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Parsun F60 BEL-D, Service Manual


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Contents 

Overview ..................................................................................................................................................................... 1

 

Identification Marks ..................................................................................................................................................... 1

 

Propeller Selection ....................................................................................................................................................... 1

 

Protective Measure at Work ......................................................................................................................................... 1

 

Disassembling and Assembling ................................................................................................................................... 2

 

Disposable Parts .......................................................................................................................................................... 2

 

Inspection before Delivery .......................................................................................................................................... 3

 

Special Tools and Testing Equipment .......................................................................................................................... 4

 

Decomposition Schematic Diagram and Symbolic Description .................................................................................. 5

 

Specifications ............................................................................................................................................................... 7

 

Parameters of Outboard Motor .................................................................................................................................... 7

 

Repair Information....................................................................................................................................................... 8

 

Engine .................................................................................................................................................................. 8

 

Measurement conditions: ..................................................................................................................................... 9

 

Lower casing Installation ..................................................................................................................................... 9

 

Electrical System ......................................................................................................................................................... 9

 

Ignition and Ignition Control System .................................................................................................................. 9

 

Locking Torque ............................................................................................................................................................ 9

 

Specified Torque .................................................................................................................................................. 9

 

General Torque .................................................................................................................................................. 10

 

Dimensions ................................................................................................................................................................ 11

 

Outline Dimension(D/T model) ......................................................................................................................... 11

 

Mounting dimensions of clamp bracket ............................................................................................................. 13

 

Basic Maintenance ..................................................................................................................................................... 14

 

Maintenance Interval Chart ....................................................................................................................................... 14

 

Fuel System ............................................................................................................................................................... 14

 

Engine ........................................................................................................................................................................ 15

 

Engine Oil Level ................................................................................................................................................ 15

 

Replace Engine Oil ............................................................................................................................................ 15

 

Valve Clearance ................................................................................................................................................. 16

 

Spark Plug .......................................................................................................................................................... 16

 

Control System .......................................................................................................................................................... 17

 

Throttle Cable .................................................................................................................................................... 17

 

Shift Operation ................................................................................................................................................... 17

 

Lower Casing Unit ..................................................................................................................................................... 18

 

Gear Oil ............................................................................................................................................................. 18

 

Change gear oil .................................................................................................................................................. 18

 

Air tightness Inspection of Lower casing Unit .................................................................................................. 18

 

General maintenance ................................................................................................................................................. 18

 

Anode ................................................................................................................................................................. 18

 

Lubrication Point ............................................................................................................................................... 19

 

Cooling Water Channel ...................................................................................................................................... 19

 

Thermostat ......................................................................................................................................................... 19

 

Propeller ............................................................................................................................................................. 20

 

Electrical System ....................................................................................................................................................... 20

 

Attention: ................................................................................................................................................................... 20

 

Decomposition Schematic Diagram .......................................................................................................................... 21

 

Wiring Diagram ......................................................................................................................................................... 27

 

Summary of Contents for F60 BEL-D

Page 1: ...PARSUN OUTBOARD MOTOR SERVICE MANUAL F60 50 Suzhou Parsun Power Machine Co Ltd...

Page 2: ...essary the Company will distribute the revised part to the dealers When the following characters appear in the Manual please read the Manual carefully and follow the relevant instructions and descript...

Page 3: ...l System 9 Locking Torque 9 Specified Torque 9 General Torque 10 Dimensions 11 Outline Dimension D T model 11 Mounting dimensions of clamp bracket 13 Basic Maintenance 14 Maintenance Interval Chart 14...

Page 4: ...mp 41 Check the Fuel Pipe and Fuel Filter 42 Check the Fuel Common Rail 42 Check the fuel common rail for leaks or cracks and damage and replace it if necessary 42 Engine 42 Attention 42 Decomposition...

Page 5: ...Lower casing Part 90 Decomposition Schematic Diagram D T model 90 Decomposition Schematic Diagram CD CT model 97 Disassembling and Check 99 Propeller Shaft and Clutch Block 100 Install the Claw Clutc...

Page 6: ...ntain normal operation of the engine When the engine is running at full throttle refer to the speed and fuel performance of the engine for the most suitable propeller In this way the propeller can pro...

Page 7: ...ff the spilled grease 5 Developing good working habits 1 Tighten nuts bolts and screws according to the specified torque from the center outward and from large ones to small ones 2 Use recommended spe...

Page 8: ...the low position mark 2 Check gear oil level Unscrew the oil level hole plug and observe whether there is oil overflow from the oil level plug hole If yes install the oil level hole plug and tighten i...

Page 9: ...rm to the specified value Idle value 750 850rpm Turn the throttle stop screw clockwise or counterclockwise until the specified idle speed is reached After adjusting the idle speed speed up several tim...

Page 10: ...e shaft bearing Lower unit Lower unit cover mounting tool Drive shaft bearing Drive shaft seat oil seal Forwarder gear bearing mounting tool mounting kit mounting tool kit Drive shaft spline sleeve Pi...

Page 11: ...F25 02010100 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...

Page 12: ...ace filter Full throttle operating range 5000 6000 r min 2 0L do not replace filter Max fuel consump tion F50 18 5 L h 6000 r min Gear oil type Hypoid gear oil F60 20 L h 6000 r min Gear oil grade API...

Page 13: ...wn 1 490 1 484mm Camshaft Height Intake cam 30 83 31 03mm Oil pump Type Cycloid pump Exhaust cam 30 83 31 03mm Pressure relief valve opening pressure 382 442 kPa Diameter of base circle 25 90 26 10mm...

Page 14: ...ary output voltage 34KV Spark plug clearance 0 8 0 9mm Primary resistance 2 2 0 22 Trigger coil Peak voltage 13 V 1000 r min Secondary resistance 9 84 0 98K Resistance 260 290 Rectifier regulator outp...

Page 15: ...rip Screw M5 3 Nm Shift linkage bracket Bolt M6 10 Nm Gear spring piece Bolt M6 10 Nm Bottom cover flat Bolt M6 10 Nm Clamp bracket Self locking nut 45 Nm Oil drain bolt Bolt M14 27 Nm Tilting system...

Page 16: ...11 Dimensions Outline Dimension D T model...

Page 17: ...12 Outline Dimension CD CT model...

Page 18: ...13 Mounting dimensions of clamp bracket...

Page 19: ...ce Water pump Check Propeller and cotter pin Check replace Timing band Check replace Throttle cable Check adjust Shift lever shift cable Check adjust Attention Flush the outboard motor with fresh wate...

Page 20: ...tion mark and add oil if it is below the low position mark Attention Turn off the engine after running it and let it stand for several minutes Check the oil level again with the oil dipstick If the oi...

Page 21: ...el counterclockwise to avoid damage to the valve system Note Adjust valve clearance when the engine is cold Valve clearance Cold state Intake valve 0 15 0 25mm Exhaust valve 0 25 0 35mm 8 Loosen the l...

Page 22: ...n the lock nut of the cable joint 1 Cotter pin 2 Cable joint 3 Lock nut 4 Adjust the screw in depth of the joint so that the joint hole is aligned with the pin of the throttle actuator driving pulley...

Page 23: ...6 Install the oil drain screw Wipe off the spilled gear oil Note Check the drained gear oil If gear oil is emulsified check the seal and replace it if necessary If there are metal debris in the gear o...

Page 24: ...necessary 1 Inlet of cooling water channel 2 Place the outboard motor in the water to ensure that the water level is above the anti swirl plate and start the engine 3 Check whether there is cooling wa...

Page 25: ...g the ignition system Do not place your hands clothes hair or accessories close to the running flywheel Test the ignition coil on an insulated workbench to prevent electric leakage and electric shock...

Page 26: ...21 Decomposition Schematic Diagram M20 mm 160 Nm...

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Page 32: ...itch 6 Lighting coil 12 Rectifier 13 Electric fuel pump 14 14 Intake temperature pressure sensor 15 Throttle position sensor R Red P Pink B Black G Green W White L Blue Br L Brown Blue P B Pink Black...

Page 33: ...11 10 pin plug 6 Lighting coil 9 Alarm indication lamp 12 Rectifier 13 Electric fuel pump 14 Intake temperature pressure sensor 15 Throttle position sensor 18 Canister solenoid valve 19 Stepper motor...

Page 34: ...Remove the flywheel nut using the flywheel gripper Remove the flywheel using the flywheel puller 2 Check whether the flywheel is damaged and whether the permanent magnet is firm Replace it if necessar...

Page 35: ...n relay terminals If it is not conductive replace the relay 4 Disconnect the lead connection to the battery and check the conductivity between relay terminals If it is conductive replace the relay Che...

Page 36: ...temperature sensor line 112 Short circuit to ground or open circuit in intake air temperature sensor line 113 Water temperature failure Short circuit to ground in coolant temperature sensor line 117...

Page 37: ...ault light Fault indicator lamp failure 650 Oil pressure failure Short circuit to ground in oil pressure sensor line 523 Short circuit to high level in oil pressure sensor line 522 Carbon canister sol...

Page 38: ...el leakage can cause fire and explosion Do not attempt to start the engine before determining that the components of the fuel system are connected or installed After completing all repair steps apply...

Page 39: ...34 Decomposition Schematic Diagram...

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Page 44: ...1 Fuel pump check valve 2 Insert the pressure relief pipe into a suitable container Attention Do not release the pressure directly and the fuel will be discharged while the pressure is released Fuel...

Page 45: ...Specified pressure 30kPa 6 Connect a vacuum manometer to the outlet of the fuel pump 7 Block the inlet of the oil pump with your fingers and apply the specified negative pressure Check for air leaks I...

Page 46: ...and disconnect the wiring harness connection 3 Remove the mounting screws of the electric fuel pump and remove the electric fuel pump from the engine 4 Disconnect the line connection between the fuel...

Page 47: ...Fuel Pipe and Fuel Filter 1 Check the fuel pipe for damage 2 Check whether the high pressure fuel filter is cracked and whether the fuel flows smoothly Replace it if necessary Check the Fuel Common R...

Page 48: ...43 Decomposition 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 60: ...x remove the throttle linkage fully open the carburetor throttle lever by hand and then detect the pressure 5 If the pressure is lower than the specified value or there is a difference between the cyl...

Page 61: ...round wire and the water pipe 11 Remove the ignition coil ECU device ignition coil and spark plug 12 Remove the bolts connecting the engine to the water unit 13 Lift the engine and remove the locating...

Page 62: ...lley counterclockwise otherwise the valve system will be damaged 9 Install the timing pulley cover plate and temporarily tighten the timing pulley nut 10 Turn the timing pulley clockwise for 2 turns t...

Page 63: ...acing valve be sure to use new valve guides and valve seal Valve spring 1 Check the free length of the valve spring If it is less than the specified value replace it Free length 39 85 mm Min free leng...

Page 64: ...head and body 1 Remove carbon deposits from the combustion chamber and check for damage 2 Use a ruler and gap gauge to check the bending of the joint surface If the specified value is not met replace...

Page 65: ...alve sealing surface is too narrow and at the top edge of the valve surface trim the top edge of the seat ring with a 30 cutter if so adjust the width of the sealing surface with a 45 cutter 4 If the...

Page 66: ...e the oil pump Note Ensure that the mark on the outer rotor face the oil pump cover 6 Fit oil pump by aligning oil pump drive shaft and camshaft pin Attention Before installing the oil pump make sure...

Page 67: ...asure respectively Height of measuring point 1 20 mm 2 60 mm 3 100 mm Cylinder bore 65 000 65 013 mm 2 Calculate the taper limit and roundness limit If the specified value is exceeded replace the cran...

Page 68: ...thread diameter of the connecting rod bolt at the position shown 2 Calculate the difference between the diameters of the two threads If it does not conform to the specified value replace it Diameter d...

Page 69: ...te Do not place the plastic clearance gauge on the oil hole of the main journal 4 Install the bearing bush on the engine base and install the engine base on the body 5 Tighten the bolts with the speci...

Page 70: ...iston ring Install Crankshaft 1 Install the bearing bush to the body Note Insert the raised part on the bearing bush into the groove of the corresponding part of the body 2 Install the crankshaft to t...

Page 71: ...values in 2 steps according to the sequence marked on the cylinder head Specified torque 1st tightening M9 23 Nm 2nd tightening 46 Nm 1st tightening M6 6 Nm 2nd tightening 12 Nm Attention Do not use o...

Page 72: ...67 Upper Casing Top Cowling Decomposition Schematic Diagram...

Page 73: ...ok and hook 5 Check the top cover for cracks damage or wear Replace it if necessary 6 Check the sealing rubber strip for cracks or damage Replace it if necessary 7 Check the top cover silencer for cra...

Page 74: ...69 Bottom Cowling Decomposition Schematic Diagram...

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Page 77: ...72...

Page 78: ...hrottle swing rod seat and remove the cotter pin on the throttle swing rod assembly 8 Remove the shift support remove the shift linkage assembly and remove the brake rocker 9 Check the top cover for c...

Page 79: ...74 Steering Handle Decomposition Schematic Diagram...

Page 80: ...75...

Page 81: ...ar fracture and sticking Replace it if necessary 8 Check the Steering handle for cracks or damage Replace it if necessary 9 Check the handle anti wear ring and waveform washer for cracks or damage Rep...

Page 82: ...77 Upper casing unit and Brackets Decomposition Schematic Diagram...

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Page 88: ...nstalling it Avoid accidental injuries Do not disassemble unless necessary 7 Pull out the steering bracket assembly and remove the liner bushing and O ring 8 Check the rotary bracket and clamping brac...

Page 89: ...e 8 Check the water unit casing and oil pan for cracks or damage Replace it if necessary 9 Check the exhaust partition for damage or cracks Replace it if necessary 10 Check the exhaust duct and manifo...

Page 90: ...85 Manual Tilting Device Disassembly Schematic Diagram...

Page 91: ...s and lower the support frame to support the outboard motor 2 Remove the steel wire retaining ring for the shaft and remove the tilting pin shaft 3 Remove the bolt and remove the hydraulic tilting pos...

Page 92: ...87 Hydraulic Tilting Device Disassembly Schematic Diagram...

Page 93: ...device vertically 2 Connect the tilting motor wire of the hydraulic tilting device to the battery 3 Extend the push rod completely remove the oil screw and observe the oil level Note The liquid level...

Page 94: ...ed on the outboard outboard motor please follow the following steps 1 Turn the hand control valve counterclockwise until it cannot turn 1 Hand control valve 2 Tilt the outboard motor completely upward...

Page 95: ...90 Lower casing Part Decomposition Schematic Diagram D T model...

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Page 102: ...97 Decomposition Schematic Diagram CD CT model...

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Page 104: ...and pump inner casing 4 Remove the semicircular key and outer baffle 5 Check the water pump casing and outer baffle for cracks twists or damages Replace it if necessary 6 Check the water pump inner ca...

Page 105: ...e the pinion nut with an internal splined wrench and remove the drive shaft 17 Remove shift cam remove forward gear Remove shift cam cover plate and remove shift cam Remove the forward gear CD CT 18 R...

Page 106: ...on the reverse gear Note Install the oil seal and bearing with special tools Pay attention to the installation direction and depth Ensure that the manufacturer s mark of the bearing faces the reverse...

Page 107: ...le the Lower casing Device Casing 1 Install the needle roller bearing with special tools Needle roller bearing mounting tool kit 2 Install new forward gear bearing If replace it Forward gear bearing c...

Page 108: ...ied torque insert the cotter pin and bend the foot of the cotter pin 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...

Page 109: ...g adjusting piece of the Lower casing unit is engraved with deviation value marks namely F R and P respectively Represents the difference between the actual size and the theoretical size on the casing...

Page 110: ...orward gear bearing so that the roller falls completely into the bearing casing 3 Measure the bearing height and calculate the thickness T1 according to the formula Formula T1 26 70 F 100 M1 Formula f...

Page 111: ...t type of spark plug Fuel system is clogged Check the fuel pipe for extrusion winding or blockage Fuel is contaminated or obsolete Fill up the fuel tank with clean fresh fuel Fuel filter is blocked Re...

Page 112: ...broken wire Ignition parts failure Replace The engine oil grade is incorrect or too much oil is added Change to the oil of the specified grade or add it to the appropriate position of the oil dipstic...

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