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Suzuki DF 25 Service Manual Download Page 67

POWER UNIT     6-1

POWER UNIT

CONTENTS

6

POWER UNIT ................................................................................................6-  2

REMOVAL ...............................................................................................6-  2
INSTALLATION.......................................................................................6-  4

CYLINDER HEAD / VALVE / ROCKER ARM ...............................................6-  7

REMOVAL ...............................................................................................6-  7
INSTALLATION.......................................................................................6-  8
DISASSEMBLY .......................................................................................6-10
INSPECTION AND SERVICING .............................................................6-11
REASSEMBLY ........................................................................................6-17

CYLINDER / PISTON / CRANKSHAFT / CONROD / CAMSHAFT...............6-18

DISASSEMBLY .......................................................................................6-18
INSPECTION AND SERVICING .............................................................6-22
REASSEMBLY ........................................................................................6-31

THERMOSTAT ..............................................................................................6-38

REMOVAL ...............................................................................................6-38
INSPECTION ...........................................................................................6-38
INSTALLATION.......................................................................................6-38

OPERATION ..................................................................................................6-39

WATER COOLING SYSTEM ..................................................................6-39
ENGINE LUBRICATION SYSTEM..........................................................6-40

Summary of Contents for DF 25

Page 1: ...99500 97J00 01E Printed in Japan TK K6 9 9 5 0 0 9 7 J 0 0 0 1 E ...

Page 2: ...able service NOTE This manual is compiled based on 2006 K6 model This manual has been prepared on the basis of the latest specifications available at the time of publication If a modification has been made since then differences may exist between the content of this manual and the actual outboard motor Illustrations in this manual are used to show the basic principles of operation and work procedu...

Page 3: ...ion to help you find the item and page you need COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS Under the name of each system or unit an exploded view is provided with work instructions and other ser vice information such as the tightening torque lubrication and locking agent points Example 45 N m 4 5 kg m 32 5 lb ft Crankshaft NOTE Clean the flywheel and crankshaft mating surfaces with cleaning ...

Page 4: ...le if you are not sure of any symbol s meanings SYMBOL DEFINITION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply SUZUKI SILICONE SEAL Apply oil Use the engine oil unless otherwise specified Apply THREAD LOCK 1342 Apply SUZUKI OUTBOARD MOTOR GEAR OIL Measure in resistance range Apply SUZUKI SUPER GREASE A Measure in continuity test range Apply SUZUKI WATER...

Page 5: ...IONS 1 2 IDENTIFICATION NUMBER LOCATION 1 4 FUEL AND OIL 1 4 GASOLINE RECOMMENDATION 1 4 ENGINE OIL 1 5 ENGINE BREAK IN 1 6 WARM UP RECOMMENDATION 1 6 THROTTLE RECOMMENDATION 1 6 PROPELLERS 1 7 SPECIFICATIONS 1 8 SERVICE DATA 1 10 TIGHTENING TORQUE 1 14 SPECIAL TOOLS 1 15 MATERIALS REQUIRED 1 17 ...

Page 6: ...ether pay attention to the safety of each other When it is necessary to run the outboard motor indoors make sure that exhaust gas is vented outdoors When testing an outboard motor in the water and on a boat ensure that the necessary safety equipment is on board Such equipment includes flotation aids for each person fire extin guisher distress signals anchor paddles bilge pump first aid kit emergen...

Page 7: ... and case bolts and nuts beginning with larger diameter and ending with smaller diameter Always tighten from inside to outside diagonally to the specified tight ening torque Whenever you remove oil seals gaskets packing O rings locking washers locking nuts cotter pins circlips and certain other parts as specified always replace them with new Also before installing these new parts be sure to remove...

Page 8: ... OIL GASOLINE RECOMMENDATION Suzuki highly recommends that you use alcohol free unleaded gasoline with a minimum pump octane rating of 87 R 2 M 2 method or 91 Research method However blends of unleaded gasoline and alcohol with equivalent octane content may be used Allowable maximum blend of a single additive not combination 5 Methanol 10 Ethanol 15 MTBE THAI SUZUKI MOTOR CO LTD MADE IN THAILAND F...

Page 9: ...y oils that are rated SE SF SG SH or SJ under the API American Petroleum Institute classification system The viscosity rating should be SAE 10W 40 If an SAE 10W 40 motor oil is not available select an alternative according to the chart at right ...

Page 10: ...ngine speed for an extended period at any time during the engine break in by varying the throttle position occasionally 1 FIRST 2 HOURS For first 15 minutes operate the engine in gear at idling speed During the remaining 1 hour and 45 minutes operate the engine in gear at less than 1 2 half throttle 3 000 r min NOTE The throttle may be briefly opened beyond the recommended setting to plane the boa...

Page 11: ... the above requirement use another pitch propeller to hold the engine speed within the range specified above Propeller selection chart Recommended operating range 5 250 5 750 r min Code Number Blade Diameter Pitch A400 A510 3 188 mm 7 3 8 in 115 mm 4 1 2 in 3 188 mm 7 3 8 in 135 mm 5 3 8 in Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed which...

Page 12: ...height S mm inch type 435 15 Maximum output kW PS 1 8 2 5 Recommended operating range r min 5 250 5 750 Idle speed r min 1 900 100 in gear approx 1 500 Engine type 4 stroke OHV Number of cylinders 1 Bore mm in 48 0 1 89 Stroke mm in 38 0 1 50 Total displacement cm3 cu in 68 4 1 Compression ratio 1 9 0 Spark plug NGK CR6HSA Ignition system Transistorized ignition Fuel supply system Carburetor Exhau...

Page 13: ...ne oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 0 38 0 40 0 33 Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 60 2 0 2 1 Trim angle Degrees 6 20 Number of tilt pin position 4 Maximum tilt angle Degrees 74 from lowest tilt pin position Reversing system Gear Transmission Forward Neutral Reduction sy...

Page 14: ... 0 137 199 Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 0 38 0 40 0 33 Thermostat operating temperature C F 48 52 118 126 Type Walbro LMJ 26 I D mark 97J10 Main jet 70 Pilot jet 32 Pilot screw Turns open Pre set Float height mm 10 2 Cylinder head distortion Limit mm in 0 05 0 002 Cam height IN EX STD mm in 28 480 28 680 1 1213 1 1291 Limit...

Page 15: ...uide inside diameter IN EX STD mm in 4 000 4 012 0 1575 0 1580 Valve stem outside diameter IN STD mm in 3 975 3 990 0 1565 0 1571 EX STD mm in 3 960 3 975 0 1559 0 1565 Valve stem deflection IN EX Limit mm in 0 35 0 014 Valve stem runout IN EX Limit mm in 0 05 0 002 Valve head radial runout IN EX Limit mm in 0 08 0 003 Valve head thickness IN EX Limit mm in 0 5 0 02 Valve seat contact width IN EX ...

Page 16: ... 0 020 Piston ring free end gap 1st STD mm in Approx 6 1 0 24 Limit mm in 4 9 0 19 2nd STD mm in Approx 5 7 0 22 Limit mm in 4 6 0 18 Piston ring to groove clearance 1st 2nd STD mm in 0 020 0 060 0 0008 0 0024 Limit mm in 0 120 0 0047 Piston ring groove width 1st 2nd STD mm in 1 21 1 23 0 048 0 049 Oil STD mm in 1 51 1 53 0 059 0 060 Piston ring thickness 1st 2nd STD mm in 1 17 1 19 0 046 0 047 Pi...

Page 17: ...0 7476 0 7480 Crank pin out side diameter difference out of round and taper Limit mm in 0 010 0 0004 Conrod big end side clearance STD mm in 0 20 0 70 0 008 0 028 Limit mm in 1 00 0 039 Conrod big end width STD mm in 17 50 17 80 0 689 0 701 Crank pin width STD mm in 18 00 18 20 0 709 0 717 Crankshaft runout Limit mm in 0 05 0 002 Ignition timing Degrees BTDC 30 Ignition coil resistance Primary Ω a...

Page 18: ... mm 10 1 0 7 0 Engine oil drain plug 10 mm 10 1 0 7 0 Power unit mounting bolt 6 mm 10 1 0 7 0 Tiller handle pivot bolt 8 mm 17 1 7 12 5 Lower cover bolt 6 mm 8 0 8 6 0 Swivel shaft nut 8 mm 10 1 0 7 0 Gearcase bolt 6 mm 8 0 8 6 0 Water pump case bolt 6 mm 5 0 5 3 5 Propeller shaft bearing housing bolt 6 mm 8 0 8 6 0 TYPE OF BOLT THREAD DIAMETER TIGHTENING TORQUE N m kg m lb ft 5 mm 2 4 0 2 0 4 1 ...

Page 19: ...6 7 8 09900 20602 Dial gauge 09900 20605 Dial calipers 10 34 mm 09900 20701 Magnetic stand 09900 20803 Thickness gauge 9 10 11 12 09900 21304 Steel V block set 09900 22301 Plastigauge 0 025 0 076 mm 09900 26006 Engine tachometer 09913 50121 Oil seal remover 13 14 15 16 09915 63311 Compression gauge adaptor 09915 64512 Compression gauge 09916 10911 Valve lapper 09921 20210 Bearing remover ...

Page 20: ...el holder 09930 40120 Rotor holder attachment 09930 76420 Timing light 21 22 23 24 09930 99320 Digital tester 09950 69512 Gearcase oil leakage tester 09950 69710 Gear oil leakage tester attachment 09951 09530 Gear adjusting gauge 25 26 27 09952 99310 Air pump assy 99954 53008 820 Digital voltmeter 99954 53883 Gear oil filler ...

Page 21: ...t only SUZUKI OUTBOARD MOTOR GEAR OIL SUZUKI WATER RESIS TANT GREASE SUZUKI SILICONE SEAL SUZUKI BOND 1207B 99000 22540 400 ml 24 pcs 99000 25161 250 g 99000 31120 50 g 99104 33140 99000 31140 100 g THREAD LOCK 1342 4 STROKE MOTOR OIL 99000 32050 50 g API SE SF SG SH SJ SAE 10W 40 ...

Page 22: ...CE AND TUNE UP PROCEDURES 2 3 ENGINE OIL 2 3 GEAR OIL 2 5 LUBRICATION 2 6 SPARK PLUG 2 7 VALVE CLEARANCE 2 8 IDLE SPEED 2 11 CARBURETOR 2 12 IGNITION TIMING 2 12 BREATHER HOSE AND FUEL LINE 2 13 FUEL FILTER 2 13 WATER PUMP 2 13 WATER PUMP IMPELLER 2 13 PROPELLER AND PIN 2 14 ANODE 2 14 BOLTS AND NUTS 2 15 CYLINDER COMPRESSION 2 16 ...

Page 23: ...er severe conditions PERIODIC MAINTENANCE CHART I Inspect and clean adjust lubricate or replace if necessary T Tighten R Replace Interval Initial 20 hrs or 1 month Every 50 hrs or 3 months Every 100 hrs or 6 months Every 200 hrs or 12 months Item to be serviced Spark plug I R Breather hose and Fuel line I I I I Replace every 2 years Engine oil R R R Gear oil R R R Lubrication I I I Anode I I I Fue...

Page 24: ...mits If the level is low add the recommended oil to the upper limit Recommended oil 4 stroke motor oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Perform the following steps in order to add the oil to the upper limit 3 Remove the motor cover 4 Remove the oil filler cap 2 5 Add the recommended engine oil until the oil level reaches the upper limit 6 Tighten the oil filler cap sec...

Page 25: ...ten the plug to the specified torque Engine oil drain plug 10 N m 1 0 kg m 7 0 lb ft 6 Pour the recommended engine oil to the upper limit 7 Tighten the oil filler cap securely Engine oil amounts 0 38 L 0 40 0 33 US Imp qt 8 Start the engine Allow the engine to run for several minutes at the idle speed Check for oil leakage 9 Turn off the engine and wait for approx two minutes Re check the engine o...

Page 26: ...mounts 60 ml 2 0 2 1 US Imp oz Recommended oil SUZUKI OUTBOARD MOTOR GEAR OIL or SAE 90 HYPOID GEAR OIL 5 Install the oil level plug before removing the oil filler tube from the drain hole 6 Install the oil drain plug NOTE To avoid insufficient injection of the gear oil check the gear oil level 10 minutes after doing the procedure in the step 6 If the oil level is low slowly inject the gear oil up...

Page 27: ... MAINTENANCE LUBRICATION Apply the Water Resistant Grease to the following points 99000 25161 SUZUKI WATER RESISTANT GREASE Inspect every 50 hours 3 months Throttle cable Swivel bracket Propeller shaft Clamp screw ...

Page 28: ...ge CONDITION OF ELECTRODE INSULATOR Check the electrode and insulator condition If the electrode is extremely worn or burnt replace the spark plug If the spark plug has a broken insulator damaged threads etc replace the spark plug Spark plug 11 N m 1 1 kg m 8 0 lb ft Inspect every 100 hours 6 months Replace every 200 hours 12 months Only resistor R type spark plugs must be used with this engine Us...

Page 29: ...t the TDC position on a com pression stroke or on a exhaust stroke rotate the flywheel within 15 beyond the TDC position If both rocker arms do not move at all the piston is at the posi tion on a compression stroke If any rocker arm moves the piston is at the TDC position on an exhaust stroke Rotate the flywheel one more turn The valve clearance specification is for COLD engine condi tion Inspect ...

Page 30: ...the valve clearance is out of the specification adjust the clear ance ADJUSTMENT 5 Loosen the lock nut 1 while holding the adjusting screw 2 6 Turn the adjusting screw 2 to bring the valve clearance to within the specification 09900 20803 Thickness gauge 7 Tighten the lock nut 1 to the specified torque while holding the adjusting screw 2 Valve adjusting lock nut 7 N m 0 7 kg m 5 0 lb ft 8 Recheck ...

Page 31: ...ecial attention to the following steps Tighten the four cylinder head cover bolts diagonally to the specified torque Cylinder head cover bolt 7 N m 0 7 kg m 5 0 lb ft Make sure that the cylinder head cover gasket is installed cor rectly Do not re use the removed gasket Always use a new gasket ...

Page 32: ... holder 1 and the starter grip 2 Completely remove the motor cover 5 Install the starter grip and the holder to the end of the rope 6 Loosen the knot previously tied in the rope 7 Attach the tachometer cord to the spark plug high tension cord 09900 26006 Engine tachometer 8 Start the engine 9 Warm up the engine for about 5 minutes 10 Make sure the engine is in NEUTRAL and the throttle is fully clo...

Page 33: ...t If crack or other damage is found replace IGNITION TIMING NOTE Before checking the ignition timing make sure that the idle speed is adjusted within the specification 1 Start and warm up the engine 2 Attach the timing light cord to the spark plug high tension cord 09930 76420 Timing light 3 Check the ignition timing while operating the engine at the idling speed Ignition timing Approx BTDC 30 Ins...

Page 34: ...nd replace the fuel cock assy WATER PUMP Inspect the pump case the sleeve and the under panel If wear crack distortion or corrosion is found replace WATER PUMP IMPELLER If cut tear or excessive wear is found replace the impeller Inspect initially after 20 hours 1 month and every 50 hours 3 months thereafter Replace every 2 years Replace every 400 hours or 2 years Inspect every 200 hours 12 months ...

Page 35: ...damage Make sure that the cotter pin is installed securely ANODE If 2 3 of the anode has corroded away replace the anode NOTE Apply the silicone seal to the anode securing bolts 99000 31120 SUZUKI SILICONE SEAL Inspect initially after 20 hours 1 month and every 100 hours 6 months thereafter Cotter pin Propeller Shear pin Inspect every 50 hours 3 months Do not paint the anode Anode ...

Page 36: ...initially after 20 hours 1 month and every 100 hours 6 months thereafter ITEM THREAD DIAMETER TIGHTENING TORQUE N m kgf m lb ft Cylinder head cover bolt 5 mm 7 0 7 5 0 Cylinder head bolt 6 mm 13 1 3 9 5 Flywheel nut 10 mm 45 4 5 32 5 Power unit mounting bolt 6 mm 10 1 0 7 0 Swivel shaft nut 8 mm 10 1 0 7 0 Gearcase bolt 6 mm 8 0 8 6 0 ...

Page 37: ...engine then shut the engine off 2 Remove the spark plug 3 Install the compression gauge into the plug hole 09915 64512 Compression gauge 09915 63311 Compression gauge adaptor 4 Disconnect the safety lanyard from the emergency stop switch 5 Move and hold the throttle control grip in the full open posi tion 6 While cranking the engine with the recoil starter note the maximum compression pressure rea...

Page 38: ...IGNITION AND ELECTRICAL 3 1 IGNITION AND ELECTRICAL CONTENTS 3 IGNITION SYSTEM 3 2 OUTLINE 3 2 IGNITION TROUBLESHOOTING 3 4 INSPECTION 3 5 REMOVAL AND INSTALLATION 3 7 ...

Page 39: ...n system is employed on the DF2 5 This system consists of flywheel magneto igniter unit spark plug and emergency engine stop switch SPECIFICATIONS Ignition type Transistorized ignition Ignition timing BTDC 30 Flywheel magneto Igniter unit Spark plug Emergency engine stop switch ...

Page 40: ...ection of the series circuit R2 and R3 connected in parallel to the primary circuit As the flywheel turns further the ter minal voltage of the resistor R3 in the resistor circuit R2 and R3 rises to the level of working voltage of the transistor TR2 when the ignition timing approaches and thus the transistor TR2 is turned on As a result the base current of TR1 flowing through the resistor R1 is by ...

Page 41: ...resistance See page 3 5 Primary 0 5 0 9 Ω Secondary 10 16 kΩ Check the spark plug cap resistance See page 3 5 Cap resistance 4 6 kΩ Check the air gap between the igniter unit core and the flywheel Air gap 0 5 mm OK OK OK OK OK No or weak sparks No or weak sparks Check the ignition timing by using the timing light Approx BTDC 30 The cause will not be in the ignition system Not good Not good Not goo...

Page 42: ...PARK PLUG CAP 09930 99320 Digital tester Tester range Ω Resistance Measure the spark plug cap resistance Spark plug cap resistance 4 6 kΩ If the measurement is out of the specification replace the spark plug cap IGNITER TO FLYWHEEL MAGNETO AIR GAP Measure the air gap of between the flywheel magneto and igniter unit 09900 20803 Thickness gauge Air gap 0 5 mm 0 02 in Tester probe connection Probe Ot...

Page 43: ...e emergency engine stop switch Emergency engine stop switch continuity If the result is out of the specification replace the emer gency engine stop switch Tester probe connection Probe Other probe Black Black Switch condition Continuity Lock plate IN No Lock plate OUT Yes Lock plate IN button depressed Yes B B 1 Lock plate 2 Button 1 2 ...

Page 44: ...ot remove flywheel nut at this time This nut prevents damage to crankshaft when using flywheel remover tools 09930 40113 Flywheel holder 09930 40120 Rotor holder attachment Prior to removing the electrical parts disconnect the spark plug cap from the spark plug 45 N m 4 5 kg m 32 5 lb ft Crankshaft NOTE Clean the flywheel and crankshaft mating surfaces with cleaning solvent Nut 1 Starter pulley 1 ...

Page 45: ...ith clean ing solvent Tighten the flywheel nut to the specified torque 09930 40113 Flywheel holder 09930 40120 Rotor holder attachment Flywheel nut 45 N m 4 5 kg m 32 5 lb ft Igniter unit Install the igniter unit with an air gap of 0 5 mm between the both core ends and the flywheel Check the gaps at the machining part of the flywheel as shown in the figure 09900 20803 Thickness gauge Air gap 0 5 m...

Page 46: ... FUEL SYSTEM SERVICE 4 2 GENERAL PRECAUTION 4 2 FUEL LINE 4 2 REMOVAL AND INSTALLATION 4 2 CARBURETORS 4 5 REMOVAL AND INSTALLATION 4 5 DISASSEMBLY 4 7 CLEANING AND INSPECTION 4 10 REASSEMBLY 4 11 FUEL TANK AND FUEL COCK 4 13 REMOVAL 4 13 INSPECTION 4 14 ...

Page 47: ...nyone else to smoke near the working areas Post a NO SMOKING sign Keep a fully charged CO2 fire extinguisher and readily available for use To avoid potential fire hazards do not allow fuel to spill on hot engine parts or on operating electrical components Wipe up fuel spills immediately Do not over bend kink or twist the hoses when installing When installing the hose clamps clips position the tabs...

Page 48: ...crew 1 securing the throttle control inner cable 5 Detach the choke rod 2 from the carburetor 6 Remove the fuel hose 3 from the fuel cock 4 7 Remove the two bolts 5 securing the carburetor 8 Remove the fuel hose 6 from the carburetor INSPECTION Inspect the fuel hose If cracks swelling or other damage is found replace the fuel hose ...

Page 49: ...specified torque Carburetor mounting bolt 10 N m 1 0 kg m 7 0 lb ft Throttle control cable installation and adjustment See page 4 6 CHECK FOR FUEL LEAKAGE 1 Twist the air vent screw 1 on the fuel tank cap counter clockwise to open the vent 2 Turn the fuel cock lever ON position 3 Check the fuel line for leaks Do not re use the removed gasket Always use a new gasket ...

Page 50: ...sen the screw 1 securing the throttle control inner cable 5 Detach the choke rod 2 from the carburetor 6 Remove the two bolts 3 securing the carburetor Remove the carburetor assy 4 and the silencer 5 7 Remove the fuel hose 6 from the carburetor Before servicing the fuel system read and understand PRECAUTION ON FUEL SYSTEM SERVICE in the previous section ...

Page 51: ...hrottle control cable installation and adjustment 1 Fully close the throttle control grip 2 Turn the idle adjusting screw 1 counterclockwise until the screw do not touch the stopper plate 2 3 Insert the throttle control inner cable 3 into the linkage hole 4 While pulling the cable 3 tighten the screw 4 in order to secure the cable 5 Adjust the idle speed See page 2 11 and 2 12 Do not re use the re...

Page 52: ...d plate 3 Idle adjusting screw 1 Screw 4 Plate 1 Main air jet 1 Pilot air jet 1 Screw 1 Pilot jet 1 Bolt 1 Float chamber 1 Float pin 1 Float 1 Float spring 1 Needle valve 1 Main jet 1 Main nozzle 1 Gasket 1 Screw 1 Spring 1 Carburetor body 1 Float chamber gasket 1 Drain screw 1 Spring 1 Gasket ...

Page 53: ... the pilot air jet 5 and the screw 6 4 Remove the pilot jet 7 5 Remove the bolt 8 and the float chamber 9 6 Remove the float pin 0 the float A and the float spring B Always remove the float pin from the right side to the left side See the figure ...

Page 54: ...FUEL SYSTEM 4 9 7 Remove the needle valve C from the float 8 Remove the main jet D 9 Remove the main nozzle E ...

Page 55: ...ZZLE Inspect the jets and the nozzle If crack or other damage is found replace the jet and or the nozzle Clean the jets and the nozzle in order to remove obstructions NEEDLE VALVE Inspect the needle valve If broken tip or wear is found replace the valve Wear safety glasses when using compressed air to expel solvent carburetor cleaner etc Do not place any rubber plastic and non metallic parts in cl...

Page 56: ...rder of disassembly with the special attention to the following steps MAIN JET AND MAIN NOZZLE Install the main nozzle 1 to the carburetor body before installing the main jet 2 FLOAT 1 Install the float 1 with need valve 2 2 Install the float pin 3 Always install the float pin from the left side to the right side See the figure ...

Page 57: ...ect for smooth movement of float CHECKING FLOAT HEIGHT Measure the float height NOTE Make sure that float weight is not applied to needle valve 09900 20101 Vernier calipers Float height H 10 2 mm PILOT JET AND AIR JET Install the pilot jet 1 the pilot air jet 2 and the main air jet 3 ...

Page 58: ...VAL 1 Remove the motor cover 2 Remove the recoil starter 1 See page 5 2 3 Turn the fuel cock lever 2 OFF position 4 Remove the fuel hose 3 from the fuel cock 4 5 Remove the fuel tank 5 6 Loosen the screw 6 Remove the fuel cock 4 from the fuel tank ...

Page 59: ...terioration is found replace the tank If water or other contamination is found drain and clean the tank Tank cap Check that the fuel tank vent opens and relieves internal tank pressure properly If vent is suspect replace the tank cap INSTALLATION Installation is reverse order of removal with special attention to the following steps Place the fuel tank bracket 1 in position Install the fuel tank 2 ...

Page 60: ...RECOIL STARTER 5 1 RECOIL STARTER CONTENTS 5 REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 5 REASSEMBLY 5 6 INSTALLATION 5 7 ...

Page 61: ...ewinding onto the recoil reel when the starter grip is removed 3 Remove the knot from grip holder 1 Remove the grip holder 1 and the starter grip 2 Completely remove the motor cover 4 Install the starter grip and the grip holder to the end of the rope 5 Loosen the knot previously tied in the rope 6 Remove the recoil starter assy ...

Page 62: ...coiled tension in the recoil spring wear safety glasses and hand protection when wind ing or unwinding the component Rope 1 Reel 1 Screw 1 Friction plate 1 Spring 1 Ratchet 1 Recoil spring 1 Recoil case 1 Bolt 1 Bolt 2 Starter grip 1 Grip holder 1 ...

Page 63: ...and the friction plate 3 NOTE Screw 2 is a left hand thread 3 Remove the spring 4 and the ratchet 5 4 Slowly remove the reel 1 with the recoil spring from the recoil case 5 Remove the recoil spring 6 from the reel 1 NOTE Do not remove the recoil spring unless replacement is neces sary Inspect the spring in the assembled position ...

Page 64: ...any component replace Inspect the ratchet and the all springs If excessive wear or other damage is found replace Inspect the reel and the recoil case If crack or other damage is found replace Inspect the recoil rope If wear or fraying is found replace Inspect the recoil spring If crack deformation or excessive curve is found replace ...

Page 65: ...n a counterclockwise direction Apply the Water Resistant Grease to the recoil spring 99000 25161 SUZUKI WATER RESISTANT GREASE Install the rope 7 Install the reel 1 and the recoil spring to the recoil case align ing the inner end of the spring with the boss cutaway on the case Install the ratchet 5 and the spring 4 Because of the coiled tension in the recoil spring wear safety glasses and hand pro...

Page 66: ...2 NOTE Screw 2 is a left hand thread 99000 32050 THREAD LOCK 1342 Rotate the reel approximately 4 turns counterclockwise until the recoil spring is tensioned INSTALLATION Installation is reverse order of removal with the special attention to the following steps Check to ensure that all removed parts are back in place ...

Page 67: ...7 INSTALLATION 6 8 DISASSEMBLY 6 10 INSPECTION AND SERVICING 6 11 REASSEMBLY 6 17 CYLINDER PISTON CRANKSHAFT CONROD CAMSHAFT 6 18 DISASSEMBLY 6 18 INSPECTION AND SERVICING 6 22 REASSEMBLY 6 31 THERMOSTAT 6 38 REMOVAL 6 38 INSPECTION 6 38 INSTALLATION 6 38 OPERATION 6 39 WATER COOLING SYSTEM 6 39 ENGINE LUBRICATION SYSTEM 6 40 ...

Page 68: ...emove the carburetor assy 3 See page 4 5 4 Remove the igniter unit 4 5 Remove the flywheel magneto 5 See page 3 7 and 3 8 09930 40113 Flywheel holder 09930 40120 Rotor holder attachment 6 Remove the tiller handle assy 6 See page 7 11 Before removing the power unit Drain the engine oil See page 2 4 Shift into NEUTRAL position ...

Page 69: ...NIT 6 3 7 Remove the four engine mounting bolts 8 Detach the power unit with the lower cover 9 Remove the four bolts then detach the power unit from the lower cover 10 Remove a bolt 7 and oil seal protector 8 ...

Page 70: ...KI WATER RESISTANT GREASE 3 Apply the Water Resistant Grease to the seal lips of the driveshaft oil seal 99000 25161 SUZUKI WATER RESISTANT GREASE 4 Install the oil seal protector 3 and tighten the bolt after applying the Thread Lock to the bolt 99000 32050 THREAD LOCK 1342 5 Install the power unit to the lower cover then tighten the four bolts to the specified torque Lower cover bolt 8 N m 0 8 kg...

Page 71: ...unit mounting bolt 10 N m 1 0 kg m 7 0 lb ft FLYWHEEL MAGNETO Install the flywheel magneto and tighten the flywheel nut to the specified torque See page 3 8 09930 40113 Flywheel holder 09930 40120 Rotor holder attachment Flywheel nut 45 N m 4 5 kg m 32 5 lb ft IGNITER UNIT Install the igniter unit with an air gap of 0 5 mm between the both core ends and the flywheel See page 3 8 09900 20803 Thickn...

Page 72: ...All parts removed have been returned to the original posi tions Lower unit gear engagement is properly adjusted See page 8 19 Fuel hose routing matchs service manual illustration See page 9 2 Wire routing matchs service manual illustration See page 9 3 No fuel leakage is evident No water leakage is evident during final test running ...

Page 73: ...2 2 Remove the four bolts 3 and the cylinder head cover 4 3 Remove the valve adjusting lock nuts 5 then remove the valve adjusting screw 6 4 Remove the rocker arm shaft 7 and the rocker arms 8 5 Remove the push rods 9 6 Remove the gasket 0 7 Remove the five bolts A and the cylinder head assembly from the cylinder block ...

Page 74: ...BOND 1207B 2 Insert the dowel pins 1 and place a new cylinder head gas ket 2 into position on cylinder 3 Position cylinder head assembly on cylinder 4 Apply engine oil to cylinder head bolts 5 Lightly seat all cylinder head bolts at first According to tightening order in figure tighten bolts in two steps Cylinder head bolt 1st step 7 N m 0 7 kg m 5 0 lb ft Final step 13 N m 1 3 kg m 9 5 lb ft Do n...

Page 75: ...the rocker arms 5 and the rocker arm shaft 6 8 Adjust the valve clearance See page 2 8 and 2 9 9 Install the cylinder head cover and the gasket then tighten the four cylinder head cover bolts diagonally to the specified torque Cylinder head cover bolt 7 N m 0 7 kg m 5 0 lb ft 1 2 3 4 ...

Page 76: ... thumbs of both hands move it in the arrow direction and force it off the valve shaft 2 Remove the valve springs 2 NOTE Reassemble each valve spring to their original position 3 Remove the intake valve 3 and exhaust valve 4 4 Remove the valve stem seals 5 Do not re use the removed valve stem seal ...

Page 77: ...e and the exhaust ports the combustion chamber and the head sur face Valve seat Inspect the valve seats for crack or other damage Cylinder head distortion Using a straightedge and the thickness gauge measure the gasket surface of the cylinder head at a total of six locations as shown in the figure 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in If the measuremen...

Page 78: ...other damage Replace it necessary Rocker arm shaft hole diameter Measure the rocker arm shaft hole diameter using a small bore gauge Rocker arm shaft hole diameter Standard 4 015 4 027 mm 0 1581 0 1585 in Rocker arm shaft outside diameter Measure the rocker arm shaft diameter using the micrometer 09900 20205 Micrometer Rocker arm shaft outside diameter Standard 3 990 4 005 mm 0 1571 0 1577 in PUSH...

Page 79: ...ve guide inside diameter Standard IN EX 4 000 4 012 mm 0 1575 0 1580 in Valve guide to valve stem clearance Standard IN 0 010 0 037 mm 0 0004 0 0015 in EX 0 025 0 052 mm 0 0010 0 0020 in Service limit IN 0 075 mm 0 0030 in EX 0 090 mm 0 0035 in If the measurement exceeds the service limit replace the valve and or the cylinder head Valve stem deflection If unable to measure the valve guide inside d...

Page 80: ...ice limit 0 05 mm 0 002 in If the measurement exceeds the service limit replace the valve Valve head radial runout Measure the valve head radial runout 09900 20602 Dial gauge 09900 20701 Magnetic stand 09900 21304 V block set Valve head radial runout Service limit 0 08 mm 0 003 in If the measurement exceeds the service limit replace the valve Valve head thickness Measure the thickness T of the val...

Page 81: ... the seat 6 Continuously pattern on the valve seating face with Prussian blue 7 Measure the valve seat contact width A 09900 20101 Vernier calipers Valve seat contact width A Standard IN EX 0 8 1 0 mm 0 03 0 04 in If measurement exceeds specification repair valve seat NOTE Clean and assemble the cylinder head and the valve compo nents Fill the intake and the exhaust ports with solvent in order to ...

Page 82: ...N EX 21 52 mm 0 847 in If the measurement exceeds the service limit replace the valve spring Valve spring preload Measure the valve spring preload 09900 20101 Vernier calipers Valve spring preload Standard IN EX 36 5 41 9 N 3 65 4 19 kg 8 05 9 24 lbs for 15 mm 0 6 in Service limit IN EX 33 N 3 3 kg 7 34 lbs for 15 mm 0 6 in If the measurement exceeds the service limit replace the valve spring ...

Page 83: ...ide bore and valve stem 4 Install the valve 2 to the valve guide 5 Install the valve spring 3 and the retainer 4 NOTE Reassemble each valve spring to their original position 6 Push down the retainer with both thumbs to admit the valve stem into the side hole A of the retainer and let it slide side wise into the center hole 7 Make sure the retainers are properly seated in groove B Do not re use the...

Page 84: ...e the power unit See page 6 2 2 Remove the cylinder head See page 6 7 3 Remove the bolt 1 and the under oil seal plate 2 4 Remove the eight bolts and the crankcase 3 5 Remove the thrust washer 4 6 Remove the cam rocker arm 5 washer 6 cam rocker arm 7 spring 8 washer 9 and shaft 0 ...

Page 85: ... Remove the two conrod bolts D and the conrod cap E 9 Remove the piston with the conrod through the top of the cylinder bore 10 Remove the crankshaft F from the cylinder block 11 Remove the circlips G the piston pin H the conrod I and the piston rings J from the piston K ...

Page 86: ...e the screw L and the oil pump outer plate M 13 Remove the inner rotor N and the outer rotor O 14 Remove the four bolts and the thermostat cover P 15 Remove the thermostat Q 16 Remove the three screws and the breather plate R ...

Page 87: ...POWER UNIT 6 21 17 Remove a screw S and the reed valve T ...

Page 88: ...m wear Measure the cam height H 09900 20202 Micrometer Cam height Standard IN EX 28 480 28 680 mm 1 1213 1 1291 in Service limit IN EX 28 180 mm 1 1094 in If the measurement exceeds the service limit replace the cam shaft Camshaft gear Inspect the camshaft gear for wear or other damage Replace it necessary CAM ROCKER ARM Inspect the cam rocker arm for wear or other damage Replace it necessary ...

Page 89: ...g or obstruction Clean the water jackets if necessary Cylinder bore Inspect the cylinder wall for scratches roughness or ridges which indicate excessive wear If the cylinder bore is very rough or deeply scratched or ridged rebore the cylinder and use a oversize piston Cylinder bore wear difference Using the cylinder bore gauge measure the cylinder bore in the thrust and axial directions at the thr...

Page 90: ...07 0 0013 in Service limit 0 100 mm 0 0039 in If the clearance exceeds the service limit replace the piston and or the cylinder or rebore the cylinder Cylinder bore Standard 48 000 48 015 mm 1 8898 1 8904 in Piston skirt diameter Standard 47 975 47 990 mm 1 8888 1 8894 in Identification of oversize piston and piston ring Oversize piston and piston ring are marked as show in the fig ures Piston 1st...

Page 91: ...easurement exceeds the service limits replace the pis ton and or the piston ring Piston ring groove width Standard 1st 2nd 1 21 1 23 mm 0 048 0 049 in Oil 1 51 1 53 mm 0 059 0 060 in Piston ring thickness Standard 1st 2nd 1 17 1 19 mm 0 046 0 047 in Piston ring end gap Measure the piston ring end gap with the piston ring in the low est position of the cylinder bore 09900 20803 Thickness gauge Pist...

Page 92: ... thrust and axial directions 09900 20205 Micrometer 09900 20605 Dial calipers Pin clearance in piston pin hole Standard 0 002 0 013 mm 0 0001 0 0005 in Service limit 0 040 mm 0 0016 in Pin clearance in conrod small end Standard 0 006 0 019 mm 0 0002 0 0007 in Service limit 0 050 mm 0 0020 in If the clearance exceeds the service limit replace the piston the piston pin and or the conrod assembly Pis...

Page 93: ...nrod big end width Standard 17 50 17 80 mm 0 689 0 701 in Crank pin width Standard 18 00 18 20 mm 0 709 0 717 in Crank pin Inspect the crank pin for uneven wear or damage Measure the crank pin outside diameter for out of round or taper using the micrometer Out of round A B Taper a b 09900 20205 Micrometer Crank pin outside diameter difference Out of round and Taper Service limit 0 010 mm 0 0004 in...

Page 94: ...p 3 5 N m 0 35 kg m 2 5 lb ft 2nd step 7 N m 0 7 kg m 5 0 lb ft 5 Remove the conrod and the conrod cap from the crank pin 6 Using the scale on the plastigauge envelop measure the plastigauge with the widest point Conrod big end oil clearance Standard 0 15 0 035 mm 0 0006 0 0014 in Service limit 0 080 mm 0 0031 in If the measurement exceeds the service limit replace the conrod assembly and or crank...

Page 95: ...tting noisy rough or other damage NOTE If neither defective nor any damage is found on the oil seals and the bearing do not remove the oil seals and the bearing Drive the oil seal down into the position as shown in the figure A Crankshaft upper oil seal B Crankshaft lower oil seal C Driveshaft oil seal Do not re use the oil seal once removed Always use a new oil seal Crankcase inside A Crankcase i...

Page 96: ...6 30 POWER UNIT OIL PUMP Inspect the outer rotor the inner rotor and the rotor plate for excessive wear or other damage Replace it necessary ...

Page 97: ...through the piston and the conrod 3 Install the piston pin circlips 4 NOTE Make sure that the conrod is installed in the direction shown in the figure Install the circlips with a gap facing either up or down as shown in the figure If the original components are not replaced each piston piston pin and conrod is to be assembled and installed in the original order and position Do not re use the gaske...

Page 98: ...shape Distinguish the 1st ring from the 2nd ring by referring to the fig ure Ring gap direction Position the piston rings so that the ring gaps are staggered at approximately 90 degree angles as shown in the figure 1 1st ring 3 2nd ring 2 Oil ring lower side rail 4 Oil ring upper side rail When installing the spacer do not allow the ends to overlap in the groove Incorrect Correct R R 1 2 3 Mark 1 ...

Page 99: ...per oil seal 09900 25161 SUZUKI WATER RESISTANT GREASE 3 Install the crankshaft 1 to the cylinder block 4 Apply engine oil to the piston and the cylinder wall 5 Insert the piston conrod assembly into the cylinder bore from the cylinder head side using the piston ring compressor Piston ring compressor NOTE Position the mark on the piston head to the flywheel side Flywheel side Mark ...

Page 100: ...ten the two conrod bolts to the specified torque in two steps Conrod bolt 1st step 3 5 N m 0 35 kg m 2 5 lb ft 2nd step 7 N m 0 7 kg m 5 0 lb ft CAMSHAFT 1 Apply engine oil to the shaft 1 2 Install the shaft 1 to the cylinder block 3 Apply engine oil to the cam faces the cam journals and the timing gear 4 While aligning each mark on the camshaft gear and the crankshaft gear install the camshaft 2 ...

Page 101: ...nd the cam rocker arm 6 NOTE Be sure the cam rocker arms are positioned as shown in the fig ure OIL PUMP 1 Apply engine oil to the inner rotor and the outer rotor 2 Install the inner rotor 1 and the outer rotor 2 to the crank case as shown in the figure 3 Install the outer plate 3 4 Apply the THREAD LOCK to the screw 4 99000 32050 THREAD LOCK 1342 5 Secure the outer plate 3 with the screw 4 Match ...

Page 102: ...he crankshaft 4 Apply engine oil to the crank journals 5 Apply engine oil to the crankcase bearing the crankshaft lower oil seal and the driveshaft oil seal 6 Install the crankcase to the cylinder block 7 Tighten the eight crankcase bolts to the specified torque in the order indicated Crankcase bolt 11 N m 1 1 kg m 8 0 lb ft BREATHER PLATE AND THERMOSTAT 1 Install the reed valve 1 to the cylinder ...

Page 103: ... 3 4 Apply sealant to both surfaces of thermostat cover gasket as shown with hatched lines 99000 31120 SUZUKI SILICONE SEAL 5 Install the gasket and the thermostat cover 4 to the cylinder block and secure with the four bolts CYLINDER HEAD Install the cylinder head See page 6 8 and 6 9 POWER UNIT Install the power unit See page 6 4 to 6 6 ...

Page 104: ...n a container filled with water 2 Place the thermometer in the container and heat water Observe water temperature when the thermostat valve opens and releases the thread Thermostat operating temperature Standard 48 52 C 118 126 F INSTALLATION Installation is reverse order of removal with special attention to the following steps 1 Install the thermostat 1 2 Apply sealant to both surfaces of thermos...

Page 105: ... in schematic form below If overheating occurs the components of the cooling system must be inspected for blockage corrosion build up or damage Component inspection Refer to page Water pump Impeller 8 8 Water tube 7 6 Thermostat 6 38 Cylinder head 6 11 Cylinder block 6 23 COOLING SYSTEM SCHEMATIC When open Driveshaft housing Exhaust outlet Thermostat Exhaust water jacket Cylinder Cylinder head Dri...

Page 106: ...d type pump provides engine oil to all power unit components requiring lubrication ENGINE OIL LUBRICATION CHART Crankshaft upper bearing Connecting rod Piston Timing gear Lower bearing ENGINE OIL Lower crankcase Oil pan Oil pump Cylinder block Cylinder head Valve train ...

Page 107: ...MID UNIT 7 1 MID UNIT CONTENTS 7 DRIVESHAFT HOUSING SWIVEL BRACKET CLAMP BRACKET 7 2 DISASSEMBLY 7 2 INSPECTION 7 5 REASSEMBLY 7 7 TILLER HANDLE 7 11 REMOVAL 7 11 DISASSEMBLY REASSEMBLY 7 12 ...

Page 108: ...ee page 6 2 Remove the lower unit See page 8 2 Remove the water tube 1 with the grommet upside Remove the spring pin 3 and the tilt lock wing nut 4 Remove the tilt lock spacer 5 Remove the swivel shaft nut 6 and swivel shaft washer 7 Remove the port side clamp bracket 8 and tilt friction washer 9 ...

Page 109: ...e lower thrust mount 0 Remove the starboard side clamp bracket A the tilt friction washer B and the swivel shaft bolt C Remove the two swivel bracket bolts D Remove the port side swivel bracket E Take out the steering adjuster plate F with the steering adjuster rubber G ...

Page 110: ...7 4 MID UNIT Remove the stopper bracket H Remove the starboard side swivel bracket I Take out the steering upper bush J from the driveshaft housing K ...

Page 111: ...cket If crack or other damage is found replace STEERING UPPER BUSHING Inspect the upper bushings If crack excessive wear deterioration or other damage is found replace STOPPER BRACKET STOPPER SPRING Inspect the stopper bracket and the stopper spring If crack or other damage is found replace THRUST BLOCK LOWER THRUST MOUNT Inspect the thrust block and the lower thrust mount If crack excessive wear ...

Page 112: ... MID UNIT SWIVEL SHAFT BOLT Inspect the swivel shaft bolt If wear twist bend or other damage is found replace WATER TUBE Inspect the water tube If clog obstruction or other damage is found clean or replace ...

Page 113: ...3 Steering adjuster rubber 14 Steering adjuster plate 15 Clamp bracket STBD 16 Clamp bracket PORT 17 Clamp handle screw 18 Clamp plate 19 Clamp handle screw cap 20 Swivel shaft bolt 21 Tilt lock spacer 22 Tilt lock wing nut 23 Tilt lock pin 24 Tilt lock bolt 25 Stopper shaft 26 Stopper bracket 27 Swivel shaft washer 28 Swivel shaft nut 29 Lower thrust mount 30 Thrust block 31 Driveshaft housing kn...

Page 114: ...tside surfaces of the bushings Inside surface of the lower thrust mount Steering adjuster 99000 25161 SUZUKI WATER RESISTANT GREASE Install the steering upper bushings 1 in position as shown in the figure Install the swivel bracket STBD 2 Install the stopper bracket 3 Install the steering adjuster rubber 4 with the steering adjuster plate 5 Install the swivel bracket PORT 6 Install the two swivel ...

Page 115: ...thrust block 5 with the lower thrust mount and the tilt lock bolt 4 Install the tilt friction washer 6 and the clamp bracket port side 7 Install the tilt friction washer 8 and the swivel shaft nut 9 Tighten the swivel shaft nut to the specified torque Swivel shaft nut 10 N m 1 0 kg m 7 0 lb ft Apply the Thread Lock to the swivel shaft nut 99000 32050 THREAD LOCK 1342 Install the tilt lock spacer 0...

Page 116: ...7 10 MID UNIT LUBRICATION After completing reassembly of the mid unit apply the Water Resistant Grease through grease nipple 99000 25161 SUZUKI WATER RESISTANT GREASE ...

Page 117: ... 2 and remove the throttle cable 1 from the throttle cable holder 3 Remove the igniter unit bolt 5 and ground lead 4 of the emergency engine stop switch Remove the plus lead 6 of the emergency engine stop switch from the igniter unit Remove the throttle cable clamp 7 Remove the handle pivot bolt 8 and tiller handle washer 9 Remove the tiller handle 0 ...

Page 118: ... tiller handle DISASSEMBLY REASSEMBLY DISASSEMBLY Remove the throttle adjust knob 1 Remove the throttle cable screw 3 and the cable stopper 2 Remove the two throttle cable screws 5 Take out the throttle lower case 4 and the throttle upper case 6 from the tiller handle Remove the throttle cable end from the tiller handle ...

Page 119: ...ottle handle spacer 3 and the throttle handle bushings 2 2 4 1 9 12 8 16 6 5 7 10 11 14 13 11 10 15 17 3 Consisting parts 17 N m 1 7 kg m 12 5 lb ft 1 Tiller handle 2 Throttle grip 3 Throttle case upper 4 Throttle case lower 5 Throttle adjust knob 6 Throttle adjust knob nut 7 Throttle cable screw 8 Throttle handle mount 9 Throttle handle spacer 10 Throttle handle bush 11 Throttle handle washer 12 ...

Page 120: ... 1 7 kg m 12 5 lb ft Install the throttle cable 6 to the throttle cable holder 8 Install the throttle cable 6 to the carburetor 7 Check that the throttle control is smoothly operated from the full closed position to the full opened position Install the choke rod connector 0 to the carburetor 7 Install the choke rod 9 to the choke rod connector 0 Check that the choke control is smoothly operated fr...

Page 121: ...LOWER UNIT 8 1 LOWER UNIT CONTENTS 8 REMOVAL AND DISASSEMBLY 8 2 INSPECTION 8 6 REASSEMBLY AND INSTALLATION 8 10 LOWER UNIT GEARS SHIMMING AND ADJUSTMENT 8 19 ...

Page 122: ...er unit with the lower cover 2 Remove the spring 1 3 Remove the E ring 2 4 Take out the shift rod 3 from the clutch rod arm 4 5 Remove the two bolts 5 6 Separate the gearcase assembly from the driveshaft hous ing 6 Disconnect the spark plug cap from the spark plug before removing the lower unit ...

Page 123: ...level plug 7 and drain the gear oil 8 Remove the cotter pin 9 then detach the propeller 0 9 Remove the shear pin A 10 Pull out the shift rod B 11 Remove the four bolts C 12 Remove the pump case D 13 Remove the following parts Water pump impeller E Key F Pump under panel G ...

Page 124: ... two bolts H securing the propeller shaft bearing housing 15 Remove the propeller shaft bearing housing I 16 Remove the E ring J 17 Pull out the driveshaft K 18 Take out the following parts Pinion gear L Pinion gear backup shim M ...

Page 125: ...TS 1 Separate the following parts Bearing housing 1 Washer 2 Propeller shaft assy 3 2 Push rod out the propeller shaft 4 Remove the clutch dog 6 3 Remove the spring 5 4 Remove the circlip 7 DISASSEMBLY OF WATER PUMP COMPONENTS Separate the following parts Water pump case seal 1 Water pump case sleeve 2 Water pump case 3 O ring 4 ...

Page 126: ...ASE Inspect the gearcase If crack or other damage is found replace the gearcase Visually check the forward gear bearing If pitting noisy rough or other damage is found replace the bearing Visually check the driveshaft bushing If excessive wear pit ting or other damage is found replace the bushing GEAR Inspect the teeth of the forward gear and pinion gear If excessive wear chip or other damage is f...

Page 127: ...ropeller shaft If excessive wear twist or other damage is found replace SHIFT ROD AND SHIFT CAM Inspect the stepped surfaces of the shift cam If excessive wear chip or other damage is found replace the cam PROPELLER SHAFT BEARING HOUSING Inspect the housing If crack or other damage is found replace the housing Visually check the oil seal and O ring If cut nick excessive wear or other damage is fou...

Page 128: ...ATER PUMP AND RELATED ITEMS Inspect the impeller If cut tear or excessive wear is found replace the impeller Inspect the pump case the inner sleeve and the under panel If wear crack distortion or corrosion is found replace Inspect the impeller pin If excessive wear or other damage is found replace the pin Inspect the seal and the O ring If cut excessive wear or other damage is found replace DRIVES...

Page 129: ... Drive the oil seals down into the housing with lipped portion toward the water pump case one at a time 4 Apply the Water Resistant Grease to the seal lips 09921 20210 Bearing remover 09930 30104 Sliding hammer 99000 25161 SUZUKI WATER RESISTANT GREASE DRIVESHAFT Inspect the driveshaft If wear twist or other damage is found on the splines replace the driveshaft ...

Page 130: ...Clutch shaft bush No 2 8 Clutch rod arm 9 Clutch lever pin 10 Clutch notch spring 11 E ring 12 Shift rod 13 O ring 14 Water pump case grommet 15 Bolt 16 Water pump case 17 Water pump case seal 18 Water pump case sleeve 19 Water pump impeller 20 Pump case impeller pin 21 Pump case under panel 22 Pump case panel gasket 23 Bolt 24 Protection anode 25 Protection anode bolt 26 Driveshaft oil seal 27 Ge...

Page 131: ...n gear backup shim 35 Forward gear backup shim 36 Forward gear 37 Push rod 38 Return spring 39 Propeller shaft circlip 40 Shifter clutch dog 41 Propeller shaft 42 Thrust washer 43 Propeller shaft housing O ring 44 Propeller shaft housing 45 Bolt 46 Propeller shaft housing oil seal 47 Shear pin 48 Propeller 49 Cotter pin 8 N m 0 8 kg m 6 0 lb ft ...

Page 132: ...4 99000 22540 SUZUKI OUTBOARD MOTOR GEAR OIL Make sure that all parts used in assembly are clean and lubricated After assembly check the parts for tightness and smoothness of operation Before final assembly be absolutely certain that all gear contact shim adjustments and toler ances are correct Failure to correctly adjust these areas will result in lower unit damage See the LOWER UNIT GEARS SHIMMI...

Page 133: ...ply the Water Resistant Grease to the oil seal lips 99000 25161 SUZUKI WATER RESISTANT GREASE Apply the gear oil to the bushing in the housing 99000 22540 SUZUKI OUTBOARD MOTOR GEAR OIL Install the driveshaft 1 Install the E ring 2 ...

Page 134: ...eller shaft assy bearing housing Insert the thrust washer 2 and the bearing housing 3 to the propeller shaft 1 Apply the Water Resistant Grease to the O ring 4 and the oil seals of the bearing housing 99000 25161 SUZUKI WATER RESISTANT GREASE Install the propeller shaft housing assembly to the gearcase and tighten the two bolts to the specified torque Propeller shaft bearing housing bolt 8 N m 0 8...

Page 135: ...Install the impeller pin 3 Install the impeller 4 Apply SUZUKI BOND 1207B onto the outer surface of water pump sleeve 5 99000 31140 SUZUKI BOND 1207B Install the water pump sleeve into the water pump case 6 by confirming the boss on the sleeve should be meeting with the groove on the pump case Install the water pump case seal 7 Apply the Water Resistant Grease to the O ring 8 Install the O ring 8 ...

Page 136: ...e driveshaft clockwise in order to flex the impeller vanes in the correct direction Tighten the water pump case bolts 0 to the specified torque Water pump case bolt 5 N m 0 5 kg m 3 5 lb ft SHIFT ROD Install the shift rod 1 with the stepped section of the shift cam A toward the propeller shaft ...

Page 137: ...w initial pressure of 20 40 kPa 0 2 0 4 kg cm2 2 8 5 7 psi first then apply the specified pressure Leakage test pressure 100 kPa 1 0 kg cm2 14 2 psi 4 Once stabilized the pressure should remain steady for at least 5 minutes If the pressure does not fall sealing performance is correct PROPELLER Apply the Water Resistant Grease to the propeller shaft 99000 25161 SUZUKI WATER RESISTANT GREASE Install...

Page 138: ... retaining bolts 2 and tighten the bolts to the specified torque 09900 31120 SUZUKI SILICONE SEAL Gearcase bolt 8 N m 0 8 kg m 6 0 lb ft Install the shift rod 3 to the clutch rod arm 4 Install the E ring 5 Install the clutch notch spring 6 Shift the clutch lever from neutral and forward to check GEAR OIL Fill the gearcase with the specified gear oil See page 2 5 99000 22540 SUZUKI OUTBOARD MOTOR G...

Page 139: ...AR PINION GEAR SHIM ADJUSTMENT Adjust the forward gear pinion gear shimming as shown below Install the forward gear bearing 1 the backup shim 3 and the forward gear 2 Install the driveshaft 6 the pinion gear backup shim 4 the pinion gear 5 and E ring 7 Numerical index item Available thickness mm Design specification thickness mm 1 Pinion gear backup shim 1 8 1 9 2 0 2 1 2 2 2 0 2 Forward gear back...

Page 140: ...tact pattern Pinion and Forward gear Check tooth contact pattern by using the following procedure To assess tooth contact apply a light coat of Prussian Blue on the convex surface of the forward gear Install the propeller shaft and the housing assembly Do not install the push rod NOTE Securing the propeller shaft housing with the bolts is not required Push the propeller shaft inward and hold in po...

Page 141: ...kness of the forward gear shim Slightly decrease the pinion gear shim thickness The backlash of the gear should be checked when increasing or decreasing the thickness of the shim to adjust tooth contact Do not set tooth contact in the top side toe contact position Damage and chipping of the forward and pin ion gear may result Do not set tooth contact in the bottom side toe contact position Chippin...

Page 142: ...shaft as shown in the figure 09951 09530 Gear adjusting gauge 2 Push the propeller shaft inward 3 Hold the propeller shaft in and set the dial gauge pointer to zero 4 Slowly pull the propeller shaft outward and read the maxi mum thrust play on the dial If the measurement is more than the specification increase the propeller shaft thrust washer thickness If the measurement is less than the specific...

Page 143: ...WIRE AND HOSE ROUTING 9 1 WIRE AND HOSE ROUTING CONTENTS 9 HOSE ROUTING 9 2 WIRE ROUTING 9 3 WIRING DIAGRAM 9 4 ...

Page 144: ...id contact with other parts Check that hoses do not contact rods and levers during either engine operation or standstill Extreme care should be taken not to cut abrade or cause any other damage on hoses Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted Fuel tank Fuel cock Fuel hose Breather hose ...

Page 145: ...WIRE AND HOSE ROUTING 9 3 WIRE ROUTING Emergency stop and engine stop switch Clamp Emergency stop and engine stop switch lead Igniter unit ...

Page 146: ...ROUTING WIRING DIAGRAM IGNITER UNIT FLYWHEEL MAGNETO SPARK PLUG Wire collor B Black EMERGENCY STOP AND ENGINE STOP SWITCH Emergency stop switch Lock plate IN RUN Lock plate OUT STOP Engine stop switch Button pushed STOP ...

Page 147: ...Prepared by Service Department May 2006 Manual No 99500 97J00 01E Printed in Japan 148 ...

Page 148: ...99500 97J00 01E Printed in Japan TK K6 9 9 5 0 0 9 7 J 0 0 0 1 E ...

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