Parsun F40 EFI Maintenance Manual Download Page 1

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Maintenance Manual for Outboard Motor

F40/30 EFI

Suzhou Parsun Power Machine Co., Ltd.

Summary of Contents for F40 EFI

Page 1: ...1 Maintenance Manual for Outboard Motor F40 30 EFI Suzhou Parsun Power Machine Co Ltd...

Page 2: ...sary our Company will distribute the revised part to the dealers in various places When the following characters appear in this Manual please read the Manual carefully and execute the relevant instruc...

Page 3: ...tion and ignition control system 9 Charging system 10 Seating torque 10 Specified torque 10 Average torque 11 Dimensions 11 Overall dimensions 11 Mounting dimensions of clamp bracket 16 Basic maintena...

Page 4: ...inspection 45 Disassembly and inspection of electric fuel pump 46 Inspection of fuel pipe and fuel filter 47 Check the fuel common rail 47 Engine 47 Precautions 47 Disassembly schematic diagram 48 Sp...

Page 5: ...vice 99 Underwater part 101 Disassembly schematic diagram 101 Disassembly and inspection 106 Propeller shaft and clutch block 106 Install the claw clutch 107 Housing cover of underwater unit 107 Insta...

Page 6: ...operation of the engine When the engine is at maximum load if the throttle is half or more of the full throttle range the selected propeller is appropriate Propeller dimensions Material 3 11 8 3 12 A...

Page 7: ...outboard motor please follow the following principles 1 Please use special tools when disassembling and assembling the parts of the outboard motor 2 Remove dust and dirt before decomposing the parts 3...

Page 8: ...he throttle grip operates smoothly from the full close position to the full open position 5 Check the emergency stop switch assembly Check whether the engine stops when the emergency stop switch assem...

Page 9: ...d other faults of the engine Special tools and testing equipment Various special tools and testing equipment will be used when repairing and maintaining the outboard motor Using these tools and equipm...

Page 10: ...tion kit Forward gear bearing casing installation kit Drive shaft spline sleeve Pinion nut spanner Testing equipment Digital tachometer Digital multimeter Peak voltage adapter Disassembly schematic di...

Page 11: ...00 F25 02010006 GB T97 1 2000 GB T5783 2000 F25 02010200 GB T5783 2000 F25 00000014 F25 02000006 F25 02010007 F15 00000006 F15 04000003 F15 04000002 M6x25 M6X16 8x12 6x12 6 RELIEF VALVE AUY HEXAGON BO...

Page 12: ...F40 29 4 Kw 5500r min Engine oil level 1 9 L Change oil filter Full throttle operating range 5000 6000 r min 1 7 L without changing oil filter Maximum fuel consumpti on F30 10 5 L h 6000 r min Type of...

Page 13: ...alve guide 5 500 5 518mm Lateral clearance 0 02 0 06mm Clearance between guide and valve stem 0 025 0 058mm Second ring Thickness 1 47 1 49mm Valve stem roundness limit 0 03mm End face width 2 60 2 80...

Page 14: ...diamete r Intake valve 31 9 32 1mm Exhaust valve 25 9 26 1mm Measurement conditions The ambient temperature is 20 Underwater unit Item Data Item Data Backlash Pinion to forward gear 0 18 0 66mm Option...

Page 15: ...Bolt M9 23 Nm Second tightening 47 Nm Frist tightening Bolt M6 6 Nm Second tightening 12 Nm Oil filter 18 Nm Oil filter stud 40 Nm Lock nut rocker arm Nut M6x0 75 13 5Nm Engine assembly Bolt M8 21 Nm...

Page 16: ...10 Nm Throttle grip Screw M5 2 Nm Shift linkage bracket Bolt M6 10 Nm Gear spring plate Bolt M6 10 Nm Small cover plate of bottom cover Bolt M6 10 Nm Clamp bracket Self locking nut 45 Nm Oil drain bo...

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Page 21: ...16 Mounting dimensions of clamp bracket...

Page 22: ...r pump Check Propeller and cotter pin Check replace Timing belt Check replace Throttle cable Check adjust Shift lever shift cable Check adjust Note Flush the outboard motor with fresh water immediatel...

Page 23: ...il dipstick 1 Oil dipstick 2 High mark 3 Low mark 2 If the oil level is above the high mark discharge the engine oil If the oil level is below the low mark add engine oil Note Run and then turn off th...

Page 24: ...with the mark on the cylinder head Check the clearance between intake and exhaust valves of Cylinder 3 Correct it if necessary Note It is strictly forbidden to turn the flywheel counterclockwise so a...

Page 25: ...throttle cable 1 Check plate 3 Loosen the throttle cable adjusting nut and adjust the throttle cable position After adjustment tighten the throttle cable adjusting nut The throttle control is realized...

Page 26: ...remove the oil level plug screw Drain gear oil 1 Oil level plug screw 2 Oil drain screw 4 Use the pressure filling device to inject gear oil into the oil drain screw hole 5 When gear oil overflows fr...

Page 27: ...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 Apply anti corrosion grease to t...

Page 28: ...observation hole Thermostat 1 Remove thermostat cover and then remove thermostat 2 Hang the thermostat in a container containing water 3 Heat the container 4 Check the opening of thermostat valve at t...

Page 29: ...ctric leakage and electric shock When the engine is running do not touch the ignition coil or spark plug so as to avoid electric shock Make sure that the wires are kept away from the running flywheel...

Page 30: ...25 Disassembly schematic diagram M20 1 25 mm 157 Nm...

Page 31: ...26 REMARKS...

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Page 37: ...WIRING DIAGRAM...

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Page 40: ...lywheel is damaged and whether the permanent magnet is firm Replace it if necessary Check engine startup switch Check the conductivity of the engine startup switch If it is not conductive replace it N...

Page 41: ...that there is a fault in the engine At this time connect the fault diagnosis tester with the corresponding detection port on the engine and display the running parameters and fault codes of the engine...

Page 42: ...ump relay fault 230 Crankshaft position sensor fault Signal interference of crankshaft position sensor line 336 No signal of crankshaft position sensor line 337 Ignition coil fault 1 Cylinder ignition...

Page 43: ...ile 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...

Page 44: ...39 Disassembly schematic diagram...

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Page 49: ...he electric fuel pump 1 Oil pump detection valve 2 Insert the pressure relief pipe into a suitable container Note Do not release the pressure directly The fuel will be discharged while pressure is rel...

Page 50: ...pply a specified negative pressure Check for air leakage If necessary disassemble the oil pump and check it Specified pressure 50kPa 8 Remove the 4 bolts and separate the fuel pump cover and from the...

Page 51: ...remove the fuel cooler 5 Remove 5 cross recessed pan head screws M4 16 and the electric fuel pump body assembly 6 Pull off the oil pump assembly and disconnect the oil pump joint assembly 7 Check and...

Page 52: ...ck whether the high pressure fuel filter is cracked and whether the fuel flows smoothly Replace it if necessary Check the fuel common rail Check the fuel common rail for leakage or cracking and replac...

Page 53: ...48 Disassembly schematic diagram M8x82 mm 1st 15 Nm 2nd 30 Nm 18 Nm M6x35 mm 1st 6 Nm 2nd 12 Nm 40 Nm...

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Page 65: ...e carburetor throttle lever fully by hand and check the pressure 5 If the detected pressure is lower than the specified value or there is a difference between cylinders add a small amount of oil into...

Page 66: ...emove the high voltage ignition coil ECU device ignition coil and spark plug 12 Remove the bolts connecting the engine and the water unit 13 Lift the engine and remove the locating pin Pulley and timi...

Page 67: ...clockwise or it will damage the valve system 9 Install the cover plate of the timing pulley and temporarily tighten timing pulley nut 10 Turn the timing pulley clockwise for 2 turns to eliminate the s...

Page 68: ...diameter of the valve guide Valve guide inner diameter 5 50 5 51 mm Note When replacing the valve be sure to use new valve guide and valve oil seal Valve spring 1 Check the free length of valve spring...

Page 69: ...eet the specified value replace it Clearance a between outer rotor and shell 0 09 0 15 mm Clearance b between outer rotor and inner rotor 0 01 0 10 mm Clearance c between rotor and cover 0 03 0 08 mm...

Page 70: ...e with a 45 valve seat ring cutter and adjust the width of the sealing surface Turn the cutter clockwise until the surface of the seat ring is smooth 2 If the valve sealing surface is too wide and in...

Page 71: ...ner Assemble cylinder head 1 Install a new oil seal with the special tool 2 Fit the camshaft into cylinder head in the oil pump direction 3 Check whether the spline position faces the cylinder joint s...

Page 72: ...on pin seat 16 002 16 008 mm Cylinder bore 1 Measure the piston outer diameter at specified measuring points 1 2 3 At each measuring point measure the diameters parallel to the crankshaft directions D...

Page 73: ...nner diameter of small end 15 985 15 998 mm Connecting rod large end backlash Measure the big end backlash If it does not meet the specified value replace the connecting rod or crankshaft or both Larg...

Page 74: ...rnal and the mounting surface of the engine body and engine base 2 Install the bearing bush and crankshaft to the engine body 3 Place a plastic clearance gauge on the main journal and parallel it to t...

Page 75: ...ic ring 2 Oil ring upper retaining ring 3 Second ring 4 Top ring 5 Installing piston Install piston with piston slideway Make sure that the UP mark on the top of the piston faces the flywheel Note Whe...

Page 76: ...xhaust cover plate Seating torque First time 6 Nm The first 12 Nm 6 Install the locating pin cylinder gasket and cylinder head assembly 7 Check the keyway position of semicircular key on the camshaft...

Page 77: ...nstall 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...

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Page 79: ...heck the top cover for cracks or damage Replace it if necessary 6 Check the sealing rubber strip for cracks or damage Replace it if necessary 7 Check the top cover muffler cover for cracks or damage R...

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Page 82: ...77 Continued...

Page 83: ...78 Back operation model...

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Page 85: ...80 Front operation model...

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Page 87: ...on Remove the control cable connector A and remove the throttle actuator Remove the control cable retainer Front operation 7 Remove the shift lever support shift lever assembly and brake rocker arm Re...

Page 88: ...83 Steering handle Disassembly schematic diagram...

Page 89: ...84 Disassembly and inspection...

Page 90: ...the steering handle for cracks or damage Replace it if necessary 9 Check the handle anti wear ring and wave washer for cracks or damage Replace it if necessary 10 Check whether the cable in the thrott...

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Page 100: ...heck the support frame assemblies A B for deformation or damage Replace it if necessary 11 Check the left and right absorber rubber for aging cracking or degumming Replace it if necessary Disassembly...

Page 101: ...96 Hydraulic warping device Disassembly schematic diagram...

Page 102: ...he outboard motor upward and push it in the warping limit shaft to support the outboard motor 2 Remove the circlip 9 and remove the warping hinge pin 3 Remove bolts and hydraulic positioning shaft 4 R...

Page 103: ...98 Manual warping device Disassembly schematic diagram...

Page 104: ...the oil hole 1 Oil drain screw 4 If necessary add oil to the edge of the oil hole 5 Install the oil drain screw and tighten it Specified torque 6 5 Nm Exhaust the air in the oil line of the hydraulic...

Page 105: ...er it downward by its own gravity Repeat 4 5 times 3 Turn the manual valve clockwise until it cannot turn 4 Wait for 5 minutes to stabilize the oil 5 Press and hold the warping switch until the outboa...

Page 106: ...101 Underwater part Disassembly schematic diagram...

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Page 111: ...ove the propeller and cushion block 10 Remove the anode 11 Remove the housing cover of the underwater unit Remove the reverse gear and shim and remove the oil seal 12 Remove the propeller shaft assemb...

Page 112: ...al and needle bearing please use new parts to replace them 4 Clean the housing cover with a soft brush and solvent 5 Check the housing cover Replace it if cracked or damaged Install the oil seal and b...

Page 113: ...a new bearing it is required to adjust the shim Check the housing of the underwater unit Check whether the housing of underwater unit is cracked or damaged and check whether the cooling water inlet is...

Page 114: ...e propeller Tighten the nut according to the specified torque Specified torque 35 Nm Note If the groove on the nut is not aligned with the cotter pin hole on the propeller shaft tighten the nut furthe...

Page 115: ...110 T3 M2 T2 M1 T1 Deviation value mark The installation surface of the anode heading tab of the underwater unit is engraved with...

Page 116: ...ckness T3 with the formula Formula T3 M3 P 100 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 thicker than T3 and choose the closest size...

Page 117: ...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 Engine fails to start There is no fuel in...

Page 118: ...Fuel oil polluted or obsoleted Fill the fuel tank with clean new fuel Fuel filter blocked Replace the fuel filter Incorrect spark plug gap Adjust the gap to the specified value Ignition circuit failu...

Page 119: ...ken wire Ignition component failure Replace it Incorrect engine oil grade or excessive oil Change to the specified oil grade or add it to the proper position of the oil dipstick Thermostat failure Rep...

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