Suzuki outboard motors 1988 2003 repair manual., Page 33Get this manual
MAINTENANCE 3-1 7 bend the center electrodeAlso, be careful not to bend the side electrode too far or too often as it may weaken and break off within the engine, requiring removal of the cylinder head to retrieve itoperatingAn alternate method is to check the static timing-with the powerhead not operatingThis second method requires the use of dial indicator gaugeVarious models have unique methods of checking ignition timingThese differences are explained in detail later in this sectionSYNCHRONIZATION TESTING
At every tune-uplinspection, visually check the spark plug wires for burns, cuts, or breaks in the insulationCheck the boots on the coil and at the spark plugReplace any wire that is damagedOnce year, usually when you change your spark plugs, check the resistance of the spark plug wires with an ohmmeterWires with excessive resistance will cause misfiring and may make the engine difficult to startIn addition worn wires will allow arcing and misfiring in humid conditionsRemove the spark plug wire from the engineTest the wires by connecting one lead of the ohmmeter to the coil end of the wire and the other lead to the spark plug end of the wireResistance should measure approximately 7000 ohms per foot of wireWhen installing new set of spark plug wires, replace the wires one at time so there will be no confusionCoat the inside of the boots with dielectric grease to prevent stickingInstall the boot firmly over the spark plug until it clicks into placeThe click may be felt or heardGently pull back on the boot to assure proper contactRoute the wire the same as the original and install it in similar manner on the engineRepeat the process for each wireIn simple terms, synchronization is timing the fuel system to the ignitionAs the throttle is advanced to increase powerhead rpm, the carburetor and the ignition systems are both advanced equally and at the same rateAny time the fuel system or the ignition system on powerhead is serviced to replace faulty part or any adjustments are made for any reason, powerhead timing and synchronization must be carefully checked and verifiedFor this reason the timing and synchronizing procedures have been separated from all others and presented alone in this sectionBefore making adjustments with the timing or synchronizing, the ignition system should be thoroughly checked and the fuel system verified to be in good working orderOn the breaker point ignitions, synchronization is automatic once the point gap and the piston travel or timing mark alignments are correctModels equipped with electronic ignitions are statically timed by aligning the timing marks on the throttle cam or throttle stopper with timing marks on the flywheelInitial timing and timing advance are both set this way before using timing light to check the timingBefore making adjustments with the timing or synchronizing, the ignition system should be thoroughly checked and the fuel system verified to be in good working orderREMOVALINSTALLATION
When installing new set of spark plug wires, replace the wires one at time so there will be no confusionCoat the inside of the boots with dielectric grease to prevent stickingInstall the boot firmly over the spark plug until it clicks into placeThe click may be felt or heardGently pull back on the boot to assure proper contactRoute the wire the same as the original and install it in similar manner on the engineRepeat the process for each wirePREPARATION
Timing and synchronizing the ignition and fuel systems on an outboard motor are critical adjustmentsThe following equipment is essential and is called out repeatedly in this sectionThis equipment must be used as described, unless otherwise instructed by the equipment manufacturerNaturally, the equipment is removed following completion of the adjustmentsSuzuki also recommends the use of test wheel instead of normal propeller in order to put load on the engine and propeller shaftThe use of the test wheel prevents the engine from excessive rpmThe Synchronizing of the fuel systems on an outboard motor are critical adjustmentsThe following equipment is essential and is called out repeatedly in this sectionThis equipment must be used as described, unless otherwise instructed by the equipment manufacturerNaturally, the equipment is removed following completion of the adjustmentsThe electronic CDI ignition system has become one of the most reliable components on the modern outboard engineThere is very little maintenance involved in the operation of the ignition and even less to repair if the component failsMost systems are sealed and there is no option other than to replace the failed componentIt is very important to narrow down the ignition problem and replace the correct component rather than just replace parts hoping to solve the problemElectronic components can be very expensive and are usually not returnablePlease refer to the "Ignition and Electrical" Section for more information on troubleshooting and repairing the CDI ignition systemDial Indicator