suzuki-outboards-workshop-manual-1.pdf

OUTBOARD WORKSHOP SERVICE MANUAL ALL MOTORS 2 TO 225 HP  YEARS 1988 TO 2003

2-6

TOOLS AND EQUI PM ENT

Fig    inch socket set i s probably the most ersatil e tool i n any mechan ics tool box

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Fig 2  swiel (Ujoint) adapter (left) a inchto inch adapt er (center) and a inchto inch adapter (right)

Fig  atchets come in all sizes and configurations from rigid to swielheaded

04920 049215

Fig 4 tandard length sockets (top) are good for just about all jobs oweer some bolts may require deep sockets (bottom)

Fig 5 exhead fasteners retain many components on modern powerheads These fasteners require a socket with a hex shaped drier

Fig   Torx® driers 

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0492

o sic o h socs o an gh asnr and lav h hx s or I ighr appl icaios x drivr socs ar availal individa ll or in ss js li convnioal socts Mor and mor manacrrs ar sin g Torx had asnrs, whic h wr onc nown as ampr rssta asnrs (cas man po pl did no hav ools wih h ncssar odd drivr shap) Th a sill sd whr h man acrr wold prr onl nowldgal mchanics or advancd o--Yor slrs ( Yrs) o wor Trque Wreche  See Figure 18

I n mos applicaions a orq wrch can  sd o assr propr insalla ion o a asnr Torq wrchs co m  n varios dsi gs and mos sors wi ll carr a vari to si o nds A orq wrnch sh ol d  sd an im o hav a spciic orq val  or a asnr p i  mind ha cas hr s n o worldwid sandardiaion o asnrs h chars a h d o hi s scion ar a gnral gid in and shold  sd wih caio.  o ar sing h rgh ool or h j o, o shol d no hav o srain o ighn a asn 049219

Fig      and tamper resistant driers are requir ed to remoe special fasteners installed by the manufacturers

soc itsl ach has advanags Th 6 poin soc is srongr and lss pron o sli ppng which wold srip a ol had or   2 poin socts ar mor commo, sall lss xpnsiv and ca opra r in tigh placs whr h rach had l can swing ar Sandard l ngh socs ar good or js ao all jo s, howvr som sd-had ols, hardo-rach ols ns on log sds c  rqir h dp socs Mos manacrrs s rcssd hx-had astrs o rain ma  o h ng in pars. Ths asnrs rqir a soc wih a hx shapd drvr or a larg sd hx  To hlp prvn or c ls, w wol d rcomm nd ha

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4920

Fig  8 Three types of torque wrenches Top to bottom a  inch drie beam type that reads in inc h lbs  a inch drie clicker type and a inch drie beam type

NTNT HOW TO USE THIS MANUA BOATING SAFETY SAFETY IN SERVICE

TOOS AND EQUIPMENT TOOS FASTENERS MEASUREM ENTS AND AND CONVERSIONS

 · ·

· 2·5

·

·

ENGINE MAINTENANCE BOAT MAINTENANCE TUNE-UP WINTER STORAGE CHECKIST SPRING COMMISSIONING CH ECKIST ECKIST

·  ·

FUE AND COMBUSTION FUE SYSTEM SYSTEM TROUBESHOOTING CARBURETOR SERVICE REED VAVE SERVICE FUE PUMP SERVICE EECTRONIC FUE INJECTION

·  ·  ·  ·

UNDERSTANDING AND AND TROU BESHOOTING EECTRICA SYSTEMS BREAKER POINTS IGNITION (MAGNETO IGNITION) CAPACIT CAPACITOR OR DISCHARGE IGNITION (CDI) SYSTEM EECTRONIC IGNITION CHARGING CIRCUIT

3 ·8

5·2



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OI INJECTION SYSTEM COOING SYSTEM OI INJECTION WARNING SYSTEMS OVERHEAT WARNING SYSTEM

· · · ·

IGNITION AND EECTRICA WIRING DIAGRAMS

· · · ·9 ·

NTNT ENGINE MECHANICAL POWERHEAD RECONDITIONING

 

LOWER UNIT LOWER UNIT OVERHAUL JET DRIVE

  

MANUAL TILT GAS ASSISTED TILT POWER TILT POWER TRIM/TILT

REMOTE CONTROL BOX TILLER HANDLE

9 9 9 9

 

HAND REWIND STARTER OVERHEAD TYPE STARTER STARTER BENDIX TYPE STARTER

  

GLOSSARY





INDEX



ME EX

·

EME

SUPPLEMENT: DTY AND ADDITIONAL INFORMATION ON MOST OTHER MODELS, INCLUDING UPDATED CARBURETOR A ND IGNITION SPECIFICATIONS SPECIFICATIONS

W T S T S ANA  CA YOU DO I? 1-2 WHERE O BEGI 12 AVOID AVOID IG ROUBE 12 12 MAIEA MAIEACE CE OR R EPAIR? 1-2 1-2 DI REC IOS AD AD OCAIOS 1-2 PROFESSIOA HEP 12 PURCHASIG PARS 1-3 AVODIG AVODIG HE MOS C OM MO MISAKES 13 ATNG SAFT  REG UAI UAI OS FOR YOU R BOA BOA 14 DOCUMEIG OF VESSES 14 RE GI SRAI SRAI O OF BOAS 14 UMBERIG OF VESSES 14 SAES AD RASFERS 14 HU DEIFCAIO UMBER EGH OF BOAS 1-4 CAPACIY IFORMAIO 14 CERIFICAE OF COMPIACE 14 VEAIO 15 VEIAIO SYSEMS 15 REQURED SAFEY EQUPME 15 YPES OF FIRES 15 FIR E EX EXGU GU ISHERS 1-5 1-5 WARIG SYSEM 1-7 PERSOA FOAIO DEVCES 17 SOUD PRODUCIG DEVICES 19 VISUA DSRESS SIGAS 19 EQUPME O REQUIRED BU RECOMMEDED 1-10 SECOD MEAS OF PROPUSIO 110 BAIIG DEVICES 110 FRS AID KI 110 ACHORS 110 VHFFM RADO 1-11 OO S AD SPARE PARS PARS 111 COURESY MARIE EXAMIAIOS 11 SAF SAFT T  N SR   DO'S 112 DOS 112



-2

G ENE RAL I N FORMATI FORMATI ON AND BOATI BOATI NG SAFET SAFETY Y

W  US S U his mnul is sign o b  hny rnc rnc gui o minining n rpiring your Suzuki 2-srok 2-srok oubor. W srongly srongly biv h rgrlss o how mny or how w yrs yrs xprinc you my hv hr is so mhin g nw wiing hr o you This mnul covrs h opics h  co cory ry srvic mnul (sgn or coy coy rin mch nics) n  mnucur mnucurr r ownr's m nu ( sign mor by lwyrs lwyrs hs ys) covrs covrs  wi ll k k you hrough h bsics o mnini ng n rpiring you oubor, spby-sp o hlp you unrsn wh h c ory n mchnics lry know by hr. y using h inormon n his mnul, ny bo ownr shoul b bl o mk b b inorm cisions bou wh hy n o o o minin n  njo y hir oubor vn i you nvr pln on ouching  wnch (n i so, w hop h you will chng your your min) hs mnul wil l sil l h lp you unrs unrsn n wh wh  mchnic ns o o in or o minin your ngin.

an You o t? I you r no h yp who is pon o king  wrnch o somhin g, NVR AR. h procurs n h is mnul covr covr opics   lv virully nyon will b bl o hn  . An jus h c c h h you puchs hs mnul shows your ins in br unrsning your oubor You my in h mininin g your oubor yoursl is prbl prbl in mos css rom  mony mony snpoin, i coul lso b bnici l Th mony spn on h ulin g you bo o  mrin n pying  ch o sic h ngin co ul buy you u l or  whol wkn's boing. I you r unsur  o your own mchnicl bi liis,  h vry vry ls ls you shoul  ull y un rsn rsn wh wh  mrin mchnic os o your bo. You my ci h nyhng nyhng oh r hn minnnc n jusmns shoul  b prorm by  mchnic (n h' h's you cl) , bu know h h vry vry im you bor your bo, you r plci ng ih i n h m chnics wok n using him or hr wih you wll- bing, n  myb your li  shoul lso b no h in mos rs  coy rn mchnic will commn   hy ho ur ly r r o r o o si srvc his h our y r r is chrg  rom h im hy lv hir shop o h im hy rurn h om T h cos sv sv ings in oing h h job yousl shoul b ril ril y pprn pprn  his poin

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