Suzuki 9 Service Manual Download Page 214

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9-4 WIRE/HOSE ROUTING

DF9.9R/DF15R

PUSH

TURN

GND

B.Z

RESET

OFF

FREE

PUSH

REMO

TE CONTR

OL BO

SUZUKI

CDI UNIT

TTER

Y 12V 35AH

GNET

CONDENSER

CHARGE COIL

TER MO

FUSE 15A

FUSE 20A

RECTIFIER &

REGULA

IGNITION

SWITCH

TER

OTO

RELA

B P

Y/G

O
B

Y/G

R/G

Y
B

Y/G

uto-enric

hener

(PTC heater)

OIL PRESSURE SWITCH

15 kP

(0.15 kgf/cm

) or less

NEUTRAL SWITCH

N ON

.R OFF

UTION LAMP

(OIL PRESSURE)

PULSER COIL

TTER

CHARGE COIL

EMERGENCY ST

OP SWITCH

Loc

k plate IN R

Loc

k plate OUT ST

R/B

Y/B

B/R

Bl/R

IGNITION COIL

ARK PLUG

W Bl Br O Gr G B

Gr W Bl Br O Y G B

W Bl Br

Y/B Bl/R

UTION

UZZER

WIRE COLOR

B .........

Blac

Bl ........

Blue

Br ........

Bro

G .........

Green

Gr .......

O .........

ange

P .........

Pink

R .........

Red

W .........

White

Y ..........

ello

B/R .......

Blac

k with Red tr

acer

BI/R .......

Blue with Red tr

acer

R/B ........

Red with Blac

k tr

acer

R/G .......

Red with Green tr

acer

Y/B ........

ello

w with Blac

k tr

acer

Y/G ........

ello

w with Green tr

acer

Summary of Contents for 9

Page 1: ...For 2005 model 9 9 5 0 0 9 4 J 0 1 0 1 E ...

Page 2: ...ustomers with optimum and quick service NOTE This manual is compiled based on 2005 K5 model This manual has been prepared using the latest information available at the time of publication Differences may exist between the content of this manual and the actual outboard motor Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the...

Page 3: ...able of contents to easily locate the item and page you need COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS Under the name of each system or unit an exploded view is provided with work instructions and other ser vice information such as the tightening torque lubrication and locking agent points Example 1 2 4 7 8 6 5 3 10 9 11 12 80 N m 8 0 kg m 58 0 lb ft NOTE Clean flywheel and crankshaft matin...

Page 4: ...TION SYMBOL DEFINITION Torque control required Data beside it indicates specified torque Apply the THREAD LOCK 1342 Apply the oil Use the engine oil unless otherwise specified Apply the THREAD LOCK SUPER 1333B Apply the SUZUKI OUTBOARD MOTOR GEAR OIL Measure in DC voltage range Apply the SUZUKI SUPER GREASE A Measure in resistance range Apply the SUZUKI WATER RESISTANT GREASE Measure in continuity...

Page 5: ...IONS 1 2 IDENTIFICATION NUMBER LOCATION 1 4 FUEL AND OIL 1 5 GASOLINE RECOMMENDATION 1 5 ENGINE OIL 1 5 ENGINE BREAK IN 1 6 WARM UP RECOMMENDATION 1 6 THROTTLE RECOMMENDATION 1 6 PROPELLERS 1 7 SPECIFICATIONS 1 8 SERVICE DATA 1 10 TIGHTENING TORQUE 1 17 SPECIAL TOOLS 1 19 MATERIALS REQUIRED 1 22 ...

Page 6: ...gether pay attention to the safety of each other When it is necessary to run the outboard motor indoors make sure that exhaust gas is vented outdoors When testing an outboard motor in the water and on a boat ensure that the necessary safety equipment is on board Such equipment includes flotation aids for each person fire extin guisher distress signals anchor paddles bilge pump first aid kit emerge...

Page 7: ...bolts and nuts beginning with larger diameter and ending with smaller diameter Always tighten from inside to outside diagonally to the specified tight ening torque Whenever you remove oil seals gaskets packing O rings locking washers locking nuts cotter pins circlips and certain other parts as specified always replace them with new Also before installing these new parts be sure to remove any left ...

Page 8: ...of motor are stamped on a plate attached to the clamp bracket Example ENGINE SERIAL NUMBER A second engine serial number plate is pressed into a boss on the cylinder block Model THAI SUZUKI MOTOR CO LTD MADE IN THAILAND FABRIQUE AU THAILANDE Pre fix Serial number 1 Serial number plate 1 Serial number plateS 1 1 1 XXXXXX ...

Page 9: ...ivalent octane content may be used Allowable maximum blend of a single additive not combination 5 Methanol 10 Ethanol 15 MTBE ENGINE OIL Use only oils that are rated SE SF SG SH or SJ under the API American Petroleum Institute classification system The viscosity rating should be SAE 10W 40 If SAE 10W 40 motor oil is not available select an alternative according to the chart at right If leaded gaso...

Page 10: ...ngine speed for an extended period at any time during the engine break in by varying the throttle position occasionally 1 FIRST 2 HOURS For first 15 minutes operate the engine in gear at idling speed During the remaining 1 hour and 45 minutes operate the engine in gear at less than 1 2 half throttle 3 000 r min NOTE The throttle may be briefly opened beyond the recommended setting to plane the boa...

Page 11: ...ent use another pitch propeller to hold the engine speed within the range specified above Propeller selection chart Recommended full throttle speed range DF9 9 4 900 5 500 r min DF15 5 400 6 000 r min Blade Diam in Pitch in 3 9 1 4 7 M701 3 9 1 4 8 M821 3 9 1 4 9 M901 M911 3 9 1 4 10 M1001 M1011 3 9 1 4 11 M1101 Installing a propeller with pitch either too high or too low will cause incorrect maxi...

Page 12: ... type 422 15 L mm in type 549 20 Maximum output kW PS 7 3 9 9 11 0 15 Recommended operating range r min 4 900 5 500 5 400 6 000 Idle speed r min 900 50 In gear idle speed r min Approx 820 920 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK BKR6E Ignition system SUZUKI PEI Digita...

Page 13: ...on SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 170 5 7 6 0 Trim angle Degrees 4 20 Number of tilt pin position 5 Maximum tilt angle Degrees 67 Reversing system Gear Transmission Forward Neutral Reverse Reduction sys...

Page 14: ... Engine oil amount L US lpm qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distor tion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil clearance STD mm in 0 020 0 062 0 0008 0 0024...

Page 15: ...e stem outside diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide protrusion IN STD mm in 10 0 0 39 EX STD mm in 10 0 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve he...

Page 16: ... 0 25 0 004 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clear ance 1st STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21...

Page 17: ...nce STD mm in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft jour nal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in ...

Page 18: ...S lmp oz 170 5 7 6 0 Gear ratio 2 08 12 25 Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCMII 23 11 5 BCMII 25 21 I D mark 94J2 94J3 94J6 94J7 Main jet 70 115 Pilot jet 38 40 Pilot screw Turns open PRE SET 1 7 8 1 2 PRE SET 2 7 8 1 2 Float height mm 13...

Page 19: ...20 C 0 9 1 3 DF9 9E 15E DF9 9 15 0 3 0 4 DF9 9R 15R R Y Battery charge coil output 12V Watt 80 Tiller handle model 120 Remote control model Standard spark plug Type NGK BKR6E Gap mm in 0 7 0 8 0 028 0 031 Fuse amp rating A 20 Electric start model Recommended battery capacity 12V Ah kC 35 126 or over Electric start model Starter motor relay coil resistance Ω at 20 C 145 190 Electric start model Max...

Page 20: ...ster range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Test 1 Ignit...

Page 21: ...iming pulley nut 26 mm 50 5 0 36 0 Flywheel nut 14 mm 80 8 0 58 0 Spark plug 27 2 7 19 5 Power unit mounting bolt and nut 8 mm 23 2 3 16 5 Driveshaft housing bolt 8 mm 23 2 3 16 5 Oil pressure switch 13 1 3 9 5 Oil regulator 14 mm 27 2 7 19 5 Camshaft pulley bolt 6 mm 10 1 0 7 0 Engine oil drain plug 12 mm 13 1 3 9 5 Upper mount bolt 8 mm 23 2 3 16 5 Upper mount bracket bolt 8 mm 23 2 3 16 5 Lower...

Page 22: ... N m kg m lb ft 5 mm 2 4 0 2 0 4 1 5 3 0 6 mm 4 7 0 4 0 7 3 0 5 0 8 mm 10 16 1 0 1 6 7 0 11 5 Conventional or 4 marked bolt 10 mm 22 35 2 2 3 5 16 0 25 5 5 mm 2 4 0 2 0 4 1 5 3 0 6 mm 6 10 0 6 1 0 4 5 7 0 8 mm 15 20 1 5 2 0 11 0 14 5 Stainless steel bolt 10 mm 34 41 3 4 4 1 24 5 29 5 5 mm 3 6 0 3 0 6 2 0 4 5 6 mm 8 12 0 8 1 2 6 0 8 5 8 mm 18 28 1 8 2 8 13 0 20 0 7 marked or marked bolt 10 mm 40 60...

Page 23: ... 10 09900 20203 Micrometer 50 75 mm 09900 20205 Micrometer 0 25 mm 09900 20530 Cylinder gauge set 40 100 mm 09900 20602 Dial gauge 09900 20605 Dial calipers 10 34 mm 11 12 13 14 15 09900 20701 Magnetic stand 09900 20803 Thickness gauge 09900 21304 Steel V block set 09900 22301 Plastigauge 0 025 0 076 mm 09900 26006 Engine tachometer 16 17 18 19 20 09900 28403 Hydrometer 09911 49310 Crankshaft hold...

Page 24: ...adapter N 503 1 09916 24450 Solid pilot N 100 5 52 09916 34542 Valve guide reamer handle 09916 34550 Valve guide reamer 5 5 mm 31 32 33 34 35 09916 38210 Valve guide reamer 11 mm 09916 44910 Valve guide remover installer 09916 54910 Handle N 505 09916 77310 Piston ring com pressor 09916 84511 Tweezers 36 37 38 39 40 09917 14910 Valve adjuster driver 09930 30104 Sliding hammer 09930 39210 Flywheel ...

Page 25: ...09950 69512 Gearcase oil leakage tester 09951 09530 Gear adjusting gauge Pinion bearing installer and remover 09951 59910 Pinion bearing installer shaft A 09951 49910 Pinion bearing remover shaft B 09951 69910 Bearing C 01500 08403 Bolt D 09951 39914 Pinion bearing plate E 09951 19311 Attachment F 09951 79311 Spacer G 09951 29910 Nut H 50 51 52 53 09900 25010 Pocket tester 99954 53008 820 Digital ...

Page 26: ...I SUPER GREASE A WATER RESISTANT GREASE SUZUKI SILICONE SEAL SUZUKI BOND 1207B 99000 22540 400 ml 24 pcs 99000 25030 99000 25011 500 g 99000 25161 250 g 99000 31120 50 g 99104 33140 99000 31140 100 g THREAD LOCK 1342 THREAD LOCK SUPER 1333B 4 Stroke Motor Oil 99000 32050 50 g 99000 32020 50 g API SE SF SG SH SJ SAE 10W 40 ...

Page 27: ...INE OIL FILTER 2 4 GEAR OIL 2 5 LUBRICATION 2 6 SPARK PLUG 2 7 VALVE CLEARANCE 2 8 TIMING BELT 2 10 IDLE SPEED 2 13 CARBURETOR 2 13 IGNITION TIMING 2 14 BREATHER AND FUEL LINE 2 14 FUEL FILTER 2 14 WATER PUMP WATER PUMP IMPELLER 2 15 PROPELLER NUT PIN 2 15 ANODES AND BONDING WIRES 2 16 BATTERY 2 17 BOLTS AND NUTS 2 18 OIL PRESSURE 2 19 CYLINDER COMPRESSION 2 21 TEST PROCEDURE 2 21 ...

Page 28: ...Inspect and clean adjust lubricate or replace if necessary T Tighten R Replace Interval Initial 20 hrs or 1 month Every 50 hrs or 3 months Every 100 hrs or 6 months Every 200 hrs or 12 months Item to be serviced Spark plug I R Breather Hose and Fuel line I I I I Replace every 2 years Engine oil R R R Gear oil R R R Lubrication I I I Anodes and bonding wire I I I Battery I I I Bolts and nuts T T T ...

Page 29: ... level surface 2 Remove the motor cover 3 Remove the oil filler cap 1 4 Place a container under engine oil drain plug 2 then remove engine oil drain plug and gasket to drain engine oil 5 Install new gasket and oil drain plug Tighten engine oil drain plug to specified torque Engine oil drain plug 13 N m 1 3 kg m 9 5 lb ft Change initially after 20 hours 1 month and every 100 hours 6 months Do not r...

Page 30: ...nd wipe it clean 9 Reinsert the dipstick fully into the dipstick tube then remove to check oil level 10 Oil level should be between full level Max mark hole and low level Min mark hole If level is low add recommended oil to full level hole Max ENGINE OIL FILTER NOTE When replacing engine oil filter change engine oil at the same time For oil change see pages 2 3 and 2 4 Necessary engine oil amounts...

Page 31: ...il oil just starts to flow out from oil level hole Gear oil amounts 170 ml 5 7 6 0 US Imp oz Recommended oil SUZUKI OUTBOARD MOTOR GEAR OIL or SAE 90 HYPOID GEAR OIL 5 Install oil level plug before removing oil filler tube from drain hole 6 Install oil drain plug NOTE To avoid a possible low gear oil level recheck gear oil level 10 minutes after doing procedure in step 6 If oil level is low add ad...

Page 32: ... Apply SUZUKI Water Resistant Grease to the following points 99000 25161 SUZUKI WATER RESISTANT GREASE Inspect every 50 hours 3 months Carburetor linkage Throttle cable NSI cable Propeller shaft Steering bracket Clamp screw Swivel bracket ...

Page 33: ...ECTRODE INSULATOR Check the electrode and insulator condition If the electrode is extremely worn or burnt replace the spark plug If the spark plug has a broken insulator damaged threads etc replace the spark plug Spark plug 27 N m 2 7 kg m 20 0 lb ft Inspect every 100 hours 6 months Replace every 200 hours 12 months Only resistor R type spark plugs must be used with this engine Using a non resisto...

Page 34: ...e to check or adjust valve clearance The valve clearance specification is for COLD engine condi tion 5 Insert the thickness gauge between valve stem end and valve adjusting screw on rocker arm 09900 20803 Thickness gauge Valve clearance cold engine condition IN 0 18 0 22 mm 0 007 0 009 in EX 0 18 0 22 mm 0 007 0 009 in If measurement is out of specification adjust valve clearance Inspect initially...

Page 35: ... adjustment driver 8 Tighten valve adjusting lock nut while holding valve adjusting screw Valve adjusting lock nut 11 N m 1 1 kg m 8 0 lb ft 9 Recheck valve clearance 10 Tighten the cylinder head cover bolts to specified torque Cylinder head cover bolt 10 N m 1 0 kg m 7 0 lb ft Checking All parts removed have been returned to their original posi tions Check hose routing Do not re use gasket once r...

Page 36: ...lywheel holder attachment 09930 39411 Flywheel remover 09930 39210 Flywheel remover attachment bolt 6 Disconnect stop switch lead wire connector Disconnect starter button lead wire connector 7 Remove nut 1 and positive battery cable 2 positive battery charge cable 3 from the magnetic switch B termi nal of starter motor Disconnect the red lead wire 4 from starter motor magnetic switch S terminal In...

Page 37: ...base from cylinder block and lay it on port side as shown figure 11 Rotate the crankshaft to align the PUNCH mark on the tim ing pulley with the INDEX mark on the cylinder block 09911 49310 Crankshaft holder Rotate the crankshaft in the normal running direction clockwise to prevent water pump impeller damage Do not rotate the cam pulley with timing belt removed 1 2 1 PUNCH mark 2 INDEX mark ...

Page 38: ...lowing must be checked The PUNCH mark on the timing pulley aligns with the INDEX mark on the cylinder block Either of the PUNCH marks on the cam pulley aligns with the INDEX mark on the cylinder head block If the timing pulley or the cam pulley is rotated with the timing belt removed or installed but misaligned this may cause the valves to become bent If the alignment marks are not correctly match...

Page 39: ...Check engine idle speed Idle speed in neutral gear 850 950 r min Adjustment If engine idle speed is out of specification adjust engine speed as follows Turn the throttle stop screw 1 Turning clockwise The engine speed becomes higher Turning counterclockwise The engine speed becomes lower CARBURETOR If crack or other damage is found on carburetor body lever rod connector inlet manifold or silencer ...

Page 40: ...nition timing while operating the engine at 1 000 r min Ignition timing Approx ATDC 5 at 1 000 r min BREATHER AND FUEL LINE If leakage cracks swelling or other damage is found replace the breather line and or the fuel line FUEL FILTER If water accumulation sediment leakage cracks or other dam age is found replace the fuel filter Inspect every 200 hours 12 months Inspect initially after 20 hours 1 ...

Page 41: ...r broken blades Replace propeller if damage noticeably affects operation Inspect propeller splines Replace propeller if splines are worn damaged or twisted Inspect propeller bush for slippage Replace if necessary Make sure that propeller nut is torqued to specification and cotter pin is installed securely WATER PUMP Inspect every 200 hours 12 months WATER PUMP IMPELLER Replace every 200 hours 12 m...

Page 42: ...ensure maximum effectiveness NOTE The anode securing bolt should be covered with SUZUKI SILI CONE SEAL 99000 31120 SUZUKI SILICONE SEAL BONDING WIRES If breakage or other damage is found on the wire replace the wire If rust corrosion or other damage is found on terminal clean with cleaning solvent or replace the wire Inspect every 50 hours 3 months Never paint the anode Anode ...

Page 43: ...rate gas which is flammable and explosive Battery acid is poisonous and corrosive Avoid con tact with eyes skin clothing and painted surfaces If battery acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate med ical attention Batteries should always be kept out of reach of chil dren When checking or servicing battery d...

Page 44: ...ced NEVER add diluted sulfuric acid or battery damage will occur Follow the battery manufacture s instructions for spe cific maintenance procedures Inspect initially after 20 hours 1 month and every 100 hours 6 months ITEM THREAD DIAMETER TIGHTENING TORQUE N m kg m lb ft Cylinder head cover bolt 6 mm 10 1 0 7 0 Cylinder head bolt 8 mm 27 2 7 20 0 Intake manifold bolt 8 mm 23 2 3 16 5 Carburetor mo...

Page 45: ...ogged oil filter Leakage from oil passages Defective oil pump Defective oil pressure regulator Damage O ring Combination of above items High oil pressure Using an engine oil of too high viscosity Clogged oil passage Clogged oil pressure regulator Combination of above items TEST PROCEDURE 1 Check the engine oil level 2 Remove the plate 1 by sliding it upward 3 Remove CDI unit 2 from electric parts ...

Page 46: ...tion coil then secure with bolts 8 Attach the engine tachometer to ignition coil high tension cord 09900 26006 Engine tachometer 9 Start engine and allow to warm up as follows Summer 5 min at 2 000 r min Winter 10 min at 2 000 r min 10 After warming up shift into forward gear and increase engine speed to 3 000 r min then compare pressure indi cated on gauge to specifications 11 After testing reins...

Page 47: ... the STBD PORT engine side lower cover 3 Remove all spark plugs 4 Install the compression gauge into the plug hole 09915 64512 Compression gauge 5 Disconnect the safety lanyard from the emergency stop switch 6 Disconnect the remote control throttle cable from the throttle lever R model 7 Move and hold the throttle lever in the full open position R model Move and hold the throttle control grip in t...

Page 48: ... 5 REMOVAL INSTALLATION 3 9 CAUTION SYSTEM 3 14 OVER REVOLUTION CAUTION SYSTEM 3 14 LOW OIL PRESSURE CAUTION SYSTEM 3 15 TESTING OIL PRESSURE CAUTION SYSTEM 3 16 REMOVAL AND INSTALLATION 3 17 BATTERY CHARGING SYSTEM 3 18 OUTLINE 3 18 INSPECTION 3 19 REMOVAL INSTALLATION 3 22 ELECTRIC STARTER SYSTEM 3 23 OUTLINE 3 23 TROUBLESHOOTING 3 25 INSPECTION 3 26 STARTER MOTOR 3 29 ...

Page 49: ...gs by the ignition timing signal calculated by the CDI microcomputer from the pulser coil signals SPECIFICATION Ignition type CDI Advance Electronic microcomputer control Ignition timing ATDC 5 BTDC 30 Power source circuit Charging circuit Power source circuit Base signal circuit Hardware ignition signal circuit Software ignition signal control circuit Input circuit Input circuit Output circuit Ou...

Page 50: ... to the primary winding of the ignition coil Control mode When starting at the time of cranking The ignition timing is fixed at ATDC 10 until the engine starts When operating normal operation The ignition timing varies in the range of ATDC 5 BTDC 30 according to the engine operating condition Basic sensor Ignition timing is deter mined by a digital map de signed in relation to engine speed CDI uni...

Page 51: ... resistance See page 3 8 Cap resistance 8 12 kΩ Check the condenser charge coil resistance See page 3 5 Coil resistance 12 5 18 8 Ω Check the pulser coil resistance See page 3 6 Coil resistance 148 222 Ω Check the CDI unit See page 3 7 OK OK OK OK OK OK No or weak sparks No or weak sparks Check the ignition timing by using the timing light ATDC 5 at 1 000 r min The cause will not be in the ignitio...

Page 52: ...on replace the condenser charge coil CONDENSER CHARGE COIL RESISTANCE 09930 99320 Digital tester Tester range Ω Resistance 1 Disconnect the condenser charge coil lead wire connector 2 Connect the tester probe to the coil lead wires as shown Condenser charge coil resistance 12 5 18 8 Ω If measurement is out of specification replace the condenser charge coil Always disconnect the battery cables from...

Page 53: ...or over If measurement is out of specification replace the pulser coil PULSER COIL RESISTANCE 09930 99320 Digital tester Tester range Ω Resistance 1 Disconnect the pulser coil lead wire connector 2 Connect the tester probe to the coil lead wires as shown Pulser coil resistance 148 222 Ω If measurement is out of specification replace the pulser coil Tester probe connection Red Black Red Black Black...

Page 54: ...lace the ignition coil CDI UNIT OUTPUT 09930 89920 6 pin connector test cord Peak Voltmeter Stevens CD 77 Tester range NEG 500 1 Disconnect 6 pin wire harness connector from CDI unit 2 Connect the 6 pin test cord between CDI unit and wire har ness as shown in figure 3 Connect the tester probe to the test cord lead wires as shown 4 Remove all spark plugs 5 Crank with the recoil starter then measure...

Page 55: ... tester Tester range Continuity Check continuity infinity between the wiring leads under the con dition shown below Note 1 Remote control model Note 2 Tiller handle model If out of specification replace the engine stop switch Tester probe connection Probe Other probe Cap end Other cap end Tester probe connection Probe Other probe Blue Red Green Note 1 Black Switch condition Continuity Lock plate I...

Page 56: ...page 5 2 Before removing electrical parts Disconnect battery cables from battery Remove all spark plug caps from the spark plug 1 2 4 7 8 6 5 3 10 9 11 12 80 N m 8 0 kg m 58 0 lb ft NOTE Clean flywheel and crankshaft mating surfaces with cleaning solvent 1 Nut 2 Washer 3 Flywheel 4 Key 5 Battery condenser charge coil 6 Pulser coil 7 Screw 8 Screw 9 Stator base 10 Bolt 11 Bolt 12 Dowel pin ...

Page 57: ...1 Flywheel remover 09930 39210 Flywheel remover bolt 4 Remove flywheel nut 1 washer 2 flywheel 3 and key 4 Battery Condenser charge coil Pulser coil 5 Remove side covers See page 7 2 6 Disconnect stop switch lead wire connector 1 Disconnect starter button lead wire connector 2 Tiller handle model 7 Remove nut and positive battery cable 3 positive bat tery charge cable 4 from the magnetic switch B ...

Page 58: ...g stator base 9 10 Cut the cable ties 0 securing pulser coil wiring harness to stator base 11 Disconnect the 4 pin wiring harness connector from CDI unit 12 Lift up and remove stator base from cylinder block 13 Cut the cable ties securing coil wiring harness to stator base 14 Disconnect battery charge coil lead wire connector from rec tifier 15 Remove the bolt A securing pulser coil GND lead wire ...

Page 59: ...re with cable ties then check that coil lead wire is routed properly and away from hot or rotating parts Wire routing Pulser coil Pulser coil ground lead wire Bolt Battery Condenser charge coil Main wiring harness Cable tie Cable tie Cable tie Cable tie Clamp Pulser coil ground lead wire Bolt Main wiring harness Cable tie Clamp Manual starter model Electric starter model To PTC heater R model ...

Page 60: ... LOCK 1342 Flywheel Clean flywheel and crankshaft mating surfaces with cleaning solvent Tighten flywheel nut to specified torque 09930 48720 Flywheel holder 09930 49210 Flywheel holder attachment Flywheel nut 80 N m 8 0 kg m 58 0 lb ft Final assembly check Perform the following checks to ensure proper and safe opera tion All parts removed have been returned to their original posi tions Wire routin...

Page 61: ...or decreases engine speed to less than approximately 6 200 r min within 10 seconds the over revolution caution control will be cancelled If the engine is operated at a speed above 6 500 r min for more than 10 seconds the engine speed will be automatically lowered to approximately 3 000 r min by intermittent ignition During operation of the over revolution caution control the caution lamp is ON RES...

Page 62: ...r min or higher RESET Stop the engine and check the engine oil level Refill the engine oil to the correct level The low oil pressure caution system is reset when the oil pressure is restored to over 15 kPa 0 15 kg cm2 2 psi with approx 1 500 r min for 1 5 seconds If the engine oil level is correct the following causes may be considered Improper oil viscosity Malfunctioning oil pressure switch Clog...

Page 63: ... LAMP CIRCUIT a Remove the blue lead wire from the oil pressure switch b Start the engine c Touch the blue lead wire to the engine body ground If the caution lamp comes on the oil pressure switch circuit and the oil pressure caution lamp are normal CAUTION LAMP Check for illumination of the caution lamp 1 Disconnect lamp lead wires from engine harness 2 For tests using 1 5V power source or battery...

Page 64: ... Remove oil pressure switch from cylinder block INSTALLATION Installation is reverse order of removal with special attention to the following steps Before installing oil pressure switch wrap screw threads with sealing tape then tighten switch to specified torque NOTE Cut off any excess sealing tape from switch threads before installation Oil pressure switch 13 N m 1 3 kg m 9 5 lb ft Start engine a...

Page 65: ... charge the battery Manual start model Electric start model Rectifier Regulator Magneto Battery charge coil 12 V 80 W Fuse 20A Y tube Receptacle plug Battery 12 V R tube Option B W W B W B Y R W Y R B R M Battery Magneto Starter motor To starter button Tiller handle model Fuse 20A Starter motor relay R Rectifier Regulator PTC heater To ignition switch Remote control model 1 Battery charge coil 12 ...

Page 66: ...t of specification replace the battery charge coil BATTERY CHARGE COIL RESISTANCE 09930 99320 Digital tester Tester range Ω Resistance 1 Disconnect the battery charge coil wires from the rectifier 2 Connect tester probe to battery charge coil lead wires as shown Coil resistance 0 9 1 3 Ω 80 W coil DF9 9E 15E DF9 9 15 0 3 0 4 Ω 120 W coil DF9 9R 15R If measurement is out of specification replace th...

Page 67: ... pocket tester is used Rectifier regulator resistance Remote control model Unit Approx kΩ Tiller handle model Unit Approx kΩ If measurement exceeds specification replace rectifier regula tor Tester probe Red Tester probe Black Black White Yellow 1 Red Yellow 2 Yellow 3 Black 7 11 2 4 2 4 2 3 7 11 White 0 Yellow 1 160 240 2 4 400 600 400 600 2 4 Red 160 240 2 4 400 600 400 600 2 4 Yellow 2 Yellow 3...

Page 68: ...nd replace with a new 20 amp fuse if needed Fuse case 1 Disconnect battery cables from battery 2 Disconnect white lead wire of rectifier from engine wire har ness 3 Check continuity between White lead wire 1 of engine wire harness and Red lead wire 2 of starter motor magnetic switch B terminal If no continuity is indicated replace engine wire harness and or fuse Fuse Starter motor magnetic switch ...

Page 69: ... block and lay it on port side as shown figure Remove the screws securing the rectifier regulator 1 Disconnect lead wire connectors INSTALLATION Installation is reverse order of removal with special attention to the following steps Battery Condenser charge coil Install stator base and charge coil See page 3 12 Wire routing Check wire routing See page 9 3 to 9 9 Before removing electrical parts Dis...

Page 70: ...hift lever movement causes the pinion to engage the engine flywheel gear the magnetic switch main contacts to close and engine cranking to take place When the engine starts the pinion over running clutch protects the armature from excessive speed until the starter button is opened at which time the torsion spring causes the pinion to disengage Pinion over running clutch Ring gear Shift lever Plung...

Page 71: ...netic switch Starter motor Battery Fuse 20A B Br Br W R R R R R B B Br Br W R R R R R R R R R Y G Y G Y G Y G Y G Y G Y G Y G Ignition switch Neutral switch Starter relay For Remote control model PUSH TURN GND STOP BATT IG START B Z RESET Gr W G B Br O ST IG OFF FREE PUSH SUZUKI B Movable contact Stationary contact ...

Page 72: ... motor turn under no load condi tions by connecting bat tery terminal to M terminal of starter motor and battery terminal to the starter motor body The magnetic switch and or connection is faulty Replace it Check function of neu tral switch See page 3 27 Check ignition switch function See page 3 26 Check starter relay See page 3 27 Check starter button function See page 3 26 Check wiring system an...

Page 73: ...l 09930 99320 Digital tester Tester range Continuity 1 Disconnect the starter button lead wire 2 Check continuity between the wiring leads under the condi tion shown below If out of specification replace the starter button Tester probe connection Continuity Probe Other probe Starter button not depressed White Red Brown No Starter button depressed Yes OFF ON START FREE PUSH Black Green White Gray B...

Page 74: ...mo con handle or shift lever STARTER MOTOR RELAY 09930 99320 Digital tester Tester range Continuity 1 Remove the plate a by sliding it upward 2 Remove CDI unit b 3 Pull out relay c from electric parts holder then disconnect starter motor relay from wire 4 Check continuity between terminal 1 and 2 each time 12 V is applied Connect positive side to terminal 4 and nega tive side to terminal 3 Starter...

Page 75: ...GNITION AND ELECTRICAL 5 Measure resistance between relay terminals 3 and 4 Tester range Ω Resistance Starter motor relay solenoid coil resistance 145 190 Ω If out of specification replace starter motor relay ...

Page 76: ...chment bolt 3 Remove nut 3 and positive battery cable 4 positive battery charge cable 5 from the magnetic switch B termi nal of starter motor Disconnect the red lead wire 6 from starter motor magnetic switch S terminal 4 Disconnect engine stop switch lead wire connector 7 Disconnect starter switch lead wire connector 8 Tiller handle model 5 Remove the PORT side bolt 9 securing starter motor band P...

Page 77: ... Check wire routing See page 9 2 to 9 9 DISASSEMBLY When overhauling starting motor it is recommended that com ponent parts be cleaned thoroughly However the yoke assembly armature coil over running clutch assembly magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent These parts should be cleaned with compressed air or w...

Page 78: ...wire 2 2 Remove two bolts 3 securing magnetic switch 3 Remove the magnetic switch 4 4 Remove screws 5 long through bolts 6 and rear cover 7 5 Remove thrust washer 8 with screwdriver 6 Pull the brush spring 9 up to separate the brush from the surface of the commutator then remove the brush holder 0 ...

Page 79: ... E 10 Remove the center bracket F with shift lever H pinion I and pinion shaft J from front housing G 11 Remove the shift lever H 12 Push the pinion stopper K down then remove stopper ring L Remove the pinion stopper and pinion I NOTE Using a screw driver pry off the stopper ring Wear safety glasses when disassembling and assem bling stopper ring ...

Page 80: ...outside diameter 09900 20101 Vernier calipers Commutator outside diameter Standard 29 0 mm 1 14 in Service limit 28 0 mm 1 10 in If measurement exceeds service limit replace armature Check that mica insulator between the segments is undercut to specified depth Commutator undercut 1 Standard 0 5 0 8 mm 0 02 0 03 in Service limit 0 2 mm 0 01 in If measurement exceeds service limit cut to specified d...

Page 81: ... of each brush 09900 20101 Vernier calipers Brush length Standard 15 5 mm 0 61 in Service limit 9 5 mm 0 37 in If brushes are worn down to the service limit they must be replaced BRUSH HOLDER Check brush holder continuity 09930 99320 Digital tester Tester range Continuity Brush holder continuity Replace brush holder if the tester doesn t show the above Wear safety glasses when using compressed air...

Page 82: ...r wear Replace if necessary PINION AND OVER RUNNING CLUTCH Inspect pinion for wear damage or other abnormal conditions Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction Replace if necessary Inspect spline teeth for wear or other damage Inspect pinion for smooth movement Replace if necessary GEAR Inspect planetary gears and internal gear for wear...

Page 83: ...haft bush for wear or other damage Replace if necessary FRONT HOUSING Inspect front housing for wear damage or other abnormal conditions Replace if necessary Inspect bush for wear or other damage Replace if necessary ARMATURE SHAFT BUSH Inspect bush for wear or other damage Replace if necessary PLUNGER Inspect plunger for wear or other damage Replace if necessary ...

Page 84: ...oil Open circuit Test 09930 99320 Digital tester Tester range Continuity Check for continuity across magnetic switch S terminal and coil case If no continuity exists the coil is open and should be replaced Contact points Test 09930 99320 Digital tester Tester range Continuity Put the plunger on the under side and then push the magnetic switch down At this time check for continuity between terminal...

Page 85: ...re use care to avoid breaking brushes 7 N m 0 7 kg m 5 1 lb ft 5 5 N m 0 55 kg m 4 0 lb ft 1Nut 2Bolt 3Magnetic switch 4Gasket 5Spring 6Plunger 7Torsion spring 8Rubber packing 9Shift lever 0Front housing AScrew BThrough bolt CRear cover DThrust washer EBrush holder FYoke GArmature HCenter cover plate IInternal gear JPlanetary gear KPinion shaft LPinion ME ring NWasher OCenter bracket PRubber ring ...

Page 86: ...ck that plunger and pinion remain out If plunger and pinion return inward replace magnetic switch PLUNGER AND PINION RETURN TEST Disconnect negative lead from switch motor body Check that plunger and pinion return inward If plunger and pinion don t return inward replace magnetic switch Each test must be performed within 3 5 seconds to avoid coil damage from overheating When performing the followin...

Page 87: ...y and ammeter to starter motor as shown 2 Check that starter rotates smoothly and steadily with pinion moving out Check that ammeter indicates specified current No load current Within 90 A at 11 V Before performing following test secure the starter motor to the test bench ...

Page 88: ...OCEDURE 4 3 FUEL HOSE CONNECTION 4 3 CARBURETOR 4 4 REMOVAL 4 4 INSTALLATION 4 5 DISASSEMBLY 4 6 CLEANING INSPECTION 4 9 REASSEMBLY 4 11 THROTTLE CONTROL 4 13 INSTALLATION ADJUSTMENT 4 13 FUEL PUMP 4 15 REMOVAL INSTALLATION 4 15 DISASSEMBLY REASSEMBLY 4 16 INSPECTION 4 17 FUEL TANK 4 18 DISASSEMBLY REASSEMBLY 4 18 INSPECTION 4 19 OPERATION 4 20 CARBURETOR 4 20 ...

Page 89: ...ke or allow anyone else to smoke near the working areas Post a NO SMOKING sign Keep a fully charged CO2 fire extinguisher and readily available for use Always use appropriate safety equipment and wear safety glasses when working around pressurized fuel system To avoid potential fire hazards do not allow fuel to spill on hot engine parts or on operating electrical components Wipe up fuel spills imm...

Page 90: ...ection varies with each type of pipe Be sure to connect and clamp each hose correctly by referring to the figure For type A short barbed end pipe hose must completely cover pipe For type B bent end pipe hose must cover straight part of pipe by 20 30mm 0 8 1 2 in For type C pipe hose must fit up against flanged part of pipe For type D pipe hose must cover pipe by 20 30 mm 0 8 1 2 in Clamp Clip Hose...

Page 91: ...case 1 carburetor 2 and insulator 3 4 Detach the fuel hose 4 from carburetor inlet Remove the throttle rod 5 from carburetor 5 On tiller handle model Unscrew the starter cable lock nut 6 then remove starter cable with starter plunger 7 Before servicing the fuel system read and understand PRECAUTION ON FUEL SYSTEM SERVICE in the previous section ...

Page 92: ...ulator gasket 3 insulator 4 carburetor gasket 5 carburetor 6 and silencer case 7 then tighten carburetor mounting bolts 8 to specified torque Carburetor mounting bolt 10 N m 1 0 kg m 7 0 lb ft NOTE When installing carburetor gasket be sure that starter fuel passage is not obstructed The projection of insulator must be faced to STBD and intake manifold sides 1 Auto enrichener 1 Do not re use gasket...

Page 93: ...uel system is pressurized See page 4 3 DISASSEMBLY NOTE Carburetor depicted is carburetor with acceleration pump 1 On remote control model Remove the screw 1 and the auto enrichener 2 with plate 3 2 Remove the four 4 screws securing the top cover 4 then remove the cover and rubber gasket 5 NOTE On the carburetor with covered pilot screw Do not remove the cover and adjust pilot screw Pilot screw co...

Page 94: ...EL SYSTEM 4 7 3 Remove the four 4 screws securing the float chamber 6 then remove the chamber and rubber gasket 7 4 Remove the screw 8 securing float pin Account for float 9 float pin 0 and needle valve A ...

Page 95: ...4 8 FUEL SYSTEM 5 Remove the main jet B and main nozzle C 6 Remove the cap D and pilot jet E 7 Remove the acceleration pump plunger F and spring G ...

Page 96: ...ect the needle valve seat Replace carburetor body if wear damage or other abnormal condition JET NOZZLE Inspect the jet and nozzle If cracks or other damage are found on the jet and nozzle replace them Clean the jet and nozzle thoroughly so that there is no obstruction NEEDLE VALVE ASSEMBLY Inspect the needle valve assembly If broken tips or wear are found on the needle valve assembly replace it W...

Page 97: ...e positive terminal of 12 V battery to Yellow lead and the negative terminal to other yellow lead Check that the auto enrichener section PTC heater built in area is heated in 5 minutes after the battery has been con nected NOTE To inspect the function check for change of temperature from the cold condition Do not attempt to disassemble the auto enrichener for the purpose of checking temperature PT...

Page 98: ...ve 8 Needle valve pin 9 Clip 10 Pin 11 Screw 12 Stop screw 13 Spring 14 Gasket 15 Float chamber 16 Drain screw 17 O ring 18 U ring 19 Top cover 20 Screw 21 Cable holder 22 Cable guide 23 Cable sealing cap 24 Starter valve 25 Spring 26 O ring 27 Drain hose 28 Clip 29 Plate 30 Screw 31 Starter assy 32 Clip 33 Cap 34 Plunger 35 Spring 36 Starter knob assy 37 Cable protector 23 22 2126 25 24 31 30 29 ...

Page 99: ...oat height NOTE Make sure that float weight is not applied to needle valve 09900 20101 Vernier calipers Float height H 13 5 2 mm ACCELERATION PUMP Check that the acceleration pump plunger operates smoothly and together with the throttle lever when turned ...

Page 100: ... can contact the stopper B on the cylinder block 5 Return the throttle control grip to its completely closed position Adjust the throttle cable 2 by turning the lock nuts 9 to the appropriate direction so that the matching mark C can align with the rib D on the cylinder block 6 With the throttle control grip in completely closed position check that there are clearances X and Y between the throttle...

Page 101: ...essive REMOTE CONTROL MODEL 1 Adjust the length of throttle rod 1 to the specification below Throttle rod length L 88 5 mm 3 48 in 2 Fit one end of the throttle rod 1 to the throttle lever 2 and other end to the carburetor throttle arm 3 3 Turn the throttle drum 4 clockwise to allow the throttle drum stopper A to contact the cylinder block stopper B At this time check that there is 0 2 mm of clear...

Page 102: ...order of removal with special attention to the following steps Fuel pump bolt 10 N m 1 0 kg m 7 0 lb ft Before servicing for the fuel system read and under stand PRECAUTION ON FUEL SYSTEM SERVICE in the previous section Before installing the fuel pump rotate the crankshaft to bring the No 1 top cylinder piston to Top Dead Center on a compression stroke Do not re use the O ring once removed Always ...

Page 103: ...n sequence the outer plate 2 gasket 3 and valve body 4 Turn the piston 5 until the pin 6 comes out through cutaway of pump body 7 Remove the following parts Piston 5 Pin 6 Pump body 7 Spring 8 Diaphragm 9 Spring 0 Do not re use the diaphragm set once removed Always use a new diaphragm set ...

Page 104: ...ragm Align the projections on the pump body the diaphragm valve body gasket and outer plate when assembling INSPECTION Check valves Inspect the fuel pump check valves If tears distortion or dam age is found replace the fuel pump Pump body Inspect the fuel pump body and outer plate If cracks nicks distortion or damage is found replace the fuel pump Do not re use the diaphragm set once removed Alway...

Page 105: ...bling or reassembling the fuel tank refer to the construction diagram below Bolt 1 Fuel plug 1 Fuel hose assembly 1 Socket 1 Socket 1 Clip 4 Primer bulb Fuel tank assembly 1 Fuel connector plug 1 Outlet 1 Outlet filter 1 O ring 1 Fuel tank cap Fuel tank cap gasket ...

Page 106: ... check valve function is defective replace the bulb Fuel hose Inspect the fuel hoses If cut crack leakage abrasion tear or deterioration is found replace the hoses Fuel tank Inspect the fuel tank If crack leakage or deterioration is found replace the tank If water or other contamination is found drain and clean the tank Tank cap Check that the fuel tank vent opens and relieves internal tank pressu...

Page 107: ...upstream but these ports serve as air passage As the pilot screw 5 is turned clockwise screwed in the mixture A F will become leaner As the screw is turned counterclockwise screwed out the mixture will become richer The throttle stop screw is designed to adjust the idling trolling speed When the stop screw is turned clock wise screwed in the speed raises and when turned counterclockwise screwed ou...

Page 108: ... F is maintained to be optimum thereby the engine speed being raised smoothly Mid High speed When the throttle valve opens further and engine speed rises fuel passes through the main jet 7 and enters the main nozzle 9 in which it is mixed with air supplied from the main air jet 8 before sprayed into the main bore Pilot jet Pilot air jet Pilot outlet Bypass port Pilot screw Throttle valve AIR FUEL ...

Page 109: ...n be accelerated smoothly Operation of acceleration pump When the throttle lever 8 is opened quickly the acceleration pump lever 1 moves to the direction indicated by the arrow with the spring 7 force causing the plunger 2 to be depressed Because the check valve 4 closes due to pressure fuel inside the acceleration pump chamber forces the check valve 5 open causing fuel to be sprayed to the main b...

Page 110: ...loat chamber 5 The mixture rich in fuel content reaches upper part of the fuel pipe and mixes again with the air coming through a passage extending from main bore 6 The two successive mixings of fuel with air are such that proper fuel air mixture for starting is produced when the mixture is sprayed out through outlet port 7 into the main bore When the engine is cold The automatic enrichener passag...

Page 111: ... the air coming from the upper part of float chamber 4 The mixture rich in fuel content reaches starter plunger 5 and mixes again with the air coming through a passage extending from main bore 6 The two successive mixings of fuel with air are such that proper fuel air mixture for starting is produced when the mixture is sprayed out through starter outlet port 7 into the main bore AIR FUEL AIR MIXT...

Page 112: ...RECOIL STARTER 5 1 5 RECOIL STARTER CONTENTS REMOVAL 5 2 DISASSEMBLY 5 3 INSPECTION 5 5 REASSEMBLY 5 6 INSTALLATION 5 8 NEUTRAL START INTERLOCK NSI 5 9 INSTALLATION ADJUSTMENT 5 9 ...

Page 113: ...VAL 1 Loosen the lock nuts 1 and remove NSI cable 2 from cable bracket stator base 3 2 Remove the NSI cable from clutch notch lever 4 3 Remove the four 4 bolts securing recoil starter 4 Remove the recoil starter assembly Bolt ...

Page 114: ...d tension in the recoil spring 2 Remove the bolt 2 then remove the friction plate 3 with the friction spring 4 3 Remove the reel 1 4 Remove the screw 5 first and then take off the ratchet pawl 6 ratchet guide 7 and return spring 8 Because of the coiled tension in the recoil spring wear safety glasses and hand protection when wind ing or unwinding this component ...

Page 115: ...TE Do not remove the recoil spring unless replacement is neces sary It should be visually inspected in its assembled position 7 Remove the NSI cable 0 with spring A Remove the cotter pin B washer C and stopper arm D 8 Remove the reel stopper spring E and reel stopper F ...

Page 116: ...er arm and all springs If there is any defect such as excessive wear or damage replace it Inspect the reel and recoil case If any cracks or damage is found on them replace it Inspect the recoil rope If the recoil rope is worn or damaged replace it Inspect the recoil spring If there is any cracks deformation or excessive curve on the recoil spring replace it ...

Page 117: ... steps Install the stopper spring as shown figure 1NSI cable 1 2NSI set 3Cotter pin 1 4Washer 1 5Stopper arm 1 6Spring 1 7Reel stopper 1 8Bolt 1 9Bolt 3 0Recoil case 1 ARope guide 1 BGrip 1 CScrew 1 DRecoil spring 1 EReel 1 FRope 1 GRatchet set HFriction spring 1 IFriction plate 1 JBolt 1 KRatchet 1 LRatchet guide 1 MReturn spring 1 ...

Page 118: ...coil case NOTE Apply grease to reel as shown figure 99000 25161 SUZUKI WATER RESISTANT GREASE Align groove in the reel with bent end of spring Install the friction plate 1 with friction spring 2 and secure it with bolt 3 Apply THREAD LOCK to thread of bolt 99000 32050 THREAD LOCK 1342 NOTE Twist friction plate slightly to align holes in plate with square lugs A on center boss Because of the coiled...

Page 119: ...ate the reel approximately 5 turns counterclockwise until the spring is tensioned INSTALLATION Installation is in the reverse order of removal with special atten tion to the following Check to ensure that all removed parts are back in place Check the neutral start interlock function ...

Page 120: ...nch mark 5 on the recoil starter case 4 Pull the recoil starter and make sure that the starter does not work when the shift lever is in FORWARD and REVERSE position 5 Tighten the lock nuts 6 6 Apply SUZUKI WATER RESISTANT GREASE to the inner cable the cable end and cable holding area 99000 25161 SUZUKI WATER RESISTANT GREASE If the NSI cable is removed or left without correct adjustment there is a...

Page 121: ...REMOVAL 6 9 ASSEMBLY 6 9 DISASSEMBLY 6 10 INSPECTION SERVICING 6 12 REASSEMBLY 6 21 CYLINDER CRANKSHAFT PISTON 6 24 DISASSEMBLY 6 24 INSPECTION SERVICING 6 26 REASSEMBLY 6 37 THERMOSTAT 6 43 REMOVAL 6 43 INSPECTION 6 43 INSTALLATION 6 43 OPERATION 6 44 WATER COOLING SYSTEM 6 44 ENGINE LUBRICATION SYSTEM 6 45 ...

Page 122: ...ge 5 2 3 Disconnect water hose 1 from thermostat cover and oil pan Disconnect breather hose 2 from cylinder head cover and silencer 4 Remove silencer and carburetor assembly 3 See page 4 4 5 Remove fuel pump 4 See page 4 15 Before removing power unit Disconnect battery cable from battery Drain engine oil ...

Page 123: ...1 Flywheel remover 09930 39210 Remover bolt 9 Unscrew the bolts securing stator base 1 then remove the stator base and the battery and condenser charge coil 2 Disconnect the engine stop switch lead wire connector 10 Remove starter motor 3 See page 3 29 11 Loosen screw and disconnect oil pressure switch lead wire 1 Remove two 2 bolts and ignition coil 2 then disconnect ignition coil primary lead wi...

Page 124: ... parts holder 5 then remove stator base and engine main harness assem bly 15 Remove six 6 cylinder head cover bolts 1 and then cylin der head cover 2 and gasket 16 Loosen all valve adjusting lock nuts 1 Loosen the four 4 valve adjusting screws 2 fully Leave the screws in place 17 Remove the timing belt See page 2 12 To prevent valve damage loosen valve adjusting screws fully before removing timing...

Page 125: ...e the screw 3 securing clutch notch lever 5 Remove clutch lever shaft 4 20 Remove clutch notch lever 5 then account for clutch notch ball 6 and spring 7 21 Separate the clutch rod from the shift rod See page 8 2 Push the clutch rod arm 8 out from pivot eyelet on crank case 22 Remove bolt 1 and oil dipstick tube 2 ...

Page 126: ...pply sealant to the two hatched areas shown in the illustration right 99000 31140 SUZUKI BOND 1207B Install dowel pins 1 gasket 2 Apply Suzuki Water Resistant Grease to driveshaft splines 99000 25161 SUZUKI WATER RESISTANT GREASE 99000 31140 SUZUKI BOND 1207B NOTE Apply sealant to both surfaces of oil pan gasket at the indi cated positions as shown with hatched lines Lower the power unit onto oil ...

Page 127: ... m 16 5 lb ft TIMING BELT Install timing belt See page 2 11 to 2 12 CLUTCH LEVER SHAFT Install clutch rod arm 1 Install clutch notch spring 2 ball 3 and clutch notch lever 4 Install clutch lever shaft 5 by passing it from PORT side through the clutch notch lever and then the clutch rod arm Tighten the clutch notch lever with screw 6 Install clutch control lever 7 then tighten screw 8 securely ...

Page 128: ... head cover 1 then tighten cover bolts 2 to specified torque Cylinder head cover bolt 10 N m 1 0 kg m 7 0 lb ft FINAL ASSEMBLY CHECK Perform the following checks to ensure proper and safe opera tion of the repaired unit All parts removed have been returned to their original posi tions Lower unit gear engagement is properly adjusted See page 8 19 Fuel and water hose routing match s service manual i...

Page 129: ...nd place a new cylinder head gas ket 2 into position on cylinder NOTE Before installing cylinder head gasket apply sealant to both sur faces of the hatched areas shown in illustration 99000 31140 SUZUKI BOND 1207B 2 Position cylinder head assembly on cylinder 3 Apply engine oil to cylinder head bolts 4 Lightly seat all cylinder head bolts at first According to tightening order in figure tighten bo...

Page 130: ... 4 and oil gallery block 3 Turn the oil pump shaft 5 until the pin 6 comes out through hole of oil gallery block 3 3 Remove the rocker arm shaft 1 NOTE Install the 8 mm bolt a into the lower end of rocker arm shaft and pull the rocker arm shaft out 4 Remove the washer 2 wave washer 3 rocker arms 4 and spring 5 NOTE Reassemble each rocker arm to original position ...

Page 131: ...n side 6 Using valve lifter and attachment remove valve cotters 1 while compressing valve spring 09916 14510 Valve lifter 09916 14521 Attachment 09916 84511 Tweezers 7 Remove valve spring retainer 2 valve spring 3 and valve 4 8 Remove valve stem seal 5 and valve spring seat 6 ...

Page 132: ...hen decarbon ing Inspect the intake and exhaust ports combustion chambers and head surface If cracks or other damage is found replace cylinder head Valve seat Check the valve seat If cracks or other damage is found replace cylinder head Cylinder head distortion Using a straightedge and thickness gauge measure the cylinder head distortion gasket surface at a total of six 6 locations as shown 09900 ...

Page 133: ...tches and wear Cam wear Measure cam height H 09900 20205 Micrometer Cam height Standard DF9 9 15 DF9 9E R DF15E R IN 23 394 23 454 mm 0 9210 0 9234 in EX 23 397 23 457 mm 0 9211 0 9235 in Service limit IN 23 294 mm 0 9171 in EX 23 297 mm 0 9172 in If measurement exceeds service limit replace camshaft NOTE DF9 9 and DF15 use the same camshaft on 2005 model Cam shaft identification on 2005 model is ...

Page 134: ...icrometer 09900 20605 Dial calipers Camshaft journal outside diameter Standard Upper side 24 959 24 980 mm 0 9826 0 9835 in Lower side 22 959 22 980 mm 0 9039 0 9047 in Camshaft holder inside diameter Standard Upper side 25 000 25 021 mm 0 9843 0 9851 in Lower side 23 000 23 021 mm 0 9055 0 9063 in Decompression parts For manual starter model Inspect the decompression parts on the camshaft If abno...

Page 135: ... 984 mm 0 5107 0 5112 in Rocker arm inside diameter Standard 13 000 13 018 mm 0 5118 0 5125 in VALVE VALVE GUIDE Valve guide to valve stem clearance Standard IN 0 010 0 037 mm 0 0004 0 0015 in EX 0 035 0 062 mm 0 0014 0 0024 in Service limit IN 0 070 mm 0 0028 in EX 0 090 mm 0 0035 in If measurement exceeds service limit replace valve and or valve guide To check the clearance measure the following...

Page 136: ... X Y and measure deflection 09900 20602 Dial gauge 09900 20701 Magnetic stand Service limit IN EX 0 16 mm 0 006 in If measurement exceeds service limit replace valve If measurement still exceeds service limit with new valve replace valve guide NOTE For valve guide replacement see VALVE GUIDE REPLACE MENT section on page 6 18 Valve stem end Inspect valve stem end face for pitting and wear If pittin...

Page 137: ... 09900 20102 Vernier Calipers Service limit IN EX 0 5 mm 0 02 in If measurement exceeds service limit replace valve Valve seat contact width Measure valve seat contact width A as follows 1 Coat valve seat evenly with Prussian blue or equivalent 2 Install valve into valve guide 3 Put valve lapper on valve 09916 10911 Valve lapper 4 Rotate valve while gently tapping valve contact area against seat 5...

Page 138: ...542 Valve guide reamer handle NOTE Turn reamer clockwise never counterclockwise 3 Drive valve guide in from valve spring side to the specified height 09916 44910 Valve guide Remover installer 4 Measure valve guide protrusion H 09900 20102 Vernier calipers Valve guide protrusion Standard IN EX 10 0 0 5 mm 0 39 0 02 in 5 Ream valve guide bore with 5 5 mm reamer 09916 34550 Valve guide reamer 5 5 mm ...

Page 139: ... wide reface valve seat using the 15 cutter If width A is too low or narrow reface valve seat using the 45 cutter 4 Clean up any burrs using the 45 cutter very lightly 5 Lap valve on seat in two steps first with coarse grit lapping compound applied to face and the second with fine grit com pound 6 Recheck valve seat contact width A NOTE Clean and assemble cylinder head and valve components Fill in...

Page 140: ...asurement is lower than service limit replace valve spring Valve spring tension Measure the valve spring tension 09900 20102 Vernier caliper Standard 90 N 9 0 kg 19 8 lbs for 28 5 mm 1 12 in Service limit 76 N 7 6 kg 16 8 lbs for 28 5 mm 1 12 in If measurement is lower than service limit replace valve spring OIL SEAL Inspect condition If cracked cut or damaged replace oil seal ...

Page 141: ...e guide bore and valve stem 5 Install valve 3 valve spring 4 and valve retainer 5 NOTE Reassemble each valve and valve spring to their original posi tion Set valve spring in place with narrow spiral area facing valve spring seat 6 Install valve cotters 6 while compressing valve spring by tool 09916 14510 Valve lifter 09916 14521 Attachment 09916 84511 Tweezers 7 Make sure valve cotters A are prope...

Page 142: ... 2 Install the rocker arms rocker arm spring 3 washer 4 wave washer 5 and rocker arm shaft 2 NOTE Reassemble each rocker arm to its original position Install the rocker arm shaft with its threaded end down OIL PUMP 1 Install oil gallery block and oil pump assembly by aligning the pin on the oil pump shaft with the recess on the camshaft 2 Tighten four 4 oil pump bolts securely Oil pump bolt 14 N m...

Page 143: ...POWER UNIT 6 23 CAMSHAFT PULLEY 1 Install the key and camshaft pulley and secure with bolt Camshaft pulley bolt 10 N m 1 0 kg m 7 0 lb ft ...

Page 144: ...e 6 9 1 Using screw driver drive locking edges of lock washer 2 downward and then remove timing pulley nut 1 09911 49310 Crankshaft holder Remove the lock washer 2 upper guide 3 timing pulley 4 key 5 and lower guide 6 2 Remove screws 1 oil filter cap 2 and oil filter 3 3 Remove oil pressure switch 4 Remove oil pressure regulator 1 Remove oil hose 2 ...

Page 145: ...NOTE For proper assembly mark cylinder number on all conrod caps using quick dry paint 8 Remove crankshaft 1 9 Remove oil seals 2 from crankshaft 10 Push piston with conrod out through the top of cylinder bore NOTE For proper assembly mark cylinder number on all conrods and pistons using quick dry paint To prevent damage to piston rings decarbon top of cylinder bore wall before removing piston 1 2...

Page 146: ...und on any component replace component CYLINDER PISTON Cylinder distortion Using a straightedge and thickness gauge measure cylinder distortion gasketed surface at a total of six 6 locations as shown 09900 20803 Thickness gauge Service limit 0 05 mm 0 002 in If measurement exceeds service limit resurface or replace cylin der NOTE The cylinder can be resurfaced using a surface plate and 400 grit we...

Page 147: ... mm 0 0011 0 0017 in Service limit 0 100 mm 0 0039 in If measurement exceeds service limit replace the piston and or the cylinder or rebore the cylinder To check the clearance measure the following items Cylinder bore at 50 mm below the cylinder head gasket sur face Piston skirt diameter at a point 15 mm above the skirt end 09900 20530 Cylinder gauge set 09900 20203 Micrometer Cylinder bore Standa...

Page 148: ...6 mm 0 001 0 002 in Service limit 1st 2nd 0 10 mm 0 004 in If measurement exceeds service limit replace the piston and or piston ring 09900 20102 Vernier calipers 09900 20205 Micrometer Piston ring groove width Standard 1st 2nd 1 21 1 23 mm 0 0476 0 0484 in Oil 2 51 2 53 mm 0 099 0 100 in Piston ring thickness Standard 1st 2nd 1 17 1 19 mm 0 046 0 047 in Oversize I D mark 0 50 mm 0 020 in 50 I D m...

Page 149: ...Check for the followings The piston pin and the piston pin hole are free from excessive wear and damage Apply engine oil on piston pin so that the piston pin can move smoothly in the piston pin hole If improper condition is found replace the piston pin and or pis ton Pin clearance in piston pin hole Standard 0 002 0 013 mm 0 0001 0 0005 in Service limit 0 040 mm 0 0016 in If measurement exceeds se...

Page 150: ...is out of specification replace the conrod CONROD CRANKSHAFT CRANKCASE Conrod big end side clearance Measure conrod big end side clearance with conrod installed on crank pin as shown 09900 20803 Thickness gauge Standard 0 10 0 20 mm 0 004 0 008 in Service limit 0 60 mm 0 024 in If measurement exceeds service limit replace the conrod and or crankshaft 09900 20205 Micrometer 09900 20605 Dial caliper...

Page 151: ... measurement exceeds service limit replace the crankshaft Crank pin outside diameter Standard 28 989 29 000 mm 1 1413 1 1417 in Conrod big end inside diameter Measure the conrod big end inside diameter as follows 1 Clean the surface of the conrod and the conrod cap 2 Install the conrod cap to the conrod 3 Apply the engine oil to the conrod bolts and tighten the bolts to the specified torque Conrod...

Page 152: ...ge over the oil hole 09900 22301 Plastigauge 3 Install conrod and conrod cap to crank pin 4 Apply engine oil to conrod bolts and tighten the bolts to the specified torque Conrod cap bolt 12 N m 1 2 kg m 8 5 lb ft NOTE Do not rotate conrod with Plastigauge in place 5 Remove conrod and conrod cap from crank pin 6 Measure the compressed plastigauge width at its widest point CRANKSHAFT THRUST CLEARANC...

Page 153: ...it replace crankshaft Crankshaft journal outside diameter Standard 31 989 32 000 mm 1 2594 1 2598 in Crankshaft main bearing condition If pitting flaking burn or excessive wear is found replace both upper and lower halves Always replace both bearing halves never replace only one half of a bearing set Crankshaft journal oil clearance Standard 0 020 0 047 mm 0 0008 0 0019 in Service limit 0 060 mm 0...

Page 154: ...ankcase with the bearing to cylinder 6 Apply engine oil to crankcase bolts and tighten bolts to the specified torque following the order indicated Crankcase bolt 6 mm 14 N m 1 4 kg m 10 0 lb ft 8 mm 25 N m 2 5 kg m 18 0 lb ft NOTE The crankcase must be torqued to specification in order to assure proper compression of Plastigauge and accurate read ing of clearance Do not rotate crankshaft while Pla...

Page 155: ...older inside diam eters shown below Standard 1 Top side I D code 2 Lower side I D code 3 There are two 2 main bearings available each of differ ing thickness To distinguish them a color mark is painted at the position indicated in figure Each color represents the following thickness measured at the center of the bearing Standard Code Crankshaft journal outside diameter 31 989 32 000 mm 1 2594 1 25...

Page 156: ...ction table NOTE Measure the crankshaft journal oil clearance again after install ing the new bearings selected See page 6 33 OIL SEAL Inspect condition If cracked cut or damaged replace Item Crankshaft journal outside diameter Crankcase bearing holder inside diameter Code A Black B Green ...

Page 157: ...onrod to the original direction Install the circlips with a gap facing either up or down as shown in the figure PISTON RING TO PISTON Oil ring 1 Apply engine oil to piston rings 2 Install spacer 1 first then side rails 2 to piston If original components are not replaced each piston piston pin and conrod is to be assembled and installed in its original order and position Do not re use the gasket oi...

Page 158: ...ON TO CYLINDER 1 Apply engine oil to piston and cylinder walls 2 Insert piston and conrod assembly into cylinder bore from cylinder head side using the special tool 09916 77310 Piston ring compressor NOTE Position the CIRCLE mark on piston head to flywheel side Install 2nd ring to piston with the R mark toward the piston head side Install 1st ring to piston with its original direction There is no ...

Page 159: ... of the cylinder as shown 99000 31140 SUZUKI BOND 1207B A Oil seal fitting surface Apply the bond B Groove for the oil seal tab Do not apply the bond 4 Apply engine oil to the lip area of the oil seals 5 Install oil seals to crankshaft NOTE Install oil seals with its spring lipped side facing inward Reassemble each bearing to its original position Do not apply oil between crank bearing holder and ...

Page 160: ...s to specified torque Conrod cap bolt 12 N m 1 2 kg m 8 5 lb ft CRANKCASE TO CYLINDER 1 Clean mating surface of cylinder and crankcase 2 Apply the bond to mating surface of crankcase as shown 99000 31140 SUZUKI BOND 1207B A Fitting surface of the oil seal Apply the bond B Groove for the oil seal tab Do not apply the bond C Mating surface of the crankcase Apply the bond Reassemble each conrod cap t...

Page 161: ...all key 3 Install timing pulley 2 and upper guide 3 with direction as shown 4 Install lock washer 4 with direction as shown NOTE Timing pulley direction Position the PUNCH mark to the upper side Belt guide direction Install the belt guides with flanges towards outside 5 Apply THREAD LOCK to timing pulley nut 5 99000 32050 THREAD LOCK 1342 6 Install timing pulley nut 5 Tighten timing pulley nut 5 t...

Page 162: ...cover 2 to cylinder and secure with bolts 3 Thermostat cover bolt 10 N m 1 0 kg m 7 0 lb ft OIL PRESSURE REGULATOR Install oil pressure regulator 1 to cylinder then tighten regulator securely Oil pressure regulator 27 N m 2 7 kg m 19 5 lb ft ENGINE OIL FILTER Install the engine oil filter Refer to page 2 4 ...

Page 163: ... a length of thread between thermostat valve body and suspend thermostat in a container filled with water Place thermometer in container and heat water Observe water temperature when thermostat valve opens and releases thread Thermostat operating temperature Standard 58 62 C 136 144 F INSTALLATION Installation is reverse order of removal with special attention to the following steps Assemble therm...

Page 164: ... occurs the components of the cooling system must be inspected for blockage corrosion build up or damage Component inspection Refer to page Water pump Impeller 8 10 Water tube 7 9 Thermostat 6 43 Cylinder head 6 13 Cylinder block 6 26 COOLING SYSTEM SCHEMATIC When OPEN Air vent hole Water Exhaust gas Exhaust tube THERMOSTAT CYLINDER HEAD CYLINDER WATER TUBE WATER PUMP WATER INLET PILOT WATER HOLE ...

Page 165: ... CHART CRANKSHAFT UPPER BEARING OIL PRESSURE SWITCH CAMSHAFT UPPER JOURNAL ROCKER ARM SHAFT AND ROCKER ARM CAM FACES OIL FILTER CAM SHAFT LOWER JOURNAL OIL PUMP OIL HOSE OIL REGULATOR CRANKSHAFT LOWER BEARING No 1 CRANK PIN No 1 CYLINDER WALL No 1 PISTON PIN No 2 CYLINDER WALL No 2 PISTON PIN No 2 CRANK PIN OIL PAN M A I N G A L L E R Y ...

Page 166: ...SWITCH To CRANKSHAFT UPPER BEARING To OIL PUMP OIL PUMP OIL HOSE OIL RELIEF To 2 CRANK PIN To 1 CRANK PIN CRANKSHAFT LOWER BEARING CRANKSHAFT UPPER BEARING OIL REGULATOR MAIN GALLERY OIL FILTER OIL FILTER To CAMSHAFT UPPER JOURNAL To OIL PUMP From OIL PUMP OIL HOSE OIL RELIEF To CRANKSHAFT LOWER BEARING From OIL PAN ...

Page 167: ...TALLATION 7 3 TILLER HANDLE 7 4 REMOVAL 7 4 INSTALLATION 7 5 DISASSEMBLY ASSEMBLY 7 6 DRIVESHAFT HOUSING AND OIL PAN 7 7 REMOVAL 7 7 INSPECTION 7 9 REASSEMBLY 7 10 SWIVEL BRACKET STEERING BRACKET CLAMP BRACKET 7 13 REMOVAL DISASSEMBLY 7 13 INSPECTION 7 16 REASSEMBLY 7 17 ...

Page 168: ...OVAL 1 Remove the side cover rubber 1 2 Remove the two screws 2 3 Remove the snap pin 3 washer 4 pin 5 and fastener 6 4 Remove the screw 7 5 Remove three screws 8 and STBD side cover 9 Disconnect water hose 0 6 Remove PORT side cover A ...

Page 169: ... removal 1Side cover rubber 1 2Screw 2 3Nut 2 4Plug 1 5Cable grommet 1 6Side cover Starboard 1 7Side cover Port 1 8Side cover plug 1 9Bolt 1 0Bolt 2 AFastener 1 BPin 1 CWasher 1 DSnap pin 1 EScrew 1 FNut 1 GProtector 2 HScrew 4 IProtector 2 JSide cover seal 1 ...

Page 170: ...nuts 1 3 Remove the throttle rod 2 from throttle lever 3 4 Remove the bolt 4 throttle lever 3 and throttle drum 5 5 Remove the throttle cables 6 from throttle drum 6 Disconnect emergency stop switch lead wire Disconnect starter switch lead wire 7 Remove screw 7 and cable clamp 8 ...

Page 171: ...r of removal with special attention to the following Tiller handle Place bush 1 bush 2 and friction rubber 3 on tiller han dle Install tiller handle and handle cover Tighten handle cover bolts to the specified torque 99000 25161 WATER RESISTANT GREASE Tiller handle cover bolt 17 N m 1 7 kg m 12 5 lb ft Installation of throttle cables See page 4 13 Check wire and cable routing See page 9 8 to 9 10 ...

Page 172: ...agram below 13 13 1 21 2 3 4 14 8 12 10 11 16 17 15 5 18 7 19 9 6 14 20 1 Tiller handle 2 Bush 2 3 Friction rubber 4 Tiller handle cover 5 Grip 6 Handle rod 7 Stopper 8 Plate 9 Bush 10 Support 11 Knob 12 Nut 13 Throttle cable 14 Bolt 15 Screw 16 Screw 17 Washer 18 Pin 19 Spring 20 Emergency stop switch 21 Washer ...

Page 173: ...nding wire from driveshaft housing 4 Remove screw and bonding wire from swivel bracket 5 Remove the two lower mount cover bolts and remove STBD PORT lower mount cover 1 6 Remove two bolts and driveshaft housing with oil pan 7 Remove the upper mount stoppers 2 During the removing the upper mount bolts the drive shaft housing must be firmly secured ...

Page 174: ...7 8 MID UNIT 8 Remove six bolts and oil pan 3 from the driveshaft housing 4 9 Remove four bolts and upper mounts 5 10 Remove four bolts and lower mount 6 11 Remove bolt 7 and water tube 8 ...

Page 175: ...tive or other damage is found replace MOUNT Inspect the upper mount and lower mount If excessively wear corrosion or other damage is found replace OIL SEAL Inspect the oil seal If crack cut or other damage is found replace NOTE Install oil seal with lip spring side facing downward driveshaft housing side WATER TUBE Inspect the water tube If clog is found clean If crack corrosion or other damage is...

Page 176: ... ABolt 4 BUpper mount 2 CBolt 2 DStud bolt 2 ENut 2 FDowel pin 2 GBolt 6 HPipe 1 IDriveshaft housing 1 JBolt 4 KLower mount 1 LBolt 2 MLower mount cover STBD 1 NPin 2 OLower mount cover Port 1 PWasher 2 QNut 2 RBonding wire 1 SScrew 2 TBonding wire 1 UBolt 1 VGrommet 2 WWater tube 1 23 N m 2 3 kg m 16 5 lb ft 23 N m 2 3 kg m 16 5 lb ft 23 N m 2 3 kg m 16 5 lb ft 23 N m 2 3 kg m 16 5 lb ft 23 N m 2...

Page 177: ...mount bolt 23 N m 2 3 kg m 16 5 lb ft UPPER MOUNT 1 Apply THREAD LOCK to the upper mount bracket bolts 99000 32050 THREAD LOCK 1342 2 Tighten the upper mount bracket bolts to the specified torque Upper mount bracket bolt 23 N m 2 3 kg m 16 5 lb ft OIL PAN TO DRIVESHAFT HOUSING 1 Install two dowel pins 1 to the driveshaft housing 2 2 Apply sealant to mating surfaces of driveshaft housing and oil pa...

Page 178: ...4 Tighten upper mount bolts to the specified torque Upper mount bolt 23 N m 2 3 kg m 16 5 lb ft LOWER MOUNT COVER 1 When attaching the lower mount cover 1 to steering shaft 2 ensure that the pin 3 properly fits into the hole 4 of steering shaft 2 Apply THREAD LOCK to lower mount cover bolts 99000 32050 THREAD LOCK 1342 3 Tighten lower mount cover bolts to the specified torque Lower mount cover bol...

Page 179: ...steering friction adjuster plate a to the steering bracket Tiller handle model 3 Remove steering adjuster bolt 1 cover 2 washer 3 and spring 4 4 Lift steering bracket 5 upward to remove from swivel bracket Remove washer 6 upper bush 7 from swivel bracket 5 Remove steering friction adjuster set 8 Tiller handle model 6 Remove the washer 9 O ring 0 and lower bush A ...

Page 180: ...cket shaft 9 Remove tilt lock pin 2 Remove the nut 3 bolt 4 and spacer 5 10 Slide PORT clamp bracket 6 off clamp bracket shaft 11 Pull STBD clamp bracket 7 outward to remove clamp bracket and bracket shaft 8 from swivel bracket 9 Remove bushings 0 from each side of swivel bracket ...

Page 181: ...nd shallow drive arm 3 13 Remove two springs 4 from reverse lock arm and swivel bracket 14 Remove the release arm pin 5 and release link 6 15 Remove the cotter pin 1 washer 2 pin 3 and reverse lock arm link 4 Remove the cotter pin 5 pin 6 and reverse lock arm 7 ...

Page 182: ...if necessary If bushing fit is loose when installing replace the bushing O RING Inspect swivel bracket O ring for cuts nicks excessive wear or other damage CLAMP BRACKET SHAFT Inspect the clamp bracket shaft for bend twist or other damage Replace if necessary BRACKET Inspect the clamp brackets steering bracket and swivel bracket for excessive wear cracks or other damage Replace if necessary ...

Page 183: ...vel bracket 1 HSteering adjuster 1 ISpring 1 JWasher KCover 1 LBolt 1 MBushing NBushing ORelease lever 1 PRelease arm pin 1 QRelease link 1 RScrew 1 SWasher 2 TBushing 2 UO ring 1 VNipple 3 WReverse lock arm 1 XReverse lock arm link 1 YCotter pin 2 ZWasher 1 Spring 2 Pin 1 Pin 1 Shallow drive 1 aSpring 1 bBolt 2 cSteering adjuster plate 1 dBolt 2 eNut 1 fWasher 2 gSteering adjuster 1 hFriction pla...

Page 184: ...42 Shallow drive arm bolt 25 N m 2 5 kg m 18 0 lb ft Install arm spring 3 as shown CLAMP BRACKET AND SWIVEL BRACKET NOTE Before installing clamp bracket to swivel bracket apply grease to clamp bracket shaft and bushings 99000 25161 SUZUKI WATER RESISTANT GREASE 1 Connect the release link 1 to release lever 2 2 Insert PORT and STBD bushings 3 into the swivel bracket 4 ...

Page 185: ...eering adjuster plate 1 to swivel bracket 99000 25161 SUZUKI WATER RESISTANT GREASE NOTE Apply grease to bushings O ring and pilot shaft portion of steer ing bracket 2 Install upper bushing 2 washer 3 to swivel bracket NOTE The bushing 2 4 outside face is tapered Install the bushing into the swivel bracket with the smaller diameter side being inserted first Be certain that steering adjuster 1 is p...

Page 186: ... bracket shaft 99000 25161 SUZUKI WATER RESISTANT GREASE 6 Install steering bracket 8 to swivel bracket 7 Install steering friction adjuster plate a to steering bracket then securely tighten it with bolts Tiller handle model LUBRICATION After completing reassembly of the mid unit apply grease through each grease nipple ...

Page 187: ...R SHAFT COMPONENTS 8 9 PROPELLER SHAFT BEARING HOUSING 8 9 SHIFT CAM AND RELATED ITEMS 8 10 WATER PUMP AND RELATED ITEMS 8 10 WATER INLET HOUSING 8 10 DRIVESHAFT 8 11 ASSEMBLY INSTALLATION 8 12 LOWER UNIT GEARS SHIMMING AND ADJUSTMENT 8 21 FORWARD GEAR PINION GEAR 8 21 PINION GEAR REVERSE GEAR 8 23 CHECKING PROPELLER SHAFT THRUST PLAY 8 24 ...

Page 188: ... Place a drain pan under oil drain plug Remove oil drain plug 3 first then oil level plug 4 and allow gear oil to drain 4 Remove bolt and zinc 5 if necessary 5 Remove cotter pin 6 from the propeller shaft and remove propeller nut 7 6 Remove washer 8 spacer 9 propeller 0 and stopper A from propeller shaft Before removing lower unit Disconnect spark plug caps from all spark plugs Disconnect the batt...

Page 189: ...l F under panel gasket water inlet housing G gasket H exhaust seal rubber I and exhaust seal core J 10 Remove the two bolts securing the propeller shaft bearing housing K to the gearcase To prevent injury from propeller blades wear gloves and place a block of wood between the anti cavitation plate and the propeller blade tips to lock the propeller in place ...

Page 190: ... the pinion gear L pinion gear back up shim M thrust washer N thrust bearing O and thrust washer P 14 Remove the forward gear Q thrust washer R and forward gear back up shim S 15 Remove the nut T and shift rod assembly U Disassembly of propeller shaft component 1 Slide propeller shaft 2 away from reverse gear 3 and bear ing housing assembly 1 Account for the reverse gear back up shim 4 and reverse...

Page 191: ...o push the dog pin 9 out of clutch dog shifter 09922 89810 Shift pin remover 4 Remove the clutch dog shifter 0 and spring A Disassembly of shift rod components 1 Push the pin 1 out and remove the clutch cam 2 2 Remove the pin 3 washer 4 O ring 5 O ring 6 shift rod guide 7 and boot 8 ...

Page 192: ...achment 6 09951 79311 Spacer Attachment 7 09951 29910 Nut 8 09930 30104 Sliding hammer 9 REMOVAL 1 Set the plate 5 on the gearcase with two bolts 4 NOTE Using the two water pump bolt holes 2 Set the shaft removal 2 bearing 3 attachment 6 and nut 8 as shown 3 To push the pinion bearings A out of gearcase turn the lower nut B clockwise while holding bolt C tightly Do not re use the pinion bearing on...

Page 193: ...se 3 Secure the plate 5 by tightening bolts 4 4 Thread the sliding hammer 9 into the top of the shaft 1 5 Drive the pinion bearing A down into position by gently strik ing the shaft 1 until the coupler touches the spacer 7 6 Repeat Nos 1 5 to install the second bearing Before installing the bearing ensure that the inside of the gearcase is clean and free of debris Ensure that the bearing stamped m...

Page 194: ...place if necessary GEARCASE Inspect the gearcase for cracks or other damage Replace if necessary Inspect the pinion bearing for pitting rough or other damage Replace if necessary NOTE If removal and replacement are required see the PINION BEARING section on page 8 6 GEARS Inspect the forward gear reverse gear and pinion gear teeth and engaging dogs for excessive wear or other damage Replace if nec...

Page 195: ...ch return spring PROPELLER SHAFT BEARING HOUSING Inspect the housing for cracks or other damage Replace if necessary Inspect the propeller shaft bush and the reverse gear bearing for pitting rough or other damage Replace if necessary Inspect the oil seals and the O ring for cuts nicks or tears Replace if necessary Replacing propeller shaft oil seal 1 Extract the oil seals using the oil seal remove...

Page 196: ...PUMP AND RELATED ITEMS Inspect the impeller vanes for cuts cracks tears or excessive wear Replace if necessary Inspect the pump case and the under panel for cracks distor tion or corrosion Replace if necessary WATER INLET HOUSING Inspect the housing for cracks or other damage Replace if necessary Inspect the oil seal for wear cuts nicks or tears Replace if necessary Replacing oil seal 1 Extract th...

Page 197: ... seal should face toward the water pump case Apply the grease to the seal lips 99000 25161 SUZUKI WATER RESISTANT GREASE DRIVESHAFT Inspect the driveshaft splines for wear twist or other damage Replace if necessary Inspect the driveshaft bearing for pitting rough or other dam age Replace if necessary 1 Dust lip 1 ...

Page 198: ...t 4 Gearcase 1 Zinc 1 Bolt 1 Water filter 1 Screw 1 Bearing 1 Shim 1 Forward gear 1 Thrust washer 1 Push rod 1 Push pin 1 Clutch dog shifter 1 Dog pin 1 Dog spring 1 Return spring 1 Propeller shaft 1 Washer 1 Reverse gear 1 Shim 1 Bearing 1 O ring 1 Propeller shaft bearing housing 1 Oil seal 2 Bolt 2 Propeller bush stopper 1 Propeller 1 Propeller bush 1 Spacer 1 Washer 1 Nut 1 Cotter pin 1 13 N m ...

Page 199: ... drain tube 1 Oil seal 1 Gasket 1 Grommet Bolt 1 Water inlet tube 1 Grommet 1 18 N m 1 8 kg m 13 0 lb ft Make sure that all parts used in assembly are clean and lubricated After assembly check parts for tightness and smoothness of operation Before final assembly be absolutely certain that all gear contact shim adjustments and tolerances are correct Failure to correctly adjust these areas will resu...

Page 200: ...he figure and insert the spring pin 7 Install the shift rod shift cam assembly to gearcase with the face A of cam facing toward propeller side Install the shift rod guide 4 to gearcase as shown in the fig ure PROPELLER SHAFT CLUTCH DOG ASSEMBLY Install the clutch dog shifter with F mark toward forward gear side Insert the return spring 1 into propeller shaft Depress the return spring and slide the...

Page 201: ...1 Apply gear oil to the thrust bearing 4 and pinion gear 1 99000 22540 SUZUKI OUTBOARD MOTOR GEAR OIL 2 Place the pinion gear 1 back up shim 2 thrust washer I D 20 mm 3 thrust bearing 4 and thrust washer I D 21 mm 5 in gearcase 3 Lower the driveshaft assembly down into the gearcase until the bottom of shaft passes to center of pinion gear 4 Install the circlip 6 5 Check the backlash exists between...

Page 202: ... thrust washer 5 reverse thrust washer 4 reverse gear 3 reverse gear back up shim 2 and propeller shaft housing 1 Insert the push pin 6 and push rod 7 into propeller shaft Install the propeller shaft and bearing housing assembly to gearcase with the arrow mark A of housing toward upside When the housing is fully seated tighten both retaining bolts to the specified torque Bearing housing bolt 8 N m...

Page 203: ... to the gearcase Place the water inlet tube 2 and drain tube 3 into position WATER PUMP 1 Place the dowel pins 1 under panel gasket 2 and under panel 3 into position 2 Insert the key 4 in the driveshaft and slide the impeller 5 onto driveshaft ensuring that key and keyway are aligned 3 Install the pump case 6 while rotating driveshaft clockwise to flex the impeller vanes in correct direction 4 Tig...

Page 204: ...m2 2 8 5 7 psi first then apply specified pressure Leakage test pressure 100 kPa 1 0 kg cm2 14 2 psi 4 Once stabilized pressure should remain steady for at least 5 min If pressure does not fall sealing performance is correct PROPELLER INSTALLATION 1 Install the propeller stopper 1 onto the propeller shaft then slide on the propeller 2 2 Install the spacer 3 washer 4 and nut 5 then tighten nut to s...

Page 205: ... m 2 3 kg m 16 5 lb ft CLUTCH ADJUSTMENT 1 Install the hose 1 on the clutch rod 2 Connect the clutch rod to shift rod as shown Adjustment step 1 Shift the clutch lever from Neutral N through Forward F and Reverse R to check that proper engagement of both gears is at an equal angle from Neutral If Forward gear engages earlier at a smaller angle than Reverse the turnbuckle should be rotated counterc...

Page 206: ...ise 2 Lock the upper nut securely against the turnbuckle when clutch lever adjustment is correct GEAR OIL Fill the gearcase with specified gear oil See the PERIODIC MAINTENANCE GEAR OIL section on page 2 5 Necessary amount of gear oil 170 ml 5 7 6 0 US lmp oz 99000 22540 SUZUKI OUTBOARD MOTOR GEAR OIL ...

Page 207: ...ng adjustment Adjusting gear backlash Check a slight amount of backlash exists between the pinion gear and forward gear by slightly rotating driveshaft or forward gear by hand If backlash is larger than the specified thickness of the for ward gear back up shim must be increased If backlash is smaller the forward gear back up shim thick ness must be decreased Numerical index item Available thicknes...

Page 208: ... shaft and housing assembly minus reverse gear and internal components Propeller shaft bearing housing bolt 8 N m 0 8 kg m 6 0 lb ft 3 Push propeller shaft inward and hold in position 4 Rotate the driveshaft clockwise 5 6 times by hand 5 Carefully pull out propeller shaft and housing to check tooth contact pattern Concave side Convex side Heel Tooth top Tooth bottom Toe TOOTH CONTACT PATTERN Tooth...

Page 209: ...g housing assembly to the gearcase Propeller shaft bearing housing bolt 8 N m 0 8 kg m 6 0 lb ft 3 Check the amount of backlash by slightly rotating the drive shaft by hand 4 Backlash should not be less than when checked step 1 If backlash is less reduce the reverse gear back up shim thickness Gear backlash should be checked when increasing or decreasing shim thickness to adjust tooth contact Do n...

Page 210: ...ard thick ness 1 5 mm and adjust only the reverse gear thrust washer with shim 1 Assemble gear adjusting gauge to the propeller shaft 09951 09530 Gear adjusting gauge 2 Slowly push the propeller shaft inward 3 Hold shaft in and set dial gauge pointer to zero 4 Slowly pull shaft outward and read the maximum thrust play on the dial gauge If measurement is more than specification increase reverse gea...

Page 211: ...WIRE HOSE ROUTING 9 1 9 WIRE HOSE ROUTING CONTENTS WIRING DIAGRAM 9 2 DF9 9 DF15 9 2 DF9 9E DF15E 9 3 DF9 9R DF15R 9 4 WIRE ROUTING 9 5 FUEL WATER HOSE ROUTING 9 11 ...

Page 212: ...Button pushed STOP Bl R B Bl R B B P B P B W B W Br Y G B B Br Y G B G R B B R Y B Br Bl P Bl R Y B B Y R W W Bl Y R B B B B B R OIL PRESSURE SWITCH 15 kPa 0 15 kgf cm 2 or less ON Y TUBE PULSER COIL CONDENSER CHARGE COIL R TUBE NEUTRAL SWITCH N ON F R OFF Optional parts O O O WIRE COLOR B Black Bl Blue Br Brown G Green O Orange P Pink R Red W White Y Yellow B R Black with Red tracer BI R Blue wit...

Page 213: ...WITCH 15 kPa 0 15 kgf cm 2 or less ON START SWITCH PUSH START NEUTRAL SWITCH N ON F R OFF O O O IGNITION COIL SPARK PLUG PULSER COIL CONDENSER CHARGE COIL WIRE COLOR B Black Bl Blue Br Brown G Green O Orange P Pink R Red W White Y Yellow B R Black with Red tracer BI R Blue with Red tracer R B Red with Black tracer W R White with Red tracer Y B Yellow with Black tracer Y G Yellow with Green tracer ...

Page 214: ...ter OIL PRESSURE SWITCH 15 kPa 0 15 kgf cm 2 or less ON NEUTRAL SWITCH N ON F R OFF CAUTION LAMP OIL PRESSURE PULSER COIL BATTERY CHARGE COIL EMERGENCY STOP SWITCH Lock plate IN RUN Lock plate OUT STOP Bl B G R B Y B B R O Br Bl P Bl R IGNITION COIL SPARK PLUG W Bl Br O Gr G B W Bl Br O Gr G B Gr W Bl Br O Y G B B B R R R W Bl Br Y B Bl R B CAUTION BUZZER WIRE COLOR B Black Bl Blue Br Brown G Gree...

Page 215: ...Neutral switch connector Starter motor relay Flywheel Fuse Case CDI stopper plate Ignition coil Electric parts holder Wiring harness assembly H T cord protector Spark plug cap Apply the THREAD LOCK 1342 Switch bracket Bolt Neutral switch Receptacle GND lead wire option Starter motor band Damper ...

Page 216: ...s Starter motor magnetic switch Nut Negative battery cable Positive battery cable Positive battery cable Cap Neutral switch lead wire Fuel hose Caution lamp lead wire Remote control harness Clamp Fix the lead wire and fuel hose with clamp ...

Page 217: ...d Bolt Main wiring harness Cable tie Clamp Electric starter model To Auto enrichener PTC heater R model Manual starter model Bolt Tighten the bolt and rectifier ground lead wire together Ignition coil Carburetor Auto enrichener PTC heater R model Pulser coil Cable tie CDI unit Battery and condenser charge coil Cable tie Lead wire ...

Page 218: ...tarter model Route the engine stop switch lead wire under starter cable Emergency engine stop switch lead wire Cable tie Emergency engine stop switch lead wire Starter button lead wire Starter cable Starter cable Tube Switch lead wire and starter button lead wire passes in the tube ...

Page 219: ...el Routing of Receptacle lead wire Optional part Fuse lead wire Route the fuse lead wire between CDI unit and electric parts holder PTC heater lead wire Auto enrichener PTC heater Cable tie Fuse case assembly Receptacle ground lead wire Clamp ...

Page 220: ... lamp Starter button Emergency engine stop switch lead wire Emergency engine stop switch Wiring harness assembly R model Cable clamp Throttle cable Battery cable Tiller handle model B B The lead wire of each switch is passed through this hole Emergency engine stop switch ...

Page 221: ...tact rods and levers during either engine operation or standstill Extreme care should be taken not to cut abrade or cause any other damage on hoses Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted Clamp Fuel hose protector Breather hose Hose clamp Fuel pump Water hose Water inspection hose Hose clamp Fuel hose protector Clip Set the clip as shown direct...

Page 222: ...ose protector Clutch notch lever Fuel pump Route the fuel hose under the clutch lever shaft Do not route the fuel hose under the clutch notch lever When installing fuel filter ensure that arrow mark points toward the fuel pump side Fuel filter ...

Page 223: ...F9 9 15 K6 06 MODEL 10 1 CONTENTS DF9 9 15 K6 2006 MODEL 10 SPECIFICATIONS 10 2 SERVICE DATA 10 4 BATTERY CHARGE COIL 10 11 NEUTRAL SWITCH BRACKET 10 11 SHIFT CAM SPRING PIN SHIFT CAM AND SHIFT ROD 10 12 ...

Page 224: ...n type 422 15 L mm in type 549 20 Maximum output kW PS 7 3 9 9 11 0 15 Recommended operating range r min 4 900 5 500 5 400 6 000 Idle speed r min 900 50 In gear idle speed r min Approx 820 920 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK BKR6E Ignition system SUZUKI PEI Digit...

Page 225: ...W 40 Engine oil amounts L US lmp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 170 5 7 6 0 Trim angle Degrees 4 20 Number of tilt pin position 5 Maximum tilt angle Degrees 67 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 12 25 2 083 Dri...

Page 226: ... Engine oil amount L US lpm qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distor tion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil clearance STD mm in 0 020 0 062 0 0008 0 0024...

Page 227: ...e stem outside diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide protrusion IN STD mm in 10 0 0 39 EX STD mm in 10 0 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve he...

Page 228: ... 0 25 0 004 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clear ance 1st STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21...

Page 229: ...ance STD mm in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft jour nal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in...

Page 230: ...US lmp oz 170 5 7 6 0 Gear ratio 2 08 12 25 Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCMII 23 11 5 BCMII 25 21 I D mark 94J2 94J3 94J6 94J7 Main jet 70 115 Pilot jet 38 40 Pilot screw Turns open PRE SET 1 7 8 1 2 PRE SET 2 7 8 1 2 Float height mm 1...

Page 231: ...e Ω at 20 C 0 9 1 3 DF9 9 15 0 3 0 4 DF9 9E 15E 9 9R 15R R Y Battery charge coil output 12V Watt 80 DF9 9 15 120 DF9 9E 15E 9 9R 15R Standard spark plug Type NGK BKR6E Gap mm in 0 7 0 8 0 028 0 031 Fuse amp rating A 20 Electric start model Recommended battery capacity 12V Ah kC 35 126 or over Electric start model Starter motor relay coil resistance Ω at 20 C 145 190 Electric start model Max contin...

Page 232: ...ester range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Test 1 Igni...

Page 233: ...be to battery charge coil lead wires as shown Coil resistance 0 9 1 3 Ω 80 W coil DF9 9 15 0 3 0 4 Ω 120 W coil DF9 9E 15E 9 9R 15R If measurement is out of specification replace the battery charge coil NEUTRAL SWITCH BRACKET The neutral switch bracket has been changed in shape In accordance with this change the direction of installation of neutral switch actuator has been changed Tester probe con...

Page 234: ... been changed from 2 15 mm to 2 65 mm The thickness of shift cam spring pin has been changed 0 4 to 0 5 In accordance with this change the pin hole diameter of shift cam and shift rod has been changed 2 0 mm 2 5 mm Shift rod Shift cam Spring pin 2 15 mm 2 65 mm 2 0 mm 2 5 mm 2 3 mm 2 6 mm Thickness 0 4 mm 0 5 mm ...

Page 235: ... K7 2007 MODEL 11 SPECIFICATIONS 11 2 SERVICE DATA 11 4 TIGHTENING TORQUE 11 11 CYLINDER HEAD RECOIL STARTER ASSY AND TIMING BELT COVER 11 12 CAM SHAFT PULLEY BOLT 11 12 OIL PAN GASKET 11 13 CLUTCH NOTCH LEVER 11 13 WATER PUMP AND GEARCASE 11 14 ...

Page 236: ...n type 422 15 L mm in type 549 20 Maximum output kW PS 7 3 9 9 11 0 15 Recommended operating range r min 4 900 5 500 5 400 6 000 Idle speed r min 900 50 In gear idle speed r min Approx 820 920 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK BKR6E Ignition system SUZUKI PEI Digit...

Page 237: ...E 10W 40 Engine oil amounts L US lmp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 170 5 7 6 0 Trim angle Degrees 4 20 Number of tilt pin position 5 Maximum tilt angle Degrees 67 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 12 25 2 083...

Page 238: ... Engine oil amount L US lpm qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distor tion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil clearance STD mm in 0 020 0 062 0 0008 0 0024...

Page 239: ...e stem outside diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide protrusion IN STD mm in 10 0 0 39 EX STD mm in 10 0 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve he...

Page 240: ... 0 25 0 004 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clear ance 1st STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21...

Page 241: ...ance STD mm in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft jour nal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in...

Page 242: ...US lmp oz 170 5 7 6 0 Gear ratio 2 08 12 25 Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCMII 23 11 5 BCMII 25 21 I D mark 94J2 94J3 94J6 94J7 Main jet 70 115 Pilot jet 38 40 Pilot screw Turns open PRE SET 1 7 8 1 2 PRE SET 2 7 8 1 2 Float height mm 1...

Page 243: ...e Ω at 20 C 0 9 1 3 DF9 9 15 0 3 0 4 DF9 9E 15E 9 9R 15R R Y Battery charge coil output 12V Watt 80 DF9 9 15 120 DF9 9E 15E 9 9R 15R Standard spark plug Type NGK BKR6E Gap mm in 0 7 0 8 0 028 0 031 Fuse amp rating A 20 Electric start model Recommended battery capacity 12V Ah kC 35 126 or over Electric start model Starter motor relay coil resistance Ω at 20 C 145 190 Electric start model Max contin...

Page 244: ...ester range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Test 1 Igni...

Page 245: ... 11 1 1 8 0 Timing pulley nut 26 mm 50 5 0 36 0 Flywheel nut 14 mm 80 8 0 58 0 Spark plug 27 2 7 19 5 Power unit mounting bolt and nut 8 mm 23 2 3 16 5 Driveshaft housing bolt 8 mm 17 1 7 12 5 Oil pressure switch 13 1 3 9 5 Oil regulator 14 mm 27 2 7 19 5 Camshaft pulley bolt 6 mm 10 1 0 7 0 Engine oil drain plug 12 mm 13 1 3 9 5 Upper mount bolt 8 mm 23 2 3 16 5 Upper mount bracket bolt 8 mm 23 2...

Page 246: ...The recoil starter case has been changed in shape The timing belt cover and cover screw have been eliminated Recoil starter case Timing belt cover CAM SHAFT PULLEY BOLT The length of cam shaft pulley bolt has been changed from 16 mm to 18 mm Boss Oil filler cap Boss Oil filler cap 26 5 mm 21 mm Screw Timing belt cover Eliminated Cam shaft pulley bolt 16 mm 18 mm ...

Page 247: ...he screw of clutch notch lever has been changed to bolt The screw of clutch control lever has been changed to bolt Apply thread lock to clutch lever notch bolt and clutch control lever bolt and tighten bolts to specified torque 99000 32050 THREAD LOCK 1342 Clutch notch lever bolt 10 N m 1 0 kg m 7 0 lb ft Clutch control lever bolt 10 N m 1 0 kg m 7 0 lb ft Added silicone print Screw Clutch control...

Page 248: ...een changed from 8 mm to 6 mm Tightening torque has been changed from 18 N m to 8 N m The water pump case sleeve has been added A water pump case gasket has been added between pump case and pump case under panel An O ring has been added on the water inlet housing The locating pins have been eliminated 18 N m 1 8 kg m 13 0 lb ft Bolt 8 mm Water pump case Material Stainless steel Pin Water inlet hou...

Page 249: ...207B onto the outer surface of water pump case sleeve 2 Install the water pump sleeve into the water pump case by confirming the projection on the sleeve should meet with the groove on the pump case 99000 31140 SUZUKI BOND 1207B Water pump case Water pump case sleeve Projection Groove ...

Page 250: ...TS DF9 9T TH K8 2008 MODEL 12 SPECIFICATIONS 12 2 SERVICE DATA 12 4 TIGHTENING TORQUE 12 11 CYLINDER CRANKSHAFT BEARING 12 12 POWER TILT 12 13 PT MOTOR RELAY 12 26 PT SWITCH 12 27 OPERATION 12 28 WIRING DIAGRAM 12 35 WIRE ROUTING 12 37 ...

Page 251: ... type 672 25 Maximum output kW PS 7 3 9 9 Recommended operating range r min 4 900 5 500 Idle speed r min 900 50 In gear idle speed r min Approx 820 920 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK BKR6E Ignition system SUZUKI PEI Digital CDI Fuel supply system Carburetor Numb...

Page 252: ... NMMA FC W classification SE SF SG SH SJ Viscosity rating SAE 10W 40 or NMMA FC W 10W 40 Engine oil amounts L US lmp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 170 5 7 6 0 Trim angle Degrees 0 12 Number of tilt pin position 4 Maximum tilt angle Degrees 66 Reversing system Gear Transmi...

Page 253: ...S lpm qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distor tion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil clearance STD mm in 0 020 0 062 0 0008 0 0024 Limit mm in 0 100 0 0...

Page 254: ...side diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide protrusion IN STD mm in 10 0 0 39 EX STD mm in 10 0 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve head thickne...

Page 255: ...4 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clear ance 1st STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21 1 23 0 04...

Page 256: ... in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft jour nal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in 0 060 0 00...

Page 257: ... oil amounts ml US lmp oz 170 5 7 6 0 Gear ratio 2 08 12 25 Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCMII 23 11 5 I D mark 94J3 94J2 Main jet 70 Pilot jet 38 Pilot screw Turns open PRE SET 1 7 8 1 2 Float height mm 13 5 2 ...

Page 258: ...il output 12V Watt 120 Standard spark plug Type NGK BKR6E Gap mm in 0 7 0 8 0 028 0 031 Fuse amp rating A 20 Recommended battery capacity 12V Ah kC 35 126 or over Starter motor relay coil resistance Ω at 20 C 145 190 PT motor relay coil resis tance Ω at 20 C 25 37 Max continuous time of use Sec 30 Motor output kW 1 4 Brush length STD mm in 15 5 0 61 Limit mm in 9 5 0 37 Commutator under cut STD mm...

Page 259: ...ester range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Test 1 Igni...

Page 260: ... 26 mm 50 5 0 36 0 Flywheel nut 14 mm 80 8 0 58 0 Spark plug 25 2 5 18 0 Power unit mounting bolt and nut 8 mm 23 2 3 16 5 Driveshaft housing bolt 8 mm 17 1 7 12 5 Oil pan bolt and nut 8 mm 23 2 3 16 5 Oil pressure switch 13 1 3 9 5 Oil regulator 14 mm 27 2 7 19 5 Camshaft pulley bolt 6 mm 10 1 0 7 0 Engine oil drain plug 12 mm 13 1 3 9 5 Upper mount bolt 8 mm 23 2 3 16 5 Upper mount bracket bolt ...

Page 261: ...duced to one as follows NOTE When the crankshaft bearing is replaced the oil clearance should be checked in the crankshaft journal Standard NOTE The above change applies also to 2008 Model DF9 9 15 Code Crankcase bearing holder inside diameter A 35 008 35 016 mm 1 3783 1 3786 in B 35 000 35 008 mm 1 3780 1 3783 in Code Crankcase bearing holder inside diameter 35 000 35 008 mm 1 3780 1 3783 in Code...

Page 262: ...trol box PT switch Fuse Starter relay Starter motor Battery PT motor For DF9 9T Bl G Bl G Lbl P R Lbl P R R B R R Lbl Lg R Lbl W R P Lbl W P W R W TUBE UP UP DN DN PT relay PT switch For DF9 9TH Fuse Starter relay Starter motor Battery PT motor Bl G Bl G P Lbl R R B R R UP DN W R Lbl W P W R ...

Page 263: ...smission fluid or equivalent 6 Reinstall oil filler plug AIR BLEEDING 1 Check that the manual release valve 1 is tightened to the specified torque Manual release valve 1 8 N m 0 18 kg m 1 3 lb ft Counterclockwise Open Clockwise Close 2 Operate the PT switch raising and lowering the motor up and down full tilt position to full tilt down position 4 to 5 times 3 Check oil level topping off if necessa...

Page 264: ... side cover 2 Raise the motor to the full tilt position and push in the tilt up lock knob 3 NOTE Since this outboard motor is not equipped with an engine hook it is necessary to install the option parts Engine Hook 11291 91B50 and a bolt 01550 08207 Remove the tilt rod snap ring 4 and push tilt cylinder upper shaft pin 5 out During the following procedures the motor must be firmly secured and its ...

Page 265: ... 6 securing bonding wire 7 Cut the cable ties 8 binding PT motor cable Using flat screw driver drive locking edge of lock washer 9 to clamp bracket side Loosen the clamp bracket shaft nut 0 NOTE Complete removal of the clamp bracket shaft nut is not required Nut should be loosened as far as the end of the shaft threads only to facilitate removal of the PT unit Remove a PORT engine mounting bolt A ...

Page 266: ...MODEL 12 17 Remove the two 2 bolts C securing tilt cylinder lower shaft to STBD PORT clamp bracket Slide the PORT clamp bracket D fully outward to the left hand side Remove the PT unit E from between the clamp brackets ...

Page 267: ...con tainer Remove the screw 2 securing clamp of PT motor cable Place the upper eye of the tilt rod in a vise Tighten the vise only enough to secure the tilt rod DO NOT OVER TIGHTEN NOTE To prevent damage to the tilt rod use wood blocks vise jaw pro tectors etc between the vise jaws and PT components before tightening vise Remove the two 2 bolts 3 securing PT motor then detach the PT motor assembly...

Page 268: ...re and commutator Check for continuity between the commutator and the armature core shaft Replace armature if continuity is indicated 09930 99320 Digital tester Tester range Continuity Check continuity between adjacent commutator segments Replace armature if no continuity is indicated Inspect the commutator surface If surface is gummy or dirty clean with 400 grit emery paper Measure commutator out...

Page 269: ...pers Brush length Standard 10 0 mm 0 39 in Service limit 5 0 mm 0 20 in If brushes are worn down to the service limit they must be replaced O ring Inspect the O ring between the PT motor and PT pump case Replace if cuts nicks or tears are found ASSEMBLY Assembly is reverse of disassembly with special attention to fol lowing steps Install armature to brush holder first When installing the armature ...

Page 270: ...l of PT fluid contained in the PT pump case If level is low add recommended PT fluid until level with mating surface of PT motor Ensure that the faces of the PT motor and pump unit are free of dirt or debris When attaching the PT motor to the PT pump case ensure that the tip of armature shaft 3 fits firmly into the drive joint 1 Tighten the two 2 bolts to specified torque PT motor bolt 5 N m 0 5 k...

Page 271: ... illustration Operate the PT motor until the PT rod is in the fully trimmed down posi tion completely contracted If the rod does not come down smoothly push it in by hand while operating the motor 6 Reverse the two extension cable lead wires Bl to pos G to neg Operate the PT motor until the PT rod is in the full tilt up position fully extended If the rod does not come up smoothly pull it up by han...

Page 272: ...e tilt cylinder lower shaft and lower shaft bushes Install bushes 1 and tilt cylinder lower shaft 2 to PT unit 99000 25161 SUZUKI WATER RESISTANT GREASE Place the PT unit in position between the clamp brackets Tighten the clamp bracket shaft nut 3 to specified torque Clamp bracket shaft nut 43 N m 4 3 kg m 31 0 lb ft NOTE After tightening clamp bracket shaft nut with specific torque bend lock wash...

Page 273: ...ten screws securely Apply Water Resistant Grease to tilt rod upper bushes 7 then install bushes in tilt rod Operate the PT motor to extend the tilt rod upward Align the tilt rod with the hole in the swivel bracket as the tilt rod extends 99000 25161 SUZUKI WATER RESISTANT GREASE Apply Water Resistant Grease to the tilt rod upper shaft 8 then insert the shaft through the swivel bracket and tilt rod...

Page 274: ...DF9 9T TH K8 08 MODEL 12 25 Route the PT motor cable in through the port side cover 0 and connect the PT cable connector A to the PT relay Cable routing See the WIRE ROUTING section on page 41 ...

Page 275: ...connect a jumper wire from the P lead wire to the battery positive terminal then check voltage between G wire and B wire 09930 99320 Digital tester Tester range DCV Between G wire and B wire 12 V Battery voltage 6 Temporarily connect a jumper wire from the Lbl lead wire to the battery positive terminal then check voltage between Bl wire and B wire Between Bl wire and B wire 12 V Battery voltage 7 ...

Page 276: ...d Red Lg with white tube Continuity Pink White UP side depressed Light Blue Lg with white tube Continuity White Not depressed Red Pink Lg with white tube Infinity Light Blue White W Lbl P Tester probe connection Tester indicates Red Black DN side depressed Red Lg with white tube Continuity Pink White Red UP side depressed Light Blue Lg with white tube Continuity White Red Not depressed Red Pink Lg...

Page 277: ...position PRINCIPLES OF OPERATION By motor operation the geared pump will be driven and by turning the motor to the right or to the left oil flow will change its direction and this causes up and down movements of the piston rod of the tilt cylinder Tilt rod PT cylinder Down check valve Up relief valve PT motor Filter Down relief valve Manual valve Check valve Check valve Oil reservoir Gear pump Imp...

Page 278: ...g the tilt piston upward 4 Oil in the upper chamber D of the tilt cylinder is returned to the gear pump through the down check valve C 5 Throughout the tilt up action operation range there is a difference in oil volume between the upper and lower chambers of the tilt cylinder and in order to settle the oil shortage oil is returned from the reservoir to the gear pump through the check valve A 6 Whe...

Page 279: ...mp will then open the down check valve C oil will enter the upper chamber D of the tilt cylinder and thereby pushing the tilt piston downward 4 Oil in the lower chamber F of the tilt cylinder is returned to the gear pump through the up check valve E 5 Throughout the tilt down action operation range there is a difference in oil volume between the upper and lower chambers of the tilt cylinder and an...

Page 280: ... prevention of internal PT pressure build up in the event of an impact 1 The pressure from a sudden impact will make impact relief valve J open allowing oil from the upper chamber D of the tilt cylinder to flow into the area between the tilt piston and the lower chamber F The tilt rod will then extend Tilt rod Tilt piston ...

Page 281: ... to the fully tilted position 2 Oil from the upper chamber D of the tilt cylinder will flow through manual release valve K into the lower chamber F of the cylinder 3 The upward movement of the tilt rod will increase the cylinder area beneath it thereby allowing oil from the reservoir to flow into this area Tilt rod Tilt piston Reservoir ...

Page 282: ...ng position Oil underneath the tilt piston will be directed through this valve into the area above the tilt piston 2 The volume of oil flowing from under the tilt piston will be larger than the area above the tilt piston can accommodate Excess oil therefore returns through the manual release valve K to the reservoir Tilt rod Tilt piston Reservoir ...

Page 283: ...the boat transom Should the propeller strike an underwater object whilst in reverse gear a build up of pressure will be induced in the lower cylinder chamber F whereby the outboard mounting bracket and or the boat transom may sus tain damage To prevent this the thermal valve L will open to relieve the oil pressure thereby softening the impact Internal PT circuits are protected as the thermal valve...

Page 284: ...H PUSH START O O O IGNITION COIL SPARK PLUG PULSER COIL CONDENSER CHARGE COIL WIRE COLOR B Black Bl Blue Br Brown G Green Lbl Light blue O Orange P Pink R Red W White Y Yellow B R Black with Red tracer BI R Blue with Red tracer R B Red with Black tracer W R White with Red tracer Y B Yellow with Black tracer Y G Yellow with Green tracer STARTER MOTOR R R R Bl R B Bl R B EMERGENCY STOP ENGINE STOP S...

Page 285: ...Bl B G R B Y B B R O Br Bl P Bl R IGNITION COIL SPARK PLUG W Bl Br O Gr G B Lbl W R P Lbl Lg R Lbl W R P Lbl W R P W Bl Br O Gr G B Gr W Bl Br O Y G B B B R R R W R Bl Br Y B Bl R B CAUTION BUZZER WIRE COLOR B Black Bl Blue Br Brown G Green Gr Gray O Orange Lbl Light blue Lg Light green P Pink R Red W White Y Yellow B R Black with Red tracer BI R Blue with Red tracer R B Red with Black tracer R G ...

Page 286: ... PT relay assy Fuse Case CDI stopper plate PT relay holder PT relay bracket Ignition coil Electric parts holder Wiring harness assembly H T cord protector Spark plug cap Route white lead wire inside Red lead wire Yellow lead wire and ground lead wire White lead wire Apply the THREAD LOCK 1342 Switch bracket Bolt Neutral switch PT relay GND lead wire Red lead wire Starter motor band Damper Flywheel...

Page 287: ...d wire PT switch connector DF9 9TH Nut Positive battery cable Positive battery cable Cap Fuel hose Caution lamp lead wire PT switch lead wire DF9 9T PT switch lead wire DF9 9TH Clamp Fix the lead wire and fuel hose with clamp Negative battery cable PT relay lead wire ...

Page 288: ...e tie Pulser coil ground lead Bolt Main wiring harness Cable tie Clamp DF9 9T To Auto enrichener PTC heater R model DF9 9TH Bolt Tighten the bolt and rectifier ground lead wire together Ignition coil Carburetor Auto enrichener PTC heater Pulser coil Cable tie CDI unit Battery and condenser charge coil Cable tie Lead wire ...

Page 289: ... heater Route starter switch lead wire and emergency engine stop switch lead wire in tube Emergency engine stop switch lead wire Clutch control lever Starter switch lead wire PT switch connector Clutch control lever Cable tie Tube PT switch lead wire Route the PT switch lead wire so that the PT switch connector should not interfere with the clutch lever and set the connector to the position shown ...

Page 290: ...DF9 9T TH K8 08 MODEL 12 41 PT motor cable PT relay connector Joint connector bracket PT cable grommet Cable tie Gray tape ...

Page 291: ...re Emergency engine stop switch Cable clamp PT switch PT switch screw Battery cable Cable clamp Throttle cable Clamp PT switch lead wire Battery cable B B The lead wire of each switch is passed through this hole Starter button Wiring harness Emergency engine stop switch PT switch PT switch bracket bolt Cable tie PT switch screw ...

Page 292: ...Prepared by Service Department 1st Ed July 2004 2nd Ed January 2008 Manual No 99500 94J01 01E Printed in Japan 296 ...

Page 293: ......

Page 294: ...ERVICE MANUAL Applicable model and effective serial number 00993F 110001 and later 01503F 110001 and later Use this supplement with the following service manual DF9 9 15 Service Manual P no 99500 94J0 01E 9 9 5 0 1 9 4 J 2 0 0 1 E ...

Page 295: ...sing it for your ser vice activities Applicable model and effective serial number 00993F 110001 and later 01503F 110001 and later NOTE Use this supplement with the following service manual DF9 9 15 Service Manual P no 99500 94J0 01E GENERAL INFORMATION 2 SPECIFICATIONS DF9 9T TH 2 SPECIFICATIONS DF15 4 SERVICE DATA DF9 9T TH 6 SERVICE DATA DF15 13 SPECIAL TOOLS 20 PERIODIC MAINTENANCE 21 MAINTENAN...

Page 296: ...in type 545 20 X mm in type 672 25 Maximum output kW PS 7 3 9 9 Recommended operating range r min 4 900 5 500 Idle speed r min 900 50 In gear idle speed r min Approx 820 920 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK CPR6EA 9 Ignition system SUZUKI PEI Digital CDI Fuel supp...

Page 297: ...MA FC W classification SG SH SJ SL SM Viscosity rating SAE 10W 40 or NMMA FC W 10W 40 Engine oil amounts L US lmp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil API classification GL 5 Gearcase oil amounts ml US lmp qt 170 5 7 6 0 Trim angle Degree 0 12 Number of tilt pin position 4 Maximum tilt angle Degree 66 Reversi...

Page 298: ...n 3 S mm inch type 422 15 L mm inch type 549 20 Maximum output kW PS 11 0 15 Recommended operating range r min 5400 6000 Idle speed r min 900 50 in gear approx 870 Engine type 4 stroke SOHC Number of cylinders 2 Bore mm in 58 0 2 28 Stroke mm in 57 0 2 24 Total displacement cm3 cu in 302 18 4 Compression ratio 1 9 0 Spark plug NGK CPR6EA 9 Ignition system SUZUKI PEI Digital CDI Fuel supply system ...

Page 299: ... or NMMA FC W 10W 40 Engine oil amounts L US Imp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil API classification GL 5 Gearcase oil amounts ml US Imp oz 170 5 7 6 0 Trim angle Degree 4 20 Number of tilt pin position 5 Maximum tilt angle Degree 67 Reversing system Gear Transmission Forward Neutral Reverse Reduction sys...

Page 300: ...il amount L US lpm qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distor tion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil clearance STD mm in 0 020 0 062 0 0008 0 0024 Limit mm...

Page 301: ...e stem outside diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide protrusion IN STD mm in 10 0 39 EX STD mm in 10 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve head t...

Page 302: ... 004 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clear ance 1st STD mm in 0 02 0 06 0 0008 0 0024 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 0008 0 0024 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21 1 ...

Page 303: ...ce STD mm in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft jour nal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in 0...

Page 304: ... Gearcase oil amount ml US lmp oz 170 5 7 6 0 Gear ratio 2 08 12 25 Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCMII 23 11 5 I D mark 94J3A 94J2A Main jet 70 Pilot jet 38 Pilot screw Turns open PRE SET 1 7 8 1 2 Float height mm 13 5 2 ...

Page 305: ...coil output 12V Watt 120 Standard spark plug Type NGK CPR6EA 9 Gap mm in 0 8 0 9 0 031 0 035 Fuse amp rating A 20 Recommended battery capacity 12V Ah kC 35 126 or over Starter motor relay coil resistance Ω at 20 C 145 190 PT motor relay coil resis tance Ω at 20 C 25 37 Max continuous time of use Sec 30 Motor output kW 1 4 Brush length STD mm in 15 5 0 61 Limit mm in 9 5 0 37 Commutator under cut S...

Page 306: ...voltage Tester range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Te...

Page 307: ...scosity rating SAE 10W 40 or NMMA FC W 10W 40 Engine oil amounts L US Imp qt 1 0 1 1 0 9 Oil change only 1 1 1 2 1 0 Oil filter change Thermostat operating temperature C F 58 62 136 144 Cylinder head distortion Limit mm in 0 05 0 002 Cam height IN STD mm in 23 394 23 454 0 9210 0 9234 Limit mm in 23 294 0 9171 EX STD mm in 23 397 23 457 0 9211 0 9235 Limit mm in 23 297 0 9172 Camshaft journal oil ...

Page 308: ...em out side diameter IN STD mm in 5 475 5 490 0 2156 0 2161 EX STD mm in 5 450 5 465 0 2146 0 2152 Valve guide pro trusion IN Limit mm in 10 0 0 39 EX Limit mm in 10 0 0 39 Valve stem deflection IN Limit mm in 0 16 0 006 EX Limit mm in 0 16 0 006 Valve stem runout IN Limit mm in 0 05 0 002 EX Limit mm in 0 05 0 002 Valve head radial runout IN Limit mm in 0 03 0 001 EX Limit mm in 0 03 0 001 Valve ...

Page 309: ...0 0 25 0 004 0 010 Limit mm in 0 50 0 020 Piston ring free end gap 1st STD mm in Approx 5 8 0 23 Limit mm in 4 6 0 18 2nd STD mm in Approx 7 4 0 29 Limit mm in 5 9 0 23 Piston ring to groove clearance 1st STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 2nd STD mm in 0 02 0 06 0 001 0 002 Limit mm in 0 10 0 004 Piston ring groove width 1st STD mm in 1 21 1 23 0 0476 0 0484 2nd STD mm in 1 21...

Page 310: ...ance STD mm in 0 10 0 20 0 004 0 008 Limit mm in 0 60 0 024 Conrod big end width STD mm in 19 95 20 00 0 785 0 787 Crank pin width STD mm in 20 10 20 15 0 791 0 793 Crankshaft thrust clearance Limit mm in 0 60 0 024 Crankshaft length STD mm in 126 8 126 9 4 992 4 996 Crankcase length STD mm in 127 0 127 1 5 000 5 004 Crankshaft journal oil clearance STD mm in 0 020 0 047 0 0008 0 0019 Limit mm in ...

Page 311: ... 170 5 7 6 0 Gear ratio 2 08 12 25 Preliminary gear shim thrust washer Pinion back up shim mm in 1 0 0 04 Forward back up shim mm in 1 0 0 04 Reverse back up shim mm in 1 0 0 04 Forward thrust washer mm in 1 5 0 06 Reverse thrust washer mm in 1 5 0 06 Type KEIHIN BCM 25 21 I D mark 94J6A 94J7A Main jet 115 Pilot jet 40 Pilot screw Turns open PRE SET 2 7 8 1 2 Float height mm 13 5 2 ...

Page 312: ...e kΩ at 20 C 4 6 Battery charge coil resistance Ω at 20 C 0 9 1 3 R Y 0 3 0 4 R Y Battery charge coil output 12 V Watt 80 120 Standard spark plug Type NGK CPR6EA 9 Gap mm in 0 8 0 9 0 031 0 035 Fuse amp rating A 20 Recommended battery capacity 12 V Ah kC 35 126 or over Starter motor relay coil resistance Ω at 20 C 145 190 Max continuous time of use Sec 30 Motor output kW 1 4 Brush length STD mm in...

Page 313: ...voltage Tester range Remarks Red Black 1 CDI output Orange Black 128 V or over NEG 500 With ignition coil connected Use the 6 pin connector test cord 2 Condenser charge coil output Green Black Red 15 V or over POS 50 With CDI unit disconnected 3 Pulser coil output Red Black Black Ground 0 8 V or over SEN 5 4 Battery charge coil out put Red Yellow 5 6 V or over POS 50 With rectifier disconnected Te...

Page 314: ...20 DF9 9T TH DF15 Serial No 110001 and later SPECIAL TOOLS 09915 63311 Compression gauge adaptor ...

Page 315: ...00 20803 Thickness gauge CONDITION OF ELECTRODE INSULATOR Check the electrode and insulator condition If the electrode is extremely worn or burnt replace the spark plug If the spark plug has a broken insulator damaged threads etc replace the spark plug Spark plug 11 N m 1 1 kg m 8 0 lb ft Inspect every 100 hours 6 months Replace every 200 hours 12 months Only resistor R type spark plugs must be us...

Page 316: ...ORT engine side lower cover 3 Remove all spark plugs 4 Install the compression gauge into the plug hole 09915 64512 Compression gauge 09915 63311 Compression gauge adapter 5 Disconnect the safety lanyard from the emergency stop switch 6 Disconnect the remote control throttle cable from the throttle lever R model 7 Move and hold the throttle lever in the full open position R model Move and hold the...

Page 317: ...TEM INSPECTION SPARK PLUG CAP 09930 99320 Digital tester Tester range Ω Resistance Measure the spark plug cap resistance Spark plug cap resistance 4 6 kΩ If measurement is out of specification replace the spark plug cap Tester probe connection Probe Other probe Cap end Other cap end ...

Page 318: ...HEAD The thread diameter of the spark plug hole on the cylinder head has been changed from 14 mm to 10 mm NOTE Interchangeability The new cylinder head can be installed on the early model with the new cylinder head spark plug and spark plug cap used together as a set ...

Page 319: ...Prepared by Outboard Motor Engineering Department September 2010 Manual No 99501 94J20 01E Printed in Japan 24 ...

Page 320: ......

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