INSPECTION AND MAINTENANCE
MAINTENANCE, REPLACEMANT OR REPAIR OF EMISSION CONTROL DEVICES AND SYSTEMS MAY BE PERFORMED BY ANY MARINE SI ENGINE REPAIR ESTABLISHMENT OR INDIVIDUAL USING ANY PART WHICH HAS BEEN CERTIFIED UNDER THE PROVISIONS IN THE CLEAN AIR ACT Sec. 207 (a) (2).
MAINTENANCE SCHEDULE
It is important to inspect and maintain your outboard motor regularly. Follow the chart below.
At each interval, be sure to perform the indicated service. Maintenance intervals should be judged by number of hours or number of months, whichever comes first.
Never start the engine or let it run indoors or where there is little or no ventilation.
Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.
I: Inspect and clean, adjust, lubricate, or replace, if necessary T: Tighten R: Replace
Water-separating fuel filter
Replace the filter element every 12-months (or more frequently if recommended by the filter manufacturer)
Improper maintenance or failure to perform recommended maintenance can be hazardous. Poor maintenance increases the chance of an accident or equipment damage.
Suzuki recommends that only your authorized Suzuki Marine Dealer or a qualified service mechanic perform maintenance on those items in the chart above which are marked with an asterisk (*) .
You may perform maintenance on the unmarked items by referring to the instructions in this section if you have mechanical experience. If you are not sure whether you can successfully complete any of the unmarked maintenance jobs, ask your authorized Suzuki Marine Dealer to do the maintenance for you.
• The safety of you and your passengers depends on how well you maintain your outboard motor. Follow all inspection and maintenance instructions carefully.
• Do not attempt to perform maintenance on this outboard motor if you do not have prior mechanical experience. You could be injured or may damage the motor.
• The maintenance intervals in the chart were established for normal usage of your outboard motor. If your outboard motor is used under severe conditions such as frequent full throttle operation or frequent operation in muddy, silty, sandy, acidic, or shallow water, you should perform maintenance more often than indicated in the chart. If you have any questions regarding appropriate maintenance intervals, consult your authorized Suzuki Marine Dealer.
• When replacing parts on your outboard motor, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
SPARK PLUG
Remove the spark plugs as follows:
Remove the bolt securing the ignition coil.
Pull out the ignition coil.
Loosen and remove the spark plug using the box wrench in the tool bag.
Your outboard motor comes equipped with the following “standard” spark plug for normal usage.
| Standard spark plug | NGK BKR6E |
|---|
It is important that you use ONLY resistor-type spark plugs. Non-resistor types will interfere with the function of the electronic ignition, causing misfiring, or cause problems with other electronic boat equipment and accessories.
Your authorized Suzuki Marine Dealer can determine if the standard spark plug is suitable for your type of motor usage by inspecting the color of the plug’s porcelain center electrode insulator after operation.
If the plug tends to run hot (usually evidenced by whitening of the insulator or a burnt electrode), stop using your motor immediately as severe engine damage may result. If the plug tends to run cold (usually evidenced by blackening of the insulator or a wet electrode), performance may suffer. Ask your authorized Suzuki Marine dealer to evaluate either of these problems to determine the cause.
Use of improper spark plug can cause severe engine damage.
• Do not experiment with other spark plug brands unless you can determine that they are directly equivalent to the specified brand, or you may experience engine damage which will not be covered under warranty. Note that aftermarket cross-reference charts may not be accurate.
• To install spark plug; seat it as far as possible by hand, then use wrench to secure to either recommended torque setting or rotation angle.
Do not overtighten or cross thread the spark plug, as this will damage the aluminum threads of the cylinder head.
• Spark plugs must be seated properly and securely tightened. Loosely installed spark plugs may get abnormally hot and engine damage could result.
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To maintain a strong spark, you should clean and adjust the plug at the interval shown in the maintenance schedule.
Remove carbon deposits from the spark plug using a small wire brush or spark plug cleaner, and adjust the gap as follows;
| Spark plug gap | 0.7 – 0.8 mm (0.028 – 0.031 in.) |
|---|
If the electrode or insulator is damaged, or if either shows excessive wear, then the spark plug should be replaced.
BREATHER AND FUEL LINE
Inspect the breather and fuel line for leaks, cracks, swelling, or other damage. If the breather and fuel line are damaged in any way, they must be replaced. Consult your authorized Suzuki Marine dealer if it is necessary to replace them.
Fuel leakage can contribute to an explosion or fire, causing serious personal injury. Have your authorized Suzuki
Marine Dealer replace the fuel line if there is any evidence of leaking, cracking or swelling.
ENGINE OIL
The motor must be shut off before any ENGINE OIL procedures are performed.
The oil should be changed more often when the engine is operated under adverse conditions like extended trolling
Engine oil change
The oil should be changed when engine is warm so that the oil will drain thoroughly from the engine.
To change the engine oil:
- Place the motor in a vertical position and remove the motor cover. 2. Remove the oil filler cap.
Place a drain pan under the engine oil drain screw.
Remove the engine oil drain screw (1) and gasket (2), then let the engine oil drain.
- After draining, secure the engine oil drain screw with a new gasket.
Do not re-use gasket removed. Be sure to use new gasket.
There are spare gaskets in the tool bag.
- Fill with recommended engine oil to the upper level.
Oil capacity: 8.0 L (8.5/7.0 US/Imp. qt.)
Engine oil: SAE (or NMMA FC-W) 10W-40 API (or NMMA FC-W) Classification SE, SF, SG, SH, SJ
7. Check the engine oil level.
To avoid incorrect measurement of engine oil level, check oil level only when the engine has cooled.
- Reinstall the oil filler cap.
The engine oil temperature may be high enough to burn your fingers when the drain plug is loosened. Wait until the drain plug is cool enough to touch with bare hands.
• New and used oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used engine oil has been found to cause skin cancer in laboratory animals. Brief contact with used oil may irritate skin.
• Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long-sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil.
Recycle or properly dispose of used engine oil.
Do not throw it in the trash, pour it on the ground, down a drain, or into the water
GEAR OIL
To check the gear oil level, adjust the engine to an upright position, remove the gear oil level plug 1 and look into the hole. The oil level should be at the bottom edge of the hole. If the oil level is low, add the specified gear oil until the level reaches the bottom edge of the hole. Then, reinstall and tighten the plug.
Periodic gear oil replacement is essential for long life of your outboard motor. To change the gear oil:
Make sure the motor is in an upright position. Place a drain pan under the lower casing.
Remove the gear oil drain plug (2), then remove the air vent hole plug (3).
After the oil has drained completely, inject the specified gear oil into the gear oil drain hole (2) until it just starts to come out of the air vent hole (3) Approximately 1100 ml (37.2/38.7 US/lmp. oz.) will be required.
Reinstall and tighten the air vent hole plug (3), then quickly reinstall and tighten the gear oil drain plug (2).
To avoid insufficient injection of gear oil, check the gear oil level 10 minutes after doing the procedure in the step (4) If the oil level is low, slowly inject the gear oil into the gear oil level hole (1) up to the correct level.
New and used oil can be hazardous. Children and pets may be harmed by swallowing new or used oil. Continuous contact with used gear oil has been found to cause skin cancer in laboratory animals. Brief contact with used oil may irritate skin.
To minimize your exposure to used oil, wear a long-sleeve shirt and moistureproof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil.
Recycle or properly dispose of used oil.
If fishing line should wrap around the rotating propeller shaft, this may damage the propeller shaft oil seal allowing water to enter the gear case causing severe mechanical damage.
The seal will need to be replaced and the internal gear case components should be inspected for damage.
Gear oil contaminated with water will have a milky color. If you notice any water in the gear oil, immediately contact your authorized Suzuki Marine Dealer. Do not operate until the oil is changed and the reason for contamination is eliminated.
LOW PRESSURE FUEL FILTER
Gasoline is extremely flammable and toxic.
• Stop the motor before cleaning the fuel filter.
• Be careful not to spill fuel. If you do, wipe it up immediately.
• Do not smoke, and keep away from open flames and sparks.
Keep cleaning solvent away from children and pets. Dispose of used solvent properly
Inspect and clean the fuel filter as follows:
Turn the engine off and allow it to cool.
Remove the bolts (1) securing the fuel filter cap (2) in place.
Loosen the ring nut (3) and remove the cup (4).
Pull out the filter element (5) Inspect the element and the O-rings 6 for damage. If they are damaged, replace them.
Wash the element with clean solvent and dry it.
Reinstall the element and O-rings in their original positions.
Screw the ring nut to the cap until the cup is lightly seated.
Tighten the ring nut approximately an additional 1/4 turn to secure the cup.
Reinstall the fuel filter cap with the bolts.
10.Restart the engine and check that there are no leaks around the fuel filter.
If any water exists in the fuel filter cup, the red ring (7) will float. If so, remove the cup and drain the water. Always dispose of excess fuel safely.
For questions, consult your authorized Suzuki Marine Dealer.
LUBRICATION
Proper lubrication is important for the safe, smooth operation and long life of each working part of your outboard motor. The following chart shows the lubrication points of your motor and the recommended lubricant:
Your authorized Suzuki Marine Dealer may also have additional recommendations due to regional climate or operating conditions.
Please consult him for advice.
CORROSION PREVENTION
ANODES
The motor is protected from exterior corrosion by anodes. These anodes control electrolysis and help prevent corrosion. The anodes will corrode in place of the parts they are protecting. You should periodically inspect each of the anodes and replace them when 2/3 of the metal has corroded away.
In certain areas of the country, the water is unusually harsh on metal. Additional anti-corrosion measures may be helpful under those conditions. Consult your authorized Suzuki Marine Dealer for details.
• If anodes have become detached or corroded away, underwater aluminum surfaces (such as the lower unit) will suffer galvanic corrosion damage.
• Do not paint anodes, as this will render them ineffective.
• All anodes should be cleaned periodically with a wire brush to remove any coating which might decrease their protective ability
BONDING WIRES
Bonding wires are used to electrically connect the engine components so they exist in a com mon ground circuit. This allows them to be protected against electrolysis by the anodes. These wires and their terminals should be checked periodically to be sure they have not been damaged.
BATTERY
If you are using a maintenance-free battery, inspect the window area according to the instructions on the battery to make sure the battery is in good condition.
If you are not using a maintenance-free battery, the battery fluid level should be checked every 50 hours of operation or 3 months. The battery solution level must be kept between the MAX and the MIN level lines at all times. If the level drops below the MIN level line, add DISTILLED WATER ONLY until the battery solution level reaches the MAX level line.
Battery acid is poisonous and corrosive.
Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water.
If acid contacts the eyes or skin, get immediate medical attention
When checking or servicing the battery, disconnect the negative (black) cable. Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the motor at the same time.
Battery posts, terminals, and related accessories contain lead and lead compounds. Wash hands after handling.
Once the battery has been initially serviced, NEVER add diluted sulphuric acid, or you will damage the battery. Follow the battery manufacturer’s instructions for specific maintenance procedures.
ENGINE OIL FILTER
The engine oil filter must be changed by authorized Suzuki Marine Dealer periodically. Replace engine oil filter with a new one at initial 20 hours (1 month).
Replace engine oil filter with a new one at every 200 hours (12 months).
FLUSHING THE WATER PASSAGES
FLUSHING THE WATER PASSAGES
After operation in muddy, brackish, or salt water, you should flush the water passages and motor surface with clean, fresh water.
If you do not flush the water passages, salt can corrode the motor and shorten its life. Flush the water passages as follows.
ENGINE RUNNING – Vertical position –
Suzuki recommends that you flush the water passage by using this method.
To flush the water passages, you must obtain a commercially available engine flush device.
• Never start the engine or let it run indoors or where there is little or no ventilation. Exhaust gas contains carbon monoxide, a gas that is colorless and odorless and can cause death or severe injury.
• Make sure the engine remains in NEUTRAL while flushing out the water passages. If shifted into gear, the propeller shaft will turn, possibly resulting in personal injury.
• Make sure the motor is properly clamped to a secure stand or boat and remain in attendance until flushing is completed.
• Keep children and pets away from the area, and stay clear of all moving parts during this procedure.
Never start the motor without supplying water to the cooling system as water pump damage could result in as little as 15 seconds. Severe engine damage could result from no water supply.