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Suzuki DF 40, Service Manual

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Suzuki DF 40 Service Manual Download Page 271

10-9   WIRE / HOSE ROUTING

Fuel hose
(H fuel filter to vapor separator)

.

Fuel hose / Protector
(H fuel filter to 3-way joint)

.

Fuel hose / Protector
(H fuel filter to 3-way joint)

.

Fuel hose / Protector
(Vapor separator to 
  low fuel pump)

High pressure fuel filter

Clamp

3-way joint

Fuel hose / Protector
(3-way joint to vapor separator)

Vapor separator

Gas filter

IAC hose

IAC valve

IAC hose

IAC valve silencer

Throttle body

MAP sensor hose

MAP sensor

Clamp

3-way joint

Fuel hose / Protector
(3-way joint to vapor 
  separator) 

Clamp

Water hose
(Vapor separator to 3-way)

Water hose
(Engine holder to vapor separator)

Clamp

High pressure fuel filter

Evaporation hose

MAP sensor

Summary of Contents for DF 40

Page 1: ...99500 87J00 01E ...

Page 2: ...don t have the proper tools and equipment may not be able to properly per form the services described in this manual Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers FOREWORD 1 2 3 4 5 6 7 8 9 10 This manual has been prepared using the lat est information available at the time of publi cation If a modification has been made ...

Page 3: ...ach section lists a table of con tents 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 service information such as the tightening torque lubrication and locking agent points Example 1 Flywheel bolt 2 Washer 3 Key 4 Flywheel 5 CKP sensor 6 Screw 7 CMP sens...

Page 4: ...342 Apply THREAD LOCK SUPER 1333B Measure in DC voltage range Measure in resistance range Measure in continuity test range Use peak voltmeter Stevens CD 77 Use special tool Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUZUKI OUTBOARD MOTOR GEAR OIL ApplySUZUKISUPERGREASE A Apply SUZUKI WATER RESISTANT GREASE Apply SUZUK...

Page 5: ...INE RECOMMENDATION 1 3 ENGINE OIL 1 3 ENGINE BREAK IN _______________________________________ 1 4 PROPELLERS ___________________________________________ 1 5 SPECIFICATIONS_________________________________________ 1 6 SERVICE DATA ___________________________________________ 1 8 TIGHTENINGTORQUE ____________________________________ 1 15 SPECIAL TOOLS _________________________________________ 1 17 MA...

Page 6: ...together 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 extinguisher distress signals anchor paddles bilge pump first aid kit emerg...

Page 7: ...olts and nuts beginning with larger diameter and ending with smaller diameter Always tighten from inside to outside diagonally to the specified tightening 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 ov...

Page 8: ...ol with equivalent octane con tent may be used Allowable maximum blend of a single additive not combina tion 5 Methanol 10 Ethanol 15 MTBE B If leaded gasoline is used engine damage may re sult 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 an SAE 10W 40 motor oil is not availab...

Page 9: ...gine 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 3000 r min NOTE The throttle may be briefly opened beyond the recommended setting to plane the boat ...

Page 10: ...11 1 2 9 S900 3 11 1 2 10 S1000 3 11 1 2 11 S1100 3 11 5 8 12 S1200 3 11 1 2 13 S1301 SS1300 3 11 3 8 14 S1400 SS1400 3 11 1 4 15 S1500 3 11 1 8 16 S1600 SS1600 3 11 17 S1700 If the standard propeller fails to meet the above requirement use another pitch propeller to hold the engine speed within the range specified above Propeller selection chart Recommended full throttle speed range DF40T 5200 58...

Page 11: ...ded operating range r min Idle speed r min 36 8 50 5200 5800 5900 6500 850 50 in gear approx 850 50 POWERHEAD Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transistorized ignition Fuel supply system Multi point sequential electronic fuel injection Ex...

Page 12: ...oil Gearcase oil capacity SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil 610 20 6 21 5 BRACKET Trim angle PTT system Number of trim position PTT system Maximum tilt angle degree 73 LOWER UNIT Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 27 Drive line impact protection Spline drive rubber hub Propeller Blade Diam in Pitch in These ...

Page 13: ...tween any two cylinders 100 1 0 14 kPa kg cm2 psi Engine oil pressure 295 373 3 0 3 8 42 54 at 4000 r min at normal operating temp kPa kg cm2 psi Engine oil Engine oil amounts L US Imp qt Thermostat operating temperature 48 52 126 134 C F API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Figures shown are guidelines only not abs...

Page 14: ...900 1 4858 1 4921 STD Limit mm in 37 640 1 4819 37 640 1 4819 EX 0 045 0 087 0 0018 0 0034 mm in Camshaft journal oil clearance STD Limit 0 12 0 0047 mm in Camshaft journal housing inside diameter Top 2nd 3rd 4th mm in STD Limit mm in 23 000 23 021 0 9055 0 9063 23 171 0 9122 Camshaft journal outside diameter Top 2nd 3rd 4th mm in STD Limit mm in 22 934 22 955 0 9029 0 9037 22 784 0 8970 0 10 0 00...

Page 15: ...eter mm in STD STD mm in IN EX 5 465 5 480 0 2152 0 2157 5 440 5 455 0 2142 0 2148 IN EX mm in Limit 3 2 0 1260 Valve stem end length Valve stem end deflection mm in Limit Limit mm in IN EX 0 14 0 0055 0 18 0 0071 IN EX mm in Limit 0 05 0 0020 Valve stem runout IN EX mm in Limit 0 08 0 0031 Valve head radial runout Valve head thickness mm in STD Limit mm in IN 1 0 0 0394 0 7 0 0276 mm in STD Limit...

Page 16: ...mit mm in 6 0 2362 1st mm in Approx 11 0 4330 STD Limit mm in 8 8 0 3465 2nd Piston ring groove width mm in 1 01 1 03 0 0398 0 0406 1st mm in 1 01 1 03 0 0398 0 0406 mm in 1 51 1 53 0 0594 0 0602 2nd Oil Piston ring to groove clearance mm in 0 020 0 060 0 0008 0 0024 STD Limit mm in 0 10 0 0039 1st mm in 0 020 0 060 0 0008 0 0024 STD Limit mm in 0 10 0 0039 2nd Piston ring thickness mm in 0 97 0 9...

Page 17: ...98 mm in STD 0 350 0 0138 mm in Limit 21 950 22 000 0 8642 0 8661 mm in STD Conrod big end width 22 100 22 200 0 8700 0 8740 mm in STD Crank pin width Crankshaft journal oil clearance 0 020 0 040 0 0008 0 0016 mm in STD 0 065 0 0026 mm in Limit Crankshaft center journal runout 0 04 0 0016 mm in Limit Crankcase bearing holder inside diameter 49 000 49 018 1 9291 1 9298 mm in STD Crankshaft journal ...

Page 18: ... W at 20 C IAC valve resistance k W at 25 C IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor characteristic W at 20 C ECM main relay resistance W at 20 C Starter motor relay resistance W at 20 C PTT motor relay resistance 1 8 2 3 80 120 3 5 5 1 3 0 4 5 STARTER MOTOR 30 Sec Max continuous time of use 0 9 kW Motor output 17 0 0 67 mm in STD Brush length 10 0 0 39 mm in Limit 0 5 0 8 0 ...

Page 19: ...O 3 IAC valve By pass air screw adjustment 3 1 on off NO 4 CMP sensor 2 4 on off YES 5 CTP switch 2 2 on off NO 6 Cylinder temp sensor 1 4 on off YES 7 IAT sensor 2 3 on off YES 8 MAP sensor 2 Sensor hose 3 2 on off NO 9 1 1 on off NO Rectifier regulator Over charging If more than two items fail at once the self diagnostic indication appears according to priority order The indication repeats three...

Page 20: ...Thermostat cover bolt 6 mm 10 1 0 7 0 Flywheel bolt 16 mm 200 20 0 145 Starter motor mounting bolt 8 mm 23 2 3 16 5 Engine oil filter 14 1 4 10 0 Engine oil drain plug 12 mm 13 1 3 9 5 Power unit mounting bolt nut 8 mm 23 2 3 16 5 10 mm 50 5 0 36 0 Driveshaft housing bolt 10 mm 50 5 0 36 0 Upper mount nut 10 mm 40 4 0 30 0 Upper mount cover bolt 8 mm 23 2 3 16 6 Lower mount nut 12 mm 60 6 0 43 5 1...

Page 21: ... kg m N m Ib 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 10 mm 22 35 2 3 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 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 10 mm 40 60 4 0 6 0 29 0 43 5 Conventional or 4 marked bolt Stainless steel bolt 7 mar...

Page 22: ...01 150 mm 09900 20102 200 mm Vernier calipers 09900 20508 Cylinder gauge set 40 80 mm 09900 20803 Thickness gauge 09900 28403 Hydrometer 09900 00411 Hexagon socket included in 09900 00410 09900 20202 Micrometer 25 50 mm 09900 20605 Dial calipers 10 34 mm 09900 21304 Steel V block set 09921 29510 Driveshaft holder 09913 50121 Oil seal remover 09900 00413 5 mm 09900 00414 6 mm Hexagon bit included i...

Page 23: ...eway 126 09916 34542 Valve guide reamer handle 09916 57330 Valve guide installer 09915 77310 Oil pressure gauge 09916 24450 Solid pilot N 100 5 52 09916 20620 Valve seat cutter Neway 122 09916 37320 Valve guide reamer f f f f f 10 5 mm 09916 77310 Piston ring compressor 09915 78211 Oil pressure gauge adapter 09916 24440 Handle adaptor N 503 1 09916 44310 Valve guide remover 45 36 09916 20610 Valve...

Page 24: ...30 76420 Timing light 09930 89920 6 pin connector test cord 09932 79910 Diagnostic harness A 09950 69511 Gearcase oil leakage tester B 09821 00004 Air pump A 18213 74F00 O2 sensor B 18498 99E40 Protector 48 09922 89810 Shift lock pin remover 52 09930 39420 Rotor remover bolt 51 09930 39411 Flywheel rotor remover 55 56 09930 89240 4 pin connector test cord 09930 89260 Injector test cord A 59 60 099...

Page 25: ...g 99000 25030 99000 25010 500 g 99104 33140 99000 31140 100 g 99000 25160 250 g 99000 32050 50 g 99000 31120 50 g API SE SF SG SH SJ SAE 10W 40 SUZUKI SUPER GREASE A WATER RESISTANT GREASE SUZUKI SILICONE SEAL SUZUKI BOND 1104 SUZUKI BOND 1207B THREAD LOCK 1342 4 Stroke Motor Oil NOTE Marked part No is in U S market only NOTE Marked part No is in U S market only 71 99954 53008 820 Digital voltmete...

Page 26: ... IDLE SPEED 2 14 IGNITION TIMING 2 15 BREATHER AND FUEL LINE 2 16 LOW PRESSURE FUEL FILTER 2 16 HIGH PRESSURE FUEL FILTER 2 17 WATER PUMP WATER PUMP IMPELLER 2 17 PROPELLER NUT COTTER PIN 2 17 ANODES AND BONDING WIRES 2 18 BATTERY 2 19 BOLT AND NUTS 2 20 FUEL MIXTURE CHECK O2 FEEDBACK 2 21 OIL PRESSURE ___________________________________________ 2 26 CYLINDER COMPRESSION __________________________...

Page 27: ...st lubricate or replace if necessary T Tighten R Replace Interval Item to be serviced Initial 20 hrs or 1 month Every 50 hrs or 3 months Every 100 hrs or 6 months Every 200 hrs or 12 months Spark plug I R Breather Hose 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 Bonding wires I I I Battery I I I Fuel mixture check O2 feedback Perform every 2 yea...

Page 28: ...riodic maintenance requirements ENGINE OIL ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use 1 Place the outboard motor upright on a level surface 1 5 Oil level should be between the full level line Max and low level line Min If the level is low add recommended oil to full level line Recommended oil 4 stroke motor oil API classification SE SF SG SH SJ Viscosity rating SAE...

Page 29: ...ngine oil at the same time 1 Place the outboard motor upright on a level surface 2 Remove the oil filler cap 3 Place a container under the engine oil drain plug 4 Remove the engine oil drain plug and gasket to drain en gine oil z o 5 ENGINE OIL FILTER REPLACEMENT NOTE For engine oil change only go to step 6 To replace the engine oil filter 1 Remove the PORT side lower cover See page 7 1 2 Using oi...

Page 30: ...e engine oil drain plug to the specified torque Engine oil drain plug 13N m 1 3 kg m 9 5 lb ft B Do not re use gasket Always replace with a new gas ket 7 Pour recommended engine oil into the oil filler opening then install the oil filler cap Engine oil amounts Oil change only 2 2L 2 3 1 9 US Imp qt Oil filter change 2 4L 2 5 2 1 US Imp qt 8 Start the engine and allow it to run for several minutes ...

Page 31: ...evel plug and drain the gear oil 1 2 1 Oil level plug 2 Oil drain plug 4 Fill with the recommended gear oil through the oil drain hole until oil just starts to flow out from the oil level hole Gear oil amount 610 ml 20 6 21 5 US Imp oz Recommended oil Suzuki Outboard Motor Gear Oil or SAE 90 Hypoid gear oil 5 Install the oil level plug before removing the oil filler tube from the drain hole 6 Inst...

Page 32: ...NCE 2 6 LUBRICATION Inspect every 50 hours 3 months Apply Suzuki Water Resistant Grease to the following points 99000 25160 Water Resistant Grease l Swivel bracket Steering bracket Propeller shaft Throttle Shift linkage ...

Page 33: ... Adjust to within the specified range if the gap is out of specifica tion Spark plug gap 0 9 1 0 mm 0 035 0 039 in 09900 20803 Thickness gauge CONDITION OF ELECTRODE Check the electrode for a worn or burnt condition If it is extremely worn or burnt replace the spark plug Also be sure to replace the plug if it has a broken insulator damaged thread etc B Confirm the thread size and reach when replac...

Page 34: ...e tappet clearance is increased or decreased by replacing the shim disc made of a special wear resistant material fitted to the top of the tappet The shim discs are easy to remove and refit Tappet clearance adjustment must be checked and adjusted at the time of periodic inspection when the valve mechanism is serviced when the camshafts are disturbed by removing them for in spection CHECKING AND AD...

Page 35: ...n IN 0 18 0 24 mm 0 007 0 009 in EX 0 18 0 24 mm 0 007 0 009 in 09900 20803 Thickness gauge B Rotate crankshaft clockwise to prevent water pump impeller damage NOTE Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface All tappet clearances can be measured during two turns of crankshaft 7 If out of specification adjust tappet clearance b...

Page 36: ...ith the tappet holder Use a magnet to remove and install shim When installing shim identification mark on the shim must face towards tappet side 5 After removing shim measure thickness of original shim and determine correct thickness of shim for proper tappet clear ance as calculated by the following formula 09900 20205 Micrometer A B C 0 20 mm A Correct thickness of shim for proper tappet clearan...

Page 37: ...e adjustment and securing camshaft housing bolts inspect tappet clearance again Thickness mm I D No 218 2 18 246 2 46 274 2 74 220 2 20 248 2 48 276 2 76 222 2 22 250 2 50 278 2 78 224 2 24 252 2 52 280 2 80 226 2 26 254 2 54 282 2 82 228 2 28 256 2 56 284 2 84 230 2 30 258 2 58 286 2 86 232 2 32 260 2 60 288 2 88 234 2 34 262 2 62 290 2 90 236 2 36 264 2 64 292 2 92 238 2 38 266 2 66 294 2 94 240...

Page 38: ...moval proce dure for installation Install the cylinder head cover See page 6 8 NOTE Examine cylinder head cover gasket for damage Always replace gasket if sealing performance is suspect Tighten cylinder head cover bolts to specification Cylinder head cover bolts 10 N m 1 0 kg m 7 2 lb ft ...

Page 39: ...6 268 270 272 274 276 278 280 282 2 20 2 22 2 24 2 26 2 28 2 30 2 32 2 34 2 36 2 38 2 40 2 42 2 44 2 46 2 48 2 50 2 52 2 54 2 56 2 58 2 60 2 62 2 64 2 66 2 68 2 70 2 72 2 74 2 76 2 78 2 80 2 82 2 84 2 86 2 88 2 90 2 92 2 94 2 96 2 98 3 00 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 230 2...

Page 40: ...ed no load 800 900 r min ADJUSTMENT If the idle speed is out of specification adjust it as follows 6 Remove IAC hose from silencer case 7 To stop the airflow from the IAC passage pinch the IAC valve hose closed 8 Adjust the engine speed to approx 800 r min by turning the by pass airscrew Turning airscrew clockwise Engine speed will decrease Turning airscrew counterclockwise Engine speed will incre...

Page 41: ...n gear idle speed is the same as idle speed 10 Reinstall parts removed earlier IGNITION TIMING Inspect every 200 hours 12 months NOTE Before checking the ignition timing make sure idle speed is adjusted within the specification 1 Start the engine 2 Attach the timing light cord to the No 1 ignition coil primary wire 09930 76420 Timing light 3 Check the ignition timing while operating the engine at ...

Page 42: ...onths thereafter Replace every 2 year If leakage cracks swelling or other damage is found replace the breather line and or fuel line LOW PRESSURE FUEL FILTER Inspect before every use Replace every 400 hours or 2 years If water accumulation sediment leakage cracks or other dam age is found replace the fuel filter ...

Page 43: ...TER PUMP IMPELLER Replace every 200 hours 12 months Inspect water pump impeller Replace if vanes are cut torn or worn PROPELLER NUT COTTER PIN Inspect initially after 20 hours 1 month and every 100 hours 6 months thereafter Inspect the propeller for bent chipped or broken blades Replace propeller if damage noticeably affects operation Inspect propeller splines Replace propeller if splines are worn...

Page 44: ...bolt should be covered with Suzuki Sili cone Seal 99000 31120 Suzuki Silicone Seal k 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 NOTE The insulation washer must be installed between the terminal and the motor body Anode k Insulation washer Bonding wire terminal...

Page 45: ... attention Batteries should always be kept out of reach of chil dren When checking or servicing the battery disconnect the negative black cable Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the motor at the same time Wear approved eye protection Recommended battery 12 V 70 Ah 252 kC or larger CONNECTING BATTERY Upon completion of connection ligh...

Page 46: ...ravity of battery solution using a hydrometer Battery solution gravity 1 28 at 20 C 09900 28403 Hydrometer BOLT AND NUTS Inspect initially after 20 hours 1 month and every 100 hours 6 months thereafter Check that all bolt and nuts listed below are tightened to their specified torque z ITEM Tighten torque N m kg m lb ft Cylinder head cover bolt 10 1 0 7 2 Intake manifold bolt nut 11 1 1 7 9 23 2 3 ...

Page 47: ...ration a Using a personal computer and the Suzuki Diagnostic Sys tem software Suzuki recommends using this method as it is possible to monitor the feedback condition b Using the diagnostic harness without a personal computer Refer to the Suzuki Diagnostic System operation manual for the a method procedure The b method procedure is as follows A To prevent any sudden boat movement the boat must be s...

Page 48: ...ed se curely If either sensor or installation is improper the O2 feed back operation will be performed incorrectly and could possibly result in engine operating problems NOTE The O2 sensor is NOT WATERPROOF Cover O2 sensor with the protector sleeve to protect from water spray Cut off the protector P N 18498 99E40 to a length of 20 30 cm 7 8 11 8 in The O2 sensor must be completely covered as shown...

Page 49: ...d 7 Install motor cover 8 Warm up the engine until it is stable at idle speed then shift into forward NOTE The O2 feedback operation must be performed under engine load Do not perform the O2 feedback operation using warm up lever without first shifting into forward gear 9 Connect one of the diagnostic harnesses single Black lead wires and the single Red lead wire together NOTE If engine stalls whe...

Page 50: ...E 3 13 If the feedback operation at any ZONE failed repeat the feedback operation at that ZONE 14 Return the throttle to a full closed position only after the feedback operation at all ZONEs has been successfully finished NOTE Do not close throttle fully for more than 10 seconds while feed back operation is being performed This will cause the O2 feedback operation to finish with incom plete data 1...

Page 51: ...Repeat the O2 feedback operation with a new O2 sensor if The total feedback operation finished without returning the throttle to a fully closing position The total feedback operation failed repeatedly B The O2 sensor is only used when performing the O2 feedback operation After O2 feedback operation is completed the original plug must be installed in the oil pump case 18 Assembly is reverse order o...

Page 52: ...mal operating temp 295 373 kPa 3 0 3 8 kg cm2 42 54 psi at 4000 r min NOTE The figure shown above is a guideline only not an absolute service limit High oil pressure Using an engine oil of too high viscosity Clogged oil passage Clogged oil pressure regu lator Combination of above items TEST PROCEDURE 1 Check the engine oil level 2 Remove the PORT side lower cover 3 Remove the plug1 for oil pressur...

Page 53: ... After warming up shift into forward gear and increase the engine speed to 4000 r min then compare the pressure indicated on the gauge to specifications 10 After testing reinstall parts removed earlier plug side lower cover etc z 5 Remove bolt and No 1 ignition coil 6 Connect special tool H T cord with plug cap adapter be tween No 1 ignition coil and spark plug 09930 88720 H T cord with plug cap a...

Page 54: ... piston or piston rings Stuck piston rings Poor seating of valves Ruptured or otherwise damaged cylinder head gasket TEST PROCEDURE 1 Start engine and allow to warm up then shut engine off 2 Remove the STBD PORT engine side lower cover 3 Remove all spark plugs 4 Install the compression gauge into the plug hole 09915 64510 Compression gauge 09915 63210 Compression gauge adaptor 5 Disconnect the saf...

Page 55: ...ION SYSTEM 3 23 OVERHEAT CAUTION 3 24 LOW BATTERY VOLTAGE CAUTION SYSTEM 3 25 SELF DIAGNOSTIC SYSTEM ________________________________ 3 26 PRIORITY CODE PATTERN FOR SELF DIAGNOSTIC SYSTEM OPERATION 3 26 CONDITION FOR SELF DIAGNOSTIC SYSTEM OPERATION 3 28 FAIL SAFE SYSTEM _______________________________________ 3 29 PRE PROGRAMMED VALUE FOR FAIL SAFE SYSTEM 3 29 OPERATING HOUR INDICATION SYSTEM ___...

Page 56: ...e air temperature sensor CTP Close throttle position switch IAC Idle air control valve INPUT sensor switch CONTROL ECM OUTPUT actuator etc Fuel injection system IAT sensor Cylinder temp sensor Exhaust manifold temp sensor CTP switch Neutral switch O2 sensor optional MAP sensor CMP sensor CKP sensor Ignition system Idle air system Fuel pump system Caution system Self diagnostic system Fail safe sys...

Page 57: ...llery Fuel injector CTP switch Intake manifold By pass air screw Silencer Throttle body IAT sensor Neutral switch IAC valve MAP sensor CKP sensor Alternator Battery charge coil Rectifier regulator Battery Ignition switch ECM main relay Engine control module CKP sensor CKP sensor O 2 sensor Exhaust manifold temp sensor Ignition coil Cylinder temp sensor O 2 Sensor must be installed when performing ...

Page 58: ... 30A fuse To PTT sw ECM main relay Rectifier regulator ENGINE CONTROL MODULE Communication connector Stop sw IAC valve 1 2 3 4 5 6 7 8 1 2 3 4 5 6 1 2 3 5 6 7 4 8 9 10 11 12 1 2 3 5 6 7 4 8 9 10 11 12 1 2 3 4 A4 A7 A8 E2 E4 E3 E1 B1 D1 D6 D3 C9 D2 D7 D8 D4 C2 C5 C3 C4 C6 C12 C7 C11 C8 C1 B2 D5 D9 D12 C11 C10 B5 B4 A5 A1 A3 A2 A6 B3 B6 A B C D E OIL TEMP C E REV Gr Gr Gr Gr Gr Gr Gr Gr Gr Gr Gr Gr ...

Page 59: ...g Idle air control Controls idling trolling speed by adjusting intake air amount through IAC valve Fuel pump control Controls high pressure fuel pump drive Caution system control Informs operator of abnormal engine condition Controls engine speed Self diagnostic system control Informs operator of sensor switch malfunction Fail safe system control Allows operation during sensor switch malfunction O...

Page 60: ...2 Y B Tachometer C3 G W CHECK ENGINE lamp C4 G Y TEMP lamp C5 P REV LIMIT lamp C6 Bl B OIL lamp C7 Bl W Buzzer C8 Br Neutral switch C9 V W Ex manifold temperature sensor C10 Bl Y PC communication C11 R Y PC communication C12 O Buzzer cancel TERMI NAL WIRE COLOR CIRCUIT D1 B W Ground for sensors D2 R Power source for MAP sensor D3 Lg W Cylinder temperature sensor D4 Bl Oil pressure switch D5 B G O2...

Page 61: ...pump IAC valve Ignition sw MAP sensor Neutral sw Ex mani sensor IAT sensor CTP switch Oil pressure switch CKP sensor No 1 CKP sensor No 3 CKP sensor No 2 CMP sensor Emergency stop switch Rectifier regulator Flywheel Cyl temp sensor 12V Battery Buzzer Cancel sw ECM main relay Power Source circuit CPU ECM Buzzer Oil lamp TEMP lamp Tachometer Ign coil 1 Ign coil 2 Ign coil 3 CHECK ENGINE lamp REV LIM...

Page 62: ...ins a Hall Effect semiconductor and a magnet The semiconductor generates a voltage in proportion to the line of magnetic force passed through it When the single trigger vane on the camshaft reluctor aligns with the sensor internal magnet a large amount of magnetic force is gener ated allowing a high voltage to pass through the semiconduc tor When the trigger vane moves away from the sensor no magn...

Page 63: ... time duration ignition timing etc CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder top side and used to detect the cylinder temperature This is a thermistor type sensor resistance of which changes depending on the temperature and inputs a signal to the ECM as a voltage value This input signal is used to compensate the fuel injection time duration ignition t...

Page 64: ...ing is fixed at BTDC 9 For two seconds after shifting into forward or reverse from neutral the IAC valve is controlled so that intake air increases to prevent unstable engine idle or stalling ECM MAIN RELAY The ECM main relay is installed in the electric parts holder When energized by the turning ignition switch ON it forms the circuit which supplies battery voltage to the ECM injector igni tion c...

Page 65: ... the oxygen concentration The terminal voltage decreases when the oxy gen concentration is high and increases when it is low NOTE As the zirconia element is not conductive below 250 C the O2 sensor will not function properly until the engine is at normal operating temperature NOTE Zirconia element The zirconia element produces a potential difference voltage when there is a difference in the oxygen...

Page 66: ...tration At the calculated time of ignition the transistor in the ECM turns OFF breaking the ground circuit In this way a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated Basic sensors Compensating sensors Switches Spark plug MAP sensor Informs ECM of intake manifold pressure CKP sensor Informs ECM of engine speed and crankshaft angle Cylinder temperat...

Page 67: ...urning the CTP switch ON ignition timing is delayed for a programmed duration to prevent engine stalling or unstable running IGNITION TIMING CHART The following chart is an example for ignition at BTDC30 SPECIFICATION Ignition system Full transistorized ignition Advance Electronic microcomputer control Ignition timing DF 40 BTDC 0 32 DF 50 BTDC 0 25 Firing order 1 3 2 CKP Sensor Signal 1 CKP Senso...

Page 68: ...sors Compensating sensors Injector MAP sensor Informs ECM of intake manifold pressure CKP sensor Informs ECM of engine speed and crankshaft angle Cylinder temperature sensor Informs ECM of cylinder temperature Fuel injection time duration amount is determined by a digital map designed in relation to intake manifold pressure and engine speed ECM Fuel amount compensation Others CMP sensor Informs EC...

Page 69: ...mount is controlled to maintain a stable engine speed at the specified idle trolling rpm WHEN ACCELERATING The fuel injection amount is controlled to increase WHEN DECELERATING The fuel injection amount is controlled to decrease The fuel injection is also cut off on very rapid engine deceleration FUEL INJECTION TIMING CHART CKP Sensor Signal 1 CKP Sensor Signal 2 CKP Sensor Signal 3 CMP Sensor Sig...

Page 70: ... maintains fuel pressure in the feed line between the high pressure fuel pump and fuel injector This pressure maintained at a constant level is higher than the pressure in the vapor separator chamber When fuel feed line pressure exceeds vapor separator chamber pressure by more than approx 250 kPa 2 55 kg cm2 36 3 psi the valve in the fuel pressure regulator will open and return the excess fuel to ...

Page 71: ...rom the fuel pressure regulator This vapor is routed through the evaporation hose connecting the vapor separator cover to the air inlet cover over the flywheel HIGH PRESSURE FUEL PUMP The high pressure fuel pump is an integral type in which the pump mechanism is located within the fuel vapor separator To supply the optimum fuel amount the pump is driven by the duty cycle signal from ECM Fuel outle...

Page 72: ...kg cm2 36 3 psi By pass fuel is returned back to the fuel vapor separator chamber FUEL INJECTOR The fuel injector is an electromagnetic valve operated by a signal from the ECM When the injection signal is supplied to the fuel injector the solenoid coil is energized pulling up the plunger This opens the injector needle valve and injects fuel Because the fuel pressure is kept constant the amount of ...

Page 73: ...rolled to operate at 100 duty in order to initially pressurize the high pressure line WHEN CRANKING The pump is controlled to operate at 100 duty WHEN RUNNING NORMAL OPERATION The pump is controlled to operate at 80 90 duty based on the current engine speed and battery voltage CKP sensor Informs ECM of engine speed Battery voltage Ignition switch Informs ECM of START signal ECM Fuel pump Signal FP...

Page 74: ...ol passage THROTTLE BODY The throttle body assembly consists of the main bore throttle valve air bypass IAC passages air by pass adjustment screw and CTP switch The throttle body adjusts the intake air amount with the throttle valve which is connected to the throttle linkage lever The CTP closed throttle position switch installed on the top of throttle body informs of throttle valve position NOTE ...

Page 75: ...rom the ECM IDLE AIR CONTROL SYSTEM OUTLINE The ECM controls the duty cycle signal of the IAC valve to regulate a portion of the intake air flow to the intake manifold This system is used for the following purposes To keep idling trolling at the specified speed To improve driveability when decelerating Dash pot effect To improve engine starting and warm up performance Fast idle function The sensor...

Page 76: ...which depends on the current engine conditions WHEN DECELERATING DASH POT EFFECT When the throttle valve is suddenly returned to full close and the CTP switch signal changes to ON the IAC valve operates at a controlled gradual return to idle troll operating duty to prevent engine stalling or unstable running NOTE Due to the limited intake air flow from the IAC passage and in order to effectively u...

Page 77: ...Low battery voltage 1 REV LIMIT lamp 2 OIL lamp 3 TEMP lamp 4 CHECK ENGINE lamp MONITOR TACHOMETER 1 2 3 4 OVER REVOLUTION CAUTION SYSTEM CONDITION When the engine speed exceeds 6500 r min DF40 or 7000 r min DF50 the ECM initiates an intermittent fuel injection signal to provide a 6500 r min or 7000 r min maximum Over revolution limiter ACTION RESET Close throttle to reduce engine speed below appr...

Page 78: ...ion Caution buzzer Sounds in a series of long 1 5 sec beeps RESET Stop engine and check engine oil level Refill engine oil to the correct level if below the low oil mark If the engine oil level is correct the following causes may be considered Improper oil viscosity Malfunctioning oil pressure switch Clogged oil strainer or oil filter Worn oil pump relief valve Oil leakage from the oil passage Exc...

Page 79: ...shown below ACTION Engine speed Automatically reduced to approx 3000 r min by intermittent fuel injection signal if the system is activated at 3000 r min or higher Caution lamp TEMP lamp lights continuously REV LIMIT lamp lights continuously during engine speed limiter activation Caution buzzer Sounds in a series of long 1 5 sec beeps Temperature range Temperature difference 60 C 94 C 1 6 C 95 C 0...

Page 80: ...e speed limiter is activated Caution lamp CHECK ENGINE lamp lights continuously Caution buzzer Sounds in a series of long 1 5 sec beeps RESET This caution system is automatically reset when battery voltage increases to more than 9 volts Refrain from using electrical equipment requiring high amperage such as hydraulic trim tabs hydraulic jack plate etc after this caution is activated ...

Page 81: ...lamp flash The buzzer sound activated by the self diagnostic system can be temporally canceled by pushing the ignition key in PRIORITY CODE PATTERN FOR SELF DIAGNOSTIC SYSTEM OPERA TION PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN FAIL SAFE SYSTEM ACTIVE 1 MAP sensor 1 3 4 on off YES 2 CKP sensor 4 2 on off NO NOTE1 3 IAC valve By pass air screw adjustment 3 1 on off NO 4 CMP sensor 2 4 on off ...

Page 82: ...ation will be canceled after corrective action by turning the ignition switch ON The ECM will require 10 20 seconds after turning the ignition switch ON to cancel the self diagnostic indication NOTE 1 No spark or injection signal will be supplied to the cylinder corresponding to the faild CKP sensor If two or more CKP sensors have failed at the same time the engine will stop NOTE 2 The self diagno...

Page 83: ...om any CKP sensors while receiving 8 signals from other CKP sensors No signal from one CKP sensor while receiving 6 signals from CMP sensor One CKP sensor fail IAC valve By pass air screw IAC valve operates at 90 duty or higher when CTP switch is ON adjustment IAC valve operates at 10 duty or lower when CTP switch is ON NOTE 1 CMP sensor No signal while receiving 12 signals from CKP sensors CTP sw...

Page 84: ...g under the fail safe condition PRE PROGRAMMED VALUE FOR FAIL SAFE SYSTEM NOTE There is no back up system for the ECM itself The engine will stop if it has failed MAP sensor 1 319 475 mmHg 750 4000 r min CMP sensor Fuel Injection 1 simultaneous injection for all cylinders per 2 crankshaft rotations Ignition Timing Normal ignition timing based on signals from CKP sensor s Cylinder temp sensor 60 C ...

Page 85: ... TACHOMETER INDICATION REV LIMIT lamp1 OIL lamp2 TEMP lamp3 Needle indication 0 h off off off 0 rpm 50 h flash off off 0 rpm 100 h on off off 1000 rpm 150 h flash off off 1000 rpm 200 h on off off 2000 rpm 250 h flash off off 2000 rpm 300 h on off off 4000 rpm 350 h flash flash off 0 rpm 400 h on on off 1000 rpm 450 h flash flash off 1000 rpm 500 h on on off 2000 rpm 550 h flash flash off 2000 rpm...

Page 86: ...tch is also ON in neutral and OFF in forward or reverse When this switch is OFF no power is supplied to the starter motor relay preventing starter motor engagement Using the combination of neutral switches the fuel supply circuit as well as the starter motor circuit is regu lated The engine will not start even by emergency rope with the shift in the forward or reverse position Battery charge coil ...

Page 87: ...d to the exhaust manifold This sensor is used to measure the concentration of oxygen in the exhaust gas at engine speeds of 2500 3500 and 4500 r min The ECM uses the input data from the O2 sensor to correct the compensation coefficient of the fuel injection duration map within the ECM itself NOTE See the FUEL MIXTURE CHECK O2 FEEDBACK section on page 2 21 for the O2 feedback operation procedure O2...

Page 88: ... diagnostic code memory in ECM will remain even if battery is disconnected As each terminal voltage is affected by battery voltage use a full charged battery Make sure all ground points have good electrical contact Make sure all wires cables are securely connected INSPECTION FOR ECM CIRCUIT VOLTAGE B ECM cannot be bench checked It is strictly prohibited to connect any tester voltmeter or ohmmeter ...

Page 89: ...IAC valve solenoid ECM power source Ground for ECM Emergency stop switch Tachometer CHECK ENGINE lamp TEMP lamp REV LIMIT lamp OIL lamp Buzzer Neutral switch Ex manifold temperature sensor PC communication PC communication Buzzer cancel Ground for sensors Power source for MAP sensor Cylinder temperature sensor Oil pressure switch O2 feedback PC communication IAT sensor MAP sensor CTP switch PC com...

Page 90: ...ary A3 G to B5 Gr Ignition coil No 1 Secondary B5 Gr to No 1 spark plug cap Ignition coil No 2 Secondary B5 Gr to No 2 spark plug cap Ignition coil No 3 Secondary Fuel injector No 1 Fuel injector No 2 Fuel injector No 3 IAC valve Cylinder temperature sensor Ex mani temperature sensor C9 V W to D1 B W ECM main relay B2 P B to TerminalA NOTE1 Starter motor relay D11 Y G to Ground A4 O B to B5 Gr A7 ...

Page 91: ...o body ground 3 Momently touch Black Yellow wire to starter motor relay right terminal connected to battery positive terminal and check for injector operating sound Injector operating sound Click NOTE1 Disconnect remote control wire harness and connect tester probe to terminal A Gray wire Starter motor relay ECM E D C B A z FUEL INJECTOR OPERATING SIGNAL 09930 89930 8 pin test cord Peak voltmeter ...

Page 92: ...ter probe Black to starter motor relay right terminal connected to battery positive terminal as shown 3 Connect the tester probe Red to each terminal Ignition coil Terminal Engine Wire color Test cord No 1 A5 O O No 2 A1 Bl Bl No 3 A3 G B W 4 Crank engine and measure voltage Ignition coil operating signal 6 10 V Injector Terminal Engine Wire color Test cord No 1 A4 O B B R No 2 A7 B Y B Y No 3 A8 ...

Page 93: ...as shown then turn ignition switch ON 2 Connect the tester probe Red to terminal Terminal Wire color Test cord E2 O G Engine O G 3 Connect the tester probe Black to body ground then measure voltage CMP sensor signal When ignition switch ON Approx 1 V or 5 V 4 Measure voltage at cranking CMP sensor signal When cranking Approx 5 V z q ECM A B C D E ...

Page 94: ...essure to MAP sensor measure D7 terminal voltage See page 3 33 and 3 34 for proce dure MAP sensor output voltage change Negative pressure kPa kg cm2 mm Hg D7 terminal voltage V 0 0 0 40 0 4 300 80 0 8 600 4 00 2 42 0 84 at 1013 hPa baro CTP SWITCH z z z z z 09930 99320 Digital tester r r r r r Tester range Continuity 1 Disconnect CTP switch wire 2 Check continuity between CTP switch terminal and b...

Page 95: ...MAIN RELAY 09930 99320 Digital tester Tester range Continuity 1 Disconnect ECM main relay from wire 2 Check continuity between terminal 1 and 2 each time 12V is applied Connect positive side to terminal 4 and nega tive side to terminal 3 ECM main relay function 12 V power Continuity Applied Yes Not applied No B Be careful not to touch 12V power supply wires to each other or with other terminals Oi...

Page 96: ...Ignition switch ON Check D2 terminal voltage Is result OK See page 3 34 Ignition switch ON Check D7 terminal voltage Is result OK See page 3 34 Possible cause ECM failure Wire continuity connection failure YES YES ECM failure NO MAP sensor failure NO CHART2 SELF DIAGNOSTIC CODE 4 2 START Ignition switch OFF Check CKP sensor resistance Is result OK See page 3 35 Possible cause ECM failure Wire cont...

Page 97: ...ECM failure NO CHART4 SELF DIAGNOSTIC CODE 2 4 START Ignition switch ON cranking Check CMP sensor signal Is result OK See page 3 38 Possible cause ECM failure Wire continuity connection failure YES CMP sensor failure NO NOTE It will be possible to start engine if CMP sensor has failed CHART5 SELF DIAGNOSTIC CODE 2 2 START Ignition switch ON Check D8 terminal voltage Is result OK See page 3 34 Poss...

Page 98: ...nce Is result OK See page 3 35 Possible cause ECM failure Wire continuity connection failure YES IAT sensor failure NO CHART8 SELF DIAGNOSTIC CODE 3 2 START Individual check Check MAP sensor hose is in good condition connection Is result OK Ignition switch ON Check MAP sensor output voltage change Is result OK See page 3 39 YES YES MAP sensor hose failure NO MAP sensor failure NO Cylinder temp sen...

Page 99: ...lator failure NO YES NOTE This self diagnostic code indication may be canceled by turning ignition switch ON because ECM detects battery voltage NOTE1 It is difficult to check rectifier regulator completely Before replacing with new one check if its ground point has good electrical contact START Ignition switch OFF Check exhaust manifold temp sensor resistance Is result OK See page 3 35 Possible c...

Page 100: ...e page 3 46 NO ECM main relay failure YES Ignition switch ON Check C1 terminal voltage Is result OK See page 3 34 YES YES Cranking Check ignition spark using timing light P no 09930 76420 Is there light flashing Ignition switch OFF Check ignition primary coil resistance See page 3 35 Check ignition secondary coil resistance See page 3 35 Are results OK Power supply wire Gr failure ECM failure Fuel...

Page 101: ...ure clogged hose silencer etc NOTE3 Spark plug failure Ignition coil failure ECM failure Wire continuity connection failure Failure of high pressure fuel system components Fuel injector clog stuck valve etc Fuel pressure regulator incorrect regulated pressure etc Fuel pump clogged suction filter leakage in tank etc Fuel filter clog etc Hose clog kink leakage etc NOTE1 If neutral switch has failed ...

Page 102: ...FLYWHEEL CKP SENSOR CMP SENSOR 1 Flywheel bolt 2 Washer 3 Key 4 Flywheel 5 CKP sensor 6 Screw 7 CMP sensor 8 Bolt 1 2 3 4 5 5 5 6 7 8 NOTE Clean flywheel and crankshaft mating surfaces with cleaning solvent Crankshaft 200 N m 20 0 kg m 145 lb ft o h ...

Page 103: ... at this time This bolt prevents damage to the crankshaft when using fly wheel remover tools 3 Using special tools loosen flywheel from crankshaft 09930 39411 Flywheel remover 09930 39420 Flywheel remover bolt 4 Remove flywheel bolt 1 washer 2 flywheel 3 and key 4 5 Remove screws 5 and CKP sensors 6 then disconnect CKP sensor connector z z 1 2 3 4 6 5 6 6 Disconnect CMP sensor connector Remove bol...

Page 104: ... and washer before installing Tighten flywheel bolt to specified torque 09930 48720 Flywheel holder Flywheel bolt 200 N m 20 0 kg m 145 lb ft z INSTALLATION Installation is reverse order of removal with special attention to the following steps CKP sensors Apply Thread Lock 1342 to the sensor mounting screws 99000 32050 Thread Lock 1342 h ...

Page 105: ...e 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 in stallation Oil pressure switch 13 N m 1 3kg m 9 5 lb ft Start engine and check oil pressure switch for oil leakage Reseal switch if oil leakage is found ...

Page 106: ... 4 1 INSPECTION 4 2 REMOVAL INSTALLATION 4 4 ELECTRIC STARTER SYSTEM_______________________________ 4 6 OUTLINE 4 6 TROUBLESHOOTING 4 7 INSPECTION 4 8 STARTING MOTOR 4 11 MONITOR TACHOMETER ___________________________________ 4 17 INSPECTION 4 17 4 ELECTRICAL CONTENTS ...

Page 107: ...hase AC current generated from battery charge coil is converted by the rectifier regulator into regulated DC cur rent which is used to charge the battery OUTPUT REGULATED VOLTAGE 216 W 14 5 15 5 V Battery charge coil Alternator Magneto HIC Rectifier regulator Battery 12V To Starter motor Starter motor relay 30A Fuse To PTT switch To ECM main relay To Ignition switch B Y Y Y W W W R W W W ...

Page 108: ......

Page 109: ...stors diodes etc are used inside this rectifier regula tor the resistance values will differ when an ohmmeter other than SUZUKI digital tester is used Rectifier regulator resistance If measurement exceeds specification replace rectifier regu lator z Tester probe Red Tester probe Black Black White Yellow 1 Yellow 2 Yellow 3 Black White Yellow 1 Yellow 2 Yellow 3 B W Y1 Y3 Y2 t 9 14 0 F Unit MW W W ...

Page 110: ...arge coil lead wire connector from rec tifier regulator Rectifier regulator Remove two bolts securing the Rectifier regulator Disconnect lead wire connectors 1 1 1 1 1 Bolt 1 2 2 2 2 2 Washer 1 3 3 3 3 3 Key 1 4 4 4 4 4 Flywheel 1 5 5 5 5 5 Battery charge coil 1 6 6 6 6 6 Screw 3 7 7 7 7 7 Rectifier regulator 1 8 8 8 8 8 Bolt 2 9 9 9 9 9 Fuse case 1 0 0 0 0 0 30A fuse 1 1 200 N m 20 0 kg m 145 Ib ...

Page 111: ...nd starter motor relay terminal INSTALLATION Installation is reverse order of removal with special attention to the following step Battery charge coil Apply Thread Lock 1342 to the coil securing screws 99000 32050 Thread Lock 1342 Wire routing Check wire routing See page 10 1 to 10 4 h ...

Page 112: ...t is mainly composed of Battery Starter motor Relay Neutral switches and Ignition switch To ECM main relay To Rectifier regulator 30A Fuse To ECM Neutral switch Neutral switch Remote control box Ignition switch Battery Starter motor M B W Br GND BATT START OFF ON START FREE PUSH Br Br W W W W W R B R B W Br Br Y G Y G Y G ...

Page 113: ...Is there click sound Measure voltage at terminal2 with ignition switch at START It must be above 12 V Is result OK Measure voltage at terminal3 with ignition switch at START It must be above 12 V Is result OK Starter motor failure Sub cable failure Measure voltage at terminal1 It must be above 12V Is result OK Check 30A fuse and fuse case See page 4 2 Is result OK Check ignition switch function Se...

Page 114: ...s 2 Check continuity between wiring leads at the key positions shown in the chart z If out of specification replace ignition switch Key Position 1 1 1 1 1 OFF Switch Lead Wires Black Green White Gray Brown Orange 2 2 2 2 2 ON 3 3 3 3 3 START 4 4 4 4 4 FREE 5 5 5 5 5 PUSH Continuity Black Green White Gray Orange Brown 1 OFF 2 ON 3 START 4 FREE 5 PUSH PUSH r ...

Page 115: ...pecification replace neutral switch Shift position Tester indicates Neutral Continuity Forward Infinity Reverse Infinity Neutral switch on cylinder block 1 Disconnect neutral switch lead wires 2 Check continuity infinity betweenYellow Green and Brown lead wires while operating remo con handle If out of specification replace neutral switch NOTE After installing neutral switch check for proper corre...

Page 116: ... Method 2 Connect the wiring leads of the relay to battery 12V and check relay operation Tester range Continuity 1 Disconnect all cables wires from starter motor relay 2 ConnectYellow Green wire to positive terminal and Black wire to negative terminal of battery When 12V applied Continuity between relay terminal 1 1 1 1 1 and 2 2 2 2 2 3 Disconnect wiring leads from battery No voltage applied No c...

Page 117: ...AT Intake air tem perature sensor 4 Remove bolt and negative battery cable 3 5 Remove starter motor sub cable 4 6 Remove two bolts 5 and starter motor band 6 7 Remove two bolts 7 and starter motor 8 INSTALLATION Installation is reverse order of removal with special attention to the following steps Install starter motor and tighten starter motor mounting bolts securely Starter motor mounting bolt 2...

Page 118: ... 1 3 3 3 3 3 Spring 1 4 4 4 4 4 Pinion 1 5 5 5 5 5 Bolt 2 6 6 6 6 6 Front cover 1 7 7 7 7 7 Washer 8 8 8 8 8 Washer 9 9 9 9 9 Stator 1 0 0 0 0 0 Armature 1 A A A A A Washer B B B B B Rear cover 1 C C C C C Nut 1 D D D D D Washer 1 E E E E E Washer 1 F F F F F Screw G G G G G Brush holder H H H H HBrush I I I I IBrush spring 1 2 3 4 6 7 8 0 A 9 B C D E F 5 G H I v v v ...

Page 119: ...and assembling stopper ring NOTE Using a screw driver pry off the stopper ring Remove two bolts 5 Remove following parts Front cover 6 Washer 7 8 Stator 9 Armature 0 Washer A Rear cover B Remove the nut C washer D and E from rear cover B Remove two screws F and brush holder assembly G with brush H and brush spring I 1 2 3 4 6 7 8 0 A 9 5 B C D E F H G I B ...

Page 120: ...tor outside diameter Standard 33mm 1 30 in Service limit 32mm 1 26 in If measurement exceeds service limit replace armature Check that mica insulator between the segments is undercut to specified depth Commutator undercut Standard 0 5 0 8mm 0 02 0 03 in Service limit 0 2 mm 0 008 in If measurement exceeds service limit cut to specified depth NOTE Remove all particles of mica and metal using compre...

Page 121: ...ester range Continuity BRUSHES Check the length of each brush 09900 20101 Vernier calipers Brush length Standard 17 0 mm 0 67 in Service limit 10 0 mm 0 39 in If brushes are worn down to the service limit they must be re placed BRUSH HOLDER Check brush holder continuity 09930 99320 Digital tester Tester range Continuity Brush holder continuity z z z Tester probe connection Continuity Brush holder ...

Page 122: ...ase to armature shaft and shaft holes 99000 25010 Suzuki Super Grease A Align front cover stator and rear cover with alignment lines scribed earlier and assemble starter A Wear safety grasses when disassembling and reassem bling stopper ring Install pinion spring pinion stopper and stopper ring NOTE Make sure stopper ring 1 fit tightly in pinion stopper 2 and armature shaft 3 v 1 2 3 ...

Page 123: ...ive terminal and Black wire to negative terminal of battery 3 Check if lamp lights when connecting battery to test cord terminal as shown Monitor lamp check If out of specification replace monitor tachometer Battery terminal Terminal for battery connection Test cord Meter Lighting lamp Negative Bl G W Lamp 1 Negative W G Y Lamp 2 Negative Y Bl B Lamp 3 Positive R P Lamp 4 1 2 3 4 B Gr 12V Battery ...

Page 124: ...FUEL VAPOR SEPARATOR HIGH PRESSURE FUEL PUMP______ 5 7 REMOVAL INSTALLATION 5 7 DISASSEMBLY 5 8 INSPECTION 5 9 ASSEMBLY 5 11 FUEL INJECTOR __________________________________________ 5 12 INSPECTION 5 12 REMOVAL 5 12 INSTALLATION 5 13 LOW PRESSURE FUEL PUMP _______________________________ 5 14 REMOVAL INSTALLATION 5 14 DISASSEMBLY REASSEMBLY 5 15 INSPECTION 5 16 FUEL TANK___________________________...

Page 125: ...moke 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 immediately A The components af...

Page 126: ...h pressure fuel pump 3 Disconnect the ignition coil primary lead wire connector from all ignition coils 4 Crank the engine 5 10 times 3 seconds each time to dissipate fuel pressure in lines 5 Make sure fuel pressure has been removed by pinching high pressure fuel hose with finger tips line should feel soft with out pressure 6 Upon completion of servicing connect ignition coil primary wire and fuel...

Page 127: ...mponents with engine either operating or at rest Extreme care should be taken not to cut abrade or cause any other damage to hoses Use care not to excessively compress hoses when tightening clamps NOTE Check fuel hose routing See page 10 7 and 10 9 Check for fuel leakage OFF ON FUEL LEAKAGE CHECK PROCEDURE After performing any fuel system service always be sure there is not fuel leakage by checkin...

Page 128: ...bed end pipe hose must completely cover pipe Clamp Clip Hose Joint piep 3 7 mm 0 1 0 3 in 3 7 mm 0 1 0 3 in 20 30 mm 0 8 1 2 in 3 7 mm 0 1 0 3 in 3 7 mm 0 1 0 3 in 20 30 mm 0 8 1 2 in For type B bent end pipe hose must cover straight part of pipe by 20 30mm 0 8 1 2in For type C pipe hose must fit up against flanged part of pipe For type D pipe hose must cover pipe by 20 30mm 0 8 1 2 in A B C D ...

Page 129: ...prox 235 kPa 2 4 kg cm2 34 1 psi 5 Stop engine and wait 5 minutes z OFF ON FUEL PRESSURE INSPECTION 1 Relieve fuel pressure in fuel feed line See page 5 2 2 Connect special tools pressure gauge pressure hose pressure joint between fuel feed hose and 3 way joint pipe as shown in figure Clamp hose securely to ensure no leaks occur during check ing 09912 58441 Pressure gauge a a a a a 09912 58431 Fue...

Page 130: ...5 6 FUEL SYSTEM 6 After checking fuel pressure remove fuel pressure gauge 7 Reconnect fuel line 8 With engine not running and ignition switch ON check fuel system for leaks ...

Page 131: ... spray relieve fuel line pressure before disconnecting or removing components Remove intake manifold assembly See page 6 1 Remove three bolts and fuel vapor separator assembly from intake manifold Installation Installation is reverse order of removal See page 6 2 for installation of intake manifold assembly FUEL VAPOR SEPARATOR HIGH PRESSURE FUEL PUMP ...

Page 132: ...uel pump from separator case 3 NOTE Separator cover and case are a set Make sure paint marks on both items are matched when as sembling Remove float pin 4 and float 5 Remove needle valve 6 screw plate and valve seat 7 Remove plate 8 Remove screw and fuel pressure regulator 9 from separator case ...

Page 133: ...nent Needle valve Valve seat Check needle valve and valve seat If grooved or damaged replace valve and seat If dirt is found clean Remove screw and pump bracket 0 Remove high pressure fuel pump A from separator cover and then disconnect pump lead wire connector Float Check float If cracked or damaged replace float ...

Page 134: ...ect special tools to inlet side of regulator as shown 2 Pump air into regulator using pump 1 until air is released through outlet side 3 Note pressure on gauge when air is released Regulator operating pressure 240 270 kPa 2 4 2 7 kg cm2 34 1 38 4 psi If measurement exceeds specification replace regulator z 1 2 3 4 Filter Check pump suction filter If clogged or damaged clean or replace filter ...

Page 135: ...arator case and tighten screws securely NOTE Separator cover and case are a set Make sure paint marks on both items are matched when as sembling b ASSEMBLY Assembly is reverse order of disassembly paying special atten tion to the following steps Float Float pin Install float and float pin NOTE After assembling check for smooth and free float movement Fuel pressure regulator Install fuel pressure r...

Page 136: ...ital tester Tester range W W W W W Resistance Fuel injector resistance 11 0 16 5 W W W W W If out of specification replace fuel injector 4 Connect lead wire connector to fuel injector securely z t REMOVAL 1 Relieve fuel pressure according to procedure described on page 5 2 2 Disconnect lead wire connectors from each injector 3 Remove the screw securing the fuel injector stopper 4 Remove fuel injec...

Page 137: ... rings before installing injector into intake manifold 4 Install injector stopper and tighten stopper screw securely 5 Connect lead wire connector to injector securely 6 Turn ignition switch ON for 3 seconds to operate fuel pump then turn it OFF Repeat this ON and OFF procedure 3 or 4 times to pres surize the fuel system Check for fuel leaks around fuel injector 1 Cushion 3 O ring 2 Injector 4 O r...

Page 138: ... pump 4 and O ring 5 B Before installing fuel pump rotate the crankshaft to bring No 1 top cylinder piston to Top Dead Center on compression stroke Discard O rings after removal always use new O ring to ensure proper sealing Low pressure fuel pump bolt 10 N m 1 0 kg m 7 2 lb ft INSTALLATION Installation is reverse order of removal with special attention to the following steps ...

Page 139: ...t through cutaway of pump body 0 Remove following parts Pin 5 Piston 6 Spring 7 Diaphragm 8 Spring 9 ASSEMBLY Assembly is reverse order of disassembly with special atten tion the following steps NOTE After connecting diaphragm rod 8 to piston 6 with pin 5 align the six diaphragm holes to pump body holes by turning pis ton 6 and diaphragm 8 together Turning them together pre vents the pin from comi...

Page 140: ...n tears or other damage is found replace diaphragms Check valves Inspect the fuel pump check valves If tears distortion or dam age is found replace fuel pump Pump body Inspect each fuel pump body and outer plate If cracks nicks distortion or damage is found replace fuel pump ...

Page 141: ...2 b Connector 3 Clip 4 4 Primer bulb 1 5 Tank cap 1 6 Gasket 1 7 Connector plug 1 8 Outlet 1 9 Filter 1 0 O ring 1 A Fuel tank 1 1 Tank cap 1 2 Gasket 1 3 Screw 4 4 Gasket 4 5 Connector plug 1 6 Gasket 1 7 Fuel gauge assy 1 8 Cover 1 9 Gasket 1 0 Lens 1 A Gasket 1 B Screw 2 C Float 1 D Push nut 1 E Gasket 1 F Fuel hose assy 1 G Connector 1 H Clip 4 I Connector 1 J Primer bulb 1 K Fuel tank 1 1 2 a...

Page 142: ...function is defective replace primer bulb Fuel hose Inspect fuel hose If cuts cracks leakage tears or deterioration is found replace fuel hose Fuel tank Inspect fuel tank if cracks leakage or deterioration is found replace fuel tank If water or other contamination is found drain and clean fuel tank Tank cap Check that the fuel tank vent opens and relieves internal tank pressure properly Replace ta...

Page 143: ..._________________________ 6 15 REMOVAL 6 15 INSPECTION 6 17 INSTALLATION 6 18 CYLINDER HEAD ASSEMBLY _______________________________ 6 21 REMOVAL 6 21 ASSEMBLY 6 21 DISASSEMBLY 6 24 INSPECTION SERVICING 6 25 REASSEMBLY 6 38 CYLINDER CRANKSHAFT PISTON _________________________ 6 40 DISASSEMBLY 6 40 INSPECTION SERVICING 6 43 REASSEMBLY 6 57 THERMOSTAT ____________________________________________ 6 6...

Page 144: ...ead wire connector 3 from CTP switch 4 Remove throttle rod 4 from throttle body 5 Remove bolts and side cover holder 5 6 Remove water inlet hose 6 and outlet hose 7 from vapor separator 7 Place a suitable container under the vapor separator then disconnect fuel return hose 8 from vapor separator 8 Disconnect MAP sensor lead wire connector 9 at MAP sen sor Disconnect low pressure fuel inlet hose 0 ...

Page 145: ...e manifold assembly G INSTALLATION Installation is reverse order of removal with special attention to the following steps NOTE Do not re use gasket Always use a new gasket Install gasket and intake manifold Tighten bolts and nuts securely Check to ensure that all removed parts are back in place Checking Check fuel and water hose routing See page 10 7 to 10 9 Check wire routing See page 10 1 to 10 ...

Page 146: ...tion coil connectors Remove the bolt securing the ignition coil 2 Remove all ignition coils 2 and spark plugs Disconnect CMP sensor connector 3 Remove the twelve 12 cylinder head cover bolts and then remove cylinder head cover 4 Remove starter motor See page 4 11 Remove flywheel See page 3 48 09930 48720 Flywheel holder 09930 39411 Flywheel remover 09930 39420 Flywheel remover bolt z ...

Page 147: ...er bracket Disconnect water hose 4 from thermostat cover and engine holder Disconnect exhaust manifold temperature sensor connector and remove sensor 5 Loosen screw and disconnect oil pressure switch lead wire 6 Disconnect neutral switch lead connector wire 7 Disconnect all engine wiring harness connectors from ECM then remove ECM 8 Disconnect the PTT motor cable wire leads G Bl from the PTT relay...

Page 148: ...osening lock nut and turnbuckle Remove throttle control lever 1 and clutch control lever 2 Remove bolt and neutral switch 3 with bracket Remove two bolts 1 securing front panel bracket 2 Remove screw 3 and clutch lever shaft 4 Remove clutch rod arm 5 from crankcase Remove pin 6 and side cover seal 7 Remove oil level dipstick 8 ...

Page 149: ...POWER UNIT 6 6 Remove eight bolts and nut Lift up and remove power unit from engine holder ...

Page 150: ...splines 99000 25160 Suzuki Water Resistant Grease Lower the power unit onto engine holder NOTE Rotate crankshaft to aid alignment of driveshaft and crankshaft splines Apply Suzuki Silicone Seal to power unit mounting bolts and tighten bolts and nut to specified torque 99000 31120 Suzuki Silicone Seal Power unit mounting bolt and nut 8 mm 23 N m 2 3kg m 16 5 lb ft 10 mm 50 N m 5 0kg m 36 0 lb ft FL...

Page 151: ... figure 99000 31140 Suzuki Bond No 1207B Assemble new O rings and cylinder head cover gasket to cylin der head cover NOTE Be sure to check all parts for wear or any damage before instal lation and replace any found defective Install cylinder head cover to cylinder head and tighten cover bolts to specified torque Cylinder head cover bolt 10 N m 1 0kg m 7 2 lb ft NOTE Use care when installing cylind...

Page 152: ...moved have been returned to their original posi tions Lower unit gear engagement is properly adjusted See page 9 22 Fuel and water hose routing match s service manual illustra tion See page 10 7 to 10 9 Wire routing match s service manual illustration See page 10 2 to 10 6 No fuel leakage is evident when fuel system is pressurized See page 5 3 No water leakage is evident during final test running ...

Page 153: ...ase then remove the under oil seal hous ing 3 Remove the seven 7 bolts securing the oil pump case to cylinder block then remove oil pump case with oil pump DISASSEMBLY 1 Remove the screws securing oil pump rotor plate to the oil pump case then remove the oil pump rotor plate 2 Take out inner rotor and outer rotor Rotor plate 1 2 1 Outer rotor 2 Inner rotor ...

Page 154: ...surement is not within specifications replace the outer rotor and or case Side clearance Using straightedge and feeler gauge measure side clearance Side clearance Service limit 0 15 mm 0 0059 in If measurement is not within specifications replace the outer rotor and or pump case Oil pump components Check outer and inner rotors rotor plate and oil pump case for excessive wear or damage Replace as n...

Page 155: ...ase 4 Install outer plate Tighten six 6 screws securely After mounting the outer plate check to be sure that each rotor turns smoothly by hand INSTALLATION Installation is reverse of removal with special attention to fol lowing steps 1 Check for proper timing chain installation see page 6 20 2 Install two 2 dowel pins to cylinder block Before fitting the pump case oil the oil seal lip 1 2 1 Outer ...

Page 156: ...alant to oil pump case mating surface as shown in figure 99000 31140 Suzuki Bond 1207B 5 Install oil pump case to cylinder block and tighten seven 7 bolts securely NOTE When installing oil pump case be sure position of oil pump inner rotor matchs with crankshaft Tighten bolts in the indicated order Sealant Sealant b b b b ...

Page 157: ...POWER UNIT 6 14 8 Install under oil seal housing and tighten bolts 6 Install dowel pin and gasket to oil pump case 7 Apply grease to oil seal lip 99000 25160 Water Resistant Grease l ...

Page 158: ...ming chain has been removed never turn crank shaft or camshaft 2 Remove the bolts and timing chain tensioner link 5 3 Remove the bolts and tensioner adjuster 6 4 Remove the bolts and timing chain guide No 1 3 1 Crankshaft timing sprocket 2 Timing chain 3 Timing chain guide No 1 4 Timing chain tensioner 5 Timing chain tensioner link 6 Timing chain tensioner adjuster 7 Timing chain guide No 2 8 Exha...

Page 159: ... hexagon area of the camshaft 7 Remove the three 3 bolts securing the intake timing sprocket to camshaft 8 Remove the intake timing sprocket dowel pin and timing chain 5 Remove the bolt and timing chain tensioner 4 6 Remove the bolts and timing chain guide No 2 7 ...

Page 160: ...n tensioner chain guide Check shoe for wear or damage Timing sprocket Check teeth of sprocket for wear or damage 1 Latch 2 Tooth surface 1 2 INSPECTION NOTE If any component is worn excessively cracked defective or damaged in any way it must be replaced Timing chain Inspect timing chain Replace if worn or damaged ...

Page 161: ...shown in figure 3 Install timing chain by aligning blue plate of timing chain and arrow on exhaust camshaft timing sprocket as shown in figure Install timing chain by aligning yellow plate of timing chain and crankshaft timing mark S as shown in figure 4 Bring blue plate of timing chain into alignment with arrow mark on intake camshaft timing sprocket then install intake cam timing sprocket to int...

Page 162: ...heck to make sure that plunger will not come out 5 Install timing chain guide No 2 1 6 Insert spacer into chain tensioner Install chain tensioner 2 as shown in figure Apply oil to chain tensioner 7 Install timing chain guide No 1 3 9 Install timing chain tensioner adjuster 4 Apply engine oil to timing chain 1 1 Plunger 2 Latch 3 Body 4 Stopper 2 4 3 1 2 ...

Page 163: ...mal running direction 2 revolutions and check that match marks are aligned as shown in figure 13 Install oil pump case See page 6 12 14 Install under oil seal housing See page 6 14 1 2 1 Match mark slit on camshaft sprocket 2 Match mark rib on cylinder head 3 Match mark on crank shaft 4 Match mark on crankcase 4 3 ...

Page 164: ... head bolts in the order indicated in figure and remove them 4 Remove cylinder head assembly and head gasket NOTE Use a special tool 10mm deep socket wrench when loosen ing the cylinder head bolts 09919 16010 Deep socket wrench 10 mm 1 Remove the bolts securing the camshaft housing to cylin der head then remove each camshaft housing NOTE For ease of assembly note position of each individual camsha...

Page 165: ... tighten the cylinder head bolt 09919 16010 Deep socket wrench 10 mm z 2 Position cylinder head on cylinder 3 Apply engine oil to cylinder head bolts and tighten them gradually as follows a Tighten all bolts to 30 N m 3 0 kg m 21 5 lb ft ac cording to numerical order in figure b Loosen all bolts to 0 N m 0 kg m 0 lb ft according to reverse order in figure c Again tighten all bolts to 30 N m 3 0 kg...

Page 166: ...to housing bolts 10 Lightly seat all housing bolts at first Following numerical order in figure tighten bolts to 1 3 of specified torque then 2 3 of specified torque and finally to full specified torque Camshaft housing bolt 10 N m 1 0 kg m 7 2 lb ft 11 Install timing chain see page 6 18 12 Adjust tappet clearance see page 2 8 I Intake side E Exhaust side Position from flywheel magneto side Pointi...

Page 167: ... while compressing valve spring 09916 14510 Valve lifter 09916 14910 Attachment 09916 84511 Tweezers 3 Remove valve spring retainer 2 valve spring 3 and valve 4 4 Remove valve stem seal 5 and valve spring seat 6 NOTE Reassemble each valve and valve spring in their original posi tions z z z z z 1 1 2 3 5 6 4 1 5 6 z ...

Page 168: ...lace cylinder head Cylinder head distortion Using a straightedge and thickness gauge measure cylinder head distortion gasket surface at a total of six 6 locations as shown 09900 20803 Thickness gauge Cylinder head distortion Service limit 0 05 mm 0 002 in If measurement exceeds service limit resurface or replace cyl inder head NOTE Cylinder head can be resurfaced using a surface plate and 400 grit...

Page 169: ...ed or obstructed clean water jack ets CAMSHAFT Cam face Inspect cam face for scratches and wear Cam wear Using micrometer measure cam height H 09900 20202 Micrometer Cam height Standard DF40 IN 37 530 37 690 mm 1 4776 1 4839 in EX 37 740 37 900 mm 1 4858 1 4921 in DF50 IN 38 230 38 390 mm 1 5051 1 5114 in EX 37 740 37 900 mm 1 4858 1 4921 in Service limit DF40 IN 37 430 mm 1 4736 in EX 37 640 mm 1...

Page 170: ...mshaft or cylinder head with housing NOTE Camshaft housing and cylinder head must be replaced as a set Model Identification Groove No groove DF50 Groove DF40 Camshaft runout Position camshaft between two V blocks and measure runout using a dial gauge 09900 20606 Dial gauge 09900 21304 V block set 09900 20701 Magnetic stand Camshaft runout Service limit 0 10 mm 0 004 in If measurement exceeds servi...

Page 171: ...NOTE Do not rotate camshaft while Plastigauge is installed 5 Remove camshaft housing 6 Using scale on Plastigauge envelope measure Plastigauge at its widest point Camshaft journal oil clearance Standard 0 045 0 087 mm 0 0018 0 0034 in Service limit 0 12 mm 0 0047 in 1 Plastigauge 2 Scale 1 2 z Camshaft journal outside diameter Standard 22 934 22 955 mm 0 9029 0 9037 in Service limit 22 784 mm 0 89...

Page 172: ...found replace component Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance 09900 20202 Micrometer If measurement exceeds service limit replace tappet or cylin der head Cylinder head bore to tappet clearance Standard 0 025 0 062 mm 0 0010 0 0024 in Service limit 0 150 mm 0 0059 in Tappet outer diameter Standard 26 959 26 975 mm 1 0614 1 0620 in Cyl...

Page 173: ...tem clearance Valve guide to valve stem clearance Standard IN 0 020 0 047 mm 0 0008 0 0019 in EX 0 045 0 072 mm 0 0018 0 0028 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 NOTE For valve guide replacement see VALVE GUIDE REPLACE MENT section on page 6 35 z VALVE VALVE GUIDE Valve guide to valve stem clearance Usin...

Page 174: ...deflec tion Valve stem end deflection Service limit IN 0 14 mm 0 0055 in EX 0 18 mm 0 0071 in If measurement exceeds service limit replace valve If measurement still exceeds service limit with new valve re place valve guide z X Y 1 Valve stem end length Inspect valve stem end face for pitting and wear If pitting or wear is found valve stem end may be resurfaced Use caution when resurfacing do not ...

Page 175: ...e head radial runout 09900 20606 Dial gauge 09900 20701 Magnetic stand 09900 21304 V block set Valve head radial runout service limit 0 08 mm 0 0031 in If measurement exceeds service limit replace valve Valve head thickness Measure thickness T of valve head 09900 20101 Vernier calipers Valve head thickness Standard IN 1 0 mm 0 0394 in EX 1 15 mm 0 0453 in Service limit IN 0 7 mm 0 0276 in EX 0 5 m...

Page 176: ...10910 Valve lapper 5 Rotate valve while gently tapping valve contact area against seat 6 Continuously pattern on valve seating face with Prussian blue 7 Measure valve seat contact width A 09900 20101 Vernier calipers Valve seat contact width A Standard IN 1 80 2 20 mm 0 0709 0 0866 in EX 1 65 2 05 mm 0 0650 0 0984 in If measurement exceeds specification repair valve seat NOTE For valve seat repair...

Page 177: ...valve and valve seat 2 Using 45 angle cutter reface valve seat 3 Check valve seat contact width A See the Valve seat contact width section on page 6 33 4 If width A is too high or wide reface valve seat using small angle cutter Intake side 30 Exhaust side 15 If width A is too low or narrow reface valve seat using 45 angle cutter 5 Clean up any burrs using 45 angle cutter very lightly B Grind seat ...

Page 178: ...valve guide out from com bustion chamber side towards valve spring side 09916 44310 Valve guide remover NOTE Do not reuse valve guide once it has been removed Always use a new valve guide oversize when assembling 2 Ream valve guide hole with f10 5 mm reamer to true hole and remove burrs 09916 37320 Valve guide reamer f f f f f10 5mm 09916 34542 Reamer handle NOTE Turn reamer clockwise never counte...

Page 179: ...m 09916 34542 Reamer handle NOTE Clean and oil valve guide bore after reaming z z z z A B H 3 Install valve guide to cylinder head Heat cylinder head to a temperature of 80 100 C 176 212 F Apply heat uniformly so that head will not be distorted Use special tools to drive new valve guide into hole Drive in new valve guide until special tool valve guide installer attachment contacts cylinder head Af...

Page 180: ...pring free length Check spring strength by measuring free length 09900 20101 Vernier calipers Valve spring free length Standard IN EX 33 13 mm 1 3043 in Service limit IN EX 31 80 mm 1 2520 in If lower than service limit replace valve spring Valve spring preload Measure valve spring preload 09900 20101 Vernier calipers Valve spring preload Standard IN EX 95 111 N 9 7 11 3 kg 21 4 24 9 lbs for 28 5 ...

Page 181: ...k to be sure that seal is properly fixed to valve guide 09917 87010 Installer attachment A 09916 57330 Installer handle B B Do not reuse stem seal once removed Always install new seal Apply engine oil to stem seal valve guide bore and valve stem Install valve 3 to valve guide NOTE Reassemble each valve and valve spring to their original posi tion z z A B 2 o z Install valve spring 4 and valve reta...

Page 182: ...Hold valve spring compressed with special tool and install valve cotters 6 Make sure valve cotters are properly seated in groove A 09916 14510 Valve lifter 09916 14910 Attachment 09916 84511 Tweezers z z z z z A 6 6 z ...

Page 183: ...9915 47340 Oil filter wrench Remove oil pressure switch CYLINDER CRANKSHAFT PISTON DISASSEMBLY Before performing service work in this section Remove power unit see page 6 3 to 6 6 Remove timing chain see page 6 15 to 6 16 Remove cylinder head see page 6 21 z Remove eight 8 bolts 1 Remove eight 8 bolts 2 Remove crankcase from cylinder block ...

Page 184: ...rank pin and cylinder walls install a piece of hose over threads of rod bolts Remove crankshaft Mark cylinder number on pistons using quick dry paint Push piston with conrod out through the top of cylinder bore NOTE To prevent damage to piston rings decarbon top of cylinder bore wall before removing piston Reassemble each conrod cap to its original position after removing piston from bore Guide ho...

Page 185: ...and oil ring from piston Mark cylinder number on conrod using quick dry paint Remove piston pin circlips as shown 1 1 Piston pin circlip Remove piston pin from conrod NOTE Reassemble each piston piston pin and conrod in their original combination and position ...

Page 186: ...ion Service limit 0 06 mm 0 0024 in If measurement exceeds service limit resurface or replace cylinder NOTE Cylinder can be resurfaced using a surface plate and 400 grit wet sand paper Use a figure eight sanding pattern when resurfacing Water jackets Check water jackets If clog or obstruction is found clean water jacket Cylinder bore Inspect cylinder walls for scratches roughness or ridges which i...

Page 187: ...Standard 71 000 71 020 mm 2 7953 2 7961 in z 19 mm z z 50 mm z z z 1 50 mm 1 96 in 2 90 mm 3 54 in 1 2 Cylinder bore wear difference Using cylinder gauge measure cylinder bore in both axial vertical line following crankshaft and transverse horizontal line across crankshaft directions at two positions as shown in figure 09900 20508 Cylinder gauge set Check for following Difference between measureme...

Page 188: ... 100 mm 0 0039 in If clearance exceeds service limit replace piston and or cylinder or rebore cylinder Piston Oversize I D mark 0 25 mm 0 25 0 50 mm 0 50 1st 2nd Piston ring Oversize I D mark 1st ring 2nd ring N25 2N25 0 25 mm N50 2N50 0 50 mm Oil ring Oversize I D mark 0 25 mm White paint 0 50 mm Blue paint I D mark 0 25 or 0 50 I D mark 1st 2nd ring I D mark Oil ring spacer Identification of ove...

Page 189: ...09900 20803 Thickness gauge Piston ring to groove clearance Standard 1 st 0 020 0 060 mm 0 0008 0 0024 in 2 nd 0 020 0 060 mm 0 0008 0 0024 in Service limit 1 st 0 10 mm 0 0039 in 2 nd 0 10 mm 0 0039 in If measurement exceeds service limit replace piston and or piston ring Piston ring groove width Standard 1 st 1 01 1 03 mm 0 0398 0 0406 in 2 nd 1 01 1 03 mm 0 0398 0 0406 in Oil 1 51 1 53 mm 0 059...

Page 190: ...in Service limit 1 st 0 70 mm 0 0276 in 2 nd 1 00 mm 0 0394 in If measurement exceeds service limit replace piston ring Piston ring free end gap Measure piston ring free end gap using vernier calipers 09900 20101 Vernier calipers Piston ring free end gap Standard 1 st Approx 7 5 mm 0 2953 in 2 nd Approx 11 mm 0 4330 in Service limit 1 st 6 mm 0 2362 in 2 nd 8 8 mm 0 3465 in If measurement exceeds ...

Page 191: ... 20205 Micrometer 09900 20605 Dial calipers Piston pin outside diameter Standard 17 996 18 000 mm 0 7085 0 7087 in Service limit 17 980 mm 0 7079 in Piston pin hole diameter Standard 18 006 18 014 mm 0 7089 0 7092 in Service limit 18 040 mm 0 7102 in Conrod small end bore Standard 18 003 18 011 mm 0 7088 0 7091 in Pin clearance in piston pin hole Standard 0 006 0 018 mm 0 0002 0 0007 in Service li...

Page 192: ...r crankshaft Conrod big end width Standard 21 950 22 000 mm 0 8642 0 8661 in Crank pin width Standard 22 100 22 200 mm 0 8700 0 8740 in CRANK PIN Inspect crank pin for uneven wear or damage Measure crank pin for out of round or taper with micrometer If crank pin is damaged out of round or taper is out of ser vice limit replace crankshaft 09900 20202 Micrometer Out of round A B Taper a b Out of rou...

Page 193: ...to conrod and conrod cap NOTE Reassemble each bearing and conrod cap to their original position Do not apply oil to bearing 3 Place a piece of Plastigauge on crank pin parallel to crank shaft Avoiding placing Plastigauge over oil hole 09900 22301 Plastigauge 4 Install conrod cap with bearing to conrod with the arrow mark on cap toward flywheel side z 5 Apply engine oil to conrod bolts and tighten ...

Page 194: ... 20606 Dial gauge 09900 20701 Magnetic stand Crankshaft runout Service limit 0 04 mm 0 0016 in If measurement exceeds service limit replace crankshaft Crankshaft thrust play Measure thrust play with crankshaft thrust bearing journal bearing and crankcase cylinder block assembled in a normal manner Tighten crankcase bolts to specified torque Crankcase bolt 8 mm 25 N m 2 5 kg m 18 1 Ib ft 10 mm 53 N...

Page 195: ...ws up as a differ ence in diameter at a cross section or along its length or both This difference if any is determined by taking micrometer readings If any journal is badly damaged or if measurements exceed service limit replace crankshaft 09900 20202 Micrometer Out of round A B Taper a b Out of round and taper Service limit 0 01 mm 0 0004 in Crankshaft journal outside diameter Standard 44 982 45 ...

Page 196: ...rank case Do not apply engine oil to bearing Install the bearing half with oil hole groove to cylinder side 3 Install crankshaft to cylinder 4 Place a piece of Plastigauge across full width of bearing parallel to crankshaft on journal Do not place Plastigauge over oil hole 09900 22301 Plastigauge NOTE Do not rotate crankshaft while Plastigauge is installed Plastigauge CRANKSHAFT MAIN BEARING Check...

Page 197: ...orqued to specification in order to assure proper compression of Plastigauge and accurate reading of clearance 7 Remove crankcase from cylinder 8 Using scale on Plastigauge envelope measure Plastigauge width at its widest point Crankshaft journal oil clearance Standard 0 020 0 040 mm 0 0008 0 0016 in Service limit 0 065 mm 0 0026 in If measurement exceeds service limit replace crankshaft main bear...

Page 198: ...the STBD side of cylinder block has four 4 stamped codes letters The letters A B C represent the bearing holder inside diameters shown below Numeral stamped Journal diameter 1 44 994 45 000 mm 1 7714 1 7717 in 2 44 988 44 994 mm 1 7712 1 7714 in 3 44 982 44 988 mm 1 7709 1 7712 in Code Crank bearing holder inside diameter w o bearing A 49 000 49 006 mm 1 9291 1 9294 in B 49 006 49 012 mm 1 9294 1 ...

Page 199: ...0 in No Color mark 2 005 2 009 mm 0 0789 0 0790 in 4 Select crankshaft main bearing referring the below table Yellow 2 008 2 012 mm 0 0790 0 0792 in Blue 2 011 2 015 mm 0 0792 0 0793 in Numeral stamped on crank web journal outside diameter 1 2 3 A Code stamped on cylinder block Bearing holder inside diameter Green Black No Color B Black No Color Yellow C No Color Yellow Blue Color mark NOTE Measur...

Page 200: ... and position PISTON TO CONROD Apply engine oil to piston pin 2 piston pin bore and conrod 3 Fit conrod 3 to piston 1 as shown in figure and insert piston pin 2 through piston and conrod Install piston pin circlips 4 NOTE Make sure conrod is installed in the direction shown Circlip should be installed with gap facing either up or down as shown in figure Always use new piston pin circlip Up mark O ...

Page 201: ...e towards top of piston Ring gap direction Position rings so that their gaps are staggered at approxi mately 90 degree angles as shown 1 1st ring 3 2nd ring 2 Oil ring lower side rail 4 Oil ring upper side rail B Failure to stagger piston ring gaps may result in crank case oil dilution 1 1st ring 2 2nd ring 3 Oil ring Mark N 2N 1st ring 2nd ring Up mark O 1 2 3 4 2 1 2 Incorrect Correct PISTON RIN...

Page 202: ...osi tion Do not apply oil between conrod and bearing or be tween bearing cap and bearing Apply engine oil to piston and cylinder walls Insert piston and conrod assembly into cylinder bore from cyl inder head side using special tool 09916 77310 Piston ring compressor NOTE Position the circle mark on piston head to flywheel side z z ...

Page 203: ...ut oil groove to crankcase Do not apply oil between crank bearing holder and crank main bearing NOTE Align bearing tab a with notch in cylinder and crankcase Thrust bearing Apply engine oil to thrust bearing and install in cylinder block between the No 2 and No 3 cylinders Oil groove sides of thrust bearing must face towards crank webs Crankshaft Apply engine oil to crank pin and crankshaft main j...

Page 204: ... Apply engine oil to crank pin and conrod bearing Install conrod cap with bearing to conrod with arrow mark on cap toward flywheel side B Reassemble each conrod cap to its original position Apply engine oil to conrod bolts Tighten conrod cap nuts in two steps Conrod cap nut 1st step 18 N m 1 8 kg m 13 0 lb ft 2nd step 35 N m 3 5 kg m 25 3 lb ft 99000 31030 Suzuki Bond No 1104 a a a Apply Bond to m...

Page 205: ...moothly when turned by hand Crankcase bolt 1st step 8 mm 5 N m 0 5 kg m 3 6 lb ft 10 mm 11 N m 1 1 kg m 8 0 lb ft 2nd step 8 mm 20 N m 2 0 kg m 14 5 lb ft 10 mm 42 N m 4 3 kg m 31 0 lb ft Final step 8 mm 25 N m 2 5 kg m 18 1 lb ft 10 mm 53 N m 5 3 kg m 38 3 lb ft UPPER OIL SEAL HOUSING Apply engine oil to lip area of upper oil seal Install upper oil seal housing and secure with bolts Tightening or...

Page 206: ...LINDER HEAD Install cylinder head see page 6 21 to 6 23 TIMING CHAIN Install timing chain see page 6 18 to 6 20 OIL PUMP CASE Install oil pump case see page 6 12 to 6 14 POWER UNIT Install power unit see page 6 7 to 6 9 ...

Page 207: ...gth 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 48 52 C 126 134 F Thermometer Heater INSTALLATION Installation is reverse order of removal with special attention to the following steps A...

Page 208: ...he components of the cooling system must be inspected for blockage corrosion build up or component damage Component inspection Refer to page Water pump Impeller 9 9 Water tube 7 5 Thermostat 6 64 Water pressure valve 7 5 Cylinder head 6 26 Cylinder block 6 43 ENGINE HOLDER OIL PUMP CASE CYLINDER THERMOSTAT OIL PAN OIL PAN WATER TUBE ENGINE HOLDER PROPELLER EXHAUST OUTLET DRIVESHAFT HOUSING CYLINDE...

Page 209: ...RNAL EX No 3 CAMSHAFT JOURNAL EX No 1 CAM FACE No 3 CAM FACE No 2 CAM FACE No 3 CAM FACE No 1 CAM FACE No 2 CAM FACE ENGINE LUBRICATION SYSTEM A crankshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication Oil from the oil pan is drawn through the oil strainer and passed through a spin on type oil filter before entering the main oil gallery A pressure...

Page 210: ...LT UNIT ________________________________ 8 3 REMOVAL 8 3 DISASSEMBLY 8 4 CLEANING AND INSPECTING 8 6 REASSEMBLY 8 8 PTT MOTOR 8 10 INSTALLATION 8 14 PTT MOTOR RELAY________________________________________ 8 16 PTT SWITCH _____________________________________________ 8 17 OPERATION ______________________________________________ 8 18 COMPONENTS 8 18 PRINCIPLES OF OPERATION 8 19 CONTENTS 8 ...

Page 211: ...T SYSTEM WIRING DIAGRAM PTT switch UP DN Lbl P W tube Gr Gr To ignition switch Remote control box P Lbl P P PTT relay DOWN W G W Bl PTT relay UP B PTT motor Starting motor relay Battery Y G Lbl Lbl P Lbl W R UP DN PTT switch ...

Page 212: ... unit is full 5 If oil level is low refill with the recommended oil Recommended oil Dexron automatic transmission fluid or equivalent B To ensure consistent pump operation do not mix dif ferent types of oil 6 Reinstall oil filler plug AIR BLEEDING 1 Open manual release valve before performing air bleeding 2 Manually raise and lower engine full up to full down 5 6 times 3 Check oil level topping of...

Page 213: ...r upper shaft pin 3 out Lower tilt rod to full down position and disconnect the battery cable Disconnect the PTT motor cable wire leads G Bl from the PTT relays Remove the PTT motor cable from engine lower cover Remove the two STBD motor mounting bolts 4 Loosen the clamp bracket shaft nut 5 NOTE Complete removal of the clamp bracket shaft nut is not required Nut should be loosened as far as the en...

Page 214: ...and or dirt and dry the PTT body with compressed air Connect the PTT motor cable leads G Bl to battery and oper ate PTT motor until tilt piston rod is at maximum stroke full tilt up position Place the lower mounting eye of the PTT cylinder in a vise Tighten the vise only enough to secure the PTT unit do not over tighten NOTE To prevent damage to the PTT cylinder use wood blocks vise jaw protectors...

Page 215: ...dy 2 Remove the PTT motor Note the position of drive joint 3 and O ring 4 before remov ing them see page 8 10 Unscrew the fill plug and drain PTT oil into suitable container Remove the manual release valve snap ring 5 then unscrew the manual release valve 6 Remove the seal washer 7 Remove the main check valve 8 and spool valve 9 ...

Page 216: ... off the rod end CLEANING AND INSPECTING Thoroughly wash all metal components with cleaning solvent and dry them with compressed air Arrange all components on a clean sheet of paper NOTE Do not lay PTT components out on a rag as dirt or lint may be transferred to these items which may cause possible system operating problems Inspect tilt rod replace if damaged or bent Inspect the surface of tilt r...

Page 217: ... disassembled Inspect the shock valves spring rod and ball Replace if there are any signs of rust or pitting Inspect the cylinder bore for evidence of a rough or grooved surface Light honing may rectify slight surface roughness or scarring but a deeply scarred surface will require replacement of the tilt cylinder Inspect all O ring manual release valve and main check valve Replace if nicked or cut...

Page 218: ... 1 and main check valve 2 Tighten the main check valve 2 to specified torque Main check valve plug 20 N m 2 0 kg m 14 5 lb ft MANUAL RELEASE VALVE Oil and install the seal washer 1 and manual release valve 2 Tighten the valve to specified torque Install snap ring 3 Manual release valve 1 7 N m 0 17 kg m 1 2 lb ft TILT ROD When tightening the piston retaining nut on the tilt rod piston apply Thread...

Page 219: ...l it is topped off Insert the tilt rod piston into cylinder and thread the tilt cylin der head by hand until fully seated Tighten the cylinder head to specified torque using special tool Tilt cylinder head 44 N m 4 5 kg m 32 5 lb ft 09944 08711 PTT cylinder cap tool PTT MOTOR See the PTT Motor Installation section on page 8 13 AIR BLEEDING See the AIR BLEEDING section on page 8 2 z Cylinder Free p...

Page 220: ...ly scribe an alignment mark on the field case and brush holder Remove the three 3 screws securing the field case to the brush holder Using a soft face hammer gently tap the field case from side to side to unseat it from the brush holder Slide the field case upward and away from the brush holder Note the position of the O ring encircling the brush holder Slide the armature free of the brushes 1 Scr...

Page 221: ...0 grade emery paper Measure commutator outside diameter 09900 20101 Vernier calipers Commutator outside diameter Standard 22 mm 0 87 in Service limit 21 mm 0 83 in If measurement exceeds service limit replace armature Ensure that the mica insulator between the segments is un dercut to specified depth Commutator undercut Standard 0 5 0 8 mm 0 02 0 03 in Service limit 0 2 mm 0 008 in If undercut is ...

Page 222: ... 8 mm 0 19 in If brushes are worn down to the service limit they must be re placed O ring Inspect the O ring between the PTT motor and pump reser voir Replace if cuts nicks or tears are found z Assembly Assembly is reverse of disassembly with special attention to following steps When installing the armature exercise care not to break the brushes ...

Page 223: ...voir Check the level of PTT fluid contained in the pump reser voir If level is low add recommended PTT fluid until level with mating surface of PTT motor Ensure that the faces of the PTT motor and pump unit are free of dirt or debris When attaching the PTT motor to the pump reservoir en sure that the tip of armature shaft fits firmly into the drive joint Tighten the four 4 screws to specified torq...

Page 224: ...Grease Place the PTT unit in position between the clamp brackets Tighten the clamp bracket shaft nut to specified torque Clamp bracket shaft nut 43 N m 4 3 kg m 31 0 lb ft Slide the PTT cylinder lower shaft bolt through the clamp bracket and lower shaft then secure with the nut Apply Water Resistant Grease to tilt rod upper bushes 3 then install bushs in tilt rod Operate the PTT motor to extend th...

Page 225: ...the shaft through the swivel bracket and tilt rod 99000 25160 Water Resistant Grease Secure the upper shaft with the snap ring 5 Route the PTT motor cable in through the lower cover and con nect the terminals to the PTT relays Cable routing see the WIRE HOSE ROUTING section on page 10 2 to 10 6 l ...

Page 226: ...it is considered to be without defect With Black lead wire connected to the battery negative ter minal and Light blue or Pink lead wires are connected to bat tery positive terminal there should be continuity between 2 3 4 With the lead wires disconnected from the battery there should be no continuity between 3 4 The relay is considered to be without defect if continuity test results are as stated ...

Page 227: ...tch positions 09930 99320 Digital tester Tester range Continuity z r Tester probe connection Tester indicates Red Black DN side depressed Pink Gray White Red Continuity UP side depressed Light Blue Continuity not depressed Pink Infinity Gray White Red Gray White Red Light Blue LBI Gr P P W R Lbl ...

Page 228: ...red to the electric motor via the relevant relay The relay with the Blue wire connected to the PTT pump is for trim tilt up while the relay with the Green wire is for trim tilt down COMPONENTS Oil reservoir Tilt rod PTT cylinder Piston Free piston Gear pump Check valveB PTT motor Check valveA DOWN relief valve Spool valve DOWN pressure main check valve Manual release valve UP relief valve UP press...

Page 229: ...p by the pump will then open the up pressure main check valve and oil will enter the lower cylinder chamber When trim motor stops both the DOWN pressure main check valve and the up pressure main check valve will close to retain tilt trim position When full trim tilt up position is attained sustained operation of the up relay will have no effect as pump oil flow will be returned to the reservoir th...

Page 230: ... pump will open the down pressure main check valve and oil will enter the upper cylinder chamber The piston will retract move inward which will tilt the outboard down Oil in the lower cylinder chamber is returned to the pump through the up pressure main check valve When full down position is reached continued operation of the down relay will have no effect as pump oil flow will be returned to the ...

Page 231: ...ng oil to flow into the area between the tilt ram piston and the free piston thereby dampening absorbing the impact Return valve When the point of impact has passed propeller thrust and motor weight will force the tilt ram piston back downwards The oil from between the ram piston and the free piston is then expelled through the return valve before flowing into the upper cylinder chamber Shock valv...

Page 232: ...loosened oil will flow unimpeded without resistance through the internal pump tubes thereby facilitating manual tilting or lowering of the outboard To hold the engine in a selected position the manual valve must be closed again Upper cylinder chamber Tilt rod Piston Lower cylinder chamber UP pressure main check valve Manual release valve Tilt up Tilt down ...

Page 233: ...m Should the propeller strike an underwater object whilst in reverse gear a build up of pressure will be induced in the lower cylinder chamber whereby the outboard mounting bracket and or the boat transom may sustain damage To prevent this the thermal valve will open to relieve the oil pressure thereby softening the impact Internal PTT circuits are protected as the thermal valve will open to reduc...

Page 234: ...9 7 PROPELLER 9 7 GEARCASE 9 7 GEAR 9 8 PROPELLER SHAFT COMPONENTS 9 8 PROPELLER SHAFT BEARING HOUSING 9 8 SHIFT ROD AND SHIFT CAM 9 9 WATER PUMP AND RELATED ITEMS 9 9 DRIVESHAFT BEARING HOUSING 9 10 DRIVESHAFT 9 11 ASSEMBLY INSTALLATION _______________________________ 9 12 TRIM TAB ________________________________________________ 9 22 LOWER UNIT GEARS SHIMMING AND ADJUSTMENT ___________ 9 23 9 ...

Page 235: ...eshaft housing Place a drain pan under the oil drain plug Remove oil drain plug first 6 then oil level plug 5 and allow gear oil to drain Remove cotter pin 7 from propeller nut and remove propeller nut 8 Remove washer 9 spacer 0 propeller A and stopper B from the propeller shaft 7 8 9 0 A B A To prevent injury from propeller blades wear gloves and place a block of wood between the anti cavitation ...

Page 236: ...lts 1 securing the propeller shaft bear ing housing to the gearcase Using special tools draw out the propeller shaft bearing hous ing Remove the propeller shaft and bearing housing assembly 09930 30102 A Sliding hammer 09930 30161 B Propeller shaft remover Hold the pinion nut securely then fit special tool to the driveshaft and loosen the pinion nut 09921 29510 Driveshaft holder z z A B z z ...

Page 237: ...e the forward gear 2 with thrust washer 5 back up shim 4 and bearing 3 Lift out driveshaft 1 driveshaft bearing housing 2 and shift rod assembly 3 Account for the seal 4 on the driveshaft bearing housing Remove the detent ball 1 spring 2 and plate 3 Remove driveshaft 2 from driveshaft bearing housing 1 and take off shim 3 thrust washer 4 and thrust bearing 5 Pull out the spring pin 6 then remove t...

Page 238: ...and reverse gear thrust washer 4 To disassemble propeller shaft components refer to the follow ing a Pull the push rod 6 out of the propeller shaft b Remove the spring 7 from the clutch dog shifter Slide the shift rod out of the shift rod guide Separate the shift cam 2 from the shift rod 3 by driving out the spring pin 1 Remove the lower shift rod guide 5 by driving out the spring pin 4 Remove the...

Page 239: ...val Installation Tools 09951 59910 Shaft removal installation 1 09951 39914 plate 2 01107 08408 Bolt 3 09951 19430 Attachment 4 09930 30102 Sliding hammer 5 REMOVAL 1 Remove the water pump stud bolts a 1 2 3 4 5 c Use special tool to push the dog pin 8 out of the clutch dog shifter 09922 89810 Shift pin remover z 8 z z a ...

Page 240: ...of the installer shaft 11 Drive the bearing down into position by gently striking the installer shaft until the coupler touches the plate 2 4 5 1 3 198 mm 7 79 in Pinion bearing 5 1 4 Pinion bearing Wood block 2 Place the attachment 4 inside the pinion bearing 3 Insert the removal shaft 1 into attachment 4 Thread sliding hammer 5 into top of removal shaft 5 Put wood block under pinion bearing 6 Dr...

Page 241: ...pect the propeller for bent chipped or broken blades Replace or repair propeller if in damaged condition Inspect propeller bush splines Replace or repair propeller if splines are worn or damaged Inspect propeller bush for deterioration or slipping Replace if necessary GEARCASE Inspect the gearcase Replace if cracked or damaged Visually check the pinion bearing Replace if pitted noisy or rough NOTE...

Page 242: ...r worn Inspect propeller shaft splines Replace if worn twisted or damaged PROPELLER SHAFT BEARING HOUSING Inspect housing Replace if cracked or damaged Inspect reverse gear bearing Replace bearing if pitted noisy or rough Inspect bearing Replace bearing if pitted noisy or rough Check condition of oil seal and O ring Replace the seals if nicked cut or worn L Check clutch return spring by measuring ...

Page 243: ...pitted stiff or corroded Inspect O ring Replace if nicked cut or torn Inspect shift rod boot Replace if cracked or damaged 3 Using an oil seal installer drive the two oil seals one at a time into the propeller shaft bearing housing The lipped portion of the seal must face towards the pro peller Apply Water Resistant Grease to the seal lips WATER PUMP AND RELATED ITEMS Inspect impeller Replace if v...

Page 244: ...Bearing remover 2 With the oil seal remover draw the two oil seals out of the driveshaft bearing housing 09913 50121 Oil seal remover 3 Apply Water Resistant Grease to the inner circumference of the driveshaft bearing housing 99000 25160 Water Resistant Grease 4 Grease the inner lips of the seal With the lips facing away from driveshaft bearing place seal in position and drive it into the bearing ...

Page 245: ...9 11 LOWER UNIT DRIVESHAFT Inspect driveshaft splines Replace if worn twisted or dam aged Inspect driveshaft bearing replace if pitted noisy or rough ...

Page 246: ...t rod guide 3 O ring 4 O ring 5 Circlip 6 Shift rod 7 Pin 8 Magnet set 9 Pin 0 Shift rod lower guide A Pin B Shift cam C Ball D Spring E Notch plate F Nut G Turnbuckle H Grommet I Water pump case J Nut K Lock washer L Water pump impeller M Key N Pump case under panel O Gasket P Stud bolt Q Driveshaft bearing housing R Stud bolt S Oil seal T Bearing U Seal ring V Pin W Pin X Gear case Y Screw Z Wat...

Page 247: ...g n Gasket o Pinion bearing p F gear bearing q Shim r Forward gear s Thrust washer t Push rod u Push pin v Clutch dog shifter w Dog pin x Dog spring y Return spring z Propeller shaft Thrust washer Reverse gear Shim O ring Bearing Propeller shaft bearing housing Bearing Oil seal Bolt Stopper Propeller Propeller Bush Spacer Washer Nut Pin j 17 N m 1 7 kg m 12 3 lb ft b Shim c Washer d Bearing e Driv...

Page 248: ...t damage See the GEARS SHIMMING AND ADJUSTMENT section on page 9 23 SHIFT CAM AND SHIFT ROD Apply Water Resistant Grease to the shift rod guide O ring 2 3 and the inside of the dust boot 4 Slide complete dust boot 4 and shift rod guide 1 into the drive shaft bearing housing then secure it with the snap ring 5 Attach lower shift rod guide 7 to shift rod 6 then secure it with the pin 8 Attach shift ...

Page 249: ... in posi tion then install forward gear 1 99000 22540 Suzuki Outboard Motor Gear Oil DRIVESHAFT THRUST WASHERS Install the two driveshaft thrust washers 1 2 The lower washer with the tab is located as shown DRIVESHAFT SPRING COLLAR Install the collar 3 on top of the two thrust washers PINION GEAR Place pinion gear in gearcase j 1 3 2 Shift cam 2 3 1 j ...

Page 250: ...se to the driveshaft oil seal 99000 25160 Water Resistant Grease Install the gearcase seal ring 1 into the groove on the driveshaft bearing housing Apply Suzuki Silicone Seal to gearcase and driveshaft bearing housing surfaces 99000 31120 Suzuki Silicone Seal Install complete housing and shift rod assembly on gearcase NOTE Be sure the stepped section A of shift cam faces towards pro peller shaft A...

Page 251: ...ECK ING DRIVESHAFT THRUST PLAY section on page 9 26 09951 09510 Gear adjusting gauge PROPELLER SHAFT Slide the clutch dog shifter 2 onto the propeller shaft 1 NOTE For correct installation the side of the clutch dog shifter which must face towards forward gear is marked with the letter F Insert the return spring 3 push pin 4 and push rod 5 into propeller shaft Align the holes in the shifter dog an...

Page 252: ...tools install the propeller shaft and housing as sembly in the gear case 09922 59410 Propeller shaft housing installer 09922 59420 Housing Installer Handle When the housing is fully seated tighten both retaining bolts to the specified torque Bearing housing bolt 17 N m 1 7 kg m 12 3 lb ft RECHECKING DRIVESHAFT THRUST PLAY Recheck the driveshaft thrust play This should not be less than previously c...

Page 253: ...s and nuts placed through the two diagonally opposite gearcase mounting holes Apply the specified pressure through the oil level hole and ro tate the drive and propeller shafts If pressure does not fall sealing performance is correct 09950 69511 Oil leakage tester 09821 00004 Air pump Leakage test pressure 100 kPa 1 0 kg cm2 14 2 psi NOTE Apply low initial pressure of 0 2 0 4 kg cm2 2 8 5 7 psi fi...

Page 254: ...e to flex the impeller vanes in the correct direction Securely tighten the four 4 pump case nuts to the specified torque Pump case nut 8 N m 0 8 kg m 5 8 lb ft PROPELLER INSTALLATION Install propeller stopper 1 onto propeller shaft then slide on the propeller 2 Fit spacer 3 washer 4 and nut 5 then tighten nut to speci fied torque Push cotter pin 6 through nut and shaft then bend to secure 99000 25...

Page 255: ...roperly with the crankshaft and that water tube locates in the water pump case outlet Apply Suzuki Silicone Seal to the retaining bolts 3 and tighten them to specified torque 99000 25160 Water Resistant Grease 99000 31120 Suzuki Silicone Seal Gearcase bolt 23 N m 2 3 kg m 16 6 lb ft NOTE Apply Suzuki Silicone Seal to the six 6 gearcase bolts GEAR OIL Fill the gearcase with specified gear oil See t...

Page 256: ...e with the same amount of clutch lever travel If Reverse gear engages earlier than Forward the turn buckle should be rotated counterclockwise TRIM TAB Adjusting The trim tab counteracts or minimizes propeller torque pull felt through the steering system To compensate for a veer to starboard set trailing edge of tab to the right as viewed from behind To compensate for a veer to port set trailing ed...

Page 257: ...9 14 to 9 17 NOTE When installing forward gear back up shim choose shim thin ner than design specification for calculating adjustment 2 Tighten pinion nut to specified torque Pinion nut 50 N m 5 0 kg m 36 2 lb ft 3 Temporarily fasten the driveshaft bearing housing to the gearcase with two bolts and nuts Numerical index item Available thickness mm Design specification Thickness mm Pinion gear back ...

Page 258: ...510 Gear adjusting gauge B When adjusting gauge align the gauge rod end to con tact the gear tooth at the convex side heel end Make sure the rod does not contact the adjacent tooth Rod end alignment is as illustrated in the figure 2 Hold the driveshaft by hand then gently rock forward gear back and forth by hand Read the backlash on the dial gauge Gear backlash 0 1 0 2 mm 0 004 0 008 in If backlas...

Page 259: ...ncorrect topside toe contact Correction measures Decrease thickness of forward gear shim Slightly increase pinion gear shim thickness B Do not set tooth contact in this position top side toe contact Damage and chipping of forward and pinion gear may result Example 2 Incorrect bottom side toe contact Correction measures Increase thickness of forward gear shim Slightly decrease pinion gear shim thic...

Page 260: ... forward gear tooth contact pattern correctly assemble propeller shaft housing assembly reverse gear and related components see page 9 17 to 9 18 2 Screw sliding hammer assembly onto propeller shaft and strike a few gentle outward taps 09930 30161 Propeller shaft remover B B B B B 09930 30102 Sliding hammer A A A A A 3 Affix gear adjusting gauge to driveshaft 09951 09510 Gear adjusting gauge 4 Pus...

Page 261: ... thickness 2 0 mm and adjust only the reverse gear thrust washer with shim Measurement step 1 Assemble gear adjusting gauge to the propeller shaft 09951 09510 Gear adjusting gauge 2 Push 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 If measurement is more than specification increase re verse gear t...

Page 262: ...HOSE ROUTING CONTENTS WIRING DIAGRAM _________________________________________ 10 1 WIRE ROUTING ___________________________________________ 10 2 FUEL WATER HOSE ROUTING______________________________ 10 7 10 ...

Page 263: ...10 1 WIRE HOSE ROUTING WIRING DIAGRAM DF40T DF50T ...

Page 264: ...T relay plate PTT motor relay DOWN PTT relay plate Battery cable Starter motor relay Starter motor sub cable Engine main wiring harness Route engine main wiring harness under water hose Rectifier regulator Clamp Fix rectifier regulator lead wire Clamp Fix Ex mani temp sensor lead wire Ex mani temperature sensor ECM ECM main relay CKP sensor connector ...

Page 265: ... lead wire and fuel pump lead wire Fuel injector 2 Fuel injector 3 Engine harness PTT switch lead connector Neutral switch Gas filter 3 N m 0 3 kg m 2 0 Ib ft MAP sensor hose Protector hose clip hose clip MAP sensor Oil pressure switch Clamp Fix neutral switch lead wire Neutral switch lead wire connector ...

Page 266: ...ngine harness CKP sensor MAP sensor Clamp Fix CKP sensor lead wire with clamp as shown Battery charge coil Route CKP sensor lead wire under upper oil seal housing Starter motor CKP sensor Clamp Fix lead wire not to contact with flywheel Electric parts holder cover Electric parts holder Engine harness CKP sensor Cylinder temp sensor lead wire connector Cylinder temp sensor When installing sensor ap...

Page 267: ... cable on fuel hose Wiring harness IAT sensor IAT sensor grommet IAC valve Starter motor sub cable Tighten bolt with PTT relay ground wire battery cable ground wire and harness ground wire Starter motor Bolt Ignition coil 1 Ignition coil 3 Ignition coil 2 Clamp Clamp Clamp Clamp CMP sensor ...

Page 268: ...RE HOSE ROUTING 10 6 PTT switch Fix PTT cable and trim sender lead to clamp bracket PTT motor cable Clamp Trim sender cable Clamp Trim sender Bind the trim sender cable and PTT motor cable PTT attachment ...

Page 269: ...ngine holder to 3 way Water hose Engine holder to vapor separator Pilot water hole Fuel hose Protector fuel connector to fuel filter FUEL WATER HOSE ROUTING B Do not over bend kink or twist hoses when installing When installing hose clips position tabs to avoid contact with other parts Check that hoses do not contact rods and levers during either engine operation or standstill Extreme care should ...

Page 270: ... hose Vapor separator to H fuel filter Fuel hose Protector H filter to 3 way joint High pressure fuel filter Drain hose Clamp Water hose Engine holder to vapor separator Water hose 3 way to vapor separator Fuel hose Protector 3 way joint to vapor separator Low fuel pump Clamp Fuel hose Protector Low fuel pump to vapor separator Fuel hose Protector H fuel filter to 3 way joint High pressure fuel fi...

Page 271: ...h pressure fuel filter Clamp 3 way joint Fuel hose Protector 3 way joint to vapor separator Vapor separator Gas filter IAC hose IAC valve IAC hose IAC valve silencer Throttle body MAP sensor hose MAP sensor Clamp 3 way joint Fuel hose Protector 3 way joint to vapor separator Clamp Water hose Vapor separator to 3 way Water hose Engine holder to vapor separator Clamp High pressure fuel filter Evapor...

Page 272: ... _ _ r ...

Page 273: ...F50TH __ __ 2 SPECIFICATIONS DF50WTIDF50WQH 4 SERVICE DATA 6 TIGHTENING TORQUE 13 OVER REVOLUTION CAUTION SYSTEM ____ 14 SAFETY RELA Y SYSTEM 14 FLYWHEEL MAGNETO AND CRANKSHAFT ____ 14 BATTERY CHARGING SYSTEM __ __ 15 ELECTRIC STARTER SYSTEM 17 ASSEMBLY 31 REMOTE CONTROL BOX REMOTE CONTROL WIRE 34 CYLINDER HEAD 35 UPPER OIL SEAL HOUSING 35 UPPER MOUNT 36 LOWER MOUNT __ 37 CLAMP BRACKET 38 CLAMP BR...

Page 274: ... inch type PERFORMANCE Maximum output kW PS 29 4 40 36 8 50 Recommended Except E01 5200 5800 operating range r min 5900 6500 E01 I 5600 6 200 Idle speed r min 850 50 in gear approx 850 POWERHEAD Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke I mm in 68 6 2 70 Total displacement cm cu in I 815 49 7 Compression ratio 1 10 Spark plug I NGK DCPR6E Ignition system Full tran...

Page 275: ...r Oil SAE 90 hypoid gear oil Gearcase oil amounts ml 610 20 6 21 5 US Imp oz BRACKET Trim angle Manual trim PTT system and gas PTT system assisted tilt system Number of trim position PTT system 5 PTT system Maximum tilt angle I Degrees 73 LOWER UNIT Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio I 11 25 2 273 r Drive line impact protection Spline ...

Page 276: ...0 inch type I UL mm 655 25 I inch type PERFORMANCE Maximum output kW PS 36 8 50 Recommended operating range r min 5900 6500 Idle speed r min I 850 50 in gear approx 850 POWERHEAD IEngine type 4 stroke DOHC Number of cylinders 3 Bore mm in I 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement em cu in 815 49 7 Compression ratio i 1 10 Spark plug NGK I DCPR6E Ignition system Full transistorized igni...

Page 277: ...tor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml 610 20 6 21 5 US Imp oz BRACKET Trim angle PTT system Manual trim and gas assisted tilt system Number of trim position PTT system I 5 iMaximum tilt angle I Degrees 73 LOWER UNIT Ifl everslng system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 273 Drive line impact protection Spline drive rubber ...

Page 278: ...ence between any other kg cm psi 100 1 0 14 cylinders Engine oil pressure kPa 300 380 3 0 3 8 43 54 at 4 000 rlmin kg cm psi at normal operating temp Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Thermostat operating temperature c F 58 62 136 144 gures shown are guidelines only not a...

Page 279: ......

Page 280: ... STD I iLimit I Valve spring tension ISTD I I Limit Valve spring sequareness Limit Unit mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in mm in I mm in mm in mm in mm in mm in i mm in I mm in mm in N kg Ibs I 97 N kg Ibs mm in I Data DF40T 40QH IDF50T 50THl50WT 50WQH 24 6 0 97 21 5 0 85 0 18 0 24 0 007 0 009 0 18 0 24 0 007 0 009 30 45 15 45 0 020 0 04...

Page 281: ...x 7 5 0 30 gap Limit mm in 6 0 0 24 I 2nd STD mm in Approx 11 0 0 43 Limit mm in 8 8 0 35 Piston ring to groove STD mm in I 0 02 0 06 0 001 0 002 I ClEarance 1st I Limit mm in 0 10 0 004 STD mm in 0 02 0 06 0 001 0 002 2nd I Limit mm in 0 10 0 004 Piston ring groove 1st STD mm in 1 01 1 03 0 040 0 041 width 2nd I STD mm in 1 01 1 03 0 040 0 041 Oil STD mm in I 2 01 2 03 0 079 0 080 I on ring thick...

Page 282: ...d and taper Crankshaft bearing STD mm in thickness Crankshaft thrust play STO mm in Limit mm in Crankshaft thrust bearing i i I ISTD I mm in thickness LOWER UNIT Design specification thickness for shim washer Pinion gear back up shim I mm in Forward gear back up shim mm in I Forward gear thrust washer mm in Reverse gear thrust washer mm in Reverse gear back up shim mm in I Data DF40T 40QH iDFSOT S...

Page 283: ... 30 Recommended battery capacity Ah kG 70 252 or larger 12 V l ii l injector resistance Qat20 C 11 0 16 5 lAC valve resistance Qat20 C 21 5 32 3 iAT sensor Cylinder temp sensorl Ex man temp sensor kQ at 25 C 1 8 2 3 Thermistor characteristic ECM main relay resistance Qat20 C 145 190 Starter motor relay resistance Qat20 C 145 190 PTT motor relay resistance Qat20 C 25 37 STARTER MOTOR Max continuous...

Page 284: ...2 CKP sensor 4 2 on YES off 3 lAC valve By pass air I 3 1 on llJlJLJL I NO Ioff screw adjustment i 4 ICMP sensor 2 4 on YES off 5 CTP switch I 2 2 on NO off 6 Cylinder temp sensor 1 4 on YES off i I 7 IAT sensor 2 3 on flJLJlJ1JL YES off 8 MAP sensor 2 3 2 on NO Sensor hose off Rectifier regulator I 9 1 1 on NO i Over charging off 10 Exhaust manifold temp 1 5 Ion YES sensor I off 11 Fuel injector ...

Page 285: ... 6mm 10 1 0 7 0 Upper 35 I 3 5 25 5 lower plug Low pressure fuel pump bolt 6mm 10 i 1 0 7 0 Thermostat cover bolt 6mm 10 1 0 7 0 Flywheel bolt I 14 mm 170 I 17 0 123 0 Starter motor mounting bolt I 6mm 10 i 1 0 7 0 I I I Smm 23 2 3 16 5 Engine oil filter 14 I 1 4 10 0 Engine oil drain plug 12 mm 13 I 1 3 9 5 Power unit mounting boltlnut Smm 23 2 3 16 5 10mm 50 5 0 36 0 Driveshaft housing bolt 10mm...

Page 286: ... of the following conditions are satisfied Lock plate is attached to emergency stop switch Neutral switch is in ON position Engine is not already operating NOTE In accordance with this change ECM has been changed FlYWHEEL MAGNETO AND CRANKSHAFT The flywheel bolt has been changed from M16 to M14 rile washer has been changed in inside diameter In accordance with change of the flywheel bolt tightenin...

Page 287: ...Y CHARGING SYSTEM OUTLINE Key The battery charging system circuit is illustrated below 40mm 50mm Bo I I Crankshaft it composed of the BATTERY CHARGE COIL RECTIFIER REGULATOR and BATTERY The three phase AC current generated from battery charge coil is converted by the rectifier regulator into regulated DC current which is used to charge the battery l To PTT switch _W IR 30A Fuse To main relay w_ _w...

Page 288: ...ter l rJ1 Tester range 0 Resistance 1 Disconnect all lead wires of rectifier regulator 2 Measure resistance between leads in the combinations shown NOTE The values given below are for a SUZUKI digital tester As thyristors diodes etc are used inside this rectifier regula tor the resistance values will differ when an ohmmeter other than SUZUKI digital tester is used Rectifier regulator resistance Un...

Page 289: ...he resulting plunger and pinion shift 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 switch is opened at which time the torsion spring causes the pinion to disengage Holder in coil Plunger Shift ...

Page 290: ...ar to maintain positive engagement Final plunger movement closes the starter switch contacts which allows current to flow through the starter motor windings rotating the starter motor armature pinion gear and flywheel When the ignition key is released from start current flow to the switch is shut off and electromagnetic force ceases The torsion spring then pulls the plunger out disengaging the pin...

Page 291: ...Check battery terminals for connections and cor rosion Check battery for charg ing condition Check battery terminals for connections and cor rosion Check main 30A fuse case YES Check for starter relay Click sound when turn ing ignition switch to START Is there Click sound YES Remove starter motor from engine I Does starter motor turn I under no load condi I tions by connecting bat tery terminal to...

Page 292: ...t relay from wire 2 Check continuity between terminal CD and C2l each time 12 V is applied Connect positive side to terminal and neg ative side to terminal Q Relay function 12 V power Continuity Applied Yes Not applied No ICAUTION I Be careful not to touch 12 V power supply wires to each other or with other terminals 12V ECMmain ...

Page 293: ...ove three bolts two fastening bands and flywheel cover 2 Remove a bolt and silencer cover 3 Disconnect lead wire connector CD from lAC sensor 4 Remove flame arrester 5 Remove four bolts silencer plate and silencer seal 6 Remove two bolts negative 8 battery cable ground lead wire and motor band ...

Page 294: ...ft when using fly wheel remover tools 8 Using special tools loosen flywheel from crankshaft OOt 09930 39411 Flywheel remover 09930 39420 FlyWheel remover bolt 9 Remove flywheel bolt washer and flywheel 10 Remove three screws and battery charge coil 11 Remove seven bolts upper oil seal housing and starter motor 12 Remove nut positive battery cable and Red lead wire 2 13 Disconnect Red lead wire ...

Page 295: ...ature 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 wiped with clean cloth NOTE Before disassembling starting motor be sure to put match mArkr at two locations A and B as shown in figure at right to avoid any possible component ...

Page 296: ...er 5 Remove thrust washer with screwdriver 6 Pull the brush spring up to separate the brush from the surface of the commutator then remove the brush holder jj 7 Remove the yoke and armature 8 Remove the center cover plate 9 Remove the planetary gears and internal gear Q9 ...

Page 297: ... 12 Push the pinion stopper down then remove stopper ring Remove the pinion stopper and pinion A WARNING Wear safety glasses when disassembling and assem bling stopper ring NOTE Using a screw driver pry off the stopper ring 13 Remove the E ring 14 Remove the pinion shaft washers and rubber ring from center bracket DF40 50 K5 05 MODEL 25 ...

Page 298: ...ervice 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 ommutator undercut G 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 depth NOTE Remove al particles of mica and metal using compressed air A WARNING I Wear safety glasses ...

Page 299: ... BRUSHES Check the length of each brush 9900 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 Olt 09930 99320 Digital tester Tester range _0 _ Continuity Brush holder continuity Tester probe connection r Brush holder positive to Brush I holder nega...

Page 300: ... Replace if necessary PINION AND OVER RUNNING CLUTCH Inspect pinion for wear damage or other abnormal conditions Gheck 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 damag...

Page 301: ...or other damage Replace if necessary FRONT HOUSING Inspect front housing for wear damage or other abnormal conditions RepJace if necessary Inspect bush for wear or other damage Replace if necessary ARMATURE SHAFT BUSH Inspect bush for wear or other damage R ace if necessary 1 PLUNGER 1 j Inspect plunger for wear or other damage l ce if necessary DF40 50 K5 05 MODEL 29 ...

Page 302: ...placed Hold in coil Open circuit Test IT ili 09930 99320 Digital tester ster range _ _ Continuity Check for continuity across magnetic switch 8 terminal and coil case If no continuity exists the coil is open and should be replaced Contact points Test iut 09930 99320 Digital tester Tester range 0 _ Continuity Put the plunger on the under side and then push the magnetic switch down At this time chec...

Page 303: ...washer Rubber ring Pinion shaft W Planetary gear Internal gear Center cover plate Armature Voke 29 Brush holder Spring Thrustwasher Reareover Screw Through bolt Assembly is reverse order of disassembly with special attention to the following steps To install the center bracket in the front housing align the thread holes of front housing to holes of center bracket DF40 50 KS 05 MODEl 31 l Ir l II l...

Page 304: ...tall the center cover plate as shown in figure Install the brush holder as shown in figure IC U jQI j When installing armature use care to avoid breaking brushes When installing the rubber packing be sure the front housing boss properly fits into the rubber packing groove ...

Page 305: ...t plunger and pinion over running clutch move out ward If plunger and pinion don t move replace magnetic switch NOTE Before testing disconnect brush lead from terminal M While connected as above with plunger out disconnect nega tiVe lead from terminal M Check that plunger and pinion remain out it plunger and pinion return inward replace magnetic switch PI UNGER AND PINION RETURN TEST Disconnect ne...

Page 306: ...eter indicates specified current No load current Within 90 A at 11 V REMOTE CONTROL BOX REMOTE CONTROL WIRE The remote control box and remote control wire have been changed lJF40T 50T 2004 MODEL DF40T 50T 2005 MODEL TRIM G Top mount remote control box z PIT switch extension wire Ignition switch Emergency stop switch Ignition stop switch panel Caution buzzer J Side mount remote control box Remote c...

Page 307: ...ave been added to the cylinder head In accordance with this change the cylinder head has been changed in shape cover Cylinder O ring UPPER OIL SEAL HOUSING In accordance with change of the starter motor the upper oil seal housing has been changed in shape Late ...

Page 308: ...les in the upper mount have been eliminated The nut washers and upper thrust stopper have been changed The through holes in the steering bracket have been enlarged The mount nut tightening torque has been changed to 80 N m with applying the thread lock i1 99000 32020 THREAD LOCK SUPER 13338 Upper mount nut 80 N m 8 0 kg m S8 0 Ib ft 6 Y Upper mount bolt 80N m 8 0 kgf m 58 0Ib_tt 1 Washer Nut Upper...

Page 309: ...en changed in material The lower mount bolt has been changed in shape The washers have been changed The mount nut tightening torque has been changed to 80 N m with applying the thread lock H 99000 32020 THREAD LOCK SUPER 13338 J Lower mount nut 80 N m 8 0 kg m 58 0 Ib ft Irc 0 Early I r o oWl Late View A 11 14mm 19mm 6 wermount SON m S O kgf m Washer 5S 0 Ib ft Late Lower mount bolt Nut ...

Page 310: ...n changed to prevent loosing the nut In accordance with this change the starboard clamp bracket has been changed in shape Clamp bracket washer Starboard clamp bracket o Late CLAMP BRACKET SHAFT The clamp bracket shaft has been changed in shape Yellow paint r H c Blue paint r H U Late ...

Page 311: ...nged in shape LHole 2 places ___ 0 If Slit 3 places it L I o Late TILLER HANDLE ASSY The wire connector of the tiller handle assy has been changed to 16 pin connector PTT MOTOR RELAY The PTT relays for UP and for DOWN have been incorporated and changed in shape PTT relay assy Late ...

Page 312: ...e 8 terminal of 12 V battery CAlJTIOJij Each operation test must be performed within 3 5 seconds to avoid overheat damage to the relay coil 5 Temporarily connect a jumper wire from the P lead wire to the battery positive e terminal then check voltage between Gl wire and 1 8 wire IrULI 09930 99320 Digital tester i lJ Tester range DCV Between G wire and B wire 12 V Battery voltage 6 Temporarily conn...

Page 313: ...pring housing has been changed in shape The driveshaft bearing housing has been changed in shape The pinion gear back up shim has been changed in shape Effective Engine Number DF40 04001F 510210 and later DF50 05001 F 51 0466 and later The driveshaft and related parts have been changed to the components for the 2004 year model 2004 year model and from the middle of 200S year model Pinion gear back...

Page 314: ... case has been changed in shape SHIFT ROD GUIDE The number of shift rod guide O ring has been changed from 2 pieces to 1 piece The shift rod guide has been changed in shape Late K 0 ring Shift rod guide Late GEARCASE MAGNET The gearcase magnet has been changed in shape V Gearcase magnet V Gearcase magnet Late ...

Page 315: ...DF40 S0 KS 05 MODEL 43 PROPELLER SHAFT BEARING The number of propeller shaft bearing has been changed from 2 pieces to 1 piece 10 5 mm 2 pieces I 10 5 mm It 1Pi Late ...

Page 316: ...44 DF40 50 K5 05 MODEL WIRING DIAGRAM DF40T DF50T DF50WT REMOTO CONTROL MODEL Jli II IIIIIII I I i r I I ii ii II Ii nil j fiI Wi ...

Page 317: ...DF50TH TILLER HANDLE MODEL t 1 H o 0 1 IE g 55 Iii i II I i i i i I I DF40 50 K5 05 MODEL 45 II II i i I I I Ii II i I Ii I II II II I I I II I ...

Page 318: ...46 DF401S0 KS 05 MODEL DF40QH DF50QH DF50WQH TILLER HANDLE MODEL h h h IUm mmWmt HBHB Hh hd hi q lI IlIa lS ii i g Ii i I i I I I I II I I I I I I I I I i i ...

Page 319: ...Exhaust manifold sensor ECMmain Joint connect I Main rness lcHl p 1111G orl I 7T777 i Joint connector Main harness at U PTT relay Except for QH model e D m D o c I Z G c j l g 3 o C m r ...

Page 320: ...MAP sensor MAP hose Protector Gas filter El 3N m 0 3 kg m 2 0 Ib tl Neutral switch Oil pressuk switch connector c in C 5l 3l o c m r ...

Page 321: ...anifold temp _ _______ c_c_c_c_c ___c _____c________c __c ___ MAP sensor Fix engine wiring harness not to contact with clamp sensor MAP sensor bracket Electric parts holder cover charge coil Starter motor CKP sensor After installing flywheel magneto and securing nut with specified torque check air gap between CKP sensor and retuctor bars on flywheel maaneto J Air gap 0_75 mm 0 030 in C 11 ...

Page 322: ...MODEL Starter motor Grommet IAT sensor CMP sensor Position clip tabs Battery cable I l Route battery cable on fuel hose Inward engine side CTP switch lAC valve cable 8 Ignition coil 1 Clamp coil 2 Clamp Ignition coil 3 ...

Page 323: ...sender cable View A DF40 50 K5 OS MODEL Grommet PTI motor cable PTI motor cable Bind trim sender cable and PTT motor cable Match taping of PTT cable to PTT motor c Less than 8mm B r ViewB Trim sender cable 51 ...

Page 324: ...Prepared by SUZUKI MOTOR CORPORATION Marine Power Products Division September 2004 Manual No 9950l 87J40 01E Printed in Japan 52 ...

Page 325: ...OUTBOARD MOTOR TK 9 9 5 0 1 8 7 J 5 0 0 1 E Printed in Japan K6 K7 For 2006 and 2007 models SUPPLEMENTARY SERVICE MANUAL ...

Page 326: ...s NOTE Use this supplement with the following service manual DF40 50 Service Manual P no 99500 87J0 01E This Supplementary Service Manual describes the modification as for 2006 Model and also the modifications made in half way of production on 2006 Model SPECIFICATIONS DF40T DF40QH DF50T DF50TH 2 SPECIFICATIONS DF50WT DF50WQH 4 SERVICE DATA 6 PERIODIC MAINTENANCE SCHEDULE 13 ECM 14 FUEL FILTER 14 ...

Page 327: ... 401 15 L mm inch type 528 20 Maximum output kW PS 29 4 40 36 8 50 Recommended operating range Except E01 r min 5 200 5 800 5 900 6 500 E01 5 600 6 200 Idle speed r min 850 50 in gear approx 850 Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transisto...

Page 328: ...ange Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 610 20 6 21 5 Trim angle PTT system Manual trim and gas assisted tilt system PTT system Number of trim position PTT system 5 PTT system Maximum tilt angle Degrees 73 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 273 Drive line impact prot...

Page 329: ... type 401 15 L mm inch type 528 20 X mm inch type 655 25 Maximum output kW PS 36 8 50 Recommended operating range r min 5 900 6 500 Idle speed r min 850 50 in gear approx 850 Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transistorized ignition Fuel ...

Page 330: ...ter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 610 20 6 21 5 Trim angle PTT system Manual trim and gas assisted tilt system Number of trim position PTT system 5 Maximum tilt angle Degrees 73 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 273 Drive line impact protection Spline dr...

Page 331: ... psi 1 300 1 600 13 16 185 228 Cylinder compression max difference between any other cylinders kPa kg cm2 psi 100 1 0 14 Engine oil pressure kPa kg cm2 psi 300 380 3 0 3 8 43 54 at 4 000 r min at normal operating temp Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Thermostat operating...

Page 332: ...7 740 37 900 1 4858 1 4921 Limit mm in 37 640 1 4819 37 640 1 4819 Camshaft journal oil clearance STD mm in 0 045 0 087 0 0018 0 0034 Limit mm in 0 120 0 0047 Camshaft journal housing inside diameter Top 2nd 3rd 4th STD mm in 23 000 23 021 0 9055 0 9063 Limit mm in 23 171 0 9122 Camshaft journal outside diameter Top 2nd 3rd 4th STD mm in 22 934 22 955 0 9029 0 9037 Limit mm in 22 784 0 8970 Camsha...

Page 333: ...de diameter IN STD mm in 5 465 5 480 0 2152 0 2157 EX STD mm in 5 440 5 455 0 2142 0 2148 Valve stem end length IN EX Limit mm in 3 20 0 126 Valve stem end deflection IN Limit mm in 0 14 0 006 EX Limit mm in 0 18 0 007 Valve stem runout IN EX Limit mm in 0 05 0 002 Valve head radial runout IN EX Limit mm in 0 08 0 003 Valve head thickness IN STD mm in 1 0 0 04 Limit mm in 0 7 0 03 EX STD mm in 1 1...

Page 334: ...0 30 Limit mm in 6 0 0 24 2nd STD mm in Approx 11 0 0 43 Limit mm in 8 8 0 35 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 01 1 03 0 040 0 041 2nd STD mm in 1 01 1 03 0 040 0 041 Oil STD mm in 2 01 2 03 0 079 0 080 Piston ring thickness 1st STD mm in 0 9...

Page 335: ...0 22 000 0 8642 0 8661 Crank pin width STD mm in 22 100 22 200 0 8700 0 8740 Crankshaft center journal runout Limit mm in 0 04 0 002 Crankshaft journal oil clearance STD mm in 0 020 0 040 0 0008 0 0016 Limit mm in 0 065 0 0026 Crankcase bearing holder inside diameter STD mm in 49 000 49 018 1 9291 1 9298 Crankshaft journal outside diameter STD mm in 44 982 45 000 1 7709 1 7717 Crankshaft journal o...

Page 336: ...in fuse 30 Recommended battery capacity 12 V Ah kC 70 252 or larger Fuel injector resistance Ω at 20 C 11 0 16 5 IAC valve resistance Ω at 20 C 21 5 32 3 IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor characteristic kΩ at 25 C 1 8 2 3 ECM main relay resistance Ω at 20 C 145 190 Starter motor relay resistance Ω at 20 C 145 190 PTT motor relay resistance Ω at 20 C 25 37 Max continuou...

Page 337: ...und from the caution buzzer contained in the tiller handle Brush length STD mm in 9 8 0 39 Limit mm in 4 8 0 19 Commutator outside diameter STD mm in 22 0 0 87 Limit mm in 21 0 0 83 PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN FAIL SAFE SYSTEM ACTIVATING 1 MAP sensor 1 3 4 on off YES 2 CKP sensor 4 2 on off YES 3 IAC valve By pass air screw adjustment 3 1 on off NO 4 CMP sensor 2 4 on off YES 5...

Page 338: ...appet clearance has been changed 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 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 Bonding wires I I I Battery I I I Fuel mixture check O2 feedback Perform every 2 years Engine oil filter R R...

Page 339: ...ly If any water and impurities exists in the fuel filter remove the drain cap and drain the water and impurities IAC HOSE The inhalation location of air of IAC was changed from silencer case to atmospherer The IAC hose has been changed in length and routing The silencer cap IAC hose clamp hose clamp and clamp bolt have also been added Fuel filter bracket Fuel filter Fuel filter Clip Drain cap Fuel...

Page 340: ...06 MODEL 15 IAC HOSE ROUTING INTAKE MANIFOLD The intake manifold has been changed in shape and the plug and gasket have been eliminated IAC hose clamp Clamp bolt IAC hose clamp IAC hose Hose clamp ECM Plug Gasket ...

Page 341: ...been added to the 1st ring groove on the piston The location of the 1st ring groove has also been changed WATER PUMP CASE UNDER GASKET The water pump case under gasket has been changed in shape Thickness of gasket has been changed from 0 5 mm to 0 6 mm 4 mm 14 mm ...

Page 342: ...R P O W Br W R G Gr Bl W B Lbl W R P O W Br W R G Gr Bl B Bl B G Y P G W W Y B Br Br Gr Bl Gr Bl Br Br G B B B W Y B W Y B Bl B G Y P G W Bl B G Y P G W Gr B Y R G B R G B R G B R G B Gr B Gr B Gr B Gr B Gr B R G B B R G B R G R G R G Gr B Y P B Lg R B R Lg B Bl B Br G Y P W G W O Y B Gr Bl R Bl W B W Dg B B O Bl G B W O B B Y R W V W O G Lg W R B Bl B B W R Y B G O Y B W W B B CMP SENSOR FUEL INJ...

Page 343: ... W Y B G O Y B Lbl P Lbl P B Y O B Gr W O O Gr Gr Gr Gr Br B B G G W W Gr Br Bl Bl HIGH PRESSURE FUEL PUMP PTT SWITCH CMP SENSOR FUEL INJECTOR 1 2 3 FP UP DN CYLINDER TEMP SENSOR MAP SENSOR RUN STOP CKP SENSOR CAP COMMUNICATION CONNECTOR FUSE 30A STARTER MOTOR CTP SWITCH IAC VALVE IAT SENSOR BATTERY 12V 70AH PTT MOTOR PTT RELAY RECTIFIER REGULATOR 3 2 1 EX MANI TEMP SENSOR ENGINE CONTROL MODULE IG...

Page 344: ... B G G W W Gr Br Bl Bl CMP SENSOR FUEL INJECTOR 1 2 3 FP CYLINDER TEMP SENSOR MAP SENSOR CKP SENSOR CAP COMMUNICATION CONNECTOR FUSE 30A CTP SWITCH IAT SENSOR BATTERY 12V 70AH EX MANI TEMP SENSOR IGNITION SWITCH BZ TURN PUSH OFF ST FREE PUSH IG B G W Gr Br GND STOP BATT IG START STARTER MOTOR RELAY ECM MAIN RELAY NEUTRAL SWITCH N ON F R OFF CAUTION BUZZER OVERHEAT OIL PRESSURE BATTERY VOLTAGE DIAG...

Page 345: ...pump to vapor separator Fuel hose Protector Fuel filter to L fuel pump Fuel filter Water hose 3 way joint to Pilot water hole Water hose Engine holder to Vapor separator Water hose Engine holder to 3 way joint Clamp Hose clamp Evaporation hose Fuel filter Fuel hose Pump to separator Low pressure fuel pump Water hose Engine holder to vapor separator Water hose 3 way to vapor separator Fuel hose Pro...

Page 346: ...l filter Fuel hose Protector H filter to 3 way joint Clamp 3 way joint Fuel hose Protector 3 way to vapor separator Water hose 3 way to pilot water hole 3 way Fuel filter Low pressure fuel pump Fuel hose Protector Fuel filter to low fuel pump ...

Page 347: ...ater hose Vapor separator to 3 way Water hose Engine holder to vapor separator Throttle body Gas filter Vapor separator IAC valve IAC valve silencer Fuel hose Protector 3 way joint to vapor separator IAC hose Fuel hose Protector Vapor separator to low fuel pump 3 way joint 3 way joint Fuel hose Protector 3 way joint to vapor separator Fuel hose Protector H fuel filter to 3 way joint Clamp Map sens...

Page 348: ...g service manual DF40 50 Service Manual P no 99500 87J0 01E This Supplementary Service Manual describes the modification as for 2007 Model and also the modifications made in half way of production on 2007 Model SPECIFICATIONS DF40T DF40QH DF50T DF50TH 2 SPECIFICATIONS DF50WT DF50WQH 4 SERVICE DATA 6 TIGHTENING TORQUE 13 PERIODIC MAINTENANCE SCHEDULE 14 ECM 15 SILENCER 15 TILLER HANDLE DF40QH DF50Q...

Page 349: ... 401 15 L mm inch type 528 20 Maximum output kW PS 29 4 40 36 8 50 Recommended operating range Except E01 r min 5 200 5 800 5 900 6 500 E01 5 600 6 200 Idle speed r min 850 50 in gear approx 850 Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transisto...

Page 350: ...ange Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 610 20 6 21 5 Trim angle PTT system Manual trim and gas assisted tilt system PTT system Number of trim position PTT system 5 PTT system Maximum tilt angle Degrees 73 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 273 Drive line impact prot...

Page 351: ... type 401 15 L mm inch type 528 20 X mm inch type 655 25 Maximum output kW PS 36 8 50 Recommended operating range r min 5 900 6 500 Idle speed r min 850 50 in gear approx 850 Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transistorized ignition Fuel ...

Page 352: ...ter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil amounts ml US lmp oz 610 20 6 21 5 Trim angle PTT system Manual trim and gas assisted tilt system Number of trim position PTT system 5 Maximum tilt angle Degrees 73 Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 273 Drive line impact protection Spline dr...

Page 353: ... psi 1 300 1 600 13 16 185 228 Cylinder compression max difference between any other cylinders kPa kg cm2 psi 100 1 0 14 Engine oil pressure kPa kg cm2 psi 300 380 3 0 3 8 43 54 at 4 000 r min at normal operating temp Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts L US lmp qt 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Thermostat operating...

Page 354: ...7 740 37 900 1 4858 1 4921 Limit mm in 37 640 1 4819 37 640 1 4819 Camshaft journal oil clearance STD mm in 0 045 0 087 0 0018 0 0034 Limit mm in 0 120 0 0047 Camshaft journal housing inside diameter Top 2nd 3rd 4th STD mm in 23 000 23 021 0 9055 0 9063 Limit mm in 23 171 0 9122 Camshaft journal outside diameter Top 2nd 3rd 4th STD mm in 22 934 22 955 0 9029 0 9037 Limit mm in 22 784 0 8970 Camsha...

Page 355: ...de diameter IN STD mm in 5 465 5 480 0 2152 0 2157 EX STD mm in 5 440 5 455 0 2142 0 2148 Valve stem end length IN EX Limit mm in 3 20 0 126 Valve stem end deflection IN Limit mm in 0 14 0 006 EX Limit mm in 0 18 0 007 Valve stem runout IN EX Limit mm in 0 05 0 002 Valve head radial runout IN EX Limit mm in 0 08 0 003 Valve head thickness IN STD mm in 1 0 0 04 Limit mm in 0 7 0 03 EX STD mm in 1 1...

Page 356: ...0 30 Limit mm in 6 0 0 24 2nd STD mm in Approx 11 0 0 43 Limit mm in 8 8 0 35 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 01 1 03 0 040 0 041 2nd STD mm in 1 01 1 03 0 040 0 041 Oil STD mm in 2 01 2 03 0 079 0 080 Piston ring thickness 1st STD mm in 0 9...

Page 357: ...0 22 000 0 8642 0 8661 Crank pin width STD mm in 22 100 22 200 0 8700 0 8740 Crankshaft center journal runout Limit mm in 0 04 0 002 Crankshaft journal oil clearance STD mm in 0 020 0 040 0 0008 0 0016 Limit mm in 0 065 0 0026 Crankcase bearing holder inside diameter STD mm in 49 000 49 018 1 9291 1 9298 Crankshaft journal outside diameter STD mm in 44 982 45 000 1 7709 1 7717 Crankshaft journal o...

Page 358: ...in fuse 30 Recommended battery capacity 12 V Ah kC 70 252 or larger Fuel injector resistance Ω at 20 C 11 0 16 5 IAC valve resistance Ω at 20 C 21 5 32 3 IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor characteristic kΩ at 25 C 1 8 2 3 ECM main relay resistance Ω at 20 C 145 190 Starter motor relay resistance Ω at 20 C 145 190 PTT motor relay resistance Ω at 20 C 25 37 Max continuou...

Page 359: ...und from the caution buzzer contained in the tiller handle Brush length STD mm in 9 8 0 39 Limit mm in 4 8 0 19 Commutator outside diameter STD mm in 22 0 0 87 Limit mm in 21 0 0 83 PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN FAIL SAFE SYSTEM ACTIVATING 1 MAP sensor 1 3 4 on off YES 2 CKP sensor 4 2 on off YES 3 IAC valve By pass air screw adjustment 3 1 on off NO 4 CMP sensor 2 4 on off YES 5...

Page 360: ...w pressure fuel pump bolt 6 mm 10 1 0 7 0 Thermostat cover bolt 6 mm 10 1 0 7 0 Flywheel bolt 14 mm 170 17 0 123 0 Starter motor mounting bolt 6 mm 10 1 0 7 0 8 mm 23 2 3 16 5 Engine oil filter 14 1 4 10 0 Engine oil drain plug 12 mm 13 1 3 9 5 Power unit mounting bolt nut 8 mm 23 2 3 16 5 10 mm 50 5 0 36 0 Driveshaft housing bolt 10 mm 50 5 0 36 0 Upper mount nut 12 mm 80 8 0 58 0 Upper mount cov...

Page 361: ... R Replace The fuel mixture check O2 feedback has been abolished In accordance with this change the item of Fuel mixture check O2 feedback was deleted 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 Fuel line I I I I Replace every 2 years Engine oil R R R Gear oil R R R Lubrication I I...

Page 362: ...d SILENCER The silencer silencer seal flame arrester bolt and washer have been changed in shape The number of washer has been changed from 2 to 1 The clamp has been added 9 mm 8 mm 6 5 mm 13 0 mm 25 mm 20 mm View of A Bolt Washer Silencer A Clamp added Silencer seal Early Flame arrester ...

Page 363: ...CK 1342 Apply the water resistant grease to the bush 99000 25160 SUZUKI WATER RESISTANT GREASE 2 The tiller handle pivot bolt is tightened first to the specified torque 25 N m 2 5 kg m 18 0 lb ft 3 Then the tiller handle pivot nut is tightened to the specified torque 45 N m 4 5 kg m 32 5 lb ft Tiller handle pivot bolt 25 N m 2 5 kg m 18 0 lb ft Spring washer Spacer Washer Direction of spring washe...

Page 364: ...ck nut 50 N m 5 0 kg m 36 lb ft TILLER HANDLE The method of fixing the clutch cable and the throttle cable changed The clutch cable and throttle cable are fixed with the cable bracket Tiller handle Tiller handle bracket Stud bolt Lock nut Washer Clamp Steering bracket View of A A A A Clutch shift cable Throttle cable View of A Cable bracket ...

Page 365: ...o detent notches at forward and reverse positions are added to the shift cam CLUTCH DOG SHIFTER AND RETURN SPRING The width of clutch dog shifter has been changed The free length of return spring has been changed Return spring free length Standard 57 0 mm 2 24 in Service limit 55 0 mm 2 17 in 4 mm 6 mm Screw Bolt Screw Bolt Clutch shaft side arm Clutch shaft arm 11 mm 14 mm Shift cam Detent spring...

Page 366: ...7 07 MODEL 19 ENGINE SIDE COVER The side covers and securing screws have been changed in shape marked portion 30 mm 35 mm 7 2 mm 6 2 mm 15 mm 21 mm 7 0 mm 5 7 mm 25 mm 14 mm Starboard side cover Port side cover ...

Page 367: ... ...

Page 368: ...OUTBOARD MOTOR TK 9 9 5 0 1 8 7 J 5 0 0 1 E Printed in Japan K6 K7 For 2006 and 2007 models SUPPLEMENTARY SERVICE MANUAL ...

Page 369: ...99501 87J00 01E OUTBOARD MOTOR Printed in Japan TK ...

Page 370: ...____________ 3 SERVICE DATA ____________________________________________________ 5 TIGHTENING TORQUE ______________________________________________ 11 SPECIAL TOOLS ___________________________________________________ 13 MATERIALS REQUIRED _____________________________________________ 16 WIRING DIAGRAM _________________________________________________ 17 ENGINE CONTROL SYSTEM ______________________...

Page 371: ...342 Apply THREAD LOCK SUPER 1333B Measure in DC voltage range Measure in resistance range Measure in continuity test range Use peak voltmeter Stevens CD 77 Use special tool Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply SUZUKI OUTBOARD MOTOR GEAR OIL ApplySUZUKISUPERGREASE A Apply SUZUKI WATER RESISTANT GREASE Apply SUZUK...

Page 372: ... work together 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 extinguisher distress signals anchor paddles bilge pump first aid kit...

Page 373: ... and nuts beginning with larger diameter and ending with smaller diameter Always tighten from inside to outside diagonally to the specified tightening 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 over m...

Page 374: ...ed operating range r min Idle speed r min 36 8 50 5200 5800 5900 6500 850 50 in gear approx 850 50 POWERHEAD Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 71 0 2 80 Stroke mm in 68 6 2 70 Total displacement cm3 cu in 815 49 7 Compression ratio 1 10 Spark plug NGK DCPR6E Ignition system Full transistorized ignition Fuel supply system Multi point sequential electronic fuel injection Exh...

Page 375: ...pacity SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil 610 20 6 21 5 BRACKET Trim angle Manual Trim and Gas Assisted Tilt System Number of trim position 5 Maximum tilt angle degree 73 LOWER UNIT Reversing system Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 11 25 2 27 Drive line impact protection Spline drive rubber hub Propeller Blade Diam in Pitch in Thes...

Page 376: ... any two cylinders 100 1 0 14 kPa kg cm2 psi Engine oil pressure 295 373 3 0 3 8 42 54 at 4000 r min at normal operating temp kPa kg cm2 psi Engine oil Engine oil amounts L US Imp qt Thermostat operating temperature 48 52 126 134 C F API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Figures shown are guidelines only not absolute...

Page 377: ... 1 4858 1 4921 STD Limit mm in 37 640 1 4819 37 640 1 4819 EX 0 045 0 087 0 0018 0 0034 mm in Camshaft journal oil clearance STD Limit 0 12 0 0047 mm in Camshaft journal housing inside diameter Top 2nd 3rd 4th mm in STD Limit mm in 23 000 23 021 0 9055 0 9063 23 171 0 9122 Camshaft journal outside diameter Top 2nd 3rd 4th mm in STD Limit mm in 22 934 22 955 0 9029 0 9037 22 784 0 8970 0 10 0 004 m...

Page 378: ...r mm in STD STD mm in IN EX 5 465 5 480 0 2152 0 2157 5 440 5 455 0 2142 0 2148 IN EX mm in Limit 3 2 0 1260 Valve stem end length Valve stem end deflection mm in Limit Limit mm in IN EX 0 14 0 0055 0 18 0 0071 IN EX mm in Limit 0 05 0 0020 Valve stem runout IN EX mm in Limit 0 08 0 0031 Valve head radial runout Valve head thickness mm in STD Limit mm in IN 1 0 0 0394 0 7 0 0276 mm in STD Limit mm...

Page 379: ...mm in 6 0 2362 1st mm in Approx 11 0 4330 STD Limit mm in 8 8 0 3465 2nd Piston ring groove width mm in 1 01 1 03 0 0398 0 0406 1st mm in 1 01 1 03 0 0398 0 0406 mm in 1 51 1 53 0 0594 0 0602 2nd Oil Piston ring to groove clearance mm in 0 020 0 060 0 0008 0 0024 STD Limit mm in 0 10 0 0039 1st mm in 0 020 0 060 0 0008 0 0024 STD Limit mm in 0 10 0 0039 2nd Piston ring thickness mm in 0 97 0 99 0 ...

Page 380: ...mm in STD 0 350 0 0138 mm in Limit 21 950 22 000 0 8642 0 8661 mm in STD Conrod big end width 22 100 22 200 0 8700 0 8740 mm in STD Crank pin width Crankshaft journal oil clearance 0 020 0 040 0 0008 0 0016 mm in STD 0 065 0 0026 mm in Limit Crankshaft center journal runout 0 04 0 0016 mm in Limit Crankcase bearing holder inside diameter 49 000 49 018 1 9291 1 9298 mm in STD Crankshaft journal out...

Page 381: ... injector resistance W at 20 C IAC valve resistance k W at 25 C IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor characteristic W at 20 C ECM main relay resistance W at 20 C Starter motor relay resistance 1 8 2 3 80 120 3 5 5 1 STARTER MOTOR 30 Sec Max continuous time of use 0 9 kW Motor output 17 0 0 67 mm in STD Brush length 10 0 0 39 mm in Limit 0 5 0 8 0 02 0 03 mm in STD Commuta...

Page 382: ...t 16 mm 200 20 0 145 Starter motor mounting bolt 8 mm 23 2 3 16 5 Engine oil filter 14 1 4 10 0 Engine oil drain plug 12 mm 13 1 3 9 5 Power unit mounting bolt nut 8 mm 23 2 3 16 5 10 mm 50 5 0 36 0 Driveshaft housing bolt 10 mm 50 5 0 36 0 Upper mount nut 10 mm 40 4 0 30 0 Upper mount cover bolt 8 mm 23 2 3 16 6 Lower mount nut 12 mm 60 6 0 43 5 12 mm 40 4 0 29 0 Clamp bracket shaft nut 22 mm 43 ...

Page 383: ...m N m Ib 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 10 mm 22 35 2 3 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 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 10 mm 40 60 4 0 6 0 29 0 43 5 Conventional or 4 marked bolt Stainless steel bolt 7 marked ...

Page 384: ...0101 150 mm 09900 20102 200 mm Vernier calipers 09900 20508 Cylinder gauge set 40 80 mm 09900 20803 Thickness gauge 09900 28403 Hydrometer 09900 00411 Hexagon socket included in 09900 00410 09900 20202 Micrometer 25 50 mm 09900 20605 Dial calipers 10 34 mm 09900 21304 Steel V block set 09921 29510 Driveshaft holder 09913 50121 Oil seal remover 09900 00413 5 mm 09900 00414 6 mm Hexagon bit included...

Page 385: ...ression gauge 09915 63210 Adaptor 09916 14510 Valve lifter 09916 20630 Valve seat cutter Neway 126 09916 34542 Valve guide reamer handle 09916 57330 Valve guide installer 09915 77310 Oil pressure gauge 09916 24450 Solid pilot N 100 5 52 09916 20620 Valve seat cutter Neway 122 09916 37320 Valve guide reamer f f f f f 10 5 mm 09916 77310 Piston ring compressor 09915 78211 Oil pressure gauge adapter ...

Page 386: ...09930 30102 Sliding hammer 09930 76420 Timing light 09930 89920 6 pin connector test cord 09932 79910 Diagnostic harness A 09950 69511 Gearcase oil leakage tester B 09821 00004 Air pump A 18213 74F00 O2 sensor B 18498 99E40 Protector 48 09922 89810 Shift lock pin remover 51 09930 39411 Flywheel rotor remover 55 56 09930 89240 4 pin connector test cord 09930 89260 Injector test cord A 59 60 09930 8...

Page 387: ...000 25030 99000 25010 500 g 99104 33140 99000 31140 100 g 99000 25160 250 g 99000 32050 50 g 99000 31120 50 g API SE SF SG SH SJ SAE 10W 40 SUZUKI SUPER GREASE A WATER RESISTANT GREASE SUZUKI SILICONE SEAL SUZUKI BOND 1104 SUZUKI BOND 1207B THREAD LOCK 1342 4 Stroke Motor Oil NOTE Marked part No is in U S market only NOTE Marked part No is in U S market only 71 99954 53008 820 Digital voltmeter ...

Page 388: ... REGULATOR IGNITION COILS EX MANI TEMP SENSOR FUEL INJECTOR CMP SENSOR FUSE HIGH PRESSURE FUEL PUMP CYLINDER TEMP SENSOR MAP SENSOR ALTERNATOR FUSE COMMUNICATION CONNECTOR CAP TILLER HANDLE 1CKP SENSOR No 1 2CKP SENSOR No 2 3CKP SENSOR No 3 4BATTERY CHARGE COIL 5CAUTION BUZZER OVERHEAT OIL PRESSURE BATTERY VOLTAGE DIAGNOSIS 6NEUTRAL SWITCH N ON F R OFF 7OIL PRESSURE SWITCH 1 0 kgf cm 2 or less ON ...

Page 389: ...und sequence for that caution will be the same as that of a T specification model Refer to the illustration for the QH model buzzer sound se quence ON OFF pattern of caution and diagnostic signals NOTE The buzzer cancellation feature found on T specification Mod els is not available on QH models Due to this features re moval the ignition switch and the function of the orange lead extending from EC...

Page 390: ...ce this feature is engaged engine speed will be regulated to remain at the fixed 1500 r min limit until the feature is can celled Cancellation The engine speed control feature will be canceled if any one of the following conditions is satisfied Throttle is returned to and remains at full close CTP switch ON for at least one second Engine speed is lowered below the control speed 1500 r min and rema...

Page 391: ...t knob REMOVAL 1 Remove the rigging port grommet 1 from front panel Remove both lower side covers 2 Remove snap pin 2 washer 3 and throttle cable con nector 4 from throttle control arm Unthread connector from throttle cable 3 Remove snap pin 5 washer 6 and shift cable connec tor 7 from clutch control lever Unthread connector from shift cable 4 Remove cable stopper 8 from between cables 5 Disconnec...

Page 392: ...e seals C and connector lock nuts D from throttle shift cables Slide rigging port grommet 1 off DISASSEMBLY Remove six 6 screws 1 and take off tiller handle lower cover 2 Disconnect emergency stop switch lead connector 3 Remove E ring 4 and throttle cable 5 from throttle link 8 Remove shift cable 6 from clutch link 7 in the same manner Remove screw 9 handle grip 0 ...

Page 393: ...andle rod plate G Remove the two screws H securing the throttle link I to tiller handle housing then remove throttle link I and handle rod assembly J Remove the bolt K securing the shift lever Separate the shift lever L by installing 8mm bolt a in shift lever as shown in figure Using a hammer tap on bolt head until the shift lever sepa rates then remove 8mm bolt ...

Page 394: ...DF40QH DF50QH 23 Remove the two bolts M securing the clutch link N to tiller handle housing then remove clutch link and spacer O ...

Page 395: ...ndle housing 2 Handle grip 3 Lower cover 4 Screw 5 Cable grommet 6 Switch cover 7 Emergency switch 8 Lock plate 9 Ignition switch 10 Handle wire harness 11 Grommet Handle wire 23 Screw 24 Throttle cable 25 E ring 26 Bolt 27 Spacer shift link 28 Shift cable 29 Shift link 30 Bolt 31 Bush 32 Shift lever 33 Buzzer 12 Screw 13 Washer 14 Handle rod stopper 15 Spring 16 Bush 17 Pin 18 Handle rod 19 Handl...

Page 396: ...rs 3 and spring 4 into position Insert handle pivot bolt 5 Coat pivot bolt threads with thread lock and tighten pivot bolt to specified torque Handle pivot bolt 45 N m 4 5 kg m 32 5 lb ft h h h h h 99000 32050 Thread Lock 1342 Install washer 6 nut 7 and tighten nut to specified torque Handle pivot nut 45 N m 4 5 kg m 32 5 lb ft Handle wire harness Route the handle wire harness 1 as shown in figure...

Page 397: ...in figure Install the seals 2 and connector lock nut 3 on both cables 2 Secure the shift cable 4 and throttle cable 6 in the cable holder 5 by fitting groove on the cable into slots of holder 3 Push the cable stopper 7 into the clearance between both cables until the stopper is fixed on the cable holder 4 Screw cable connector 8 9 onto both cables ...

Page 398: ...djust the connector 8 to align with pivot pin 0 on the clutch control lever d When aligned press the connector 8 flat side of connector towards the clutch control lever over the pivot pin 0 e Install the washer A and snap pin B then tighten the cable lock nut C against the connector to maintain adjustment f Make sure that both forward and reverse gears can be engaged with the same angle of shift l...

Page 399: ... by the arrow H to remove all play in the cable D While pressing against the cable and connector adjust the connector 9 to align with the pivot pin E on the throttle control arm D E When aligned press the connector 9 flat side of con nector towards the throttle control arm over the pivot pin E F Install the washer A and snap pin B then tighten the cable lock nut C against the connector to maintain...

Page 400: ...rigging port grommet 1 Push the cable seal tube 2 into the clearance between shift throttle cable 3 4 and rigging port grommet Harness Cable routing Fix handle wire harness with clamp a as shown at right Bind shift and throttle cable with spiral tube b as shown at right a b ...

Page 401: ... cylinder rod extends thereby assisting the manual tilting process A A A A A This unit contains high pressure gas and it must not be disassembled punctured incinerated or exposed to heat REMOVAL Tilt engine fully up and lower the manual tilt lock levers 1 A A A A A During the following procedure firmly secure the engine and support its weight see right Remove the snap ring 2 and push tilt cylinder...

Page 402: ... the tilt pin 6 Loosen the tilt aid gas cylinder lower shaft nut 7 and remove the lower shaft bolt 8 Slide the STBD clamp bracket 9 fully outward to the right hand side Remove the tilt aid gas cylinder 0 from between the clamp brackets INSPECTION NOTE If any component is found to be excessively worn cracked defective or damaged in any way it must be replaced Tilt aid gas cylinder Check tilt aid ga...

Page 403: ...eplace bushing If bushing fit is loose when installing replace bushing 1 Tilt aid gas cylinder 2 Release lever 3 Rubber release lever 4 Cylinder upper shaft 5 Bush 6 Snap ring 7 Gas cylinder lower shaft 8 Bolt 9 Bush 10 Washer 11 Nut 12 Bolt 13 Nut INSTALLATION Installation is reverse order of removal with special attention to following steps ...

Page 404: ...nt Grease Place the tilt aid gas cylinder in position between the clamp brackets Tighten clamp bracket shaft nut to specified torque z z z z z Clamp bracket shaft nut 43 N m 4 3 kg m 31 0 lb ft Slide the cylinder lower shaft bolt through the clamp bracket and lower shaft then secure with the nut Align the cylinder upper eyelet with the hole in the swivel bracket then insert the upper shaft through...

Page 405: ...Prepared by Marine Power Products Division 1 st Ed January 1999 Manual No 99501 87J00 01E Printed in Japan 36 ...

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