Service Manual

F115/FL115

Suzhou Parsun Power Machine Co., Ltd.

 Preface
This Manual includes the maintenance instruction for F115 and FL115 outboard motors,
which is provided by Parsun to dealers for use in maintaining and repairing Parsun outboard motors.
Please read this Manual carefully before maintaining and servicing the outboard motors. When
repairing and maintaining the outboard motors, please use the maintenance procedures and tools
recommended in the Manual.
If you choose other maintenance procedures and tools, please follow the instructions of
experienced maintenance personnel to avoid injuries to personnel and the outboard motor.

The materials, drawings and technical parameters used in this Manual are based on the
prototype at the time of publication, so there may be some small differences between the actual motor
you purchased 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 carefully
and execute the relevant instructions and descriptions correctly and carefully.

Warning:
Failure to comply with the warnings may lead to injury to maintenance personnel and
bystanders, and severe cases may result in death.
Note:
“Note” means that preventive measures must be taken to avoid damage to the outboard
motor.
Note:
Key information are provided to make your operation steps simpler and clearer.

The last part of this Manual describes the common faults and troubleshooting methods of
the outboard motor. Please read it carefully; When overhauling the outboard motor, it can help
you quickly judge the status of the motor and improve working efficiency.

It is forbidden to copy and disseminate this Manual without written authorization

Suzhou Parsun Power Machine Co., Ltd.
Contents
Overview ................................................................................................................................................. 1
Identification mark .................................................................................................................................. 1
Selection of propeller .............................................................................................................................. 1
Protection at work ................................................................................................................................... 2
Disassembly and assembly ..................................................................................................................... 3
Disposable parts ...................................................................................................................................... 3
Pre-delivery inspection ........................................................................................................................... 3
Special tools and testing equipment ........................................................................................................ 5
Disassembly schematic diagram and symbol description ....................................................................... 7
Description of disassembly schematic diagram .............................................................................. 7
Symbol description ......................................................................................................................... 7
Specification ........................................................................................................................................... 8
Outboard motor parameters ............................................................................................................ 8
Maintenance information ........................................................................................................................ 9
Engine ............................................................................................................................................. 9
Underwater unit ............................................................................................................................ 10
Electrical system ........................................................................................................................... 11
Seating torque ....................................................................................................................................... 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
Control system ...................................................................................................................................... 22
Throttle push-pull cable ................................................................................................................ 22
Shift operation ............................................................................................................................... 22
Underwater unit .................................................................................................................................... 23
Gear oil.......................................................................................................................................... 23
Replace gear oil............................................................................................................................. 23
Air tightness inspection of underwater unit .................................................................................. 23
General maintenance ............................................................................................................................. 24
Anode ............................................................................................................................................ 24
Lubricating point ........................................................................................................................... 24
Cooling water channel .................................................................................................................. 24
Thermostat .................................................................................................................................... 25
Propeller ........................................................................................................................................ 25
Check the main switch/stop switch ............................................................................................... 25
Change the oil filter ...................................................................................................................... 26
Check the top cover ...................................................................................................................... 26
Check valve clearance................................................................................................................... 27
Electrical system ................................................................................................................................... 28
Matters needing attention ...................................................................................................................... 28
Disassembly schematic diagram ........................................................................................................... 29
Wiring diagram ..................................................................................................................................... 35
Spark plug ignition ................................................................................................................................ 37
Spark plug cap....................................................................................................................................... 37
Flywheel maintenance .......................................................................................................................... 37
Ignition coil detection ........................................................................................................................... 37
Trigger coil detection ............................................................................................................................ 37
Check engine startup switch ................................................................................................................. 38
Check engine stop switch...................................................................................................................... 38
Detection of starting relay ..................................................................................................................... 38
Detection of magneto coil ..................................................................................................................... 38
Detection of rectifier regulator.............................................................................................................. 38
Use fault diagnosis tester ...................................................................................................................... 39
Fault code table ............................................................................................................................. 39
Fuel system ........................................................................................................................................... 41
Matters needing attention ...................................................................................................................... 41
Disassembly schematic diagram ........................................................................................................... 42
Reduce fuel pressure ............................................................................................................................. 50
Check the oil filter cup .......................................................................................................................... 50
Removal and inspection of fuel pump .................................................................................................. 50
Check the fuel filter .............................................................................................................................. 51
Remove and check the fuel injector ...................................................................................................... 51
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 needing attention ...................................................................................................................... 54
Disassembly schematic diagram ........................................................................................................... 55
Special tool............................................................................................................................................ 67
Check the compression pressure ........................................................................................................... 67
Check oil pressure ................................................................................................................................. 67
Check valve clearance........................................................................................................................... 68
Adjust valve clearance .......................................................................................................................... 71
Remove the engine ................................................................................................................................ 72
Pulley and timing belt ........................................................................................................................... 73
Disassembly and inspection .................................................................................................................. 73
Cylinder cover ............................................................................................................................... 73
Check the valve tappet .................................................................................................................. 73
Check the driven pulley ................................................................................................................ 74
Check the cylinder head bolts ....................................................................................................... 74
Valve and valve guide ................................................................................................................... 74
Valve spring .................................................................................................................................. 74
Replace valve guide ...................................................................................................................... 75
Check valve seat ring .................................................................................................................... 75
Trim the valve seat ring ................................................................................................................ 75
Assemble and mount the cylinder head ........................................................................................ 76
Crankcase .............................................................................................................................................. 77
Disassembly .................................................................................................................................. 77
Piston............................................................................................................................................. 78
Cylinder bore ................................................................................................................................ 78
 Outside diameter of piston pin ...................................................................................................... 78
Piston ring ..................................................................................................................................... 78
Inner diameter of connecting rod small end ................................................................................. 79
Inner diameter of connecting rod large end .................................................................................. 79
Connecting rod large end backlash ............................................................................................... 79
Crankshaft ..................................................................................................................................... 79
Crank pin oil clearance ................................................................................................................. 80
Selection of connecting rod bearing bush ..................................................................................... 80
Main journal oil clearance ............................................................................................................ 81
Selection of crankshaft bearing bush ............................................................................................ 81
Body and engine base ................................................................................................................... 82
Check the oil pump ....................................................................................................................... 82
Check and mount exhaust pipe ..................................................................................................... 82
Reinstallation ........................................................................................................................................ 83
Assemble piston connecting rod ................................................................................................... 83
Installing the piston rings .............................................................................................................. 83
Installing piston ............................................................................................................................. 83
About water ........................................................................................................................................... 85
Top cover............................................................................................................................................... 85
Disassembly schematic diagram ................................................................................................... 85
Disassembly and inspection .......................................................................................................... 87
Bottom cover ......................................................................................................................................... 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 water unit .................................................................................... 99
Hydraulic warping device ................................................................................................................... 100
Check the oil level. ..................................................................................................................... 100
Underwater part .................................................................................................................................. 102
Disassembly schematic diagram ......................................................................................................... 102
Disassembly and inspection ................................................................................................................ 113
Propeller shaft and clutch block .................................................................................................. 114
Install the claw clutch ................................................................................................................. 114
Housing cover of underwater unit............................................................................................... 114
Install the oil seal and bearing of the housing cover ................................................................... 114
Drive shaft ................................................................................................................................... 115
Shift cam ..................................................................................................................................... 115
Gear ............................................................................................................................................. 115
Forward gear bearing .................................................................................................................. 115
Check the housing of the underwater unit .................................................................................. 115
Check the water pipe ................................................................................................................... 115
Assemble underwater unit................................................................................................................... 115
Install the underwater unit .................................................................................................................. 117
Selection of shim................................................................................................................................. 118
Deviation value mark .................................................................................................................. 119
Pinion shim ................................................................................................................................. 120
Forward gear shim ...................................................................................................................... 120
Reverse gear shim ....................................................................................................................... 121
 Backward-rotating pinion shim................................................................................................... 122
Propeller shaft shim .................................................................................................................... 122
Reverse gear shim ....................................................................................................................... 123
Forward gear shim ...................................................................................................................... 123
Common faults and solutions.............................................................................................................. 124
 Overview
Identification mark
The serial number is printed on a label which is pasted on the port side of the clamp bracket
or the upper part of the rotary bracket. The serial number is recorded in the blank of the label to help
you order spare parts from dealers or for your reference in case the engine is stolen.

1
1. Position of the serial number
The numbers are expressed as follows:
SN
发动机顺序号

生产代号

Selection of propeller
The performance of the outboard motor is seriously affected by the propeller. Improper
selection will have adverse effects on 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 should be selected to maintain the normal operation of the
engine.

When the engine is running at full throttle, the most suitable propeller for the ship is to refer
to the engine speed and fuel performance, which can provide the highest performance.
Propeller dimensions Material
3-14"×11" Aluminum alloy
5 " Aluminum alloy
3-13 8 ×13"
5 " Aluminum alloy
3-13 8 ×14"
1 " Aluminum alloy
3-13 2 ×15"
1 " Aluminum alloy
3-13 4 ×17"
3-13"×19" Aluminum alloy
5 " Aluminum alloy
3-12 8 ×21"
3-13"×23" Aluminum alloy

3-13"×25" Aluminum alloy

1 " Stainless steel

3-13 2 ×14"

1
 Continued:
Propeller dimensions Material
1 " Stainless steel
3-13 2 ×16"
3-13"×17" Stainless steel

3-13"×19" Stainless steel

3-13"×21" Stainless steel

3-13"×23" Stainless steel

3-13"×25" Stainless steel

1 " Stainless steel

3-13 2 ×17"
1 " Stainless steel
3-13 2 ×19"
1 " Stainless steel
3-13 2 ×21"
1 " Stainless steel
3-12 2 ×23"
3-13"×17" Stainless steel

3-13"×17" Stainless steel

Backward-rotating propeller:
Propeller dimensions Material
3-13"×17" Stainless steel

3-13"×19" Stainless steel

3-13"×21" Stainless steel

Note:
Backward-rotating outboard motor must use backward-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 and improve work quality, please
observe the following safety regulations.
1. Fire prevention
Gasoline and various lubricating oils and greases are easy to burn; Keep away from heat
sources, sparks and open flames during operation.

2. Ventilation
Gasoline vapor and engine exhaust gas are highly toxic. Massive inhalation of such
substances can cause shock and even death. When testing the engine indoors, please keep
good ventilation conditions.

3. Self-protection
Wear protective glasses when drilling, grinding or using air compressors. Wear

2
 protective gloves and safety shoes when necessary.
4. Use of lubricants and sealants
Only products provided or recommended by Parsun can be used when maintaining and
repairing the outboard motor.
Under normal circumstances, the lubricant mentioned in this Manual will not damage
your skin. However, please take protective measures before use to reduce risks.
○1 Apply protective cream on both hands before overhauling the outboard motor;
○2 Replace and clean the clothes as soon as possible after they are contaminated by the
lubricant;
○3 Avoid skin contact;
○4 Wash your hands and skin carefully with soap and hot water after contact with the
lubricant;
○5 Wipe the spilled grease with a clean, lint-free rag.
5. Develop good work habits
○1 Tighten nuts, bolts and screws according to the specified torque from large size to
small size, from the center to the outside.
○2 Use recommended special tools to avoid damage to parts. Use the right tools in the
proper way.

Disassembly and assembly

When disassembling 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 before decomposing the parts;
3. Apply engine oil on the contact surface of moving parts before assembly;
4. When installing the bearing, place the manufacturer's mark in the specified direction and
fully lubricate it;
5. Before installation, coat a thin layer of waterproof lubricating oil on the protruding part
and periphery of the oil seal;
6. After assembly, check whether the moving parts work normally.
7.
Disposable parts
Parts such as gasket, oil seal, O-ring, cotter pin and spring ring are disposable parts, and they
must be replaced before reinstalling the outboard motor.

Pre-delivery inspection
To ensure the normal use by customers, please carry out the following inspection before
delivery.
1. Check the fuel system.
Check whether the fuel hose is securely connected and whether the fuel tank is full.
Note:
As it is a four-stroke engine, premixed fuel cannot be used.

2. Check the oil level.

3.
○
1 Check engine oil level.

Pull out the oil dipstick and observe the oil level through the dipstick.

3
 3

1
2

1. Oil dipstick 2. High mark 3. Low mark

Make sure the oil level is between the high mark and the low mark; Drain oil when the
oil level is above the high mark and add oil when the oil level is below the low mark.
○2 Check gear oil level
Unscrew the oil level plug and observe whether the oil overflows in the oil level plug.
If yes, install the oil level plug and tighten it according to the specified torque; If not, fill
it with oil.

1.
2 Oil level plug
3. Check the steering system. 2
Check whether the steering is smooth;
Check whether the steering friction is adjusted correctly.
Turn the locking bolt clockwise to increase the resistance.
Turn the locking bolt counterclockwise to reduce the resistance.

4. Check shift and throttle operation.

Check whether the shift operation 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 the emergency stop switch assembly is pressed
and hold or the engine stop safety line is pulled out.

6. Check the cooling water peep door.

When the engine is running, check whether the cooling water flows out of the cooling
water observation hole.

1. Cooling water observation hole

1

7. Running-in operation.
○1 1st hour: The engine runs at 2000 rpm or about half of the throttle.
②2nd hour: Run the engine at 3000 rpm or about 3/4 of the throttle.
③The next 8 hours: Avoid running at full throttle for 5 minutes continuously.
8. Inspection after running-in operation
○1 Check the gear oil for water.
②Check the fuel line for leaks.
③After running-in operation, run the engine at idle speed and use the washing tool to
flush the cooling water channel with fresh water.

4
 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 Needle bearing

unit housing cover installation tool

Underwater unit Underwater unit

housing cover bearing housing cover oil
installation tool seal installation tool

Underwater unit needle Drive shaft bearing

bearing installation tool jacket installation tool

Drive shaft bearing Drive shaft seal oil Forward gear bearing
installation tool seal installation kit casing installation kit

5
Drive shaft spline sleeve pinion nut spanner

Testing equipment:

Digital tachometer Digital multimeter Peak voltage adapter

6
 Disassembly schematic diagram and symbol description
Description of disassembly schematic diagram
①

18 Nm
③

49 Nm
M10x1.5x105 mm
1st 16 Nm
2nd 42 Nm

M8x55 mm
1st 14 Nm
2nd 28 Nm

①Exploded view of parts.

②Thread specification and specified torque.
③Points where oil, sealant or locking agent are applied
④Parts list.

Symbol description

O G L GM
1277
Apply waterproof Apply thread Apply thread locker
Apply engine oil Apply sealant
grease locker 1277 1243

7
 Specification
Outboard motor parameters
Item Data Item Data

Ignition
Full length 833 mm TCI
system
Overall width 517 mm
Spark plug LKR6E
L-type 1672 mm
Overall Engine
Overall
dimensions height Exhaust
X-type 1799 mm Through the propeller hub
system
Lubrication
Stem L-type 510 mm Purging-type oil mist lubrication
system
board
Height X-type 637 mm Fuel type Regular unleaded petrol

L-type 175kg Fuel grade PON86

Weight
Recommended API: SE, SF, SG,SH, SJ
X-type 179kg
engine oil grade SAE: 10W30, 10W40

Total 3.8L
Fuel
and oil Do not change the
3.0L
Maximum output 85Kw@5600r/min Engine oil level oil filter
Change the oil
3.2L
filter
Performance Full throttle Recommended
5300～6300 r/min Hypoid gear oil SAE﹟90
operating range gear oil
Maximum fuel 38.9L/h@5600 Forward-rotating 0.760L
Gear oil level
consumption r/min Backward-rotating 0.715L
Idle (neutral
800～900r/min
position) Inclined rising
70
4-stroke, DOHC angle (degree)
Type Bracket
L4, 16 valves
Number of Steering angle
4 35+35
cylinders (degree)
Displacement 1832cm³ Gear F-N-R
Cylinder bore × Transmission
81.0mm×88.9mm 2.15
stroke ratio
Compression
10:1 Gear type Spiral bevel gear
ratio
Minimum
Engine compression 945kPa Clutch type Claw clutch
pressure
Drive
Propeller shaft
Device Spline
Lubricating oil 440kPa (at idle type
pressure speed) Clockwise (rear
Forward-rotating
view)
Propeller
Remote
direction Counterclockwise
Control system control/steering Backward-rotating
(rear view)
handle

Start-up system Electric starting

8
 Maintenance information
Engine

Item Data Item Data

Cylinder cover Warping limit 0.1mm Valve Edge Intake valve 0.8~1.2mm
thickness
Inner diameter of 25.000~25.021m Exhaust 1.0~1.4mm
camshaft m valve
Camshaft oil clearance 0.020~0.061mm Stem Intake valve 5.475~5.490mm
diameter
Oil clearance limit 0.080mm Exhaust 5.460~5.475mm
valve
Cylinder block Cylinder bore 81.00~81.012mm Inner 5.504~5.522 mm
diameter
of valve
guide
Wear limit 81.061mm Clearance Intake valve 0.014~0.047mm
between
Piston Diameter of piston 80.938~80.950m Exhaust 0.029~0.062mm
guide and
m valve
valve stem
Height of measuring 14mm Valve stem runout limit 0.01mm
point
Piston to cylinder 0.050~0.074mm Valve Free length 41.2mm
clearance spring
Piston pin bore 18.004~18.015 Minimum free length 39.14mm
aperture
Outside diameter of piston pin 17.991~18.000m Tilt limit 1.8mm
m
Piston Top ring Thickness 1.170~1.190mm Connectin Inner diameter of small end 18.005~18.018m
ring g rod m
End face width 2.4~2.6mm Inner diameter of large end 50.025~50.045m
m
End gap 0.15~0.30mm Oil clearance of large end 0.017~0.040mm

Lateral clearance 0.04~0.08mm Thickness A Blue 1.499~1.504mm

of big-end
Second Thickness 1.170~1.190mm B Green 1.504~1.510mm
bearing
ring
bush
End face width 2.60~2.80mm C Red 1.510~1.516mm

End gap 0.7~0.9mm Crankshaf Diameter of crankshaft 51.982~52.000m

t journal m
Lateral clearance 0.03~0.07mm Crank pin diameter 46.982~47.000m
m
Oil ring Thickness 2.380~2.480mm Crank pin width 21.00~21.1mm

End face width 2.40mm Large end backlash of 0.15~0.30mm

crankshaft
End gap 0.20~0.70mm Thermosta Open temperature 58~62ºC
t
Lateral clearance 0.03~0.15mm Full open temperature 70ºC

9
Camshaf Height Intake cam 41.011~41.111m Valve opening height 4.3mm
t m
Exhaust cam 41.27~41.37mm Fuel pump Displacement 1832L

Diameter of base circle 32.950～ Pressure 196kPa

33.050mm
Journal diameter 24.96~24.98mm Crankcase Crankshaft journal oil 0.014~0.050mm
clearance
Runout limit 0.03mm Thickness A Blue 2.492~2.497mm
of
Oil Clearance between outer rotor and 0.03~0.12mm B Green 2.497~2.503mm
crankshaft
pump shell
main
Clearance between outer rotor and 0.12~0.16mm journal C Red 2.503~2.509mm
inner rotor bearing
bush
Clearance between rotor and cover 0.03~0.12mm

Valve Valve Intake valve 0.17~0.24mm

clearance
(Cold-state Exhaust valve 0.31~0.38mm
)
Contact Intake valve 1.1~1.5mm
width with
Exhaust valve
seat ring

Underwater unit
Item Data Item Data
Drive gear Forward-rotating 0.15~0.87mm Forward 0.10, 0.12, 0.15, 0.18, 0.30,
to forward
Backward-rotating 0.13~0.87mm gear shim 0.40, 0.50mm
gear
Drive gear Forward-rotating 0.74~1.56mm
Backlash Backlash Reverse 0.10, 0.12, 0.15, 0.18, 0.30,
to reverse
Backward-rotating 0.75~1.56mm gear shim 0.40, 0.50mm
gear
0.10,0.12,0.15,
Drive gear shim
0.18, 0.30, 0.40, 0.50mm

10
 Electrical system
Item Data Item Data

Trigger coil resistance* 290±20% Ω

Spark plug clearance 0.8~0.9mm Secondary output

≥34KV
voltage
Ignition coil Primary resistance 2.2±0.22Ω

Secondary resistance 9.84±0.98KΩ

1500 r/min
14.5V
Output (Load)
voltage of
rectifier 1500 r/min (no-load) 53V
regulator
3500 r/min Peak output voltage of
14.5V
(Load) magneto
3500 r/min (no-load) 115V

Magneto resistance
0.2Ω～0.3Ω
(green-green)
Peak voltage of trigger coil 1000 r/min ≥13V
* Data for reference only

11
 Seating torque
Specified torque
Mounting position Name Specification Quantity Torque
M10X1.25X140 4 42 Nm
Fixed engine Bolt M10X1.25X45 2 42 Nm
M8X35 4 20 Nm
Upper shock absorber Bolt M14X195 2 74 Nm
Intake manifold bracket Bolt M8X35 2 24 Nm
Intake manifold Bolt M8X35 9 32 Nm
Spark plug - M12X1.25 4 25 Nm
Coil-on-plug Bolt M6X25 4 7 Nm
Driven pulley Bolt M10X1.25X35 2 60 Nm
Timing belt tensioner
Bolt M10X1.25 1 39 Nm
assembly
Oil filter stud - M20 1 49 Nm
Oil filter - M20 1 18 Nm
Oil pressure sensor - M10 1 9 Nm
1st 16 Nm
Bolt M10X1.5X105 10
Container 2nd 42 Nm
body 1st 14 Nm
Bolt M8X55 10
2nd 28 Nm
Connecting 1st 13 Nm
Bolt M8X1X36 8
Engine rod 2nd 35 Nm
1st 15 Nm
Cylinder
2nd Bolt M10X1.5X110 10 30 Nm
head
3rd 80 Nm
Camshaft 1st 6 Nm
Bolt M7X48 4
cover A 2nd 13 Nm
Camshaft 1st 6 Nm
Bolt M7X37 16
cover B 2nd 13 Nm
1st 50 Nm
Flywheel Bolt M10X1X50 6
2nd 105 Nm
Exhaust pipe 1st 14 Nm
Bolt M8X70 4
A 2nd 21 Nm
1st 14 Nm
Bolt M8X70 2
Exhaust pipe 2nd 21 Nm
B 1st 14 Nm
Bolt M8X100 2
2nd 21 Nm
Temperature sensor Bolt M14X1.5 1 23 Nm
Knock sensor Bolt M8 1 18 Nm
Limber board Bolt M6X25 9 12 Nm
Motor bracket Bolt M8X30 3 25 Nm
Start motor Bolt M8X45 3 33 Nm

12
 Mounting position Name Specification Quantity Torque
Drive bearing house Bolt M8x25 4 18 Nm
Cover nut - M102x2 1 103Nm
Underwa
Pinion Nut M16X1.5 90 Nm
ter unit
Propeller nut Nut M18X1.5 1 55 Nm
Course tab Bolt M10X1.25X45 1 42 Nm
About Upper shock absorber Nut M14 2 74 Nm
water Lower shock absorber Nut M14 2 74 Nm
Oil pan exhaust manifold Bolt M10X1.25X45 6 42 Nm
Clamp bracket double
Nut 7/8-14UNF 2 22 Nm
nipples
Oil drain bolt Bolt M14X1.5 1 27 Nm
Coarse filter Bolt M6X24 3 12 Nm
Double-en 2
M10X1.25X28 20 Nm
Steering bracket d bolt
Nut M10X1.25X28 2 40 Nm

Average torque
Nut a Bolt b Torque
8mm M5 5 Nm
10mm M6 8 Nm
12mm M8 18 Nm
14mm M10 36 Nm
17mm M12 43 Nm

13
 Overall dimensions
X-type:

X-type two-engine:

14
L-type:

15
L-type two-engine:

16
Mounting dimensions:
17
18
 Basic maintenance
Maintenance Interval Chart
The outboard motor should be maintained regularly, operated in normal environment and
maintained correctly, which can effectively prolong the service life of the outboard motor.
The following table gives the general principles of the maintenance intervals, which can be
adjusted according to the operating conditions.
“”refers to the work that can be done by the user.
“”refers to the work that should be done by the distributor.
Initial Interval
20 hours
Item Operation 100 hours 300 hours 500 hours
(3
(1 year) (3 years) (5 years)
months)
Anode (external) Check/replace /
Anode (internal)* Check/replace 
Anode (internal)** Replace 
Battery (electrolyte,
Check / /
terminal)
Cooling water channel Clean  
Top cover clamp handle Check /
Engine startup Check / /
Engine idle speed Check / /
Engine noise Check / /
Engine oil Replace / /
Oil filter Replace /
Fuel filter (decomposable) Check/clean/replace / /
Fuel line Check  
Fuel line Replace  
Fuel pump Check/replace 
Fuel/oil leakage Check 
Gear oil Replace / /
Lubricating oil refueling
Add lubricating oil / /
point
Water pump Check 
Water pump impeller/inner
Replace 
shell
Hydraulic warping device Check / /
Propeller/slotted nut/cotter
Check/replace / /
pin
Overflow valve Check/replace 
Shift linkage/shift cable Check/adjust  
Thermostat Check 
Spark plug cap/high-tension
Check/replace  
cable
Spark plug Clean/adjust/replace /
Throttle linkage/throttle
Check/adjust/replace 
cable
Cooling water observation
Check / /
hole
Cooling water inlet Check / /
19
 Main switch/engine stop
Check/replace  
switch
Timing belt Check/replace 
Valve clearance Check/adjust 
Electrical circuit Check/replace  
Ignition coils and wire Check/replace  
Note:
*Cylinder head anode; **Anode at engine body, cooling water channel, exhaust pipe
and exhaust manifold.
Flush the outboard motor with fresh water immediately after running in salt water,
sewage or muddy water.
If leaded gasoline is used frequently, check the 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 and fuel pipe.
Check the fuel pump and fuel pipe for leakage or damage, and replace them if necessary.

2. Check the fuel filter.

Check whether the fuel filter is cracked or damaged, and check whether there is dirt in
the fuel filter.
If yes, replace the fuel filter.

Note:
Wipe off the spilled fuel.

Engine
Engine oil level
1. Remove the oil dipstick and check whether the oil level is between the upper and
lower marks of the oil dipstick;

20
 2
3
1

1. Oil dipstick 2. High mark 3. Low mark

2. If the oil level is above the high mark, discharge the engine oil; If the oil level is
below the low mark, add engine oil.
Note:
Run and then turn off the engine, and let it stand for several minutes; Check the oil level
with the oil dipstick again.
If the oil level is not within the specified range, add/discharge the oil to the specified
value.
Change engine oil
1. Remove the oil cap, oil drain bolt and bolt gasket; Discharge the oil.

2. Install new bolt gasket and install oil drain bolt.

3. Add engine oil through the oil port.
Engine oil level: 3.0 L (oil filter 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 fill the engine oil.
Otherwise, the engine will be severely damaged.

Spark plug
1. Remove the spark plug cap and then remove the spark plug.

2. Remove carbon deposits from the spark plug electrodes.

3. Check whether the electrodes are corroded, whether there are deposits and whether the
gaskets are damaged. If necessary, change the spark plug.
Spark plug model: NGK LKR6E
4. Check whether the electrode gap meets the specified value; If necessary, replace the
spark plug.

0.8-0.9mm

5. Install the spark plug and tighten it with the spark plug wrench according to the specified
torque.
Specified torque: 25 Nm

21
 Control system
Throttle push-pull cable
1. Please put the shift lever to the neutral position for the front operating model.

2. Check the contact between the throttle actuator driving pulley and the box. If there is no
contact between the throttle actuator and the box, adjust the screw-in length of the
control cable joint.

1
2
1. Box; 2. Throttle actuator driving pulley.
3. Remove the cotter pin, remove the push-pull cable joint, and loose the lock nut of the
push-pull cable joint.
2 3
1

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
throttle actuator driving pulley.
Note:
The push-pull cable joint must be screwed in more than 8 mm.

5.Mount the cotter pin and tighten the lock nut.

Shift operation
1. Check whether the shift operation is smooth;

2. Please put the shift lever to the neutral position.

3. Observe that the mark on the shift slider of the swing rod is aligned with the mark on the
microswitch.

1
2
1.Throttle swing rod seat； 2. Mark.

22
 4. If the shift slider is not aligned with the mark on the microswitch, adjust the screw-in
depth of the push-pull cable joint. (Refer to the adjustment mode of throttle push-pull
cable joint)

Underwater unit
Gear oil
Check the amount of gear oil:
Remove the oil level plug screw, if there is gear oil overflow, the oil amount is correct; If
there is no overflow of gear oil, add gear oil.

1. Oil level plug screw

Replace gear oil

1. Position the outboard motor vertically.

2. Place a container with sufficient capacity under the outboard motor.

3. Remove the oil drain screw, and then remove the oil level plug screw; Drain gear oil.

1
2

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 hole, install the oil level plug screw.

6. Install the oil drain screw; Wipe off the spilled gear oil.
Note:
Check the discharged gear oil. If the gear oil is emulsified, check the seal and replace the
oil seal if necessary; If the gear oil contains metal debris, check the gears and bearings.
Note:
A new drain plug gasket must be replaced every time.

Air tightness inspection of underwater unit

Connect the leak detection device to the oil level plug hole to detect the air tightness of the
underwater unit. If the pressure drops (the pressure is 0.69kg/cm3], check the oil seal and
other components.

23
 General maintenance
Anode
Check the anode of underwater unit and the anode of the engine (mounted on the thermostat
cover); Remove oil stains and scale; If damage or corrosion exceeds 1/2, replace the anode.
Note:
Do not oil or paint the anode to avoid anode failure.

Lubricating point
1. Fill or apply waterproof grease with an 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 of cooling water channel

2. Place the outboard motor in water, ensure that the water level is above the anti-swirl baffle,
and start the engine.

3. Check whether there is water flowing out of the cooling water observation hole. If there
is no water flow or the water flow is interrupted, check the cooling water channel in the

24
 outboard motor.

1. Cooling water observation hole

Thermostat
1. Remove thermostat cover and then remove thermostat.

2
1

1. Thermostat cover 2. Thermostat

2. Hang the thermostat in a container containing water.

3. Heat the container.

4. Check the opening of thermostat valve at the specified water temperature; If it does not
meet the specifications, replace it.
Water temperature Valve opening height
Below 58℃ Do not open
Above 70℃ Greater than 4.3mm

5. Install thermostat and 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 switch

1. Check if the engine starts when the startup switch is turned to start (START). If it cannot
start, check the startup switch.

2. When the startup switch is turned off (OFF), check if the engine stops. If the engine does
not stop, please check the startup switch.

1. Close 2. Open 3. Start

25
 3. When the engine stop safety line is removed from the emergency stop switch,
check if the engine stops. If the engine does not stop,
please check the emergency stop switch.

Change the oil filter

1. Drain the engine oil, see "Change engine oil".

2. Remove the oil filter with special tools; And clean up the spilled oil.

2
1
1. Oil filter 2. Oil filter spanner

3. Install 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 for 5-10 minutes.

6. Turn off the engine and stop the fuel for 5-10 minutes.

7. Check the oil level.

Check the top cover

1. Push the top cover with both hands to check if the top cover is mounted tightly. If it is loose, please
adjust it.

﹣
2
1

2. Loosen the lock nut "2".

3. Move the pulley "1" up or down slightly and adjust it to the appropriate position.
Note:
26
 Move it up in the direction of "a" to loosen the locking device;
Move it down in the direction of “b" to tighten the locking device;

4. Tighten the 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 to "Engine-Check valve clearance". If the
specified value is not met, adjust the valve clearance with reference to “Engine-Adjust valve
clearance".

27
 Electrical system
Matters needing attention
When monitoring and repairing the ignition system, be careful not to put your hands, clothes,
hair or accessories close to the running flywheel.
Check the ignition coil on the insulated workbench to prevent 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 flywheel to avoid cutting off
the wires or wearing the insulation of the wires.
When replacing fasteners (nuts, bolts), please use the parts provided by the manufacturer or
of the same material and strength, and tighten according to the specified torque.

28
Disassembly schematic diagram

29
30
31
32
33
34
 R
29 Y Lg
R R B
G Lg
P Sb Sb
Y/B R
P/W Sb
9 P/B 21
R/W Lg
B 6 27
B
Gr Gr
8 G
Sb O/B GG G
Sb B
10 G/B B Lg 25
Y B 13 Lg
O B 26
15 O/B B
1 R
L R B
B
2 Br
30
4# 1# B B 22 Sb
Gr B 23
4 1
3 2 R
3# 2# L 31 GG G B
L R R R B B
B 7
O 12
28 L
1# B R R B 11
Gr/B
3 R Sb
Lg W SB
2# Br L
L/B Y
R 24 Y
R R
3# G 止位槽
O/B B P B
R W G Br
4# R L
B
Lg P
P/B
R W
B B
L
16 R 20 Fuse box
R 8 Oil pressure sensor
Lg R 4 21 Pulser coil
14 Sb 9 Multi-function gauge connector
Y R 22 Start relay
Gr Lg 10 Water temperaturesensor
23 Start motor
Pu
17 W R 11 10-pin plug
B R 5 24 Battery
Gr 12 Rectifier
R 25 Power trim&tilt relay
18 R Sb 13 Electric fuel pump
G/B 26 Power trim&tilt motor
Y Lg 1 Spark plug 14 Intake temperature/
19 27 Power trim&tilt switch (Bottom)
Br R 2 Ignition coil pressure sensor
28 Knock sensor
R 3 Fuel injector coil 15 Throttle position sensor
R 29 Power trim&tilt switch (Remote)
B 4 Fuel pump relay 16 EFI diagnostic connector
20 R 30 Water detector switch
R 5 Main relay 17 Oxygen sensor back-up connector 31 Shifting gear switch
Y
R 6 Lighting coil 18 Canister solenoid valve
R
R 19 Stepper motor
R 7 E.C.U.unit
B: Black Br: Brown B/R: Black/Red Y/B:Yellow/Black
Power tilt&trim switch state table G: Green Gr: Grey O/B: Orange/Black Y/G:Yellow/Green
L: Blue Pu: Purple G/B: Green/Black Y/R: Yellow/Red
Sb R Lg O: Orange Lg: Pale green L/B: Blue/Black
UP P: Pink Br/L: Brown/Blue P/B: Pink/Black
R: Red Gr/B: Grey/Black P/W: Pink/White
停止
W: White B/W: Black/White L/W: Blue/White
DOWN Y: Yellow G/W: Green/White R/W: Red/White
 1
Start switch state table

R Y Br

OFF

ON
Lg R Sb 1 P.T.T. switch
启动

2 Main switch
Power trim&tilt switch state table
3 Engine stop switch
Sb R Lg
4 Buzzer
UP
5 Neutral switch
FREE

DOWN
6 10 Pin connector plug
2 5 7 Multi-function device
R
Y
Br
R : Red
3
P : Pink
W
B : Black
B
G : Green
4
P W : White
L : Blue
Y
Y : Yellow
Lg: Light green
6
Sb: Sky blue
Y Br: Brown
P
B
W
L
R Lg
Sb B B
4 Br Y Y
G G G

7
5
Y/B
P/W
P/B
 Spark plug ignition
1. Remove the spark plug cap from the spark plug.

1 2
1. Spark plug cap; 2. Spark plug

2. Connect the ignition detector to the spark plug cap.

3. Start the engine and observe the spark through the discharge window of the detector.
Warning:
Do not touch any connection part of the detector lead.
Keep away from combustible gases or liquids to avoid accidents caused by sparks.

Spark plug cap

1. Remove the spark plug cap. Check the spark plug cap for damage. Replace it if
necessary.

2. Install the spark plug cap.

Flywheel maintenance
1. Remove the bolts and nuts fixing the flywheel and remove the flywheel.

2. Check 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 of the ignition coil. If the specified value is not met, replace it.
Primary resistance: 2.2±0.22Ω
Secondary resistance 9.84±0.98kΩ

Trigger coil detection

1. Peak voltage of trigger coil
Use digital multimeter and peak voltage adapter to measure the peak output voltage of
the coil. If it is lower than the specified value, check the trigger coil resistance.

Digital multimeter peak voltage adapter

Peak voltage of pulse coil: ≥13 V@1000 r/min (load)

2. Trigger coil resistance

Measure coil resistance. If the specified value is not met, replace it.
Resistance: 260 ～ 290Ω (detector positive pole is connected with red/white wire,

37
negative pole with black wire)
Note: The data are for reference only.

Check engine startup switch

Check the conductivity of the engine startup switch. If it is not conductive, replace it.
Note: See wiring diagram for startup switch status,

Check engine stop switch

Check the conductivity of the engine stop switch. If it is not conductive, replace it.
Remove the locking plate: Conducting
Install locking plate: Non-conducting
Press the button: Conducting
Detection of starting relay
1. Connect the brown lead to the positive electrode of the battery.

2. Connect the black lead to the negative electrode of the battery.

3. Check the conductivity between relay terminals. If it is not conductive, replace the relay.

4. Disconnect the lead connection with the battery and 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 and peak voltage adapter to measure the peak output voltage of
the coil. If it is lower than the specified value, replace the magneto coil.
Peak 1500 r/min (no-load) 53V
voltage
of
magnet 3500 r/min (no-load) 115V
o coil

Detection of rectifier regulator

Measure the peak voltage (DC) of the rectifier regulator.
Open the rectifier output (red wire and black wire) and use a digital multimeter to measure
the voltage between the red wire and black wire at the rectifier regulator output.
If it is lower than the specified value, check the peak output voltage of magneto coil. If the
peak output voltage of magneto coil is higher than the specified value, replace the rectifier
regulator.
Peak 1500 r/min (load) 14.5V
voltage
of
rectifier
regulator 3500 r/min (load) 14.5V

38
 Use fault diagnosis tester
When the engine is running, if the fault indicator or service indicator on the handle or multifunction
tester is always on/buzzer is always on, it indicates that there is a fault in the engine. At this time,
connect the fault diagnosis tester with the corresponding detection port on the engine, and display the
running parameters and fault codes of the engine on the mobile phone through the APP. Then check
the fault code table to determine the engine fault and replace the faulty electrical components.

Service indicator Fault indicator

Fault code table

Fault type Fault item Code
Short circuit to ground or open circuit of
107
intake pressure sensor line
Intake pressure fault
Short circuit to high level of intake pressure
108
sensor line
Short circuit to high level of intake
112
Intake temperature temperature sensor line
fault Short circuit to ground or open circuit of
113
intake temperature sensor line
Short circuit to ground of coolant temperature
117
Water temperature sensor line
fault Short circuit to high level of coolant
118
temperature sensor
Short circuit to ground of throttle position
122
sensor
Throttle fault
Short circuit to high level of throttle position
123
sensor
Short circuit to ground of oxygen sensor 131
Oxygen sensor fault
Short circuit to high level of oxygen sensor 132
Oxygen sensor
Oxygen heater fault 135
heating fault
Cylinder 1 nozzle line fault 201
Cylinder 2 nozzle line fault 202
Fuel injector fault
Cylinder 3 nozzle line fault 203
Cylinder 4 nozzle line fault 204
Fuel pump fault Oil pump relay fault 230
Signal interference of crankshaft position
Crankshaft position sensor line 336
sensor fault
No signal of crankshaft position sensor line 337
Cylinder 1/4 ignition coil fault 351
Ignition coil fault
Cylinder 2/3 ignition coil fault 352

39
 Excessive idle speed fault 507
Idle fault
Low idle speed fault 506
Low system voltage 562
System voltage fault
High system voltage 563

Continued：
Fault type Fault item Code
Fault indicator Fault indicator fault 650
Short circuit to ground of oil pressure sensor
523
line
Oil pressure fault
Short circuit to high level of oil pressure
522
sensor
Carbon canister
Short circuit to ground of carbon canister
solenoid valve 443
solenoid valve
fault
Main relay fault Main relay fault 685
Water detection
Water detection switch fault 534
switch fault
Knock sensor
Knock sensor fault 327
fault
Knock system
Knock system fault 325
fault

40
 Fuel system
Matters needing attention
Fuel oil is a highly flammable and 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 steps, apply pressure to the fuel system for a short time to check for
leakage.

41
Disassembly schematic diagram

42
43
44
45
46
`

47
 M4x12 mm
2 Nm

M5x12 mm M4x12 mm
3.5 Nm 2 Nm

M4x16mm
2 Nm

M4x8 mm
2 Nm

M4x8 mm
2 Nm

M5x12 mm
4 Nm

2 Nm

48
49
 Reduce fuel pressure
Warning:
Make sure to reduce the fuel pressure in the fuel line before maintaining the fuel line or
high-pressure fuel pump. Otherwise, high-pressure fuel will be sprayed out, causing injury or
accident.
1. Disconnect the joint of oil pump power supply connection line.

2. Start the engine.

Note:
Run at idle speed until the engine is cut off.

3. After the engine is turned off, turn the flywheel to rotate the crankshaft 2 or 3 times.
Warning:
Do not turn the flywheel counterclockwise to avoid damage to the valve mechanism.

4. Turn the outboard motor startup switch to OFF.

5. Connect the joint of 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 water detection switch.

2. Disconnect fuel line.

3. Remove the nuts securing fuel filter assembly.

4. Remove the oil filter cup.

5. Remove oil filter cup holder.

6. Use a vacuum manometer to check whether the oil filter cup leaks.
Specified pressure: 80kPa

7. Check whether the filter screen is blocked or there are sundries in it, and check whether the
filter cup is damaged or leaked.
Note:
If necessary, clean it with gasoline or replace it

8. Re-mount the oil filter cup

Note:
Before reassembling the filter cup, apply engine oil to the O-ring.

Removal and inspection of fuel pump

1. Remove the bolts securing the fuel pump.

50
 2. Remove the fuel pump.

3. Connect a vacuum manometer to the fuel pump inlet.

4. Plug the outlet of the oil pump and apply the specified positive pressure. Check for air
leakage.
Specified pressure: 50kPa

5. Apply a specified negative pressure. Check for air leakage.

Specified pressure: 30kPa

6. Connect a vacuum manometer to the fuel pump outlet.

7. Apply a specified negative pressure. Check for air leakage. If necessary, disassemble the oil
pump and check it.
Specified pressure: 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 fuel filter.

3. Plug the outlet of the fuel filter and apply the specified positive pressure. Check for air
leakage.
Specified pressure: 200kPa

Remove and check the fuel injector

1. Reduce fuel pressure

2. Wrap a rag around the quick connector to prevent fuel spraying.

3. Remove the quick connector from the common rail.

Note:
Cover the quick connector and fuel rail with a plastic bag to prevent damage and protect them
from dust.

4. Disconnect the joint of the fuel injector.

51
 5. Remove the fuel injector and the common rail.

6. Check the fuel common rail. If there is crack or deformation, please replace it.

7. Check the electrical characteristics of the fuel injector.

8. Re-mount the common rail and fuel injector.

Check throttle body

1. Check the exterior of the throttle body. If there is crack, please replace it.

2. Turn the throttle valve manually and check its smooth movement.

3. Check the electrical characteristics of the throttle position sensor.

Check the intake manifold

1. Check the intake manifold. If there is crack or deformation, please replace it.

2. Check the exterior of the intake manifold 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 the carbon canister and carbon canister solenoid

valve
1. Disconnect the line to the carbon canister.

2. Disconnect the power connector of the canister solenoid valve.

3. Remove the canister solenoid valve.

4. Remove the carbon canister and the bracket.

5. Remove the bracket from the carbon canister.

6. Check the carbon canister. If there are cracks, please replace it.

7. Connect a vacuum gauge to the atmospheric communication port and block the two ports on
the other side.

8. Apply the specified positive pressure and check for air leakage. If there is leakage, please
replace the carbon canister.
Specified pressure: 19.6kPa

52
 9. Check the exterior of the carbon canister solenoid valve. If there is crack, please replace it.

10. Check the functional characteristics of the carbon canister solenoid valve.

11. Assemble the carbon canister and carbon canister solenoid valve in reverse order according
to the disassembly sequence.

Disassemble and check the electric fuel pump

Cover the fuel parts with a rag to prevent the fuel from overflowing.
1. Release the pressure in the fuel line.

2. Loosen the oil drain screw of the oil cup and drain the fuel in the electric fuel pump through
the oil drain hose.

3. Disconnect the fuel line connected to the electric fuel pump, and disconnect the cooling
water pipe and power cable connector.
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 pump return pipe and oil pump tee.

6. Remove the pressure valve switch and the pressure valve.

7. Remove the cooler cover.

8. Remove the panel.

9. Remove the electric fuel pump body assembly.

10. Disconnect the oil pump connection line and remove the oil pump assembly.

11. Remove the screws fixing the float pin, remove the float pin and float.

12. Remove the screws fixing the needle valve assembly and remove the needle valve
assembly.

13. Check the electrical characteristics of the high-pressure fuel pump. See section "Check the
high-pressure fuel pump" (5-24).

14. Check the needle valve. If it is bent or worn, replace the needle valve assembly.

15. Check the float. If it is damaged or corroded, please replace it.

53
 16. Check the screen filter on the rubber pad of the oil pump. If there is fuel colloid or other
residues, please clean them.

17. Mount the float and invert the electric fuel pump body, and measure the float height.
Note:
When measuring the height of the float, the float should be placed on the needle valve. Do
not pressurize 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 the
previous marks.

Engine
Matters needing attention
In order to avoid accidental start during engine maintenance, please take adequate
protective measures to disconnect the ignition system. For example, remove the engine stop safety
line from the emergency stop switch assembly, remove the spark plug cap from the spark plug.

54
 Disassembly schematic diagram

硅胶

55
56
 M10x1.5x35 mm
60 Nm

39 Nm
M10x1.5x35 mm
60 Nm
O

57
58
 GM

18 Nm

49 Nm
M10x1.5x105 mm
1st 16 Nm
2nd 42 Nm

M8x55 mm
1st 14 Nm
2nd 28 Nm

59
60
 O

O O

M8x1x36 mm
1st 13 Nm
2nd 35 Nm

61
62
O

63
64
65
66
 Special tool

Piston slideway Flywheel gripper and flywheel puller Clearance gauge

Oil filter spanner

Check the compression pressure

1．Start the outboard motor, warm it up at idle speed for 5 minutes, and then turn it off.

2．Remove the spark plug and connect the pressure gauge to the spark plug hole.
Note:
Before removing the spark plug, clean the pit where the spark plug is installed with
compressed air to prevent dust or other sundries from entering the cylinder.

3．Fully open the throttle, turn the crankshaft (start), and check the cylinder pressure when
the reading on the pressure gauge is stable.
Note:
When checking cylinder pressure, do not change throttle opening.

4．If 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
Note:
If the cylinder pressure continues to increase, check whether the piston and piston ring
are damaged. Replace it if necessary.
If cylinder pressure does not increase, check valve clearance, valve, valve seat, cylinder
liner, cylinder head and cylinder head seal ring. Adjust or replace them if necessary.

Check oil pressure

1. Start the engine, warm it up for 5 minutes, and then shut it down.
2. Remove the oil pressure sensor and connect the pressure gauge.
Note:
Use a pressure gauge with 1/8 pitch thread adapter.
3. Test oil pressure
Oil pressure (reference data): 440kpa (at idle speed)
660kpa（@3000 r/min）
Note:
The actual oil pressure varies according to temperature and oil viscosity.

67
 Check valve clearance
Please measure the valve clearance when the engine is cold.
Note:
Don't turn the flywheel counterclockwise. Otherwise, the valve mechanism will be damaged.
1. Remove the spark plug.

2. Turn the flywheel clockwise until the mark 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. Ignition indicator

3. Turn the timing belt tensioner with a hexagon wrench clockwise and insert a 5mm pin into
hole A
on the tensioner.
Note:
Turn the tensioner with a force less than 15Nm.

4. Remove the timing belt.

5. Remove the tensioner assembly.

Note:
Do not pull out the 5mm pin
68
 6. Remove the bolts that hold the driven pulley with the flywheel gripper and remove the
driven pulley.

7. Remove cylinder head cover.

8. Mount the driven pulley and fasten the pulley bolts with the flywheel gripper.

9. Screw the timing belt in the order of crankshaft end, driven pulley B ("EX”) and driven
pulley A ("IN" mark).
Note:
Do not apply oil or grease to the timing belt.
Ensure that the characters on the belt are mounted upwards

10. Tighten the timing belt and keep the belt and pulley in meshing.

11. Mount the belt tensioner assembly.

12. Align the swing arm hole 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 clockwise with a hexagon wrench and remove the 5mm pin
previously inserted from hole A.
Note:
Turn the tensioner with a force less than 15Nm.

15. Turn the timing belt tensioner gradually counterclockwise until the timing belt is in
tightened position.

16. Measure and record the clearance between the specified cylinder cam and the valve
tappet with a clearance gauge.
Valve clearance (cold state) Intake valve clearance 0.17~0.24 mm
Exhaust valve clearance 0.31~0.38 mm

17. Designated cylinder.

No.1 No.2 No.3 No.4
IN (intake) √ √ × ×
EX √ × √ ×
(exhaust)
x: Unmeasurable valve clearance

69
 √: Measurable valve clearance

18. Turn the flywheel clockwise until the mark on the flywheel is aligned with the indicator
mounted on the box, making sure that the “EX" and “IN” marks on the two driven pulleys
are opposite.

19. Measure and record the clearance between the specified cylinder cam and the valve
tappet with a clearance gauge.
No.1 No.2 No.3 No.4
IN (intake) × × √ √
EX (exhaust) × √ × √

x: Unmeasurable valve clearance

√: Measurable valve clearance

20. Remove the two driven pulleys according to the aforementioned method and steps.

21. Mount the cylinder head cover.

Note:
Use a new cylinder head cover sealing ring and apply silica gel as shown in the
exploded view.

22. Mount 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).
Note:
Do not apply oil or grease to the timing belt.
Ensure that the characters on the belt are mounted upwards

24. Tighten the timing belt and keep the belt and pulley in meshing.

25. Mount the belt tensioner assembly.

26. Align the swing arm hole of the tensioner in the tensioner assembly with the positioning
hole on the body, and insert the tensioner positioning pin.

27. Slightly tighten the tensioner bolts.

28. Turn the tensioner gradually clockwise with a hexagon wrench and remove the 5mm pin
previously inserted from hole A.
Note:
Turn the tensioner with a force less than 15Nm.

70
 A

29. Turn the timing belt tensioner gradually counterclockwise until the timing belt is in
tightened position.

30. Tighten the bolts of the tensioner at specified torque.

Specified torque: 39 Nm

31. Adjust the timing belt height so that it is located in the middle of the pulley.

32. When the mark on the flywheel is aligned with the indicator mounted on the box, make
sure that the " " marks on the two driven pulleys are opposite.

33. Turn flywheel 2 a circle clockwise and check that the " " mark on the driven pulley is
aligned.

34. Mount the spark plug and lock it at the specified torque.
Specified torque: 25 Nm

Adjust 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 clearance 0.31~0.38 mm
Note:
When the engine is cold, adjust the valve clearance.
Do not turn the flywheel magnet counterclockwise. Otherwise, the pump impeller will be
damaged.
The steps are as follows:
1. Remove cylinder head cover. Refer to steps 1-15 in the section "Check the valve
clearance".

2. Check the valve clearance. Refer to steps 16-19 in the section "Check the valve
clearance".

3. Remove the camshaft cover plate A&B, remove the camshaft; Remove the valve tappet of
the valve where the valve clearance does not conform to the regulations.

4. Measure the thickness a of the valve tappet shown in the figure below.

71
 5. Calculate the required thickness of the replaced valve tappet based on the formula.
Formula:
Required thickness of the valve tappet = a + measured valve clearance -specified valve
clearance

6. Load the selected valve tappet into the cylinder head, then mount the camshaft and
camshaft cap.

7. Mount the cylinder head cover with reference to steps 20-34 in the section "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 electrical parts and fuel system components with reference to the two
sections Electrical System and Fuel System.
5. Remove the housing of the water unit.

6. Remove the bolts connecting the engine and the water unit.

7. Lift the engine with a crane and remove the engine locating pin.

8. Remove the flywheel with special tools, remove the flywheel locating pin and keep it
well.

72
 Flywheel gripper and flywheel puller

9. Remove relevant parts according to the exploded view of the two sections Electrical
System and Fuel System.

10. Disconnect the control system with reference to the exploded view on page P85.

Pulley and timing belt

1. Remove the timing belt and driven pulley with reference to steps 1-4 in the section
"Check the valve clearance”.

2. Check pulley and timing belt for cracks, damage or wear. Replace it if necessary.

3. Check the tooth profile of crankshaft-end pulley for cracks, damage or wear. Replace it if
necessary

4. Mount the timing belt and driven pulley with reference to steps 22-33 in the section
"Check the valve clearance"

Disassembly and inspection

Cylinder cover
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 cover.

3. Remove the cylinder head bolts in reverse order according to the numerical symbols on
the cylinder head.

4. Remove the cylinder head.

5. Turn the driven pulley 90° counterclockwise with the flywheel gripper.

6. Remove the camshaft cover A&B.

Note:
Arrange the removed camshaft cover plates in sequence to avoid confusion during
installation.

7. Remove the valve tappet.

Note:
Arrange the removed valve tappet in sequence to avoid confusion during installation.

8. Remove the intake and exhaust valves using the valve spring compressor.

Check the valve tappet

Check the outer diameter and appearance of the valve tappet. Replace it if damaged,
scratched or worn.
Outer diameter of valve tappet: 27.965～27.375 mm

73
 Check the driven pulley
Check whether the driven pulley is deformed, cracked and worn; If yes, replace it.

Check the cylinder head bolts

Measure D1 and D2 at specified measuring points. Calculate the value of D2 minus D1. If it
is greater than 0.17mm, replace it.
D1 D2

68 mm 10 mm

Valve and valve guide

1. Check the width of valve sealing surface; If it is not within the prescribed scope, Trim
the valve seat ring.
Width of sealing surface:
Intake 1.10～1.50 mm
valve
Exhaust 1.10～1.50 mm
valve

2. Check the valve edge thickness T; Replace the valve if it does not meet the specified
value. T
Valve edge thickness:
Intake 0.8～1.2 mm
valve
Exhaust 1.0～1.4 mm
valve

3. Check valve stem diameter. If it is not within the prescribed scope, replace the valve.
Valve stem diameter:
Intake 5.475～5.490mm
valve
Exhaust 5.460～5.475mm
valve
Note:
When replacing the valve, be sure to use new valve guide and valve oil seal.

4. Check valve stem runout. If it is beyond the limit, replace the valve.
Valve stem runout limit: 0.01mm

5. Check the inner diameter of the valve guide.

Valve guide inner diameter: 5.504～5.522mm

6. Calculate the clearance between valve stem and valve guide hole. If it exceeds the
clearance range, please replace it
Intake 0.014～0.047mm
valve
Exhaust 0.029～0.062mm
valve
Valve spring
1. Check the free length of valve spring; Replace it if it is less than the specified value.
Minimum free length: 41.2 mm

74
 2. Check the inclination of the valve spring; Replace it if it is beyond the limit.
Inclination limit: 1.8 mm

Camshaft
1. Check the cam dimensions.
Replace the camshaft if necessary.
Intake cam
41.011~41.111 mm
height
Exhaust cam 41.260~41.360 mm
height 2. Check camshaft radial runout.
Replace it if necessary.
Runout limit: 0.03mm

3. Check camshaft bearing journal diameter and camshaft cover inner diameter. Replace it
if necessary.
Diameter of camshaft bearing journal: 24.960~24.980 mm
Inner diameter of camshaft cover: 25.000~25.021mm

Replace valve guide

1. Knock off the valve guide from the combustion chamber side.

2. Knock in the new valve guide from the top surface of the cylinder head.
Mounting height: 11.3～11.7 mm
Note:
Apply oil to the surface of the valve guide before installation.

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 counterclockwise when taking it out;
Make sure that metal debris generated by reaming is removed.

Check valve seat ring

1. Remove carbon deposit from the valve.

2. Coat a thin layer of dye evenly on the sealing surface of the valve seat ring.

3. Grind the valve on the valve seat with the valve grinding tool.

4. Measure the width of valve sealing surface.

Dye will stick to the valve sealing surface.
If the valve and valve seat ring fit incorrectly or the sealing surface width does not meet
the specified value, trim the valve seat.
If the contact surface is uneven, replace the valve guide.
Width of valve sealing surface: 1.1～1.5 mm

Trim the valve seat ring

75
 1. Trim the valve with a 45° valve seat ring cutter and adjust the width of the
sealing surface. Turn the cutter clockwise until the surface of the seat ring is smooth.

2. If the valve sealing surface is too wide and in the middle of the valve surface, trim
the top edge of the seat ring with a 30° cutter and trim the bottom edge of the seat
ring with a 60° cutter, and adjust the width of the sealing surface.

3. If the valve sealing surface is too narrow and at the top edge of the valve surface,
trim the top edge of the seat ring with a 30° cutter, and adjust the width of the
sealing surface with a 45 tool.

4. If the valve sealing 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 thin layer of abrasive evenly to the valve seat ring, and grind the valve with a
valve grinding tool.

6. Remove the residual abrasive.

7. Check the width of valve sealing surface again.

Note:
Do not excessively cut the valve, and turn the cutter evenly with a downward force of 40
~ 50N.
Do not stick the abrasive on the valve stem and valve guide.

Assemble and mount the cylinder head

1. Install a new valve oil seal and apply engine oil to the valve guide.

2. Install the valve, valve spring plate, valve spring and spring seat in sequence.

3. Compress the valve spring with the valve spring compressor and install the valve spring
retainer.

76
 4. Tap the valve spring seat with a plastic or rubber hammer to secure the retainer.

5. Install the valve tappet.

6. Install the camshaft and tighten the camshaft cover bolts at the specified torque and in
sequence.
Specified torque: First time 6 Nm
13 Nm for the second time
Tightening sequence: Cylinder No.1 position -Cylinder No.3 position-Cylinder No.4
position-Cylinder No.2 position-Driven pulley end position

7. Turn the driven pulley with the flywheel gripper, and align the “ " marks on the two
driven pulleys for next mounting steps.

8. Install cylinder head bolts and tighten them in the specified order and 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 shown in the exploded view.

10. Mount the driven pulley and tighten it at the specified torque.
Specified torque: 60 Nm

Crankcase
Disassembly
1. Remove the oil filter using a special tool.
Remove the filter bracket.
Note:
Place a cloth under the oil filter.

Oil filter spanner

2. Remove the exhaust pipe A&B.

3. Remove the thermostat cover and the limber board.

Clean the anode surface, inspect the anode, and replace the anode if the corrosion
exceeds half.
Check the exhaust cover for cracks, deformation or corrosion. Replace it if necessary.
4. Remove the box bolts and the engine base in the order shown in the figure.

77
 5. Remove the connecting rod bolts and connecting rod cover, remove the crankshaft, and
then remove the connecting rod and piston assembly.
6. Remove piston pin clamp spring with pliers, then remove the piston pin and piston.

7. Remove the oil seal, locating pin and bearing bush.

Piston
1. Measure the outside diameter of piston at the specified measuring point.
If it does not meet the specified value, replace it.
Diameter of piston: 80.938～80.950 mm a
Measuring point○a : 14 mm
D
2. Check the inner diameter of piston pin. If it does not meet the specified value, replace it.
Inner diameter of piston pin seat: 18.004～18.015mm

Cylinder bore
1. Measure the piston outer diameter at specified 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 measuring point: ○1 5 mm;
○2 35 mm;
①

D1&D2
○3 94 mm
②

Cylinder bore: 81.000～81.012 mm

③

D3&D4

D5&D6

2. Calculate the taper limit and roundness limit. If it exceeds the specified value, replace
the crankcase.
Taper limit: 0.08 mm (D1-D5, D2-D6)
Roundness limit: 0.05 mm (D2-D1, D6-D5)

Outside diameter of piston pin

Check the outside diameter of piston pin; If it does not meet the specified value, replace it.
Outside diameter of piston pin: 17.991～18.000 mm
Piston ring
1. Push the piston ring into the cylinder in parallel with the piston to the specified
measuring point (10mm from the joint surface).
2. Measure the clearance of piston ring end face with a clearance gauge; If it does not meet
78
 the specified value, replace it.
End face clearance (during installation): Top ring 0.15～0.30 mm
Second ring 0.70～0.90 mm
Oil ring 0.20～0.70 mm
3. Install the piston ring on the piston, and measure the clearance between the piston ring
and the piston ring groove with a clearance gauge; If it does not meet the specified value,
replace it.
Specified clearance: Top ring 0.04~0.08 mm
Second ring 0.03~0.07 mm
Oil ring 0.03~0.15 mm

Inner diameter of connecting rod small end

Measure the inside diameter of the small end. If it does not meet the specified value, replace
it.
Inner diameter of small end: 18.005～18.018 mm

Inner diameter of connecting 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 the specified torque before measurement

Specified torque: 13 Nm for the first time

35 Nm for the second time

Connecting rod large end backlash

Measure the large end backlash.
If it does not meet the specified value, a
replace the connecting rod or crankshaft or both.
Large end backlash: 0.15～0.30 mm

Crankshaft
1. Measure crankshaft journal diameter, crank pin diameter and crank pin width. If they do
not meet the specified value, replace the crankshaft.

Diameter of
crankshaft 51.982~52.000mm
journal
Crank pin
46.982~47.000mm
diameter
Crank pin
21.000~21.100mm
width

2. Check the crankshaft runout; If it exceeds the specified value, replace it.

79
 Crankshaft runout limit: 0.04mm

Crank pin oil clearance

1. Place a plastic clearance gauge on the crank pin and make it parallel to the crankshaft.

2. Fit the connecting rod and bearing bush on the crank pin.

3. Tighten the connecting rod bolts according to the specified torque.

Seating torque: 13 Nm for the first time
35 Nm for the second time

4. Remove the connecting rod and measure the compressed width of the plastic clearance
gauge; If it exceeds the specified value, replace the connecting rod bearing bush.
Oil clearance: 0.017～0.040mm
Note:
Do not turn the connecting rod until the measurement is completed.

Selection of connecting rod bearing bush

Select the appropriate connecting rod bearing bush according to the group number on the
connecting 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 the
inner diameter of the big end hole from small to large.

The group number of crank pins of crankshaft is engraved on the first fan plate of
crankshaft, and it is divided into three groups 1, 2 and 3 according to the diameter from large to small.

曲柄销分组标识(4位）

Examples of pairing:
If the group numbers of connecting rod and crank pin are the same, then 1. select the
blue-marked bearing bush, 2. select the green-marked bearing bush, and 3. select the
red-marked bearing bush. If the group numbers of corresponding positions of the connecting
rod and crank pin are different, the bearing bush is selected according to the larger number;
For example, if the group numbers of the two are 1 and 3 respectively, the red-marked
bearing bush will be selected according to 3.

80
 Main journal oil clearance
1. Clean the bearing bush, main journal, and the mounting surface of the engine body and
engine base.

2. Install the bearing bush and crankshaft to the engine body.

3. Place a plastic clearance gauge on the main journal and parallel it to the crankshaft
Note:
Do not place the plastic clearance gauge on the oil hole of the main journal.

4. Install the bearing bush on the engine base and the engine base on the engine body.

5. Tighten bolts with specified torque in the order of numerical symbols on the engine base.
Seating torque:
Frist
16 Nm
tightening
M10×1.5
Second
42 Nm
tightening
Frist
14 Nm
tightening
M8
Second
28 Nm
tightening

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 turn the crankshaft until the measurement is completed.

Selection of crankshaft bearing bush

Select the corresponding crankshaft bearing bush according to the group number on the
engine body and crankshaft.
The group numbers on the engine body are engraved on the side of the body, and are divided
into three groups 1, 2 and 3 according to the bore diameter from small to large.

There are 5 in total, and each one corresponds to the shaft hole group at the point.
The group number of bearing journal of crankshaft is engraved on the first fan plate of
crankshaft, and it is divided into three groups 1, 2 and 3 according to the diameter from large
to small.

81
 主轴颈分组标识(5位）

Crankshaft bearing bushes are divided into three groups according to their thickness.
From thin to thick, blue, green and red marks are painted on the side of the bushes to
distinguish them.
Examples of pairing:
If the group numbers of the corresponding positions of the engine body and the
crankshaft are the same, then 1 select the blue-marked bearing bush, 2 select the
green-marked bearing bush, 3 select the red-marked bearing bush,
If the group numbers of the corresponding positions of the engine body and the
crankshaft are different, the bearing bush is selected according to the larger number; For
example, if the group numbers of the two are 1 and 3 respectively, the red-marked
bearing bush will be selected 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 yes, clean it.

Check the oil pump

1. Remove the screws and the oil pump.

2. Remove the screws fixing the oil pump cover and remove the oil pump cover.

3. Check the clearance of oil pump rotor. If it does not meet the specified value, replace it.
Clearance between outer
0.12～0.16 mm
rotor and shell
Clearance between outer
0.1～0.2 mm
rotor and inner rotor
Clearance between rotor
0.03~0.12mm
and oil pump cover

Check and mount exhaust pipe

1. Remove the exhaust assembly.

2. Disassemble the exhaust pipe assembly

3. Check the anode

If the anode has been corroded by more than half, please replace it
If there is scale, peeling or oil stain on the anode surface, please clean it.
Note:
Do not apply grease, oil or paint to the anode.

82
 4. Re-mount the exhaust pipe assembly.
Alternately tighten the bolts (M6x30mm) to mount the exhaust pipe A&B and control the
clearance shown in the figure to the specified value.
Specified clearance: 9.5 mm

Note:
Use a new O-ring.

5. Remove the bolts (M6x30mm).

6. Use new exhaust pipe gasket A and exhaust gasket B.

7. Mount the exhaust pipe assembly and tighten the bolts twice at the specified torque.
Seating torque: 14 Nm for the first time
21 Nm for the second time

Reinstallation
Assemble piston connecting 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 side.

Installing the piston rings

1. Install piston rings in the order of oil ring, second ring and top ring.
Note:
When installing the second ring, ensure that the mark faces the top of the piston.

2. Schematic diagram of piston ring notch position.

3 4
Oil ring lower retaining ring 1
Oil ring elastic ring 2 UP
Oil ring upper retaining ring 3
Second ring 4
Top ring 5
2,5 1
Installing piston
Install piston with piston slideway,
Make sure that the “ ” mark on the top of the piston faces the flywheel.
Note:
83
When installing, apply oil to the sides of the piston and piston ring.

Installing crankshaft
1. Install crankshaft bearing bushes on the body separately.

2.Install the crankshaft to the engine body and install the oil seal.
Note:
Apply oil on the inside of the oil seal before installation.

3. Install the connecting rod bearing bush on the connecting rod.

4. Install the connecting rod cover to the connecting rod according to the connecting rod
pairing number and tighten the connecting rod bolts at the specified torque.
Seating torque: 13 Nm for the first time
35 Nm for the second time

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:
Face the notched side towards the crankshaft.
3. Coat sealant on the joint surface of the engine base, and install the locating pin and the
engine base.
Tighten the bolts twice in the order shown in the figure.
Seating torque:
Frist
16 Nm
tightening
M10×1.5
Second
42 Nm
tightening
Frist
14 Nm
tightening
M8
Second
28 Nm
tightening
Note:
Before installation, apply oil to the moving surface.
Apply oil to the bolts before installation.

4. Install oil filter bracket.

Note:
Use new rubber sealing rings.

5. Install oil filter with special tools and tighten it at specified torque.
Seating torque: 18 Nm

84
 Note:
Before installation, inject oil into the oil channel.

6. Install the anode, exhaust cover plate, thermostat and thermostat cover 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 is in the top dead center position.

9. Remove the flywheel for further installation.

About water
Top cover
Disassembly schematic diagram

85
86
Disassembly and inspection
87
 1. Remove the sealing rubber strips.

2. Remove the top cover screws.

3. Remove the top cover.

4. Remove the locking pulley retaining plate screws and remove the front and rear
locking 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 for cracks or damage. Replace it if necessary.

8. Check the locking pulley assembly for cracks, deformation or damage. Replace it if
necessary.

Bottom cover
Disassembly schematic diagram

88
89
90
91
Disassembly and inspection
92
Water unit and bracket
Disassembly schematic diagram

93
94
95
96
97
SN.

98
 Disassembly and inspection of bracket
1. Remove the left and right absorber covers, and remove the left and right absorbers and
double-hole absorber fixing nuts. Remove the left and right absorbers

2. Remove the water unit, oil pan and exhaust manifold seat as a whole from the bracket.

3. Remove the screw of the anode retaining plate and remove the bracket anode.

4. Remove the elastic retainer ring for shaft and remove the warping pin shaft. Remove the
screw of hydraulic warping positioning shaft and the hydraulic warping positioning shaft,
and remove the hydraulic warping assembly.

5. Remove the solenoid clamp, the bracket clamping nut and clamping bracket twin-headed
thread assembly. Remove the grounding cable and left and right clamp brackets.

6. Remove the retainer ring, pull off the fixed block of the shock absorber, pull out the
steering bracket assembly, and remove the inner bushing, upper bushing and O-ring.

7. Remove the tension spring bracket and swing rod spring. Remove the elastic cylindrical
pin, and remove the swing 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 and clamp bracket for cracking or damage. Replace it if
necessary.

10. Check the inner bushing and upper bushing; Replace it if damaged or cracked.

11. Check the support frame assembly for deformation or damage. Replace it if necessary.

12. Check the left and right absorber rubber for aging, cracking, or degumming. Replace it if
necessary.

13. Check whether the anode is seriously corroded. Replace it if necessary.

Disassembly and inspection of water unit

1. Drain the oil.

2. Remove the mounting bolts on the water and underwater, and remove the water unit.

3. Remove the exhaust manifold set and oil pan.

4. Remove the coarse filter assembly from the exhaust manifold seat, and remove the
double-hole shock absorber, pressure valve assembly and exhaust rubber pipe.

5. Remove the exhaust partition, oil drain bolt and oil drain rubber sleeve and exhaust
rubber elbow from the oil pan.

6. Check the water unit housing and oil pan for cracking or damage. Replace it if
necessary.

7. Check the exhaust manifold for cracking or damage. Replace it if necessary.

99
 8. Check the exhaust rubber pipe and exhaust rubber elbow for aging and cracking.
Replace it if necessary.

Hydraulic warping device

Check the oil level.
1. Position the hydraulic warping device vertically and fix it.

2. Connect the lead of the warping motor of the hydraulic warping device to the battery.

3. Extend the push rod completely, remove the oil screw, and observe the oil level.
Note:

The oil level should be at the edge of the oil hole,

1. Oil drain screw

4. If necessary, add oil to the edge of 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.

1. Connect the lead of the warping motor of the hydraulic warping device to the battery.

2. Extend the push rod completely.

3. Exchange the positive and negative wire connections.

4. Completely compress the push rod.

5. Repeat steps 1~4 to make the push rod move up and down 4~5 times.

6. Extend the push rod completely, remove the oil screw, and observe the oil level.

7. If necessary, repeat the above steps until the oil level is correct.

8. Install the oil drain screw and tighten it.

Specified torque: 6.5 Nm
100
 If the hydraulic warping device is installed on the outboard motor and exhausting is required,
please follow the following steps.
1. Turn the manual valve counterclockwise until it cannot turn.

1. Manual valve.

2. Tilt the outboard motor completely upward, and then lower it downward 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 the outboard motor is completely warped.

6. Wait for 5 minutes to stabilize the oil.

7. Remove the oil drain screw and observe the oil level.

8. If necessary, repeat the above steps until the oil level is correct.

9. Install the oil drain screw and tighten it.

Specified torque: 6.5 Nm

101
 Underwater part
Disassembly schematic diagram

103 Nm

94 Nm

102
O型 密 封 圈 58.8x3.1 O-RING 58.8x3.1

103
104
 M10x1.25x45
42 Nm 55 Nm

L
1277

M10x1.25x65
40 Nm

L
1277
L
1277

M10x1.25x40
40 Nm

105
106
FL115 rotates backward：

103 Nm

94 Nm

107
108
109
110
 M10x1.25x45
42 Nm 55 Nm

L
1277

M10x1.25x65
40 Nm

L
L
1277

M10x1.25x40
40 Nm

111
112
 Disassembly and inspection
1. Drain the gear oil; remove the cotter pin.

2. Place a piece of wood between the anti-swirl baffle and the propeller to prevent the
propeller from rotating freely. Remove the slotted hexagon nut and the water inlet.

3. Remove the propeller and cushion block.

4. Remove the anode.

5. Remove the connecting bolts of the underwater unit and remove the underwater unit.

6. Remove the water pipe.

7. Remove pump casing, impeller and pump inner casing.

8. Remove the semicircular key and outer plate.

9. Place the shift cam assembly in a neutral position; Remove shift cam cover plate and
pull out shift cam assembly.

10. Check the shift cam assembly for cracks, twists, or damage. Replace it if necessary.

11. Check the pump casing and outer plate for cracks, distortions or damage. 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 the reverse gear and the cushion block of reverse gear, remove the deep
groove ball bearing, needle roller bearing and oil seal.
FL115 rotates backward： Remove the forward gear and the cushion block of the
forward gear, and remove the plane thrust bearing, propeller shaft shim and needle
roller bearing; Remove the oil seal.

14. Remove the propeller shaft assembly.

15. Remove the clutch ring, clutch pin and claw clutch from the propeller shaft assembly.
Remove shift plunger, clutch spring and bearing ball.

16. Remove the drive shaft seat.

Remove the pinion nut using an internal spline wrench and remove the pinion and
drive shaft.

17. F115: Remove the forward gear, remove the bearing on the forward gear.
FL115 rotates backward： Remove the reverse gear assembly and the reverse gear
washer.

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 18. Remove the needle bearing from the underwater unit.

19. Remove the oil seal and plane thrust bearing of the drive shaft seat, and remove the
drive shaft shim and needle roller bearing.

Propeller shaft and clutch block

1. Check the claw clutch; If broken or damaged, replace it.

2. Check the propeller shaft; Replace it if worn or bent.

Install the claw clutch

1. Fit the bearing ball (large) and clutch spring into the hole of shift plunger.

2. Place four bearing balls (small) in the corresponding holes of the shift plunger and
insert them into the propeller shaft.

3. Install the claw clutch. "F" or "●" faces the forward direction of the engine. Fix the
clutch pin.

Note:
The figure shows the propeller shaft of forward-rotating model; The claw clutch
installation 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 there is noise during rotation; If so, replace it.

2. Remove the bearing and oil seal with bearing puller.

Note:
Do not remove the bearing unless it needs to be replaced.

3. Remove the needle bearing with special tool.

Note:
When reinstalling the oil seal and needle bearing, please use new parts to replace
them.

4. Clean the housing cover with a soft brush and solvent.

5. Check the housing cover; Replace it if cracked or damaged.

Install the oil seal and bearing of the housing cover

1. Install the oil seal.

2. Fit the new bearing on the reverse gear.

Note:
Use special tools to install the oil seal and bearing.
Pay attention to the installation direction and depth.
Make sure that the manufacturer's mark of the bearing faces the reverse gear.
Mounting depth:

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 Needle roller
24.75～25.25 mm
bearing
Depth
4.75～5.25 mm
Oil 1
seal Depth
11.75～12.25 mm
2

Underwater unit housing cover Underwater unit housing cover Underwater unit housing cover
bearing installation tool oil seal installation tool needle bearing installation tool

3. Install reverse gear and shim.

Note:
Shim adjustment is required when installing new reverse gears and bearings.
Install forward gear and shim (FL115 backward-rotating model).
Note:
When installing new forward gear and cushion block of the forward gear, please adjust
the shim.

Drive shaft
Check the drive shaft for bending or wear. Replace 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.

Forward gear bearing

Check whether the bearing is corroded and whether there is noise when rotating; Replace it
if necessary.
Note:
Do not remove the bearing unless it needs to be replaced.
When installing a new bearing, it is required to adjust the shim.

Check the housing of the underwater unit

Check whether the housing of underwater unit is cracked or damaged, and check whether the
cooling water inlet is blocked; Replace them if necessary.

Check the water pipe

Check the water pipe for corrosion or bending. Replace it if necessary.

Assemble underwater unit

1. Use special tools to install the needle bearing.

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 Needle bearing installation tool kit

2. Install the new forward gear bearing. (Replace it if necessary)

Forward gear bearing jacket installation kit

3. Install the oil seal for drive shaft seat and the needle bearing

Drive shaft seat oil seal installation tool kit Drive shaft seat needle bearing installation tool
Mounting depth:
Needle roller
5.75～6.25 mm
bearing
Depth
0.25～0.75 mm
Oil 1
seal Depth
7.25～7.75 mm
2

4. F115 forward-rotating model:

Install forward gear, long nylon sleeve, drive shaft, plane thrust bearing, shim, install
drive shaft seat, pinion and shift cam.
F115 backward-rotating model:
Install shift cam, drive shaft, shim, install reverse gear, drive shaft seat, long nylon sleeve,
plane thrust bearing and pinion.
Note:
When installing a new drive shaft, it is required to adjust the shim.

5. Tighten the pinion nut.

Specified torque: 94 Nm

6. Install the propeller shaft assembly.

7. Install the underwater unit housing cover.

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 8. Tighten the housing cover nut and pry up a tongue piece on the locking washer.
Specified torque: 103 Nm

Cover nut installation tool

9. Check whether the gear shift is working properly.

10. Install the water pump assembly.

11. Install the anode and water inlet.

12. Install the propeller and slotted hexagon nut, place a piece of wood between the
anti-swirl baffle and the 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 until they are aligned.

Install the underwater unit

1. Install the locating pin.

2. Please put the shift cam to the neutral position. Install the underwater unit to the housing
of the water unit and tighten the bolts to the specified value.
Specified torque: 40 Nm

3. Perform shift operation and check whether it is operating normally.

4. Add gear oil with pressure filling device.

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 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.

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FL115 rotates backward：

Deviation value mark

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 The installation surface of the anode/heading tab of the underwater unit is engraved with
deviation value marks, which are F, R and P respectively; they represent the difference between the
actual size and the theoretical size on the housing of the underwater unit.
For example, the mark P is followed by +3, which means that the actual size is 0.03 mm more than
the theoretical size; If no number is engraved after the deviation value, then P is regarded as 0.

Pinion shim
1. Attach the drive shaft to the special 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)
专用工装拧紧后的尺寸
塞尺

2. Measure the clearance M3 between the special tooling and the pinion with a filler
gauge. According to M3, look up the table to get the temporary value T3 of the shim.
According to M3, look up the table to get the temporary value t3 of the shim
According to M3
3. Pinion shim calculation formula: T3=t3+P/100

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. Optional shim.
0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

Forward gear shim

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 1. Use standard block to calibrate the special tooling, ensure a compression of 0.5-0.8
mm, push the standard block several times, and clear zero position.

2. Turn tapered roller bearing 25580/25520 outer ring two or three times so that the
rollers fall completely into the bearing outer ring.

3. Measure the bearing thickness with special tooling, measure three points and
calculate 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 possible)

6. Forward gear shims (T1) that can be selected.

0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

Reverse gear shim M1

1. Check the R value marked on the housing of the underwater unit.

2. Formula: T2=0.7＋(R/100)

3. The shim can be increased by 0-0.05mm compared with T2 (try to choose the most similar
size as possible)

4. Reverse gear shims (T2) that can be selected

0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

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 Backward-rotating pinion shim
1. Attach the drive shaft to the special 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)

专用工装拧紧后的尺寸
塞尺

2. Measure the clearance M3 between the special tooling and the pinion with a filler
gauge. According to M3, look up the table to get the temporary value T3 of the shim.
According to M3, look up the table to get the temporary value t3 of the shim
According to M3

3. Pinion shim calculation formula: T3=t3+P/100

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 that can be selected.

0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

Propeller shaft shim

1. Turn tapered roller bearing 32010JR outer ring two or three times so that the rollers fall
completely into the bearing outer ring.

2. Measure the bearing thickness with special tooling, measure three points and calculate
the average value, as shown in the figure:

3. Formula: T4=18-6-6.5-0.3-M4=5.2-M4
The shim can be reduced by 0~0.05mm compared with T4 (try to choose the most
similar size as possible).

4. Propeller shaft shims (T4) that can be selected:

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 0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

Reverse gear shim

1. Check the F size marked on the housing of the underwater unit.

2. Formula: T1=58.7-20-4.5-33.3＋(F/100)=0.9+(F/100)

3. The shim can be reduced by 0~0.05mm compared with T1 (try to 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 unit.

2. Formula: T2=39.8-33.2-6+(R/100)=0.6+(R/100)

3. The shim can be increased by 0~0.05mm compared with T2 (try to choose the most
similar size as possible).

4. Forward gear shims (T2) that can be selected:

0.10, 0.12, 0.15, 0.18, 0.3, 0.4, 0.5 mm

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 Common faults and solutions
Fault type Fault cause Solution

There is no fuel in the fuel tank

Fill the fuel tank with clean new fuel
Contaminated or obsolete fuel oil

Fuel filter blocked Replace the fuel filter

Fuel pump failure Overhaul or replace it

Vent screw of fuel tank cap not
Loosen the vent screw
loosened
The spark plug is contaminated or Check the spark plug. Clean it or replace with the
the model is incorrect correct spark plug
Engine fails to
Incorrect installation of spark plug
start Check and reinstall the spark plug cap
cap
Check the wiring. Tighten the loose wire and replace
Ignition circuit failure the old or broken wire.

Ignition component failure Replace it

The engine stop safety line is not
connected to the emergency stop
Connect the line to the switch
switch assembly.

Internal parts failure of the

Repair it
engine
The spark plug is contaminated or
Clean it or replace with the correct spark plug
the model is incorrect
Check the fuel line for extrusion, entanglement or
Fuel system blocked
blockage
Fuel oil polluted or obsoleted Fill the fuel tank with clean new fuel

Fuel filter blocked Replace the fuel filter

Incorrect spark plug gap Adjust the gap to the specified value
Check the wiring. Tighten the loose wire and replace
Engine idle is Ignition circuit failure the aging or broken wire.
abnormal or
stalls
Incorrect engine oil grade Change it to the specified oil grade

Thermostat failure Replace it

Fuel pump failure Replace it

Vent screw of fuel tank cap not
Loosen the vent screw
loosened
The fuel joint is not connected
Connect it correctly
correctly
The angle of the outboard motor is
Return it to its normal running position
too high
Propeller damaged Repair or replace the propeller
The engine is
Incorrect trim angle Adjust the trim angle to the appropriate angle
weak.
Incorrect installation height of
Adjust it to the correct height
outboard motor

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Continued：
Fault type Fault cause Solution
The bottom of the ship is polluted
Clean the bottom of the ship
by underwater organisms
Gear box twined by aquatic plants
Remove the foreign matters and clean it
or foreign matters
The spark plug is contaminated or
Clean it or replace with the correct spark plug
the model is incorrect
Check the fuel line for extrusion, entanglement or
Fuel system blocked
blockage
Fuel filter blocked Replace the fuel filter

Fuel oil polluted or obsoleted Fill the fuel tank with clean new fuel

Incorrect spark plug gap Adjust the gap to the specified value
The engine is
weak. Check the wiring. Tighten the loose wire and
Ignition circuit failure
replace the old or broken wire.

Ignition component failure Replace it

Incorrect engine oil grade or
Change to the specified oil grade or add it to the
excessive oil
proper position of the oil dipstick

Thermostat failure Replace it

Fuel pump failure Replace it

The fuel joint is not connected
Connect it correctly
correctly
Incorrect spark plug specification Replace it with the correct model

Propeller damaged Repair or replace the propeller

Propeller shaft damaged Replace it

Excessive Propeller twined by aquatic plants
Remove the foreign matters and clean it
vibration of or foreign matters
outboard motor Mounting bolts of outboard motor
Tighten the bolts
loosened
Steering shaft loosened Tighten the shaft

Steering shaft damaged Replace it

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