Parsun F4BM Service Manual Download

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PARSUN OUTBOARD ENGINE

SERVICE MANUAL

F4BM (F5BM)

SUZHOU PARSUN POWER MACHINE CO., LTD.

https://www.boat-manuals.com/

Summary of Contents for F4BM

Page 1: ...PARSUN OUTBOARD ENGINE SERVICE MANUAL F4BM F5BM SUZHOU PARSUN POWER MACHINE CO LTD https www boat manuals com...

Page 2: ...tribute 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 c...

Page 3: ...FORMATION 10 Power unit 10 Ignition system 11 TIGHTENING TORQUE 11 Specified torque 11 General torque 12 PERIODIC SERVICE 13 MAINTENANCE TIME TABLE 13 FUEL SYSTEM 13 POWER UNIT 14 Engine oil level 14...

Page 4: ...E 30 EXPLOSIVE DRAWING 30 FUEL TANK REMOVAL AND INSPECTION 36 OIL SWITCH REMOVAL AND INSPECTION 37 FUEL JOINT REMOVAL AND INSPECTION 37 FUEL PUMP REMOVAL AND INSPECTION 38 INTAKE SYSTEM REMOVAL AND IN...

Page 5: ...ting rod installation 56 Piston ring installation 56 Piston installation 56 Oil seal housing installation 57 Crankshaft installation 57 Camshaft installation 57 Crankcase cover installation 58 UPPER U...

Page 6: ...losive Drawing 79 Disassembling and inspection 83 Propeller shaft and clutch block 84 Clutch block installation 84 Lower casing cover 84 Lower casing cover oil seal and bearing installation 84 Barrel...

Page 7: ...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...

Page 8: ...protection device cable 2 Chock lever cable 3 Demount three bolts and remove starter 4 Assemble two bolts to fix the fuel tank 5 Insert the knot of the cable in the notch of flywheel rotor and wind t...

Page 9: ...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 precaution...

Page 10: ...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 no...

Page 11: ...p switch assembly or pulling out the stopper hang rope 6 CHECK COOLING WATER CHECKING HOLE When the engine is running check if cooling water overflows at the cooling water checking hole 1 1 Cooling wa...

Page 12: ...peed picking up RPM several times to check the engine s stability SPECIAL TOOLS AND DETECTION DEVICE When performing maintenance and repair you need to use all kinds of special tools and detection dev...

Page 13: ...Lower casing bracket and barrel bearing without guard board installer tool Lower casing bracket and drive shaft oil seal installer tool DETECTION DEVICE Digital tachometer Digital circuit tester Peak...

Page 14: ...03000015 F4 03060000 F4 03000017 F4 03000018 F4 03000019 F4 03000013 F4 03000021 F4 03000020 DESCRIPTION PART NO REMARKS Parts explosive drawing Oil fluid sealant or locking substance daubing point S...

Page 15: ...0W30 10W40 Max fuel consumption 1 6L h 5000r min Engine oil quantity 0 5L Performance Idle speed Neutral 1500 50 r min Recommended gear oil Hypoid gear oil SAE 90 Type 4 stroke OHV Fuel and Oil Gear o...

Page 16: ...utside diameter 12 995 13 000mm Intake 5 475 5 490mm Thickness 1 5mm Stem outside diameter Exhaust 5 460 5 475mm Breadth 2 6mm Intake End gap 0 10 0 20mm Guide inside diameter Exhaust 5 500 5 512mm We...

Page 17: ...Ignitor ass y resistance Secondary coil 5 8 7 0K TIGHTENING TORQUE Specified torque Part to be tightened Part name Thread size Quantity Torque Oil drain Bolt M8 1 20Nm Spark plug M14 1 25 Nm Recoil st...

Page 18: ...d tightening Bolt M6 4 8 Nm 1st tightening 3 Nm Lower unit Water pump base 2nd tightening Bolt M6 1 8 Nm Steering handle mounting Bolt M8 1 18 Nm Shift lever bracket Bolt M6 1 4 5 Nm 1st tightening 3...

Page 19: ...ngine oil Replacement Valve cleanrance Inspection adjustment Ignition timing Inspection T C I air gap Inspection adjustment Thermostat Inspection Cooling water passage Inspection Cleaning Gear oil Rep...

Page 20: ...LTER Check if fuel filter is cracked damaged or has dirt inside If so replace it CAUTION The arrow mark of the fuel filter must face toward the fuel pump Clean the spilled oil POWER UNIT Engine oil le...

Page 21: ...oil level plug drain plug with washer and gasket drain off the engine oil 2 Install new gasket and washer install drain plug 3 Fill engine oil into the crankcase through oil filler hole Engine oil qua...

Page 22: ...damaged If necessary change the spark plug Spark plug type BPR7HS 4 Inspect if the spark plug gap is within specification If necessary change the spark plug 0 6 0 7mm 5 Install spark plug Use spark pl...

Page 23: ...ckwise 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 id...

Page 24: ...plug and then drain the gear oil 1 Oil level plug 2 Drain plug 2 1 1 4 Add gear oil through the drain plug using pressure filling device 5 When gear oil overflows at the oil level checking hole insta...

Page 25: ...nd 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 Greas...

Page 26: ...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 1 2 RECOIL STARTER NOTICE When you service ple...

Page 27: ...04130011 F4 04130102 F4 04130101 MEATUS START ROPE PAWL DRIVE SPRING DRIVE WIRE STARTER COVER HANDLE STARTER SEAL RUBBER GUIDE ROPE CASE STARTER STARTER ASSY F4 04130003 F4 04130004 F4 04130013 F4 04...

Page 28: ...ARKS 1 3 1 1 1 1 1 1 1 1 6 F4 04130008 BOLT STARTER F4 04130006 F4 04130007 PLATE PRELL SPRING PLATE F4 04130019 DRULL SHEAVE F4 04130005 F4 04130014 SPRING VOLUTE WASHER THRUST F4 04130002 F4 0413001...

Page 29: ...21 22 23 24 6 5Nm G G G M6x35 mm 8Nm M6x20 mm 8Nm G REMARKS DESCRIPTION PART NO 2 1 1 1 BOLT HEXAGON M6x35 M6x20 F4 02000013 F4 04000005 BOLT HEXAGON 23 https www boat manuals com...

Page 30: ...notch of the sheave drum Turn the sheave drum clockwise until the volute spring is free 2 Pull the starter rope completely 3 Remove the starter handle cover from the starter handle and remove the star...

Page 31: ...move the sheave drum WARNING Uninstall the sheave drum carefully to ensure that the volute spring does not pop out to hurt people 4 Remove the volute spring 5 Remove the detent and detent wrest spring...

Page 32: ...t and tighten it according to the specified torque 3 Install the detent tightwire 4 Adjust the adjusting nut on the tightwire of the dent and align the triangle marking of the dent with the triangle m...

Page 33: ...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...

Page 34: ...e 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...

Page 35: ...Replace if necessary IGNITION COIL INSPECTION 1 Ignition coil peak voltage Remove spark plug cap Disconnect ignition coil tip W Measure the ignition coil peak voltage output by a digital universal met...

Page 36: ...se 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...

Page 37: ...REMARKS PART NO DESCRIPTION 31 https www boat manuals com...

Page 38: ...Nm REMARKS PART NO DESCRIPTION M3 5 F4 04090011 SEAT FUEL PUMP ROLLER NEEDLE DIAPHRAGM ASSY FUEL PUMP SHELL PLATE DIAPHRAGM TOP COVER FUEL PUMP F4 04090001 F4 04090008 GB T309 2000 F4 04090100 F4 0409...

Page 39: ...4090007 F4 04090006 F4 04090000 F4 04090009 GB T93 1987 GB T97 1 85 F4 04000028 F4 04000030 GB T6170 2000 F4 04000031 2 SPRING PLUNGER PLUNGER NUT FUEL PUMP ASSY O RING CLIP NYLON B PIPE FUEL E SPRING...

Page 40: ...m C F4 05000010 FUEL FILTER ASSY PIPE FUEL A OIL SWITCH PIPE FUEL B THREE THROUGH PIPE FUEL C PIPE FUEL D HEXAGON BOLT F4 05000008 F4 05000007 F4 05000006 F4 05000005 F4 05000100 F4 05000300 F15 05000...

Page 41: ...4 04000025 F4 04110000 F4 04000035 F4 04110006 F4 05000400 F4 04000031 1 F4 04000024 JASO F404 96 GB T97 1 85 GB T5284 86 HEXAGON BOLT WASHER PLATE O RING GASKET CARBURETOR PIPE RETURN GAS CLAMP NYLON...

Page 42: ...0025 GB T97 1 85 F4 04000025 F4 04000022 2 1 1 MANIFOLD INTAKE HEXAGON BOLT CARBURETOR M6x25 FUEL TANK REMOVALAND INSPECTION 1 Open the top cowling 2 Remove three bolts fixing the starter 3 Remove the...

Page 43: ...oil switch and remove the thumb wheel 2 1 3 4 1 Oil switch 2 Thumb wheel 3 Plus pan head screw M4X12 4 Thumb wheel block 3 Remove the bolts fixing the oil switch and remove oil switch 1 Screw 2 Gasket...

Page 44: ...e 50kPa 5 Force a prescribed negative pressure and check for leakage Prescribed pressure 50kPa 6 Connect the fuel pump exit with a vacuum pressure gauge 7 Force a prescribed negative pressure and chec...

Page 45: ...Throttle cable stop screw Remove choke cable from carburetor Remove choke cable Remove the bolt fixing air filter Remove air filter and carburetor Remove intake manifold from engine Check if air filte...

Page 46: ...spark plug EXPLOSIVE DRAWING 232221 20 17 14 19 18 15 16 1 4 5 2 3 9 11 10 8 15 13 12 7 6 6 15 M6x45 mm 1st 8Nm 2nd 12Nm 1st 15Nm 2nd 30Nm 25Nm M6x20 mm 8Nm PART NO DESCRIPTION REMARKS 2 1 1 4 2 1 1 1...

Page 47: ...8 19 14 17 20 21 22 23 DESCRIPTION PART NO REMARKS M8 14 M6 20 6 8 B 1 8 1 1 3 1 1 1 1 1 F4 04000034 GB T97 1 85 GB T97 1 85 F4 04000012 F4 04010002 F4 04070001 BOLT HEXAGON WASHER PLATE THERMOSTAT WA...

Page 48: ...t 15Nm 2nd 30Nm M6x45 mm 1st 8Nm 2nd 12Nm 15 6 6 7 12 13 15 8 10 11 9 3 2 5 4 1 16 15 18 19 14 17 20 21 22 23 REMARKS PART NO DESCRIPTION 1 M5 25 1 1 F4 04070003 GB T818 85 ANODE F4 04000011 42 https...

Page 49: ...2 2 2 1 1 1 2 PS2700 03 02 LIFTER VALVE DESCRIPTION F4 04080007 F4 04080006 F4 04080005 PS2700 04 18 PS2700 04 13 PS2700 04 12 PS2700 04 12 F4 04080009 F4 04000015 M6x0 75 DOOR EXHAUST DOOR INTAKE BOL...

Page 50: ...7 L O O 14 13 12 11 7 5 4 2 9 14 4 5 2 3 13 6 6 1 1 10 10 7 8 11 12 10Nm REMARKS PART NO DESCRIPTION 2 2 2 2 F4 04080008 PS2700 04 03 F4 04080010 F4 04080011 SEAT VALVE STEM CLAMP VALVE 44 https www b...

Page 51: ...8x50mm 1st10Nm 2nd 22Nm O O O DESCRIPTION PART NO REMARKS F4 04010100 F4 04010002 1 1 CRANK CASE PIPE JOINT F4 04010003 SCREW PAN HEAD WASHER HEXAGON BOLT COVER BREATHER GASKET BEARING OIL SEAL GB T27...

Page 52: ...8 O REMARKS PART NO DESCRIPTION F4 04050001 F4 04000002 F4 04000003 F4 04060002 F4 04060001 HOLLOW PIN COVER CRANK CASE BOLT HEXAGON OIL SEAL OIL SEAL O RING SHELL OIL SEAL F4 04060003 F4 04060004 GB...

Page 53: ...1 13 14 2 16 5 17 18 6 15 1 2 3 4 19 12 19 20 21 22 27 23 24 25 26 28 O DESCRIPTION PART NO REMARKS 1 1 1 1 1 1 1 1 F4 04000001 F4 04000007 F4 04000008 F4 04050000 F4 04000006 HEXAGON BOLT WASHER BOLT...

Page 54: ...INED OIL RING CRANK ASSY ROD CONNECTING PISTON CIRCLIP PISTON RING 2 PISTON RING 1 F4 04000004 F4 04030000 F4 04020103 F4 04020100 F4 04020001 F4 04020005 F4 04020006 F4 04020004 F4 04020003 F4 040200...

Page 55: ...uge DISASSEMBLING POWER UNIT FROM OUTBOARD ENGINE 1 Open the top cowling 2 Remove the starter and fuel pump 3 Remove choke cable and throttle cable 4 Remove air filter and carburetor 5 Remove bolts co...

Page 56: ...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 v...

Page 57: ...ve pipe from the direction of combustion room 2 Knock in the 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 inne...

Page 58: ...eat 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 4 If the val...

Page 59: ...NKCASE Disassembling 1 Remove the bolts according to the reverse numbering sequence of the crankcase cover 2 Remove the cover of crankcase 3 Remove the camshaft and valve lifter 4 Remove the connectin...

Page 60: ...imit 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 12 995 13 000mm Piston ring 1 Push the piston...

Page 61: ...crankshaft 2 Assemble the connecting rod to the crankpin 3 Tighten the connecting rod bolts to the specified torque Tightening torque 12Nm 4 Remove the connecting rod measure the compressed width of t...

Page 62: ...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...

Page 63: ...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 n...

Page 64: ...il splasher gear assembly 3 Install crankcase cover and tighten the bolts twice as shown Tightening torque 1st 10 Nm 2nd 22 Nm NOTE Apply motor oil to moving parts before installing 1 5 4 3 2 7 6 UPPE...

Page 65: ...5Nm 5Nm DESCRIPTION PART NO REMARKS F4 06000000 GB T8 8 2000 F4 06000005 F15 08000004 F4 06000003 GB T845 85 F4 06000002 F4 06000001 GB T818 2000 59 https www boat manuals com...

Page 66: ...5Nm 5Nm REMARKS PART NO DESCRIPTION F4 06000006 F4 06000004 60 https www boat manuals com...

Page 67: ...Inspect if top cowling is cracked or damaged Replace it if necessary 6 Inspect if airproof rubber bar is cracked or damaged Replace it if necessary 7 Inspect if top cowling muffling cover is cracked...

Page 68: ...REMARKS PART NO DESCRIPTION F4 05000001 F15 05000036 F15 05000023 F15 05000022 F15 05030000 GB T5783 86 GB T818 2000 F4 05000016 GB T818 2000 F4 05000012 62 https www boat manuals com...

Page 69: ...783 2000 GB T97 1 85 GB T5783 2000 DESCRIPTION PART NO REMARKS Disassembling and inspection 1 Remove rubber cover B 2 Remove handle bolt and handle 3 Remove top cowling clamp lever bolt and clamp leve...

Page 70: ...9 Inspect if wave washer and clamp lever bush are cracked or damaged Replace if necessary STEERING HANDLE Explosive drawing 9 10 8 7 1 2 3 4 5 6 M8x25mm 18Nm L 1243 G G G G 1243 L DESCRIPTION PART NO...

Page 71: ...m 18Nm REMARKS PART NO DESCRIPTION 2x5 10 F4 01090200 F4 01090006 F4 01090007 F4 01090302 F4 01090301 F4 01090303 GB T848 85 GB T820 85 GB T827 86 F4 01090300 BUSH WASHER PLATE RUBBER HANDLE SCREW RIN...

Page 72: ...1090401 STAY SCREW PAN HEAD LEVER THROTLLE GB T818 85 F4 01090100 F4 01090002 F4 01090008 22 23 24 25 26 1 2 1 1 1 1 M5x12 27 Disassembling and inspection 1 Remove steering handle cover 2 Remove handl...

Page 73: ...pect if bush bush washer and wave washer are cracked or damaged Replace if necessary 11 Inspect if steering handle shock damper is cracked or damaged Replace if necessary 12 Inspect if throttle cable...

Page 74: ...1 1 2 1 1 M8 M6 6 10 9 8 7 6 4 1 1 1 1 5 4 3 2 1 DESCRIPTION PART NO REMARKS NUT PLATE WASHER HEXAGON NUT BRACKET SWIVEL GB T6170 86 F4 01030001 GB T97 1 85 F4 01000002 TILT ROD ASSY SPRING CONICAL F4...

Page 75: ...2nd 8Nm G G G G DESCRIPTION PART NO REMARKS 2 2 1 1 1 1 2 1 1 M6 20 2 F4 01030100 F4 01030004 F4 01030003 F4 01030103 F4 01030002 F4 01030005 F4 01000006 F4 01000007 F4 01000003 WASHER NYLON SHEATH HA...

Page 76: ...25 26 27 28 29 30 M6 12 1 2 1 1 2 M6 120 M8 135 1 1 2 2 2 DESCRIPTION PART NO REMARKS HEXAGON BOLT HEXAGON BOLT CLAMP PLATE CLAMP BOLT F4 01010003 F4 01010002 F4 01010004 BUSHER BOLT HEXAGON BOLT F4 0...

Page 77: ...HANDLE RIVET LOCKED SCREW F4 01000005 GB T5782 86 HEXAGON BOLT F4 01020000 DESCRIPTION PART NO REMARKS 38 1 6 1 M6x35 1 1 1 4x11 2 1 31 32 33 34 35 36 37 Disassembling and inspection 1 Remove tilt loc...

Page 78: ...t 7 Inspect the the swivel bracket and clamp bracket for damage or crack Replace if necessary 8 Inspect the bush and shock absorption for damage or crack Replace if necessary 9 Inspect whether the til...

Page 79: ...x25mm 4 5Nm G REMARKS PART NO DESCRIPTION GB T820 2000 WASHER PLATE 5 PIN COTTER BOLT BALL 8 SPRING GEAR SCREW OVAL HEAD BUSHING SHIFT ROD LEVER O RING SHAFT CHANGE HANDLE GEAR SHIFT GB T308 84 GB T97...

Page 80: ...0Nm DESCRIPTION PART NO REMARKS F4 02000004 F4 02000006 F4 00000005 F4 00000003 F4 00000004 GB T5284 86 LEVER SHIFT ROD ROD SHIFT CONNECTOR SHIFT ROD A CONNECTOR SHIFT ROD B BOLT BIG WASHER F4 0000000...

Page 81: ...ET ENGINE F4 02030001 F4 02030002 F4 02030003 F4 02000012 F4 02000011 F4 02000001 F4 00000006 REMARKS PART NO DESCRIPTION F4 02040002 F4 02040000 30 Disassembling and inspection 1 Remove the water tub...

Page 82: ...upper casing and extension for crack or wear Replace if necessary 5 Check gear shift handle and change shaft for crack or wear Peplace if necessary LOWER UNIT WATER PUMPASSEMBLY 76 https www boat manu...

Page 83: ...1st 3Nm 2nd 8Nm PART NO DESCRIPTION REMARKS 1 2 3 4 5 6 7 8 9 10 M6 45 4 2 1 2 1 1 1 1 1 1 OUT PLATE PIN WATER PUMP HEXAGON BOLT F4 03000014 F4 03000015 F4 03060000 F4 03000017 F4 03000018 F4 0300001...

Page 84: ...T97 1 85 F4 03000012 F4 03000011 HEXAGON BOLT WASHER PLATE HERMETIC GASKET REMARKS PART NO DESCRIPTION 1 Disassembling and inspection 1 Remove water pump fixed plate 2 Remove water pump housing 3 Rem...

Page 85: ...amage Replace if necessary 6 Check inner water pump cover and impeller for crack deform burn or damage Replace if necessary 7 Check water pump base for crack crank scratch or damage Replace if necessa...

Page 86: ...5 24 20 21 22 28 23 3 4 5 1 2 6 7 8 9 10 REMARKS PART NO DESCRIPTION 37 2 1 1 1 1 1 1 1 1 1 M6 12 6 6 2 5 30 WASHER PIN COTTER NUT ASSY PROPELLER ASSY SPACER ANODE WASHER PLATE HEXAGON BOLT HOLLOW PIN...

Page 87: ...14 13 11 12 19 18 17 16 15 14 13 12 11 G M6x16mm 8Nm L 1277 G M6x16mm 1st 3Nm 2nd 8Nm 1277 L G M6 1st 3Nm 2nd 8Nm L 1277 F4 03000009 F4 03040000 GB T276 94 JISB2401 P48 F4 03050001 GB T5783 2000 F4 03...

Page 88: ...9 35 34 33 32 31 30 29 14 36 18 27 21 22 26 25 24 20 21 22 28 23 3 4 5 1 2 6 7 8 9 10 BEARING PLUGER SHIFT CLUTCH BLOCK F4 03030002 F4 03010000 F4 03000008 F4 03000002 INITIATIVE GEAR CIRCLIP LOWER CA...

Page 89: ...SCRIPTION 1 S L M6 40 M6 167 2 1 2 2 1 1 31 35 36 34 33 32 F4 03020000 F4 03000003 F4 03030001 F4 03000004 SHAFT PROPELLER SHAFT DRIVE F4 03000005 HEXAGON BOLT CLIP F4 03000016 PIN HEXAGON BOLT F4 030...

Page 90: ...ropeller shaft for wear or damage Replace if necessary Clutch block installation 1 Put clutch block spring into the hole of the propeller shaft tail 2 Install the clutch block as shown Take note of th...

Page 91: ...ear 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 1 Inspect lower casing cover f...

Page 92: ...perates Engine inner parts are damaged Repair Spark plug s fouled or of incorrect type Inspect spark plug s Clean or replace with recommended type Fuel system is obstructed Check for pinched or kinked...

Page 93: ...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 broken wires Ign...

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