling the motor.
It is forbidden to copy and distribute this Manual without written authorization.
Suzhou Parsun Power Machine Co., Ltd.
After-sales service: 400-882-6659
0512-66212797

Contents
Overview ..................................................................................................................................................................... 1
Identification Marks ..................................................................................................................................................... 1
Propeller Selection ....................................................................................................................................................... 1
Protective Measure at Work ......................................................................................................................................... 1
Disassembling and Assembling ................................................................................................................................... 2
Disposable Parts .......................................................................................................................................................... 2
Inspection before Delivery .......................................................................................................................................... 3
Special Tools and Testing Equipment .......................................................................................................................... 4
Decomposition Schematic Diagram and Symbolic Description .................................................................................. 5
Specifications ............................................................................................................................................................... 7
Parameters of Outboard Motor .................................................................................................................................... 7
Repair Information....................................................................................................................................................... 8
Engine .................................................................................................................................................................. 8
Measurement conditions: ..................................................................................................................................... 9
Lower casing Installation ..................................................................................................................................... 9
Electrical System ......................................................................................................................................................... 9
Ignition and Ignition Control System .................................................................................................................. 9
Locking Torque ............................................................................................................................................................ 9
Specified Torque .................................................................................................................................................. 9
General Torque .................................................................................................................................................. 10
Dimensions ................................................................................................................................................................ 11
Outline Dimension(D/T model) ......................................................................................................................... 11
Mounting dimensions of clamp bracket ............................................................................................................. 13
Basic Maintenance ..................................................................................................................................................... 14
Maintenance Interval Chart ....................................................................................................................................... 14
Fuel System ............................................................................................................................................................... 14
Engine ........................................................................................................................................................................ 15
Engine Oil Level ................................................................................................................................................ 15
Replace Engine Oil ............................................................................................................................................ 15
Valve Clearance ................................................................................................................................................. 16
Spark Plug .......................................................................................................................................................... 16
Control System .......................................................................................................................................................... 17
Throttle Cable .................................................................................................................................................... 17
Shift Operation ................................................................................................................................................... 17
Lower Casing Unit ..................................................................................................................................................... 18
Gear Oil ............................................................................................................................................................. 18
Change gear oil .................................................................................................................................................. 18
Air tightness Inspection of Lower casing Unit .................................................................................................. 18
General maintenance ................................................................................................................................................. 18
Anode ................................................................................................................................................................. 18
Lubrication Point ............................................................................................................................................... 19
Cooling Water Channel ...................................................................................................................................... 19
Thermostat ......................................................................................................................................................... 19
Propeller ............................................................................................................................................................. 20
Electrical System ....................................................................................................................................................... 20
Attention: ................................................................................................................................................................... 20
Decomposition Schematic Diagram .......................................................................................................................... 21
Wiring Diagram ......................................................................................................................................................... 27

Spark Plug Ignition .................................................................................................................................................... 29
Spark Plug Cap .......................................................................................................................................................... 29
Flywheel Maintenance ............................................................................................................................................... 29
Check the Ignition Coil .............................................................................................................................................. 29
Check the trigger coil ................................................................................................................................................. 29
Check the Engine Start Switch .................................................................................................................................. 30
Check the Engine Start Switch .................................................................................................................................. 30
Check the Starting Relay ........................................................................................................................................... 30
Check the Magneto Coil ............................................................................................................................................ 30
Check the Rectifier Regulator.................................................................................................................................... 30
How to Use the Diagnostic Scan Tool ....................................................................................................................... 31
Fault Code Table ................................................................................................................................................ 31
Fuel System ............................................................................................................................................................... 33
Attention: ................................................................................................................................................................... 33
Decomposition Schematic Diagram .......................................................................................................................... 34
Relieve the Fuel Pressure in the Fuel Lines ............................................................................................................... 39
Remove and Check the Fuel Joint ............................................................................................................................. 39
Remove and Check the Fuel Pump ............................................................................................................................ 40
Check the Fuel Filter ................................................................................................................................................. 41
Remove and Check the Electric Fuel Pump .............................................................................................................. 41
Disassembly of electric fuel pump ............................................................................................................................. 41
Check the Fuel Pipe and Fuel Filter ........................................................................................................................... 42
Check the Fuel Common Rail .................................................................................................................................... 42
Check the fuel common rail for leaks or cracks and damage, and replace it if necessary. ........................................ 42
Engine ........................................................................................................................................................................ 42
Attention: ................................................................................................................................................................... 42
Decomposition Schematic Diagram .......................................................................................................................... 43
Special Tools .............................................................................................................................................................. 55
Check the Compression Pressure ............................................................................................................................... 55
Check the Oil Pressure ............................................................................................................................................... 55
Disassemble the Engine ............................................................................................................................................. 56
Pulley and Timing Belt .............................................................................................................................................. 56
Disassembling and Check .......................................................................................................................................... 57
Cylinder Head .................................................................................................................................................... 57
Crankcase ........................................................................................................................................................... 61
Reinstall ..................................................................................................................................................................... 65
Assemble Piston Connecting Rod ...................................................................................................................... 65
Install the piston, connecting rod, piston pin and piston pin clip clutch. ........................................................... 65
Install Piston Ring .............................................................................................................................................. 65
Install Piston ...................................................................................................................................................... 65
Install Crankshaft ............................................................................................................................................... 65
Assemble the Engine ......................................................................................................................................... 65
Upper Casing ............................................................................................................................................................. 67
Top Cowling .............................................................................................................................................................. 67
Decomposition Schematic Diagram .................................................................................................................. 67
Disassembling and Check .................................................................................................................................. 68
Bottom Cowling ........................................................................................................................................................ 69
Decomposition Schematic Diagram .................................................................................................................. 69
Disassembling and Check .................................................................................................................................. 73
Steering Handle ......................................................................................................................................................... 74

Decomposition Schematic Diagram .................................................................................................................. 74
Disassembling and Check .................................................................................................................................. 76
Upper casing unit and Brackets ................................................................................................................................. 77
Decomposition Schematic Diagram .................................................................................................................. 77
Disassembling and Check of Bracket ................................................................................................................ 83
Disassembling and Check of Water Unit ........................................................................................................... 83
Manual Tilting Device ............................................................................................................................................... 85
Disassembly Schematic Diagram ...................................................................................................................... 85
Disassembling .................................................................................................................................................... 86
Hydraulic Tilting Device ........................................................................................................................................... 87
Disassembly Schematic Diagram ...................................................................................................................... 87
Disassembling .................................................................................................................................................... 88
Oil Level Check ................................................................................................................................................. 88
Discharge Air from Oil Circuit of the Hydraulic Tilting Device ....................................................................... 88
Lower casing Part ...................................................................................................................................................... 90
Decomposition Schematic Diagram(D/T model) ...................................................................................................... 90
Decomposition Schematic Diagram (CD/CT model) ................................................................................................ 97
Disassembling and Check .......................................................................................................................................... 99
Propeller Shaft and Clutch Block .................................................................................................................... 100
Install the Claw Clutch .................................................................................................................................... 100
Lower casing Unit Casing Cover ..................................................................................................................... 101
Install the Casing Cover Oil Seal and Bearing ................................................................................................ 101
Drive Shaft ....................................................................................................................................................... 101
Shift Cam ......................................................................................................................................................... 101
Gear ................................................................................................................................................................. 101
Forward Gear Bearing ..................................................................................................................................... 102
Check the Lower casing Unit Casing .............................................................................................................. 102
Check the Water Pipe ....................................................................................................................................... 102
Assemble the Lower casing Device Casing ..................................................................................................... 102
Install the Lower casing Unit ........................................................................................................................... 103
Selection of Shims ................................................................................................................................................... 104
Deviation Value Mark ...................................................................................................................................... 104
Pinion Shim ..................................................................................................................................................... 105
Shims for Forward Gear .................................................................................................................................. 105
Shims for Reverse Gear ................................................................................................................................... 105
Common Faults and Solutions ................................................................................................................................. 106

1
Overview
Identification Marks
The serial number of the outboard motor is printed on a label, which is attached to the port side of
the clamp bracket or the upper part of the rotary bracket. The serial number is shown in the
whitespace of the label to help you order spare parts from the dealer or for reference when the engine
is stolen.
1. SN of the outboard motor
The SN indicates the following:
排量
发动机顺序号
年代号
Propeller Selection
The performance of the outboard motor is seriously affected by the selection of propellers. Improper
propeller may have adverse effects on the engine. When running with heavy load, the engine will run
at low speed for a long time.
At this time, the propeller with smaller pitch should be selected, otherwise the pitch should be
selected.
Larger propeller to maintain normal operation of the engine.
When the engine is running at full throttle, refer to the speed and fuel performance of the engine for
the most suitable propeller. In this way the propeller can provide the highest performance.
Model Propeller Dimension Material
C/D Model
Gear ratio: 1.85:1
Gear box capacity:430cc
3-11 "
8
3
×12" Aluminium alloy
3-11 "
8
1
×13" Aluminium alloy
CD/CT Model
Gear ratio: 2.0:1
Gear box capacity:610cc
3-13 "
4
1
×17" Aluminium alloy
3-13 "
8
5
×13" Aluminium alloy
Protective Measure at Work
In order to prevent hazards or accidents during maintenance and improve work quality, please
observe the following safety regulations.
1. Fire control
Gasoline and various lubricating oils and greases are highly combustible, so please keep away from
heat sources, sparks and open flames when working.
2. Ventilation
Gasoline steam and engine exhaust gas are highly toxic. Massive inhalation of them can
1
Outboard motor series number
Made Year Code
Engine displacement

2
cause shock and even death. Maintain good ventilation conditions when debugging the
engine indoors.
3. Self-protection
Wear protective glasses when drilling, grinding or using air compressors. Wear
protective gloves and safety shoes when necessary.
4. Use of lubricants and sealants
When maintaining and repairing outboard motors, only products provided or
recommended by Parsun can be used.
Under normal circumstances, the lubricants mentioned in this Manual will not damage
your skin. However, please take protective measures before use to reduce risks.
○
1 Apply protective cream to both hands before overhauling outboard motors;
○
2 If clothes are contaminated by lubricant, replace and clean them as soon as possible.
○
3 Avoid contact with skin;
○
4 Please wash your hands and skin carefully with soap and hot water after touching
lubricant.
○
5 Use a clean, non-fuzzing rag to wipe off the spilled grease.
5. Developing good working habits
○
1 Tighten nuts, bolts and screws according to the specified torque from the center
outward and from large ones to small ones.
○
2 Use recommended special tools to avoid damage to parts. Use the right tools in the
right way.
Disassembling and Assembling
When disassembling and assembling an outboard motor, please observe the following
principles:
1. Use special tools when disassembling and assembling parts;
2. Remove dust and dirt before disassembling parts;
3. Apply engine oil to the contact surface of moving parts before assembly;
4. When installing the bearing, place the manufacturer's mark in the specified direction
and lubricate it fully.
5. Before installation, coat a thin layer of waterproof lubricating oil on the protruding part
and periphery of the oil seal;
6. After the assembling is completed, check whether the moving parts are working
properly.
Disposable Parts
Parts such as gaskets, oil seals, O-rings, cotter pins and spring rings are disposable parts and must be
replaced when reinstalling the outboard motor.

3
Inspection before Delivery
In order to ensure the normal use of the products by customers, please carry out the following
inspections before delivery.
1. Check the fuel system.
Check that the fuel hose is securely connected and that the fuel tank is full of fuel.
Attention:
This is a four-stroke engine and premixed fuel cannot be used.
2. Check oil level.
○
1 Check engine oil level.
Pull out the oil dipstick and observe the oil level through the oil dipstick.
1. Oil dipstick 2. High position mark 3. Low position mark
Ensure that the oil level is between the high position mark and the low position mark;
Drain the oil when the oil level is higher than the high position mark, and add oil when it is lower
than the low position mark.
○ 2 Check gear oil level
Unscrew the oil level hole plug and observe whether there is oil overflow from the oil
level plug hole.
If yes, install the oil level hole plug and tighten it according to the specified torque. If
not, fill in oil.
1.Oil level hole plug
3. Check the steering system.
Check whether the steering is smooth;
4. Check shift and throttle operation.
Check whether the gear shift operation is smooth; Check whether the throttle grip
operates smoothly from the fully closed position to the fully open position.
5. Check the emergency stop switch assembly.
Check whether the engine stops when the emergency stop switch assembly is pressed or
the motor stop safety rope is pulled out.
6. Check the cooling water observation hole.
When the engine is running, check whether the cooling
water is flowing out of the cooling water observation hole.
1. Cooling water observation hole
1
1
2
3

4
7. Running-in operation.
① The 1st hour: Run the engine at 2000 rpm or at about half the throttle.
② The 2nd hour: Run the engine at 3000 rpm or at about 3/4 of the throttle.
③ Next 8 hours: Avoid running the motor at full throttle for 5 consecutive minutes.
8. Check after running-in operation
① Check the gear oil for water.
② Check the fuel oil pipeline for leaks.
③ After running-in operation, run the engine at idle speed and flush the cooling
water channel with fresh water using flushing tools.
9. After running-in operation, check the idle speed of the engine.
① Preheat the engine for 5 minutes.
② Use a tachometer to measure the idle speed of the engine.
Make corresponding adjustment if it does not conform to the specified value. Idle
value: 750 ~ 850rpm.
③ Turn the throttle stop screw clockwise or counterclockwise until the specified idle
speed is reached.
④ After adjusting the idle speed, speed up several times to check the stability of the
engine.
Attention:
Idle speed adjustment needs to be carried out by qualified maintenance personnel using
professional equipment; Random adjustment may cause starting difficulties, weakness, jitter
and other faults of the engine.
Special Tools and Testing Equipment
Various special tools and testing equipment will be used in the repair and maintenance of outboard
motors. Skilled and correct use of these tools and equipment can help improve your work efficiency
avoid damage to personnel and outboard motors.
Special tools:
Clearance gauge Piston slideway Flywheel gripper and
flywheel puller
Oil filter spanner Bearing puller Valve spring compressor kit
1

5
Bearing mounting tool Oil seal mounting tool Needle bearing mounting tool
Lower unit Lower unit Lower unit
Shell cover tool Needle bearing tool Drive shaft bearing
Lower unit Lower unit cover mounting tool
Drive shaft bearing Drive
shaft seat oil seal Forwarder gear bearing
mounting tool mounting kit mounting tool kit
Drive shaft spline sleeve Pinion nut wrench
Testing equipment:
Digital tachometer Digital multimeter Peak voltage adapter
Decomposition Schematic Diagram and Symbolic Description

6
Decomposition schematic description
10
9
12
5
4
11
19
1817
放油螺塞垫片
机油尺组件
PLATE ,ANODE
阳极锁止片
F15-07010012
WASHER
平垫圈6
GB/T97.1-1985
BOLT
六角螺栓M6x20
GB/T5783-2000
六角螺栓M5x12
平垫圈5
BOLT
GB/T5783-2000
WASHER
GB/T97.1-1985
SEAL.ANODE
COVER ,ANODE
阳极盖板
F15-07010011
F15-07010009 阳极密封圈
ANODE
阳极
F25-02010005
22
21
20
19
18
17
16
15
1
1
1
1
1
1
1
1
REMARKSDESCRIPTIONPART NO. DESCRIPTION
零件名称(中文) 零件名称(英文)
1
6
2
3
4
5
7
8
9
10
11
12
13
14
1
1
1
1
1
1
WASHER ,PLAIN 15
13
HEXAGON BOLT
HEXAGON BOLT
2
2
2
1
1
1
F25-00000100
F25-02010100
F25-02010006
GB/T97.1-2000
GB/T5783-2000
F25-02010200
GB/T5783-2000
F25-00000014
F25-02000006
F25-02010007
F15-00000006
F15-04000003
F15-04000002
六角螺栓M6x25
粗滤器组件
六角螺栓M6X16
定位销8x12
油底壳
排气歧管座垫
定位销6x12
放油螺塞
放油口胶套
平垫圈6
溢流阀垫片
溢流阀组件 RELIEF VALVE AUY
HEXAGON BOLT
STRAINER,OIL
F25-02000007
GASKET
PLUG,OIL LEVEL
PIN,DOWEL
OIL SUMP
PIN,DOWEL
BOLT,OIL DRAIN
JACKET,OIL DRAIN
22 21
20
①
④
13
M14x12 mm
27 Nm
14
G②
③
○
1 Decomposition schematic diagram of parts.
○
2 Thread specification and specified torque.
○
3 Application point of oil, sealant or locker.
○
4 Parts list
Symbolic description
O G
L
1277
L
1243
GM
Apply engine
oil
Apply waterproof
grease
Apply thread
locker 1277
Apply thread
locker 1243 Apply sealant

7
Specifications
Parameters of Outboard Motor
Item Data Item Data
Dimension
Overall length
(BE/FE) 1383/713 mm
Engine
Spark plug DPR7EA-9 (NGK))
Overall width 427 mm Cooling system Water cooling
Overall
height
D/T 1435 mm Exhaust system Through the propeller
hub
CD/CT 1476 mm Lubrication system Pressure lubrication
Height of stem
board 508 mm
Fuel and
oil
Fuel type Ordinary unleaded
gasoline
Weight
BEL-D/BEL-CD 113 kg/126.5 kg Fuel grade PON86
BEL-T/BEL-CT 114.5 kg/128 kg Engine oil type Four-stroke engine oil
FEL-T/FEL-CT 113.5 kg/127 kg Engine oil
grade
API SE, SF, SG, SH, SJ
Performance
Max.
output
F50 36.8Kw@5500r/m
in SAE 10W30, 10W40
F60 44.1Kw@5500r/m
in Engine oil level
2.2L (replace filter)
Full throttle
operating range 5000～6000 r/min 2.0L (do not replace filter)
Max.
fuel
consump
tion
F50 18.5 L/h@6000
r/min Gear oil type Hypoid gear oil
F60 20 L/h@6000
r/min Gear oil grade API GL-4
Idle (neutral) 800±50 r/min SAE 90
Engine
Engine type In-line four-stroke,
overhead cam Gear oil level
D/T 0.43L
Number of
cylinders 4 CD/CT 0.61L
Displacement 996 cm³
Bracket
Tilt raise angle 69°
Bore×Stroke 65 mm×75 mm Steering angle 40°+40°
Compression ratio 9.3 Trim angle -4°～20° (when stem
board is 12°)
Oil supply mode
Electronically
controlled fuel
injection
Drive
device
Gear F-N-R
Control
mode
BE Steering handle Transmissi
on ratio
D/T 2.08
FE Remote control CD/CT 2.0
Starting mode Electrical starting Gear type Spiral bevel gear
Ignition system ECU Clutch type Claw clutch
Ignition
timing
TDC 2°±0.5° Propeller shaft type Spline
BTDC 25°±0.5° Propeller direction Clockwise (rear view)

8
Repair Information
Engine
Item Data Item Data
Drive
device
Min. compression pressure 840 kPa Diameter of piston 64.950~64.965m
m
Lubricating oil pressure 100 kPa Height of measuring point 5mm (from
bottom of piston)
Cylinder
head
Bending limit 0.03mm Piston-to-cylinder clearance 0.035~0.065mm
Inside diameter of camshaft
bore
37.00~37.02mm Piston pin hole aperture 15.974~15.985m
m
Inner diameter of shaft hole of
rocker arm
16.000~16.01m
m Piston pin outer diameter 15.965~15.970m m
Cylinder
block
Cylinder bore 65.00~65.013m
m
Piston ring
Top
ring
Thickness 1.17~1.19mm
Wear limit 65.1mm Width of end face 2.25~2.4mm
Taper limit 0.08mm End gap 0.15~0.30mm
Roundness limit 0.05mm Backlash 0.02~0.06mm
Second ring
Thickness 1.47~1.49mm
Va lv e s pr in g
Free length 40.0mm
Width of
end face 2.60~2.80mm Min. free length 38.4mm
End gap 0.30~0.50mm Tilt limit 1.7mm
Backlash 0.02~0.06mm
Connecting
rod
Inner diameter of small end 15.985~15.998m
m
Oil ring
Thickness 2.36~2.48mm Inner diameter of big end 36.000~36.016m
m
Width of end
face 2.75mm Large head oil clearance 0.020~0.052mm
End gap 0.20~0.70mm Thickness
of big-end
bearing
A black 1.496~1.490 mm
Backlash 0.04~0.18mm B brown 1.490~1.484mm
Camshaft
Height
Intake cam 30.83~31.03mm
Oil pump
Type Cycloid pump
Exhaust
cam 30.83~31.03mm Pressure relief valve opening pressure 382~442 kPa
Diameter of base circle 25.90~26.10mm Clearance between outer
rotor and casing 0.09~0.15 mm
Journal diameter 36.935~36.955
mm
Clearance between outer
rotor and inner rotor 0.12 mm
Roundness limit 0.03mm Clearance between rotor
and cover 0.03~0.08 mm
Clearance between journal and
oil 0.045~0.085mm
Crankshaft
Diameter of crankshaft
main journal
42.984~43.000
mm
Va lv e
Valve clearance
(Cold state)
Intake valve 0.15~0.25mm Crank pin diameter 32.984~33.000
mm
Exhaust
valve 0.25~0.35mm Crank pin width 21.00~21.07mm
Valve cone
Width
Intake valve 1.84~2.97mm Crankshaft big-end backlash 0.05~0.22mm
Exhaust
valve 1.98~3.11mm Roundness limit 0.05mm
Width of contact with race 0.9~1.1mm
Thermostat
Opening temperature 58~62ºC
Edge thickness
Intake valve 0.8mm Full open temperature 70ºC
Exhaust
valve 0.9mm Mini. opening height of valve 3mm
Head diameter
Intake valve 31.9~32.1mm
Fuel pump
Displacement 70 L@6000 r/min
Exhaust
valve 25.9~26.1mm Pressure 49kPa
Rod diameter
Intake valve 5.475~5.490mm Plunger stroke 5.85~9.65 mm
Exhaust
valve 5.460~5.475mm
Crankcase
Inner diameter of crankshaft
main journal
46.000~46.024m
m
Inner diameter of pipe 5.500~5.512mm Clearance between
crankshaft main journal and 0.012~0.044mm

9
oil
Clearance between pipe and
valve stem clearance 0.025~0.052mm Thickness of
crankshaft
bearing
bush
A black 1.500~1.494 mm
Valve stem roundness limit 0.03mm B brown 1.494~1.488mm
Measurement conditions:
Ambient temperature 20 ℃.
Lower casing Installation
Item Data Item Data
Backlash
Pinion to spur gear 0.18~0.54mm Optional gear
shim
0.10,0.12,0.15,0.18, 0.30,0.40,0.50
mm
Pinion to reverse gear 0.71 ~ 1.07 mm
Electrical System
Ignition and Ignition Control System
Item Data Item Data
Ignition
timing
At idle speed TDC 2º±0.5° Magneto resistance (Green-Green) 0.59±0.1Ω
Optional gear filler
plate BTDC 25°±0.5º Peak output
of electronic
igniter
Voltage
Secondary output voltage ≥ 34KV
Spark plug clearance 0.8~0.9mm Primary resistance 2.2±0.22Ω
Trigger
coil
Peak voltage ≥13 V@1000 r/min Secondary resistance 9.84±0.98KΩ
Resistance* 260～290 Ω Rectifier
regulator
output peak
voltmeter
1500 r/min (no load) 41.9 V
Magneto
output
peak
voltage
1500 r/min (no load) 47.2 V 3500 r/min (no load) 99.8 V
3500 r/min (no load) 106 V
* Data for information only
Locking Torque
Specified Torque
Position Name Thread
specification Torque
Engine
Spark plug — — 18 Nm
Flywheel Nut M20 160 Nm
Cylind
er head
1st tightening
Bolt M9
23Nm
2nd tightening 47 Nm
1st tightening
Bolt M6
6 Nm
2nd tightening 12 Nm
Oil filter — — 18 Nm
Oil filter stud — — 40 Nm
Lock nut (rocker arm) Nut M6x0.75 14 Nm
Engine assembly Bolt M8 21 Nm
Exhaus
t cover
plate
1st tightening
Bolt M6
6 Nm
2nd tightening 12 Nm
Thermostat cover Bolt M6 7Nm
Crankc 1st tightening Bolt M8 15 Nm

10
ase 2nd tightening 30 Nm
1st tightening
Bolt M6
6 Nm
2nd tightening 12 Nm
Connec
ting rod
1st tightening
Bolt M6
6 Nm
2nd tightening 17 Nm
Driven pulley Bolt M10 38 Nm
Lower
casing unit
Lower casing assembly Bolt M10 40Nm
Ring nut — — 105Nm
Water inlet Screw M5 5 Nm
Oil drain bolt Bolt — 7Nm
Oil check hole Bolt — 7 Nm
Pinion gear Nut M22 95 Nm
Propeller nut Nut M14 35 Nm
Upper
Casing
Steering handle Nut M10 10 Nm
Steering handle Self-locking nut M10 22 Nm
Exhaust manifold Bolt M6 10 Nm
Throttle grip Screw M5 3 Nm
Shift linkage bracket Bolt M6 10 Nm
Gear spring piece Bolt M6 10 Nm
Bottom cover flat Bolt M6 10 Nm
Clamp bracket Self-locking nut — 45 Nm
Oil drain bolt Bolt M14 27 Nm
Tilting
system
Inclined cylinder end Screw — 90 Nm
Tilting motor Screw M5 4 Nm
Fuel tank cap — — 6.5 Nm
Trim cylinder end Screw — 80 Nm
Tilt piston Bolt M12 61 Nm
Pressure relief valve bracket Bolt M5 5.3 Nm
Gear pump assembly Bolt M6 6.5 Nm
Gear pump bracket Bolt M5 5.3 Nm
Electrical
system
Trigger coil Screw — 4 Nm
Starter motor
Nut — 30 Nm
Bolt M8 30 Nm
Starter motor terminal Nut — 7 Nm
Magneto coil Bolt M6 7 Nm
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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Dimensions
Outline Dimension(D/T model)

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Outline Dimension (CD/CT model)

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Mounting dimensions of clamp bracket

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Basic Maintenance
Maintenance Interval Chart
Item Content
Initial maintenance
General
maintenance
interval
10 hours
(1 month)
50 hours
(3 month)
100
hours
(6
month)
200
hours
(1 year)
Anode Check/replace ○ ○
Anode (internal) Check/replace ○
Cooling water channel Clean ○ ○
Spark plug Clean/adjust/replace ○ ○
Grease filling point Add grease ○
Fuel filter Check/replace ○ ○ ○
Fuel system Check ○ ○ ○
Fuel tank Check/clean ○
Idle speed Check/adjust ○ ○
Engine oil Replace ○ ○
Oil filter Replace ○
Valve clearance (OHC) Check/adjust ○ ○
Ignition timing Check ○ ○
Thermostat Check ○
Gear oil Replace ○ ○
Water pump Check ○
Propeller and cotter
pin Check/replace ○ ○
Timing band Check/replace ○ ○
Throttle cable Check/adjust ○
Shift lever/shift cable Check/adjust ○
Attention:
Flush the outboard motor with fresh water immediately after operation in brine, sewage or
muddy water.
If leaded petrol is frequently used, check valves and related parts every 100 hours.
Replace the timing band every 1000 hours (5 years).
Fuel System
1. Check the fuel tank, fuel pump and fuel pipe.
Check the fuel tank, fuel pump and fuel pipe for leaks or damage and replace it if
necessary.
Check the fuel oil filter core on the oil tank for any dirt, and clean or replace it if
necessary.
2. Check the fuel joint.
Check the fuel joint for cracks, leaks or damage. Replace it if necessary.

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3. Check the fuel filter.
Check whether the fuel filter is cracked or damaged, and check whether there is any dirt
in the fuel filter.
If yes, replace the fuel filter.
Attention:
Wipe up the spilled fuel.
Engine
Engine Oil Level
1. Remove the oil dipstick and check whether the oil level is between the upper and
lower marks of the oil dipstick.
1. Oil dipstick 2. High position mark 3. Low position mark
2. Drain the oil if it is above the high position mark, and add oil if it is below the low
position mark.
Attention:
Turn off the engine after running it and let it stand for several minutes. Check the oil level again with
the oil dipstick.
If the oil level is not within the specified range, add/drain oil to the specified value.
Replace Engine Oil
1. Remove the oil cap, oil drain bolt and bolt gasket; Drain the oil out.
2. Install a new bolt pad and install the oil drain bolt.
3. Add engine oil through the oil port.
Engine oil level: 2.0 L (The oil filter is not replaced)
2.2 L (oil filter is changed)
Oil type: API： SE, SF, SG, SH, SJ or SAE: 10W30, 10W40
4. Install oil filter cap.
5. Check oil level.
2
3
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