Coleman F5BMS-C Service manual
PARSUN OUTBOARD ENGINE
SERVICE MANUAL
F4BM (F5BM)
SUZHOU PARSUN POWER MACHINE CO., LTD.
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.
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
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
EXPLOSIVE DRAWING······································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
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
TOP COWLING············································58
Explosive drawing·······································58
Disassembling and inspection······························61
BOTTOM COWLING·······································61
Explosive drawing·······································61
Disassembling and inspection······························63
STEERING HANDLE········································64
Explosive drawing·······································64
Disassembling and inspection·····························66
BRACKET··················································68
Explosive drawing······································68
Disassembling and inspection······························71
UPPER UNIT················································73
Explosive drawing······································73
Disassembling and inspection······························75
LOWER UNIT····················································76
WATER PUMP ASSEMBLY···································76
Explosive drawing·······································76
Disassembling and inspection······························78
LOWER UNIT···············································79
Explosive Drawing······································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
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
Aluminum alloy
7 1/2×7
7 1/4×6 1/2
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
1
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
3.
Demount three bolts and remove starter.
4.
Assemble two bolts to fix the fuel tank.
2. Chock lever cable
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.
2
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.
DISASSEMBLY AND ASSEMBLY
When disassembly and assembly, please follow the following principles:
3
1.
2.
3.
4.
Use special tools when disassembling and assembling.
Clean dirt before disassembling the parts.
Oil the contact surfaces of moving parts before assembly.
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..
re-assembling outboard engine, you must change the one-time use parts.
When
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
1. Oil cap
2. Oil rule
3. High position mark
4
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.
4
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
1. Clamp handle screw
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.
② Check if the fuel line leaks.
③ After breaking-in running, operate the engine at idling speed. Use cleaning tool to wash
5
over the cooling water passage by fresh water.
9.
After breaking-in running, inspect idling speed.
①
②
③
④
Preheating engine for 5 minutes.
Using the tachometer to measure idling speed RPM.
If out of specification, adjust it.
Idling speed: 1450~1550 r/min
Turn the throttle stop screw clockwise or counter clockwise
until the specified idling speed is attained.
After adjusting idling speed, picking up RPM several times to check the engine’s stability.
SPECIAL TOOLS 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.
SPECIAL TOOLS:
Piston slider
Flywheel holder and puller
Valve spring compressor
Housing bearing installer
Oil seal installer tool
Housing oil seal installer
6
Bearing puller
Lower casing cover bearing installer
Space gage
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:
Digital tachometer
Digital circuit tester
7
Peak voltage adaptor
EXPLOSIVE DRAWING AND SYMBOL
EXPLOSIVE DRAWING
①
M6x45 mm
1st 3Nm
2nd 8Nm
②
L
1277
③
G
M6x25 mm
1st 3Nm
2nd 8Nm
G
L
1277
14
15
PART NO.
1
2
3
4
5
6
7
8
9
10
①
②
③
④
④
DESCRIPTION
REMARKS
六角头螺栓M6×45 HEXAGON BOLT
泵壳固定板
泵壳橡胶管
水泵座定位销
水泵壳
泵壳密封垫
水泵内壳
水泵叶轮
F4-03000015 外档板
F4-03000020
F4-03000021
F4-03000013
F4-03000019
F4-03000018
F4-03000017
F4-03060000
PIN ,WATER PUMP
OUT PLATE
F4-03000014
4
2
1
2
1
1
1
1
1
1
Parts explosive drawing
Oil, fluid sealant or locking substance daubing point
Screw specification and specified torque
Spare parts details
SYMBOL
O
Daub engine oil
L
1277
L
1243
Daub screw locking
substance 1277
Daub screw locking
substance 1243
G
Daub waterproof
grease
8
SPECIFICATIONS
OUTBOARD ENGINE SPECIFICATIONS
Description
Item
Description
Choke valve
Spark plug
BPR7HS
Exhaust system
Under water
1156mm
Lubrication
system
Splash lubrication
S
24.5kg
Fuel type
Unleaded regular
gasoline
L
25.5kg
Fuel standard
PON86、RON91
Max output
2.9Kw(4hp)@4500r/min
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/[email protected]/min
Idle speed(Neutral)
1500±50 r/min
Type
4 stroke, OHV
Overall width
361mm
S
1029mm
L
Overall
height
Fuel and Oil
717mm
Power Unit
Starting
enrichment
Overall length
Engine oil
quantity
Recommended
gear oil
Hypoid gear oil
SAE﹟90
Gear oil quantity
100 mm3
Tilt angle
4 o,8 o,12 o,
16 o,20 o
Tilt-up angle
76 o
Shallow water
cruising angle
30 o, 42 o, 54 o
0.5L
1
Displacement
112cm³
Bore×Stroke
59mm×41mm
Compression ratio
8.4
Steering angle
360o
660kPa
Gear positions
F-N-R
1
Gear ratio
2.08
Gear type
Bevel gear
Propeller
direction
Clockwise
Propeller drive
system
Spline
Compression
pressure
Number of
carburetors
Control system
Tiller control
Starting system
Recoil starter
Ignition control
system
T.C.I
Bracket
Number of cylinders
Drive Unit
Power Unit
Performance
Weight
Dimension
Item
9
MAINTENANCE INFORMATION
Power Unit
Wear limit
Taper limit
0.08mm
Out of round limit
0.05mm
Piston diameter
58.950~58.965mm
Measuring point
height
10mm (from the
bottom of piston)
Piston-to-cylinder
clearance
0.035~0.065mm
Pin boss inside
diameter
13.009~13.017mm
Cylinder
Piston
Piston pin outside diameter
End gap
Wear limit
0.40mm
Side clearance
0.04~0.08mm
Thickness
1.5mm
Breadth
2.6mm
End gap
0.25~0.40mm
Wear limit
Seat width
Margin
thickness
Head
diameter
Stem outside
diameter
Guide inside
diameter
Stem to
guide
clearance
Intake
0.10±0.02mm
Exhaust
0.10±0.02mm
Intake
1.84~2.26mm
Exhaust
1.84~2.26mm
Intake
0.6~0.8mm
Exhaust
Intake
0.6~0.8mm
0.7mm
Exhaust
1.0mm
Intake
23.9~24.1mm
Exhaust
21.9~22.1mm
Intake
5.475~5.490mm
Exhaust
5.460~5.475mm
Intake
Exhaust
5.500~5.512mm
Intake
0.010~0.037mm
Exhaust
0.025~0.052mm
0.5mm
Free length
35.0mm
Free length limit
34.0mm
0.60mm
Tilt limit
1.2mm
Side clearance
0.02~0.06mm
Small end inside
diameter.
13.006~13.02mm
Thickness
2.5mm
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
Wear limit
0.90mm
Crankshaft
Push rod runout limit
Connecting
rod
Top ring
2nd ring
Oil ring
Piston ring
Breadth
Face width
12.995~13.000mm
1.5mm
2.6mm
0.10~0.20mm
Thickness
Description
Valve
clearance
(cold)
0.1mm
59.00~59.02mm
59.1mm
Bore
Item
Valve
Warp limit
Description
Round limit
0.03mm
Valve
spring
Cylinder
Head
Item
10
Cont’d
Item
Item
Description
Valve opening
temperature
58~62ºC
Full-open
temperature
70ºC
26.736~26.836mm
Exhaust
26.532~26.623mm
Round diameter
21.950~22.050mm
Valve lift
Journal diameter
14.966~14.984mm
Discharge
Camshaft round limit
0.03mm
Fuel
pump
Valve lifter outside diameter
Thermostat
Intake
Height
Camshaft
Description
7.978~7.987mm
Pressure
Plunger stroke
3mm
8L/h
50kPa
1.8~2.2mm
Ignition system
Item
Description
Item
Ignition timing
BTDC28º ~32º
T.C.I system output
peak voltage
130V
T.C.I air gap
0.4~0.6mm
Description
0.6~0.7mm
Spark plug gap
Ignitor
ass’y
resistance
Primary coil
0.7~0.96Ω
Secondary coil
5.8~7.0KΩ
TIGHTENING TORQUE
Power unit
Part to be tightened
Specified torque
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
Bolt
M8
4
Bolt
M6
1
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
Bolt
M8
7
1st tightening
Cylinder
head
2nd tightening
1st tightening
2nd tightening
Crankcase
1st tightening
2nd tightening
11
15 Nm
30 Nm
6 Nm
11 Nm
10 Nm
22 Nm
Cont’d
Power
unit
Part to be tightened
Part name
Thread size
Quantity
Torque
Connecting rod
Bolt
M7
2
12 Nm
Oil splash gear unit
Bolt
M6
1
8 Nm
Bolt
M6
2
Bolt
M6
2
Lower unit
Lower unit
mounting
Lower unit
housing
cover
2nd tightening
1st tightening
8 Nm
6Nm
2nd tightening
1st tightening
3 Nm
11 Nm
3 Nm
Bolt
M6
1
Bolt
M6
4
Bolt
M6
1
Steering handle mounting
Bolt
M8
1
18 Nm
Shift lever bracket
Bolt
M6
1
4.5 Nm
Bolt
M6
2
Anode
Water pump
housing
Water pump
base
Upper Unit
1st tightening
Bracket fixed
cover
Tilt lock plate
2nd tightening
1st tightening
2nd tightening
1st tightening
2nd tightening
1st tightening
2nd tightening
1st tightening
1st tightening
2nd tightening
Clamp bracket
Ignitor ass’y
Nut
M6
Bolt (b)
Torque
8mm
10mm
12mm
14mm
17mm
M5
M6
M8
M10
M12
5Nm
8 Nm
18 Nm
36 Nm
43 Nm
8 Nm
3 Nm
8 Nm
3 Nm
2
3 Nm
8 Nm
3 Nm
Nut
M6
6
Nut
M8
1
13 Nm
Bolt
M6
2
8Nm
General torque
Nut (a)
3 Nm
8 Nm
2nd tightening
Swivel
bracket
8 Nm
a b
12
8 Nm
PERIODIC SERVICE
MAINTENANCE TIME TABLE
Initial maintenace
Items
Contents
10 hours
(1 month)
Anode
Spark plug
Inspection/replacement
Grease points
Bolts and nuts
Fuel tank and fuel line
Fuel filter
Fuel cock
Carburetor
Throttle cable
Idling speed
Greasing
Start-in-gear projection
Inspection/ adjustment
Cleaning/adjustment
/replacement
○
General maintenance
period
50 hours
100 hours
(3 months) (6 months)
○
○
○
○
200 hours
(1 year)
○
○
Inspection
Inspection
○
○
○
○
○
○
○
○
○
○
Inspection/replacement
Inspection/replacement
Inspection/replacement
Inspection/replacement
Inspection/ adjustment
○
○
○
○
○
○
○
○
○
○
○
○
○
Replacement
Engine oil
Inspection/ adjustment
Valve cleanrance
Inspection
Ignition timing
Inspection/ adjustment
T.C.I air gap
Inspection
Thermostat
Cooling water passage Inspection/Cleaning
○
○
Replacement
Gear oil
○
○
Inspection
Water pump
○
Inspection/replacement
Propeller
○
○
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 PUMP AND 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.
13
○
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.
14
2
1
1. Oil level plug
2. Oil rule
3
3. High position mark
4
4. Low position mark
b) If above the upper mark, drain the engine oil; if below lower mark, add engine oil up to upper
mark.
CAUTION:
Run the engine and then turn it off, wait for several minutes, and check the engine oil level by
the oil rule again.
If the engine oil still not within the proper level, add/drain as needed.
Changing engine oil
1. Remove oil level plug, drain plug with washer and gasket; drain off the engine oil.
2. Install new gasket and washer; install drain plug.
3. Fill engine oil into the crankcase through oil filler hole.
Engine oil quantity: 0.5L
Oil type: API SE, SF, SE-SF, SG-CD SAE 10W30, 10W40
4. Install oil level plug.
5. Check engine oil level.
Valve clearance
CAUTION:
Rotate the flywheel clockwise so that rocker arm is in free position, before adjusting valve
clearance (Dead point position on compression stroke).
1. Remove stopper hang rope from engine stop switch assy.
Remove spark plug cap from spark plug.
15
2.
Remove cylinder head cover
3.
Use feeler gauge to measure the clearance between rocker arm and valve rod top: if out of
specification, adjust.
Valve clearance (cold position):
Inlet valve: 0.10±0.02mm
Outlet valve: 0.10±0.02mm
Spark plug
1. Remove spark plug cap and spark plug.
2. Clean off carbon build-up on the electrodes.
3. Check if the electrodes are corroded or have deposit, or if the washer is damaged.
If necessary, change the spark plug.
Spark plug type: BPR7HS
4. Inspect if the spark plug gap is within specification.
If necessary, change the spark plug.
0.6-0.7mm
5. Install spark plug. Use spark plug spanner to tighten it according to specified torque.
Specified torque: 25 Nm
CONTROL SYSTEM
Throttle grip
1. Turn the throttle grip to fully closed position.
2. Check if the throttle cable is slack and if the throttle lever touches the throttle stop screw.
3. Loosen throttle cable stopper screw, adjust throttle cable position, and tighten throttle cable stop
screw.
16
1
1.throttle cable stop screw
Idling speed
Check idling speed, and adjust it if necessary.
1. Preheat engine for 5 minutes.
2. Attach the tachometer to the spark plug wire to measure idling speed RPM.
specification, adjust it.
Idling speed: 1450~1550 r/min
If out of
3. Turn the throttle stop screw clockwise or counter clockwise, until the specified idling speed is
attained.
NOTE:
Turning clockwise to increase idling speed.
Turning counter clockwise to decrease idling speed.
CAUTION:
Before adjusting the idling speed, the throttle cable slack should be properly adjusted.
adjusting the idling speed, if necessary you can adjust the throttle cable again.
After
Start-in-gear protection
Set the shift lever in neutral, and check if the triangle marking of the detent aligns with the triangle
marking of the starter. If necessary, adjust the adjusting nut on the tightwire of the detent.
1
2
3
1. Triangle marking 2. Adjusting nut 3.Tightwire ass’y, detent
17
LOWER UNIT
Gear oil
Check gear oil level:
Remove the oil level plug. If the gear oil overflows at the oil level checking hole, the oil volume
added is correct; otherwise please add gear oil.
1
1.Oil level plug
Changing gear oil
1. Hold the outboard engine in an upright position.
2. Place a container under the drain plug.
3. Remove the drain plug, the oil level plug, and then drain the gear oil.
1
2
1. Oil level plug
2. Drain plug
4. Add gear oil through the drain plug using pressure filling device.
5. When gear oil overflows at the oil level checking hole, install the oil level plug.
6. Install the drain plug, then clean overflowing gear oil.
NOTE:
Check the drained gear oil.
If the gear oil is milky, please check the oil seal. If necessary, replace the oil seal.
If the gear oil contains metal chippings, please check the gear and bearing.
CAUTION:
Must change drain plug washer each time.
18
Lower unit leakage check
Connecting the leakage tester to the oil level checking hole to check the lower unit leakage.
pressure drops (pressure: 1kg/cm³), inspect the oil seal and components.
If the
GENERAL INSPECTION
Anode
Inspect lower unit anode and engine anode (on the thermostat cover). Clean the greasy dirt and
scales. If wear or damage is above 1/2, replace the anode.
CAUTION:
Cannot grease or paint the anode, or it will not operate properly.
Grease points
1. Refer the illustration for greasing points, paint the water resistant grease.
2. Paint anti-corrosion grease on the propeller shaft.
Cooling water passage
1. Inspect cooling water passage
If blocked, clean it.
19
1
Cooling water passage inlet
2. Place the outboard engine in the water and ensure the water level is above the anti-vortex plate,
then start the engine.
3. Check if water overflows at the cooling water checking hole. If there is no flow or intermittent
flow, check the cooling water passage.
1
2
1. Cooling water inlet
2. Cooling water checking hole
RECOIL STARTER
NOTICE
When you service, please wear safety glasses and gloves. Please remove spark plug cap and
stopper hang rope from stop switch assy, in case of the accidental start of the engine.
20
EXPLOSIVE DRAWING
M6x20 mm
8Nm
M6x35 mm
8Nm
G
G
G
G
6.5Nm
PART NO.
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
REMARKS
F4-04130000
F4-04130001
F4-04130012
F4-04130018
F4-04130101
F4-04130102
STARTER ASSY
起动器组件
CASE,STARTER
起动器外壳
起动绳导向器 GUIDE,ROPE
SEAL,RUBBER
起动减震块
HANDLE,STARTER
起动手柄
COVER
起动手柄盖
F4-04130013
F4-04130011
F4-04130004
F4-04130003
起动绳导管
起动绳
卡瓣弹簧
卡瓣
MEATUS,START ROPE
WIRE,STARTER
SPRING,DRIVE
PAWL,DRIVE
21
1
1
1
1
1
1
1
1
2
2
M6x20 mm
8Nm
M6x35 mm
8Nm
G
G
G
G
6.5Nm
PART NO.
11
12
13
14
15
16
17
18
19
20
F4-04130008
F4-04130006
F4-04130007
F4-04130019
F4-04130005
F4-04130014
F4-04130002
F4-04130010
F4-04130009
GB/T97.1-85
DESCRIPTION
REMARKS
BOLT,STARTER
起动压板螺钉
PLATE,PRELL
起动压板
起动压板夹簧 SPRING,PLATE
DRULL,SHEAVE
起动轮
SPRING,VOLUTE
涡形弹簧
起动轮减磨片 WASHER,THRUST
起动器外壳衬管
制动器扭簧
DETENT
制动器
WASHER,THRUST
平垫圈 6
22
1
1
1
1
1
1
1
1
1
3
M6x20 mm
8Nm
M6x35 mm
8Nm
G
G
G
G
6.5Nm
PART NO.
DESCRIPTION
REMARKS
21
六角头螺栓M6x35 BOLT,HEXAGON
22
六角头螺栓M6x20 BOLT,HEXAGON
23 F4-04000005 钢索固定架
24 F4-02000013 制动器钢索组件
23
2
1
1
1
DISASSEMBLING
1.
Open the top cowling
2. Screw loosely the adjusting nut of the dent tightwire.
1
1. Adjusting nut
3. Remove the tightwire from the detent.
4. Remove the starter fixing bolt, and remove the starter.
STARTER ROPE REPLACEMENT
1. Pull the starter rope out, and insert it in the notch of the sheave drum.
clockwise until the volute spring is free.
Turn the sheave drum
2. Pull the starter rope completely.
3. Remove the starter handle cover from the starter handle, and remove the starter rope.
Untie the knot at the end of the starter rope.
4. Pull out the starter rope completely.
5. Insert the new starter rope into the starter assembly, and fix the
rope onto the sheave drum and starter handle.
At the end of the rope tie a knot as shown.
24
6. Insert the start rope in the notch of the sheave drum and turn the sheave drum several rounds in
counter clockwise direction.
7. Pull the starter handle many times to check if the sheave drum rotates stably. If necessary, repeat
step 6 and step 7.
DISASSEMBLING AND INSPECTION
1. Remove the start rope.
2. Remove starter bolt, and remove press plate.
3. Remove the sheave drum
WARNING
Uninstall the sheave drum carefully, to ensure that the volute spring does not pop out to hurt
people.
4. Remove the volute spring.
5. Remove the detent and detent wrest spring.
6. Inspect if the detent is cracked, worn or damaged.
7. Check if the drive pawl is cracked, worn or damaged.
If necessary, replace it.
If necessary, replace it.
8. Inspect if the drive spring is broken, cranked or damaged.
9. Check if the volute spring is broken, cranked or damaged.
25
If necessary, replace it.
If necessary, replace it.
ASSEMBLING
Reverse the steps of disassembling.
INSTALLATION
1. Put starter onto the power unit.
2. Screw the hexagon bolt, and tighten it according to the specified torque.
3. Install the detent tightwire.
4. Adjust the adjusting nut on the tightwire of the dent, and align the triangle marking of the dent
2
with the triangle
marking of the starter case.
1
2
3
1. Triangle mark
2. Adjusting nut
3. Detent tightwire
26
IGNITION SYSTEM
NOTICE
When checking and repairing the ignition system, keep your hand, clothes, hair or personal
belongings away from the rotating flywheel.
Check ignition coil on insulated working table, to prevent electricity leak and electroshock.
Don’t touch the ignition coil or spark plug when the engine is running, to avoid electroshock. Keep
the wires away from the rotating flywheel, to prevent the wire from being cut, or the insulating layer
of the wire from being worn.
When replacing fixing parts such as nuts and bolts, only parts from original manufacturer or parts
made of same material and with strength can be used. Parts must be tightened according to the
specified torques.
EXPLOSIVE DRAWING
44Nm
1
2
O
M6x25 mm
8Nm
3
4
5
6
O
9
87
M6x25 mm
8Nm
PART NO.
DESCRIPTION
REMARKS
27
WIRING DIAGRAM
5
W
B
W
B
1 Flywheel
○
2 Ignition coil
○
3 Engine stop switch
○
4 Grounding
○
5 Spark plug
○
Wire beam color:
W White
B Black
SPARK PLUG IGNITION
1. Remove spark plug cap from spark plug. .
2. Connect the ignition tester to the spark plug cap.
3. Start the engine, and observe the sparks through the discharge window of the tester.
WARNING
Do not touch any joint part of the lead wire of the tester.
Keep away from inflammable gas or liquid, to prevent accident resulting from spark ignition.
28
SPARK PLUG CAP
1. Remove the spark plug.
Check if the spark plug cap is broken.
Replace if necessary.
2. Measure the resistance. If it’s out of specification, replace.
Spark plug cap resistance: 4.0~6.0kΩ
3. Install the spark plug cap
Turn it clockwise until it is tight.
FLYWHEEL MAINTENANCE
1.
Use flywheel holder to remove the nut and starter pulley; use flywheel puller to remove
flywheel.
2. Check if the flywheel is damaged or the permanent magnet part is firm.
Replace if necessary.
IGNITION COIL INSPECTION
1.
①
②
③
Ignition coil peak voltage
Remove spark plug cap.
Disconnect ignition coil tip (W).
Measure the ignition coil peak voltage output by a digital universal meter and a peak voltage
adapter. If below specification, check the ignition coil.
Peak voltage output: 130V(1500 r/min)
Digital universal meter
Peak voltage adapter
2. Ignition coil resistance
① Remove ignition coil and spark plug cap.
② Measure ignition coil resistance. If out of specification, replace it.
Resistance: 0.7~0.96Ω (Tester (+) pole: white wire; Tester (-) pole: black wire)
11.6~7.0kΩ (Tester (+) pole: white wire; Tester (-) pole: high-voltage wire)
29
FUEL SYSTEM
NOTICE
Gasoline is inflammable and highly volatile liquid. Its leakage can cause fire and explosion.
Don’t start the engine before all joints of the fuel system are connected or installed. When
completing all maintenance steps, force short-time pressure to the fuel system to check for leakage.
EXPLOSIVE DRAWING
PART NO.
DESCRIPTION
REMARKS
30
PART NO.
DESCRIPTION
REMARKS
31
1
2
34
5
6
13
5 4
78
9
M6x30 mm
8Nm
16
17
10 12
11
18
21
19
18
20
14
PART NO.
15
18
18
24
18
25
18
DESCRIPTION
GB/T823-88
F4-04090003 燃油泵盖
F4-04090004 上隔膜
COVER,FUEL PUMP
DIAPHRAGM ,TOP
F4-04090011 阀片螺钉M3×5
F4-04090005 单向阀片
F4-04090002 燃油泵壳
SCRRW ,VALVE
PLATE
FUEL PUMP SHELL
F4-04090100 隔膜组件
DIAPHRAGM ASSY
ROLLER NEEDLE
4
1
1
2
2
1
1
1
SEAT ,FUEL PUMP
1
1
滚针φ3x12
F4-04090008 隔膜弹簧
F4-04090001 燃油泵座
24
18
26
REMARKS
十字槽小盘头螺钉M4×25
GB/T309-2000
18
22
23
18 27 18 28
32
29 30
1
2
34
5
6
13
5 4
78
9
M6x30 mm
8Nm
16
17
10 12
11
18
21
19
18
20
14
PART NO.
15
18
18
24
18
25
18
DESCRIPTION
24
18
26
REMARKS
SPRING,FUEL PIPE "B"
1
1
4
1
1
1
1
9
WASHER ,SPRING
WASHER ,PLATE
2
2
F4-04090007 柱塞弹簧
F4-04090006 柱塞
SPRING ,PLUNGER
PLUNGER
GB/T6170-2000 螺母 M4
NUT
FUEL PUMP ASSY
F4-04090000 燃油泵组件
F4-04090009 燃油泵座O形圈 O-RING
CLIP ,NYLON "B"
F4-04000031-2 尼龙管夹
F4-04000028 燃油管E
PIPE ,FUEL "E"
F4-04000030 油管夹簧
GB/T93-1987 弹簧垫圈 6
GB/T97.1-85 平垫圈 6
18
22
23
18 27 18 28
33
29 30
1
2
34
5
6
13
5 4
78
9
M6x30 mm
8Nm
16
17
10 12
11
18
21
19
18
20
14
PART NO.
15
18
18
24
18
25
18
DESCRIPTION
F4-05000300 燃油管接头组件
F4-05000006 燃油管B
F4-05000100 油开关
F4-05000010 油管夹簧A
F4-05000005 燃油管A
24
18
26
REMARKS
OIL SWITCH
2
1
1
1
1
1
1
1
PIPE FUEL "A"
1
1
GB/T5783-2000 六角头螺栓 M6×30 HEXAGON BOLT
F4-05000008 燃油管D
F4-05000300 燃油过滤器组件
F4-05000007 燃油管C
F15-05000011 三通
18
22
23
18 27 18 28
PIPE ,FUEL "D"
FUEL FILTER ASSY
PIPE ,FUEL "C"
THREE THROUGH
PIPE ,FUEL "B"
34
29 30
M6x90 mm
8Nm
1
2 3
4
14
7
5
6
5
8
11
9
12
10
PART NO.
DESCRIPTION
GB/T5284-86 六角头螺栓M6x90
GB/T97.1-85 平垫圈6
F4-04110000 进气消音器组件
13
M6x25 mm
8Nm
REMARKS
HEXAGON BOLT
WASHER ,PLATE
JASO F404-96 O形密封圈2-24-031
O-RING
F4-04000024 化油器密封垫
F4-04000025 化油器垫块
F4-04110006 齿形尼龙卡箍
GASKET ,CARBURETOR
F4-04000035 回气管
PIPE , RETURN GAS
尼龙管卡(A)
F4-05000400 阻风门拉柄组件
CLAMP ,NYLON "A"
F4-04000031-1
2
CHOKE HANDLE ASSY
2
4
1
1
2
1
1
1
1
1
`
35
M6x90 mm
8Nm
1
2 3
4
14
7
5
6
5
8
11
9
10
PART NO.
12
DESCRIPTION
F4-04000022 进气弯管密封垫
F4-04000025 进气岐管
GB/T97.1-85 六角头螺栓 M6x25
F4-04000025 化油器
2
13
M6x25 mm
8Nm
REMARKS
MANIFOLD ,INTAKE
HEXAGON BOLT
CARBURETOR
1
1
2
1
FUEL TANK REMOVAL AND INSPECTION
1. Open the top cowling.
2. Remove three bolts fixing the starter.
3. Remove the starter. Pull the fuel tank out.
4. Remove the fuel pipe from fuel tank.
36
5. Inspect the fuel tank and fuel tank cover for crack, leakage or damage.
Replace if necessary.
6. Inspect the tank strainer for dirt or clog.
Clean or replace if necessary.
OIL SWITCH REMOVAL AND INSPECTION
1. Remove the fuel tank.
2. Remove the bolts fixing the thumb wheel of the oil switch, and remove the thumb
wheel.
1
2
3
4
1. Oil switch
2. Thumb wheel
3. Plus pan head screw M4X12
4. Thumb wheel block
3. Remove the bolts fixing the oil switch, and remove oil switch.
1. Screw
2. Gasket
3. Oil switch
4. Bottom cowling
4. Inspect the oil switch for leakage under prescribed pressure, replace if necessary.
Prescribed air pressure: 0.1Mpa
FUEL JOINT REMOVAL AND INSPECTION
1. Remove the bolts fixing the fuel joint.
2. Remove the fuel joint.
37
3. Inspect the fuel joint for crack or damage.
4. Connect the fuel joint exit with a vacuum pressure gauge.
5. Check whether the negative pressure can be maintained for over 10 minutes under
the prescribed pressure. Replace if necessary.
Prescribed pressure: 50kPa.
FUEL PUMP REMOVAL AND INSPECTION
1. Remove the bolts fixing the fuel pump.
2. Remove the fuel pump.
3. Connect the fuel pump intake with a vacuum pressure gauge.
4. Block the exit of fuel pump with finger, and force a prescribed positive pressure to
check for leakage.
Prescribed pressure: 50kPa
5. Force a prescribed negative pressure and check for leakage.
Prescribed pressure: 50kPa
6. Connect the fuel pump exit with a vacuum pressure gauge.
7. Force a prescribed negative pressure and check for leakage.
fuel pump to check if necessary.
Prescribed pressure: 50kPa
Disassemble the
8. Remove four bolts, and separate fuel pump cover from fuel pump seat.
9. Remove the valve screw bolt from fuel pump, and remove the valve plate.
10. Press the plunger and diaphragm, rotate the fuel pump seat, and align the notch
with the notch on the plunger. Take the roller needle out.
11. Inspect the diaphragm for crack and valve for damage.
12. Reverse above step 8 to step 10 to install the fuel pump.
38
Replace if necessary.
INTAKE SYSTEM REMOVAL AND INSPECTION
1. Loose throttle cable stop screw, and remove throttle cable.
1
1. Throttle cable stop screw
2. Remove choke cable from carburetor.
Remove choke cable.
3. Remove the bolt fixing air filter.
4. Remove air filter and carburetor.
5. Remove intake manifold from engine.
6. Check if air filter and intake manifold are cracked or damaged.
39
Replace it if necessary.
POWER UNIT
NOTICE
To prevent the engine from accidental starting, you should adopt adequate safeguard measures to cut
off the ignition system. For example: remove the hang rope stopper from stop switch assembly,
and remove spark plug cap from spark plug.
EXPLOSIVE DRAWING
14
23 22
20
15
16
21 19
18
1
2
3
5
17
7
M6x20 mm
8Nm
15
4
1st 15Nm
2nd 30Nm
6
11
9
10
6
13 12
25Nm
PART NO.
DESCRIPTION
REMARKS
GB/T5783-86 六角头螺栓M6×16 HEXAGON ,BOLT
F4-04000018 缸头罩
F4-04000017 缸头罩密封垫
PIPE ,VALVE
F4-04080002 气门导管
CYLINDER ,HEAD
F4-04080101 气缸头
PIN ,HOLLOW
F4-04000003 空心定位销
F4-04000014 缸头复合垫
GB/T5782-1986 六角螺栓M6×45 HEXAGON ,BOLT
火花塞
BPR7HS
F4-04000033 气缸头螺栓A
PLUG ,SPARK
40
4
1
1
2
1
2
1
1
1
3
15
8
M6x45 mm
1st 8Nm
2nd 12Nm
14
23 22
20
15
16
21 19
18
1
2
3
5
17
7
M6x20 mm
8Nm
15
4
1st 15Nm
2nd 30Nm
6
11
9
10
6
13 12
25Nm
PART NO.
DESCRIPTION
REMARKS
BOLT
F4-04000034 气缸头螺栓B
六角头螺栓M8×14 BOLT ,HEXAGON
GB/T97.1-85 平垫圈8
WASHER ,PLATE
F4-04000036 节温器
THERMOSTAT
GB/T97.1-85 平垫圈6
WASHER ,PLATE
六角头螺栓M6×20 BOLT ,HEXAGON
F4-04000012 回水管
PIPE ,RETURN
SPILE WATER
F4-04010002 水咀
F4-04070001 节温器盖
F4-04070100 节温器盖水咀组件
41
1
1
1
1
8
3
1
1
1
1
15
8
M6x45 mm
1st 8Nm
2nd 12Nm
14
23 22
20
15
16
21 19
18
1
2
3
5
17
7
M6x20 mm
8Nm
15
4
1st 15Nm
2nd 30Nm
6
11
9
10
6
13 12
25Nm
PART NO.
DESCRIPTION
REMARKS
F4-04000011 节温器盖密封垫
ANODE
F4-04070003 节温器盖阳极
GB/T818-85 十字槽盘头螺钉M5×25
42
1
1
1
15
8
M6x45 mm
1st 8Nm
2nd 12Nm
13
11
10
O
14
6
12
7
10Nm
5
O
4
8
3
L
1277
6
2
5
O
O
1
4
L
1277
2
1
13
O
11
10
14
12
9
PART NO.
DESCRIPTION
REMARKS
PS2700.03.02 气门挺柱
F4-04000015 气门推杆
LIFTER,VALVE
ROD,VALVE PUSH
PLATE,PUSH ROD
F4-04080009 导向板
PS2700.04.12 摇臂螺杆
BOLT,ROCKER ARM
PS2700.04.12 气门摇臂
ARM,VALVE ROCKER
PS2700.04.13 摇臂球座
PIVOT,ROCKER ARM
PS2700.04.18 六角螺母M6x0.75 BOLT
DOOR,INTAKE
F4-04080005 进气门
DOOR,EXHAUST
F4-04080006 排气门
F4-04080007 气门弹簧垫圈
43
2
1
1
2
2
2
1
1
1
2
7
13
11
10
O
14
6
12
7
10Nm
5
O
4
8
3
L
1277
6
2
5
O
O
1
4
L
1277
2
1
13
O
11
10
14
12
9
PART NO.
DESCRIPTION
PS2700.04.03 气门油封
F4-04080008 气门弹簧
F4-04080010 气门弹簧座
F4-04080011 气门锁片
REMARKS
SEAT,VALVE STEM
CLAMP,VALVE
44
2
2
2
2
7
7
8
6
5
3
M6x12mm
8Nm
9
10
O
28
2
1
O
26
13
25
4
O
11
24
12
23
2
O
15
19
14
M8x50mm
1st10Nm
2nd 22Nm
O
17
22
L
1277
1
2
3
4
5
6
7
8
9
10
18
20
27
PART NO.
16
19
M8x20mm
18Nm
21
DESCRIPTION
F4-04010100 曲轴箱体
F4-04010002 气嘴
F4-04010003 曲轴油封A25x40x5
GB/T276-94 深沟球轴承6205C3
F4-04000009 呼吸器密封垫
F4-04000010 呼吸器盖板
REMARKS
CRANK CASE
PIPE,JOINT
OIL SEAL
BEARING
BREATHER GASKET
COVER
六角头螺栓M6x14 HEXAGON ,BOLT
GB/T97.1-85 平垫圈6
WASHER
GB/T818-85 十字槽盘头螺钉M4x6
F4-04010003 呼吸器阀片
SCREW,PAN HEAD
45
1
1
1
1
1
1
3
3
1
1
7
8
6
5
3
M6x12mm
8Nm
9
10
28
O
2
1
O
26
13
25
4
O
11
24
12
23
2
O
15
19
14
M8x50mm
1st10Nm
2nd 22Nm
O
16
17
22
27
L
1277
PART NO.
11
12
13
14
15
16
17
18
19
20
18
20
19
M8x20mm
18Nm
21
DESCRIPTION
F4-04000003 空心定位销φ10x8.4x14
F4-04050001 曲轴箱盖
F4-04000002 曲轴箱体复合垫
REMARKS
HOLLOW PIN
COVER,CRANK CASE
六角法兰面螺栓M8x50 BOLT,HEXAGON
F4-04060003 曲轴油封20x30x7(B) OIL,SEAL
F4-04060004
OIL,SEAL
O-RING
F4-04060002 油封壳体0型圈
SHELL,OIL SEAL
F4-04060001 油封壳体
F4-04060000 油封壳体组件
GB/T97.1-85 平垫圈8
WASHER,PLATE
46
2
1
1
7
1
2
1
1
1
8
7
8
6
5
3
M6x12mm
8Nm
9
10
28
O
2
1
O
26
13
25
4
O
11
24
12
23
2
O
15
19
14
M8x50mm
1st10Nm
2nd 22Nm
O
16
17
22
27
L
1277
PART NO.
21
22
23
24
25
26
27
28
18
20
19
M8x20mm
18Nm
21
DESCRIPTION
REMARKS
六角头螺栓M8x20 HEXAGON ,BOLT
F4-04000006 放油螺栓密封垫 WASHER
GEAR UNIT ASSY
F4-04050000 甩油轮组件
六角头螺栓M6x12 BOLT,HEXAGON
F4-04000008 机油盖阻油圈
O-RING
F4-04000007 带尺机油盖
F4-04000001 放油螺栓
CAMSHAFT ASSY
F4-04040000 凸轮减压组件
47
1
1
1
1
1
1
1
1
4
5
6
1
23
9
4
O
7
M7x35mm
12Nm
8
O
10
PART NO.
F4-04020002
F4-04020003
F4-04020004
F4-04020006
F4-04020005
F4-04020001
F4-04020100
F4-04020103
F4-04030000
F4-04000004
DESCRIPTION
气环1
气环2
组合油环
活塞销卡簧
活塞销
活塞
连杆组件
连杆螺栓
曲轴组件
箱盖减磨片
REMARKS
PISTON RING 1
PISTON RING 2
COMBINED OIL RING
CIRCLIP
PIN ,PISTON
PISTON
ROD ,CONNECTING
BOLT,ROD CLEVEL
CRANK ASSY
WASHER , PLATE
48
1
1
1
2
1
1
1
2
1
1
SPECIAL TOOLS
Piston slider
Bearing puller
Housing bearing installer
Oil seal installer tool
Valve spring compressor
Housing oil seal installer
Space gauge
DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE
1. Open the top cowling.
2. Remove the starter and fuel pump.
3. Remove choke cable and throttle cable.
4. Remove air filter and carburetor.
5. Remove bolts connecting the engine and upper casing.
6. Carry the power unit and put it onto the working table.
DISASSEMBLING AND INSPECTION
49
CYLINDER COVER
Disassembling
1. Remove the bolts of cylinder head cover.
2. Remove the bolts of the cylinder cover according to the reverse numbering sequence of the
cylinder cover.
3. Remove the crankcase cover. Remove the valve push rod.
4. Remove the rocker arm pivot, rocker arm, rocker arm shaft and push rod plate.
5. Use the valve spring compressor to remove intake door and exhaust door.
Push rod
Inspect valve push rod runout. Replace if exceeding the specified value.
Valve push rod runout limit: 0.5mm
1. Inspect the valve seat width.
Valve seat width: 0.6~0.8mm
Valve and valve pipe
If not in the prescribed range, repair the valve seat.
2. Inspect the valve margin thickness (T).
The margin thickness of valve:
Intake door: 0.7mm
Exhaust door: 1.00mm
If not as in the prescribed value, replace the valve.
T
3. Inspect the valve stem diameter. If not in the prescribed range, replace the valve.
The diameter of valve stem:
Intake valve: 5.475~5.490mm
Exhaust valve: 5.460~5.475mm
50
4. Measure the valve stem runout. If exceeding the limit, replace the valve.
Valve stem runout limit: 0.03mm
5. Measure the inner diameter of the valve pipe.
The inner diameter of the valve pipe: 5.500~5.512mm
CAUTION:
When replacing the valve, please use the new valve pipe and valve oil seal.
Valve spring
1. Measure the free length of valve spring. If less than prescribed value, replace.
The minimum free length: 34mm
2. Measure the valve spring tilt. If exceeding the prescribed limit, replace.
The maximum tilt limit: 1.2mm
Valve rocker arm
Check the rocker arm for crack, perforation or damage. Replace if necessary.
Valve pipe replacement
1. Knock out the valve pipe from the direction of combustion room.
2. Knock in the new valve pipe from the direction of the top of cylinder cover.
NOTE:
Coat the oil on the surface of pipe before installation.
3. Bore the inner diameter of pipe to the prescribed value by reamer.
Inner diameter of valve pipe: 5.500~5.512mm
NOTE:
When taking out the reamer, don’t rotate it in counter clockwise direction.
Valve seat inspection
1. Clean the carbon on the valve.
2. Coat a thin layer of bluing dye evenly onto the seal face of the valve seat.
3. Lap the valve on valve seat by valve lapping tool.
4. Measure the valve seat width.
The valve face is with bluing dye.
If the valve and valve seat do not match, or the valve seat width does not conform to specified
value, reface and lap the valve seat.
If the contact surface is not even, replace the valve pipe.
51
The valve seat width:
The maximum valve seat width:
0.6~0.8mm
1.1mm
Valve seat cutting
1. Use 45 cutter to adjust the valve seat width. Turn the cutter clockwise until the valve seat face
is smooth.
o
2. If the valve seat is centered on the valve face but it’s too wide, to reduce the valve seat width, use
30 o cutter to adjust the top edge of the seat, and use 60o cutter to adjust the bottom edge of the
seat.
3. If the valve seat is too narrow and on the top edge of valve surface, use 30°cutter to adjust the
top margin of the seat, and use 45°cutter to adjust the valve seat width if necessary.
4.
If the valve seal surface is too narrow and on the bottom edge of valve surface, use 60°cutter to
adjust the bottom edge of the seat, and use 45°cutter to adjust the valve seat width if necessary.
5. Coat evenly a thin layer of lapping compound onto valve seat, and lap the valve by lapping tool.
6. Clean up the remaining lapping compound.
7. Inspect again the valve seat width.
CAUTION:
52
Do not overlap the valve. Turn the lapping tool evenly with a downward force of 40~50N.
Do not contaminate push rod and valve pipe with lapping compound.
Thermostat
1. Remove thermostat cover and thermostat.
2. Suspend thermostat in the container with water.
3. Heat the container.
4. Inspect valve lift situation in the prescribed water temperature. If out of specification, replace.
Water temperature
The lift height
58~62℃
0.05mm valve lift
Over 70℃
Over 3mm
5. Install thermostat and thermostat cover. Tighten the bolts to specified torque.
CRANKCASE
Disassembling
1. Remove the bolts according to the reverse numbering sequence of the crankcase cover .
2. Remove the cover of crankcase.
3.
Remove the camshaft and valve lifter.
4.
Remove the connecting rod bolt and connecting rod cap, and remove connecting rod and piston
assembly.
5.
Use clipper to remove circlip, and remove piston pin and piston.
6. Remove crankcase and crankcase gasket.
7.
Remove oil splasher gear assembly.
8. Remove breather cover bolts, and remove breather cover.
9. Remove valve bolts and remove valve.
10. Remove oil seal shell bolts, and remove oil seal shell and oil seal.
Breather
1. Inspect breather flap valve, if damaged/cranked/cracked, replace.
2. Inspect breather hole.
If clogged, clean.
53
3. Inspect breather return pipe.
If cracked/leaked/damaged, replace.
Piston
Measure piston outside diameter at the specified measuring point.
Piston diameter: 58.950~58.965mm
a : 10mm
Measuring point○
If out of specification, replace.
a
D
Cylinder bore
Measure cylinder bore separately at measuring point ○
1, ○
2, ○
3 . At each point, measure the
cylinder bore at places D1, D3, D5 parallel to the crankcase and at places D2, D4, D6 vertical to
the crankshaft.
①
1.
2.
D1&D2
③
②
Measuring point height:
1 100mm;
○
2 40mm;
○
3 70mm
○
Cylinder bore: 59~59.02mm
Limit size:
59.10mm
D3&D4
D5&D6
Calculate taper limit and round limit. If out of specification, replace crankcase.
Taper limit: 0.08mm(D1-D5, D2-D6)
Round limit: 0.05mm(D2-D1, D6-D5)
Piston pin diameter
Measure piston pin outside diameter. If out of specification, replace the piston pin.
Piston pin outside diameter: 12.995~13.000mm
Piston ring
1. Push the piston ring parallel with the piston crown into the specified measuring point of the
cylinder (10mm from conjunction surface).
2. Measure end gap by space gauge. If out of specification, replace the piston ring.
End gap (installed) / limit size:
Top ring 0.10~0.20mnm/0.4mm
2nd ring 0.25~0.40mm/0.6mm
Oil ring 0.2~0.7mm/0.9mm
3. Install piston ring to piston, and measure side clearance between piston ring and its slot by
clearance gauge. If out of specification, replace the piston ring.
Side clearance: Top ring 0.04~0.08mnm
2nd ring 0.02~0.06mm
1.
Camshaft decompressor
Inspect camshaft decompressor, gear, and weight. If gear is worn/damaged/cracked, replace.
54
If weight is unsmoothly moving, replace.
a and height ○
b . If out of specification, replace it.
2. Measure camshaft lobe diameter○
a
○ Intake camshaft: 21.950~22.050mm
Exhaust camshaft: 21.950~22.050mm
b
b
○ Intake camshaft: 26.736~26.836mm
Exhaust camshaft: 26.532~26.623mm
a
3. Measure camshaft diameter. If out of specification, replace the camshaft.
Camshaft journal wear limit: 14.934mm
Measure crankshaft runout.
Crankshaft
If out of specification, replace.
Crankshaft runout limit: 0.03mm
Oil clearance
1. Put a piece of plastic space gauge on to the crankpin in parallel to the crankshaft.
2. Assemble the connecting rod to the crankpin.
3. Tighten the connecting rod bolts to the specified torque.
Tightening torque:
12Nm
4.
Remove the connecting rod, measure the compressed width of the plastic space gauge. If out
of specification, replace the connecting rod.
Oil clearance:
0.020~0.052mm
Note:
Don’t rotate the connecting rod before completing measurement.
Valve lifter
1. Inspect valve lifter for wear or damage. Replace if necessary.
2. Measure valve lifter outside diameter. If out of specification, replace the valve lifter.
Valve lifter outside diameter: 7.9650mm
Oil splash gear
Inspect oil splash gear unit, if slow-moving/wear/damage/crack, replace.
Crankshaft bearing
Inspect bearing, if pitting/rumbling, replace.
55
NOTE:
Don’t remove bearing unless you replace it.
1.
Oil seal housing
Inspect oil seal housing for crack/damage. Replace if necessary.
2.
Inspect O-ring for crack/damage.
1.
Crankcase and crankcase cover
Inspect crankcase cover. If cracked/damaged, replace.
2.
Inspect cooling water passage for dirt or clog.
Replace if necessary.
Clean if necessary.
FULL INSTALLATION
Piston connecting rod installation
Install piston, connecting rod, piston pin and piston pin circlip.
NOTE:
When installing, make sure that the mark on the connecting rod is at the same side of the mark on
the piston crown.
Use new piston pin circlip.
Make sure that circlip gap is not aligned with the circlip slot gap.
Piston ring installation
1. Install oil ring, 2nd ring and top ring.
NOTE:
Make sure that the mark is toward the piston crown when installing the 2nd ring.
2.
Picture of the piston ring gap
Oil ring end gap 1 (lower rail)
Oil ring end gap 2 (expanded ring)
Oil ring end gap 3 (upper rail)
2nd piston ring end gap 4
Top piston ring end gap 5
3
4
UP
2、5
1
Piston installation
Use piston slider to install piston, and make sure the piston crown “UP” is toward the flywheel side.
56
NOTE:
Apply motor oil to the piston and piston ring side when installing.
Oil seal housing installation.
1.
Install oil seals 10.8x21x7 (2 pieces) by oil seal installer tool.
2. Install oil seals B20×30×7 by oil seal installer tool.
NOTE:
① Apply grease onto new seal before installation.
② Make sure the oil seal direction as shown.
1.
Crankshaft installation
Install the crankshaft bearing to crankcase by special tools (if change bearing).
Housing bearing installer
Housing oil seal installer
Install oil seal.
Oil seal installing direction
NOTE:
Fit the bearing with its manufacturer’s mark toward the direction of the flywheel side. Apply motor
oil to the new oil seal installing.
2.
Install crankshaft to crankshaft case.
3.
Install connecting rod cover, and tighten the connecting rod bolt to the specified torque.
Specified torque: 12 Nm
NOTE:
Apply motor oil to moving parts before installing.
Camshaft installation
Make sure that the camshaft gear mark is aligned with the camshaft timing gear
Install camshaft.
mark.
NOTE:
Apply motor oil to moving parts before installing.
57
Crankcase cover installation
1.
Install oil seal housing.
2.
Install oil splasher gear assembly.
3.
Install crankcase cover, and tighten the bolts twice as shown.
Tightening torque:
1st 10 Nm
2nd 22 Nm
NOTE:
Apply motor oil to moving parts before installing.
5
1
4
3
6
2
7
UPPER UNIT
TOP COWLING
EXPLOSIVE DRAWING
58
5Nm
5Nm
PART NO.
DESCRIPTION
REMARKS
F4-06000000
GB/T8.8-2000
F4-06000005
F4-06000002
GB/T845-85
F4-06000003
F15-08000004
F4-06000001
GB/T818-2000
59
5Nm
5Nm
PART NO.
DESCRIPTION
REMARKS
F4-06000006
F4-06000004
60
Disassembling and inspection
1.
Remove airproof rubber bar.
2.
Remove top cowling muffling cover bolt and rubber underlay.
3.
Remove top cowling muffling cover.
4.
Remove lock hook and pothook.
5.
Inspect if top cowling is cracked or damaged.
6.
Inspect if airproof rubber bar is cracked or damaged.
7.
Inspect if top cowling muffling cover is cracked or damaged.
8.
Inspect if lock hook and pothook is cracked, deformed or damaged.
Replace it if necessary.
Replace it if necessary.
BOTTOM COWLING
Explosive drawing
61
Replace it if necessary.
Replace it if necessary.
PART NO.
DESCRIPTION
REMARKS
F4-05000001
GB/T818-2000
F4-05000016
GB/T818-2000
GB/T5783-86
F15-05030000
F15-05000022
F15-05000023
F15-05000036
F4-05000012
62
PART NO.
DESCRIPTION
REMARKS
F4-05000013-2
GB/T6170-86
GB/T5783-2000
GB/T97.1-85
GB/T5783-2000
Disassembling and inspection
1.
Remove rubber cover B.
2.
Remove handle bolt and handle.
3.
Remove top cowling clamp lever bolt and clamp lever.
63
4.
Remove top cowling clamp lever bush A and clamp lever bush B.
5.
Remove wave washer.
6.
Inspect if bottom cowling is cracked or damaged.
7.
Inspect if clamp lever handle is cracked or damaged.
8.
Inspect if clamp lever is cracked or damaged.
9.
Inspect if wave washer and clamp lever bush are cracked or damaged.
necessary.
Replace if necessary.
Replace if necessary.
Replace if necessary.
STEERING HANDLE
Explosive drawing
L
1243
M8x25mm
18Nm
G
G
G
L
1243
PART NO.
1
2
3
4
5
6
7
8
9
10
G
DESCRIPTION
REMARKS
1
操舵手柄
BUSGING,HANDTE A 1
手柄衬套A
手柄衬套波形垫圈 BUSH
1
WASHER,BUSHING B 2
衬套垫圈B
操舵手柄减震器 BUSHING,RABBER
1
WASHER BUSHING A 1
衬套垫圈A
BUSHING
1
F4-01000008 操舵手柄衬套B
1
F4-01000014 操舵手柄盖板
六角头螺栓M8x25 BOLT
1
GB/T91-86
开口销φ1.6x12 PIN,COTTER
1
F4-01090001
F4-01000009
F4-01000012
F4-01000010
F4-05000014
F4-01000011
HANDLE,STEERING
64
Replace if
L
1243
M8x25mm
18Nm
G
G
G
L
1243
PART NO.
11
12
13
14
15
16
17
18
19
20
G
DESCRIPTION
REMARKS
F4-01090200 阻力调整旋钮组件
F4-01090006 衬套
F4-01090007 压缩弹簧
BUSH
GB/T848-85 小垫圈10
F4-01090303 油门标志牌
WASHER,PLATE
F4-01090301 操舵手柄塑胶套
F4-01090302 操舵手柄橡胶套
RUBBER,HANDLE
GB/T820-85 十字槽半沉头螺钉M5x24 SCREW
GB/T827-86 标牌铆钉2x5
F4-01090300 油门握把组件
RINET
65
1
1
1
1
1
1
1
1
1
1
L
1243
M8x25mm
18Nm
G
G
G
L
1243
PART NO.
21
22
23
24
25
26
27
G
DESCRIPTION
REMARKS
F4-01090003 操舵手柄握把摩擦块 FRICTION
LEVER,THROTLLE
F4-01090100 节气门杆组件
GB/T818-85 十字槽盘头螺钉M5x12 SCREW,PAN HEAD
F4-01090002 节气门杆固定板 STAY
F4-01090008 油门钢索组件
F4-01090401 引擎停止安全索
F4-01090400 急停开关组件
1
1
2
1
1
1
1
1.
Disassembling and inspection
Remove steering handle cover.
2.
Remove handle bush, bush washer and wave washer.
3.
Remove steering handle shocker damper.
66
4. Remove cotter pin and friction adjusting bolt.
5. Remove steering handle.
6. Remove throttle cable.
7. Remove throttle lever stay and throttle lever.
8. Remove engine stop switch.
9. Inspect if steering handle is cracked or damaged.
Replace if necessary.
10. Inspect if bush, bush washer and wave washer are cracked or damaged.
necessary.
11. Inspect if steering handle shock damper is cracked or damaged.
12.
Inspect if throttle cable is cracked or damaged.
13. Inspect the conduction of engine stop switch.
Remove lockplate:
Conducting
Install lockplate:
Not conducting
Push stop switch button: Conducting
67
Replace if
Replace if necessary.
Replace if necessary.
If not to specification, replace it.
BRACKET
Explosive drawing
G
M6x35mm
1st 3Nm
2nd 8Nm
G
13Nm
G
M6x10mm
1st 3Nm
2nd 8Nm
G
PART NO.
1
2
3
4
5
6
7
8
DESCRIPTION
REMARKS
HEXAGON NUT
4
1
1
1
1
1
2
1
1
WASHER
11
F4-02000008 减震圈衬管
F4-02000007 上减震圈
F4-02020000 水上装置锁紧圈组件
F4-01050002 锥形弹簧
F4-01050000 角度调整杆组件
SPRING ,CONICAL
TILT ROD ASSY
非金属嵌件六角锁紧螺母M8
F4-01000002 双孔固定板
F4-01030001 旋转支架座
9 GB/T6170-86 六角螺母M6
10 GB/T97.1-85 平垫圈6
NUT
PLATE
BRACKET ,SWIVEL
68
G
M6x35mm
1st 3Nm
2nd 8Nm
G
13Nm
G
M6x10mm
1st 3Nm
2nd 8Nm
G
PART NO.
11
12
13
14
15
16
17
18
DESCRIPTION
REMARKS
WASHER ,NYLON
F4-01000003 尼龙垫圈
F4-01030003 支撑架扭簧(左)
F4-01030002 支撑架尼龙衬套 BUSHING ,NYLON
六角头螺栓M6×20 HEXAGON ,BOLT
F4-01030005
F4-01030103
F4-01030004
F4-01030100
支撑架固定盖
手柄套
SHEATH HANDLE
支撑架扭簧(右)
角度定位支撑架组件
19 F4-01000006 锁紧钩扭簧(左) SPRING
20 F4-01000007 锁紧钩扭簧(右) SPRING
69
2
1
2
2
1
2
1
1
1
1
G
M6x35mm
1st 3Nm
2nd 8Nm
G
13Nm
G
M6x10mm
1st 3Nm
2nd 8Nm
G
PART NO.
21
22
23
24
25
26
27
28
29
30
DESCRIPTION
六角头螺栓M6×12
F4-01070000
F4-02000009
F4-01000004
F4-01010005
REMARKS
HEXAGON BOLT
起翘锁紧钩组件
下减震圈
螺栓垫管
BUSHER ,BOLT
艉板夹紧手柄铆钉
F4-01010004 艉板夹紧手柄
F4-01010002 艉板夹紧螺杆
F4-01010003 艉板夹紧圆盘
六角螺栓M6×120
六角螺栓M8×135
CLAMP BOLT
CLAMP PLATE
HEXAGON BOLT
HEXAGON BOLT
70
2
1
1
1
2
2
2
2
1
1
G
M6x35mm
1st 3Nm
2nd 8Nm
G
13Nm
G
M6x10mm
1st 3Nm
2nd 8Nm
G
PART NO.
31
32
33
34
35
36
37
38
DESCRIPTION
REMARKS
F4-01010001 夹紧托架(右)
F4-01000005 旋转支架座盖
GB/T5782-86 六角头螺栓M6x35 HEXAGON BOLT
F4-01060002 锁紧手柄
CLAMP HANDLE
RIVET
GB/T875-86 扁平头半空心铆钉φ4x11
LOCKED SCREW
F4-01060001 锁紧螺杆
GB/T96-1985 大垫圈
BIG WASHER
F4-01020000 夹紧托架(左)组件
1
1
6
1
1
1
2
1
Disassembling and inspection
1. Remove tilt locked clasp.
2. Remove swivel bracket cover.
3. Remove bottom shock absorption assembly and shock absorption bush.
71
4. Remove clamp bracket
5. .Remove swivel bracket.
6. Remove bracket fixed cover, and the tilt lock bracket.
7. Inspect the the swivel bracket and clamp bracket for damage or crack.
8. Inspect the bush and shock absorption for damage or crack.
Replace if necessary.
Replace if necessary.
9. Inspect: whether the tilt lock bracket and tilt locked clasp were distorted, replace if needed.
72
UPPER UNIT
Explosive drawing
G
M6x25mm
4.5Nm
M6x20mm
10Nm
PART NO.
DESCRIPTION
1
2
F4-00000007 变档手柄
F4-02010000 变档拨叉组件
3
4
5
6
JISB2401
"O"形密封圈P9
F4-02000002 水上装置壳体铜套
7
REMARKS
HANDLE,GEAR SHIFT
SPRING,GEAR
BALL 8
1
1
2
1
1
1
1
BOLT
PIN,COTTER
WASHER,PLATE 5
1
1
2
SHAFT,CHANGE
O-RING
BUSHING,SHIFT ROD LEVER
GB/T820-2000 十字半沉头螺钉M5x20 SCREW,OVAL HEAD
F4-02000003 变档弹簧
钢珠8
GB308-84
8 GB/T5783-2000 六角螺栓M5x25
9 GB/T308-84 开口销1.6x12
平垫圈5
10 GB/T97.1
73
G
M6x25mm
4.5Nm
M6x20mm
10Nm
PART NO.
DESCRIPTION
11 F4-02000006 变档连杆支架
12
13
14
15
16
17
F4-02000004
F4-00000003
F4-00000004
F4-00000005
GB/T5284-86
F4-00000001
REMARKS
LEVER,SHIFT ROD
1
ROD,SHIFT
1
变档连杆
变档连杆连接器A CONNECTOR,SHIFT ROD1 A
变档连杆连接器B CONNECTOR,SHIFT ROD1 B
大垫圈
BIG,WASHER
1
六角头螺栓M6x20 BOLT
1
PIN ,HOLLOW
空心定位销
直通式压注油杯M6 GREASE CUP
18
WASHER
19 GB/T97.1-85 平垫圈6
20 GB/T5284-86 六角头螺栓M6×35 HEXAGON BOLT
74
Type S:2
G
M6x25mm
4.5Nm
M6x20mm
10Nm
PART NO.
DESCRIPTION
REMARKS
21 F4-02000011 变档轴密封圈
22 F4-02000001 水上装置壳体
CASING ,UPPER
23 F4-02000012 水上装置橡胶堵头
24 F4-02040002 工形橡胶圈
25 F4-02040000 进水管
26 F4-02030001 接长体
EXTENSION
27
孔用弹性挡圈22 CIRCLIP
28 F4-02030003 驱动轴橡胶衬套 RUBBER BUSHING
29 F4-02030002 驱动轴衬套
GASKET ,ENGINE
30 F4-00000006 发动机密封垫
1
1
2
1
1
1
Disassembling and inspection
1. Remove the water tube.
2. Remove the gear shift handle and change shaft.
3. Remove the shift rod and shift rod lever.
75
4. Check upper casing and extension for crack or wear.
Replace if necessary.
5. Check gear shift handle and change shaft for crack or wear.
Peplace if necessary.
LOWER UNIT
WATER PUMP ASSEMBLY
76
Explosive drawing
M6x45 mm
1st 3Nm
2nd 8Nm
G
M6x25 mm
1st 3Nm
2nd 8Nm
G
L
1277
14
15
PART NO.
1
2
3
4
5
6
7
8
9
10
DESCRIPTION
REMARKS
六角头螺栓M6×45 HEXAGON BOLT
泵壳固定板
泵壳橡胶管
水泵座定位销
水泵壳
泵壳密封垫
水泵内壳
水泵叶轮
F4-03000015 外档板
F4-03000020
F4-03000021
F4-03000013
F4-03000019
F4-03000018
F4-03000017
F4-03060000
PIN ,WATER PUMP
OUT PLATE
F4-03000014
77
4
2
1
2
1
1
1
1
1
1
M6x45 mm
1st 3Nm
2nd 8Nm
G
M6x25 mm
1st 3Nm
2nd 8Nm
G
PART NO.
L
1277
DESCRIPTION
六角头螺栓M6×25
11
12 GB/T97.1-85 平垫圈6
13 F4-03000012 水泵座
14 F4-03000011 水泵座密封垫
REMARKS
HEXAGON BOLT
WASHER ,PLATE
BASE ,WATER PUMP
HERMETIC GASKET
1
5
1
1
Disassembling and inspection
1. Remove water pump fixed plate.
2. Remove water pump housing.
3. Remove water pump impeller and inner water pump cover.
4. Remove water pump base.
78
5. Check water pump housing and out plate for crack, crank or damage.
Replace if necessary.
6. Check inner water pump cover and impeller for crack, deform, burn or damage.
necessary.
7.
Check water pump base for crack, crank, scratch or damage.
LOWER UNIT
Explosive drawing
79
Replace if necessary.
Replace if
G
33
1
M6x16mm
8Nm
37
19
2 3
4
34
G
18
17 16
35
5
14
L
1277
15
13
12
11
20
32
G
31
30
10
29
14 28
27
6
7
8
9
M6x16mm
1st 3Nm
2nd 8Nm
PART NO.
L
1277
23
22 21
22 26
25
21
24
M6
1st 3Nm
2nd 8Nm
DESCRIPTION
开口销2.5×30
螺母组件
不锈钢垫片
螺旋桨组件
不锈钢垫块
F4-03000022 阳极
GB/T97.1-85 平垫圈6
GB/T861.1-87 内齿锁紧垫圈6
GB/T91-86
F4-03080000
F4-03000026
F4-03070000
F4-03000025
REMARKS
PIN ,COTTER
NUT ASSY
WASHER
PROPELLER ASSY
SPACER
ANODE
WASHER ,PLATE
GB/T5783-2000 六角头螺栓M6×12
HEXAGON BOLT
F4-00000001 空心定位销
HOLLOW PIN
80
1
1
1
1
1
1
1
1
1
2
18
L
1277
36
G
33
1
M6x16mm
8Nm
37
19
2 3
4
34
G
18
17 16
35
5
14
L
1277
15
20
32
G
31
30
10
29
14 28
27
6
7
8
9
L
1277
M6x16mm
1st 3Nm
2nd 8Nm
PART NO.
11
12
13
14
15
16
17
18
19
20
13
12
11
22 26
25
21
24
M6
1st 3Nm
2nd 8Nm
DESCRIPTION
REMARKS
F4-03000027 油封 10.8×21×7
OIL SEAL
F4-03000009 倒档齿轮垫圈
F4-03040000 倒档齿轮组件
GB/T276-94 深沟球轴承6004C2 BEARING
OIL SEAL
F4-03050002 油封13×22×7
JISB2401 P48 水下装置壳体盖O形圈 O-RING
F4-03050001 水下装置壳体盖
GB/T97.1-85
23
22 21
平垫圈6
GB/T5783-2000 六角头螺栓M6×18 HEXAGON BOLT
F4-03000003 不带档边筒形轴承 BEARING
81
2
2
1
2
2
1
1
5
2
1
18
L
1277
36
G
33
1
M6x16mm
8Nm
37
19
2 3
4
34
G
18
17 16
35
5
14
13
12
11
L
1277
15
20
32
G
31
30
10
29
14 28
27
6
7
8
9
L
1277
M6x16mm
1st 3Nm
2nd 8Nm
PART NO.
21
22
23
24
25
26
27
28
29
30
23
22 21
22 26
25
21
24
M6
1st 3Nm
2nd 8Nm
DESCRIPTION
REMARKS
F4-03000023 注油孔螺塞
PLUG ,OIL HOLE
F4-03000024 注油孔螺塞垫圈 GASKET
F4-03000001 水下装置壳体
GB/T-896-86 开口档圈6
LOWER CASING
CIRCLIP
F4-03000007 主动齿轮
F4-03000006 主动齿轮垫圈
F4-03000002 带档边筒形轴承
INITIATIVE GEAR
F4-03000008 变档柱塞
PLUGER ,SHIFT
F4-03010000 正档齿轮组件
F4-03030002 离合器块
CLUTCH BLOCK
BEARING
82
3
3
1
1
1
1
1
1
1
1
18
L
1277
36
G
33
1
M6x16mm
8Nm
37
19
2 3
4
34
G
18
17 16
5
35
14
13
12
11
L
1277
15
20
32
G
31
30
10
29
14 28
27
6
7
8
9
L
1277
M6x16mm
1st 3Nm
2nd 8Nm
PART NO.
23
22 21
22 26
25
21
24
M6
1st 3Nm
2nd 8Nm
DESCRIPTION
31 F4-03000003 离合器块压簧
32 F4-03030001 螺旋桨轴
33 F4-03000004 驱动轴
F4-03000004S
REMARKS
SHAFT ,PROPELLER
SHAFT ,DRIVE
SHAFT ,DRIVE
34 F4-03000016 叶轮定位销
PIN
CLIP
35 F4-03000005 轴用钢丝档圈
六角头长螺栓M6×167 HEXAGON BOLT
36
六角头长螺栓M6×40
HEXAGON BOLT
37 F4-03020000 变档凸轮组件
F4-03020000S 变档凸轮组件
1
1
1
1
2
1
2
2
L
S
L
S
L
S
Disassembling and inspection
1. Remove cotter pin and nut assy.
2. Remove propeller assembly and spacer.
3. Remove the lower casing cover.
83
18
L
1277
36
4. Remove the reverse gear assy, drive shaft, positive gear assy, and shift pluger.
5. Remove shift rod cam assy and drive shaft.
6. Remove barrel bearing with guard board (F4-03000002).
7. Remove barrel bearing without guard board (F4-03000003) by using barrel bearing installer
tool.
8. Remove the clutch block from the propeller shaft.
Propeller shaft and clutch block
1. Check clutch block for wear or damage.
2. Check propeller shaft for wear or damage.
Replace if necessary.
Replace if necessary.
Clutch block installation
1. Put clutch block spring into the hole of the propeller shaft tail.
2. Install the clutch block as shown. Take note of the direction.
L
L
Lower casing cover
1. Check bearing for rust or rumbling when run. Replace if necessarary.
2. Remove bearing and oil seal by bearing puller.
Note:
Don’t remove bearing unless change it.
3. Clean casing cover by a soft brush and solvent.
4. Check casing cover for crack or damage.
Replace if necessary.
Lower casing cover oil seal and bearing installation
1. Install oil seal.
2. Install bearing.
84
Note:
Please use special tool to install oil seal and bearing.
Pay attention to the oil seal installation direction and installation depth.
Make sure the manufacturer mark faces toward the reverse gear.
Barrel bearing
Inspect barrel bearing with guard board and barrel bearing without guard board for wear, crack or
damage. Replace if necessary.
Inspect the drive shaft for crank or wear.
Drive shaft
Replace if necessary.
Gear
Inspect the forward gear, reverse gear and mini gear for wear or damage.
Replace if necessary. .
Forward gear bearing
Inspect bearing for rust and rumbling when rotating. Replace if necessary.
Lower unit casing
1. Inspect lower casing cover for crack or damage. Check if the cooling water inlet is blocked.
Replace if necessary.
2. Install the barrel bearing with guard board and barrel bearing without guard board by special tool.
Barrel bearing with guard board installer tool
Lower casing bracket and barrel bearing
without guard board installer tool
3. Install new oil seal, with the depth as shown.
(unit: mm)
Lower casing bracket and drive shaft oil seal installer tool
85
COMMON TROUBLES AND SOLUTIONS
Trouble type
Starter will not
operate
Possible reason
Recovery action
Starter components are faulty
Repair or replace
Shift level is not in neutral
Shift to neutral
Fuel tank is empty
Fill tank with clean, fresh fuel
Fuel is contaminated or stale
Engine will not
start (starter
operates)
Engine idles
irregularly or
stalls
Fuel filter clogged
Replace fuel filter
Fuel pump has malfunctioned
Repair or replace
Air vent screw not loosened
Loosen air vent screw
Spark plug(s) fouled or of incorrect type.
Inspect spark plug(s). Clean or replace
with recommended type
Spark plug cap(s) fitted incorrectly
Check and re-fit cap(s)
Ignition wiring damaged or poorly
connected
Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires
Ignition parts are faulty
Replace
Engine stop switch lanyard is not
attached
Attach lanyard
Engine inner parts are damaged
Repair
Spark plug(s) fouled or of incorrect type.
Inspect spark plug(s). Clean or replace
with recommended type
Fuel system is obstructed
Check for pinched or kinked fuel line or other
obstructions in fuel system
Fuel is contaminated or stale
Fill tank with clean, fresh fuel
Fuel filter clogged
Replace with recommended type
Spark plug gap is incorrect
Inspect and adjust as specified
Ignition wiring damaged or poorly
connected
Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires
Specified engine oil is not being used
Check and replace oil as specified
Thermostat is faulty or clogged
Replace
Carburetor adjustments are incorrect
Replace
Fuel pump is damaged
Replace
Air vent screw on fuel tank is closed
Loosen air vent screw
Fuel joint connection is incorrect
Connect correctly
Choke knob is pulled out
Return to home position
Motor angle is too high
Return to normal operating position
86
Cont’d
Trouble type
Possible reason
Recovery action
Propeller is damaged
Repair or replace propeller
Trim angle is incorrect
Adjust trim angle to achieve most efficient
operation
Motor is mounted at incorrect transom
height
Adjust motor to proper transom height
Boat bottom is fouled with marine growth
Clean boat bottom
Weeds or other foreign matter are tangled
on gear housing
Remove foreign matter and clean lower unit
Spark plug(s) are fouled or incorrect type
Inspect spark plug(s).
recommended type
Fuel system is obstructed
Check for pinched or kinked fuel line or other
obstructions in fuel system
Fuel filter is clogged
Replace with recommended type
Fuel is contaminated or stale
Fill tank with clean, fresh fuel
Spark plug gap is incorrect
Inspect and adjust as specified
Ignition wiring is damaged or poorly
connected
Check wires for wear or breaks. Tighten all
loose connections. Replace worn or broken
wires
Ignition parts have failed
Replace
Specified engine oil is not being used or
oil is added too much
Check and replace oil as specified, or add
engine oil to specified position
Thermostat is faulty
Replace
Fuel pump has malfunctioned
Replace
Fuel joint connection is incorrect
Connect correctly
Specified spark plug(s) are not being used
Check and replace spark plug(s) as specified
Propeller is damaged
Repair or replace propeller
Propeller shaft is damaged
Replace
Weeds or other foreign matter are tangled
on propeller
Remove and clean propeller
Motor mounting bolt is loose
Tighten bolt
Steering pivot is loose
Tighten steering pivot
Steering pivot is damaged
Replace
Engine power loss
Engine vibrates
excessively
87
Clean or replace with
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