MODEL U4-60 SUZUKI SERIES 60 HP
ASSEMBLY INSTRUCTIONS
57.4 CU. IN. STARTING 2010
1
1. Place the motor on the transom of your boat so that it is mounted vertically, in the normal fashion.
Disconnect the gearshift rod coupling near the gearbox and remove the bolts holding the gearbox to the
exhaust housing. Remove the gearbox assembly.
2. Remove the water pump assembly from the gear box, including the lower stainless steel plate and impeller
drive key.
3. Next, install the jet pump driveshaft assembly into the spiral pump housing, locking it in place with two #10-
24 fil head screws and spring lock washers.
4. Install the water pump assembly on top of the 3/4 inch thick aluminum adapter and stainless steel plate. Be
sure also to install the water pump impeller and drive key removed from the propeller drive. Lock in place
using four 1/4-20 x 2 1/4 bolts and lock washers. Grease the threads. 8 Ft-lbs.
5. The large 3/4 inch adapter plate is attached to the exhaust housing to hold the jet drive. The tube guides the
disconnected shift rod. Two 6 x 16 mm dowels locate the plate and six M8 x 30 mm hex head bolts and lock
washers secure it. Grease the bolt threads and the threaded end of the shift rod where it slides in the tube. 12
ft-lbs.
6. Next, attach the jet drive to the motor. Two 3/16 x 1/2 dowel pins center the jet drive on the adapter plate.
Four 5/16-18 x 2 3/4 bolts and lock washers from below and one 3/8-16 x 1 1/4 bolt from above rear are
used. Grease the bolt threads, driveshaft spline generously, rubber water tube sleeve and guide the jet into
place. Tighten the 5 bolts, 5/16 bolts to 12 ft-lbs and 3/8 bolt to 22 ft-lbs.
7. Next, install the impeller. Grease the shaft threads, key and impeller bore. Place the plastic sleeve inside the
impeller; hold the key in the nose of the impeller with your forefinger and slide onto the driveshaft. Install
the shim washers, torsional damper and nut retainer on the shaft, and bring the nut up snug by hand.
Place the liner wear ring in position and observe the clearance between the impeller blade edge and the
intake liner.
When, after use in sand and gravel, the blade clearance becomes more than about 1/32” between the
impeller edge and the water intake liner, one or more of the shim washers can be transferred from the bottom
stack to the top of the impeller, which moves the impeller down into the tapered casing to reduce the
clearance.
Shims should not be used above the impeller on new installations where no wear has occurred unless the
blade clearance exceeds 1/32 inch. Insufficient blade clearance will do more harm than good from any
performance gains it might provide.
When the impeller clearance is satisfactory, bump the nut up tight with a wrench. If the ears of the retainer
do not line up with the flats on the nut, spin the nut off, turn the retainer over, and tighten the nut again. In
one of these two positions you will have alignment and can fold the ears up against the nut to retain it. The
flat in the retainer is angled to the ears to allow this.
8. Place the intake casing in position with the lower end at the rear and tighten the six 1/4-20 fiber lock nuts.
No lock washers are used. Grease the threads. See the diagram on page 3.
9. If your jet drive was ordered for use with a steering tiller handle, see the attached shift cable assembly
instruction page for installing shift cable #2039.