Related Manuals for Parsun F40 EFI
Summary of Contents for Parsun F40 EFI
- Page 1 Maintenance Manual for Outboard Motor F40/30 EFI Suzhou Parsun Power Machine Co., Ltd.
- Page 2 Preface This Manual is a maintenance instruction for F30/40, which is provided by Parsun to dealers for use in maintaining and repairing Parsun outboard motors. Please read this Manual carefully before maintaining and servicing the outboard motors. When repairing and maintaining the outboard motors, please use the maintenance procedures and tools recommended in the Manual.
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Page 3: Table Of Contents
Contents Overview ..................................1 Identification Mark ..............................1 Selection of propeller ..............................1 Protection at work ................................ 1 Disassembly and assembly ............................2 Disposable parts ................................2 Pre-delivery inspection ..............................2 Special tools and testing equipment ..........................4 Disassembly schematic diagram and symbol description .................... 5 Specification ................................ - Page 4 Electrical system ................................ 24 Precautions ................................. 24 Disassembly schematic diagram ..........................25 Wiring diagram ................................32 Spark plug ignition ..............................35 Spark plug cap ................................35 Flywheel maintenance ............................... 35 Check engine startsup switch ............................. 35 Check engine stop switch ............................35 Detection of starting relay ............................
- Page 5 Disassembly and inspection ..........................84 Water unit and bracket ............................... 85 Disassembly schematic diagram ..........................86 Disassembly and inspection of bracket ........................95 Disassembly and inspection of water unit ......................... 95 Hydraulic warping device ............................96 Disassembly schematic diagram ........................96 Disassemble ...............................
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Page 6: Overview
Overview Identification Mark The serial number is printed on a label which is fixed to the port side of the clamp bracket or the upper part of the rotary bracket. The serial number is recorded in the blank of the label to help you order spare parts from dealers or for your reference in case the engine is stolen. -
Page 7: Disassembly And Assembly
4. Use of lubricants and sealants Only products provided or recommended by Parsun can be used when maintaining and repairing the outboard motor. Under normal circumstances, the lubricant mentioned in this Manual will not damage your skin. However, please take protective measures before use to reduce risks. - Page 8 1. Oil dipstick 2. High mark 3. Low mark Make sure the oil level is between the high mark and the low mark; Drain oil when the oil level is above the high mark and add oil when the oil level is below the low mark. ②...
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Page 9: Special Tools And Testing Equipment
③ After running-in operation, run the engine at idle speed and use the washing tool to flush the cooling water channel with fresh water. 9. After running-in operation, check the idle speed of the engine. ① Preheat the engine for 5 minutes. ②... -
Page 10: Disassembly Schematic Diagram And Symbol Description
Drive shaft bearing shaft seal oil seal Forward gear bearing Drive installation tool installation kit casing installation kit Drive shaft spline sleeve Pinion nut spanner Testing equipment: Digital tachometer Digital multimeter Peak voltage adapter Disassembly schematic diagram and symbol description Description of disassembly schematic diagram... - Page 11 ① M14x12 mm 27 Nm ② PART NO. DESCRIPTION DESCRIPTION REMARKS ③ 零件名称(英文) 零件名称(中文) F25-00000100 PLUG,OIL LEVEL 机油尺组件 RELIEF VALVE AUY F25-02010100 溢流阀组件 F25-02010006 溢流阀垫片 WASHER ,PLAIN GB/T97.1-2000 平垫圈6 HEXAGON BOLT GB/T5783-2000 六角螺栓M6x25 F25-02010200 STRAINER,OIL 粗滤器组件 HEXAGON BOLT GB/T5783-2000 六角螺栓M6X16 PIN,DOWEL F25-00000014 定位销8x12...
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Page 12: Specification
Specification Outboard motor parameters Item Data Item Data Overall length 1173/768 mm Spark plug DPR7EA-9 (NGK) (B/F) Overall width (B/F) 426/410 mm Firing order 1-2-3 Maximum 1361 mm 12 V, 17A generator output Overall Cooling height 1234 mm Water cooling system Exhaust Through the propeller... -
Page 13: Maintenance Information
Maintenance information Engine Item Data Item Data Minimum Cyli compression 840 kPa Taper limit 0.08mm nder pressure bloc Lubricating oil unit 230 kPa Roundness limit 0.05mm pressure (idle speed) Buckling limit 0.1mm Diameter of piston 64.930~64.945mm Cyli Inner diameter Height of measuring 3mm (from bottom of nder 37.00~37.025mm... -
Page 14: Underwater Unit
Journal oil Roundness limit 0.05mm 0.045~0.085mm clearance Intake Valve Open temperature 58~62º C 0.15~0.25mm valve clearance (cold Exhaust Full open temperature 70º C 0.25~0.35mm position) valve Intake stat Minimum opening height 1.84~2.97mm Valve of valve valve cone Exhaust Inner diameter of Width 1.98~3.11mm 46.000~46.016mm... -
Page 15: Charging System
Measurement conditions: Unless otherwise specified, the ambient temperature is 20℃ during measurement. Charging system Item Data Item Data Start (no-load) Fuse 30 A 14.0 V Outp Output 45.0 V 13.0 V 1500 r/min (no-load) 1500 r/min (no-load) Ligh peak peak ting voltage of volta... -
Page 16: Average Torque
Pinion 74 Nm Propeller nut 35 Nm Steering handle 10 Nm Self-locking Steering handle 22 Nm Exhaust manifold Bolt 10 Nm Throttle grip Screw 2 Nm Above Shift linkage bracket Bolt 10 Nm water Gear spring plate Bolt 10 Nm Small cover plate of bottom Bolt 10 Nm... - Page 18 BWS-D:...
- Page 19 FWL-T:...
- Page 20 FWS-T:...
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Page 21: Mounting Dimensions Of Clamp Bracket
Mounting dimensions of clamp bracket... -
Page 22: Basic Maintenance
Basic maintenance Maintenance Interval Chart General Initial maintenance maintenance interval Project Content 50 hours 10 hours hours hours (1 month) months) (1 year) months) ○ ○ Anode Check/replace ○ Anode (internal) Check/replace Cooling water ○ ○ Clean channel ○ ○ Spark plug Clean/adjust/replace ○... -
Page 23: Engine
2. Check the fuel connector. Check the fuel connector for cracks, leakage or damage. Replace it if necessary. 3. Check the fuel filter. Check whether the fuel filter is cracked or damaged, and check whether there is dirt in the fuel filter. If yes, replace the fuel filter. -
Page 24: Valve Clearance
1.9 L (oil filter changed) Oil type: API: SE, SF, SG, SH, SJ or SAE: 10W30, 10W40 4. Install oil cap. 5. Check the oil level. Valve clearance 1. Unplug the engine stop safety line from the emergency stop switch assembly and remove the spark plug cap from the spark plug. -
Page 25: Control System
Spark plug model: DPR7EA-9 4. Check whether the electrode gap meets the specified value; If necessary, replace the spark plug. 0.8-0.9mm 5. Install the spark plug and tighten it with the spark plug wrench according to the specified torque. Specified torque: 18 Nm Control system Throttle push-pull cable 1. -
Page 26: Shift Operation
3. Sleeve the adjusted push-pull cable joint into the fixed column, install the clip clutch and tighten the lock nut. Shift operation When shifting from neutral to forward or backward, check the smoothness of shift operation. Adjust the columnar nut if necessary. Underwater unit Gear oil Check the amount of gear oil:... -
Page 27: Lubricating Point
Check the anode of underwater unit; Remove oil stains and scale; If damage or corrosion exceeds 1/2, replace the anode. Note: Do not oil or paint the anode to avoid anode failure. Lubricating point 1. Fill or apply waterproof grease with an oil gun at the position shown. 2. -
Page 28: Thermostat
1. Inlet of cooling water channel 2. Place the outboard motor in water, ensure that the water level is above the anti-swirl baffle, and start the engine. 3. Check whether there is water flowing out of the cooling water observation hole. If there is no water flow or the water flow is interrupted, check the cooling water channel in the outboard motor. -
Page 29: Electrical System
Electrical system Precautions When monitoring and repairing the ignition system, be careful not to put your hands, clothes, hair or accessories close to the running flywheel. Check the ignition coil on the insulated workbench to prevent electric leakage and electric shock. -
Page 30: Disassembly Schematic Diagram
Disassembly schematic diagram M20×1.25 mm 157 Nm... - Page 31 REMARKS 备注...
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Page 37: Wiring Diagram
WIRING DIAGRAM... -
Page 40: Spark Plug Ignition
Spark plug ignition 1. Remove the spark plug cap from the spark plug. 1. Spark plug cap; 2. Spark plug 2. Connect the ignition detector to the spark plug cap. 3. Start the engine and observe the spark through the discharge window of the detector. Warning: Do not touch any connection part of the detector lead. -
Page 41: Detection Of Magneto Coil
Detection of magneto coil Measure the peak voltage of magneto coil (between green wires). Use digital multimeter and peak voltage adapter to measure the peak output voltage of the coil. If it is lower than the specified value, replace the magneto coil. Peak 1500 r/min (no-load) 47.2 V... - Page 42 temperature sensor Short circuit to ground of throttle position sensor Throttle fault Short circuit to high level of throttle position sensor Short circuit to ground of oxygen sensor Oxygen sensor fault Short circuit to high level of oxygen sensor Continued： Fault type Fault item Code...
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Page 43: Fuel System
Fuel system Precautions Fuel oil is a highly flammable and volatile liquid, and fuel oil leakage can cause fire and explosion. Do not attempt to start the engine until the fuel system components are connected or installed. After completing all maintenance steps, apply pressure to the fuel system for a short time to check for leakage. -
Page 44: Disassembly Schematic Diagram
Disassembly schematic diagram... -
Page 49: Release The Fuel Pressure In The Fuel Line
Release the fuel pressure in the fuel line Before the maintenance and inspection of the fuel system, please release the fuel pressure in the fuel line; Avoid accidents caused by high-pressure fuel injection during maintenance. 1. Connect the pressure gauge with the pressure relief pipe to the oil pump detection valve of the electric fuel pump;... -
Page 50: Removal And Inspection Of Fuel Pump
3. Check the fuel joint for cracks or damage. 4. Connect a vacuum manometer to the fuel joint outlet. 5. Check whether the negative pressure can be maintained for more than 10 seconds under the specified pressure. Replace it if necessary. Specified pressure: 50kPa Removal and inspection of fuel pump 1. -
Page 51: Disassembly And Inspection Of Electric Fuel Pump
３. Float ４. O-ring ５. Oil filter cup Disassembly and inspection of electric fuel pump Disassembly of electric fuel pump 1. Loosen the oil drain screw of the oil cup and drain the fuel in the oil cup into a suitable container. -
Page 52: Inspection Of Fuel Pipe And Fuel Filter
14. After inspection, clean the parts and install the electric fuel pump in reverse order of disassembly; Note: Use a new oil cup sealing ring; The screws should be tightened according to the specified torque! Inspection of fuel pipe and fuel filter 1. -
Page 53: Disassembly Schematic Diagram
Disassembly schematic diagram 18 Nm M8x82 mm 40 Nm 1st 15 Nm 2nd 30 Nm M6x35 mm 1st 6 Nm 2nd 12 Nm... -
Page 65: Special Tool
Special tool Piston slideway flywheel gripper and flywheel puller Valve spring compressor kit Clearance gauge Oil filter spanner Check the compression pressure 1．Start the engine, warm it up for 5 minutes, and then shut it down. 2．Remove the engine stop safety line. 3．Remove the spark plug and connect the pressure gauge to the spark plug hole. -
Page 66: Remove The Engine
480kpa (62℃, 3000±50 r/min) Remove the engine 1. Open the top cover. 2. Remove the flywheel cover. 3. Remove the throttle cable 4. Remove carburetor. 5. Remove the flywheel using a special tool. Flywheel gripper and flywheel puller 6. Remove the semicircular key. 7. -
Page 67: Disassembly And Inspection
4. Remove the timing pulley washer, timing pulley and semicircular key. 5. Check pulley and timing belt for cracks, damage or wear. Replace it if necessary. 6. Install the semicircular key and driven pulley. Align the mark “1" on the driven pulley with the mark "▼" on the cylinder head. Then temporarily tighten the driven pulley bolt. - Page 68 1. Check the width of valve sealing surface; If it is not within the prescribed scope, Trim the valve seat ring. Width of sealing surface: Intake 1.84～2.97 mm valve Exhaust 1.98～3.11 mm valve Check the valve edge thickness T; Replace the valve if it does not meet the specified value.
- Page 69 Inta 30.83~31.09 mm height 30.83~31.09 mm aust Diameter of 25.90~26.10 mm 2. Check camshaft roundness. Replace base circle it if necessary. Roundness limit: 0.03mm 3. Check camshaft journal diameter and the inner diameter of cylinder head shaft hole. Replace it if necessary. Camshaft journal: 36.935~36.955mm Inner diameter of cylinder head shaft hole b: 37.000~37.025 mm 4.
- Page 70 Valve guide inner diameter: 5.50～5.518mm Note: Do not rotate the reamer counterclockwise when taking it out. Check valve seat ring 1. Remove carbon deposit from the valve. 2. Coat a thin layer of dye evenly on the sealing surface of the valve seat ring. 3.
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Page 71: Crankcase
valve grinding tool. 6. Remove the residual abrasive. 7. Check the width of valve sealing surface again. Note: Do not excessively cut the valve, and turn the cutter evenly with a downward force of 40 ~ 50N. Do not stick the abrasive on the valve stem and valve guide. Install the valve 1. - Page 72 3. Remove thermostat cover, exhaust cover, gasket and locating pin. Check the exhaust cover for cracks, deformation or corrosion. Replace it if necessary. 4. Remove the bolts on the body in reverse order according to the serial number on the edge of the screw hole on the engine base, and remove the engine base.
- Page 73 3. Measure the clearance of piston ring end face with a clearance gauge; If it does not meet the specified value, replace it. End face clearance (during installation): Top ring 0.15～0.30 mm Second ring 0.30～0.50 mm Oil ring 0.20～0.70 mm 4.
- Page 74 Crankshaft runout limit: 0.04mm Crank pin oil clearance 1. Place a plastic clearance gauge on the crank pin and make it parallel to the crankshaft. 2. Fit the connecting rod and bearing bush on the crank pin. 3. Tighten the connecting rod bolts according to the specified torque. Seating torque: First time 6 Nm Second time 17 Nm 4.
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Page 75: Reinstallation
1. Check whether the engine body and base are cracked, damaged and corroded; If yes, replace it. 2. Check the cooling water channel for grease content or blockage; If yes, clean it. Reinstallation Assemble piston connecting rod Install piston, connecting rod, piston pin and piston pin clip clutch. Note: When installing, make sure that the mark on the connecting rod and the mark on the top of the piston are on the same side. -
Page 76: Assemble The Engine
Assemble the engine 1. Coat sealant on the joint surface of the engine base, and install the locating pin and the engine base. Tighten the bolts twice in the order marked on the base. Seating torque: Frist 15 Nm tightening Second 30 Nm tightening... -
Page 77: About Water
12. Install electrical system components in reverse order according to the removal sequence 13. Connect the wires of the electrical system. 14. Install fuel system. About water Top cover Disassembly schematic diagram... -
Page 79: Disassembly And Inspection
Disassembly and inspection 1. Remove the sealing rubber strips. 2. Remove the top cover screws. 3. Remove the top cover. 4. Remove the locking hook and the hook. 5. Check the top cover for cracks or damage. Replace it if necessary. 6. - Page 82 Continued:...
- Page 83 Back operation model...
- Page 85 Front operation model...
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Page 87: Disassembly And Inspection
Disassembly and inspection 1. Remove rubber bulkhead, corrugated sheath and throttle cable sheath. Remove the ignition lead assembly. 2. Remove the bolts fixing the small cover plate of the bottom cover, remove the small cover plate of the bottom cover, and remove the square rubber sealing strip. Remove the retainer of the outlet and the rectangular rubber bulkhead. -
Page 88: Steering Handle
Steering handle Disassembly schematic diagram... -
Page 89: Disassembly And Inspection
Disassembly and inspection... -
Page 90: Water Unit And Bracket
1． Remove handle bracket, shift handle and steering handle. 2． Remove the throttle push-pull cable assembly. 3． Remove the cotter pin and remove the resistance adjustment knob. 4． Remove the throttle grip. 5． Remove throttle retaining plate and throttle lever. 6．... -
Page 91: Disassembly Schematic Diagram
Disassembly schematic diagram... - Page 97 Continued：...
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Page 100: Disassembly And Inspection Of Bracket
Disassembly and inspection of bracket 1. Remove the left and right absorber covers, and remove the left and right absorbers and double-hole absorber fixing nuts. 2. Remove the water unit, oil pan and exhaust manifold seat as a whole from the bracket 3. -
Page 101: Hydraulic Warping Device
Hydraulic warping device Disassembly schematic diagram... -
Page 102: Disassemble
Disassemble 1. Completely warp the outboard motor upward, and push it in the warping limit shaft to support the outboard motor. Remove the circlip 9, and remove the warping hinge pin. Remove bolts and hydraulic positioning shaft. Remove the manual cylinder assembly... -
Page 103: Manual Warping Device
Manual warping device Disassembly schematic diagram... -
Page 104: Disassemble
Disassemble 1. Completely warp the outboard motor upward, and push it in the warping limit shaft to support the outboard motor. Remove the circlip 9, and remove the warping hinge pin. Remove bolts and hydraulic positioning shaft. Remove the manual cylinder assembly Check the oil level. - Page 105 If the hydraulic warping device is installed on the outboard motor and exhausting is required, please follow the following steps. 1. Turn the manual valve counterclockwise until it cannot turn. 1. Manual valve. 2. Tilt the outboard motor completely upward, and then lower it downward by its own gravity;...
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Page 106: Underwater Part
Underwater part Disassembly schematic diagram... - Page 110 Continued：...
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Page 111: Disassembly And Inspection
Disassembly and inspection Remove the water pipe. 2. Remove the pump housing. 3. Remove the impeller and pump inner shell. 4. Remove the semicircular key and outer plate. 5. Check the pump casing and outer plate for cracks, distortions or damage. Replace it if necessary. -
Page 112: Install The Claw Clutch
2. Check the propeller shaft; Replace it if worn or bent. Install the claw clutch 1. Fit the clutch spring into the hole at the tail of the propeller shaft. 2. Install the claw clutch. Mark "F" or "●" towards forward gear. Fix the clutch pin. 3. -
Page 113: Drive Shaft
Note: Shim adjustment is required when installing new reverse gears and bearings. Drive shaft Check the drive shaft for bending or wear. Replace it if necessary. Shift cam Check whether the shift cam is worn or deformed. Replace it if necessary. Gear Check the forward gear, reverse gear and pinion for wear or damage. -
Page 114: Install The Underwater Unit
and pinion. Note: When installing a new drive shaft, it is required to adjust the shim. 5. Tighten the pinion nut. Specified torque: 95 Nm 6. Install the propeller shaft assembly. 7. Install the underwater unit housing cover. Installation tool for housing cover assembly of underwater unit 8. -
Page 115: Deviation Value Mark
Deviation value mark The installation surface of the anode/heading tab of the underwater unit is engraved with... -
Page 116: Pinion Shim
deviation value marks, which are F, R and P respectively; they represent the difference between the actual size and the theoretical size on the housing of the underwater unit. For example, the mark P is followed by +3, which means that the actual size is 0.03 mm more than the theoretical size;... -
Page 117: Common Faults And Solutions
3. Formula: T =108.25 +(R)/100-M 4. Shims that can be selected. 0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm Note: The thickness of the shim can be 0~0.05 thinner than T2, and choose the closest size. Common faults and solutions Fault type Fault cause Solution... - Page 118 Fuel filter blocked Replace the fuel filter Fuel pump failure Overhaul or replace it Vent screw of fuel tank cap not Loosen the vent screw loosened The spark plug is contaminated Check the spark plug. Clean it or replace with the correct spark plug or the model is incorrect Incorrect installation of spark...
- Page 119 Continued: Fault type Fault cause Solution The spark plug is contaminated or Clean it or replace with the correct spark the model is incorrect plug Check the fuel line for extrusion, Fuel system blocked entanglement or blockage Fuel filter blocked Replace the fuel filter Fuel oil polluted or obsoleted Fill the fuel tank with clean new fuel...