Parsun T90BM User manual

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OUTBOARD MOTOR
OWNER’S MANUAL
T90BM/BE/FE
T85BM/BE/FE
T75BM/BE/FE
T60BM/BE/FE
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 ···································································4
1.2.1 Specifications ······································································4
1.2.2 Fueling instructions································································· 5
1.2.3 Propeller selection ································································· 6
2. Operation ············································································· 8
2.1 Installation ··········································································· 8
2.1.1 Mounting height ···································································· 9
2.1.2 Clamping the outboard motor························································ 9
2.2 Breaking in engine ···································································10
2.3 Pre-operation checks ································································· 11
2.4 Filling fuel ···········································································12
2.5 Starting engine ······································································ 13
2.6 Warming up engine ·································································· 22
2.7 Shifting ············································································· 23
2.7.1 Forward ···········································································24
2.7.2 Reverse ···········································································25
2.8 Tiller ················································································ 26
2.9 Stopping engine ·····································································27
2.10 Trimming outboard motor ··························································· 30
2.11 Tilting up and down ································································31
2.11.1 Tilting up ········································································31
2.11.2 Tilting down ······································································33
2.12 Cruising in other conditions ························································35
2.12.1 Cruising in shallow water ··························································35
2.12.2 Cruising in salt water ·····························································36

3. Maintenance ········································································· 37
3.1 Greasing ············································································37
3.2 Cleaning and adjusting spark plug ···················································38
3.3 Checking fuel system ·······························································38
3.3.1 Cleaning the fuel filter ·····························································39
3.4 Inspecting idling speed ·······························································40
3.5 Checking wiring and connectors·······················································40
3.6 Checking for leakage································································· 40
3.7 Checking propeller···································································· 41
3.7.1 Removing the propeller······························································42
3.7.2 Installing the propeller ······························································42
3.8 Changing gear oil ··································································· 43
3.9 Cleaning fuel tank ··································································· 44
3.10 Checking and replacing anode(s) ····················································45
3.11 Checking top cowling ······························································· 46
3.12 Maintenance table ·······························································47
4. Transporting and storing outboard motor ················································49
4.1 Transporting ········································································· 49
4.2 Storing ·············································································· 50
5. Action in emergency ·································································· 53
5.1 Impact damage ······································································53
5.2 Starter will not operate ·······························································53
5.3 Treatment of submerged motor ·······················································55
6. Troubleshooting ·······································································57
7. Circuit diagram ······································································· 61

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

If your model includes a portable fuel tank, its parts are as follows:
1. Fuel tank cap 3. Air vent screw
2. Fuel joint 4. Fuel gauge
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
2
1
3
2 4

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
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 3

1. Fully open
2. Fully closed
1.2 General information
1.2.1 Specifications
Parameter
Items
Data
Items
Data
Type of engine 2-stroke L Weight X (BM/BE/FE) 115kg/119kg/119kg
Displacement 1141cm
3
Transom L 508mm
Bore X stroke 82.0mm×72.0mm Transom X 635mm
Gear ratio 2.00（26/13）Recommended fuel Unleaded regular gasoline
Overall length (BM/EX) 1337mm/726mm Recommended engine oil 2-stroke engine oil
Overall width (BM/FW) 398mm/374mm Recommended gear oil Hypoid gear oil SAE#90
Overall height L (BM/BE/FE) 1623mm/1548mm/1548mm Gear oil quantity 610cm3
Overall height X (BM/BE/FE) 1497mm/1422mm/1422mm Spark plug BR8HS-10
Weight L(BM/BE/FE) 118kg/122kg/122kg Spark plug gap 0.9～1.0mm
4

Performance
Items
Data
Items
Data
Maximum output
(90HP) 66.2kw/5000 rpm Idling speed (in neutral) 800±50 rpm
(85HP) 62.5kw/5000 rpm Tightening torque
for engine Spark plug 25.0Nm
(75HP) 55.2kw/5000 rpm Propeller nut 35.0Nm
(60HP) 44.1kw/5000 rpm
Full throttle
operating range
4500～5500 rpm
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.
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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.
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
6

incorrect choice could adversely affect performance. The outboard motor is fitted with propellers chosen to
perform well 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.
7

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.
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.
8

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.
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.
9
～

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.
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.
10
Break-in period 25:1 Gasoline 1L 12L 14L 24L
Engine oil 0.04L 0.48L 0.56L 0.96L

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.
Check operation of the starter and stop switches when the outboard motor is in the water.
Engine
Check the engine and engine mounting.
11

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.
12

3. Securely close the cap after filling the tank. Wipe up any spilled fuel.
2.5 Starting engine
For BM
1. Loosen the air vent screw on the fuel tank cap, 2 or 3 turns.
2. Connect fuel joints securely and squeeze the primer pump with the outlet end up until you feel it
become firm (if equipped the fuel joint).
13

3. Place the gear shift lever in neutral.
WARNING:
The engine must be started in neutral otherwise damage to the starter can occur.
Do not attach the lanyard to clothing that could tear loose. Do not route the lanyard where it
could become entangled, preventing it from functioning.
Avoid accidentally pulling the lanyard during normal operation. Loss of engine power means the
loss of steering control. Also, without engine power, the boat could slow rapidly. This could
cause people and objects in the boat to be thrown forward.
NOTE:
The start-in-gear protection device prevents the engine from starting except when in neutral.
Attach the engine stop switch lanyard to secure place on your clothing, or your arm or leg. Then
install the lock plate on the other end of the lanyard into the engine stop switch.
14
N