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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 equipment expertly and correctly can improve your work

efficiency and effectively avoid injuries to personnel and the outboard motor.

Special tools:

Clearance gauge Piston slideway Flywheel gripper and flywheel puller

Oil filter spanner

Bearing puller

underwater

unit housing cover

Needle bearing
installation tool

Underwater unit
housing cover bearing
installation tool

Underwater unit
housing cover oil
seal installation tool

Underwater unit needle
bearing installation tool

Drive shaft bearing
jacket installation tool

Drive shaft bearing
installation tool

Drive shaft seal oil
seal installation kit

Forward gear bearing
casing installation kit

Содержание F115 BEX-T

Страница 1: ...Service Manual F115 FL115 Suzhou Parsun Power Machine Co Ltd...

Страница 2: ...d and that described in the Manual If necessary 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...

Страница 3: ...12 Specified torque 12 Average torque 13 Overall dimensions 14 Basic maintenance 19 Maintenance Interval Chart 19 Fuel system 20 Engine 20 Engine oil level 20 Change engine oil 21 Spark plug 21 Contro...

Страница 4: ...1 Check throttle body 52 Check the intake manifold 52 Disassemble and check the carbon canister and carbon canister solenoid valve 52 Disassemble and check the electric fuel pump 53 Engine 54 Matters...

Страница 5: ...over 88 Disassembly schematic diagram 88 Disassembly and inspection 92 Water unit and bracket 93 Disassembly schematic diagram 93 Disassembly and inspection of bracket 99 Disassembly and inspection of...

Страница 6: ...Backward rotating pinion shim 122 Propeller shaft shim 122 Reverse gear shim 123 Forward gear shim 123 Common faults and solutions 124...

Страница 7: ...n the motor When the ship runs in full load the motor will operate at low speed for a long time At this time the propeller with smaller pitch should be selected whereas the propeller with larger pitch...

Страница 8: ...kward rotating propeller otherwise the vessel will not advance in the desired direction which is likely to cause accidents Protection at work In order to prevent danger or accident during maintenance...

Страница 9: ...ssembling and assembling the 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 b...

Страница 10: ...ation is smooth Check whether the 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...

Страница 11: ...l tools Clearance gauge Piston slideway Flywheel gripper and flywheel puller Oil filter spanner Bearing puller underwater unit housing cover Needle bearing installation tool Underwater unit housing co...

Страница 12: ...6 Drive shaft spline sleeve pinion nut spanner Testing equipment Digital tachometer Digital multimeter Peak voltage adapter...

Страница 13: ...Nm 2nd 42 Nm M8x55 mm 1st 14 Nm 2nd 28 Nm 49 Nm 18 Nm Exploded view of parts Thread specification and specified torque Points where oil sealant or locking agent are applied Parts list Symbol descripti...

Страница 14: ...3 2L Full throttle operating range 5300 6300 r min Recommended gear oil Hypoid gear oil SAE 90 Maximum fuel consumption 38 9L h 5600 r min Gear oil level Forward rotating 0 760L Backward rotating 0 71...

Страница 15: ...e aperture 18 004 18 015 Minimum free length 39 14mm Outside diameter of piston pin 17 991 18 000m m Tilt limit 1 8mm Piston ring Top ring Thickness 1 170 1 190mm Connectin g rod Inner diameter of sma...

Страница 16: ...ce between outer rotor and inner rotor 0 12 0 16mm C Red 2 503 2 509mm Clearance between rotor and cover 0 03 0 12mm Valve Valve clearance Intake valve 0 17 0 24mm Cold state Exhaust valve 0 31 0 38mm...

Страница 17: ...tage 34KV Primary resistance 2 2 0 22 Output voltage of rectifier regulator 1500 r min Load 14 5V Secondary resistance 9 84 0 98K Peak output voltage of magneto 1500 r min no load 53V 3500 r min Load...

Страница 18: ...1 18 Nm Oil pressure sensor M10 1 9 Nm Container body 1st Bolt M10X1 5X105 10 16 Nm 2nd 42 Nm 1st Bolt M8X55 10 14 Nm 2nd 28 Nm Connecting rod 1st Bolt M8X1X36 8 13 Nm 2nd 35 Nm Cylinder head 1st Bolt...

Страница 19: ...X45 1 42 Nm About water Upper shock absorber Nut M14 2 74 Nm Lower shock absorber Nut M14 2 74 Nm Oil pan exhaust manifold Bolt M10X1 25X45 6 42 Nm Clamp bracket double nipples Nut 7 8 14UNF 2 22 Nm O...

Страница 20: ...14 Overall dimensions X type X type two engine...

Страница 21: ...15 L type...

Страница 22: ...16 L type two engine...

Страница 23: ...17 Mounting dimensions...

Страница 24: ...18...

Страница 25: ...Anode internal Replace Battery electrolyte terminal Check Cooling water channel Clean Top cover clamp handle Check Engine startup Check Engine idle speed Check Engine noise Check Engine oil Replace Oi...

Страница 26: ...valve and related parts every 100 hours Check the exhaust manifold and exhaust pipe every 1000 hours Replace them if necessary Change the timing belt every 1000 hours Fuel system 1 Check the fuel pump...

Страница 27: ...not changed 3 2 L oil filter changed Oil type API SG SH SJ SL or SAE 10W30 10W40 5W30 4 Install oil cap 5 Check the oil level Note Before starting the outboard motor for the first time make sure to fi...

Страница 28: ...joint and loose the lock nut of the push pull cable joint 1 Cotter pin 2 Push pull 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...

Страница 29: ...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 from the oil level plug...

Страница 30: ...n oil gun at the position shown 2 Apply anti corrosion grease to the propeller shaft Cooling water channel 1 Check whether the inlet of cooling water channel is blocked Clean it if necessary 1 Inlet o...

Страница 31: ...thermostat cover and tighten the bolts to the specified value Propeller Check propeller blades and internal splines for rupture damage or wear Replace them if necessary Check the main switch stop swit...

Страница 32: ...stall a new oil filter and tighten it to the specified torque as required 18Nm 4 Fill the specified amount of oil through the oil filler 5 Install the oil cover and dipstick start the engine and run f...

Страница 33: ...e lock nut 2 5 Re check if the top cover is locked tightly If the tightness cannot be adjusted please replace the top cover sealing strip Check valve clearance Check the valve clearance with reference...

Страница 34: ...ent electric 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 fl...

Страница 35: ...29 Disassembly schematic diagram...

Страница 36: ...30...

Страница 37: ...31...

Страница 38: ...32...

Страница 39: ...33...

Страница 40: ...34...

Страница 41: ...6 Lighting coil 12 Rectifier 13 Electric fuel pump 14 Intake temperature pressure sensor 15 Throttle position sensor 18 Canister solenoid valve 19 Stepper motor 20 Fuse box 23 Start motor 22 Start re...

Страница 42: ...h 4 Buzzer 5 Neutral switch R Red P Pink B Black G Green W White 1 2 3 4 5 6 Br Brown Y Yellow Lg Light green Sb Sky blue L Blue UP FREE DOWN Sb R Lg Y Power trim tilt switch state table OFF ON R Br S...

Страница 43: ...heck whether the flywheel is damaged and whether the permanent magnet is firm Replace it if necessary Ignition coil detection 1 Remove the ignition coil and the spark plug cap 2 Measure the resistance...

Страница 44: ...check the conductivity between the relay terminals If it is conductive replace the relay Detection of magneto coil Measure the peak voltage of magneto coil between green wires Use digital multimeter...

Страница 45: ...to high level of intake temperature sensor line 112 Short circuit to ground or open circuit of intake temperature sensor line 113 Water temperature fault Short circuit to ground of coolant temperatur...

Страница 46: ...0 Oil pressure fault Short circuit to ground of oil pressure sensor line 523 Short circuit to high level of oil pressure sensor 522 Carbon canister solenoid valve fault Short circuit to ground of carb...

Страница 47: ...d 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 step...

Страница 48: ...42 Disassembly schematic diagram...

Страница 49: ...43...

Страница 50: ...44...

Страница 51: ...45...

Страница 52: ...46...

Страница 53: ...47...

Страница 54: ...48 M4x12 mm 2 Nm M4x12 mm 2 Nm M5x12 mm 3 5 Nm M4x8 mm 2 Nm M4x8 mm 2 Nm M4x16mm 2 Nm M5x12 mm 4 Nm 2 Nm...

Страница 55: ...49...

Страница 56: ...oil pump power supply connection line Check the oil filter cup Before removing the oil filter cup place a rag at the lower part to prevent spilled fuel from flowing around 1 Disconnect the joint of w...

Страница 57: ...essure 50kPa 8 Remove the 4 bolts and separate the fuel pump cover and from the fuel pump seat Check the fuel filter 1 Remove the fuel filter from the fuel line 2 Connect a vacuum manometer to the fue...

Страница 58: ...anifold air temperature and pressure sensor If there is crack please replace it 3 Check the electrical characteristics of the intake manifold air temperature and pressure sensor Disassemble and check...

Страница 59: ...tor Note Mark them before disconnecting the fuel line and the cooling water line to avoid connection error when re mounting them 4 Remove the oil cup drain screw and oil drain hose 5 Remove the oil pu...

Страница 60: ...e the float Float height 67 5 mm 18 Install the electric fuel pump assembly in reverse order of removing it 19 Connect the fuel line the cooling water line and the power connection line according to t...

Страница 61: ...55 Disassembly schematic diagram...

Страница 62: ...56...

Страница 63: ...57 M10x1 5x35 mm 60 Nm O O M10x1 5x35 mm 60 Nm 39 Nm O O O O O...

Страница 64: ...58...

Страница 65: ...59 M10x1 5x105 mm 1st 16 Nm 2nd 42 Nm M8x55 mm 1st 14 Nm 2nd 28 Nm O 49 Nm O GM 18 Nm...

Страница 66: ...60...

Страница 67: ...61 M8x1x36 mm 1st 13 Nm 2nd 35 Nm O O O O O O...

Страница 68: ...62...

Страница 69: ...63 O O...

Страница 70: ...64...

Страница 71: ...65...

Страница 72: ...66...

Страница 73: ...the detected pressure is lower than the specified value or there is a difference between cylinders add a small amount of oil into the cylinders and then detect it again 5 Compression pressure 945 kPa...

Страница 74: ...ark on the flywheel is aligned with the indicator mounted on the box making sure that the marks on the two driven pulleys are opposite 1 Timing mark 2 Pin hole 3 3 Ignition indicator 3 Turn the timing...

Страница 75: ...ole of the tensioner in the tensioner assembly with the positioning hole on the body and insert the tensioner positioning pin 13 Tighten the bolts of the tensioner 14 Turn the tensioner gradually cloc...

Страница 76: ...the driven pulley and fasten the pulley bolts with the flywheel gripper Specified torque 60 Nm 23 Screw the timing belt in the order of crankshaft end driven pulley B EX and driven pulley A IN mark No...

Страница 77: ...just valve clearance If the measured valve clearance exceeds the specified range the valve tappet needs to be replaced Valve clearance cold state Intake valve clearance 0 17 0 24 mm Exhaust valve clea...

Страница 78: ...Check the valve clearance Remove the engine 1 Open the top cover 2 Remove the flywheel cover 3 Disconnect the oil line cooling water line and electrical wiring harness connector 4 Remove the electric...

Страница 79: ...r disassembly 1 Remove the timing belt and driven pulley with reference to steps 1 4 in the section Check the valve clearance 2 Remove the bolts of the cylinder head cover and remove the cylinder head...

Страница 80: ...ve 0 8 1 2 mm Exhaust valve 1 0 1 4 mm 3 Check valve stem diameter If it is not within the prescribed scope replace the valve Valve stem diameter Intake valve 5 475 5 490mm Exhaust valve 5 460 5 475mm...

Страница 81: ...n 3 Hinge the inner diameter of the guide to the specified value with a reamer Valve guide inner diameter 5 504 5 522mm Note When reaming turn the reamer clockwise Do not rotate the reamer countercloc...

Страница 82: ...surface is too narrow and at the bottom edge of the valve surface trim the bottom edge of the seat ring with a 60 cutter and adjust the width of the sealing surface with a 45 cutter if any 5 Apply a...

Страница 83: ...nd torque Specified torque 15 Nm for the first time 30 Nm for the second time 80 Nm for the third time 9 Mount the cylinder head cover Note Use a new sealing ring and apply silica gel at the position...

Страница 84: ...cified measuring points 1 2 3 At each measuring point measure the diameters parallel to the crankshaft directions D1 D3 and D5 and perpendicular to the crankshaft directions D2 D4 and D6 Height of mea...

Страница 85: ...rod large end Measure the inner diameter of the large end If it does not meet the specified value replace it Inner diameter of the large end 50 025 50 045 mm Note Tighten the connecting rod bolt at t...

Страница 86: ...ting rod and crankshaft One side of the big end of the connecting rod is engraved with the pairing number of the connecting rod and the other side is divided into three groups 1 2 and 3 according to t...

Страница 87: ...ng 28 Nm 6 Remove the engine base and measure the compressed width of each plastic clearance gauge If it exceeds the specified value replace the bearing bush Oil clearance 0 012 0 044mm Note Do not tu...

Страница 88: ...d according to 3 Body and engine base 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 ye...

Страница 89: ...cting 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 s...

Страница 90: ...5 Fit crankshaft locating plate A Note Face the notched side towards the crankshaft Assemble the engine base 1 Install the bearing bush on the engine base 2 Install crankshaft locating plate B Note Fa...

Страница 91: ...plate 7 Install the exhaust pipe Seating torque 13 Nm for the first time 35 Nm for the second time 8 Install the flywheel temporarily and turn the crankshaft clockwise until the piston of cylinder 1 i...

Страница 92: ...86...

Страница 93: ...87 Disassembly and inspection...

Страница 94: ...pulley assemblies 5 Check 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 f...

Страница 95: ...89...

Страница 96: ...90...

Страница 97: ...91...

Страница 98: ...92 Disassembly and inspection...

Страница 99: ...93 Water unit and bracket Disassembly schematic diagram...

Страница 100: ...94...

Страница 101: ...95...

Страница 102: ...96...

Страница 103: ...97...

Страница 104: ...98 SN...

Страница 105: ...rod assembly of the support frame and the A and B assemblies of the support frame 8 Remove the warping sensor retaining plate screw and remove the warping sensor assembly 9 Check the rotary bracket an...

Страница 106: ...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 warping device After adding oil discharge the excess air in the oil...

Страница 107: ...ownward by its own gravity Repeat 4 5 times 3 Turn the manual valve clockwise until it cannot turn 1 Manual valve 4 Wait for 5 minutes to stabilize the oil 5 Press and hold the warping switch until th...

Страница 108: ...102 Underwater part Disassembly schematic diagram 94 Nm 103 Nm...

Страница 109: ...103 O 5 8 8 x 3 1 O R I N G 5 8 8 x 3 1...

Страница 110: ...104...

Страница 111: ...105 1277 L 1277 L 1277 L M10x1 25x40 40 Nm 55 Nm M10x1 25x65 40 Nm M10x1 25x45 42 Nm...

Страница 112: ...106...

Страница 113: ...107 FL115 rotates backward 94 Nm 103 Nm...

Страница 114: ...108...

Страница 115: ...109...

Страница 116: ...110...

Страница 117: ...111 1277 L L 1277 L M10x1 25x40 40 Nm 55 Nm M10x1 25x65 40 Nm M10x1 25x45 42 Nm...

Страница 118: ...112...

Страница 119: ...amage Replace it if necessary 12 Check the pump inner shell and impeller for cracking deformation burning or wear Replace it if necessary 13 Remove the housing cover of the underwater unit F115 Remove...

Страница 120: ...lation method of the backward rotating model is the same as that of the forward rotating model 4 Install clutch spring ring Housing cover of underwater unit 1 Check the bearing for rust and whether th...

Страница 121: ...ace 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 Replace it if necessary For...

Страница 122: ...m Oil seal Depth 1 0 25 0 75 mm Depth 2 7 25 7 75 mm 4 F115 forward rotating model Install forward gear long nylon sleeve drive shaft plane thrust bearing shim install drive shaft seat pinion and shif...

Страница 123: ...e propeller and tighten the nut at the specified torque Specified torque 55 Nm Note If the groove on the nut is not aligned with the cotter pin hole on the propeller shaft tighten the nut further unti...

Страница 124: ...118 Selection of shim When replacing the internal parts of the underwater unit or assembling a new underwater unit it is required to adjust the shim...

Страница 125: ...119 FL115 rotates backward Deviation value mark...

Страница 126: ...l tool Install the pinion and lock the pinion nut according to the specified torque Specified torque 94 Nm Special tooling for pinion shim 201 35 2 Measure the clearance M3 between the special tooling...

Страница 127: ...te the average value as shown in the figure Reference size M1 23 95 4 The formula T1 24 65 F 100 M1 5 The shim can be reduced by 0 0 05mm compared with T1 try to choose the most similar size as possib...

Страница 128: ...0 4 The shim can be reduced by 0 0 05mm compared with T3 try to choose the most similar size as possible For example T3 0 3 0 17 shim should be selected and the actual value should be 0 15 5 Shims tha...

Страница 129: ...choose the most similar size as possible 4 Reverse gear shims T1 that can be selected 0 10 0 12 0 15 0 18 0 3 0 4 0 5 mm Forward gear shim 1 Check the R size marked on the housing of the underwater un...

Страница 130: ...ngine idle is abnormal or stalls The spark plug is contaminated or the model is incorrect Clean it or replace with the correct spark plug Fuel system blocked Check the fuel line for extrusion entangle...

Страница 131: ...ition circuit failure Check the wiring Tighten the loose wire and replace the old or broken wire Ignition component failure Replace it Incorrect engine oil grade or excessive oil Change to the specifi...

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