Suzuki Periodic Maintenance Schedule

I just got my Water Pump Repair Kit from Brown's Point Marine, was less than $50.00. I bought the kit just in case i needed the seal also.

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Winter project is to clean this room,this used to be my spare room but now it looks more like a Marine Supply Depot. Tug

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Storage Wars! I'll give you $250 for the whole room!

On the impellor replacement, be sure and turn the drive shaft clockwise as you drop the water pump housing on to orient the impellor vanes properly.
 
How about the Valve Adjustment-fairly easy, but requires Suzuki special tool. My DF 115 manual says check and adjust every 200 hrs.
Roger
 
Yes, the tappet clearance check and adjustment is pretty straightforward but is the most challenging regular maintenance task at 200 hour intervals. Or I should say making any necessary adjustments (by changing out tappet shims) is the most challenging. Checking tappet clearances (the space between cam and shim) is comparatively easy.

The "tool" you need is actually a set of small metal brackets, one for the intake valves and one for the exhaust valves that hold a valve open where a tappet shim needs to be replaced. They are horribly expensive ($100) for what they are, but you save a ton on service labor...

Follow the instructions in the official Suzi shop manual and go slow. Be sure and use a torque wrench. Note that if a tappet is out of spec, you will need to remove the shim (get a small magnet for this) and measure its thickness with a micrometer, then reinstall it, calculate the new shim thickness needed (per table in service manual), order the replacement shim then install it. If you plan to use the boat before installing the replacement shim, you should install a new valve cover gasket set (outer rim gasket AND spark plug hole gaskets). Use another new gasket set when you swap out the old shim(s) with the new one(s). Obviously it's cheaper to just wait to use the boat until after you've received and installed the replacement shim(s). I just mention this because replacing that gasket set everytime you open the cover is important. Also - be sure to use the official Suzi silicone on the valve cover as indicated in the service manual. It's good stuff and the tube lasts forever.

It all sounds somewhat complicated, but it's not. These engines are incredibly well engineered and laid out. Have fun!
 
Great advice. They actually make a chart to write down all the valve clearances as you check them, a great way to stay organized and keep records of wear. I'll try to scan a copy on here so you can download it.
Merry Xmas!
Roger
 
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