Suzuki Outboard 4-stroke Service manual 2001-2009

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SYMBOL
Listed in the table below are the symbols indicating instructions and other important information necessary for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout this manual. Refer back to this table if you are not sure of any symbol(s) meanings. SYMBOL DEFINITION Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply SUZUKI OUTBOARD MOTOR GEAR OIL. Apply SUZUKI SUPER GREASE "A". Apply SUZUKI WATER RESISTANT GREASE. Apply SUZUKI BOND "1104". Use peak voltmeter "Stevens CD-77". Apply SUZUKI BOND "1207B". Use special tool. SYMBOL DEFINITION Apply THREAD LOCK "1342".

Apply THREAD LOCK SUPER "1333B". Measure in DC voltage range.

Measure in resistance range.

Measure in continuity test range.

Apply SUZUKI SILICONE SEAL.

Apply SUZUKI MOLY PASTE.

GENERAL INFORMATION

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GENERAL INFORMATION 1
CONTENTS
WARNING / CAUTION / NOTE _______________________________ GENERAL PRECAUTIONS _________________________________ IDENTIFICATION NUMBER LOCATION _______________________ FUEL AND OIL ___________________________________________
GASOLINE RECOMMENDATION ................................................................ ENGINE OIL ..................................................................................................

ENGINE BREAK-IN _______________________________________ PROPELLERS ___________________________________________ POWERHEAD DIRECTION OF ROTATION _____________________ SPECIFICATIONS _________________________________________ SERVICE DATA ___________________________________________ TIGHTENING TORQUE ____________________________________ SPECIAL TOOLS _________________________________________ MATERIALS REQUIRED ___________________________________

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GENERAL INFORMATION

WARNING / CAUTION / NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.

Indicates a potential hazard that could result in death or injury.

Indicates a potential hazard that could result in motor damage.

NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical safety principles.

GENERAL PRECAUTIONS
· Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor. · To avoid eye injury, always wear protective goggles when filing metals, working on a grinder, or doing other work, which could cause flying material particles. · When 2 or more persons work together, pay attention to the safety of each other. · When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented outdoors. · When testing an outboard motor in the water and on a boat, ensure that the necessary safety equipment is on board. Such equipment includes : flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope, etc. · When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer's instructions. · Never use gasoline as a cleaning solvent. · To avoid getting burned
, do not touch the engine, engine oil or exhaust system during or shortly after engine operation. · Oil can be hazardous. Children and pets may be harmed from contact with oil. 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 oil. · After servicing fuel, oil / engine cooling system and exhaust system, check all lines and fittings related to the system for leaks. · Carefully adhere to the battery handling instructions laid out by the battery supplier.