Suzuki Outboard Maintenance Kit (17400-96821)

1. Introduction

This document serves as an instruction manual for the Suzuki Outboard Maintenance Kit, part number 17400-96821. This kit is specifically designed to provide essential components for routine maintenance of Suzuki DF150, DF175, and DF150SS outboard motors. Regular maintenance is crucial for ensuring the longevity, reliability, and optimal performance of your outboard engine.

2. Product Overview

The Suzuki OEM Maintenance Kit (17400-96821) contains genuine Suzuki parts necessary for a comprehensive service interval. Using authentic OEM parts ensures compatibility and maintains the manufacturer's specifications for your engine. This kit is a convenient solution for gathering multiple maintenance items in one package.

Image: A general representation of components typically found in a Suzuki Outboard Maintenance Kit. Please refer to the 'Package Contents' section for the exact items included in this specific kit (Part Number 17400-96821).

3. Package Contents

The Suzuki Outboard Maintenance Kit (17400-96821) includes the following genuine OEM components:

• Oil Filter
• Oil Drain Gasket
• 4 Spark Plugs
• Water Pump (WP) Kit
• Fuel Filter
• Water Pump (WP) Case Sleeve
• 6 Anodes
• Cotter Pin
• 2 Lower Unit Gaskets
• 5 O-rings

Important Note: The image provided in the product overview does not depict the exact contents of this specific package. Please rely on this list for accurate contents.

4. Preparation for Maintenance

Before beginning any maintenance procedures, ensure the following:

• Safety First: Always disconnect the battery and ensure the engine is cool before working on it. Wear appropriate personal protective equipment (PPE) such as gloves and eye protection.
• Consult Service Manual: Refer to your specific Suzuki outboard motor's official service manual for detailed, model-specific instructions, torque specifications, and safety warnings. This kit provides parts, not a complete procedural guide.
• Required Tools: Gather all necessary tools, including wrenches, sockets, spark plug wrench, oil filter wrench, and any specialized tools mentioned in your service manual.
• Work Area: Perform maintenance in a well-ventilated area, preferably on a level surface.

5. Maintenance Procedures

The following outlines the general application of the components included in this kit. Always refer to your Suzuki outboard's official service manual for precise, step-by-step instructions and torque specifications.

5.1. Oil Filter and Oil Drain Gasket Replacement

• Drain the old engine oil according to your service manual.
• Remove the old oil filter and replace it with the new oil filter from the kit. Ensure the new filter is properly seated and tightened to specifications.
• Replace the old oil drain gasket with the new one when reinstalling the drain plug.
• Refill the engine with the recommended type and quantity of fresh engine oil.

5.2. Spark Plug Replacement

• Remove the old spark plugs.
• Install the 4 new spark plugs provided in the kit. Ensure they are gapped correctly (refer to your service manual) and tightened to the specified torque.

5.3. Water Pump (WP) Kit and Case Sleeve

• Disassemble the lower unit to access the water pump.
• Replace the impeller and other components of the water pump using the new WP kit.
• Inspect and replace the WP case sleeve if necessary, using the new one provided.
• Reassemble the water pump and lower unit, ensuring all seals and gaskets are correctly installed.

5.4. Fuel Filter Replacement

• Locate and remove the old fuel filter.
• Install the new fuel filter, ensuring proper orientation and secure connections to prevent fuel leaks.

5.5. Anode Replacement

• Locate the 6 anodes on your engine (typically in the cylinder block, cylinder head, and lower unit).
• Remove the old, corroded anodes and replace them with the new ones from the kit. Anodes protect your engine from galvanic corrosion.

5.6. Lower Unit Gaskets and O-rings

• During lower unit disassembly and reassembly (e.g., for water pump service), replace the 2 lower unit gaskets and 5 O-rings to ensure a watertight seal.

5.7. Cotter Pin

• The cotter pin is typically used to secure the propeller nut. Always replace a bent or damaged cotter pin with a new one during propeller maintenance.

6. Troubleshooting

If you encounter any issues after performing maintenance with this kit, consider the following:

• Double-Check Connections: Ensure all components (filters, plugs, gaskets) are correctly installed and tightened to the manufacturer's specifications.
• Fluid Levels: Verify that all fluid levels (engine oil, lower unit oil) are correct after service.
• Leaks: Inspect for any signs of oil, fuel, or water leaks around newly installed components.
• Engine Performance: If the engine runs poorly, re-check spark plug gaps, fuel filter installation, and ensure no air is in the fuel system.
• Professional Assistance: If problems persist or you are unsure about any procedure, it is highly recommended to consult a certified Suzuki marine technician.

7. Specifications

8. Warranty and Support

This Suzuki OEM Maintenance Kit is covered by Suzuki's standard warranty for genuine parts. For specific warranty terms and conditions, please refer to the official Suzuki Marine website or contact your authorized Suzuki dealer.

For technical support, detailed service procedures, or assistance with any issues related to your Suzuki outboard motor or this maintenance kit, please contact an authorized Suzuki Marine service center or visit the official Suzuki Marine customer support resources.