outboard workshop service manual all motors 2 to 225 hp
Contents
1. 3 Parts catalogs giving application and part number informa tion are provided by manufacturers for most replacement parts are almost always open weeknights Saturdays and Sundays when the jobbers are usually closed The lowest prices for parts are most often found in discount stores or the auto department of mass merchandisers Parts sold here are name and private brand parts bought in huge quantities so they can offer a competitive price Pri vate brand parts are made by major manufacturers and sold to large chains under a store label Avoiding the Most Common Mistakes There are 3 common mistakes in mechanical work 1 Incorrect order of assembly disassembly or adjustment When taking something apart or putting it together performing steps in the wrong order usu ally just costs you extra time however it CAN break something Read the entire procedure before beginning disassembly Perform everything in the order in which the instructions say you should even if you can t immediately see a rea son for it When you re taking apart something that is very intricate you might want to draw a picture of how it looks when assembled at one point in order to make sure you get everything back in its proper position When making adjust ments perform them in the proper order often one adjustment affects another and you cannot expect satisfactory results unless each adjustment is made only when it cannot be changed by another 2 Overtorqu2. install a part incorrectly things may operate poorly if at all If you hook up electrical wiring incorrectly you may instantly learn a very very expensive lesson A piece of masking tape for example placed on a hose and another on its fitting will allow you to assign your own label such as the letter A or a short name As long as you remember your own code the lines can be reconnected by matching letters or names Do remember that tape will dissolve when satu rated in fluids If a component is to be washed or cleaned use another method of identification A permanent felt tipped marker can be very handy for marking metal parts but remember that fluids will remove permanent marker SAFETY is the most important thing to remember when performing mainte nance or repairs Be sure to read the information on safety in this manual Maintenance or Repair Proper maintenance is the key to long and trouble free engine life and the work can yield its own rewards A properly maintained engine performs better than one that is neglected As a conscientious boat owner set aside a Saturday morning at least once a month to perform a thorough check of items which could cause prob lems Keep your own personal log to jot down which services you performed how much the parts cost you the date and the amount of hours on the engine at the time Keep all receipts for parts purchased so that they may be referred to in case of related problems or
3. reference guide to maintaining and repairing your Suzuki 2 stroke outboard We strongly believe that regardless of how many or how few years experience you may have there is something new waiting here for you This manual covers the topics that a factory service manual designed for factory trained mechanics and a manufacturer owner s manual designed more by lawyers these days covers It will take you through the basics of maintaining and repairing your outboard step by step to help you understand what the fac tory trained mechanics already know by heart By using the information in this manual any boat owner should be able to make better informed decisions about whatthey need to do to maintain and enjoy their outboard Even if you never plan on touching a wrench and if so we hope that you will change your mind this manual will still help you understand what a mechanic needs to do in order to maintain your engine Can You Do It If you are not the type who is prone to taking a wrench to something NEVER FEAR The procedures in this manual cover topics at a level virtually anyone will be able to handle And justthe fact that you purchased this manual shows your interest in better understanding your outboard You may find that maintaining your outboard yourself is preferable in most cases From a monetary standpoint it could also be beneficial The money spent on hauling your boat to a marina and paying a tech to service the engine c
4. the forward half of your boat Do not display any other number there The registration number must be clearly visible It must not be placed on the obscured underside of a flared bow If you can t place the number on the bow place it on the forward half of the hull If that doesn t work put it on the super structure Put the number for an inflatable boat on a bracket or fixture Then firmly attach it to the forward half of the boat The letters and numbers must be plain block characters and must read from left to right Use a space or a hyphen to separate the prefix and suffix letters from the numerals The color of the char acters must contrast with that of the background and they must be at least three inches high In some states your registration is good for only one year In others it is good for as long as three years Renew your registration before it expires At that time you will receive a new decal or decals Place them as required by state law You should remove old decals before putting on the new ones Some states require that you show only the current decal or decals If your vessel is moored it must have a current decal even if it is not in use If your vessel is lost destroyed abandoned stolen or transferred you must inform the issuing authority If you lose your certificate of number or your address changes notify the issuing authority as soon as possible SALES AND TRANSFERS Your registration number is not tra
5. to determine operating expenses As a do it yourselfer these receipts are the only proof you have that the required maintenance was performed In the event of a warranty problem these receipts will be invaluable It s necessary to mention the difference between maintenance and repair Maintenance includes routine inspections adjustments and replacement of parts that show signs of normal wear Maintenance compensates for wear or deterioration Repair implies that something has broken or is not working A need for repair is often caused by lack of maintenance For example draining and refilling the engine oil is maintenance recommended by all manufacturers at specific intervals Failure to do this can allow internal cor rosion or damage and impair the operation of the engine requiring expensive repairs While no maintenance program can prevent items from breaking or wear ing out a general rule can be stated MAINTENANCE IS CHEAPER THAN REPAIR Directions and Locations b See Figure 1 Two basic rules should be mentioned here First whenever the Port side of the engine or boat is referred to it is meant to specify the left side of the engine when you are sitting at the helm Conversely the Starboard means your right side The Bow is the front of the boat and the Stern is the rear Most screws and bolts are removed by turning counterclockwise and tightened by turning clockwise An easy way to remember this is righty tighty lefty
6. AN SU UKI OUTBOARD WORKSHOP SERVICE MANUAL ALL MOTORS 2 225 HP YEARS 1988 TO 2003 CONTENTS HOW TO USE THIS MANUAL 1 2 GENERAL INFORMATION OAIN TES AND BOATING SAFETY SAFETY IN SERVICE 1 12 TOOLS AND EQUIPMENT AND EQUIPMENT 22 T 2 5 FASTENERS MEASUREMENTS AND CONVERSIONS 2 14 ENGINE MAINTENANCE 3 2 MAINTENANCE BOAT MAINTENANCE 3 8 TUNE UP 3 12 WINTER STORAGE CHECKLIST 3 35 SPRING COMMISSIONING CHECKLIST 3 35 FUEL AND COMBUSTION 4 2 FUEL SYSTEM FUEL SYSTEM 4 3 TROUBLESHOOTING 4 7 CARBURETOR SERVICE 4 11 REED VALVE SERVICE 4 25 FUEL PUMP SERVICE 4 27 ELECTRONIC FUEL INJECTION 4 32 UNDERSTANDING AND TROUBLESHOOTING IGNITION AND ELECTRICAL ELECTRICAL SYSTEMS SYSTEMS BREAKER POINTS IGNITION MAGNETO IGNITION 5 7 CAPACITOR DISCHARGE IGNITION CDI SYSTEM 5 11 ELECTRONIC IGNITION 5 38 CHARGING CIRCUIT 5 39 STARTING CIRCUIT 5 45 IGNITION AND ELECTRICAL WIRING DIAGRAMS 5 52 OIL INJECTION SYSTEM 6 2 OIL INJECTION COOLING SYSTEM 6 11 OIL INJECTION WARNING SYSTEMS 6 14 OVERHEAT WARNING SYSTEM 6 17 CONTENTS ENGINE MECHANICAL 7 2 POWERHEAD RECONDITIONING 7 32 POWERHEAD LOWER UNIT 8 2 LOWER UNIT OVERHAUL 8 6 LOWER UNIT JET DRIVE 8 51 MANUAL TILT 9 2 GAS ASSISTED TILT 9 2 TRIM AND TILT POWER TILT 9 3 POWER TRIM TILT 9 6 REMOTE CONTROL BOX 10 2 TILLER HANDLE 10 7 REMOTE CONTROL 1 0 HAND REWIND STARTER 11 2 OVERHEAD TYPE ST
7. ARTER 11 2 HAND REWIND STARTER BENDIX TYPE STARTER 11 1 GLOSSARY 11 13 GLOSSARY INDEX 11 17 MASTER INDEX SUPPLEMENT DT5Y AND ADDITIONAL INFORMATION 12 2 SUPPLEMENT ON MOST OTHER MODELS INCLUDING UPDATED CARBURETOR AND IGNITION SPECIFICATIONS HOW TO USE THIS MANUAL 1 2 CAN YOU DO IT 1 2 WHERE TO BEGIN 1 2 AVOIDING TROUBLE 1 2 MAINTENANCE OR REPAIR 1 2 DIRECTIONS AND LOCATIONS 1 2 PROFESSIONAL HELP 1 2 PURCHASING PARTS 1 3 AVOIDING THE MOST COMMON MISTAKES 1 3 BOATING SAFETY 1 4 REGULATIONS FOR YOUR BOAT 1 4 DOCUMENTING OF VESSELS 1 4 REGISTRATION OF BOATS 1 4 NUMBERING OF VESSELS 1 4 SALES AND TRANSFERS 1 4 HULL IDENTIFICATION NUMBER 1 4 LENGTH OF BOATS 1 4 CAPACITY INFORMATION 1 4 CERTIFICATE OF COMPLIANCE 1 4 VENTILATION 1 5 VENTILATION SYSTEMS 1 5 REQUIRED SAFETY EQUIPMENT 1 5 TYPES OF FIRES 1 5 FIRE EXTINGUISHERS 1 5 WARNING SYSTEM 1 7 PERSONAL FLOTATION DEVICES 1 7 SOUND PRODUCING DEVICES 1 9 VISUAL DISTRESS SIGNALS 1 9 EQUIPMENT NOT REQUIRED BUT RECOMMENDED 1 10 SECOND MEANS OF PROPULSION 1 10 BAILING DEVICES 1 10 FIRST AID KIT 1 10 ANCHORS 1 10 VHF FM RADIO 1 11 TOOLS AND SPARE PARTS 1 11 COURTESY MARINE EXAMINATIONS 1 11 SAFETY IN SERVICE 1 12 DO S 1 12 DON TS 1 12 GENERAL INFORMATION AND BOATING SAFETY HOW TO USE THIS MANUAL 1 2 BOATING SAFETY 1 4 1 1 SAFETY IN SERVICE 1 12 1 2 GENERAL INFORMATION AND BOATING SAFETY HOW TO USE THIS MANUAL This manual is designed to be a handy
8. and where professional service should begin Take your time and do your research first starting with the information in this manual and then make your own decision If you really don t feel comfortable with attempting a procedure DON T DO IT If you ve gotten into something that may be over your head don t panic Tuck your tail between your legs and call a marine mechanic Marinas and independent shops will be able to finish a job for you Your ego may be damaged but your boat will be properly restored to its full running order So as long as you approach jobs slowly and carefully you really have nothing to lose and every thing to gain by doing it yourself Purchasing Parts See Figures 2 and 3 When purchasing parts there are two things to consider The first is quality and the second is to be sure to get the correct part for your engine To get qual ity parts always deal directly with a reputable retailer To get the proper parts always refer to the information tag on your engine prior to calling the parts counter An incorrect part can adversely affect your engine performance and fuel economy and will cost you more money and aggravation in the end Just remember a tow back to shore will cost plenty That charge is per hour from the time the towboat leaves their home port to the time they return to their home port Get the picture So who should you call for parts Well there are many sources for the parts you will n
9. eed Where you shop for parts will be determined by what kind of parts you need how much you want to pay and the types of stores in your neighborhood Your marina can supply you with many of the common parts you require Using a marina for as your parts supplier may be handy because of location just walk right down the dock or because the marina specializes in your partic ular brand of engine In addition it is always a good idea to get to know the marina staff especially the marine mechanic The marine parts jobber who is usually listed in the yellow pages or whose ame can be obtained from the marina is another excellent source for parts In ddition to supplying local marinas they also do a sizeable business in over he counter parts sales for the do it yourselfer Almost every community has one or more convenient marine chain stores These stores often offer the best retail prices and the convenience of one stop shopping for all your needs Since they cater to the do it yourselfer these stores 5 05001P01 Fig 2 By far the most important asset in purchasing parts is a knowledgeable and enthusiastic parts person 0 04971 12 Fig
10. eed not be If you document your yacht you have the legal authority to fly the yacht ensign You also may record bills of sale mortgages and other papers of title with federal authorities Doing so gives legal notice that such instruments exist Documentation also permits preferred status for mortgages This gives you additional security and aids financing and transfer of title You must carry the original documentation papers aboard your vessel Copies will not suffice REGISTRATION OF BOATS If your boat is not documented registration in the state of its principal use is probably required If you use it mainly on an ocean a gulf or other similar water register it in the state where you moor it If you use your boat solely for racing it may be exempt from the requirement in your state States may also exclude dinghies Some require registration of documented vessels and non power driven boats All states except Alaska register boats In Alaska the U S Coast Guard issues the registration numbers If you move your vessel to a new state of principal use a valid registration certificate is good for 60 days You must have the registration certificate certificate of number aboard your vessel when it is in use A copy will not suffice You may be cited if you do not have the original on board NUMBERING OF VESSELS A registration number is on your registration certificate You must paint or permanently attach this number to both sides of
11. ing or undertorquing While it is more common for over torquing to cause damage undertorquing may allow a fastener to vibrate loose causing serious damage Especially when dealing with aluminum parts pay attention to torque specifications and utilize a torque wrench in assembly If a torque figure is not available remember that if you are using the right tool to perform the job you will probably not have to strain yourself to get a fastener tight enough The pitch of most threads is so slight that the tension you put on the wrench will be multiplied many times in actual force on what you are tight ening 3 Crossthreading This occurs when a part such as a bolt is screwed into a nut or casting at the wrong angle and forced Crossthreading is more likely to occur if access is difficult It helps to clean and lubricate fasteners then to start threading with the part to be installed positioned straight in Always start a fas tener etc with your fingers If you encounter resistance unscrew the part and start over again at a different angle until it can be inserted and turned several times without much effort Keep in mind that some parts may have tapered threads so that gentle turning will automatically bring the part you re threading to the proper angle but only if you don t force it or resist a change in angle Don t put a wrench on the part until it has been tightened a couple of turns by hand If you suddenly encounter resistance and the
12. loosey Corny but effective And if you are really dense and we have all been so at one time or another buy a ratchet that is marked ON and OFF or mark your own 4 BOW FORWARD FRONT un IN m ALT er STARBOARD LEFT SIDE RIGHT SIDE STERN AFT REAR 04701610 Fig 1 Common terminology used for reference designation on boats of all size These terms are used though out the manual Professional Help Occasionally there are some things when working on an outboard that are beyond the capabilities or tools of the average Do It Yourselfer DlYer This shouldn t include most of the topics of this manual but you will have to be the judge Some engines require special tools or a selection of special parts even for basic maintenance Talk to other boaters who use the same model of engine and speak with a trusted marina to find if there is a particular system or component on your engine that is difficult to maintain For example although the technique of valve adjustment on some engines may be easily understood and even performed by a DlYer it might require a handy assortment of shims in various sizes and a few hours of disassembly to get to that point Not having the assortment of shims handy might mean multiple trips back and forth to the parts store and this might not be worth your time GENERAL INFORMATION AND BOATING SAFETY 1 3 You will have to decide for yourself where basic maintenance ends
13. nsferable to another boat The number stays with the boat unless its state of principal use is changed HULL IDENTIFICATION NUMBER A Hull Identification Number HIN is like the Vehicle Identification Number VIN on your car Boats built between November 1 1972 and July 31 1984 have old format HINs Since August 1 1984 a new format has been used Your boat s HIN must appear in two places If it has a transom the primary num ber is on its starboard side within two inches of its top If it does not have a tran som or if it was not practical to use the transom the number is on the starboard side In this case it must be within one foot of the stern and within two inches of the top of the hull side On pontoon boats it is on the aft crossbeam within one foot of the starboard hull attachment Your boat also has a duplicate number in an unex posed location This is on the boat s interior or under a fitting or item of hardware LENGTH OF BOATS For some purposes boats are classed by length Required equipment for example differs with boat size Manufacturers may measure a boat s length in several ways Officially though your boat is measured along a straight line from its bow to its stern This line is parallel to its keel The length does not include bowsprits boomkins or pulpits Nor does it include rudders brackets outboard motors outdrives diving platforms or other attachments CAPACITY INFORMATION See Figure 4 Ma
14. nufacturers must put capacity plates on most recreational boats less than 20 feet long Sailboats canoes kayaks and inflatable boats are usually exempt Outboard boats must display the maximum permitted horsepower of their engines The plates must also show the allowable maximum weights of the peo ple on board And they must show the allowable maximum combined weights of people engines and gear Inboards and stern drives need not show the weight of their engines on their capacity plates The capacity plate must appear where it is clearly visible to the operator when underway This information serves to remind you of the capacity of your boat under normal circumstances You should ask yourself Is my boat loaded above its recommended capacity and Is my boat overloaded for the present sea and wind conditions If you are stopped by a legal authority you may be cited if you are overloaded U S COAST GUARD CAPACITY INFORMATION 5 MAXIMUM PERSON CAPACITY MAXIMUM WEIGHT CAPACITY PERSONS AND GEAR POUNDS 4 THIS BOAT COMPLIES WITH U 5 COAST GUARD SAFETY ANDARDS ON THE DATE OF CERTIFICATION 04701P20 Fig 4A U S Coast Guard certification plate indicates the amount of occupants and gear appropriate for safe operation of the vessel CERTIFICATE OF COMPLIANCE Manufacturers are required to put compliance plates on motorboats greater than 20 feet in length The plates must say This boat or This equi
15. ould buy you fuel for a whole weekend s boating If you are unsure of your own mechanical abilities at the very least you should fully understand what a marine mechanic does to your boat You may decide that anything other than maintenance and adjustments should be performed by a mechanic and that s your call but know that every time you board your boat you are placing faith in the mechanic s work and trusting him or her with your well being and maybe your life It should also be noted that in most areas a factory trained mechanic will command a hefty hourly rate for off site service This hourly rate is charged from the time they leave their shop to the time they return home The cost sav ings in doing the job yourself should be readily apparent at this point Where to Begin Before spending any money on parts and before removing any nuts or bolts read through the entire procedure or topic This will give you the overall view of what tools and supplies will be required to perform the procedure or what ques tions need to be answered before purchasing parts So read ahead and plan ahead Each operation should be approached logically and all procedures thor oughly understood before attempting any work Avoiding Trouble Some procedures in this manual may require you to label and disconnect a group of lines hoses or wires Don t be lulled into thinking you can remember where everything goes you won t If you reconnect or
16. part has not seated fully don t force it Pull it back out to make sure it s clean and threading properly 1 4 GENERAL INFORMATION AND BOATING SAFETY BOATING SAFETY In 1971 Congress ordered the U S Coast Guard to improve recreational boating safety In response the Coast Guard drew up a set of regulations Beside these federal regulations there are state and local laws you must fol low These sometimes exceed the Coast Guard requirements This section dis cusses only the federal laws State and local laws are available from your local Coast Guard As with other laws Ignorance of the boating laws is no excuse The rules fall into two groups regulations for your boat and required safety equipment on your boat Regulations For Your Boat Most boats on waters within Federal jurisdiction must be registered or docu mented These waters are those that provide a means of transportation between two or more states or to the sea They also include the territorial waters of the United States DOCUMENTING OF VESSELS A vessel of five or more net tons may be documented as a yacht In this process papers are issued by the U S Coast Guard as they are for large ships Documentation is a form of national registration The boat must be used solely for pleasure Its owner must be a U S citizen a partnership of U S citizens or a corporation controlled by U S citizens The captain and other officers must also be U S citizens The crew n
17. pment
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