KUMATSUGEN GM1500 Gasoline Outboard Engine Instruction Manual

KUMATSUGEN GM1500 Gasoline Outboard Engine

Introduction

This outboard engine has been designed and is intended for skippers of small boats (carrying capacity of less than 4 people), powered by outboard engine and operating in shallow waters.
Portable fuel tanks for outboard motors are fitted with a manual priming bulb. It is squeezed a few times to draw fuel when first starting the engine or to continue to provide fuel to the engine in case of fuel pump failure. Care must be taken to ensure that the bulb is not over squeezed as this may cause leaks in the fuel system or flood the engine with too much fuel, making it difficult to start. The bulb should be squeezed only until it becomes firm.
The tank is also fitted with a breather screw, which must be loosened to vent the tank when operating the engine.
Ensure the breather screw is fully closed when transporting the tank to prevent spillage.

INTERNAL LUBRICATION SYSTEM

Four-stroke petrol engines are lubricated by oil circulation from the sump (crankcase). Insufficient oil will cause the engine to overheat and eventually seize. Excessive oil will foul the spark plugs, cause smoky exhaust and heavy carbon deposits. Both will cause engine failure.

MOUNTING AN OUTBOARD MOTOR

The method of securing an outboard motor to the vessel. Use of hand-tightened screw thread clamps. These clamp the transom of the vessel between the engine mounting bracket and the screw thread plates. Their tightness should be checked each time the engine is used. A safety rope or chain should also be used to secure the motor to the vessel and prevent the motor from dropping from the boat if the clamps get loose during vessel operation. On larger outboard motors, the mounting bracket is usually bolted through the transom plate. This is a more secure method, but regular checks must be made for looseness.

Trim Angle

By changing the outboard motor’s drive angle, the vessel’s bow can be made to rise or fall. The performance and stability of a vessel depends a great deal on correctly trimming the outboard. The correct trim angle depends on the vessel’s handling characteristics, the size of the outboard, the sea and loading conditions. Care must therefore be taken to ensure the outboard is trimmed correctly under different sea and loading conditions. On smaller outboards, the trim angle is adjusted manually by moving an adjusting rod to different holes in the mounting bracket. The bigger outboards usually have a Trim Switch fitted on the remote control lever.

STARTING PROCEDURE

1. Lower engine to running position and check the following:
   • Fuel level
   • Oil level (if separate lube oil tank)
   • Engine mount secure
   • Propeller clear

2. Loosen air-vent screw on fuel tank cap by 2 or 3 turns (if fitted)

3. Firmly connect fuel hose to both fuel tank and engine

4. Squeeze primer bulb until it becomes firm

5. Make sure engine is in neutral, and throttle grip on handle in START position

6. Clip lock plate onto emergency-stop switch and tie lanyard to your wrist

7. Pull out choke if starting cold engine

8. Start motor by pulling starter handle (manual) or pushing starter switch (electric)

9. Push choke back in

10. Ensure that water is coming out of the pilot hole and allow engine to warm up before moving off

11. Check fuel pump to ensure membrane is not torn out

12. Check carburetor to ensure that draining screw is not opened

If engine starts but stops almost immediately:

1. Check choke has been pushed back in
2. Checks 1 to 12 above

If engine starts but stops when gear is engaged:

1. Check propeller is not blocked
2. Inspect spark plugs and clean if necessary
   If engine still fails to start seek mechanical advice

ENGINE OVERHEATS

1. Check water pump and thermostat operating correctly by checking if “tell-tale” water stream is at normal rate
2. Inspect/clear water intakes
3. Check oil level if separate lube oil tank is fitted If problem cannot be rectified seek mechanical advice

Servicing after submersion

1. Remove engine cover and rinse powerhead with fresh water
2. Disconnect spark plug leads and remove spark plugs
3. Disconnect fuel lines from engine. Drain and clean all fuel lines and fuel tank
4. Place engine in horizontal position (spark plug openings down) and work all water out by slowly rotating flywheel about 20 times or until there is no sign of water
5. Drain carburetor: place engine in upright position and remove carburetor for disassembly and draining
6. Disassemble, clean and flush the starter, electrical connectors and all electrical equipment with fresh water. Then treat them with a water displacing electrical spray and thoroughly dry them before assembly
7. Inject outboard lubricant into spark plug holes
8. If engine shows evidence that sand may have entered it (sand under the engine cover or a slight grinding or scraping when the flywheel is rotated) do not attempt to start the engine. It must be disassembled and cleaned.
9. Reassemble the parts. Start the engine and run for 30 minutes in fresh water.
10. If engine fails to start, remove spark plugs again and see if water is present on electrodes, if so, blow out water and reinstall or replace with new plugs.

MAINTENANCE

FUEL SYSTEM
The fuel system should be regularly inspected for leaks, cracks or malfunction.

FUEL SYSTEM INSPECTION

1. Carburetor leakage. Fuel hose cracks or other damage
2. Fuel pump malfunction or leakage. Fuel filter leakage
3. Fuel tank leakage. Fuel connector leakage
4. Fuel hose joint leakage. Primer bulb leakage or damage
5. Fuel hose cracks or other damage
6. Fuel filter leakage
7. Fuel connector leakage
8. Primer bulb leakage or damage

Cleaning the portable fuel tank and its filter
At least once every six months, empty the fuel tank, pour a small quantity of detergent, and clean the tank thoroughly by shaking it. Flush the inside with fresh water and drain it completely. Repeat the flushing and draining procedures several times until all the detergent has been removed from inside the tank.
Thoroughly clean the tank filter (located at the end of the suction pipe) with detergent and air dry

Cleaning the engine fuel filter
The engine fuel filter should be cleaned every 20 hours of operation or every month. In some countries, the fuel quality is poor so cleaning of the filter should be carried out more frequently.
Stop the engine before removing the filter. Keep away from sparks, cigarettes, flames or other sources of ignition.
Remove the fuel hoses and clean the filter with detergent. Air dry the filter then put it back in place making sure the filter case is tightly screwed.

GEARBOX OIL CHANGE

Install the angular transmition grease through the hole located at the top of the propeller neck. Warning! The outboard engine does not include grease in the propeller for safety reasons. Please add angular transmition grease.

EXTERNAL LUBRICATION

Every three months, a recommended (marine) grease should be injected through the specified points (grease nipples) on the outboard motor. This procedure will ensure all moving parts operate smoothly.

COOLING SYSTEM (Not included in all models)

The outboard motor cooling system is the part of the engine most likely to cause problems due to salt, sand and dirt entering the system. Water pumps should be inspected and the pump impeller changed every 50 hours of operation or once three month, whatever comes first.
It is important to keep an eye on the tell tale water stream as a drop in flow is likely to indicate a problem with the cooling system. It could be a blockage around water intakes (plastic bags in the water are a common cause), sand in the system, water pump failure, damaged pump impeller and so on. It may also simply be a blockage of] the outflow (sand) from the tell tale although the engine cooling system is operating correctly.

Flushing the cooling system with fresh water (Not included in all models)

You can help prevent some of the problems caused by salt buildup in and around the motor by washing the body and flushing the cooling system with fresh water after use. To clean the cooling water passages, mount the motor in a tank partly filled with fresh water (water level above the anti-cavitation plate). Put the motor into neutral, start and run at low speed for a few minutes. This procedure should be carried out at least once every month. If possible, run the engine in fresh water on completion of each trip.

SPARK PLUGS

Cleaning or replacing spark plugs
The spark plugs of an outboard motor can become oily and coated in a black deposit in a short time. When this happens the motor will run roughly or may even fail to start.
Spark plugs should therefore be removed and inspected after 20 hours of operation or once a month. If spark plugs are dirty they should be cleaned or replaced with new ones as recommended for that type of motor.

Checking for spark
If an outboard turns over but does not start, the spark plug should be checked for spark to find the problem. To do this, you should first make sure that there is good ventilation and no fuel vapor present. Remove the spark plug from the engine and reconnect it to its lead. Hold its body against the engine block (to earth it) and turn the engine over.
Spark should be seen across the gap. Keep the spark plug away from the plug hole to safeguard against the risk of ignition.
If spark present: Plugs are dry – check fuel supply, lines, and filters.
Plugs are dirty – clean or replace plugs.
Plugs are wet – engine flooded, let stand for a while and try again.
If no spark: Loose or wet wiring. Check all wiring connections for tightness, should be clean and dry. Spray dirty, wet wiring with water-repellent spray. If engine still does not start, seek mechanical advice.
Take care when replacing spark plugs not to over tighten as this may damage the plug or make it difficult to unscrew.

PROPELLERS

Propellers are easily damaged by hazards in the water, hitting the bottom and corrosion. Even slight damage can cause a reduction in speed. Propellers on outboard motors are fitted with a shear pin, which is designed to break, if the propeller hits a solid object. The pin is easily replaced.
If a propeller blade is bent or badly chipped, it is best to fit a new propeller as it will not work very well. Make sure you only fit a propeller, which is recommended by the outboard manufacturer.
Every three months, the propeller should be pulled off and the propeller shaft greased.

PERIODIC INSPECTION AND SERVICE

The following table is given as a guideline for periodic maintenance procedures.
These inspections and services are recommended for outboard motors used on an average of 20 hours per month. Depending on operating conditions, the intervals between maintenance procedures may need to be changed.

Maintenance work / Interval| Every month| Every 3 months| Every 6 months| Every year| Every 2 years
---|---|---|---|---|---
Run engine in fresh water.| |  |  |  |
Fuel filter: Check and clean.| **| |  |  |
Spark plugs: Check condition and change if necessary.|  |  |  |  |
Propeller: Pull off and clean propeller shaft.|  | **| |  |
Zinc anode: Pull off and scrub clean.|  |  |  |  |
Engine head: Flush with fresh water, clean, spray with crc and apply grease.|  |  |  |  |
Engine lubrication: Apply grease to the specified points.|  | **| | |
Fuel tank: Clean with detergent and fresh water.|  |  | **| |
Crankcase: Drain and refill with oil.|  |  | **| |
Impeller:** Replace impeller and apply grease to the crankshaft.|  |  |  | |

OUTBOARD ENGINE OPERATING BODY PART

1. PLEASE READ THIS MANUAL WHEN USE IT:

2. Outboard power rating equal to or less than the boat can adapt to the rated horsepower.
   If the rated power capacity of the ship is unknown, ask your dealer or the manufacturer of existing vessels.
   Operation
   PLEASE CHECK YOUR BOAT

3. Do not free to modify the outboard machine motor is not suitable or unsafe for use under the circumstances.

4. Do not operate the machine after drinking alcohol or taking certain drugs affect judgment. Approximately 50% of all boating accidents involve some form of poisoning.

5. All occupants need to wear a lifejacket.

6. Gasoline is highly flammable and flammable gas, careful handling and storage gasoline. Make sure that no gas or fuel leaks before starting Engine.

7. Exhaust gas emitted from this product contains carbon monoxide, a colorless, odorless gas, which may result in brain damage or death when inhaled. Symptoms include: nausea, dizziness and drowsiness. Use your outboard and avoid blocking in a well-ventilated place Exhaust port.

8. Before you start checking for throttle, shift and steering. Regularly check the fuel line.

9. Keep hands and other body parts do not touch the correct propeller and engine heat parts.

10. Aware of and comply with the relevant host country laws do not prohibit the use of time.

11. Keep abreast of the weather. In rowing query weather, to avoid the water in bad weather.

12. Tell someone you want to go where.

13. Use common sense and good judgment, boating and operate your outboard motor. Working at a safe speed and always maintain a careful observation and other traffic obstacles.

14. Away from the swimmers keep a safe distance of 20 meters above the water and paddle to avoid machine-generated danger for swimmers.

Gasoline is highly flammable and explosive gases.

1. Do not smoke when refueling, away from fire, flames and other sources of fire.

2. Shut down before refueling your outboard engine.

3. Use only unleaded gasoline. Use low smoke 2-stroke or 4-stroke engine oil.
   4.2-stroke engine petrol and oil plus oil mixed at a ratio 25: 1.
   Mixing steps: (1) mixing the oil poured into the fuel tank. (2) will provide gasoline as fuel mixing tube. (3) and mix thoroughly shaken. (4) a mixture of gasoline and oil tanks in oil is added.

4. stroke engine oil and gasoline were added to set the corresponding tank.

5. Do not spill your outboard motor fuel tank. Use clean, clean, unleaded gasoline at Prepare your external fuel mixture.

Instructions

Prepare the engine start

1.1 Make sure your outboard engine installed correctly and safely to your stern prior to use. Your outboard motor improper installation may cause harm.
1.1 (1) To the outside of your ship near your center beams as much as possible.
1.1 (2) Check your strengthening beam clamp screw and clamp the boat evenly.
1.2 You press carburetor, fuel pump into the carburetor mixing.
1.3 Choke switch (Figure 2, Figure 3) in the closed position (choke closed) (if the engine is warm, choke switch in position) (open choke).
1.4 In the engine running, the engine running to choke switch open

Start the engine

2.1 pull recoil starter handle (diagram 3, Figure 4) lightly until you feel resistance.
Then pull the handle straight strong crank the engine starts. Repeat if necessary.
2.2 In your outboard motor starts idling at a low speed 3-5 minutes, and then gradually Adjustment (Figs. 1 and 4) of the desired acceleration.
2.3 Your outboard engine is equipped with a simple idle adjustment controls, Located directly above the throttle cable throttle cable.

Reversed

The engine is rotated 180 degrees, in the idle position, and then to the desired acceleration.
4. Stop or turn off the engine.
4.1 Before closing the machine, allow the engine to return to idle the lowest two minutes cooling, and then press the button to stop the engine (Fig. 2, Fig. 1). Press this button, turn the ignition current and stop the engine.
4.2 Store the outboard motor in a cool, dry place when it is not in use.

Maintenance

If you have questions about your operation or maintenance of any outside issues, carefully read the outboard motor manual, operation information and maintenance of your outboard motor.
5.1 You outboard motor run-in period of four hours. Do not suddenly turn off during hard acceleration or high speed operation during this time. Keep oil and gasoline added separately.
5.3 Do not operate your engine at a constant speed does not run at full speed at this time for more than ten minutes.
Fluctuate the speed.

Sailing in shallow water

6.1 Your outboard motor can be tilted (diameter 4) allow operation in shallow water.
6.2 Use the machine at the lowest possible speed cruising and shallow water.
6.3 Once your boat in deeper water, your machine is adjusted to the proper position.

Pitch angle tilt adjustment

7.1 Longitudinal reclining lever (Fig. 3, Fig. 7) can be adjusted to the angle determined in relation to the stern of the outboard motor. The outer side of a sloped support positioning pins (Figure 1, Figure 9) support in an upright position, rather than on the outside.

Operation

8. Cruise
8.1 When you work outside, at full speed, to find the key to controlling your throttle position (Fig. 1, Fig. 4).
Not necessarily the throttle to maximum, and further increase the speed may reduce fuel economy. Try to keep your throttle control, at 80% or 90% of the maximum leverage effective performance.

Maintenance

9.1 Periodic Check for loose nuts or bolts. Regularly check the fuel line connections and inspect for fuel and air leakage. Every eight hours after the operation, clean the air filter (Fig. 2, Fig. 4) with gasoline.
9.2 After each use clean the machine surface, and make partial contact with water rustproof. Do not let water through the exhaust port into the cylinder of the engine, this will cause serious damage to the engine.
9.3 Always store your engine in a well-ventilated area. You should first long- term storage of your engine and the fuel tank is completely emptied.
9.4 Water and corrosion often use grease to reduce friction and wear your outboard motor parts. Inspection once every 10 days is recommended lubricant for every 40 to 60 days to clean up and change with a grease.

Replace gear oil

Warning! For safety reasons, the propeller system is supplied without lubricant at delivery, please install angular gear grease before operating the engine. Install the grease through the hole located at the top of the propeller neck.

Engine oil

Caution! For safety reasons the machine may not carry oil when delivered! Fill with 100ml of oil. Recommended oil type:
SAE 10W-30 API SE, SF, SG for four-stroke engines.

Technical Data

• The manufacturer reserves the right to make minor changes to product design and technical specifications without prior notice unless these changes significantly affect the performance and safety of the products. The parts described / illustrated in the pages of the manual that you hold in your hands may also concern other models of the manufacturer’s product line with similar features and may not be included in the product you just acquired.
• To ensure the safety and reliability of the product and the warranty validity, all repair, inspection, repair or replacement work, including maintenance and special adjustments, must only be carried out by technicians of the authorized service department of the manufacturer.
• Always use the product with the supplied equipment. Operation of the product with non-provided equipment may cause malfunctions or even serious injury or death. The manufacturer and the importer shall not be liable for injuries and damages resulting from the use of non-conforming equipment.

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