Parsun F4/F5 Outboard Engine Service Manual

Table of Contents

• General Information
  • Identification
  • Propeller Selection
  • Emergency Start
  • Safety While Working
  • Disassembly and Assembly
  • One-Time Use Parts
  • Pre-Delivery Check
  • Special Tools and Detection Device
  • Explosive Drawing and Symbol
• Specifications
  • Outboard Engine Specifications
  • Maintenance Information
  • Tightening Torque
• Periodic Service
  • Maintenance Timetable
  • Fuel System (Periodic)
  • Power Unit (Periodic)
  • Control System
  • Lower Unit (Periodic)
  • General Inspection
  • Cooling Water Passage
• Recoil Starter
  • Starter Rope Replacement
  • Disassembling and Inspection (Starter)
  • Assembling and Installation (Starter)
• Ignition System
  • Wiring Diagram
  • Spark Plug Ignition
  • Spark Plug Cap
  • Flywheel Maintenance
  • Ignition Coil Inspection
• Fuel System
  • Fuel Tank Removal and Inspection
  • Oil Switch Removal and Inspection
  • Fuel Joint Removal and Inspection
  • Fuel Pump Removal and Inspection
  • Intake System Removal and Inspection
• Power Unit
  • Disassembling Power Unit from Outboard Engine
  • Disassembling and Inspection (Power Unit)
  • Full Installation
• Upper Unit
  • Top Cowling
  • Bottom Cowling
  • Steering Handle
  • Bracket
• Lower Unit
  • Water Pump Assembly
  • Lower Unit Gear Assembly

General Information

Identification

The outboard motor serial number is marked on the label.The label can be found on the bracket left assembly or on the upper part ofthe bracket swivel.Record your outboard motor serial number in the spaces provided to assist you in ordering spare parts from yourParsun dealer or for reference in case your outb oard motoris stolen.

• 1.Outboardmotorserialnumberlocation Serial number as follows:

PRODUCTION CODE

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.

For a greater boat load and a low engine speed, a smaller-pitch propeller is more suitable. correct engine speed to be maintained.

When the engine is running at full throttle position, the suitable propeller should be used according performance.

Emergency Start

Ifthe starting device isnot working,the engine can be started by emergency start cable. /WARNING:

• The start program can only be used in emergency and to return to harbor for repairing.
• not working. So please ensure the shift rod is in NEUTRAL position.
• Please ensure nobody standing behind you in case the cable is pulled out to hurt people.
• After the engine starts up,don't fit the start device or top cowling.Put clothing or other
• When starting and operating, don't touch ignition coil, spark plug cap or other electric

The procedure is as follows:

• 1.Remove the top cowling.
• 2.Remove the start-in-gear protection device cable,and remove the chock lever cable.
• 1.Start-in-gear protection device cable
• 3.Demount threebolts and remove starter.
• 4.Assembletwobolts to fixthefuel tank.
• 5.Insert the knot of the cable in the notch of flywheel rotor, and wind the cable around flywheel severalroundsin clockwisedirection.

6. Pullthemanual starter.

• 2.Chock lever cable

7. Give a strong pull to start the engine. Repeat if necessary.

Safety While Working

To prevent the danger or accidents when performing maintenance and repair, and improve the work efficiency, please obey the following safety procedures.

1. Fire Prevention

Gasoline (petrol), lubricant and grease are highly flammable.While working,keep away from heat, sparks and open flames.

2. Ventilation

Petroleum vapor and engine exhaust gases are violent in toxicity.They are harmful to breathe and deadly if inhaled in large quantities. When test-running an engine indoors, maintain good ventilation.

3. Self-Protection

Protect your eyes with suitable safety glasses or safety goggles, when drilling, grinding or operating air compressor. Protect hands and feet by wearing protective work clothes, safety gloves and shoes if necessary.

4. Lubricants and Sealing Fluids

When performing maintenance procedures and repair to Parsun outboards, use only products provided or recommended by our Company.

Undernormalconditionsofuse,thereshouldbenohazardsfromtheuseofthelubricants 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 precautions is as follows:

• ① To protect the skin, the application of a suitable barrier cream to the hands before working is recommended.
• Clothingwhich hasbecome contaminatedwith lubricants should be changed as soon as practicable, and washed before further use.
• ③ Avoidskincontactwithlubricants.
• ① Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminatedclothing,should bethoroughlywashedwithhotwater andsoap as soon as practicable.
• A supply of clean lint-free cloths should be available for wiping run-off lubricants or grease.

5. Good Working Practices

• ① Follow the tightening torque instruction. When tightening bolts, nuts and screws, tighten the large sizes first, and tighten inner-positioned fixings before outer-positioned ones.
• O Use the recommended special tools to protect parts from damage.Use the right tool in the right manner.

Disassembly and Assembly

When disassembly and assembly, please follow the following principles:

• 1.Use specialtools when disassermbling and assembling.

2. Clean dirt before disassemb ling the parts.

• 3.Oil the contact surfaces of mov ing parts before assermbly.

4. Install bearing with the manufacburer's markings on the side exposed to view and liberally oil the bearing.

• 5.When installing oil seals, apply a light coating of water-resistant grease to the ledge and outside diarmeter.

One-Time Use Parts

One-time use parts are gasket, oil seal, O-ring, cotter pin and spring, ring, and etc. When re-assemb ling outb oard engine, you must change the one-time use parts.

Pre-Delivery Check

To ensure the using, please inspect the following before delivery.

1. Checking Fuel System

Check ifthe fuel pipe is connected firmly, and if the fuel is filled with fuel.

CAUTION: Do not use pre-mixed fuel for this 4 stoke outb oard engine.

2. Checking Oil Level

• Check the engine oil level

Remove oil cap, check engine oil level.

1. Oil cap 2. Oil rule 3. High position mark 4. Low position mark

oil; if below lower mark, add engine oil up to upper level.

Check the gear oil level:

Remove the oil level plug.Check if the gear oil overflows at the oil level checking hole. If so, install the oil level plug and tighten it according to specified torque. Otherwise please add gear oil.

1.Oil level plug

• 3. Check Steering System: Check if steering is stable. Check if steering friction is adjusted correctly. Turn clamp handle screw clockwise to increase resistance. Turn clamp handle screw counter clockwise to lower resistance. 4. Check Shift Lever and Throttle: Check if the shift lever is operated smoothly.

Checkif the throttle grip is turned smoothly from full closed position to full open position.

5. Check Engine Stop Switch Assembly: Check 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.Cooling water checking hole

7. Breaking-In Running

• ① Initial 1 hour: operate the engine at 2000 r/min or about a half throttle.
• ② The second hour: operate the engine at 3000 r/min or about 3/4 throttle.
• ? The following 8hours: operate the engine at fullthrottle continuously.Each operation time doesn't exceed 5 minutes.

8. Inspection After Breaking-In Running

• Check if gear oil contains water.
• ② Check if the fuel line leaks.
• After breaking-in running, operate the engine at idling speed.Use cleaning tool to wash

1. Clamp handle screw

over the coolingwater passage by fresh water.

9. After breaking-in running, inspect idling speed.
10. 1. Preheating engine for 5 minutes.
11. 2 Using the tachometer to measure idling speed RPM. If out of specification, adjust it. Idling speed: 1450~1550 r/min
12. Turm the throttle stop screw clockwise or counter clockwise until the specified idling speed is attained.
13. After adjusting idling speed, 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 device.The use of correct tools will improve the work efficiency and avoid of the damage to the people and outboard engines.

Special Tools

Piston slider

Valve spring compressor

Oil seal installer tool

Flywheel holder and puller

Housingbearing installer

Housing oil seal installer

Bearing puller

Lower casing cover bearing installer

Space gage

Barrel bearing with guard boardinstaller tool

Lower casing bracket and barrel bearing without guard boardinstaller tool

Lower casing bracket and drive shaft oil seal installer tool

Detection Device

Digital tachometer

Digital circuit tester

Peak voltage adaptor

Explosive Drawing and Symbol

Explosive Drawing

• 1 Parts explosive drawing
• Oil, fluid sealant or locking substance daubing point
• Screw specification and specified torque
• Spare parts details

Symbol

Specifications

Outboard Engine Specifications

Maintenance Information

Power Unit

Continued:

Ignition system

Tightening Torque

Specified torque

Cont'd

General torque

Periodic Service

Maintenance Timetable

CAUTION: After running the outboard engine in saltwater,wastewater or mudwater,wash overthe enginebyfreshwaterimmediately.

If using leadedgasoline frequently,check thevalve and components each 100 hours.

Fuel System (Periodic)

1. Check fuel tank,CARBURETOR,FUEL Check if fuel tank, carburetor, fuel pump and fuel pipe are damaged or leaked. Replace if necessary.

Check if the fuel filter on the tank is dirty.Clean dirt or replace it if necessary.

2. Check Fuel Cock and Fuel Joint: Check if fuel cock and fuel joint are cracked, damaged or leaking.

Replace if necessary.

3. Check Fuel Filter: 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 (Periodic)

Engine oil level

• a)Remove oil levelplug,check engine oil level,ifbetween the following marks of theupper and lower.

1. Oil level plug2. Oil rule3. High position mark 4. Lowposition mark

• b) If above the upper mark, drain the engine oil, if below lower mark, add engine oil up to upper mark.

CAUTION: Run the engine and then turn it off, wait for several minutes, and check the engine oil level by the oil rule again.

If the engine oil still notwithin the proper level, add/drain as needed.

Changing engine oil

• 1.Remove 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 quantity: 0.5L Oil type:API SE,SF,SE-SF,SG-CD SAE 10W30,10W40

4. Install oil level plug.

• 5.Check engine oillevel.

CAUTION: Rotate the flywheel clockwise so that rocker arm is in free position, before adjusting valve clearance (Dead point position on compression stroke).

Valve clearance

• 2.Remove cylinder head cover

3. Use feeler gauge to measure the clearance between rocker arm and valve rod top: if out of specification, adjust.
4. Remove spark plug cap and spark plug.

Valve clearance (cold position):

Inlet valve:0.10±0.02mm

Outlet valve: 0.10±0.02mm

Spark plug

• 2.Clean off carbon build-up on the electrodes.
• 3.Check if the electrodes are corroded or have deposit, or if the washer is 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.
5. Install spark plug. Use spark plug spanner to tighten it according to specified torque. Specified torque: 25 Nm

Control System

Throttle grip

• 1.Turn the throttle grip to fully closed position.
• 2.Check if the throttle cable is slack and if the throttle lever touches the throttle stop screw.

3. Loosen throttle cable stopper screw, adjust throttle cable position, and tighten throttle cable stop screw.

1.throttle cable stop screw

Idling speed

Check idling speed, and adjust it if necessary.

• 1.Preheat engine for 5 minutes.
• 2.Attach the tachometer to the spark plug wire to measure idling speed RPM.If out of specification, adjust it.
• 3.Turn the throttle stop screw clockwise or counter clockwise, until the specified idling speed is attained.

Idling speed:1450~1550 r/min

NOTE: Turning clockwise to increase idling speed.

Turning counter clockwise to decrease idling speed.

CAUTION:

Start-in-gear protection

Set the shift lever in neutral, and check if the triangle marking of the detent aligns with the triangle marking of the starter.If necessary, adjust the adjusting nut on the tightw ire of the detent.

1. Triangle marking 2. Adjusting nut 3. Tightwire ass'y, detent

Check gear oil level

Remove the oil level plug.If the gear oil overflows at the oil level checking hole, the oil volume added is correct; otherwise please add gear oil.

1.Oil level plug

Lower Unit (Periodic)

Changing gear oil

• 1.Hold the outboard engine in an upright position.
• 2.Place a containerunder the drain plug.
• 3.Remove the drain plug,the oil level plug, and then drain the gear oil.
• 4.Add gear oil through the drain plug using pressure filling device.
• When gearoil overflows at theoillevel checkinghole,nstall theoillevel lug 5.
• 6.Install the drain plug, then clean overflowing gear oil.

1.Oil level plug 2.Drain plug

NOTE: Check the drained gear oil.

Ifthe gear oil is millky, please check the oil seal. If necessary, replace the oil seal.

CAUTION: Must change drain plug washer each time.

• 1.Inspect cooling water passage Ifblocked,clean it

Lower unit leakage check

Connecting the leakage tester to the oil level checking hole to check the lower unit leakage.If the pressure drops (pressure: 1kg/cm?), inspect the oil seal and comp onents.

General Inspection

Anode

Inspect lower unit anode and engine anode(on the therrmostat cover).Clean the greasy dirt and scales.If wear or damage is above 1/2,replace the anode.

CAUTION: Cannot grease or pa int the anode, or it will not operate properly.

Grease points

• 1.Referthe illustration for greasing points, paint the water resistant grease.
• 2.Paint anti-corrosion grease on the propeller shaft.

Cooling Water Passage

Cooling water passage inlet

• 2.Place the outboard engine in the water and ensure the water level is above the anti-vortex plate, then start the engine.
• 3.Check if water overflows at the cooling water checking hole.If there is noflow or intermittent flow,check thecoolingwaterpassage.

1.Cooling water inlet

2. Cooling water checking hole

Recoil Starter

NOTICE: When you service, please wear safety glasses and gloves.Please rermove spark plug cap and

Explosive Drawing

1. Open the top cowling
2. 2.Screw loosely the adjusting nut of the dent tightwire.
3. 3.Remove thetightwirefrom thedetent.
4. 4.Remove the starter fixing bolt, and remove the starter.
5. Adjusting nut

Starter Rope Replacement

1. Pull the starter rope out, and insert it in the notch of the sheave drum.T Turn the sheave drum clockwise until the volute spring is free.
2. 2.Pull the starter rope completely.
3. Remove the starter handle cover from the starter handle, and remove the starter rope. Untie the knot at the end of the starter rope.
4. 4.Pull out the starter rope completely.
5. 5.Insert the new starter rope into the starter assembly, and fix the rope onto the sheave drum and starter handle. At the end of the rope tie a knot as shown.

Disassembling

6. Insert the start rope in the notch of the sheave drum and turn the sheave drum several rounds in counterclockwisedirection.
7. Pull the starter handle many times to check if the sheave drum rotates stably. If necessary, repeat step 6 and step 7.

Disassembling and Inspection (Starter)

1. Remove the start rope.
2. Remove starter bolt, and remove press plate.
3. Remove 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.
6. Inspect if the detent is cracked, worn or damaged. If necessary, replace it.
7. Check if the drive pawl is cracked, worn or damaged. If necessary, replace it.
8. Inspect if the drive spring is broken, cranked or damaged. If necessary, replace it.
9. Check if the volute spring is broken, cranked or damaged. If necessary, replace it.

Reverse the steps of disassembling.

• 1.Put starter onto the power unit.
• 2.Screw the hexagon bolt, and tighten it according to the specified torque.
• 3.Install the detent tightwire.

4. Adjust the adjustingnuton thetightwireof thedent,and align the trianglemarking of the dent with the triarigle marking of the starter case.
5. Triangle mark

• 2.Adjusting nut
• 3.Detent tightwire

Assembling and Installation (Starter)

Ignition System

NOTICE: When checking and repairing the ignition system, keep your hand, clothes, hair or personal belongings away from the rotating flywheel.

Check ignition coil on insulated working table, to prevent electricity leak and electroshock.

Don't touch the ignition coil or spark plug when the engine is running, to avoid electroshock. Keep the wires away from the rotating flywheel,to prevent the wire frombeing cut,or theinsulatinglayer of the wire from being worn.

When replacing fixing parts such as nuts and bolts, only parts from original manufacturer or parts made of same material and with strength can be used.Parts must be tightened according to the specified torques.

Explosive Drawing

Wiring Diagram

Wirebeamcolor:WWhite

B Black

Spark Plug Ignition

1. Remove spark plug cap from spark plug. .
2. Connect the ignition tester to the spark plug cap.
3. 3.S Start the engine, and observe the sparks through the discharge window of the tester.

WARNING: Do not touch any joint part of the lead wire of the tester.

Keep away from inflammable gas or liquid, to prevent accident resulting from spark ignition.

Spark Plug Cap

1. Remove the spark plug. Check if the spark plug cap is broken. Replace if necessary.
2. Measure the resistance. If it's out of specification, replace. Spark plug cap resistance: 4.0~6.0k Ω
3. Install the spark plug cap

Turn it clockwise until it is tight.

Flywheel Maintenance

1. Use flywheel holder to remove the nut and starter pulley; use flywheel puller to remove flywheel.
2. 2.Check if the flywheel is damaged or the permanent magnet part is firm. Replace if necessary.

Ignition Coil Inspection

1. Ignition coil peak voltage
2. 1 Remove spark plug cap.
3. 2 Disconnect ignition coil tip (W).
4. ③ Measure the ignition coil peak voltage output by a digital universal meter and a peak voltage adapter.If below specification, check the ignition coil.
5. Ignition coil resistance
6. ① Remove ignition coil and spark plug cap.
7. 2 Measure ignition coil resistance.If out of specification, replace it.

Peakvoltageoutput:130V(1500r/min)

Digital universal meter

Resistance: 0.7~0.96 Q(Tester (+) pole: white wire; Tester (-) pole: black wire)

11.6~7.0k Q (Tester (+) pole: white wire; Tester (-) pole: high-voltage wire)

Peak voltage adapter

Fuel System

NOTICE: Gasoline is inflammable and highly volatile liquid. Its leakage can cause 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 for leakage.

Explosive Drawing

Fuel Tank Removal and Inspection

1. Open the top cowling.
2. 2.Remove three bolts fixing the starter.
3. 3.Remove the starter. Pull thefuel tank out.
4. 4.Remove the fuel pipe from fuel tank.
5. Inspect the fuel tank and fuel tank cover for crack, leakage or damage. Replace if necessary.
6. Inspect the tank strainer for dirt or clog. Clean or replace if necessary.

Oil Switch Removal and Inspection

• 1.Remove the fuel tank.
• 2.Remove the bolts fixing the thumb wheel of the oil switch, and remove the thumb wheel.

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 3. Oil switch 4.Bottom cowling

4. Inspect the oil switch for leakage under prescribed pressure, replace if necessary. Prescribed air pressure: 0.1Mpa

Fuel Joint Removal and Inspection

• 1.Remove the bolts fixing the fuel joint.

2. Remove the fuel joint.
3. Inspect the fuel joint for crack or damage.
4. Connect the fuel joint exit with a vacuum pressure gauge.
5. Check whether the negative pressure can be maintained for over 10 minutes under the prescribed pressure. Replace if necessary. Prescribed pressure: 50kPa.

Fuel Pump Removal and Inspection

• 1.Remove the bolts fixing the fuel pump.

2. Remove the fuel pump.

• 3.Connect the fuel pump intake with a vacuum pressure gauge.

4. Block the exit of fuel pump with finger, and force a prescribed positive pressure to check for leakage.
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 check for leakage.Disassemble the fuel pump to check if necessary. Prescribed pressure: 50kPa

• 8.Remove four bolts, and separate fuel pump cover from fuel pump seat.

9. Remove the valve screw bolt from fuel pump, and remove the valve plate.
10. Press the plunger and diaphragm, rotate the fuel pump seat, and align the notch with the notch on the plunger. Take the roller needle out.
11. Inspect the diaphragm for crack and valve for damage. Replace if necessary.
12. Reverse above step 8 to step 10 to install the fuel pump.

Prescribed pressure:50kPa

Intake System Removal and Inspection

1. Loose throttle cable stop screw, and remove throttle cable.
2. 2.Remove choke cable from carburetor.Remove choke cable.
3. 3.Remove the bolt fixing air filter.
4. 4.Remove air filter and carburetor.
5. Remove intake manifold from engine.
6. 6.Check if air filter and intake manifold are cracked or damaged.Replace it if necessary.

1.Throttle cable stop screw

Power Unit

NOTICE: Before disassembling, disable the ignition system and turn off the ignition system. For example: remove the hang rope stopper from stop switch assembly, and remove spark plug cap from spark plug. n s e and os off the ignition system.For example: remove the hang rope stopper from stop switch assembly, and remove spark plug capfrom spark plug.

Explosive Drawing

Piston slider

Housing bearing installer

Space gauge

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.Removeairfilter andcarburetor.
• 5.Remove bolts connecting the engine and upper casing.
• 6.Carry the power unit and put it onto the working table.

Disassembling and Inspection (Power Unit)

Special Tools

Bearing puller

Oilsealinstallertool

Valve spring compressor

Housing oil seal installer

Cylinder Cover

Disassembling

• 1. Remove the bolts of cylinder head cover.
• 2.Remove the bolts of the cylinder cover according to the reverse numbering sequence of the cylinder cover.
• 3.Remove the crankcase cover.Remove the valve push rod
• 4.Remove the rocker arm pivot, rocker arm, rocker arm shaft and push rod plate.

Push rod

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 valve seat. Valve seatwidth:0.6~0.8mm
• 2.Inspect the valve margin thickness (T).If not as in the prescribed value,replace the valve. The margin thickness of valve: T
• 3.Inspect the valve stem diameter.If not in the prescribed range, replace the valve. The diameter of valve stem:

Intake door:0.7mm

Exhaust door:1.00mm

Intake:5.475~5.490mm

Exhaustvalve:5.460~5.475mm

• 4.Measure the valve stem runout.If exceeding the limit, replace the valve. Valve stem runout limit:0.03mm
• 5.Measure the inner diameter of the valve pipe. Theinner diameter of thevalve pipe: 5.500~5.512mm

CAUTION: When replacing the valve, please use the new valve pipe and valve oil seal.

Valve spring

1. Measure the free length of valve spring. If less than prescribed value, replace. The minimum free length: 34mm
2. 2.Measure the valve spring tilt. If exceeding the prescribed limit, replace.

The maximum tilt limit: 1.2mm

• 1.Clean the carbon on the valve.
• 2.Coat a thin layer of bluing dye evenly onto the seal face of the valve seat.
• 3.Lap the valve on valve seat by valve lapping tool.
• 4.Measure thevalveseatwidth. The valve face is with bluing dye. If the valve and valve seat do not match, or the valve seat width does not conform to specified value,reface and lap thevalve seat.

If the contact surface is not even, replace the valve pipe.

Valve rocker arm

Check the rocker arm for crack, perforation or damage.Replace if necessary.

Valve pipe replacement

• 1.Knock out the valve 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 inner diameter of pipe to the prescribed value by reamer.

Inner diameter of valve pipe: 5.500~5.512mm

NOTE: When taking out the reamer, don't rotate it in counter clockwise direction.

Valve seat inspection

Thevalveseatwidth:

0.6~0.8mm

Themaximumvalveseatwidth:

1.1mm

Valve seat cutting

• 1.Use 45° cutter to adjust the valve seat width. Turn the cutter clockwise until the valve seat face is smooth.
• 2.If the valve seat is centered on the valve face but it's too wide,to reduce the valve seat width, use 30° cutter to adjust the top edge of the seat, and use 60° cutter to adjust the bottom edge of the seat.
• 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 valve seal surface is too narrow and on the bottom edge of valve surface,use 60°cutter to adjust the bottom edge of the seat, and use 45° cutter to adjust the valve seat width if necessary.
• 5.Coat evenly a thin layer of lapping compound onto valve seat, and lap the valve by lapping tool.

6. Clean up the remaining lapping compound.

• 7.Inspect again the valve seat width.

CAUTION: Do not overlap the valve.Turn the lapping tool evenly with a downward force of 40~50N. Do not contaminate push rod and valve pipe with lapping compound.

Thermostat

• 1.Remove thermostat cover and thermostat.
• 2.Suspend thermostatin the containerwithwater.
• 3.Heat the container.

4. Inspect valve lift situation in the prescribed water temperature. If out of specification, replace.

• 5.Install thermostat and thermostat cover.Tighten the bolts to specified torque.

Crankcase

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 connecting rod bolt and connecting rod cap,and remove connecting rod and piston assembly.
5. Use clipper to remove circlip, and remove piston pin and piston.

• 6.Remove crankcase and crankcase gasket.

7. Remove oil splasher gear assembly.

• 8.Removebreathercover bolts,and remove breather cover.
• 9.Remove valve bolts and remove valve.
• 10.Remove oil seal shell bolts, and remove oil seal shell and oil seal.

Breather

1. Inspect breather flap valve, if damaged/cranked/cracked, replace.
2. 2.Inspect breather hole. If clogged, clean.
3. Inspect breather return pipe. If cracked/leaked/damaged, replace.

Piston

Measure piston outside diameter at the specified measuring point. If out of specification, replace.

Pistondiameter:58.950~58.965mm

Measuring point@: 10mm

Cylinder bore

1. Measure cylinder bore separately at measuring point ①, O, ③. At each point, measure the cylinder bore at places D1, D3, D5 parallel to the crankcase and at places D2, D4,D6 vertical to the crankshaft.

Measuring point height:

①100mm;

②40mm;

③70mm

Cylinder bore:

59~59.02mm

59.10mm

Limit size:

2. Calculate taper limit and round limit. If out of specification, replace crankcase.

Taper limit: 0.08mm(D1-D5, D2-D6)

Round limit: 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 ring parallel with the piston crown into the specified measuring point of the cylinder (1omm from conjunction surface).
• 2.Measure end gap by space gauge. If out of specification, replace the piston ring.

End gap (installed) / limit size:

Top ring 0.10~0.20mnm/0.4mm

2nd ring 0.25~0.40mm/0.6mm

Oil ring0.2~0.7mm/0.9mm

3. Install piston ring to piston, and measure side clearance between piston ring and its slot by clearance gauge. If out of specification, replace the piston ring.

Side clearance:

Top ring 0.04~0.08mnm

2nd ring 0.02~0.06mm

Camshaft decompressor

• 1.Inspect camshaft decompressor, gear, and weight.If gear is worn/damaged/cracked, replace.

If weight is unsmoothly moving, replace.

• 2.Measure camshaft lobe diameter@ and height .If out of specification, replace it.

@Intake camshaft:21.950~22.050mm

Exhaust camshaft:21.950~22.050mm

b

• ?

Intake camshaft:26.736~26.836mm

Exhaustcamshaft:26.532~26.623mm

• 3.Measure camshaft diameter. If out of specification, replace the camshaft.

a

Camshaft journal wear limit:14.934mm

Crankshaft

Measure crankshaft runout.If out of specification, replace.

Crankshaft runout limit: 0.03mm

Oil clearance

1. Put a piece of plastic space gauge on to the crankpin in parallel to the crankshaft.
2. Assemble the connecting rod to the crankpin.
3. 3.Tighten the connecting rod bolts to the specified torque.

12Nm

Tightening torque:

4. Remove the connecting rod, measure the compressed width of the plastic space gauge. If out of specification, replace the connecting rod.

Oil clearance:

0.020~0.052mm

Note:

Don't rotate the connecting rod before completing measurement.

Valve lifter

• 1.Inspect valve lifter for wear or damage. Replace if necessary.
• 2.Measure valve lifter outside diameter. If out of specification, replace the valve lifter.

Valvelifter outside diameter:7.9650mm

Oil splash gear

Inspect oil splash gear unit, if slow-moving/wear/damage/crack, replace.

Crankshaft bearing

Inspect bearing, if pitting/rumbling, replace.

NOTE: Don't remove bearing unless you replace it.

Oil seal housing

1. Inspect oil seal housing for crack/damage. Replace if necessary.
2. Inspect O-ring for crack/damage. Replace if necessary.

Crankcase and crankcase cover

1. Inspect crankcase cover.If cracked/damaged, replace.
2. Inspect cooling water passage for dirt or clog.Clean if necessary.

Full Installation

Piston connecting rod installation

Install piston, connecting rod, piston pin and piston pin circlip.

NOTE: When installing, make 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 installation

• Install oil ring, 2nd ring and top ring. NOTE: Make sure that the mark is toward the piston crown when installing the 2nd ring.
• Picture of the piston ring gap Oil ring end gap 1 (lower rail) Oil ring end gap 2 (expanded ring) Oil ring end gap 3 (upper rail) 2nd piston ring end gap 4

Top piston ring end gap 5

Piston installation

Use piston slider to install piston, and make sure the piston crown Up"is toward the flywheel side.

NOTE: Apply motor oil to the piston and piston ring side when installing.

Oil seal housing installation

1. Install oil seals 10.8x21x7 (2 pieces) by oil seal installer tool.
2. 2.Install oil seals B20 X 30 X 7 by oil seal installer tool.

NOTE:

• ① Apply grease onto new seal before installation.
• ② Make sure the oil seal direction as shown.

Crankshaft installation

1. Install the crankshaft bearing to crankcase by special tools (if change bearing). Install oil seal.

Housing oil seal installer

Oil seal installing direction

Housing bearing installer

NOTE: Fit the bearing with its manufacturer's mark toward the direction of the flywheel side.Apply motor oil to the new oil seal installing.

2. Install crankshaft to crankshaft case.
4. Install connecting rod cover, and tighten the connecting rod bolt to the specified torque. Specified torque: 12 Nm

NOTE: Apply motor oil to moving parts before installing.

Camshaft installation

Install camshaft. Make sure that the camshaft gear mark is aligned with the camshaft timing gear mark.

NOTE: Apply motor oil to moving parts before installing.

NOTE: Apply motor oil to moving parts before installing.

Upper Unit

Top Cowling

Explosive Drawing

Crankcase cover installation

1. Install oil seal housing.
2. 2 Install oil splasher gear assembly.
3. 3 Install crankcase cover, and tighten the bolts twice as shown.

Tightening torque:

1st 10 Nm

2nd 22 Nm

Disassembling and inspection

1. Remove airproof rubber bar.
2. Remove top cowling muffling cover bolt and rubber underlay.
3. Remove top cowling muffling cover.
4. Remove lock hook and pothook.
5. 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 or damaged.Replace it if necessary.
8. Inspect if lock hook and pothook is cracked, deformed or damaged. Replace it if necessary.

Bottom Cowling

Explosive drawing

Disassembling and inspection

1. Remove rubber coverB.
2. Remove handle bolt and handle.
3. Remove top cowling clamp lever bolt and clamp lever.
4. Removetopcowling clampleverbushA and clampleverbushB.
5. Removewavewasher.
6. Inspect if bottom cowling is cracked or damaged. Replace if necessary.
7. Inspect if clamp lever handle is cracked or damaged.Replace if necessary.
8. Inspect if clamp lever is cracked or damaged.Replace if necessary.
9. Inspect ifwave washer and clampleverbush are cracked or damaged.Replace if necessary.

Steering Handle

Explosive drawing

Disassembling and inspection

1. Remove steering handle cover.
2. Remove handle bush, bush washer and wave washer.
3. Remove steering handle shocker damper.
4. Remove cotter pin and friction adjusting bolt
5. Remove steering handle.
6. Remove throttle cable.
7. Removethrottleleverstayand throttlelever.
8. Remove engine stop switch.
9. Inspect if steering handle is cracked or damaged. Replace if necessary.
10. necessary.
11. Inspect if steering handle shock damper is cracked or damaged. Replace if necessary.
12. Inspect if throttle cable is cracked or damaged. Replace if necessary.
13. Inspect the conduction of engine stop switch. If not to specification, replace it.

Remove lockplate:

Conducting Not conducting

Install lockplate:

Push stop switch button: Conducting

Bracket

Explosive drawing

• 1.Remove tilt locked clasp.

2. Remove swivel bracket cover.

• 3.Remove bottom shock absorption assembly and shock absorption bush.

Disassembling and inspection

Remove clamp bracket.

• 5..Removeswivelbracket.
• 6.Remove bracket fixed cover, and the tilt lock bracket.

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 tilt lockbracket and tilt locked clasp were distorted,replace if needed.

Upper Unit Casing

Explosive drawing

Disassembling and inspection

• 1. Remove the water tube.
• 2.Remove the gear shift handle and change shaft.
• 3.Remove the shift rod and shift rod lever.
• 4.Check 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 Pump Assembly

Explosive drawing

Disassembling and inspection

• 1. Remove water pump fixed plate.

2. Remove water pump housing.
3. Remove water pump impeller and inner water pump cover.

• 4.Remove water pump base.
• 5.Check water pump housing and out plate for crack, crank or damage. 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 necessary.

Lower Unit Gear Assembly

Explosive Drawing

Disassembling and inspection

• 1. Remove cotter pin and nut assy.

2. Remove propeller assembly and spacer.

• 3.Remove the lower casing cover.

4. Remove the reverse gear assy, drive shaft, positive gear assy, and shift pluger.
5. 5.Remove shift rod cam assy and drive shaft.
6. 6.Remove barrel bearing with guard board (F4-03000002).
7. Remove barrel bearing without guard board (F4-03000003) by using barrel bearing installer tool.
8. Remove the clutch block from the propeller shaft.

Propeller shaft and clutch block

1. Check clutch block for wear or damage. Replace if necessary.
2. Check propeller 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. 2.Install the clutch block as shown.Take note ofthe direction.

Lower casing cover

• 1.Check bearing for rust or rumbling when run.Replace if necessarary.

2. Remove bearing and oil seal by bearing puller. Note: Don't remove bearing unless change it.
3. Clean casing cover by a soft brush and solvent.

• 4.Check casing cover for crack or damage. Replace if necessary.

Lower casing cover oil seal and bearing installation

• 1.Install oil seal.

2. Install bearing.

Note: Please use special tool to install oil seal and bearing. Pay attention to the oil seal installation direction and installation depth. Make sure the manufacturer mark faces toward the reverse gear.

Barrel bearing

Inspect barrel bearing with guard board and barrel bearing without guard board for wear, crack or damage.Replace if necessary.

Drive shaft

Inspect the drive shaft for crank or wear.Replace if necessary.

Gear

Forward gear bearing

Inspect bearing forrust and rumbling when rotating.Replace if necessary.

Lower unit casing

• Replace if necessary.
• 2.Install the barrel bearingwith guard board and barrel bearing without guard board by special tool.

Barrel bearing with guard board installer tool

Lower casing bracket and barrel bearing without guard board installer tool

• 3.Install new oil seal, with the depth as shown. (unit: mm)

Lower casing bracket and drive shaft oil seal installer tool