Oil Injection warning System: Low oil level, oil flow, troubleshooting the oil injection warning system, oil level sensor, oil flow sensor. Install the seal ring, then apply the Suzuki Bond evenly to only the outside mating surface of the separator case as shown in the figure. Remove the cylinder head assy and the gasket. Remove the cotter pin 1 from the propeller nut and remove the propeller nut 2. Production model years:2001 2002 2003 2004 2005 2006 2007 2008 2009. Lbl P Measure the resistance between the two lead wires of the relay. Align the pin holes of the shift rod 5 and the shift cam 6.
Tighten the clamp bracket shaft nut to the specified torque. This workshop service repair manual gives step by step information on maintenance, repair and mechanic overhaul. Fastener Side cover port Snap pin Front panel Grommet Washer Bolt Front panel bracket Cushion Bolt Side cover seal Washer Tube Screw Side cover plug Remocon cable holder Side cover starboard Side cover seal Stopper Screw. Coat the valve seat evenly with Prussian blue or equivalent. Apply the engine oil to the piston rings. Necessary amount of gear oil: 1050 ml 35. Install the propeller shaft and the housing assembly minus the reverse gear and the internal components.
Disconnect the evaporation hose from the fuel vapor sepa- rator. Remove the high pressure fuel pump 1 and the grommet 2 from the separator cover and then disconnect the pump lead wire connector. Fuel System: carburetion, general information, carburetor circuits, basic functions, dual throat carburetors, removing fuel from the system, fuel pump. Remove the bolt and the trim tab. Apply the engine oil to the piston pin holes and the conrod.
If excessive wear, crack distortion or corrosion is found on the pump case or the under panel, replace. Remove the water tube and the grommets. Loosen the bolt and disconnect the switch wire Blue. Pump body Inspect the pump body. This Complete Service and Repair Manual contains everything you will need to repair, maintain, rebuild, refurbish or restore your Outboard Motor.
Apply the Silicone Seal to the seven gearcase bolts and tighten them to the specified torque. Remove the bolt, the fastening band and the silencer cover. During the following procedures, the engine must be firmly secured and its weight fully supported. Measure resistance between the terminals for all combina- tions. Install the valve into the valve guide.
It will help you understand, care for, and lower the repair and maintenance cost for your Suzuki Outboard Engine motor for a overall improved satisfaction with your ownership. Remove the five screws 1. Apply the bond to both surfaces of the gasket in its mating area. Reverse Neutral switch function: Continuity. Always use a new gasket. Remove the circlip 1, the washer 2 and 3.
There are many more chapters and data in this manual. The manuals even cover troubleshooting, engine specifications, and wiring diagrams. Some engines operate on the principle of fuel intake - exhaust gases. The materials and components used are of the highest quality, so all modifications are characterized by increased reliability and correspond to the stated characteristics. Remove the four bolts and the side cover starboard. Disconnect the spark plug cap from the spark plug.
Pull out the oil level gauge 1. Remove the lower mount assy 1. Refinish the valve guide bore. Always use a new gasket. If either sensor or installation is improper, the O feed- back operation will be performed incorrectly and could possibly result in engine operating problems. Loosen all valve adjusting screws 2 fully. Install the valve stem seal onto the valve guide by pushing the tool with finger tip.