Parsun T40J BM User manual

OUTBOARD MOTOR
OWNER’S MANUAL
T40J BM/BW/FW
T40G BM/BW/FW
SUZHOU PARSUN POWER MACHINE CO., LTD.

Thank you for owning a PARSUN outboard motor.
Thank you for your trust in our company and products.
“PARSUN” outboard motors are powerful, economic and safe with advanced
technology and processing technique.
Please read this manual carefully before operating your outboard motor. A thorough
understanding of the manual will help you to know this product for proper operation,
maintenance and care. This will ensure that your outboard motor is operated well under
various conditions.
“PARSUN” seeks continuous improvement in product quality. Therefore, while this
manual contains the most current product information available at the time of printing, there
may be minor discrepancies between your machine and this manual. If there is any question
concerning the manual, please consult your local PARSUN dealer.
Data, illustrations or explanations in this Owner’s Manual do not constitute base for any
legal claim against our company.
SUZHOU PARSUN POWER MACHINE CO., LTD

Engine Identification Numbers
Outboard motor serial number
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. Outboard motor serial number location
Serial number as follows: SN
1

Engine serial number
The engine serial number is carved on the aluminum casting of engine.
Serial number as follows:

Table of contents
1. Main components and General information ..................................................................................................... 1
1.1 Main components........................................................................................................................................... 1
1.2 General information........................................................................................................................................ 5
1.2.1 Specifications.............................................................................................................................................. 5
1.2.2 Fueling instructions..................................................................................................................................... 6
1.2.3 Propeller selection....................................................................................................................................... 7
2. Operation......................................................................................................................................................... 8
2.1 Installation...................................................................................................................................................... 8
2.1.1 Mounting height........................................................................................................................................... 9
2.1.2 Clamping the outboard motor.................................................................................................................... 10
2.2 Breaking in engine ........................................................................................................................................11
2.3 Pre-operation checks................................................................................................................................... 12
2.4 Filling fuel..................................................................................................................................................... 13
2.5 Starting engine............................................................................................................................................. 14
2.6 Warming up engine...................................................................................................................................... 25
2.7 Shifting......................................................................................................................................................... 26
2.7.1 Forward..................................................................................................................................................... 26
2.7.2 Reverse..................................................................................................................................................... 27
2.8 Tiller ............................................................................................................................................................. 28

2.9 Stopping engine ........................................................................................................................................... 30
2.10 Trimming outboard motor........................................................................................................................... 32
2.11 Tilting up and down .................................................................................................................................... 33
2.11.1 Tilting up.................................................................................................................................................. 34
2.11.2 Tilting down ............................................................................................................................................. 36
2.12 Cruising in other conditions........................................................................................................................ 36
2.12.1 Cruising in shallow water ........................................................................................................................ 36
3. Maintenance .................................................................................................................................................. 38
3.1 Greasing ...................................................................................................................................................... 39
3.2 Cleaning and adjusting spark plug............................................................................................................... 40
3.3 Checking the fuel system............................................................................................................................. 40
3.3.1 Cleaning the fuel filter ............................................................................................................................... 41
3.4 Inspecting idling speed................................................................................................................................. 42
3.5 Checking wiring and connectors .................................................................................................................. 43
3.6 Checking for leakage ................................................................................................................................... 43
3.7 Checking propeller....................................................................................................................................... 44
3.7.1 Removing the propeller............................................................................................................................. 46
3.7.2 Installing the propeller............................................................................................................................... 46
3.8 Changing gear oil......................................................................................................................................... 47
3.9 Cleaning fuel tank ........................................................................................................................................ 48
3.10 Checking and replacing anode(s)............................................................................................................... 49

3.11 Checking top cowling ................................................................................................................................. 50
3.12 Maintenance Table..................................................................................................................................... 51
4. Transporting and storing ................................................................................................................................ 53
4.1 Transporting................................................................................................................................................. 53
4.2 Storing.......................................................................................................................................................... 54
5. Actions in emergency..................................................................................................................................... 56
5.1 Impact damage ............................................................................................................................................ 56
5.2 Starter will not operate ................................................................................................................................. 56
5.3 Treatment of submerged motor.................................................................................................................... 59
6. Troubleshooting ............................................................................................................................................. 60
7. Circuit diagram............................................................................................................................................... 64

1
1. Main components and General information
1.1 Main components
1. Throttle grip 7. Top cowling 13. Clamp screw
2. Tiller handle 8. Manual starter handle 14. Fuel joint
3. Cooling water inlet 9. choke knob 15. Fuel tank
4. Top cowling lock handle 10. Engine stop button/switch 16. Remote control
5. Anti-cavitation plate 11. Main switch/choke switch(FW)
6. Propeller 12. Trim rod
4
6
7
15 16
5
7
8
9
10
11
12
13
14
1
2
3

2
If your model includes a portable fuel tank, its parts are as follows:
1. Fueltankcap 3. Airventscrew
2. Fueljoint 4. Fuelgauge
WARNING：
The fuel tank supplied with this engine could only be used as supply of fuel for its running and must not
be as a fuel storage container.
Remote control
The remote control lever actuates both the shifter and the throttle. The electrical switches are mounted on the
remote control box.
1.Remoter control lever
2.Neutral interlock trigger
3.Neutral throttle lever
4.Main switch/choke switch
5.Engine stop lanyard switch
6.Throttle friction adjuster
1 3
2 4

3
Remote control lever
Moving the lever forward from the neutral position engages forward gear. Pulling the lever back from neutral
engages reverse. The engine will continue to run at idle until the lever is moved about 35º (a detent can be felt).
Moving the lever farther opens the throttle, and the engine will begin to accelerate.
1.Neutral “N”
2.Forward “F”
3.Reverse “R”
4.Shift
5.Fully closed
6.Throttle
7.Fully open
Neutral interlock trigger
To shift out of neutral, first pull the neutral interlock trigger up.
1.Neutral interlock trigger

4
Neutral throttle lever
To open the throttle without shifting into either forward or reverse, put the remote control lever in the neutral
position and lift the neutral throttle lever.
NOTE:
The neutral throttle lever will operate only when the remote control lever is in neutral.
The remote control lever will operate only when the neutral throttle lever is in the closed position
1. Fully open
2. Fully closed

5
1.2 General information
1.2.1 Specifications
Parameter Items Data Items Data
Type of engine 2-stroke L Weight L (BM/FW) 67kg/70kg
Displacement 669cm3Transom S 381mm
Bore X stroke 78mm×70mm Transom L 508mm
Gear ratio Type J 2.00（26/13）Recommended fuel Unleaded regular gasoline
Type G 1.85（24/13）Recommended engine oil 2-stroke engine oil
Overall length (BM/FW) 997mm/692mm Recommended gear oil Hypoid gear oil SAE#90
Overall width (BM/FW) 4484mm/363mm Gear oil quantity 315cm3
Overall height S (BM/FW) 1208mm Spark plug BR7HS
Overall height L (BM/FW) 1335mm Spark plug gap 0.6～0.7mm
Weight S (BM/FW) 65kg/68kg
Performance Items Data Items Data
Maximum output (40HP) 29.4kw/5000 rpm Idling speed (in neutral) 1150±50 rpm
(36HP) 26.5kw/5000 rpm Tightening torque
for engine
Spark plug 25.0Nm
Full throttle
operating range 4500～5500 rpm Propeller nut 17.0Nm

6
1.2.2 Fueling instructions
Fueling instructions:Recommended gasoline:
Regular unleaded gasoline, If it is not available,
then premium gasoline.
If knocking or pinging occurs, use a different brand of gasoline or premium unleaded fuel.
If leaded gasoline is usually used, engine valves and related parts should be inspected after every 100 hours of
operation.
WARNING：
Do not smoke when refueling, and keep away from sparks, flames, or other sources of ignition.
Stop engine before refueling.
Refuel in a well-ventilated area. Refuel portable fuel tanks off the boat.
Do not overfill the fuel tank.
Take care not to spill gasoline, if gasoline spills, wipe it up immediately.
Tighten the filler cap securely after refueling.
If you should swallow some gasoline, inhale a lot of gasoline vapor, or get gasoline in your eye, get
immediate medical attentions.
If any gasoline spills onto your skin, immediately wash with soap and water. Change clothing if
gasoline spills on it.
Touch the fuel nozzle to metal components to prevent electrostatic sparks.

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CAUTION:
Use only new clean gasoline which has been stored in clean containers and is not contaminated with
water or foreign matter.
Engine oil:
Recommended engine oil: 2-stroke outboard motor oil
Gasoline and oil mixing:
Break-in period 25:1
Gasoline 1L 12L 14L 24L
Engine oil 0.04L 0.48L 0.56L 0.96L
After break-in 50:1 Gasoline 1L 12L 14L 24L
Engine oil 0.02L 0.24L 0.28L 0.48L
CAUTION:
Be sure to mix gasoline and oil completely, otherwise the engine may be damaged.
1.2.3 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. The outboard motor is fitted with propellers chosen to perform well

8
over a range of applications, but there may be uses where a propeller with a different pitch would be more
appropriate. “PARSUN” dealers stock a range of propellers and can advise you and install a propeller on your
outboard that is best suited to your application.
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. 2. Operation
2.1 Installation
Mount the outboard motor on the center line (keel line) of the boat. For boats without a keel or which are
asymmetrical, consult your dealer.
1
1.Center line (keel line)
NOTE:
During water testing check the buoyancy of the boat, at rest, with its maximum load. Check that the
static water level on the exhaust housing is low enough to prevent water entry into the power head,
when water rises due to waves when the outboard is not running.

9
WARNING：
Overpowering a boat could cause severe instability. Do not install an outboard motor with more
horsepower than the maximum rating on the capacity plate of the boat. If the boat does not have a
capacity plate, consult the boat manufacturer.
Improper mounting of the outboard motor could result in hazardous conditions. For permanently
mounted models, your dealer or other person experienced in proper rigging should mount the motor.
If you are mounting the motor yourself, you should be trained by an experienced person. For
portable models, your dealer or other person experienced in proper outboard motor mounting
should show you how to mount your motor.
The information presented in this section is intended as reference only. Proper mounting depends in
part on experience and the specific boat and motor combination.
2.1.1 Mounting height
The mounting height of the outboard motor greatly affects your boat running efficiency. If the mounting height is
too high, cavitation tends to occur, thus reducing the propulsion. If the mounting height is too low, the water
resistance will increase and thereby reduce engine efficiency. Mount the outboard motor so that the
anti-cavitation plate is between the bottom of the boat and a level 25mm below it.
NOTE:
The optimum mounting height of the outboard motor is
affected by the boat and motor combination and the desired
use. Test runs at a different height can help determine the
optimum mounting height. For further information, consult
your "PARSUN" dealer or boat manufacturer. ～

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2.1.2 Clamping the outboard motor
1. Tighten the transom clamp screw evenly and securely. Occasionally check the clamp screws for tightness
during operation of the outboard motor because they could become loose due to engine vibration.
CAUTION:
Outboards that use clamp bracket screws alone are INSUFFICIENT to properly and safely secure the
outboard to the Transom. Proper installation of the outboard includes bolting the engine to the boat
through the transom.
WARNING：
Loose clamp screws could allow the outboard motor to fall off or move on the transom. This could
cause loss of control.
Make sure the clamp screws are tightened securely. Occasionally check the screws for tightness
during operation.
2. If the engine restraint cable attachment is equipped on your engine, an engine restraint cable or chain should
be used. Attach to a secure mounting point on the boat to avoid the engine being completely lost if it accidentally
falls off the transom.

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3. Secure the clamp bracket to the transom using the appropriate bolts. For details, consult your PARSUN
dealer.
WARNING：
Avoid using bolts, nuts or washers inappropriate. After tightening, test running the engine and check
their tightness.
2.2 Breaking in engine
Your new engine requires a period of break-in to allow mating surfaces of moving parts to wear in evenly.
Gasoline and oil mixing:
CAUTION:
Failure to follow the break-in procedure could result in reduced engine life or even severe engine
damage.
1. First 10 minutes:
Run the engine at idle.
Break-in period 25:1
Gasoline 1L 12L 14L 24L
Engine oil 0.04L 0.48L 0.56L 0.96L

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2. Next 50 minutes:
Run the engine at 3000 r/min or at approximately half throttle.
3. Next 2 hours of operation:
Run the engine at 4000 r/min or at approximately three-quarter throttle.
4. Next 7 hours of operation:
Avoid continuous operation at full throttle for more than five minutes at a time.
5. Operate the engine normally.
2.3 Pre-operation checks
Fuel
Check to be sure you have plenty of fuel for your trip.
Make sure there are no fuel leaks or gasoline fumes.
Check fuel line connections to be sure they are tight.
Be sure the fuel tank is positioned on a secure, flat surface, and that the fuel line is not twisted or flattened,
or likely to contact sharp objects.
Controls
Check throttle, shift and steering for proper operation before starting the engine.
The controls should work smoothly, without binding or unusual free play.
Look for loose or damaged connections.

13
Check operation of the starter and stop switches when the outboard motor is in the water.
Engine
Check the engine and engine mounting.
Look for loose or damaged fasteners.
Check the propeller for damage.
WARNING：
If any item in the pre-operation check is not working properly, have it inspected and repaired before
operating the outboard motor. Otherwise an accident could occur.
CAUTION:
Do not start the engine out of water. Overheating and serious engine damage can occur.
2.4 Filling fuel
WARNING：
Gasoline and its vapors are highly flammable and explosive. Keep away from sparks, cigarettes, flames,
or other sources of ignition.
1. Remove the fuel tank cap.
2. Carefully fill the fuel tank.
3. Securely close the cap after filling the tank. Wipe up any spilled fuel.