Parsun T40G BM Owner'S Manual Download Page 64

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

Do not install the starter mechanism or top cowling after engine is running. Keep loose clothing and

other objects away when starting the engine. Do not touch the flywheel or other moving parts when

the engine is running.



Do not touch the ignition coil, spark plug wire, spark plug cap, or other electrical components when

starting or operating the motor.

The procedure is as follows:

1. Remove the top cowling.

2. Remove the start-in-gear protection cable.

1. Start-in-gear protection cable

Summary of Contents for T40G BM

Page 1: ...OUTBOARD MOTOR OWNER S MANUAL T40J BM BW FW T40G BM BW FW SUZHOU PARSUN POWER MACHINE CO LTD ...

Page 2: ...enance and care This will ensure that your outboard motor is operated well under various conditions PARSUN seeks continuous improvement in product quality Therefore while this manual contains the most current product information available at the time of printing there may be minor discrepancies between your machine and this manual If there is any question concerning the manual please consult your ...

Page 3: ...be found on the bracket left assembly or on the upper part of the bracket swivel Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from your Parsun dealer or for reference in case your outboard motor is stolen 1 Outboard motor serial number location Serial number as follows SN 1 ...

Page 4: ...Engine serial number The engine serial number is carved on the aluminum casting of engine Serial number as follows ...

Page 5: ... 2 2 Fueling instructions 6 1 2 3 Propeller selection 7 2 Operation 8 2 1 Installation 8 2 1 1 Mounting height 9 2 1 2 Clamping the outboard motor 10 2 2 Breaking in engine 11 2 3 Pre operation checks 12 2 4 Filling fuel 13 2 5 Starting engine 14 2 6 Warming up engine 25 2 7 Shifting 26 2 7 1 Forward 26 2 7 2 Reverse 27 2 8 Tiller 28 ...

Page 6: ...nance 38 3 1 Greasing 39 3 2 Cleaning and adjusting spark plug 40 3 3 Checking the fuel system 40 3 3 1 Cleaning the fuel filter 41 3 4 Inspecting idling speed 42 3 5 Checking wiring and connectors 43 3 6 Checking for leakage 43 3 7 Checking propeller 44 3 7 1 Removing the propeller 46 3 7 2 Installing the propeller 46 3 8 Changing gear oil 47 3 9 Cleaning fuel tank 48 3 10 Checking and replacing ...

Page 7: ...ntenance Table 51 4 Transporting and storing 53 4 1 Transporting 53 4 2 Storing 54 5 Actions in emergency 56 5 1 Impact damage 56 5 2 Starter will not operate 56 5 3 Treatment of submerged motor 59 6 Troubleshooting 60 7 Circuit diagram 64 ...

Page 8: ...p screw 2 Tiller handle 8 Manual starter handle 14 Fuel joint 3 Cooling water inlet 9 choke knob 15 Fuel tank 4 Top cowling lock handle 10 Engine stop button switch 16 Remote control 5 Anti cavitation plate 11 Main switch choke switch FW 6 Propeller 12 Trim rod 4 6 7 15 16 5 7 8 9 10 11 12 13 14 1 2 3 ...

Page 9: ...ed as supply of fuel for its running and must not be as a fuel storage container Remote control The remote control lever actuates both the shifter and the throttle The electrical switches are mounted on the remote control box 1 Remoter control lever 2 Neutral interlock trigger 3 Neutral throttle lever 4 Main switch choke switch 5 Engine stop lanyard switch 6 Throttle friction adjuster 1 3 2 4 ...

Page 10: ...ntinue to run at idle until the lever is moved about 35º a detent can be felt Moving the lever farther opens the throttle and the engine will begin to accelerate 1 Neutral N 2 Forward F 3 Reverse R 4 Shift 5 Fully closed 6 Throttle 7 Fully open Neutral interlock trigger To shift out of neutral first pull the neutral interlock trigger up 1 Neutral interlock trigger ...

Page 11: ...remote control lever in the neutral position and lift the neutral throttle lever NOTE The neutral throttle lever will operate only when the remote control lever is in neutral The remote control lever will operate only when the neutral throttle lever is in the closed position 1 Fully open 2 Fully closed ...

Page 12: ...2 stroke engine oil Overall length BM FW 997mm 692mm Recommended gear oil Hypoid gear oil SAE 90 Overall width BM FW 4484mm 363mm Gear oil quantity 315cm 3 Overall height S BM FW 1208mm Spark plug BR7HS Overall height L BM FW 1335mm Spark plug gap 0 6 0 7mm Weight S BM FW 65kg 68kg Performance Items Data Items Data Maximum output 40HP 29 4kw 5000 rpm Idling speed in neutral 1150 50 rpm 36HP 26 5kw...

Page 13: ...arks flames or other sources of ignition Stop engine before refueling Refuel in a well ventilated area Refuel portable fuel tanks off the boat Do not overfill the fuel tank Take care not to spill gasoline if gasoline spills wipe it up immediately Tighten the filler cap securely after refueling If you should swallow some gasoline inhale a lot of gasoline vapor or get gasoline in your eye get immedi...

Page 14: ... 14L 24L Engine oil 0 04L 0 48L 0 56L 0 96L After break in 50 1 Gasoline 1L 12L 14L 24L Engine oil 0 02L 0 24L 0 28L 0 48L CAUTION Be sure to mix gasoline and oil completely otherwise the engine may be damaged 1 2 3 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 The outboar...

Page 15: ...pitch propeller is more suitable for a smaller operating load as it enables the correct engine speed to be maintained 2 Operation 2 1 Installation Mount the outboard motor on the center line keel line of the boat For boats without a keel or which are asymmetrical consult your dealer 1 1 Center line keel line NOTE During water testing check the buoyancy of the boat at rest with its maximum load Che...

Page 16: ...The information presented in this section is intended as reference only Proper mounting depends in part on experience and the specific boat and motor combination 2 1 1 Mounting height The mounting height of the outboard motor greatly affects your boat running efficiency If the mounting height is too high cavitation tends to occur thus reducing the propulsion If the mounting height is too low the w...

Page 17: ...installation of the outboard includes bolting the engine to the boat through the transom WARNING Loose clamp screws could allow the outboard motor to fall off or move on the transom This could cause loss of control Make sure the clamp screws are tightened securely Occasionally check the screws for tightness during operation 2 If the engine restraint cable attachment is equipped on your engine an e...

Page 18: ...nd check their tightness 2 2 Breaking in engine Your new engine requires a period of break in to allow mating surfaces of moving parts to wear in evenly Gasoline and oil mixing CAUTION Failure to follow the break in procedure could result in reduced engine life or even severe engine damage 1 First 10 minutes Run the engine at idle Break in period 25 1 Gasoline 1L 12L 14L 24L Engine oil 0 04L 0 48L...

Page 19: ...e operation checks Fuel Check to be sure you have plenty of fuel for your trip Make sure there are no fuel leaks or gasoline fumes Check fuel line connections to be sure they are tight Be sure the fuel tank is positioned on a secure flat surface and that the fuel line is not twisted or flattened or likely to contact sharp objects Controls Check throttle shift and steering for proper operation befo...

Page 20: ...ave it inspected and repaired before operating the outboard motor Otherwise an accident could occur CAUTION Do not start the engine out of water Overheating and serious engine damage can occur 2 4 Filling fuel WARNING Gasoline and its vapors are highly flammable and explosive Keep away from sparks cigarettes flames or other sources of ignition 1 Remove the fuel tank cap 2 Carefully fill the fuel t...

Page 21: ... Loosen the air vent screw on the fuel tank cap 2 or 3 turns 2 Connect fuel joints securely and squeeze the primer pump with the outlet end up until you feel it become firm if equipped the fuel joint 3 Place the gear shift lever in neutral ...

Page 22: ... tear loose Do not route the lanyard where it could become entangled preventing it from functioning Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward ...

Page 23: ...ept when in neutral Attach the engine stop switch lanyard to secure place on your clothing or your arm or leg Then install the lock plate on the other end of the lanyard into the engine stop switch 4 Place the throttle grip in the START start position 5 Pull out the choke knob fully ...

Page 24: ...ll straight to crank and start the engine Repeat if necessary 7 After the engine starts slowly return the manual starter handle to its original position before releasing it 8 Slowly return the throttle grip to the fully closed position CAUTION When the engine is cold it needs to be warmed up If the engine does not start on the first try repeat the procedure If the engine fails to start after 4 or ...

Page 25: ...y after loosen the air vent screw on the fuel tank cap 2 or 3 turns 2 Connect fuel joints securely and squeeze the primer pump with the outlet end up until you feel it become firm if equipped the fuel joint 3 Place the gear shift lever in neutral ...

Page 26: ...WARNING The engine must be starting in neutral otherwise damage starter and hazard can occur Do not attach the lanyard to clothing that could tear loose Do not route the lanyard where it could become entangled and preventing it functioning Avoid accidentally pulling the lanyard during normal operation Loss of engine power means the loss of steering control Also without engine power the boat could ...

Page 27: ...t and hold it for a maximum or 5 seconds 6 After the engine starts slowly return the manual starter handle to its original position before releasing it Immediately after the engine starts release the main switch and allow it to return to ON on 7 Slowly return the throttle grip to the fully closed position ON START START ON ...

Page 28: ...art after 5 seconds of cranking return the main switch to ON on wait 10 seconds and then crank the engine again When the engine is cold it needs to be warmed up If engine does not start on the first try repeat the procedure If the engine fails to start after 4 or 5 tries open the throttle a small amount between 1 8 and 1 4 and try again For FW model 1 Loosen the air vent screw on the fuel tank cap...

Page 29: ...ly pulling the lanyard during normal operation Loss of engine power means the loss of steering control Also without engine power the boat could slow rapidly This could cause people and objects in the boat to be thrown forward NOTE The start in gear protection device prevents the engine from starting except when in neutral Attach the engine stop switch lanyard to secure place on your clothing or yo...

Page 30: ...s original position before releasing it Immediately after the engine starts release the main switch and allow it to return to ON on 5 Open the throttle slightly without shifting using the neutral throttle lever or free accelerator You may need to change the throttle opening slightly depending on engine temperature After the engine starts return the throttle to the original position ...

Page 31: ...e will not start after 5 seconds of cranking return the main switch to ON on wait 10 seconds then crank the engine again On remote controls equipped with a neutral throttle lever a good starting point is to lift the lever just until you feel resistance then lift slightly more The neutral throttle lever or free accelerator can only be used when the remote control lever is in neutral It is not neces...

Page 32: ...home position as the engine warms up 2 Check for steady flow of water from the cooling water pilot hole CAUTION If water is not flowing out of the hole at all times while the engine is running stop the engine and check whether the cooling water inlet on the lower case or the cooling water pilot hole is blocked If the problem cannot be located and corrected consult your dealer ...

Page 33: ... in the water near you CAUTION To shift from forward to reverse or vice versa first close the throttle so that the engine idles or runs at low speeds 2 7 1 Forward 1 Place the throttle grip in the fully closed position 2 Move gear shift lever quickly and firmly from neutral to forward ...

Page 34: ...kly and firmly from neutral to forward 2 7 2 Reverse WARNING When operating in reverse go slowly Do not open the throttle more than half Otherwise the boat could become unstable which could result in loss of control and an accident 1 Place the throttle trip in the fully closed position ...

Page 35: ...osition For FW Pull up the neutral interlock rigger and move the remote control lever quickly and firmly from neutral to reverse 2 8 Tiller 1 Change direction To change direction move the tiller handle to the left or right as necessary 2 Change speed Turn the grip counterclockwise to increase speed and clockwise to decrease speed ...

Page 36: ...onomy for the desired operation 1 Throttle indicator 4 Throttle friction adjuster 1 The throttle friction adjuster is on the tiller handle which provides adjustable resistance to movement of the throttle grip and can be set according to operator preference To increase resistance turn the adjuster clockwise To decrease resistance turn the adjuster counterclockwise When constant speed is desired tig...

Page 37: ...gine first let it cool off for a few minutes at idle or low speed Stopping the engine immediately after operating at high speed is not recommended PROCEDURE 1 Push and hold the engine stop button until the engine comes to a complete stop NOTE If the outboard motor is equipped with an engine stop switch lanyard the engine can also be stopped by pulling the lanyard and removing the lock plate from t...

Page 38: ... Tighten the air vent screw on the fuel tank cap 3 Disconnect the fuel line if you are using an external fuel tank For FW 1 Turn the main switch to OFF off 2 Tighten the air vent screw on the fuel tank cap ...

Page 39: ...o adjust the outboard motor trim angle 1 Stop the engine 2 Remove the trim rod from the clamp bracket hole slightly tilting the outboard motor up 3 Reposition the rod in the desired hole Make test runs with the trim set to different angles to find the position that works best for your boat and operating conditions ...

Page 40: ...e outboard motor should be tilted up to protect the propeller and casing from damaged by collision with obstructions and also to reduce corrosion WARNING Be sure all people are clear of the outboard motor when tilting up and down also be careful not to pinch any body parts between the drive unit and engine bracket Tighten the air vent screw and place the fuel cock in the closed position if the out...

Page 41: ...r in neutral if equipped and face the outboard motor forward 2 Tighten the steering friction adjuster by turning it clockwise to prevent the motor from turning freely 3 Tighten the air vent screw Disconnect the fuel joint from the outboard motor N N ...

Page 42: ...35 4 Place the tilt lock lever if equipped in the up position 5 Hold the rear handle and tilt the engine up fully until the tilt support lever automatically locks ...

Page 43: ...ose the steering friction adjuster by turning it counterclockwise and adjust the steering friction according to operator preference WARNING If there is too much resistance it could be difficult to steer which could result in an accident 2 12 Cruising in other conditions 2 12 1 Cruising in shallow water The outboard motor can be tilted up partially to allow operation in shallow water ...

Page 44: ... normal position as soon as the boat is back in deeper water CAUTION The cooling water inlet on the lower unit should be not above the surface of the water when setting up for and cruising in shallow water Otherwise severe damage from overheating can result For tilting procedure see section 2 11 2 12 2 Cruising in salt water After operating in salt water wash out the cooling water passages with fr...

Page 45: ... off the engine when you perform maintenance unless otherwise specified If you or the owner is not familiar with machine servicing this work should be done by your PARSUN dealer or other qualified mechanic CAUTION If replacement parts are necessary use only genuine PARSUN parts or parts of the same type and of equivalent strength and materials ...

Page 46: ...39 3 1 Greasing ...

Page 47: ...itting the spark plug measure the electrode gap with a wire thickness gauge adjust the gap to specification if necessary 0 6 0 7mm When fitting the plug always clean the gasket surface and use a new gasket Wipe off any dirt from the threads and screw in the spark plug to the correct torque 3 3 Checking the fuel system 1 Check the fuel lines for leaks crack or malfunction If a problem is found your...

Page 48: ... Removing the nut holding the fuels filter assembly if equipped 2 Unscrew the filter cup catching any spilled fuel in a rag 3 1 Filter cup 2 O ring 3 Filter element 4 Filter housing 1 2 3 4 3 Remove the filter element and wash it in solvent Allow it to dry Inspect the filter element and O ring of the filter cup to make sure they are in good conditions Change them if necessary If any water is found...

Page 49: ...vary depending on whether testing is conducted with the flushing attachment in a test tank or with the outboard motor in the water 1 Start the engine and allow it to warm up fully in neutral until it is running smoothly 2 Verify whether the idle speed is set to specification Idle speed 1150 50Rpm CAUTION Correct idling speed inspection is only possible if the engine is fully warmed up If not warme...

Page 50: ...ecured and each connector is engaged securely 3 6 Checking for leakage Check that no exhaust or water leaks from the joints between the exhaust cover cylinder head and body cylinder Check for oil leaks on the around the engine CAUTION If any leaks are found consult your PARSUN dealer ...

Page 51: ...ug caps from the spark plugs placing the shift control in neutral and removing the lanyard from the engine stop switch etc Serious accident could occur if the engine starts when you are nearby Do not use your hand to hold the propeller when loosening or tightening the propeller nut Put a wood block between the anti cavitation plate and the propeller to prevent the propeller from turning ...

Page 52: ...or wear erosion from cavitation or ventilation or other damage 2 Check the propeller shaft for damage 3 Check the splines shear pin for wear or damage 4 Check for fish line tangled around the propeller shaft 5 Check for the propeller shaft oil seal for damage ...

Page 53: ...r nut 3 Washer 3 Washer 4 Propeller 4 Propeller 5 Thrust washer 5 Pin 3 7 2 Installing the propeller CAUTION Be sure to install the thrust washer before instating the propeller otherwise the lower case and propeller boss could be damaged Be sure to use a new cotter pin and bend the ends over securely Otherwise the propeller could come off during operation and be lost 1 Apply a marine grease or cor...

Page 54: ... Changing gear oil WARNING Be sure the outboard motor is securely fastened to the transom or a stable stand Never get under the lower unit while the outboard motor is tilted even when the tilt support lever or knob is locked Serious injury could occur if the motor falls 1 Tilt the outboard motor so that the gear oil drain screw is at the lowest point possible 2 2 Place a suitable container under t...

Page 55: ...ult PARSUN dealer 5 Use a flexible or pressurized filling device and inject the gear oil into the gear oil drain screw hole 6 When the oil begins to flow out of the oil level plug hole insert and tighten the oil level plug If necessary change the seal spacer 7 Insert and tighten the gear oil drain screw If necessary change the seal spacer 3 9 Cleaning fuel tank WARNING Keep away from sparks cigare...

Page 56: ...lvent and allow it to dry 5 Replace the gasket with a new one Reinstall the fuel joint assembly and tighten the screws firmly 3 10 Checking and replacing anode s Inspect the external anodes periodically Remove scales from the surfaces of the anodes Consult a PARSUN dealer for replacement of external anodes CAUTION Do not paint anodes as this would render them ineffective and can cause more rapid e...

Page 57: ...50 3 11 Checking top cowling Check the fitting of the top cowling by pushing it with both hands If it is loose have it repaired by your PARSUN dealer ...

Page 58: ...lines The symbol indicates the check ups which you may carry out by yourself The symbol indicates work to be carried out by your Parsun dealer Item Operations Initial Every 10 hours 1 month 50 hours 3 months 100 hours 6 months 200 hours 1 year Anode s external Check replacement Anode s internal Check replacement Cooling water passages Cleaning Cowling clamp Check Fuel filter disposable Check clean...

Page 59: ...djustment Propeller and cotter pin Check replacement Shift link shift cable Check adjustment Thermostat Check Throttle link throttle cable throttle pick up timing Check adjustment Water pump Check Spark plug s Cleaning adjustment Replacement NOTE When operating in salt water turbid or muddy water the engine should be flushed with clean water after every use ...

Page 60: ...t device CAUTION Do not use the tilt support lever or knob when trailing the boat The outboard motor could shake loose from the tilt support and fall WARNING Never get under the lower unit while it is tilted even if a motor support bar is used When transporting or storing the outboard motor while removed from a boat keep the outboard motor in the attitude shown CAUTION Place a towel or something s...

Page 61: ... motor in a dry well ventilated place not in direct sunlight 1 Wash the outboard motor body using fresh water 2 Disconnect the fuel line and tighten the air vent screw 3 Remove the engine top cowling and silencer cover 4 Install the outboard motor on the test tank 5 Fill the tank with fresh water to above the level of the anti cavitation plate CAUTION If the fresh water level is below the level of...

Page 62: ...tely into each carburetor or the fogging hole of the silencer cover if equipped 4 If Fogging Oil is not available run the engine at a fast idle until the fuel system empties and the engine stops 5 If Fogging Oil is not available remove the spark plug s Pour a teaspoonful of clean engine oil into each cylinder Crank several times manually Replace the spark plug s 6 Drain the fuel from the fuel tank...

Page 63: ...outboard motor before operating it again 5 2 Starter will not operate If the starter mechanism does not operate the engine can be started with an emergency starter rope WARNING Use this procedure only in an emergency and only to return to port for repairs When the emergency starter rope is used to start the engine the start in gear protection device does not operate Make sure the remote control le...

Page 64: ...ngine Do not touch the flywheel or other moving parts when the engine is running Do not touch the ignition coil spark plug wire spark plug cap or other electrical components when starting or operating the motor The procedure is as follows 1 Remove the top cowling 2 Remove the start in gear protection cable 1 Start in gear protection cable 1 ...

Page 65: ...ormation see section 2 5 5 Insert the knotted end of the emergency starter rope into the notch in the flywheel rotor and wind the rope several turns around the flywheel clockwise 6 Pull the rope slowly until resistance is felt 7 Give a strong pull straight out to crank and start the engine Repeat it necessary 1 ...

Page 66: ...r 2 Remove the spark plug s then face the spark plug hole downward to allow any mud or contaminants to drain 3 Fill the sump with fresh engine oil 4 Feed engine fogging oil or engine oil through the carburetor s and spark plug holes while starting the engine 5 Take the outboard motor to a PARSUN dealer as soon as possible CAUTION Do not attempt to run the outboard motor until it has been completel...

Page 67: ...ed Have serviced by your dealer Spark plug s fouled or of incorrect type Inspect spark plug s Clean or replace with recommended type Spark plug cap s fitted incorrectly Check and re fit cap s Ignition wiring damaged or poorly connected Check wires for wear or breaks Tighten all loose connections Replace worn or broken wires Ignition parts are faulty Have serviced by your dealer Engine stop switch ...

Page 68: ...aks Tighten all loose connections Replace worn or broken wires Specified engine oil is not being used Check and replace oil as specified Thermostat is faulty or clogged Have serviced by your dealer Carburetor adjustments are incorrect Have serviced by your dealer Carburetor is clogged Have serviced by your dealer Fuel pump is damaged Have serviced by your dealer Air vent screw on fuel tank is clos...

Page 69: ...ommended type Fuel system is obstructed Check for pinched or kinked fuel line or other obstructions in fuel system Fuel filter is clogged Clean or replace with recommended type Fuel is contaminated or stale Fill tank with clean fresh fuel Spark plug gap is incorrect Inspect and adjust as specified Ignition wiring is damaged or poorly connected Check wires for wear or breaks Tighten all loose conne...

Page 70: ...and replace spark plug s as specified Engine vibrates excessively Propeller is damaged Repair or replace propeller Propeller shaft is damaged Have serviced by your dealer 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 it Steering pivot is damaged Have serviced by your dealer ...

Page 71: ...ack red white blue brown W B R W L Br Spark plugs Ignition coil Engine stop switch Pulser coil Charge coil 7 6 5 4 3 Thermo switch Ignition control module CDI 2 1 DESCRIPTION SN 3 6 7 P 1 2 4 5 B T36 40BM 7 8 Lighting coil 8 green G P B B B B O B G G Br L R W B W ...

Page 72: ...Br Spark plugs Ignition coil Engine stop switch Pulser coil Charge coil 7 6 5 4 3 Thermo switch Ignition control module CDI 2 1 DESCRIPTION SN R W Br B W 6 1 Accumulator 2 4 7 3 B T36 40BW 7 P P B B B B G L R DESCRIPTION SN Starter relay Starter motor Fuse holder Rectifier Lighting coil 12 11 10 9 8 ...

Page 73: ...lugs Ignition coil Engine stop switch Pulser coil Charge coil 7 6 5 4 3 Thermo switch Ignition control module CDI 2 1 DESCRIPTION SN R W Br B W 6 1 Accumulator 2 4 7 3 B T36 40FW 7 P P P B B B B B G G Br L L L R DESCRIPTION SN Starter relay Choke solenoid Starter motor Fuse holder Rectifier Lighting coil 13 12 11 10 9 8 W ...

Page 74: ...ol Engine stop switch 4 3 2 1 Switch Ignition 4 3 2 1 DESCRIPTION SN Br G L Y R Y R R W B W brown green blue yellow red yellow red red white black white Buzzer B r B r W R G P B L B r G R P L B W B W R L Y W R Y G B Y ...

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Parsun T40G BM, Owner'S Manual

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