F2.6BM
Contents
1. Power Unit Item Description Item Description E us Valve Intake 0 08 0 12mm ES Warp limit 0 1mm clearance m cold Exhaust 0 08 0 12mm Bore 54 00 54 015mm Intake 1 84 2 26mm Face width E Wear limit 54 1mm Exhaust 1 84 2 26mm Taper limit Intak 6 0 d aper limi 0 08mm EE ntake 0 6 0 8mm Out of round limit 0 05mm Exhaust 0 6 0 8mm Piston diameter 58 950 58 965mm Intake 0 7mm Margin Measuring point Omm from the thickness Exhaust 1 0mm height Bottom of piston ki Piston to cylinder 2 0 035 0 065mm E Intake 23 9 24 1mm clearance gt Head Pin boss inside diameter 12 009 12 017mm Exhaust 21 9 22 1mm diameter Piston pin outside diameter 11 995 12 000mm Stem outside Intake 5 475 5 490mm Thickness 0 97 0 99mm diameter Exhaust 5 460 5 475mm Breadth 1 95 2 1 Guide insid Intak rea 95 5mm e inside ntake NR m End gap 0 15 0 30mm diameter Exhaust Stem to Intake 0 010 0 037mm E Wear limit 0 40mm guide clearance Exhaust 0 025 0 052mm Side clearance 0 04 0 08mm Rod runout limit 0 03mm Thickness 1 17 1 19mm Push rod runout limit 0 5mm ep Breadth 2 30 2 30mm Free length 35 0mm B S 2 E End gap 0 30 0 43mm E Free length limit 34 0mm 8 4 Wearlimit 0 60mm Tilt limit 1 2mm Sp Small end inside Side clearance 0 02 0 06mm 12 006 12 02mm diameter lt Bi2. 8 Disassembling and inspection 4 0 BOTTOM COWLING 05 Explosive drawing 5 Disassembling and inspection bs STEERING HANDLE e eececceccccccecececcccececcecececces Explosive drawing S Disassembling and inspection 2 BRACKET 3 Explosive drawing e053 Disassembling and inspection 7 UPPER UNIT oaooaooooooo Explosive drawing rg Disassembling and inspection
3. GB Forward gear bearing 4 5 Lower unit casing 08 COMMON TROUBLES AND SOLUTIONS 70 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 To prevent from theft the serial number label will be destroyed if removed from the outboard motor TT NOMINAL POWER Masufatturer 2 N J 4 1 Outboard motor serial number location Serial number as follows SN E TN 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 that the outb
4. Valve and valve pipe nnd Valve spring eene dl Valve rocker arm 2 Valve pipe replacement 4 4 2 Valve seat inspection eeeeeeccceeeeeeeeeeeiiecced Valve seat cutting 112222242 Thermostat o3 CRANKCASE eeeeeecccccccccececececececececcecececeeecececeeeecced3 Disassembling 00 3 Piston 4 Cylinder bore 4 Piston pin diameter ees Piston ring 4 Camshaft decompressor 44 e Crankshaft eceeeececeocecceccccccceccececcced5 Oil clearance
5. 4 EXPLOSIVE DRAWING eeecccccccecceccceccecccceccecceeec A WIRING DIAGRAM e eeccecccccceccecceccecceccececeecscecec S SPARK PLUG IGNITION eeecccccccccececccceeccececceecf SPARK PLUG ecececcceccccceccceccceccecceccecceecsccccedc 7 FLYWHEEL MAINTENANCE eecccccccceececcececcceccceec 7 IGNITOR COIL INSPECTION eeeeeccccccceceeeDn 7 FUEL SYSTEM ooo08 NOTICE 08 EXPLOSIVE DRAWING eeccccccccececceccecccecccecceeeedc FUEL TANK REMOVAL AND INSPECTION 32 INTAKE SYSTEM REMOVAL AND INSPECTION 3 POWER UNIT E NOTICE KT EXPLOSIVE DRAWING 3 SPECIAL TOOLS seess ee ees DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE 40 DISASSEMBLING AND INSPECTION 599999999999 CYLINDER COVER ee e e e all Disassembling ehh Push rod
6. 60 LOWER UNIT WATER PUMP ASSEMBLY G7 Explosive drawing 02 Disassembling and inspection 63 LOWER UNIT eecccccccccccccccceecccececececcccccccceo A Explosive Drawing 64 Disassembling and inspection 4 0 Propeller shaft and clutch block sss ss ses ese ose 67 Clutch block installation 67 Lower casing cover 2407 Lower casing cover oil seal and bearing installation 68 Barrel bearing 8 Drive shaft 459 Gear
7. SN PART NO DESCRI PTI CN QTY REMARKS 11 IF401090001 STEERI NG 1 12 4 0109002 0000000 AA 1 13 19 1818 85 0000000 12 SCREWPAN HEAD 2 14 2 6 02010003 000000 THROITLE CABLE ASSY 1 15 F4 009010 LEVER THROILLE ASSY 1 16 F4 01090003 1 17 4 01090006 BUSH 1 18 F4 01090007 SPRI NG 1 19 Gy T8348 85 000 10 VASHER 1 20 IF4 01090303 00000 I CATCR THROTTLE 1 21 1827 86 0000p 2 5 R VET 1 22 IT15 01020301 PLASTI C COVER HANDLE 1 23 Gy 820 85 00000000 24 SCREW 1 24 T15 01020302 0000000 RUBBER COVER HANDLE 1 25 IT15 01020300 SEER NGS 1 26 IF4 01090401 STCPER HANG ROPE ASSY 1 27 2 6 02010200 100000 ENG NE STOP SWTCH ASSY 1 Disassembling and inspection 1 Remove steering handle cover 2 Remove handle bush bush washer and wave washer 3 Remove steering handle damper assembly 52 Remove friction adjusting bolt Remove steering handle Remove throttle cable Remove throttle lever stay and throttle lever Remove engine stop switch E 59 uu ur S Inspect if steering handle is cracked or damaged Replace if necessary 10 Inspect if bush bush washer and wave washer are cracked or damaged Replace if necessary 11 Inspect if steering handle damper is cracked or damaged Replace if necessary 12 Inspect if throttl
8. Lower casing bracket and drive shaft oil seal installer tool 69 COMMON TROUBLES AND SOLUTIONS Trouble type Possible reason Recovery action Starter will not operate Starter components are faulty Repair or replace Engine will not start starter operates Fuel tank is empty Fuel is contaminated or stale Fill tank with clean fresh fuel 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 Check wires for wear or breaks Tighten all loose connections Replace worn or connected broken wires Ignition parts are faulty Replace Engine stop switch lanyard is not Attach lanyard attached Engine inner parts are damaged Repair Valve gap is incorrect Inspect and adjust as specified Engine idles irregularly or stalls Spark plug s fouled or of incorrect type Fuel system is obstructed Inspect spark plug s Clean or replace with recommended type Check for pinched or kinked fuel line or other obstructions in fuel system Fuel is contaminated or stale Fill tank with clean fresh fuel Spark plug gap is incorrect Inspect and adjust as specified Ignition wiring damaged or poorly connected Spe
9. a ease Power unit Ignition system 555999 ee ees dl TIGHTENING TORQUE Specified torque enne General torque of PERIODIC SERVICE o3 MAINTENANCE TIME TABLE eececcecceccccceccecececce 3 FUEL SYSTEM ees seess e 3 POWER UNIT Engine oil level Changing engine oil rra Valve clearance el 5 Spark plug EE ee e 5 CONTROL SYSTEM 0 Throttle grip eee 0 00
10. 5 Valve lifter 6 Oil splash gear 6 Crankshaft bearing 6 Oil seal housing 6 Crankcase and crankcase cover 44 FULL INSTALLATION eecccccccccceccececececceccccceceel Piston connecting rod installation 4 4 44 0 Piston ring installation 6 Piston installation 7 Oil seal housing installation 4 4 47 Crankshaft installation eccecccccccccccccccccce 7 Camshaft installation eceececcccccccccccccccceM 7 Crankcase cover installation 4 4 44 4 4 UPPER UNIT 59 COWLING Explosive drawing
11. m SN PART DESCRI PTI CN QTY 1 2 6 03000001 00000 LONER CASI NG 1 F2 6 03000003 00000000 BEARI NG 1 j F2 6 03000004 OO 0 000 9 8x24x9 OL SEAL 1 4 F2 603000012 000000 1 F2603003 J 0 0 0 0 3 57 PIN 1 6 F26030001 DRI VE SHAFT 1 9191 86 000 2 5x30 COITER 1 F403080000 ASSY 1 F4030096 00000 VASHER 1 10 F260301000 0 0000 PRCPELLER ASSY 1 11 F4030005 SPACER 1 1 GyT5783 2000 0 0 0 0 x16 2 B 8 97 1 85 10006 VASER 2 M F4 03050002 000000 19227 GL SEAL 2 64 M6x16mm 8Nm G ar 12 8 313 2 dy x 4 Dag E 1 2 8 31 28 lt 1st 30 2 8Nm FHRS SN PART NO DESCR PTI QN QTY REMRKS 15 F2 6 03000301 0000000 COVER LO ER CASI NG 1 16 2 6 03000302 n nnn BEAR NG SLEEVE 1 17 F26030030 000000000 COVER ASSY LOMER OSING 1 18 JISB 2401 P48 000 9105 47 13 5 OR 1 19 F26 0300001 nnnnn VASHER 1 20 F2 603000020 0000 PLUG SH FT 1 21 _NN6003EY 00000 BALL BEARI NG 1 22 F2 6 03000019 000000 PCBI TI VE GEAR ASSY 1 23 F2 603000202 0000 CLUTCH BLOCK 1 24 F4 03030003 000000 SPRI NG CLUTCH BLOCK 1 15 F2 6 030000201 0 0 O SHAFT PROPELLER 1 26 F2 603000002 0000000 BEARI NG 1 27 F2 6 03000017 0000000 102 000 SH
12. 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 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 Lower unit leakage check 17 Connecting the leakage tester to the oil level checking hole to check the lower unit leakage If the pressure drops pressure 1kg cm3 inspect the oil seal and components 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 Cooling water passage 1 Inspect cooling water passage If blocked clean it 18 Cooling water passage inlet 2 Place the outboard engine in the water and ensure the water leve
13. Remove swivel bracket cover Remove swivel bracket bushing and damper Remove clamp bracket Remove swivel bracket Remove title clamp handle and title lock lever Inspect the the swivel bracket and clamp bracket for damage or crack Replace if necessary Inspect swivel bracket bushing and damper for damage or crack Replace if necessary Inspect whether title clamp handle and title lock lever are deformed or damaged Replace if necessary 97 UPPER UNIT Explosive drawing 18 197 M6x25 L 30 5 Nm E 28 22 21 6 DA 31 7 1 9 5 M x20mm 10Nm SN PART NO DESCRI PTI CN QTY REMARKS 1 2 6 02000006 LEVEL SH FT RCD 1 2 1 85 0005 VASHER 3 3 F2 6 02000008 0000000 VASHER SH FT ROD LEVER 1 4 GyT5782 2000 0 0 0 0 12 1 5 98 791 86 000 1 6x12 PI N COTTER 1 6 2 6 02000007 0000 RCD SH FT 1 7 F2 600000001 CONNECTOR SH FT ROD A 1 8 F2 6 00000002 GONNECTQR SH FT FCD B 9 F2 e0300005 SH FT CAMSHAFT 1 10 GyT879 2 2000 000000000 2 5x14 PIN 1 11 amp T5783 2000 0 0 0 0 20 1 12 F4 02000002 00000000 BUSH NG SH ROD LEVER 1 13 1582401 900079 O RING 2 14 F2 6 02020000 SH FT ASSY 1 58 18 14 13
14. 0006 Idling speed LOWER UNIT eecceecccccccccecceceecccecocccececccce 7 Gear oaooooooooooooooo 7 Changing gear oil sess us es aes ev T Lower unit leakage check 7 GENERAL INSPECTION eccceccccceeceececcecceececececg Anode eeeeeecccccccecceceeesececcceccecceccecececcccel g Grease points e e 5 Cooling water passage 3 RECOIL STARTER e eecceccccccceccececcececceccececceececccecce NOTICE ececcccccccccccccccccccssccccccccccccceecceee O EXPLOSIVE DRAWING eececcccccceccecccececceeccececececede DISASSEMBLING eececccceccccccceccecceccecccecececcecee c START ROPE REPLACEMENT eececccecccccecccececcecceeec DISASSEMBLING AND INSPECTION toot 23 ASSEMBLING eececececcccceccececceccecceceeeeececcceeccedc A INSTALLATION eeeccccccccececceceecccccecececceccececceec A IGNITION SYSTEM NOTICE
15. 0100 4x12 PIN 2 16 dyT5783 2000 n 0 0 0 14 1 17 4 04000006 VASHER 2 18 F404001 0 000 20 D 5 NG OL 1 19 2 6 04060000 0800000 aL SEAL SHELL ASSY 1 20 F2 6 0406002 0 0 0000 K 5657 OL SEAL 2 21 F4 04060002 00009000 ORNS 1 22 F2 6 04060001 SHELL GL SEAL 1 23 5783 200 0 1 24 25 05000013 1 25 5782 200 0 0 45 BOLT 8 38 8 M6x29mm and aN 10 FHAS SN PART NO DESCRI PTI ON QTY REMARKS 1 F2 6 04020002 1 PISTON RING 1 1 2 2 6 04020003 0002 PI STON RI NG 2 1 3 2 6 04020004 0000600 NED QL NG 1 4 2 6 04020006 08 0000 2 5 2 6 04020005 STON 1 6 F2 6 04020001 pn STCN 1 1 6 04020100 0 000 ROD NG 1 F2 6 04020103 J 0 0 M 30 BOLT 2 9 F2 6 04030000 000 CRAM ASSY 1 10 2 6 04000003 O00000 VASHER PLATE 1 39 SPECIAL TOOLS Piston slider Housing bearing installer Oil seal installer tool Housing oil seal installer Space gauge DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE 1 Open the top cowling 2 Remove fuel tank remove starter 3 Remove flywheel cover and throttle cable 4 Remove air filter and carburetor DT Remove bolts
16. F2 6 01030007 0 00 LEVER 1 17 2 601030100 10000000 TILT CLAMP HANDLE ASSY 1 18 F40109006 BUSH NG 1 19 F2 6 01030003 Gg 000000 SPRI NG 1 20 F2 6 01030004 00000 LEVER TI LT LOCK 1 21 9 7879 2 2000 000000000 2x10 PIN 1 22 Gyr 40 1 95 0000000 N PPLE GREASE 1 23 2 6 01030001 0 0000 BRACKET SWVEL 1 24 F2 6 01030005 00000 ROD TI LT LOCK 1 25 Gy 896 86 000035 1 26 F2 6 01030006 PIN 1 27 2 6 01000001 0 0 135 BCLT 1 28 GyT61721 85 HDD UD M MIT 1 55 1 Q 12Nm 6 4 16 Nm 5 Nm 40 3 221 FHAS SN PART DESCRI PT CN QTY REMARKS 29 Tei70 85 TID M NT 1 30 9 1985 0008 VASHER 2 31 F2 6 01010000 0000000 BRACKET LEFT ASSY 1 32 F2 60102000 BRACKET RI ASSY 1 33 F4 01010005 00000000 RI VET 2 34 F401010002 000000 CAM BAT 2 35 F4010100 000000 QAMPSHPBOWRDHWNIH 2 36 F4 01010003 000000 CLAMP PLATE 2 37 F2 6 01000002 Tj 000 BUSH BAT 1 38 77889 1 2000 000000000006 1 39 2 6 01010001 00000 BRACKET CLAMP LEFT 1 40 75782 2000 0 0 0 0 125 BOLT 1 41 F2 6 00000100 740000 BRACKET COVER ASSY 1 42 F2 60104000 000000 THRUST RECH VE ASSY 1 43 F2 6 00000102 0 000 BUSH 1 56 Disassembling and inspection Remove clamp handle and bracket cover
17. G3 T818 85 Mx2sscrey PAN HEAD 1 F4 04010002 IPE JOIN 1 F2 6 04000007 D D g 5x 9x245 IPE WATE 1 15 04000010 000 HBRMOSTA 1 F2 6 04000005 GASKET CYLINDER COVER 1 166F 010104 0000 VALVE GUIDE BUSH 2 F2 6 04040100 00000 CYLINDER HEAD ASSY 1 15 04000005 00000 7 9 61 SPI LE VATER ASSY 1 F15 00000013 0 00 4x12 PIN 2 34 14 15 M6x20 mm Nm Ou WNE CON 12 25Nm 1st 14Nm 2nd 30Nm M6x16 mm 1st 5Nm 2nd 12Nm 19 10 SN PART NO DESCRI PTI ON QTY REMARKS 15 F2 6 04000001 00000 GASKETT OLI NER HEAD 1 16 BPR7HS 000 SPARK PLUG 1 17 F4040000 000008 4 18 G y75783 2000 16 6 19 F2 6 04000006 000 COVERT CYLINDER A 1 35 10Nm FHRS SN PART ND DESCRI PT ON QTY REMARKS 1 166F 010011 0000 LOCK NUT 2 2 166F 010010 0000 VOID ROCKER ARM 2 j 166F 010009 VALVE ROCKER 2 4 116F 010008 0000 DUT ROCKER ARM 2 5 166 010006 0000 VALVE 2 6 4 04080010 SPRING VALVE NER 2 F4 04080008 SPRI N3 VALVE STEM 2 8 166 010003 00000 SEAL VALVE STEM 2 9 166F 010001 I VALVE NTAKE 1 10 166F 010002 00 VALVE EX
18. LOWER UNIT WATER PUMP ASSEMBLY Explosive drawing M6x40 mm 8Nm 1 1 3 G 4 5 a 6 1 SCH 9 Sus 10 11 SN PART NO DESCRI PTI QTY REIMARKS 1 GyT5783 2000 0000 M6x40 0 2 F2 6 03000016 0 0000 ATE VATER PUMP FIXED 2 3 4 03000021 BBER TUBE WATER PUMP 4 JASOF404 1 033 00090 RING 5 F2 6 03000055 0 000 NER HOUSING WATER PUMP 6 F2 603000100 D000 IPELLER ASSY 7 F2 60300010 000 QUT PLATE 8 F2 6 03000009 Q 000 RING 9 F40300013 4x18 2 10 F2 6 030000071000000 GASKET WATER PUMP 11 F2 6 03000008 0 0 0 USING WATER PUMP 62 Disassembling and inspection Remove water pump fixed plate Remove water pump housing Remove impeller inner housing and O ring of water pump inner housing Remove water pump base rz Check water pump housing and out plate for crack crank or damage Replace if necessary D Check inner water pump housing and impeller for crack deform burn or damage Replace if necessary 7 Check water pump base for crack crank scratch or damage Replace if necessary 63 LOWER UNIT Explosive drawing M6x16mm 8Nm 1277 mn 31 28 1st 3Nm 30 2nd 8Nm FHAS
19. MT 2 0M4 1 28 F2 6 03000018 0000 INTIAN RE AR 1 65 M6x16mm 8Nm SC J amp 26 T e v di 31 9 NA 189 28 mm 151 3Nm 30 2nd 8Nm BURR Ez BE SN PART NO DESCRI PTI CN QTY REMARKS 19 0 7896 86 00006 1 30 F4 03000024 000000 GASKET 2 3 03000023 00000 PLUG OL 2 3 F4 03000022 00 ANIE 1 33 19 7861 1 87 G 000006 VASHER NTERNAL 1 GyT5783 2000 0000 12 1 35 5783 2000 0 0 30 BOLT 3 66 Disassembling and inspection 10 Remove cotter pin nut assy and spacer 2 Remove propeller assembly and spacer Remove the lower casing cover 4 Remove drive shaft positive gear assy and shift plug 50 Remove shift rod cam assy and drive shaft 6 Remove sleeve bearing with guard board 70 Remove sleeve bearing without guard board by using sleeve bearing installer tool 8 Remove the clutch block from the propeller shaft Propeller shaft and clutch block 11 Check clutch block for wear or damage Replace if necessary 21 Check propeller shaft for wear or damage Replace if necessary Clutch block installation Put clutch block spring into the hole of the propeller shaft tail 2 Install the clutch block as shown Take note of the direction Lower ca
20. Oil level plug 2 Oil rule 3 High position mark 4 Low position mark 2 If above the upper mark drain the engine oil if below lower mark add engine oil up to upper mark CAUTION Run the engine for a few minutes and then turn it off wait for several minutes and check the engine oil level by the oil checking hole 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 14 3 Hill engine oil into the crankcase through oil filler hole Engine oil quantity 0 35L Oil type API SE SE SE SE 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 l Remove stopper hang rope from engine stop switch assy Remove spark plug cap from spark plug Remove cylinder head cover Use feeler gauge to measure the clearance between rocker arm and valve rod top if out of specification adjust Valve clearance cold position 0 08 0 12mm Spark plug Remove spark plug cap and spark plug Clean off carbon build up on the electrodes Check if the electrodes are corroded or have deposit or if the washer is damaged If necessary change the spark pl
21. connecting power unit and upper casing 61 Carry the power unit and put it onto the working table DISASSEMBLING AND INSPECTION 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 40 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 Valve and valve pipe 1 Inspect the valve seat width If not in the prescribed range repair the valve seat Valve seat width 0 6 0 8mm 2 Inspect the valve margin thickness T If not as in the prescribed value replace the valve The margin thickness of valve Intake door 0 7mm IN Exhaust door 1 00mm 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 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 512m CAUTION When replacing the valve please use the new valve pipe and valve oil seal Valve spr
22. 4 BLEH STARTER 3 17 2 6 04000034 DAMPER FUEL 2 18 2 6 04000025 no 0008 BUSH STARTER 2 21 DISASSEMBLING 1 Open the top cowling 2 Remove bolts fixing the fuel tank 3 Remove the fuel tank and take down three bolts 4 Lift the starter and remove choke cable from carburetor 5 Remove the starter STARTER ROPE REPLACEMENT 1 Pull the starter rope out and insert it in the notch of the sheave drum Turn the sheave drum clockwise until the volute spring is free 22 2 Pullthe 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 Pullout 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 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 and drive pawl 3 Remove the sheave drum N WARNING Uninstall the sheave drum carefully to ensure that the volute spring does not pop o
23. 6 1 F2 6 05000007 n g 9 D JBE FLANGE 6 05000003 0000000 PLUG QUADRATE 9 F2 6 05000001 g OM COWLING 10 GyTe4 85 000000000 12 ge SCREW TAPPING 2 ll F26 05000009 CONNECTER ROD 2 1 G T96 85 0006 WASHER 6 13 F2 6 05000005 00000 RUBBER LOVER Disassembling and inspection 1 Remove bottom cowling seal 2 Remove top cowling locking hook 3 Remove circular rubber plug and quadrate rubber plug 50 4 Inspect if bottom cowling is cracked or damaged Replace if necessary 5 Inspect if top cowling locking hook is cracked or damaged Replace if necessary STEERING HANDLE Explosive drawing M8x25mm 18Nm SN PART NO DESCRI PTI CN QTY REMARKS 1 qyr57832000 5 1 2 F401000014 000000 COVER HANDLE STEERING 1 3 F4 01000008 BUSH B HANDLE 1 4 F401000011 0000A VASHER A BUSH 1 5 F405000014 000000000 HANDE DAMPER ASSY 1 6 F40100010 VASHER BUSH 2 7 F4010002 00000000 BUH WAE 1 8 7240100009 000000A BLPH HANDLE 1 9 T9186 000 1 6x12 PI N COITER 1 10 F4 01090200 ET FRCHONAJUSING I 1 51 1 1243 en 2 G
24. CRI PTI CN QTY REMARKS 1 GyT6172 86 KAM EMI 25 NI 1 2 4 04000021 mag WASHER 1 3 F2 6 04000016 74 JLLEY STARTER 1 4 F2 6 04000400 FLYWIELL ASSY 1 F4 0400009 tg KEY 1 6 GYT5783 2000 16 25 LT 2 1 06197 15 WASHER 3 F2 6 04000600 BEA AH H PRESSURE ASSY 1 9 GYT5783 2000 LT 1 WIRING DIAGRAM 25 W B W B CD Flywheel Q Ignition coil 2 Engine stop Switch 2 Grounding 6 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 26 OOo SPARK PLUG CAP Remove the spark plug Check if the spark plug cap is broken Replace if necessary Install the spark plug cap Turn it clockwise until it is tight FLYWHEEL MAINTENANCE Use flywheel holder to remove the nut and starter pulley use flywheel puller to remove flywheel Check if the flywheel is damaged or the permanent magnet part is firm Replace if necessary IGNITION COIL INSPECTION 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 p
25. E D4xp7x140 HOSE 1 13 F2 6 04000014 F 5 9 130 1 14 F2 6 04000200 CARBURETOR 1 31 FUEL TANK REMOVAL AND INSPECTION Open the top cowling Remove two bolts fixing the fuel tank Pull the fuel tank out Remove the fuel pipe from fuel tank Inspect if the fuel tank and fuel tank cover for crack leakage or damage Replace if necessary Inspect the tank strainer for dirt or clog Clean or replace if necessary INTAKE SYSTEM REMOVAL AND INSPECTION Remove the bolt fixing air filter Remove air filter and carburetor Check if air filter is cracked or damaged Replace it if necessary 32 POWER UNIT NOTICE To avoid accidental start of outboard engine during maintenance please take enough safety measures to cut the ignition system For instance remove engine stop lanyard from engine stop switch assembly and remove spark plug cap from spark plug EXPLOSIVE DRAWING 33 M6x20 mm 8Nm 1 2 3 4 e 5 6 25Nm M8x60 mm s 1st 14Nm x 2nd 30Nm ld 2 M6x16 mm 1st 5Nm 2nd 12Nm THAS PART ND DESCRI PTI CN QTY REMARKS 75783 2000 OO O0 NM6X20 IL 3 GyT97 1 8 0006 WASHER PLATE 9 F2 6 04000501 0000 COVER THERMOSTAT 1 F4 04000011 0000000 ASKET THERMOSTAT 1 F4 04070003 000000 ANODE 1
26. HAUST 1 11 F260404001 PLATE PUSH RCD 1 1 F2 6 04000002 0000 RCD VALVE PUSH 2 13 165 0000 LI FTER VALVE 2 14 F2 6 04000100 000000 CAMSHAFT ASSY 1 36 M6x12mm 13Nm 0 13 16 M8x14 14 17 Wm RETA de j A 18 M8x20mm 18Nm o J gt S 19 25 N JA 9 M6x45mm gem em 1st 5Nm 22 S 23 2nd 11Nm E L jJ 1277 FHAS SN PART NO DESCRI PTI CN QTY REMARKS 1 11504010202 000 PI PE VATER 1 2 F2 6 04010100 000 CRANK CASE 1 3 5 0705004 PLUG QL 1 4 JASO F404 31 0030 0 G1 D OR NG 1 5 F2 6 04010102 LEVEL 1 6 F2 6 04000008 BRACKET DAMPER 1 7 F2 6 04000009 00000 RUBBER BLOCK DAMPER 2 8 75783 2000 0 0 0 20 BOLT 2 9 GT97 185 0006 VASHER 11 10 F2 6 04010001 SD 20 30 7 HS Q L SEAL 2 11 2 6 04000004 CRANK CASE COMPLEX GASKET 1 12 62 2283 00000 BALL BEAR 5 1 13 Gy75783 2000 x12 1 14 2 6 04050100 00000 GEAR U NT ASSY 37 3 4 5 M6x12mm x 13Nm ER 13 216 M8x14 11 17 em 9 17 25 16 8 20 18Nm 24 9 19 25 M6x45mm 1st 5Nm 2nd 11Nm L 1277 SN PART ND DESCRI PT ON QTY REMARKS 15 F15 00000013
27. N 29 15 16 Dy 17 18 FHRS SN PART IQ DESCRI CN QTY REMARKS 1 F4 05000010 SPRING OIL 2 F4 0400002 DAMPER 0IL TU 3 F2 6 04000029 xt y4 4 OIL TUBE 4 F2 6 04000030 SPRING OIL 5 F2 6 04000017 CONNECTING ROD OIL SWITCH 6 JASC404 24 014 D13 8x2 4 O RING 7 F2 6 00000004 KNOB OIL SV Gy T823 2000 SCREW PAN HEA F2 6 04000022 t4 ELE VENTILATIVE COVER 20 F2 6 04000023 E 3E TUBE WASHER 3 30 M6x75 mm 8Nm SN PART NO DESCRI PTI ON QTY REMARKS 1 GyT5782 2000 M6x75 BOL 2 2 QGyT971 85 456 WASHE 2 F2 6 04000012 i EA USH INTAKE SILENCE 2 4 F2 6 04000300 SILENCE ASSY INTAKE 1 5 JASOF404 2402 0 ORN 1 6 2 6 04000015 EA BO2 5x07x72 HOSE 1 7 6 04070200 CHOCK HANDLE ASSY 1 8 2 6 04000018 GASKET CARBURETOR AIRPROOF 1 9 F2 6 04000011 INSULATOR CARBURETOR 1 10 F2 6 04000010 A GASKET CARBURETOR AIRPROOF 1 11 5 60 60x2 5 1 12 2 6 04000013 E
28. PARSUN OUTBOARD ENGINE SERVICE MANUAL F2 6BM SUZHOU PARSUN POWER MACHINE CO LTD NOTICE This manual includes service instructions for F2 6 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 N 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 g
29. ankcase cover Remove the crankcase cover Remove the camshaft and valve lifter Remove the connecting rod bolt and connecting rod cap and remove connecting rod and piston assembly Use clipper to remove circlip and remove piston pin and piston 43 6 Remove crankcase and crankcase gasket 7 Remove oil splasher gear assembly 8 Remove oil seal shell bolts and remove oil seal shell and oil seal Piston Measure piston outside diameter at the specified measuring point If out of specification replace Piston diameter 53 950 53 965mm f Measuring point Omm Cylinder bore 1 Measure cylinder bore separately at measuring point D 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 _ Measuring point height m Dep E 100 v 40mm Qi o _ 7 70mm d VT Cylinder bore 54 000 54 015mm me V Limit size 54 10mm 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 11 996 12 000mm 1 Piston ring Push the piston ring parallel with the piston into the specified measuring point of the cylinder 10mm from conjunction surface Measure end g
30. ap by space gauge If out of specification replace the piston ring End gap installed limit size Top ring 0 15 0 30mnm 0 4mm 2nd ring 0 300 0 45mm 0 6mm Oil ring 0 2 0 7mm 0 9mm 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 ring 0 04 0 08mm 2nd ring 0 02 0 06mm Oil ring 0 06 0 16mm Camshaft decompressor 44 1 Inspect camshaft decompressor gear and weight If gear is worn damaged cracked replace If weight is unsmoothly moving replace 2 Measure camshaft lobe diameter height D If out of specification replace it Camshaft 21 950 22 050mm Camshaft 26 1360 26 239 ZU X 3 Measure camshaft diameter If out of specification replace the camshaft Camshaft journal wear limit 14 934mm Crankshaft 1 Measure crankshaft brace If out of specification replace Crankshaft brace diameter 23 969 23 984mm Crankshaft brace width D 21 0 21 1mm 2 Measure crankshaft runout If out of specification replace Crankshaft runout limit 0 01mm Oil clearance Put a piece of plastic space gauge on to the crankpin in parallel to the crankshaft Assemble the connecting rod to the crankpin 3 Tighten the connecting rod bolts to the specified torque Tightening torque First time 5Nm Second time 9Nm 4 Remove the connecting rod measure the compressed w
31. bolt Bolt M6 2 10 Nm Locknut rocker arm Nut 6 0 75 2 10 Nm Oil seal housing Bolt M8 1 18 Nm Power unit mounting Bolt M6 6 11Nm Thermostat cover Bolt M6 3 8 Nm Ist tightening 5 Nm Crankcase Bolt M6 8 2nd tightening 11 Nm Cont d 12 Part to be tightened Part name Thread size Quantity Torque Ist tightening 5 Nm gt Connecting 2nd Bolt M7 2 Tod 9Nm tightening 2 2 Oil Splash gear Bolt M6 1 13 Nm Lower unit Ist tightening 3 Nm Bolt M6 3 mounting 2nd tightening 8Nm Lower unit sttightening 6Nm m housing Bolt M6 2 2nd tightening 11 Nm 5 Ist tighteni 3N Anode Bolt M6 1 5 2nd tightening 8 Nm Wat Ist tighteni 3N ater pamp 6 ig ening Boh M6 in housing 2nd tightening 8Nm Wat Ist tighteni 3N ater pump st tightening rer M6 m base 2nd tightening 8Nm e Steering handle mounting Bolt M8 1 26 Nm 5 Shift lever bracket Bolt M6 1 5 Nm 12Nm 5 Swivel bracket Nut M6 4 gt Clamp bracket Nut M8 1 16 Nm General torque Nut a Bolt b Torque 8mm M5 5Nm 10mm M6 8 Nm 12mm 8 18 Nm 14mm M10 36Nm a b ON 17mm M12 43 Nm PERIODIC SERVICE MAINTENANCE TIME TABLE Initial maintenace General maintenance Items Contents pe
32. cified engine oil is not being used Check wires for wear or breaks all loose connections broken wires Tighten Replace worn or Check and replace oil as specified Thermostat is faulty or clogged Replace Carburetor adjustments are incorrect Replace Air vent screw on fuel tank is closed Loosen air vent screw Throttle cable adjustments is incorrect Adjust correctly Choke knob is pulled out Return to home position Motor angle is too high Return to normal operating position Engine power loss 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 70 Cont d Trouble type Possible reason Recovery action Engine power loss 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 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 brok
33. e d 19 20 gt 6 25 x 30 5Nm 28 22 T 27 Al 31 N 7 9 3 M6x20mm 10Nm SN PART NO DESCRI PTI CN QTY REMARKS 15 F4 02000003 0000 SPRI NG AR 1 16 308 84 008 BAL 8 1 17 F400005 000 VASHER 1 18 F2 6 00000003 000000 GASKET ENG NE 1 19 F4 02040002 00000 1 SHAPED RUBBER BAND 1 20 F2 6 02000003 VATER TUBE 1 21 15 0000013 4 2 2 22 BT97 185 6 VASHER 7 23 B T5783 2000 0 0 0 35 BOLT 6 24 940 1 495 6 GREASE 1 25 2 6 02000001 UPPER CASI NG 1 26 F2 6 02000005 0 0000 GASKET GOMER 1 27 2 6 02000004 0000 COVER 1 28 F2 6 00000102 BUSH 1 59 218 G M6x25 5Nm 0 31 gl 811 A gs 710 vaso 10Nm FHAS SN PART NO DESCRI PTI CN QTY REMARKS 29 GyT818 2000 0000000 16 SCREW 1 30 F402000122 00000000 RUBBER PLUG UPPER 2 Disassembling and inspection 1 Remove the water tube 2 Remove gear shift handle assembly 60 3 Remove the shift rod and shift rod lever 4 Remove exhaust cover 5 Check upper casing for crack or wear Replace if necessary 6 Check gear shift handle for wear or damage Replace if necessary 7 Check exhaust cover for crack or wear Replace if necessary 61
34. e cable is cracked or damaged Replace if necessary 13 Inspect the conduction of engine stop switch If not to specification replace it Remove lockplate Conducting Install lockplate Not conducting Push stop switch button Conducting BRACKET Explosive drawing 53 54 Ihe _ gt 6 30 mm GJ A 12Nm 42 22 16 Nm 5Nm 40 3 A FHAS SN PART DESCRI PTI ON QTY REMARKS 1 GyT875 86 00000000 411 1 2 F4 01060002 0000 CLAMP HANDLE 1 F2 6 01050101 000000 LOCKED SCREW 1 4 2 6 01050002 1 00 SPRI NG 1 5 F2 6 01050001 COVER SWVEL 1 6 F2 60000101 0 0 0 D COVER BRACKET 1 7 98 7818 2000 0000000 Mee SCREW PAN HEAD 2 8 797 1 85 0006 VASHER 6 9 5783 2000 0 0 0 0 Mx30 BOT 4 10 F2 601050200 0 0000 LOCKED ASSY 1 11 2 6 01000003 BLH NG A 1 12 F2 601000000 n 1 D D B BLEH NG B 1 13 F2 6 01050100 000000 LOCKED HANDLE ASSY 1 14 F2 6 01040100 00000 DAMPER 1 1 i b EN M6x30 mm Nu 1 i 41 p 7 16 Nm 5Nm 40 32 201 FHAS D SN PART NQ PT CN QTY REMARKS 15 F2 6 01040001 000 BRACKET THRUST RECEIVE 1 16
35. e camshaft timing gear mark NOTE 47 Apply motor oil to moving parts before installing Crankcase cover installation Install oil seal housing Install oil splasher gear assembly Install crankcase cover and tighten the bolts twice as shown Tightening torque Ist 5 Nm 2nd 11 Nm RS NOTE Apply motor oil to moving parts before installing 1 6 4 d 7 3 Ia 710 UPPER COWLING Explosive drawing 48 3 ux LS 02 4 p SHAS SN PART NO DESCRI PT CN QTY REMARKS 1 6 06000001 fiz COWLING 1 2 6 06000002 SILENCER INTAKE 1 3 F2 6 06000003 a Wem me DAMPER INTAKE SILENCER 1 4 GB T845 85 SCREW TAPPING 1 Disassembling and inspection Remove intake silencer bolt Remove intake silencer and intake silencer damper Inspect if top cowling intake silencer and intake silencer damper are cracked or damaged Replace if necessary 49 BOTTOM COWLING Explosive drawing 3 Base SN PART DESCRI PT CN QTY REMARKS 1 6 05000002 g g g 00 SEAL BOTTOM COWLING 605000004 p 0 H D JBBER PLUG CIRCULAR 7 3 F260500008 H 0 0 D D K LOCKING 2 4 F2 6 05000010 00000 BTALLIC LINK ROD 2 5 amp T5783 2000 0000 1625 0 6 2 6 0500000
36. e notch of flywheel rotor and wind the cable around flywheel several rounds in clockwise direction 10 Pull the manual starter handle slowly until you feel resistance 11 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 3 4 Gasoline petrol lubricant and grease are highly flammable While working keep away from heat sparks and open flames 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 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 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 To protect the
37. eak voltage adapter If below specification check the ignition coil Peak voltage output 130V 1500 r min Digital universal meter Peak voltage adapter Ignition coil resistance Remove ignition coil and spark plug cap Measure ignition coil resistance If out of specification replace it Resistance 1 6 1 90 Tester pole white wire Tester pole black wire 5 8 7 0kQ Tester pole white wire Tester pole high voltage wire 27 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 28 EXPLOSIVE DRAWING Y 184 1 16 17 18 b FHRS SN PART NO DESCRI PT CN QTY REMARKS 1 F404120100 TANK COVER ASSY 2 F404120103 EAS SPRING PREVENT DESQUAMATING 3 F4 04120105 SHEET METAL PREVENT DESQUAUATING 2 4 72404120106 424E YELET STEEL WIRE 2 5 F4 04120104 PRS CHAIN PREVENT DESQUAMATING 6 F2 6 04000033 ing 8 WASHER DAMPE 1 F2 6 04000026 FUEL TANK INNER F2 6 04000027 A AMPER FUEL TAN 2 6 04000028 DAM 1 10 F4 04120005 gii FILTER FUEL TA
38. en 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 adjust engine oil to specified position Thermostat is faulty Replace Fuel joint connection is incorrect Connect correctly Specified spark plug s are not being used Check and replace spark plug s as specified Engine vibrates excessively 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 71
39. g end oil Thickness 1 87 1 95mm 0 016 0 046mm Q clearance Breadth 2 10 2 40mm Crankpin width 21 0 21 1mm bn E 2 Crankpin 23 969 23 984m E End gap 0 20 0 70mm SE E diameter m Crankshaft 21 980 21 993m Wear limit 0 90mm 5 journal diameter m Side clearance 0 06 0 16mm Round limit 0 01mm 10 Cont d Item Description Item Description Valve opening a 58 62 Intake Exhaust height 26 139 26 239mm temperature 8 Full open 4 70 C temperature Round diameter 21 950 22 050mm Journal diameter 14 966 14 984mm Valve lift 3mm Camshaft round limit 0 03mm Ignition system Item Description Item Description Ignition timing BTDC30 Spark plug gap 0 6 0 7mm T C I t tput i 130V EE Primary coil 1 6 1 90 peak voltage ass y T C I air gap 0 4 0 6mm resistance Secondary coil 5 8 7 0KQ TIGHTENING TORQUE Specified torque Part to be tightened Part name Thread size Quantity Torque Oil drain Bolt M8 1 18Nm Spark plug 14 1 25 Nm Recoil starter Bolt M6 3 8Nm Flywheel rotor ass y Nut M10 1 44 Nm Carburetor Bolt M6 2 8 Nm Exhaust tester Bolt M8 1 20 Nm Cylinder Isttightening 14 Nm Bolt 8 4 head 2ndtightening 30 Nm 5 Cylinder 1st tightenin 5 Nm Bolt M6 6 2 head cover 2ndtightening 12 Nm Rocker arm Screw
40. gine stops when pushing the engine stop switch assembly or pulling out the stopper hang rope CHECK COOLING WATER CHECKING HOLE When the engine is running check if cooling water overflows at the cooling water checking hole 1 Cooling water checking hole 7 BREAKING IN RUNNING Ch Initial 1 hour operate the engine at 2000 r min or about a half throttle The second hour operate the engine at 3000 r min or about 3 4 throttle 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 Check if gear oil contains water Check if the fuel line leaks After breaking in running operate the engine at idling speed Use cleaning tool to wash over the cooling water passage by fresh water 9 After breaking in running inspect idling speed Preheating engine for 5 minutes Using the tachometer to measure idling speed RPM If out of specification adjust it Idling speed 1800 2000 r min Tur 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 1 throttle stop screw SPECIAL TOOLS AND DETECTION DEVICE When performing maintenance and repair you need to use all kinds of special tools and detection device use of correct tools will improve the work efficienc
41. idth of the plastic space gauge If out of specification replace the connecting rod Oil clearance 0 019 0 046nm Note Don t rotate the connecting rod before completing measurement pA 45 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 NOTE Don t remove bearing unless you replace it Oil seal housing 1 Inspect oil seal housing for crack damage Replace if necessary 2 Inspect O ring for crack damage Replace if necessary Crankcase and crankcase cover 1 Inspect crankcase cover If cracked damaged replace 2 Inspect cooling water passage for dirt or clog 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 ri
42. ing 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 41 Valve rocker arm Check the rocker arm for crack perforation or damage Replace if necessary Valve pipe replacement Knock out the valve pipe from the direction of combustion room 2 Knockin 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 Clean the carbon on the valve Coat a thin layer of bluing dye evenly onto the seal face of the valve seat Lap the valve on valve seat by valve lapping tool 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 v alue reface and lap the valve seat If the contact surface is not even replace the valve pipe The valve seat width 0 6 0 8mm The maximum valve seat width 1 1mm gt Valve seat cutting 1 Use 45 valve seat cutter to adjust the valve seat width Turn the cutter clockwise until the valve seat face is smooth 2 If the valve seat is ce
43. iven 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 rights reserved This manual cannot be reproduced or transmitted in any form or by any means without the written approval of company Suzhou Parsun Power Machine Co Ltd INDEX GENERAL INFORMATION eceececcocoococccoceccecccccccccccccc IDENTIFICATION eececcccocoocoooooooooosooccccccccccccs PROPELLER SELECTION a el EMERGENCY START dl SAFETY WHILE WORKING eeececcecccccccccecccccceccccceec DISASSEMBLY AND ASSEMBLY eecceccccccccccceccceccecccececed ONE TIME USE PARTS of PRE DELIVERY CHECK SPECIAL TOOLS AND DETECTION DEVICE ssssssssssssssssssss 6 EXPLOSIVE DRAWING AND SYMBOL e SPECIFICATIONS ee ee see EE EE EE ee 0 OUTBOARD ENGINE SPECIFICATIONS o MAINTENANCE INFORMATION
44. l 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 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 19 EXPLOSIVE DRAWING 7 FHRS SN PART DESCRI PTI CN QTY REMARKS 1 F260407002 SEAL FORTHY RUBBER 1 2 qyT578 2000 00 00 Mx60 3 7 1 45 0006 VASER 3 4 F2 604070100 0 0 0 CASE STARTER 1 5 6 04070001 00000 SEAL FORTHY RUBBER 1 6 IF2 6 04070008 100000 DAMPER HANDLE 1 7 4 04130100 000000 STARTER HANDLE ASSY 1 8 F2 6 04070007 00 000 963 STARTER 1 9 2 60407003 000000 VASHER THRUST 1 10 IF4 04130005 0000 SPR NG VCLUTE 1 20 5 6 7 0 SN PART DESCRI PTI CN QTY REMARKS 11 F2 6 04070004 CRULL SHEAVE 1 12 F2 6 04070005 CRI VE 2 13 F4 04130007 000000 STARTER 1 14 F2 6 04070006 0000 PLATE PRESS 1 15 4 04130008 000000 SCREWSTARTER 1 16 2 6 0400002
45. nce 1277 substance 1243 SPECIFICATIONS OUTBOARD ENGINE SPECIFICATIONS system Item Description Item Description E Overall length 645mm Spark plug BPR7HS e pa gt 8 Overall width 343mm 5 Exhaust system Under water 2 Lubrication Overall height 1013nm 5 Splash lubrication system Unleaded regular h 18 0k Fuelt Weight 8 0kg uel type aasal Max output 1 9Kw 2 6hp 5500r min Fuel standard PON86U RON91 Full throttl Fuel tank noces 5250 5750r min 121 operation capacity Max fuel Recommended APLSEUSEUST SPN 1 1L h 5500r min SG CD SAE p z 10W300 10W40 Id d Engine oil geren 1900 100 r min SC 0 35L Neutral quantity Recommended Hypoid gear oil SAE T 4 stroke OHV ype gear oil 90 Number of 1 Gear E 75mm cylinders quantity 0 4 8 12 Displacement 72cm3 Tilt angle BorexStroke 54 0mmx 31 5mm E Tilt up angle 80 Q Compression 8 1 360 ratio 9 0 Steering angle D Number of z on a 1 Gear positions F N carburetors Control system Tiller control Gear ratio 2 08 27 13 Starting system Recoil starter Gear type Bevel gear gt iti Propell TC pu E Clockwise system direction tarti Propeller drive E Chock valve Spline enrichment MAINTENANCE INFORMATION
46. ng gap Ade T We 3 gt 4 Oil ring end gap 1 lower rail vi UP Oil ring end gap 2 expanded ring s Ze o Oil ring end gap 3 upper rail 2nd piston ring end gap 4 gt Top piston ring end gap 5 d 46 25 221 Piston installation Use piston slider to install piston and make sure the piston crown UP is toward the flywheel side 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 B20X 30x 7 by oil seal installer tool NOTE 2 Apply grease onto new seal before installation Q Make sure the oil seal spring direction as shown Crankshaft installation 1 Install the crankshaft bearing to crankcase by special tools if change bearing Install oil seal Housing bearing installer Housing oil seal installer 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 1 Install valve lifter 2 Install camshaft Make sure that the camshaft gear mark is aligned with th
47. ntered on the valve face but it s too wide to reduce the valve seat width use 30 cutter to adjust the top edge of the seat and use 60 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 42 4 5 6 7 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 Coat evenly a thin layer of lapping compound onto valve seat and lap the valve by lapping tool Clean up the remaining lapping compound Inspect again the valve seat width CAUTION 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 P PWN Pe Thermostat Remove thermostat cover and thermostat Suspend thermostat in the container with water Heat the container Inspect valve lift situation in the prescribed water temperature If out of specification replace Water temperature The lift height 58 62 C 0 05mm valve lift Over 70 C Over 3mm Install thermostat and thermostat cover Tighten the bolts to specified torque CRANKCASE Disassembling Remove the bolts according to the reverse numbering sequence of the cr
48. oard engine can supply the best performance Propeller sizes Material 7 14 7 1 4 x 5 1 2 7 1 4 x 7 1 4 Aluminum alloy 7 1 4 x 8 1 4 7 1 2 x 5 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 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 1 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 parts The procedure is as follows 1 Remove the top cowling 2 Remove the bolts fixing the fuel tank 3 Lift the fuel tank and remove three bolts AT Lift the starter and remove choke cable from carburetor 5 Remove the starter 6 Install the bolts to fix the flywheel cover 7 Install the bolts to fix the fuel tank 4 8 When the engine is cold circumvolve the lever of carburetor in order to operate choke system 9 Return lever to home position after engine starts Insert the knot of the cable in th
49. riod 10 hours 50 hours 100 hours 200 hours 1 month 3 6 months D 1 year Anode Inspection replacement Q Q Spark plu Cleaning adjustment TN 52 O O O Grease points Greasing O Bolts and nuts Inspection O Fuel tank and fuel line Inspection O Fuel filter Inspection replacement O O O Carburetor Inspection replacement O O Outboard outside Inspection replacement O Idling speed Inspection adjustment O O Engine oil Replacement O O Valve cleanrance Inspection adjustment O O Ignition timing Inspection O O T C I air gap Inspection adjustment O O Thermostat Inspection O Cooling water passage Inspection Cleaning O O Gear oil Replacement O O Propeller Inspection replacement O O 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 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 FUEL SYSTEM Clean dirt or replace it if necessary 2 CHECK FUEL COCK Check if fuel cock is cracked damaged or leaking Replace if necessary 13 POWER UNIT Engine oil level 1 From oil level checking hole check if engine oil level is between the following marks of the upper and lower 1
50. sing cover 1 Check bearing for rust or rumbling when run Replace if necessarily 21 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 67 Lower casing cover oil seal and bearing installation Install oil seal Note Please use special tool to install oil seal and bearing Pay attention to the oil seal installation direction and installation depth NNO gt XQ Sleeve bearing Inspect sleeve bearing with guard board and sleeve bearing without guard board for wear crack or damage Replace if necessary Drive shaft Inspect the drive shaft for crank or wear Replace if necessary Gear Inspect the forward 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 11 Inspect lower casing cover for crack or damage Check if the cooling water inlet is blocked Replace if necessary 2 Install the sleeve bearing with guard board and sleeve bearing without guard board by special tools 1 Sleeve bearing with guard board installer tool Lower casing bracket and sleeve bearing without guard board installer tool 3 Install new oil seal with the depth as shown unit mm 68 a d
51. skin the application of a suitable barrier cream to the hands before working is recommended Q Clothing which has become contaminated with lubricants should be changed as soon as practicable and washed before further use Q Avoid skin contact with lubricants 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 Asupply of clean lint free cloths should be available for wiping run off lubricants or grease 5 GOOD WORKING PRACTICES 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 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 Use special tools when disassembling and assembling Clean dirt before disassembling the parts Oil the contact surfaces of moving parts before assembly Tou dp 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 par
52. ts are gasket oil seal O ring cotter pin and spring ring and etc When re assembling outboard engine you must change the one time use parts PRE DELIVERY CHECK To ensure the using please inspect the following before delivery 1 CHECKING FUEL SYSTEM Check if the fuel pipe is connected firmly and if the fuel tank is filled with fuel CAUTION Do not use pre mixed fuel for this 4 stoke outboard engine 2 CHECKING OIL LEVEL D Check the engine oil level Check engine oil level from oil level checking hole 1 High position mark 2 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 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 1 Oil level plug CHECK STEERING SYSTEM Check if steering is stable Check if steering friction is adjusted correctly Turn clamp handle screw clockwise to increase resistance Turn clamp handle screw counter clockwise to lower resistance 1 Clamp handle screw 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 CHECK ENGINE STOP SWITCH ASS Y Check if the en
53. ug Spark plug type BPR7HS Inspect if the spark plug gap is within specification If necessary change the spark plug 22222 06 0 7nm Install spark plug Use spark plug spanner to tighten it according to specified torque Specified torque 25 Nm 15 CONTROL SYSTEM Throttle grip 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 1 throttle cable stop screw Idling speed Check idling speed and adjust it 1f necessary 1 Preheat engine for 5 minutes 2 Attach the tachometer to the spark plug wire to measure idling speed RPM If out of specification adjust it Idling speed 1800 2000 r min 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 After adjusting the idling speed if necessary you can adjust the throttle cable again 16 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 Oil level plug
54. ut to hurt people 4 Remove the volute spring 5 Check if the drive pawl is cracked worn or damaged If necessary replace it 6 Inspect if the drive spring is broken cranked or damaged If necessary replace it 7 Check if the volute spring is broken cranked or damaged If necessary replace it 23 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 Specified torque 8 Nm 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 24 _44Nm 1 6 2 gt 7 8Nm a 28 4 M6x12 mm 8Nm SRSB FHAS SN PART NO DES
55. y and avoid of the damage to the people and outboard engines SPECIAL TOOLS Piston slider Flywheel holder and puller Bearing puller 6 Housing bearing installer Lower casing cover bearing installer Housing oil seal installer Space gage Sleeve bearing with guard board installer tool Lower casing bracket and sleeve bearing without guard board installer tool Lower casing bracket and drive shaft oil seal installer tool DETECTION DEVICE Digital tachometer Digital universal meter Peak voltage adaptor EXPLOSIVE DRAWING AND SYMBOL EXPLOSIVE DRAWING EXT 8Nm FHAS Spa E SN PART NQ ESAI PTI CN QTY REMRKS 1 GyT578 2000 0 0 0 0 Mix40 BOLT 4 2 2 6 03000016 DO 000 PLATE WATER PUMP FIXED 1 3 F4 03000021 00000 RUBBER TUBE WATER PUMP 1 4 ASOF404 19 033 0000 O RING 1 5 12 6 03000015 0000 NNER HOUSING WATER PUMP 1 6 F2 6 03000100 0000 IMPELLER ASSY 1 7 F2 6 03000010 000 OUT PLATE 1 8 F2 6 03000009 9000 O RING 1 9 F4 03000013 000 9 4x18 PIN 1 10 F2 6 03000007 000000 GASKET VATER PUMP 1 10 F2 6 03000008 HOUSING VATER PUMP 1 Parts explosive drawing Screw specification and specified torque Oil fluid sealant or locking substance daubing point Oo Spare parts details SYMBOL o G L 1277 1243 Daub waterproof Daub screw locking Daub screw locking Daub engine oil grease substa
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