MODEL U4-60 SUZUKI SERIES 60 HP
ASSEMBLY INSTRUCTIONS
57.4 CU. IN. STARTING 2010
2
10.
Caution:
Two cables will be attached to the cable anchor bracket and roller cam to provide neutral start
protection. The inner cable comes from the remote control box or tiller handle to operate the reverse gate. It
does not enter the motor housing. The 5 foot neutral cable assembly #1318 enters the motor housing to
operate the neutral start safety switch and is driven by the movement of the reverse gate. The neutral start
switch prevents starting the motor in forward or reverse.
11. With the shift handle in forward and the reverse gate in forward,
with the cam roller at the end of the slot,
adjust the cable and/or cable anchor position to this condition.
Shift to reverse and back to forward. The
roller should be at the end of the cam slot such that the gate cannot be forcibly rotated toward reverse.
Pull on the gate by hand to verify this.
If this forward lock condition is not met, readjust the cable
positions.
Shift to neutral and adjust the cable end in the motor housing so that the neutral start switch is
activated. Check adjustment coming from both forward and reverse to compensate free play in cable
linkage
.
12
.
When converting to jet drive, your motor will have to be raised to the height shown in the diagram
on page 3 below, using a straight edge under the boat.
Test run the boat and then raise or lower the
motor 5/16 inch at a time to obtain the best results.
The motor has four sets of upper mounting holes. You will use one set to begin with. Mark pencil lines on
the boat transom through the other sets. Then if you wish to go up or down 5/16 inch, you can drill one
alternate set of holes 5/16 inch up or down from the pencil marks. By alternating between these two sets of
transom holes and the four sets of motor holes, the motor can be moved in 5/16 inch increments over almost
one inch. The transom height should be about 21” measured vertically from the boat bottom for short shaft
motors, and 26" for long shaft motors.
If you raise it too much it will suck air and cavitate, either on start up or when banking on turns.
When cavitating, the motor over speeds in spurts and shakes considerably in the motor mount.
This is not
a normal condition and should be avoided by proper adjustment of motor height on each individual
boat.
If you lower it too much you will have excessive drag, therefore mount the motor as high as possible
without allowing cavitation.
Caution: When starting the engine for the first time, watch to see that cooling water comes out of the
small hole at the rear side of the engine, just below the power head.
This verifies that your assembly of
the cooling water pump and its connections are correct.
The cooling system can be flushed by removing the hex bolt next to the grease fitting. A hose coupling,
24789A1, is available from a Mercury dealer. Turn on the water gently, and start the motor set to idle.
Watch for cooling water at the tell tale. Adjust the water pressure if needed.
Be sure to replace the bolt
after flushing.