Payment and download Instructions: 1 Click on the green instant download button at the top left corner of this page to buy your repair manual now. Conrod big end oil clearance Check coonrod big end oil clearance as follows: 1 Clean surface of conrod, conrod cap, conrod bearing, and crank pin. The outboard marine mechanic should carefully read the text and become familiar with the 25 hp marine engine service manual procedures before beginning the work. You may think all outboards look the same, but once you get under the surface, you'll see why those in the know, choose Suzuki Marine. Tiller handle model Circuit check schematic Starter motor relay Starter motor Starter motor. Shipping in the lower 48 states is always free. Be sure to take readings at more than one place along the length of each stem and guide.
Remove bolts I, water pressure valve cover J, pressure valve Remove bolts L and exhaust tube M. However, enough information in 25 hp outboard repair manuals is given for do-it-yourself or apprentice mechanics to correctly and safely perform repair work to their 25 hp outboard motor and components. Green technology ensures a clean, fuel efficient motor that is fuel injected and battery-less. Remove piston pin circlips as shown. Remove nut 1 from clamp bracket shaft. Lower the manual tilt lock lever 1.
Each color represents the following thickness measured at the center of the bearing. Manuals available for most year models: 1965 1967 1966 1969 1968 1971 1970 1972 1971 1973 1975 1974 1977 1976 1979 1978 1981 1980 1983 1982 1984 1983 1986 1985 1987 1986 1989 1988 1991 1990 1993 1992 1994 1993 1996 1995 1998 1997 2000 1999 2002 2001 2004 2003 2006 2005 2006 2007 2008 2009 2010 2011. Install the pump case 5 while rotating driveshaft clockwise to flex the impeller vanes in the correct direction. Disassembly of propeller shaft components 1. Check continuity between wiring leads at the key positions shown in the chart.
Immediately upon payment you will automatically be forwarded to our secure download page. Apply heat uniformly so that head will not be distorted. Anode Never paint the anode. Replace If wear, cracks, distortion or corrosion is found. If there is any defect such as excessive wear or damage, replace it. If any improper condition is found, replace both upper and lower halves. Mercury-Mariner, Johnson-Evinrude, Yamaha, Honda, Suzuki 100 Common Searches.
Once again - Thank you for shopping at marineservicemanuals. Remove three bolts C and oil pump assembly D. Early : None 09930-99320 : Digital tester Tester range : Resistance Late : S12 Secondary side 1. Install spacer shaft, then slide on propeller 2. Propeller shaft thrust play : 0. This is the world's first 25 hp outboard motor designed with Lean Burn and Battery-Less Electronic Fuel Injection. Loosen flywheel bolt 2 — 3 turns.
If excessive wear or other damage is found, replace bushing. Note the position of O-ring and remove it. To separate the clutch rod from the shift rod, unscrew the turn- buckle 2. We will also send you an email with a copy of your Suzuki 4-Stroke Outboard service manual download link. In case of twin installation, always use on both engines, the same size normal rotation and counter-rotation propellers.
Connector plug Fuel primer bulb Inspect fuel primer bulb. However, blends of unleaded gasoline and alcohol with equivalent octane con- tent may be used. Tilt cylinder upper shaft 7. If lower than service limit, replace valve spring. Then, pshing special tool by hand ,install stem seal to valve guide. Wear safety glasses when using compressed air to expel solvent, carburetor cleaner etc. Carburetor with covered pilot screw The pilot screw turns open are preset at factory and the screw is covered by plate.
Disconnect inlet hose 1 and outlet hose 2 from fuel pump. Always use a new oil seal. Chamfered edge Adjustment step : 1. This expert text guide ebook will give you the knowledge and experience you need to perform simple basic maintenance or more complicated service procedures such as engine overhaul. Remove starter motor sub cable 3. Disassembling drive shaft Remove the circlip 1 and pre-load spring collar 2, washer 3, tab lock washer 4 and pre-load spring 5.
Replace if worn, nicked or cut. Fuel efficiency was prioritized in the design of this 25 horse outboard engine. October, 2002 — Manual No. Install washer and retaining ring. Apply engine oil to crankcase bolts. Loosen and remove the three 3 bolts securing the recoil starter. Remove clutch dog shifter propeller shaft.