Indeed, the nation is right up there with the greats in terms of producing automobiles of different kinds, from the luxury sports car to the handy and reliable family car. Suzuki are more known for their sports cars and motorbikes, but like any popular brand have a diverse enough range to cater to many tastes. On reputation and knowledge, it goes without saying that Suzuki are among the brands that have the broad approval of a range of car owners, enthusiasts and experts.
Anyone who seeks to claim that their car is infallible will be lying to you. The fact is that no car is indestructible, and big problems often start out as smaller problems that get ignored. Check and repair. Water pump impeller damage. Thermometer 3. Thermostat 2. Heater 4 Install the thermostat. If salt deposits, corrosion, wear or other damage is 1 Install O-ring 1 to pressure valve cover 2. Inspect O-ring. Replace if nicked, cut or torn. I9J 2 Install pressure valve 3 and pressure valve cover I9J Always observe the following precautions when working around gasoline or servicing the fuel system.
The fuel injection system is composed of the fuel line components, air intake components, and components for system control ECM, sensors, switches, etc. Page 1G-5 Fuel System: Fuel Vapor Separator The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber. As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump. The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator.
The regulator's function in the system is to maintain constant fuel pressure to the injectors while the engine is operating. The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure balanced. Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in the fuel vapor separator chamber by approx. The duty cycle changes depending on cylinder temperature. Valve pintle 2. Screw shaft 3. Rotor 4. When cranking: The IAC valve is controlled to operate at approx.
The open position changes depending on the cylinder temperature. Page Fuel System: 1G 4 Connect special tools pressure gauge, pressure 5 Ensure the emergency stop switch lock plate is in hose and pressure joint between fuel feed hose 1 place.
I9J 4. Step Action Check fuel injector operating sound. Fuel injector circuit is in Go to step 2. Page Service Instructions 1G Fuel System: Service Instructions Fuel Pressure Relief Procedure 7 Upon completion of servicing, connect the ignition Z9J coil primary lead wire and the high pressure fuel After making sure that engine is cold, relieve fuel pump lead wire.
Disassembly b Check that the drive voltage is outputting from 1 Remove five screws 1. Page Fuel System: 1G 3 Remove screw 7 , plate 8 and valve seat 9.
Assembly Assembly is in the reverse order of disassembly with special attention to the following steps. High pressure fuel pump Connect the pump lead wire connector, then install grommet 1 and fuel pump 2. Z9J 1 Using a sound scope or equivalent, check the Replace if cracked, damaged or other abnormal operating sound of the fuel injector when the engine conditions. Page Fuel System: 1G 5 Remove the two bolts 4 and the fuel delivery pipe Installation 5 with the fuel injectors.
Installation is in the reverse order of removal with special attention to the following steps. Page Low Pressure Fuel Pump Removal And Installation 1G Fuel System: 3 Apply a thin coat of fuel to injector O-rings, then 7 Make sure the emergency stop switch lock plate is in install the injectors into the delivery pipe and cylinder place. Make sure that the injectors rotate smoothly. Do not attempt to disassemble the low pressure fuel pump. It must be replaced as a complete unit if it is defective.
This system is battery powered, with the ECM controlling all of the ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control ECM, sensor, switch etc. Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils. Basic sensors MAP sensor: Ignition timing is determined by a Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system.
These components are connected electrically as shown in the figure below. Replace over-running clutch. Poor sliding of over-running clutch. Over-running clutch slipping. Worn teeth of ring gear. Replace flywheel. Connect the battery to the magnetic switch as shown in the figure.
Check that the ammeter indicates the specified current. Disassembly When overhauling the starting motor, it is recommended that the component parts be cleaned thoroughly. However, the yoke assembly, armature coil, over- running clutch assembly, magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent. Page 1I-8 Starting System: 8 Remove the center cover plate Remove the pinion stopper and 9 Remove the planetary gears 14 and internal gear pinion If the Assembly is in the reverse order of disassembly with measurement exceeds the service limit, replace the special attention to the following steps.
Check the length of each brush 1. Replace the armature if continuity is indicated. If brushes are worn down to the service limit, they must be replaced. Replace if necessary. Inspect planetary gears and internal gear for wear, damage or other abnormal conditions. If no continuity exists, the coil is open and should be replaced.
Page Ignition Switch Inspection Starting System: 1I Contact points test Put the plunger on the under side and then push the magnetic switch down. Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below. Battery charge coil Cushion Main relay : Apply engine oil. Washer Fuse 8. Clamp Installation Installation is reverse order of removal with special attention to the following steps.
As thyristors, diodes, etc. Page 1K-9 Charging System Replace any damaged wire. Side cover rubber 9. Side cover holder Engine cover hook shaft Pin 2. Side cover seal Engine cover hook Bush 3. Lower side cover STBD Z9J Removal 1 Remove the side cover rubber 1.
I9J Installation Installation is reverse order of removal with special Upper unit stopper : Apply engine oil. Plug Dowel pin Spacer Upper mount bolt Page Water jacket cover Lower mount bracket Gasket Lower thrust mount Water plug Account for washers 4 , 5 , mount spacer Mounts Disassembly 6 , forward damper 7 , white side mount 8 , lower Z9J 1 Remove the power unit. Page Housing and Bracket: 2A-7 7 Remove the water tube I9J 8 Remove five bolts and exhaust tube housing I9J 12 Remove bolts, water pressure valve cover 20 , and water pressure valve I9J I9J 16 Remove engine holder with oil pan.
I9J 20 Remove the six bolts and the engine holder 31 I9J I9J 22 Remove the oil relief valve 33 and gasket. Thread Lock 50 g Apply sealant to mating surfaces of driveshaft housing and oil pan. Replace if cracked, specified torque.
Replace the strainer if cracked, damaged or other abnormal conditions are found. If clogged or obstructed, clean the oil strainer. Replace O-ring if nicked, cut, worn or other abnormal condition are found. Apply water resistant grease to the seal lip. NOTE Install oil seal as shown in the figure. NOTE Install oil seal with lip spring side facing downward oil pan side. Shim Anode Circlip Swivel bracket I9J I9J 10 Remove circlip 14 and push out tilt cylinder upper 14 Using flat blade screw driver, drive locking edge of rod Page Install the shaft bolt 5 , then tighten it securely.
Page 2 upward on the splines until it contacts the shim. I9J Lubrication After completing reassembly of the mid unit, apply grease through each grease nipple. I9J I9J Components Inspection Z9J If clamp bracket shaft is bent or twisted, replace shaft. PTT motor 9. Free piston Tilt rod Lower cylinder chamber Spool valve No.
Oil reservoir Manual release valve Page Power Trim and Tilt: 2B-5 Shock Absorber Circuit Shock valve Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber 1. The shock valve 2 will then open, allowing oil to flow into the area between the tilt ram piston 3 and the free piston 4 , thereby dampening absorbing the impact.
When the manual release valve 1 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. High oil pressure in the upper cylinder chamber 1 caused by rising temperature will release the thermal valve 2 and make the oil flow to the reservoir to prevent damage to the PTT unit.
PTT switch Remote control box 6. Battery ECM fuse 30 amp. Inspection and replace. Installation Z9J Removal 1 Remove the lower side cover. Cut the cable tie binding PTT motor from between the clamp brackets. Remove the PTT motor cable from engine lower cover. These manuals assume basic service skills. Some pre manuals may no longer be available. Those that are available have been scanned using different methods, which affect their quality.
See the print quality descriptions below:. Standard Scan — Scanned from the only source; photos may be dark, but text is readable. Hi-Res Scan — Scanned from a higher resolution; photos are clear; text is sharp. Digital Master Scan — Scanned from a digital master for high-quality photos and text. Provides instructions for proper operation and performing basic inspection and maintenance.
View Sample. Contains detailed procedures for all service, from performing basic periodic maintenance to a complete engine disassembly and assembly. Covers all systems and components. It contains detailed information for performing all periodic maintenance and race tuning procedures including top end, clutch and suspension service.
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