Suzuki U4-60 Assembly Manual

MODEL U4-60 SUZUKI SERIES 60 HP

ASSEMBLY INSTRUCTIONS

57.4 CU. IN. STARTING 2010

1. Place the motor on the transom of your boat so that it is mounted vertically, in the normal fashion.
Disconnect the gearshift rod coupling near the gearbox and remove the bolts holding the gearbox to the
exhaust housing. Remove the gearbox assembly.

2. Remove the water pump assembly from the gear box, including the lower stainless steel plate and impeller
drive key.

3. Next, install the jet pump driveshaft assembly into the spiral pump housing, locking it in place with two #10­24 fil head screws and spring lock washers.

4. Install the water pump assembly on top of the 3/4 inch thick aluminum adapter and stainless steel plate. Be
sure also to install the water pump impeller and drive key removed from the propeller drive. Lock in place
using four 1/4-20 x 2 1/4 bolts and lock washers. Grease the threads. 8 Ft-lbs.

5. The large 3/4 inch adapter plate is attached to the exhaust housing to hold the jet drive. The tube guides the
disconnected shift rod. Two 6 x 16 mm dowels locate the plate and six M8 x 30 mm hex head bolts and lock
washers secure it. Grease the bolt threads and the threaded end of the shift rod where it slides in the tube. 12
ft-lbs.

6. Next, attach the jet drive to the motor. Two 3/16 x 1/2 dowel pins center the jet drive on the adapter plate.
Four 5/16-18 x 2 3/4 bolts and lock washers from below and one 3/8-16 x 1 1/4 bolt from above rear are
used. Grease the bolt threads, driveshaft spline generously, rubber water tube sleeve and guide the jet into
place. Tighten the 5 bolts, 5/16 bolts to 12 ft-lbs and 3/8 bolt to 22 ft-lbs.

7. Next, install the impeller. Grease the shaft threads, key and impeller bore. Place the plastic sleeve inside the
impeller; hold the key in the nose of the impeller with your forefinger and slide onto the driveshaft. Install
the shim washers, torsional damper and nut retainer on the shaft, and bring the nut up snug by hand.

Place the liner wear ring in position and observe the clearance between the impeller blade edge and the

intake liner.

When, after use in sand and gravel, the blade clearance becomes more than about 1/32” between the

impeller edge and the water intake liner, one or more of the shim washers can be transferred from the bottom
stack to the top of the impeller, which moves the impeller down into the tapered casing to reduce the
clearance.

Shims should not be used above the impeller on new installations where no wear has occurred unless the

blade clearance exceeds 1/32 inch. Insufficient blade clearance will do more harm than good from any
performance gains it might provide.

When the impeller clearance is satisfactory, bump the nut up tight with a wrench. If the ears of the retainer

do not line up with the flats on the nut, spin the nut off, turn the retainer over, and tighten the nut again. In
one of these two positions you will have alignment and can fold the ears up against the nut to retain it. The
flat in the retainer is angled to the ears to allow this.

8. Place the intake casing in position with the lower end at the rear and tighten the six 1/4-20 fiber lock nuts.
No lock washers are used. Grease the threads. See the diagram on page 3.

9. If your jet drive was ordered for use with a steering tiller handle, see the attached shift cable assembly
instruction page for installing shift cable #2039.

1

MODEL U4-60 SUZUKI SERIES 60 HP

ASSEMBLY INSTRUCTIONS

57.4 CU. IN. STARTING 2010

10. Caution:
protection. The inner cable comes from the remote control box or tiller handle to operate the reverse gate. It
does not enter the motor housing. The 5 foot neutral cable assembly #1318 enters the motor housing to
operate the neutral start safety switch and is driven by the movement of the reverse gate. The neutral start
switch prevents starting the motor in forward or reverse.

11. With the shift handle in forward and the reverse gate in forward, with the cam roller at the end of the slot,
adjust the cable and/or cable anchor position to this condition. Shift to reverse and back to forward. The

roller should be at the end of the cam slot such that the gate cannot be forcibly rotated toward reverse.
Pull on the gate by hand to verify this. If this forward lock condition is not met, readjust the cable

positions.

Shift to neutral and adjust the cable end in the motor housing so that the neutral start switch is

activated. Check adjustment coming from both forward and reverse to compensate free play in cable
linkage.

. When converting to jet drive, your motor will have to be raised to the height shown in the diagram

12

on page 3 below, using a straight edge under the boat.

motor 5/16 inch at a time to obtain the best results.

The motor has four sets of upper mounting holes. You will use one set to begin with. Mark pencil lines on

the boat transom through the other sets. Then if you wish to go up or down 5/16 inch, you can drill one
alternate set of holes 5/16 inch up or down from the pencil marks. By alternating between these two sets of
transom holes and the four sets of motor holes, the motor can be moved in 5/16 inch increments over almost
one inch. The transom height should be about 21” measured vertically from the boat bottom for short shaft
motors, and 26" for long shaft motors.

If you raise it too much it will suck air and cavitate, either on start up or when banking on turns

When cavitating, the motor over speeds in spurts and shakes considerably in the motor mount. This is not

a normal condition and should be avoided by proper adjustment of motor height on each individual
boat. If you lower it too much you will have excessive drag, therefore mount the motor as high as possible

without allowing cavitation.

Caution: When starting the engine for the first time, watch to see that cooling water comes out of the

small hole at the rear side of the engine, just below the power head. This verifies that your assembly of
the cooling water pump and its connections are correct.

The cooling system can be flushed by removing the hex bolt next to the grease fitting. A hose coupling,

24789A1, is available from a Mercury dealer. Turn on the water gently, and start the motor set to idle.
Watch for cooling water at the tell tale. Adjust the water pressure if needed. Be sure to replace the bolt
after flushing.

Two cables will be attached to the cable anchor bracket and roller cam to provide neutral start

Test run the boat and then raise or lower the

.

2

MODEL U4-60 SUZUKI SERIES 60 HP

ASSEMBLY INSTRUCTIONS

57.4 CU. IN. STARTING 2010

SETTING MOTOR HEIGHT

STRAIGHT
EDGE

CAUTION

When starting the engine for the first time, watch to see that the cooling water comes out of the small
hole at the rear side of the engine just below the power head. This is to check your assembly of the
cooling water pump and its connections.

3

MAINTENANCE AND LUBRICATION

OUTBOARD JET DRIVE

BEARING LUBRICATION

A grease gun and tube of grease is supplied with your jet drive. We recommend greasing
the bearing every 10 hours. Make greasing a part of your cleanup after the days use
Pump in just enough grease to fill the lube hose. Then reconnect the lube hose coupling to
the zerk grease fitting.

Every 30-40 hours, pump in extra grease so as to purge any moisture. The texture of the
grease coming out gives an indication of conditions inside the bearing housing. A gradual
increase in moisture content indicates seal wear. If the grease begins to turn dark, dirty
gray, the bearing and seals should be inspected and replaced if necessary. Some
discoloration of the grease is normal during the break in period on new sets of seals.

We have selected a water resistant grease of the proper consistency for this application. If
you use a substitute grease, be sure it is water resistant and of the same consistency.

.

IMPELLER

Your jet drive is equipped with a key to protect the unit in the event of a rock jam. This can be
reached by removing the water intake, and then the driveshaft nut, similar to a propeller drive.
After replacing the key, pull the shaft nut up tight to remove any play between the impeller and
shaft. Note the position of the impeller shim washers, and replace them in the same order.

REVERSE GATE MECHANISM

Occasionally check adjustment of the gate shifting linkage. In “forward” the gate should be
firmly locked in position. Pull on the gate by hand to verify this. This will prevent wave action
from accidentally shifting the gate into reverse as the boat is violently maneuvered

GENERAL

Check all mounting bolts, intake screws, linkage connections, etc., occasionally to be sure they
are tight.

SALT WATER USE

Aluminum and stainless steel have been used in the construction of your jet drive. These
materials have either been treated or are inherently resistant to corrosion. It is recommended,
however, that when not in use the motor be tipped up so that the jet unit is out of the water.
When used in salt water more than in fresh water, remove mounting hardware, grease, and
reassemble once a year. Failure to do this may result in hardware that is difficult if not
impossible to remove at a later date.

GUARANTEE

Due to inflexible government regulation, we do not have a written warranty. We have, however,
a good reputation for fairness with our customers which we intend to maintain. If you think you
have a warranty situation, regarding material, workmanship, call us before

Specialty Manufacturing Company
Outboard Jets
2035 Edison Avenue
San Leandro, CA 94577

making repairs.

3

MODEL U4L-60

ANODE KIT 1693

MODEL U4-60 SUZUKI

2611043

SHAFT ROLLER

676623

NYLOC 1/4 20

REF QTYPART DESCRIPTION REF QTYPART DESCRIPTION

NO. NO.
1 1 860 PUMP ADAPTER , U4 44 1 477 COLLAR BACKFIT 7205
2 4 638 WASHER SPRING L OCK 1/4 45 1 1536 THRUST WASHER
3 4 586 BOLT HE X HD 1/4-20 X 2 1/4 46 1 504 BEARING 7205B-UA
4 1 869 ADAPTER PLATE & TUBE U4 47 1 511 TRUARC 5100-98
5 2 616 DOWEL PIN 6 X 16 MM 48 1 1535 SPACER
6 10 640 WASHER SPRING LOCK 5/ 16 49 1 512 TRUARC N5002-212ZD
7 6 591 BOLT HE X HD M8-1.25 X 30MM 50 1 433 UPPER SEAL CARRIER W/SEALS & "O" RINGS
8 2 631 DOWEL PIN 3/16 X 1/2 51 4 517 SPIROLOX RR- 150S
9 4 599 BOLT HE X HD 5/16-18 X 2 3/4 52 2 506 SEAL INNER

10 1 606 BOLT HEX HD 3/8-16 X 1 1/4 53 2 507 SEAL OUTER 6324-S

89200 VOLUTE WITH GATE U4 54 2 526 O RING 568-135 3/32X1 15/16X2 1/8

11 1 892 VOLUTE WITH EXHAUST TUBE U4 55 1 912 BEARING CARRIER W/SEALS & 'O" RINGS U4
12 1 80 EXHAUST TUBE ASSY MEDIUM 2 56 3 521 'O" RING 568-011 1/16X5/16X7/16
13 1 846 CLIP EXHAUST TUBE 1 57 2 637 WASHER SPRING LOCK #10
14 2 621 NYLOC 10-32 58 2 561 FIL HD SLOTTED 10-24 X 5/8
15 1 1023 WASHER FIBER 3/8 59 1 8.23 6 1/8 ALUM/ZINC IMPELLE R W /136 SLEEVE
16 1 1022 BOLT HEX HD 3/ 8-16 X 1/2 59 1 1737 6 1/8 STANLESS STEEL IMPELLER W/136 SLEEVE
17 1 553.2 BALL END 1/4X10-32 CABLE 60 1 36 SHAFT SL EEVE PL ASTIC MEDIUM
18 1 975 LUBE HOSE ASSY 61 1 782 IMPELLER TEE KEY - SQUARE
19 1 539 ZIRC FITTING 1/4-28 61 1 1705 IMPELLER TEE KEY - 1/ 2 ROUND
20 1 550 GREASE GUN 62 8 21 SHIM W ASHERS MEDIUM
21 1 552 GREASE 10 OZ TUBE NO. 630-AA 63 1 805 NUT KEEPER MED/PKG. 2 PER BAG
22 1 1175 REVERSE GATE, MEDIUM 64 1 22.1 SHAFT NUT 5/8-18 BRASS
23 2 535 NYLINER 3/8 ID X 11/16 1447.04 INTAKE ASSY 6 1/8 WITH GRILL & LINER
24 1 1177 SPRING GATE PIVOT 3/8 65 1 1521 LINER 6 1/8 W/HARDWARE
25 2 822 PIN GATE PIVOT 3/8 M E DIUM 66 6 1300 STUD - INTAKE SMALL, MEDIUM

­27 2 624 NYLOC 1/4-28 68 1 7 INTAKE PAINTED ONLY
28 1 1042 ROLLER ASSY 69 2 14 GRILL ROD
29 1 635 1/4 WASHER AN960C416 70 9 16 GRILL BAR MEDIUM
30 1 1035 SHIFT CAM MEDIUM 72 1 156 BRACKET CABLE SUPPORT
31 1 623 NYLOC 1/4-20 73 2 542 SHIM M ORSE AO35777-SUZUKI
32 1 573 BOLT HEX HD 1/4-20 X 3/4 74 2 543 CLAMP CHRYS 154317-SUZUKI
33 1 1037 BUSHING CAM 75 2 561.1 FL HD SLOTTED 10-24 X 3/4 - SUZUKI
34 1 1038 WASHER CAM 76 2 635 1/4 WASHER AN960C416
35 2 1039 SHIM-CAM 77 2 572 BOLT HEX HD 1/4- 20 X 5/8
36 1 1036 CAM ECCENTRIC DR ILLED 78 2 619 NYLOC 10-24
37 1 574.1 BOLT HEX HD 1/4-20 X 1 PATCH 79 1 1718 TORSIONAL DAMPER 5/8
38 2 574 BOLT HEX HD 1/4-20 X 3/4 PATCH
39 1 1170 SPRING GATE BUMPER
40 1 1169 GATE BUMPE R
41 1 559.2 FIL JD SLOTTED 10-32 X 1 1/4 PATCH

2070 SHAFT ASSY COMPLETE, U4L-60 12 T

42 1 2069 SHAFT ONLY , U4L-60, 12T 27 1/2 LG.

2101 SHAFT ASSY COMPLETE, U4S-60 12 T
42 1 2100 SHAFT ONLY , U4S-60, 12T 22 3/4 LG.
43 1 41 SHAFT BEARING THRUST RING

SIZE TORQUE

1/4-20 (M6) 8-9 FT-LBS
5/16-18 (M8) 12 FT-LBS
3/8-16 (M10) 22 FT-LBS

NEUTRAL CABLE ASSEMBLY:
SUZUKI 1318 SEE PG. 31 MED.

TILLER STEERING CABLE ASSEMBLY:

SUZUKI 2039, SEE PG. 25.5 LRG.
BEARING, SEAL, SNAP & “O” RING KIT 803.1

- 49.4 -

LARGE SERIES

NEUTRALCABLEASSEMBLY

MODELAIR, AN,AP,U4‐4,U4S‐60,U4L‐60SUZUKI

1318

REF QTY PART NO. DESCRIPTION

1 1 547.2 CABLE 5 FT MOR 33C SUPREME
2 1 156 BRACKET CABLE SUPT OMC, MORSE
3 2 542 SHIM MORSE A035777
4 2 543 CLAMP CHRYS 154317
5 2 561.1 FIL HD SLOTTED 10-24 X 3/4
6 2 635 1/4 WASHER AN960C416
7 2 572 BOLT HEX HD 1/4-20 X 5/8
8 2 619 NYLOC 10-24

9 2 621.1 NUT HEX 10-32
10 2 553.2 BALL END 1/4 X 10-32 CABLE
11 1 585 BOLT HEX HD 1/4-20 X 1 1/4
12 1 623 NYLOC 1/4-20

TILLER SHIFT CABLE ASSY

1. Remove the lower plastic cover from the steering handle.

2. Remove the shift cable

SUZUKI STARTING 2009

2039

3. Install the 4 1/2 ft. standard 33C cable, using the cable end 2036.

4. Attach the lower end of the cable to the jet drive with the ball rod end threaded on the cable as
far as it will go and the cable anchor bracket centered and locked. Twist the cable in the U-clamp
so that the cable rests against the motor cowling and tighten the clamp screws. The clamp base is
slotted to allow alignment for minimum cable bending.

5. Place the shift handle in forward, solidly in the detent. The reverse gate cam roller must be at the
end of the slot in the cam. If these conditions are not met, slide the cable anchor bracket on the jet
drive and/or adjust the threaded rod end on the cable.

6. Shift to reverse and back to forward. Do not be concerned if the gate does not reach reverse.
There is clearance at this position and water pressure will close the gate.

7. In forward, with the roller at the end of the cam slot, the gate cannot be forcibly rotated toward
reverse. Pull on the gate by hand to verify this.

8. Lock the nuts on the cable against the rod ends to complete the adjustment and reassemble the
lower cover of the steering arm.

CAUTION: YOU MUST RETURN THE THROTTLE TO IDLE BEFORE SHIFTING.

TILLER SHIFT CABLE ASSY

SUZUKI BH STARTING 2009

SUZUKI U4L-60 STARTING

REMOVE NUT

2010
2039

REF QTY PART NO. DESCRIPTION

1 1 547.1 CABLE 4 1/2 FT MOR 33C SUPREME LONG
2 1 2036 CABLE END SUZUKI 2009 TILLER