Section 2. 0 Outboard, Fuel, Fittings Propellers by BLASection 2. Outboard, Fuel, Fittings Propellers   Published on Mar 1. BLA Catalogue 2. 01. DOWNLOAD SERVICE MANUALS Mercury Suzuki Yamaha Johnson Mariner Evinrude. PERIODIC MAINTENANCEPERIODIC MAINTENANCE SCHEDULEThe chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. 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. ELECTRICAL PRODUCTS Ignition Switches IGNITION SWITCHES FOR WORLD OUTBOARD MOTORS Exact OEM replacement installation Ideal for DFI, EFI and MPI engines Heavy duty. Download-Online-Factory-Service-Repair-manual-PDF.gif' alt='Suzuki Dt4 Outboard Serial Numbers' title='Suzuki Dt4 Outboard Serial Numbers' />MAINTENANCE AND TUNE UP PROCEDURES1. Place mercury 4. 0hp manual outboard motor upright on a level surface. Remove motor cover. Remove oil level dipstick and wipe it clean. Insert it fully into dipstick hole, then remove it to check oil level. Oil level should be between full level hole Max. Min. Instant Download Marine factory service manuals for Inboard, Outboard, MerCruiser Sterndrive SternDrive Jet Drive Engines. Suzuki Dt4 Outboard Serial Numbers' title='Suzuki Dt4 Outboard Serial Numbers' />If level is low, add recommended oil to full level hole Max. Recommended oil 4 stroke motor oil API classification SE, SF, SG, SH, SJ. Viscosity rating SAE 1. W 4. 0. This section describes servicing procedures for each of periodic maintenance requirements. ENGINE OIL ENGINE OIL FILTER ENGINE OIL LEVEL CHECKInspect oil level before every use. ENGINE OIL CHANGE ENGINE OIL FILTER REPLACEMENT ENGINE OILChange initially after 2. ENGINE OIL FILTERReplace initially after 2. NOTE Engine oil should be changed while engine is warm. When replacing engine oil filter, change engine oil at the same time. Place outboard motor upright on a level surface. Remove oil filler cap. Place a container under engine oil drain plug. Counting The Number Of Atoms In A Molecule Activity Answers Pet. Remove engine oil drain plug and gasket to drain engine oil. ENGINE OIL FILTER REPLACEMENTNOTE For engine oil change only, go to step 6. To replace engine oil filter NOTE Before fitting new oil filter, be sure to oil O ring. Remove STBD side cover. Using oil filter wrench to loosen the oil filter, then remove filter and O ring. Screw new filter on by hand until filter O ring contacts the mounting surface. Tighten filter 34 turn from point of contact with mounting surface using an oil filter wrench. Install STBD side cover. Install gasket and oil drain plug. Tighten engine oil drain plug to specified torque. Pour recommended engine oil into oil filler opening, then install oil filler cap. Engine oil amounts Oil change only 5. L 5. 8 4. 8 US Imp. Oil filter change 5. L 6. 0 5. 0 US Imp. To reset oil change reminder systems operation time to zero cancellation 1 Turn ignition key to ON position. Pull out emergency stop switch plate 1. Pull up emergency stop switch knob 2 three times in seven seconds. A short beep will be heard if cancellation is successfully finished. Turn ignition key to OFF position, then set emergency stop switch plate 1 in original position. Start engine and allow it to run for several minutes at idle speed. Refer to the  Mer. Cruiser Repair Manual as procedures can differ depending on model and year. Check oil filter for oil leakage. Turn off engine and wait for approx. GEAR OILChange initially after 2. Place outboard motor upright on a level surface. Place a container under lower unit. Remove lower gear oil drain plug before gear oil level plug and drain gear oil. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Gear oil amounts 1. US Imp. oz Recommended oil Outboard Motor Gear Oil or SAE 9. Hypoid gear oil. 5. Install oil level plug before removing oil filler tube from drain hole. Install oil drain plug. Do not re use gaskets once removed. Always use a new gasket. NOTE To avoid insufficient injection of gear oil, check gear oil level 1. If oil level is low, slowly inject gear oil up to the correct level. LUBRICATIONInspect every 5. Apply  Water Resistant Grease to the following points. Throttle shift linkage. Propeller shaft. Swivel bracket. Swivel bracket. SPARK PLUG Inspect every 1. Replace every 2. 00 hours 1. Standard spark plug NGK BKR6. ECARBON DEPOSITInspect for a carbon deposit on spark plug bases. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. SPARK PLUG GAPUsing thickness gauge, measure for spark plug gap. Adjust to within specified range if gap is out of specification. Spark plug gap 0. CONDITION OF ELECTRODEInspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage. TAPPET CLEARANCEInspect initially after 2. The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear. When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. The shim discs are easy to remove and refit. Tappet clearance adjustment should be checked and adjusted at time of periodic inspection when valve mechanism is serviced when camshafts are disturbed by removing them for inspection. CHECKING AND ADJUSTING TAPPET CLEARANCE1. Remove following parts Engine side covers Flywheel cover Spark plugs. Remove breather hose 1 and evaporation hose 2 from cylinder head cover. Remove fuel hose 3 and 4 from low pressure fuel pump. Remove fifteen 1. Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance cold engine condition IN. EX. 0. 2. 3 0. This is a left hand LH rotation powerhead. Rotate crankshaft counterclockwise to prevent water pump impeller damage. NOTE Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface. All tappet clearances can be measured during two turns of crankshaft. If out of specification, adjust tappet clearance by changing shim. ADJUSTMENTTappet clearances are adjusted by replacing tappet shim. Close valve and turn tappet cut away toward inside as shown in figure. Rotate crankshaft to open lift up valve and then remove camshaft housing bolts where shim is to be replaced. Install special tool with camshaft housing bolts as shown in figure. Rotate top of cam 9. Two tappets can be adjusted at the same time5. After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula. A B C 0. 2. A Correct thickness of shim for proper tappet clearance mmB Thickness of original shim mmC Original tappet clearance mm6. Install shim. Identification number should face towards tappet. Rotate crankshaft to be open lift up valve. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. Camshaft housing bolt 1. N. m 1. 1 kg m, 8. Recheck tappet clearance. NOTE After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again. INSTALLATIONAfter checking and adjusting all tappet clearances, install cylinder head cover. Installation is reverse order of removal. IDLE SPEEDInspect initially after 2. NOTE Before checking idle speed, engine should be allowed to warm up. Check andor adjust idle speed after engine speed has stabilized. Before checking idle speed, check throttle link mechanism and throttle valve for smooth operation. Start engine and allow to warm up. Attach engine tachometer to the ignition high tension cord. Check engine speed. Idle speed in neutral gear 6.