suzuki 25 hp 4 stroke manual
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suzuki 25 hp 4 stroke manualGeneral knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION sec- tion to familiarize yourself with basic information concerning this motor. Select the section needed for reference. MOTOR GEAR OIL. Measure in resistance range. Apply SUZUKI SUPER GREASE “A”. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury. However, blends of unleaded gasoline and alcohol with equivalent octane con- tent may be used. How the motor is operated during this time will have direct bearing on its life span and long-term durability. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions. Standard spark plug: NGK DCPR6E Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition system malfunctions. Carburetor with covered pilot screw The pilot screw turns open are preset at factory and the screw is covered by plate. Do not try to remove the cover over the pilot screw. (B). SYNCHRONIZING THROTTLE VALVES 09913-13121: Carburetor synchronizer NOTE:. Turn each balancer air screw B. NOTE: If the engine speed has been raised or lowered due to the ad- justment, it is necessary to reset the engine at the specified idle speed by turning idle adjusting screw of No.3 carburetor. Replace If wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLER Replace every 200 hours (12 months). Inspect water pump impeller. Anode Never paint the anode.Avoid con- tact 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 the level is low, add distilled water only.http://p1p1p1.ru/userfiles/4-speed-manual-racing-transmission.xml
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Once the battery has been initially serviced, NEVER add diluted sulfuric acid, or you will damage the bat- tery. FUNCTION AND FAILURE SYMPTOMS IGNITION COIL Function There is an independent coil for each cylinder. Voltage from the CDI unit is greatly increased to produce the power needed for a spark at the plug. Its function is to store and discharge current to each ignition coil and operate the caution system.The CKP sensors monitor current engine speed and send signals to the CDI unit. Based on this signal, the CDI unit determines the optimum ignition timing and supplies voltage to the primary winding of the ignition coil. The cause will not be in ignition system. START Sparks Not good. IGNITION COIL 09930-99320: Digital tester Tester range: (Resistance) Primary side 1. Disconnect primary coil lead wires from CDI unit. 2. POWER SOURCE COIL 09930-99320: Digital tester Tester range:. NOTE: Before checking the oil pressure caution circuit, make sure the engine oil pressure is within specification.This is a thermistor type sensor (resistance of which changes depending on the temperature) and inputs a signal to the CDI unit as a voltage value. INSTALLATION Installation is reverse order of removal with special attention to the following steps.Remove oil pressure switch from crankcase.NOTE: The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc.INSTALLATION Installation is reverse order of removal with special attention to the following step. This circuit is mainly composed of Battery, Starter motor, Relay, Neutral switch and Ignition switch (or starter switch). Tiller handle model Starter motor Starter switch 25A Fuse Neutral. Tiller handle model Circuit check schematic Starter motor relay Starter motor Starter motor. Check for relay “click”. NEUTRAL Shift position Tester indicates. NOTE: Using a screw-driver, pry off the stopper ring.Replace pinion if damaged or worn. Armature and Commutator Inspect the commutator surface.http://www.rt-servis.ru/files/file/4_speed_manual_on_the_floor.xml If surface is gummy or dirty, clean with 400 grade emery paper Measure commutator outside diameter. 09900-20101: Vernier calipers Commutator outside diameter: Standard: 30 mm (1.18 in.) Shaft Replace armature if continuity is indicated. Check for continuity between the adjacent commutator segments. Replace armature if no continuity is indicated. 09930-99320: Digital tester Tester range: (Continuity) BRUSHES. Do not re-use gaskets, as sealing abilities will be in- sufficient.Do not place any rubber, plastic and non-metallic parts in cleaning solvent, as severe damage or deteriora- tion will result. If broken tips or wear are found on the needle valve assembly, replace it. FLOAT Inspect the float. If cracks or other damage are found on the float, replace it. REASSEMBLY Reassembly is reverse order of disassembly with special at- tention to the following steps. NOTE: After installing float, inspect for smooth movement of float. CHECKING FLOAT HEIGHT Measure the float height.If tears, distortion or dam- age is found, replace fuel pump. Pump body Inspect each fuel pump body and outer plate. If cracks, nicks, distortion or damage is found, replace fuel pump. If leakage,deterioration or other dam- age is found, replace fuel connector. 1. Connector 2. Connector plug Fuel primer bulb Inspect fuel primer bulb. If cracks, leakage, or deterioration is found, replace primer bulb. If check valve function is defective, replace primer bulb. This system is composed of an accelerator pump on each carburetor with brass tubes connecting the pump to the fuel output nozzles on each carburetor.It should be visually inspected in its assembled position. 6. Remove NSI cable 0 from the recoil case A. Take off the reel stopper spring B and the reel stopper C. If there is any defect such as excessive wear or damage, replace it. Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this components.http://www.drupalitalia.org/node/71109 Disconnect the switch lead wire connector. Loosen screw 3 and disconnect oil pressure switch lead wire. Remove the two bolts 4 securing front panel 5. Remove flywheel. Disconnect water hose from thermostat cover and engine holder. Remove screw, starter motor relay and relay bracket. Remove bolts and PTT motor relay bracket. Lift up remove power unit from engine holder. NOTE: Rotate crankshaft to aid alignment of driveshaft and crankshaft splines. Apply Suzuki Silicone Seal to power unit mounting bolts and tighten bolts to specified torque. 99000-31120: Suzuki Silicone Seal Power unit mounting bolt: 8 mm 23 N. Oil pump shaft Do not screw oil pump shaft stopper fully before en- gagingoil pump shaft with groove in camshaft. NOTE: Be sure to check head cover gasket for wear or any damage before installation and replace any found defective. NOTE: To bring No.1 cylinder top dead center, align mark S on the crankshaft with mark a on the crank case. NOTE: After timing chain has been removed, do not turn crankshaft or camshaft. Timing chain Inspect timing chain. Replace if worn or damaged. Tensioner adjuster Inspect tensioner adjuster for smooth operation. Replace if faulty. Then turn the camshaft to locate the dowel pin position at the top as shown in figure. Install chain tensioner 2 as shown in figure. Apply oil to chain tensioner. (7) With latch of tensioner adjuster returned and plunger pushed back into body, insert stopper into latch and body. After inserting stopper, check to make sure that plunger will not come out. Cylinder head bolt: 1 st step 10 mm 30 N. Remove intake rocker arm shaft 3 and exhaust rocker arm shaft 4. NOTE: Reassemble each valve and valve spring in their original posi-tions. If clogged or obstructed, clean water jack- ets. CAMSHAFT Cam face Inspect cam face for scratches and wear.Rocker arm shaft runout Using a set of V-blocks, support the rocker arm shaft on a sur- face plate.http://detsindustrial.com/images/bosch-pdf-manuals.pdf Be sure to take readings at more than one place along the length of each stem and guide. Valve head radial runout Measure valve head radial runout. Fill intake and exhaust ports with solvent to check for leaks be- tween valve seat and valve. If any leaks occur, inspect valve seat and face for burrs or other things that could prevent valve from sealing. Drive in new valve guide until special tool (valve guide in- staller attachment) contacts cylinder head. VALVE Install valve spring seat 1 to cylinder head. After applying engine oil to stem seal 2 and spindle of special tool ( installer attachment ), fit stem seal to spindle. Then, pshing special tool by hand,install stem seal to valve guide. Install rocker arms 1, rocker arm springs 2, intake rocker arm shaht 3 and exhaust rocker arm shaft 4. Remove all conrod cap nuts 1 and conrod caps 2. NOTE: To prevent damage to crank pin and cylinder walls, install a piece Guide hose of hose over threads of rod bolts. Mark cylinder number on conrod using quick drying paint. Remove piston pin circlips as shown. 1. Piston pin circlip Remove piston pin from conrod. NOTE: Reassemble each piston, piston pin conrod in their original com- bination and position. Fit piston ring into piston groove, and measure clearance be- tween ring and ring groove using thickness gauge. If badly worn or damaged,replace component. Replace the conrod if its small end is badly worn or damaged or if clearance exceeds service limit. Bearing shells forund in defective condition must be replaced. 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. If any improper condition is found, replace both upper and lower halves. Always replace both bearing halves, never only one half of a bearing set. Tightening order (6) Apply eingine oil crankcase bolts. Tighten crankcase bolts in three (3) steps following the or- der indicated below. Crankcase: 5 N. m (0.5 kg-m, 3.https://snabavto.com/wp-content/plugins/formcraft/file-upload/server/content/files/1626f16a4e7c4e---bosch-shu-3000-manual.pdf5 lb.-ft.) 1st step 8 mm 11 N. As show in figure, upper (flywheel side) crank web of No.1 Flywheel cylinder has four (4) stamped numerals. To distinguish them, a color mark is painted at the position indicated in figure. Each color represents the following thickness measured at the center of the bearing. Color mark Bearing thickness Color mark. If original components are not replaced, each piston, piston pin and conrod is to be assembled and installed in its original order and position. PISTON TO CONROD Apply engine oli to piston 2, piston pin bore and conrod 3. When installing spacer, do not allow ends to overlap in Incorrect groove.Apply engin oil to piston and cylinder walls. Insert piston and conrod assembly into cylinder bore from cylin- der head side using special tool. NOTE: Align bearing tab a with notch in cylinder and crankcase. Apply SUZUKI BOND to mating surface of crankcase as shown. Apply bond to mating surface only. Do not allow bond to contact surface of bearing. 99000-31140: Suzuki Bond 1207B. Apply engine oil to crankcase bolts. Tighten crankcase bolts in three (3) steps following the order indicated below. NOTE: After tightening crankcase bolts, check to be sure that crankshatf rotates smoothy when turned by hand. Crankcase bolt 5 N. This system cools both the power unit and exhaust and is shown in schematic from below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion buidup or component damage. Oil form the oil pan is drawn theough the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery. Remove tiller handle and throttle cable assembly. Disconnect emergency stop switch lead wire. Tighten handle cover bolts, pre-coated with thread lock, to the specified torque. 99000-32050: Thread lock “1342” Tiller handle bolt: 23 N. REMOVAL Tilt engine fully up and lower the manual tilt lock levers 1.BANGLENHOSPITAL.COM/UserFiles/File/91-toyota-camry-service-manual.pdf During the following procedure, firmly secure the en- gine and support its weight. Remove the gas cylinder 0 from between the clamp brackets. INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. Tighten clamp bracket shaft nut to specified torque. Remove three bolts C and oil pump assembly D. Mid unit component Check oil pan, driveshaft housing, engine holder and mount covers. If cracks, defects or other damage is found, replace it. Mount Check upper and lower mount. If a clog or obstruction is found, clean water tube. If cracks, corrosion or other damage is found, replace water tube. Check water tube grommet. If excessive wear or other damage is found, replace grommet. Water pressure valve If salt deposits, corrosion, wear, or other damage is found, clean or replace. Oil relief valve: 27 N. m ( 2.7 kg-m, 19.5 lb.-ft.) Apply engine oil to O-ring 4, then install O-ring 4 to oil strainer Install oil strainer 5 to engine holder 3, then tighten bolts 6 securely. Install upper mount cover. Tighten mount cover bolt, pre-coated with thread lock, to speci- fied torque. NOTE: Install the upper mount to the engine holder with the UP mark (arrow) pointing upside. Tighten nuts, pre-coated with thread lock, to specified torque. 99000-32050: Thread Lock “1342” Upper mount nut: 35 N. m (3.5 kg-m, 25.5 lb.-ft.) Tighten lower mount cover bolts securely. Install lower mount front nuts. Tighten nuts, pre-coated with thread lock, to specified torque. Remove circlip 1. Remove lower mount bracket 2 from the steering shaft. Account for key 3, shim 4 and washer 5. Remove tilt cylinder lower shaft bolts 2. Slide STBD clamp bracket 3 off clamp bracket shaft. Remove the PTT unit assembly. (T model) Remove the gas assisted tilt cylinder. BUSHINGS Check all bushings. If excessive wear or other damage is found, replace bushing. If bushing fit is loose when installing, replace bushing. OIL SEAL Check swivel bracket seal.https://www.medicalart.com.tr/wp-content/plugins/formcraft/file-upload/server/content/files/1626f16b279ffd---bosch-shu33a05uc-manual.pdf Install upper bushing 1, steering adjuster 2, upper plate 3 and washer 4 to swivel bracket. Reattach bonding wire to swivel bracket and lower mount bracket, then tighten screw securely. LUBRICATION After completing reassembly of the mid unit, apply grease through each grease nipple. 99000-25160: Suzuki Water Resistant Grease. Remove the PTT unit 9 from between the clamp brackets. PTT MOTOR REMOVAL NOTE: Before removing PTT motor, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air. Note the position of drive joint 1 and O-ring 2 and remove them. NOTE: Do not lay PTT components out on a rag, as dirt or lint may be transferred to these items which may cause possible system operating problems. Replace armature if continuity is indicated. 09930-99320: Digital tester Tester range: (Continuity) Check continuity between the adjacent commutator segments. Replace armature if no continuity is indicated. Lower tilt rod full down position. Apply Water Resistant Grease to the tilt cylinder lower shaft and lower shaft bushes. Install bushes 1, cylinder lower shaft 2 and lower collars 3 to PTT unit. When the switch is depressed, power is delivered to the electric motor via the relevant relay.Check valve A will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the left, opening the “down” pressure main check valve and returning oil from the upper cylinder chamber (plus oil from the reservoir) to the pump. Check valve B will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the right, thereby opening the “up”. The shock valve will then open, allowing oil to flow into the area between the tilt ram piston and the free piston, thereby dampening (absorbing) the impact.https://www.northamericatalk.com/wp-content/plugins/formcraft/file-upload/server/content/files/1626f16bec8787---bosch-shu3032uc-user-manual.pdf When the manual valve is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again. Remove the two (2) bolts 1 securing the propeller shaft bear- ing housing to the gearcase. To separate the bearing housing from the gearcase, use two (2) 6mm bolts A as screw jacks, by alternately turning each one equally. Remove the screws 1 securing the shift rod guide stopper. Pull out the shift rod assembly 2. Disassembling drive shaft Remove the circlip 1 and pre-load spring collar 2, washer 3, tab lock washer 4 and pre-load spring 5. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety grasses when using compressed air.Replace bearing if pitted, noisy or rough.Always use new oil seals. 2. Apply Water Resistant Grease to the inner circumference of the housing. Replacing driveshaft oil seal 1. With the oil seal remover, draw the two oil seals out of the driveshaft bearing housing. Firmly push down pre-load spring collar, then snap on circlip. Installation Apply Suzuki Water Resistant Grease to the O-ring of the hous- ing. Install complete driveshaft and driveshaft bearing housing as- sembly to the gearcase. Tighten nut to the specified torque. Pinion nut: 18 N. m (1.8 kg-m, 13.0 lb.-ft.) 99000-32050: Thread Lock 1342 09921-29510: Drive shaft holder CHECKING DRIVESHAFT THRUST PLAY Before installing reverse gear, driveshaft thrust play should be. Insert the key 3 in the driveshaft and slide the impeller 4 onto driveshaft, ensuring that key and keyway are aligned. Install the pump case 5 while rotating driveshaft clockwise to flex the impeller vanes in the correct direction. Apply a light coat of Suzuki Silicone Seal to mating surfaces of gearcase and driveshaft housing.BANGKOKSOLARPOWER.COM/syner_upload/images/files/91-toyota-camry-repair-manual.pdf Slide the lower unit 2 into place, making sure that the top of the driveshaft engages properly with the crankshaft and that water tube locates in the water pump case outlet. Make sure that chamfered edge of the turnbuckle faces downward to seat against the lower nut when tightened. Chamfered edge Adjustment step: 1. Shift the clutch lever from Neutral through Forward and Re- verse to check that proper engagement of both gears is at an equal angle from Neutral. If the steering is pulled to starboard or port side, adjust trim tab with following procedure: Adjusting 1. Loosen the bolt of trim tab. Bolt 2. Tooth width Convex side Heel TOOTH Tooth top CONTACT PATTERN Tooth bottom Optimum tooth contact Optimum tooth contact The optimum tooth contact is shown at right. approx. Read the maximum play. Designate this amount of play as (A). Early: None 09930-99320: Digital tester Tester range: (Resistance) Late: S12 Secondary side 1. Remove spark plug cap from high tension cord. 2. In relation to this modification, clamps have been added and wire routing has been changed. Clamp VIEW X. October, 2002 1st Ed. October, 1999 Manual No. 99500-89J02-01E Printed in Japan. His butler knew better than to interrupt unless it was a matter of extreme urgency. 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Service Manual Application: Suzuki Workshop Service Manual DT 2 THRU 225 HP 1988, 1989, 1990, 1991, 1992, 1993 whisperin bill an autobiography a life of music love tragedy triumph This 4 stroke outboard is known for quick starts, fast acceleration and superior gas economy. Standard with this engine is a 6 gallon fuel tank, fuel line, propeller and tool kit and Suzuki’s 3 year factory warranty.The Suzuki 25 HP outboard motor is the most environmentally friendly gas outboard motor on todays market. This motor is designed to run clean with optimum fuel efficiency. Suzuki 25 HP outboard model DF25AES2 comes equipped with the 15 inch short shaft, a push button electric start or manual start.By the end of 1941, Germany had failed to defeat the Soviet Union and was now embroiled in a long, enormously bitter and costly, war in the east. 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I felt as though I were at Carnival, awaiting a much-anticipated joust.User manuals, Suzuki Outboard Motor Operating guides and Service manuals. We will contact you to answer any questions you have, and to assure that youre ordering the right motor, at the right price.Riverside Mobile Home Park was his first shot at this. He always knew right away if something was going to work or not, he felt it in his gut.From a distance, their smoke resembled only a humid haze. They passed a cluster of long, thatched-roof barracks, supported on high pilings in the Lemurian way, and continued on to a slightly smaller but more traditionally constructed building. The result was a harmony of wood and stone, columns and high pagodas that had clearly been blending together long enough that it seemed somehow right. 2010 toyota corolla manual pdf He believed that nothing told more about a man than the sincerity in his eyes. 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It has pictures, tips, and easy to understand how- two’s instructions.