KUMATSUGEN GM2500 Four Stroke Gasoline Outboard Instruction Manual

GM2500 Four-Stroke Gasoline Outboard
**Instruction Manual
WWW.BORMANNTOOLS.COM

Art-Nr: 026327
**

Safety Tips

1. Please read the instruction manual carefully before use and keep it handy.
2. Don`t hang heavy things on the outboard motor, the boat could overturn.
3.  Don`t modify your motor engine for unsafe or improper use.
4. Don`t operate the outboard motor after drinking alcohol or drug that may influence your judgment.
5. Wear a life jacket when on board.
6. The gasoline is highly flammable and explosive and should be handled with great care. After refueling the engine, make sure there is no gasoline spilled before starting the engine.
7. The exhaust of the outboard motor consists of carbon monoxide, it is a colorless, odorless gas, Breathing in it may cause brain injuries or even death. The symptoms include nausea, dizziness, and drowsiness. Make sure to use the outboard motor in the Well-ventilated area and avoid blocking the vent.
8. Please check the outboard motor carefully before each operation. And check the fuel line regularly, and check the screws, nuts, grease, and the combination of the outboard motor.
9. Make sure your hands or any other part of your body don`t touch the running propeller or the parts that will become hot after the engine runs.
10. Know the laws and regulations concerning the water-surface activities or the outboard motor of the country and don`t use it when prohibited.
11. Examine the weather condition before use, don`t use it in bad weather conditions.
12. Tell the others where you go.
13. Operate the outboard carefully when using it, make sure to run the boat within the safe speed limit, and watch the barriers on the water surface carefully.
14. When using the outboard motor in the water, please make sure to keep at least 20 meters distance from the swimmers, the water flow caused by the motor and the propeller blade may cause danger to the swimmers.
15. Clean the parts that are in the water after use, or they may rust, and don`t let water get into the engine of the outboard motor or the engine will be damaged.
16. Store your outboard motor in a dry and clear environment. Clean it and empty the fuel tank before storing it.
17. Once you have a problem with your outboard motor, please contact your local dealer for repair and after-sales service.

Please read this instruction manual carefully before operation and keep this manual handy.

General Safety instructions

• Do not use it inside the house.
• Keep away from flammable materials.
• Do not smoke when filling.
• Do not spill.

Pre-Operation Check

OIL LEVEL
Caution!

• Be sure to check the engine on a level surface with the engine stopped.
• Use 4-stroke motor oil sae 10w-30(0.6L) api se,sf,sg.
• Fill the oil to the edge of the oil filler neck.
• Add the engine oil slowly to avoid overflowing, as the engine oil tank capacity is small.
• Check the fuel level from the outside of the fuel tank.
• If the fuel level is low, fill the fuel to the upper level.
• Never use an oil/gasoline mixture or dirty gasoline.
• Check for dirt in the air cleaner element, if the element is dirty, clean it.
• Check for loose bolts and nuts, and tighten them, if necessary.

Starting and Stopping the Engine

Starting the engine

• Turn the engine switch to “on”(on the equipment side).
• To start a cold engine, move the choke lever to the close position.
• Press the primer bulb several times until a fuel flow in the fuel return is visually noticed.
• Pull the starter grip lightly until resistance is felt, then pull briskly, returning the starter grip gently.
• Turn the chock lever to the open position, as the engine warms up.

Stopping the engine
Move the throttle lever to the slowest position(on the equipment side) and turn the engine switch to the “off” position(on the equipment side).
Set the throttle lever at the desired position(on the equipment side).

Maintenance

Maintenance Schedule

1: Check 2:Clean 3:Replace If Necessary 4:Change 5: Check-Readjust
This product Should Be Serviced By Professional People!

Oil Change
Remove the oil filler cap.
Drain the oil by tilting the engine.
Fill the oil to the edge of the oil filler neck.
Install the oil filler cap.
Spark Plug
Loosen the 5mm hex bolt, then remove the top cover do not pull the starter grip, and start the engine when the top cover is removed.
Remove the spark plug cap.
Clean the deposit.
Measure the clearance

Fuel Filter Service
Remove the spark plug.
Drain the fuel by tilting the engine.
Pull out the fuel filter and clean it gently.
Fuel tank cleaning
Remove the fuel filler cap.
Drain the fuel by tilting the engine.
Pull out the fuel filter and remove water and dirt standing in the fuel tank by rinsing its inside.
Cooling Fin (Available on some models)
Check the cooling fin of its dirt through the fin cover.
Fuel Tube
Check the fuel tube and the fuel return tube for its deterioration.

Storage

Drain the fuel from the fuel tank.
Press the priming pump several times and drain the fuel from the fuel tank again.
Remove the oil filler cap and drain the oil.
Fill the oil to the edge of the oil filler neck.
Store the engine in a clean area.

Troubleshooting

The engine fails to Start
Check fuel from the outside of the fuel tank and check the fuel flow in the fuel return tube by pressing the priming pump several times.
Remove the spark plug.
If the engine still does not start, take the engine to your nearest service department.

Introduction

This outboard motor has been designed and is intended for the skippers of small boats (carrying a capacity of fewer than 4 people ), powered by outboard motors and operating in near waters.

Operating the outboard motor

Our outboard motors are pure gasoline-driven, 4-stroke

1. Manual start recoil handle
2. Choke knob
3. Rod for adjusting the trim angle
4. Throttle control & steering handle
5. Rope attachment
6. Emergency-stop (kill) switch, lock plate, and lanyard
7. Shallow-water lever for raising motor
8. Tilt lock for preventing accidental
9. Propeller

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
The gasoline 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, and cause smoky exhaust and heavy carbon deposits. Both will cause engine failure. Please add 100ml oil.
Mounting An Outboard Motor
The method of securing an outboard motor to the vessel use 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 depend 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 level.

Loosening 2 screws 37 in the above picture could adjust the angle of the outboard motor.
Install part 27 as the above picture, shows. Before assembly, lose part 37, fix parts 27 and 38 with tool 41, and assemble the 4pcs part 42 as the above picture shows. Then fasten part 42 and part 37. Make sure part 37 can move appropriately after parts 37 and 42 have been fastened. Install the well- assembled outboard engine on the board of the boat. Fix it tight

Starting Procedure

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

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

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

4. Squeeze the primer bulb until it becomes firm.

5. Make sure the throttle grip on the handle is in the START position.

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

7. Pull out the choke if starting a cold engine.

8. Start the motor by pulling the starter handle (manual start).

9. Push the choke back in.

10. Check the fuel pump to ensure the membrane is not torn out.

11. Check the carburetor to ensure that the draining screw is not opened.

If the engine starts but stops almost immediately:

1. Check choke has been pushed back in.
2. Checks 1 to 11 above.

If the engine starts but stops:

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

Servicing after submersion

1. Remove the engine cover and rinse the power head with fresh water.
2. Disconnect spark plug leads and remove spark plugs.
3. Disconnect fuel lines from the engine. Drain and clean all fuel lines and fuel tanks.
4. Place the engine in a horizontal position (spark plug openings down) and work all water out by slowly rotating the flywheel about 20 times or until there is no sign of water.
5. Drain carburetor: place the engine in an upright position and remove the 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 water displacing electrical spray and thoroughly dry them before assembly.
7. Inject outboard lubricant into spark plug holes.
8. If the 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 the engine fails to start, remove the spark plugs again and see if water is present on the electrodes, if so, blow out water and reinstall or replace them with new plugs. Repeat starting procedure

Outboard Motor Maintenance

Fuel System
The fuel system should be regularly inspected for leaks, cracks, or malfunctions.

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.
Gear-Box Oil Change
Gearbox oil should be changed every 100 hours of operation or three months, whatever comes first.
Drain the gearbox into a container by opening the oil-drain plug, then the oil-level plug. With the outboard motor in the upright position, inject the recommended gear-box oil into the oil-drain plug hole until it starts to flow out of the oil-level plug hole. Insert and tighten both drain plugs.
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 the 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, filters
Plugs are dirty – clean or replace plugs
Plugs are wet – engine flooded, let stand for a while and try again
b Loose or wet wiring. Check all wiring connections for tightness, should be clean and dry.
Spray dirty, wet wiring with water-repellent spray. If the 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 the 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.
Instructions on refueling
Gasoline is highly flammable and explosive:

1. Don`t smoke, when refueling, keep away from fire, flame, and ignitions of other sources.
2. Shut off the engine of your outboard engine before refueling.
3. Use unleaded gasoline only. Use 4-stroke engine oil.
4. Don`t spill the gasoline. Use a clean cloth to wipe off the spilled gasoline.
5. When starting the engine, keep at least 3 meters distance from the refueling point.

SERVICES I INTERVALS| 1 MONTH| 3 MONTHS| 6 MONTHS| 1 YEAR| 2 YEARS
---|---|---|---|---|---
RUN ENGINE IN FRESHWATER| ><| | | |
FUEL FILTER: CHECK & CLEAN| ><| | | |
SPARK PLUGS: CHECK CONDITION & CHANGE IF NECESSARY| ><| | | |
PROPELLER: PULL OFF & CLEAN THE PROPELLER SHAFT| | ><| | |
ZINC ANODE: PULL OFF & SCRUBS| | ><| | |
ENGINE HEAD: FLUSH w/ FRESH WATER, CLEAN, SPRAY CRC, GREASE| | ><| | |
ENGINE LUBRICATION: GREASE THE SPECIFIED POINTS| | ><| | |
FUEL TANK CLEAN w/ DETERGENT & FRESH WATER| | | ><| |
CRANKCASE: DRAIN & REFILL w/ OIL| | | ><| |
IMPELLER REPLACE IMPELLER & GREASE CRANKSHAFT| | | | ><|
Technical Data

Engine Type:| Single-cylinder, 4-stroke, air-cooled
Displacement :| 196cc
Bore x stroke:| 70*51mm
Rated Power:| 3.5kw/360Orpm
Start system:| Recoil start (manual start)
Fuel tank capacity:| 1.3L
Engine oil capacity:| 0.60L
Propeller diameter:| 21.0cm
Running speed:| 15-18km/h

Caution! For safety reasons the propeller system is supplied with no lubricant during delivery, please install angle transmis- son grease before operating the machine.

• 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.
• Please note that our equipment has not been designed for use in commercial, trade, or industrial applications. Our warranty will be voided if the machine is used in commercial, trade, or industrial businesses or for equivalent purposes.
• 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.

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Documents / Resources

| KUMATSUGEN GM2500 Four Stroke Gasoline Outboard [pdf] Instruction Manual
GM2500, Four Stroke Gasoline Outboard, GM2500 Four Stroke Gasoline Outboard, Gasoline Outboard, Outboard
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