Precautions
General Precautions
The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will not necessarily be repeated for every procedure to which they apply.
Failure to take proper precautions when servicing the outboard motor can cause severe personal injury.
• To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or doing other work, which could cause debris.
• When two 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, 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.
• Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any toxic or flammable materials getting into your eye may cause inflammation. Also wear moistureproof gloves to protect your skin.
• Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or other health problems. Be especially careful not to allow children and pets to swallow these materials.
• Keep all toxic or flammable materials out of reach of children and pets.
• When working with toxic or flammable materials, make sure that the area you work in is well ventilated 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.
• Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin cancer in laboratory animals. Brief contact with used oil may irritate the 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 latex 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.
• Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing the fuel pressure, or fuel can be sprayed out under pressure.
• After servicing the fuel, lubrication, cooling and/or the 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.
Failure to take proper precautions when servicing the outboard motor can cause damage to the parts or the outboard motor. To prevent the parts or the outboard motor from damage, be sure to take the following precautions:
• When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
• Be sure to use special tools where instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
• When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery.
• Do not expose connectors and electrical parts to water, which will cause electrical systems problems.
• Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough manner.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips, and certain other parts as specified, always replace them with new ones. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw / bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and proper operation.
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.
Replacement Parts
Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to performance problems and damage.
Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high quality parts which are designed and built specially for SUZUKI outboard motors.
If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent. They are precision-made to ensure high quality and correct fit.
