Parsun F2.6 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
  • Power Unit
  • Control System
  • Check Gear Oil Level
  • General Inspection

• Recoil Starter

  • Starter Rope Replacement
  • Disassembling and Inspection

• Ignition System

  • Wiring Diagram
  • Spark Plug Ignition
  • Spark Plug Cap
  • Flywheel Maintenance
  • Ignition Coil Inspection

• Fuel System (Detailed)

  • Fuel Tank Removal and Inspection
  • Intake System Removal and Inspection

• Power Unit (Detailed)

  • Disassembling Power Unit from Outboard Engine
  • Cylinder Cover
  • Crankcase
  • Full Installation

• Upper Unit

  • Top Cowling
  • Bottom Cowling
  • Steering Handle
  • Bracket

• Lower Unit

  • Water Pump Assembly
  • Lower Unit Casing
• Common Troubles and Solutions

WARNING:

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 inthe spacesprovided to assistyou in orderingspare parts from yourParsundealer.To prevent from theft,theserialnumberlabel will be destroyedif removed from theoutboard motor.

• 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

If the starting device is not working, the engine can be started by emergency start cable.

• When you start the engine by emergency start cable, please ensure the shift rod is in NEUTRAL position.
• items far away.Don't touch flywheel or other moving parts.
• When starting and operating, don't touch ignition coil, spark plug cap or other electric parts.

The procedure is as follows:

• 1.Remove the top cowling.

2. Remove the bolts fixing the fuel tank.

• 3.Lift thefuel tankand remove threebolts.
• 4.Lift the starter and remove choke cablefrom carburetor
• 5.Remove the starter.

6. Install the bolts to fix the flywheel cover

• 7.Install theboltstofixthefueltank.
• 8.When the engine is cold , circumvolve the lever of carburetor in order to operate choke system. Return lever to home position after engine starts.
• 9.Insert the knot of the cable in the notch of flywheel rotor, and wind the cable around flywheel several rounds in clockwise direction.

10. Pull the manual starter handle slowly until you feel resistance.
11. 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

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.

Under normal conditions of use, there should 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 precautions is as follows:

• ① To protect the skin, the application of a suitable barrier cream to the hands before working is recommended.
• ? Clothingwhich has become contaminatedwithlubricantsshould be changed as soon as practicable, and washed before further use.
• ③Avoid skin contact with lubricants.
• @ Hands and any other part of the body which have been in contact with lubricants or lubricant-contaminated clothing, should be thoroughly washed with hot water and soap 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.
• Q 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 special tools when disassembling and assembling.
2. 2.Clean dirt before disassembling the parts.
3. 3.Oil the contact surfaces of moving parts before assembly.
4. 4.Install bearing with the manufacturer'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 diameter.
6. 6.After assembly, check if the moving parts operate normally.

One-Time Use Parts

One-time use parts are gasket, oil seal, O-ring, cotter pin and spring, ring, and etc.. When re-assembling outboard 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 if the fuel pipe is connected firmly, and if the fuel tank is filled with fuel.

CAUTION:

Do not usepre-mixed fuel for this 4-stoke outboard engine.

2. Checking Oil Level

Check the Engine Oil Level

Check engine oil level from oil level checking hole.

1. High position mark 2. Low position mark

Ensure the oil level between the marks of upper and lower.If above upper level, drain engine 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 fiction 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.

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

5. Check Engine Stop Switch Assembly

Check if the engine stops when pushing the engine stop switch assembly or pulling out the stopper hang rope.

6. Check Cooling Water Checking Hole

When the engine is running, check if

1. Clamp handle screw

coolingwater overflows at the coolingwater checkinghole.

7. Breaking-In Running

• 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 8 hours: operate the engine at full throttle continuously. Each operation time doesn't exceed 5 minutes.

8. Inspection After Breaking-In Running

• ① 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 over the cooling water passage by fresh water.
• 9.After breaking-in running, inspect idling speed.
• ② Using the tachometer to measure idling speed RPM. If out of specification, adjust it. Idling speed: 1800~2000 r/min
• ① Preheating engine for 5 minutes.
• ? Turn the throttle stop screw clockwise or counter clockwise1.throttle stop screw until the specified idling speed is attained.
• ④ 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

Flywheel holder and puller

1. Cooling water checking hole

Bearing puller

Valve spring compressor

Oil seal installer tool

Housing bearing installer

Lower casing cover bearing installer

Housingoil seal installer

Sleeve bearingwith guard board installer tool

Space gage

Lower casingbracket and sleeve bearing without guard board installer tool

Lower casing bracketand drive shaft oil seal installer tool

Detection Device

Digital tachometer

Digital universal meter

Peak voltage adaptor

Explosive Drawing and Symbol

Explosive Drawing

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

Symbol

Specifications

Outboard Engine Specifications

Maintenance Information

Power Unit

Ignition System

Tightening Torque

General Torque

Periodic Service

Maintenance Timetable

CAUTION:

After running the outboard engine in saltwater,waste water or mud water,wash over the engine byfreshwaterimmediately.

If using leaded gasoline frequently, check the valve and components each 100 hours.

Fuel System

1. CHECKFUELTANK,CARBURETOR,FUELPUMPANDFUELPIPE

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

Check if fuel cock is cracked, damaged or leaking. Replace if necessary.

Power Unit

Engine Oil Level

1. From oillevel checking hole,check if engine oillevelisbetween thefollowingmarks of the upper and lower.

1. Oil level plug 2.Oilrule

• 3.Highpositionmark4.Lowpositionmark

2. If above the upper mark, drain the engine oil; if below lower mark, add engine oil up to upper mark.

CAUTION:

Run the engine for a few minutes and then turn it off,wait for several minutes, and check the engine oil level bytheoil checkingholeagain.

If the engine oil still not within 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: 0.35L

Oil type: API SE, SF, SE-SF, SG-CD SAE 10W30, 10W40

4. Install oil level plug.
5. 5.Check engine oil level.

CAUTION:

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

1. Remove stopper hang rope from engine stop switch assy. Remove spark plug cap from spark plug.
2. 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.

Valve clearance (cold position):0.08~0.12mm

1. Remove spark plug cap and spark plug.

Spark Plug

• 2.Clean off carbon build-up on the electrodes.
• Check if the electrodes are corroded or have deposit, or if the washer is damaged. If necessary, change the spark plug.

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.

Spark plug type: BPR7HS

Specified torque: 25 Nm

Valve Clearance

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 idlling speed is attained.

Idling speed: 1800~2000 r/min

NOTE:

Turning clockwise to increase idling speed.

Turning counter clockwise to decrea se idling speed.

CAUTION:

Before adjusting the idling speed, the throttle cable slack should be properly adjusted. After adjusting the idling speed, if necessary you can adjust the throttle cable again.

Check Gear Oil Level

Remove the oil level plugIf the gear oil overflows at the oil 1evel checking hole, the oil volume added is correct,otherwise please add gear oil.

1. Oil level plug

Changing Gear Oil

• 1.Hold the outboard engine in an upright position.
• 2.Place a container under 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 gear oil overflows at the oil level checking hole, install the oil lev el plug 5.
• 6.Install the drain plug,then clean overflowing gear oil.

1.Oil level plug2.Drain plug

NOTE:

Check the drained gear oil.

If the gear oil is milky, please check the oil seal. If necessary, rep lace the oil seal.

CAUTION:

Must change drain plug washer each time.

Lower unit leakage check

Lower Unit Casing

Gear Oil

Connecting the leakage tester to the oil level checking hole to check the lower unit leakage.If the

General Inspection

Anode

Inspect lower unit anode and 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.

Grease Points

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

Cooling Water Passage

• 1.Inspect cooling water passage Ifblocked,clean it.

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 thecooling water passage.

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 stopper hang rope from stop switch assy, in case of the accidental start of the engine.

Explosive Drawing

1. Open the top cowling
2. 2.Remove bolts fixing the fuel tank.
3. 3.Remove thefuel tankand takedown threebolts.
4. 4.Lift the starter and remove choke cable from carburetor.
5. 5.Removethestarter.

Disassembling

Starter Rope Replacement

1. Pull the starter rope out, and insert it in the 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 starter rope. Untie the knot at the end of the starter rope.
4. Pull out the starter rope completely.
5. Insert the new starter rope into the starter assembly, and fix the rope onto the sheave drum and starterhandle. At the end of the rope tie a knot as shown.
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

1. Remove the start rope.
2. Remove starter bolt, and remove press plate and drive pawl.
3. 3.Remove the sheave drum
4. 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. Check if the drive pawl is cracked, worn or damaged. If necessary, replace it.
6. Inspect if the drive spring is broken, cranked or damaged. If necessary, replace it.
7. 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. Specified torque: 8Nm

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 from being cut, or the insulating layer 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

Assembling

Installation

Wiring Diagram

Wire beam color:W White

B Black

Spark Plug Ignition

1. Remove spark plug cap from spark plug. .
2. 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 leadwire of the tester.

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

1. Ignition coil peak voltage
2. 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.

Peak voltage output: 130V (1500 r/min)

Digital universal meter

2. Ignition coil resistance
3. （1 Remove ignition coil and spark plug cap.
4. Measure ignition coil resistance.If out of specification, replace it.

• Resistance: 1.6~1.9 Q(Tester (+) pole: white wire; Tester (-) pole: black wire) 5.8~7.0k Q (Tester (+) pole: white wire; Tester (-) pole: high-voltage wire)

Peak voltage adapter

Spark Plug Cap

• 1.Remove the spark plug. Check if the spark plug cap is broken. Replace if necessary.

2. 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.Check if the flywheel is damaged or the permanent magnet part is firm. Replace if necessary.

Ignition Coil Inspection

Fuel System (Detailed)

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.Remove two bolts fixing the fuel tank.

3. Pull the fuel tank out.

• Remove the fuel pipe from fuel tank.

5. Inspect if 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.

Intake System Removal and Inspection

• 1.Remove the bolt fixing air filter.
• 2.Remove air filter and carburetor.
• 3.Check if air filter is cracked or damaged.Replace it if necessary.

Power Unit (Detailed)

NOTICE:

To avoid accidental start of outboard engine during maintenance, please take enough safety measures assembly, and remove spark plug cap from spark plug.

Explosive Drawing

Piston slider

Housing bearing installer

Space gauge

Disassembling Power Unit from Outboard Engine

1. Open the top cowling.
2. 2.Remove fuel tank;remove starter.
3. Remove flywheel cover and throttle cable .
4. 4.Remove air filter and carburetor.
5. Remove bolts connecting power unit and upper casing.
6. 6.Carry the power unit and put it onto the working table.

Disassembling and Inspection

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.

Special Tools

Bearing puller

Oil seal installer tool

Valve spring compressor

Housing oil seal installer

• 4.Remove the rocker arm pivot,rocker arm,rocker arm shaft and pushrod plate.

Push Rod

Inspect valve push rod runout.Replace if exceeding the specified value. Valvepush rodrunout limit:0.5mm

Valve and Valve Pipe

• 1.Inspect the valve seat width. If not in the prescribed range,repair the valve seat Valve seat width: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:
• 4.Measure thevalve sterm runout.If exceeding the limit,replace the valve. Valve stem runout limit:0.03mm
• 5.Measure the inner diameter of the valve pipe.

Intake door.0.7mm

Exhiaust door:1.0omm

Intakevalve:5.475~5.490mm

Exhaustvalve:5.460~5.475mm

Theinner diameter of the valvepipe:5.500~5.512m

CAUTION:

When replacing the valve,please use the new valve pipe andvalve oil seal.

Valve Spring

• 1.Measure the free length of valve spring.If less than prescribed value, replace.
• 2.Measure the valve spring tilt.If exceeding the prescribed limit, replace.

The minimum free 1ength: 34mm

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 thevalve seat.
3. Lap the valve on valve seat by valve lapping tool.
4. Measure thevalve seatwidth.

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 v alue,reface and lap the valve seat.

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

The valve seat width: 0.6~0.8mm

The maximumvalve seatwidth:1.1mm

Valve Seat Cutting

• 1.Use 45°valve seat cutter to adjust the valve seat width.Turn the cutter clockwise until the valveseatface issmooth.
• 2.If thevalve seat is centered on thevalve face but it's toowide,to reduce thevalve 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.

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

• 4.If the valve seal surface is too narrow and on the bottom edge of valve surface, use 60°cutter toadjust thebottom edgeof the seat,anduse45°cutter toadjust 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. 2.S Suspend thermostat in the container with water.
3. 3.Heat the container.
4. 4.Inspect valve lift situation in the prescribedwater temperature.If out of specification,replace.
5. 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. 2.Remove the crankcase cover.
3. 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.Remove oil seal shell bolts, and remove oil seal shell and oil seal.

Piston

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

Piston diameter:

53.950~53.965mm

Measuring point@: Omm

Cylinder Bore

1. Measure cylinder bore separately at measuring point ①, , 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:

• ②40mm;

①100mm;

③70mm

Cylinder bore:

54.00~54.015mm

Limit size:

54.10mm

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:11.996~12.000mm

Piston Ring

1. Push the piston ring parallel with the piston into the specified measuring point of the cylinder (1omm from conjunction surface).

If out of specification,replace the piston ring.

Top ring 0.15~0.30mnm/0.4mm

• Measure end gap by space gauge. End gap (installed) / limit size:

2nd ring 0.30~0.45mm/0.6mm

Oil ring 0.2~0.7mm/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 0.04~0.08mm

2nd ring 0.02~0.06mm

Oil ring 0.06~0.16mm

Camshaft Decompressor

1. Inspect camshaft decompressor, gear, and weight. If gear is worn/damaged/cracked, replace. If weight is unsmoothly moving, replace.
2. 2.Measure camshaft lobe diameter@ and height .If out of specification, replace it.

Camshaft: 26.136~26.239mm

@Camshaft:21.950~22.050mm

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

Camshaft journal wear limit: 14.934mm

Crankshaft

• 1.Measure crankshaft brace.If out of specification, replace.

2. Measure crankshaft runout. If out of specification, replace.

Crankshaft brace diameter @ : 23.969~23.984mm

Crankshaft brace width : 21.0~21.1mm

Crankshaft runout limit: 0.01mm

1. Put a piece of plastic space gauge on to the crankpin in parallel to the crankshaft.

Oil Clearance

• 2.Assemble the connecting rod to the crankpin.
• 3.Tighten the connecting rod bolts to the specified torque.

Tightening torque:

Firsttime

• 5Nm

Second time

9Nm

• 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. 016~0. 046mm

Note:

Don't rotate the connecting rod before completing measurement.

Valve Lifter

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

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

Crankcase and Crankcase Cover

1. Inspect crankcase cover. If cracked/damaged, replace.
2. 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

1. Install oil ring, 2nd ring and top ring.

NOTE:

Make sure that the mark is toward the piston crown when installing the 2nd ring.

2. Picture of the piston ring gap

Oil ring end gap 2 (expanded ring)

Oil ring end gap 1 (lower rail)

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. 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 spring direction as shown.

Crankshaft Installation

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

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.
3. Install connecting rod cover, and tighten the connecting rod bolt to the specified torque. Specified torque:12 Nm

NOTE:

• 1.Install valve lifter.

Apply motor oil to moving parts before installing.

Camshaft Installation

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

NOTE:

Housing oil seal installer

Oil seal installing direction

Apply motor oil to moving parts before installing.

1. Install oil seal housing.

Crankcase Cover Installation

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

Tightening torque:

1st5Nm

2nd 11 Nm

NOTE:

Apply motor oil to moving parts before installing.

Upper Unit

Top Cowling

Explosive drawing

Disassembling and Inspection

1. Removeintakesilencerbolt.
2. Remove intake silencer and intake silencer damper..
3. Inspect if top cowling, intake silencer and intake silencer damper are cracked or damaged. Replace ifnecessary.

Bottom Cowling

Explosive Drawing

Disassembling and inspection

• Removebottom-cowlingseal.

2. Remove top cowling locking hook.
3. Remove circular rubber plug and quadrate rubber plug.
4. Inspect if bottom cowling is cracked or damaged.Replace if necessary.
5. Inspect if top cowling locking hook is cracked or damaged.Replace if necessary.

Steering Handle

Explosive Drawing

Disassembling and Inspection

1. Remove steeringhandle cover.
2. 2.Remove handle bush, bush washer and wave washer.
3. Remove steering handle damper assembly.
4. Removefriction adjustingbolt.
5. Remove steering handle.
6. Remove throttle cable.
7. Remove throttle lever stay and throttle lever.
8. Remove engine stop switch.
9. Inspect if steering handle is cracked or damaged. Replace if necessary.
10. a e necessary.
11. Inspect if steering handle 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

Install lockplate:

Not conducting

Push stop switch button: Conducting

Bracket

Explosive drawing

Disassembling and Inspection

• 1.Remove clamp handle and bracket cover.
• 2.Remove swivel bracket cover.
• 3.Remove swivel bracket bushing and damper.
• 4.Remove clamp bracket
• 5.Remove swivel bracket.
• 6.Remove title clamp handle and title lock lever.

7. Inspect the the swivel bracket and clamp bracket for damage or crack. Replace if necessary.
8. Inspect swivel bracket bushing and damper for damage or crack. Replace if necessary.
9. Inspect whether title clamp handle and title lock lever are deformed or damaged. Replace if necessary.

Upper Unit Explosive Drawing

Disassembling and inspection

• 1.Remove the water tube.
• 2.Remove gear shift handle assembly.
• 3.Remove the shift rod and shift rod lever.
• 4.Remove exhaust cover.

5. Check upper casing for crack or wear. Replace if necessary.

• 6.Check gear shift handle for wear or damage.Replace if necessary.
• 7.Check exhaust cover for crack or wear. Replace if necessary.

Lower Unit

Water Pump Assembly

Explosive Drawing

Disassembling and Inspection

1. Remove water pump fixed plate.
2. Removewaterpumphousing
3. Remove impeller, inner housing and O ring of water pump inner housing.
4. Removewaterpumpbase.
5. Check water pump housing and out plate for crack, crank or damage.Replace if necessary.
6. Check inner water pump housing and impeller for crack, deform, burn or damage. Replace if necessary.
7. 7.Check water pump base for crack, crank, scratch or damage. Replace if necessary.

Lower Unit Explosive Drawing

Disassembling and Inspection

1. Remove cotter pin, nut assy, and spacer.
2. 2.Remove propeller assembly and spacer.
3. 3.Remove the lower casing cover.
4. Remove drive shaft, positive gear assy, and shift plug.
5. 5.Remove shift rod cam assy and drive shaft.
6. Remove sleeve bearing with guard board.
7. Remove sleeve bearing without guard board by using sleeve bearing installer tool.
8. 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 necessarily.
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.

Install oil seal.

Note:

Please use special tool to install oil seal and bearing.

Sleeve Bearing

Drive Shaft

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

Gear

Forward Gear Bearing

Inspect bearing for rust and rumbling when rotating.Replace if necessary.

Lower Unit Casing

1. Inspect lower casing cover for crack or damage.Check if the cooling water inlet is blocked. Replace if necessary.
2. tools.

Sleeve bearing with guard board installer tool

Lower casing bracket and sleeve bearing w ithout guard board installer tool

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

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

Lower Casing Cover Oil Seal and Bearing Installation

Lower casing bracket and drive shaft oil seal installer tool

Common Troubles and Solutions