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Suzuki GF60A, Service Manual

The Suzuki GF60A Service Manual is a comprehensive user manual for this popular model, providing detailed instructions, maintenance tips, and troubleshooting advice. Available for free download on our website, it is an essential resource for Suzuki owners seeking reliable information and guidance for optimal performance and longevity.

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1-ii Table of Contents

Upper Oil Seal Housing Removal and 

Installation.........................................................1D-8

Intake Manifold and Throttle Body 

Components......................................................1D-9

Throttle Body Removal and Installation ............1D-10
Throttle Body Inspection ...................................1D-11
Intake Manifold Removal and Installation .........1D-11
Power Unit Removal and Installation ................1D-14
Timing Chain, Chain Tensioner and Camshaft 

Sprockets Components...................................1D-21

Timing Chain, Chain Tensioner and Camshaft 

Sprockets Removal and Installation................1D-22

Timing Chain, Chain Tensioner and Camshaft 

Sprockets Inspection.......................................1D-26

Camshaft, Tappet and shim Removal and 

Installation.......................................................1D-26

Camshaft, Tappet and Shim Inspection ............1D-28
Cylinder Head Assembly Components .............1D-32
Cylinder Head Removal and Installation ...........1D-33
Cylinder Head Disassembly and Assembly ......1D-34
Cylinder Head Components Inspection and 

Servicing .........................................................1D-36

Pistons, Piston Rings, Connecting Rods, 

Cylinder and Crankshaft Components ............1D-43

Pistons, Piston Rings, Connecting Rods, 

Cylinder and Crankshaft Disassembly and 
Assembly ........................................................1D-44

Cylinder, Piston and Piston Ring Inspection 

and Servicing ..................................................1D-51

Piston Pin and Conrod Inspection.....................1D-54
Crank Pin and Conrod Bearing Inspection........1D-55
Selection of Conrod Bearing .............................1D-57
Crankshaft Inspection .......................................1D-59
Crankshaft Main Bearing Inspection .................1D-60
Crankshaft Oil Seal Inspection..........................1D-63
Crankshaft Upper Oil Seal Replacement ..........1D-63

Power Unit Lubrication ............................1E-1

General Description .............................................1E-1

Engine Lubrication Description ...........................1E-1

Schematic and Routing Diagram........................1E-1

Engine Oil Lubrication Chart ...............................1E-1

Diagnostic Information and Procedures............1E-2

Oil Pressure Check .............................................1E-2
Oil Change Reminder System.............................1E-2
Low Oil Pressure Caution System ......................1E-2
Powerhead Lubrication System Diagnosis..........1E-2

Service Instructions.............................................1E-3

Oil Pump Removal and Installation .....................1E-3
Oil Pump Disassembly and Assembly ................1E-3
Inspection Oil Pump Component Parts ...............1E-4
Oil Pressure Switch Removal and Installation ....1E-5
Oil Pressure Switch Inspection ...........................1E-6
Oil Strainer Removal and Installation..................1E-6
Oil Strainer Related Parts Inspection ..................1E-6

Power Unit Cooling System ....................1F-1

General Description ............................................. 1F-1

Water Cooling System Description ..................... 1F-1

Displacement Type Water Pump Description ..... 1F-1
Water Pressure Valve Description ...................... 1F-1

Schematic and Routing Diagram ........................ 1F-2

Cooling Water Circulation Chart.......................... 1F-2

Diagnostic Information and Procedures ............ 1F-3

Powerhead Cooling System Diagnosis ............... 1F-3

Service Instructions ............................................. 1F-3

Thermostat Removal and Installation.................. 1F-3
Thermostat Inspection......................................... 1F-4
Water Pressure Valve Removal and 

Installation ......................................................... 1F-4

Water Pressure Valve Related Item 

Inspection.......................................................... 1F-5

Water Pump Removal and Installation................ 1F-5
Water Pump Related Item Inspection ................. 1F-5
Water Tube Removal and Installation ................. 1F-5
Water Tube Related Item Inspection................... 1F-5

Fuel System ............................................. 1G-1

Precautions.......................................................... 1G-1

Precautions on Fuel System Service ................. 1G-1

General Description ............................................ 1G-2

Electronic Fuel Injection System Description ..... 1G-2
Fuel Delivery System Components 

Description ....................................................... 1G-4

High Pressure Fuel Pump Control System 

Description ....................................................... 1G-7

Air Intake Components Description.................... 1G-8
Idle Air Control System Description ................... 1G-9

Diagnostic Information and Procedures ......... 1G-11

Fuel Pressure Inspection ................................. 1G-11
Fuel System Diagnosis .................................... 1G-13
Fuel Injection System Troubleshooting ............ 1G-14

Service Instructions .......................................... 1G-15

Fuel Pressure Relief Procedure ....................... 1G-15
Fuel Line Removal and Installation .................. 1G-15
Fuel Line Inspection ......................................... 1G-15
Fuel Leakage Check Procedure....................... 1G-16
Inspection of Fuel Hose Connections .............. 1G-16
High Pressure Fuel Pump Operating Sound 

Inspection....................................................... 1G-16

Fuel Vapor Separator Removal and 

Installation ...................................................... 1G-17

Fuel Vapor Separator Disassembly and 

Assembly........................................................ 1G-17

Inspection of Fuel Vapor Separator 

Component Parts ........................................... 1G-21

Fuel Injector Inspection with Injector in place .. 1G-22
Individual Fuel Injector Operating Sound 

Inspection....................................................... 1G-22

Fuel Injector Operating Signal Inspection ........ 1G-23
Fuel Injector Removal and Installation ............. 1G-24
Low Pressure Fuel Pump Removal and 

Installation ...................................................... 1G-26

Low Pressure Fuel Pump Inspection ............... 1G-26

Ignition System........................................ 1H-1

General Description .............................................1H-1

Ignition System Description.................................1H-1

Summary of Contents for GF60A

Page 1: ...9 9 5 0 0 8 8 L 0 0 0 1 E ...

Page 2: ... judgment and observe basic mechanical safety principles WARNING Indicates a potential hazard that could result in death or injury WARNING CAUTION Indicates a potential hazard that could result in motor damage NOTE Indicates special information to make maintenance easier or instructions clearer WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified servi...

Page 3: ...uick service NOTE This manual is compiled based on 2010 K10 model COPYRIGHT SUZUKI MOTOR CORPORATION 2009 This manual has been prepared using the latest information available at the time of publication Differences may exist between the content of this manual and the actual outboard motor Illustrations in this manual are used to show the basic principles of operation and work procedures and may not...

Page 4: ...es 1C 1 Power Unit Mechanical 1D 1 Power Unit Lubrication 1E 1 Power Unit Cooling System 1F 1 Fuel System 1G 1 Ignition System 1H 1 Starting System 1I 1 Charging System 1K 1 Mid Unit 2 i Precautions 2 1 Housing and Bracket 2A 1 Power Trim and Tilt 2B 1 Lower Unit 3 i Precautions 3 1 Right Hand Rotation Unit 3A 1 Wire Hose Routing 4 i Precautions 4 1 Wire Routing 4A 1 Fuel Water Hose Routing 4B 1 T...

Page 5: ...Table of Contents 00 i 00 Section 00 CONTENTS Precautions Precautions 00 1 Precautions 00 1 General Precautions 00 1 ...

Page 6: ... aid kit emergency starter rope etc When working with toxic or flammable materials make sure that the area you work in is well ventilated and that you follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil or exhaust system during or shortly after engine operation Oil can be hazardous Children and p...

Page 7: ...e bolts 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...

Page 8: ...00 3 Precautions ...

Page 9: ...B 1 General Description 0B 1 Recommended Oil and Lubricants 0B 1 Scheduled Maintenance 0B 1 Periodic Maintenance Schedule Chart 0B 1 Lubrication Point 0B 2 Service Instructions 0B 3 Engine Oil Level Check 0B 3 Engine Oil Change and Engine Oil Filter Replacement 0B 3 Gear Oil Change 0B 6 Spark Plug Removal and Installation 0B 6 Spark Plug Inspection and Cleaning 0B 7 Tappet Clearance Inspection and...

Page 10: ...ny symbol s meanings Symbol Definition Torque control required Data beside it indicates specified torque Apply oil Use engine oil unless otherwise specified Apply molybdenum oil solution Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 1 Apply SUZUKI Outboard Motor Gear Oil Apply SUZUKI Super Grease A Apply SUZUKI Moly Paste 99000 25140 Apply SUZUKI Water Resistant Grease Apply SUZUKI B...

Page 11: ...ORT Port PTT Power Trim and Tilt S SPS Shift Position Sensor STBD Starboard SIGP Start In Gear Protection T TPS Throttle Position Sensor Wire Color Symbols ZAJ6110101003 There are two kinds of colored wire used in this product One is single colored wire and the other is dual colored striped wire The single colored wire uses only one color symbol example B Black The dual colored wire uses two color...

Page 12: ...l Genuine Parts Description ZAJ6110101005 If parts replacement is necessary Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent They are precision made to ensure high quality and correct fit Outboard Motor Identification Number Location ZAJ6110101006 Model Pre fix Serial number The Model Pre fix and Serial number of motor are stamped on a plate attached to the clamp br...

Page 13: ...irst 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt How the motor is operated during this time will have direct bearing on its life span and long term durability Break in period 10 hours Warm up recommendation Allow sufficient idling time more than 5 minutes for the engine to warm up after cold engine starti...

Page 14: ... for starting the engine Additional electrical loads from the boat will require larger capacity batteries Dual purpose Cranking Deep Cycle batteries can be used if they meet the minimum specifications listed below MCA CCA or RC Do not use a Deep Cycle battery for the main cranking battery The use of Maintenance Free sealed or Gel Cell batteries is not recommended because they may not be compatible...

Page 15: ...243 Transom height S mm in type 403 15 L mm in type 524 20 X mm in type 651 25 Item Unit Data DF60AT DF60ATH Maximum output kW PS 44 1 60 Recommended operating range r min 5 300 6 300 Idle speed r min 800 50 in gear Approx 800 Item Unit Data DF60AT DF60ATH Engine type 4 stroke DOHC Number of cylinders 3 Bore mm in 72 5 2 85 Stroke mm in 76 0 2 99 Total displacement cm3 cu in 941 57 4 Compression r...

Page 16: ...Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil API classification GL 5 Gearcase oil capacity ml US lmp oz 610 20 6 21 5 Item Unit Data DF60AT DF60ATH Trim angle degree 0 22 6 to 16 Number of trim position PTT system Maximum tilt angle degree 75 6 to 69 Item Unit Data DF60AT DF60ATH Reversing system Gear Transmission Forward Neutral Reverse Reduction system Beve...

Page 17: ... 9 2 4 Oil change only 2 9 3 0 2 6 Oil filter change Thermostat operating temperature C F 58 62 136 144 Item Unit Data DF60AT DF60ATH Cylinder head distortion Limit mm in 0 06 0 002 Manifold seating faces distortion Limit mm in 0 10 0 004 Cam height IN std mm in 38 200 38 360 1 5039 1 5102 Limit mm in 38 100 1 5000 EX std mm in 37 740 37 900 1 4858 1 4921 Limit mm in 37 640 1 4819 Camshaft journal...

Page 18: ...mm in 10 8 11 2 0 43 0 44 Valve stem outside 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 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 15 0 045 Limit...

Page 19: ... 3465 Limit mm in 7 0 0 2756 2nd std mm in Approx 10 0 0 3937 Limit mm in 8 0 0 3150 Piston ring to groove clearance 1st std mm in 0 030 0 070 0 0012 0 0028 Limit mm in 0 12 0 005 2nd std mm in 0 020 0 060 0 0008 0 0024 Limit mm in 0 10 0 004 Piston ring groove width 1st std mm in 1 02 1 04 0 040 0 041 2nd std mm in 1 21 1 23 0 048 0 048 Oil std mm in 2 01 2 03 0 079 0 080 Piston ring thickness 1s...

Page 20: ...er std mm in 44 982 45 000 1 7709 1 7717 Crankshaft journal outside diameter difference out of round and taper Limit mm in 0 010 0 0004 Crankshaft bearing thickness std mm in 1 999 2 015 0 0787 0 0793 Crankshaft thrust play std mm in 0 11 0 31 0 004 0 012 Limit mm in 0 35 0 014 Crankshaft thrust bearing thickness std mm in Item Unit Data DF60AT DF60ATH Ignition timing Degrees at r min BTDC 2 25 Ov...

Page 21: ...utside diameter std mm in 22 0 0 87 Limit mm in 21 0 0 83 Failed item Code Lamp flashing pattern Fail safe system activating MAP sensor 1 3 4 YES Cylinder temp sensor 1 4 YES IAT sensor 2 3 YES CKP sensor 4 2 NO CMP sensor 2 4 NO Air intake system 2 2 YES MAP sensor 2 3 2 NO Fuel injector 4 3 NO Throttle position sensor 2 1 YES Trim sensor 3 7 NO Oil pressure switch 5 3 NO Rectifier Regulator Over...

Page 22: ... 1 8 0 Fuel delivery pipe plug union bolt Upper 12 mm 35 3 5 25 5 Lower 14 mm 35 3 5 25 5 Low pressure fuel pump bolt 6 mm 10 1 0 7 2 Thermostat cover bolt 6 mm 10 1 0 7 2 Flywheel bolt 14 mm 166 16 6 120 0 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 8 mm 23 2 3 16 5 10 mm 50 5 0 36 0 Driveshaft housing ...

Page 23: ... 2 2 3 5 16 0 25 5 Stainless steel bolt 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 7 marked bolt 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 I9J011010014 01 I9J011010015 01 I9J011010016 01 99000 22540 SUZUKI Outboard Motor Gear Oil 99000 25161 SUZUKI Water Resistant ...

Page 24: ...uge 09900 21304 Steel V block set 09900 22301 Plastigauge 0 025 0 076 mm 09900 28403 Hydrometer 09912 58432 Fuel pressure hose 09912 58442 Fuel pressure gauge 09912 58490 3 way joint hose 09913 50121 Oil seal remover 09915 47341 Oil filter wrench 09915 64512 Compression gauge 09915 69910 Compression gauge attachment 09915 77311 Oil pressure gauge 09916 10911 Valve lapper 09916 14510 Valve lifter 0...

Page 25: ...eep socket wrench 10 mm 09921 29511 Driveshaft holder 09922 59410 Propeller shaft housing installer 09922 59420 Housing installer handle 09922 89810 Shift lock pin remover 09930 25002 Pocket tester 09930 30104 Sliding hammer 09930 30161 Propeller shaft remover 09930 39411 Flywheel remover 09930 39420 Flywheel remover bolts 09930 48720 Flywheel holder 09930 76420 Timing light 09930 88730 36 pin tes...

Page 26: ...T cable extension 09950 69512 Gearcase oil leakage tester 09951 09530 Gear adjusting gauge 09951 19431 Attachment 09951 39914 Plate 09951 59910 Shaft removal and installation 09952 99310 Hand air pump 99954 53873 Stevens peak reading voltmeter CD 77 99954 53008 820 Digital voltmeter 99954 53883 Gear oil filler ...

Page 27: ...s ZAJ6110201001 Refer to Fuel and Oil Recommendations in Section 0A Page 0A 4 Scheduled Maintenance Periodic Maintenance Schedule Chart ZAJ6110205001 NOTE I Inspect and clean adjust lubricate or replace if necessary T Tighten R Replace Item to be serviced 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 Spark plug I R Breather hose an...

Page 28: ...ife of each working part of the outboard motor Apply Suzuki Water Resistant Grease to the following point Lubricate Every 50 hours 3 months Grease 99000 25161 SUZUKI Water Resistant Grease 250 g 2 2 3 3 1 1 1 4 IAJ611020001 03 1 Throttle and shift linkage 3 Grease nipple swivel bracket 2 Grease nipple swivel bracket 4 Propeller shaft ...

Page 29: ...ication SG SH SJ SL SM Viscosity rating NMMA FC W 10W 40 or SAE 10W 40 Engine Oil Change and Engine Oil Filter Replacement ZAJ6110206002 Change engine oil Initially after 20 hours 1 month and every 100 hours 6 months Replace Engine oil filter Initially after 20 hours 1 month and every 200 hours 12 months NOTE Engine oil should be changed while engine is warm When replacing engine oil filter change...

Page 30: ... amounts Oil change only 2 7 L 2 9 2 4 US Imp qt Oil filter change 2 9 L 3 0 2 6 US Imp qt 7 To reset oil change reminder system s operation time to zero cancellation NOTE Refer to Oil Change Reminder System Description in Section 1A Page 1A 14 a Turn ignition key to ON position b Pull out emergency stop switch plate 4 c Pull up emergency stop switch knob 5 three times in ten seconds A short beep ...

Page 31: ...gine oil filter a 14 N m 1 4 kgf m 10 0 lbf ft 7 Install PORT and STBD side covers Refer to Lower Side Cover Removal and Installation in Section 2A Page 2A 3 8 Pour the recommended engine oil into the oil filler opening then install oil filler cap Check the oil level in the same manner of engine oil change procedure Recommended Engine Oil 4 stroke motor oil NMMA FC W classification SG SH SJ SL SM ...

Page 32: ... CAUTION Do not reuse gaskets once removed Always use a new gasket NOTE To avoid a possible low gear oil level recheck gear oil level 10 minutes after doing procedure in step 6 If oil level is low add additional gear oil until level is correct Spark Plug Removal and Installation ZAJ6110206004 Inspect spark plug Every 100 hours 6 months Replace spark plug Every 200 hours 12 months Standard spark pl...

Page 33: ...its on spark plug base If carbon is present remove it with a spark plug cleaning machine or by carefully using a pointed tool Spark Plug Gap Measure spark plug gap with a thickness gauge Adjust to within specified range if gap is out of specification Special tool 09900 20803 Thickness gauge Spark plug gap a Standard 0 8 0 9 mm 0 031 0 035 in Condition of Electrodes Inspect electrode for a worn or ...

Page 34: ...tion 1 Remove following parts Engine lower side cover Refer to Lower Side Cover Removal and Installation in Section 2A Page 2A 3 Ring gear cover Refer to Ring Gear Cover Removal and Installation in Section 1D Page 1D 2 Ignition coils and spark plugs Refer to Spark Plug Removal and Installation Page 0B 6 and Spark Plug Inspection and Cleaning Page 0B 7 2 Remove the cylinder head cover 1 Refer to Cy...

Page 35: ...shaft and tappet while the tappet is being held with the tappet holder Use a magnet to remove and install shim When installing shim identification mark on the shim should face down towards tappet 5 After removing shim measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula Special tool B 09900 20205 Micrometer 0 25 m...

Page 36: ...r head cover gasket for damage Always replace gasket if sealing performance is suspect Tightening torque Cylinder head cover bolts b 11 N m 1 1 kgf m 8 0 lbf ft b Final assembly check All parts removed have been returned to their original positions Check hose and wire routing Refer to Wiring Harness Routing Diagram in Section 4A Page 4A 4 Check oil leakage C I D No a 2 50 mm I D No Thickness mm I ...

Page 37: ...266 268 270 272 274 276 278 280 282 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 8 2 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 22...

Page 38: ...0 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 234 236 238 240 242 244 24...

Page 39: ...Start engine and allow to warm up 3 Check engine speed and IAC duty by using Service data Engine data mode on SDS 4 If IAC duty and or idle speed is out of specification inspect idle speed control system referring to Idle air control system check Idle speed in neutral gear IAC duty 750 850 r min Duty Approx 0 30 5 Shift into forward Check in gear idle speed If not check idle air control system NOT...

Page 40: ...09 Inspect breather line and fuel line Initially after 20 hours 1 month and every 50 hours 3 months Replace breather line and fuel line Every 2 years If leakage cracks swelling or other damage is found replace the breather hose and or fuel line Fuel line check point IAJ611020028 01 ...

Page 41: ...off 2 Disconnect the inlet hose 1 and outlet hose 2 from fuel filter 3 Remove the two bolts securing filter bracket 3 then remove the filter bracket and low pressure fuel filter 4 4 Remove the cap 5 then drain and clean fuel filter 5 Install the cap then secure it with clamp 6 6 Install the fuel filter and filter bracket properly 7 Connect the fuel inlet and outlet hose to fuel filter then secure ...

Page 42: ...ly Refer to Lower Unit Removal and Installation in Section 3A Page 3A 5 Propeller Propeller Nut and Cotter Pin Inspection ZAJ6110206013 Inspect propeller propeller nut and cotter pin Initially after 20 hours 1 month and every 100 hours 6 months 1 Inspect propeller for bent chipped or broken blades Replace propeller if damage noticeably affects operation 2 Remove the propeller Refer to Propeller Re...

Page 43: ...sh to ensure maximum effectiveness CAUTION Never paint the anode NOTE The anode cover 1 may be separated from the power unit body by inserting and turning a 10 mm bolt 2 to function as a screw jack NOTE The anode 3 securing bolt should be covered with suzuki silicone seal Sealant 99000 31120 SUZUKI Silicone Seal 50 g 1 2 IAJ611020036 02 3 I9J011020023 01 1 1 IAJ611020037 03 3 IAJ611020038 01 3 IAJ...

Page 44: ...attery acid is poisonous and corrosive Avoid contact with eyes skin clothing and painted surfaces If battery acid comes in contact with any of these flush immediately with large amounts of water If acid contacts the eyes or skin get immediate medical attention Batteries should always be kept out of reach of children When checking or servicing the battery disconnect the negative black cable Be care...

Page 45: ...minal first 2 Disconnect positive terminal second Battery Solution Level Check CAUTION Once the battery has been initially serviced NEVER add diluted sulfuric acid or battery damage will occur Follow the battery manufacture s instructions for specific maintenance procedures Battery solution level should be between UPPER level and LOWER level If level is low add distilled water only Battery Solutio...

Page 46: ...plug 1 for oil pressure service port 3 Install the oil pressure gauge in place of service port Special tool A 09915 77311 Oil pressure gauge 4 Start engine and warm up Engine warm up engine speed Summer 5 min 2 000 r min Winter 10 min 2 000 r min 5 After warming up shift into forward gear and increase engine speed to 3 000 r min then compare pressure indicated on gauge to specifications NOTE The f...

Page 47: ...park plugs 5 Install compression gauge attachment into spark plug hole then connect compression gauge attachment to compression gauge Special tool A 09915 64512 Compression gauge B 09915 69910 Compression gauge attachment 6 Disconnect remote control throttle cable from throttle lever 7 Move and hold throttle lever 1 in full open position 8 While cranking engine with starter motor note maximum comp...

Page 48: ...0B 22 Maintenance and Tune Up ...

Page 49: ...ing Without Self Diagnostic Code 1A 30 IAC System Troubleshooting 1A 31 Service Instructions 1A 32 How to Use the 36 Pin Test Cord Set 1A 32 Inspection of the ECM and Its Circuit 1A 32 ECM Main Relay Inspection 1A 35 Engine Electrical Devices 1C 1 Precautions 1C 1 Precaution for Engine Electrical Device 1C 1 General Description 1C 1 Sensor and Switch Description 1C 1 ECM Power Source Line 1C 6 Com...

Page 50: ...E 6 Oil Strainer Removal and Installation 1E 6 Oil Strainer Related Parts Inspection 1E 6 Power Unit Cooling System 1F 1 General Description 1F 1 Water Cooling System Description 1F 1 Displacement Type Water Pump Description 1F 1 Water Pressure Valve Description 1F 1 Schematic and Routing Diagram 1F 2 Cooling Water Circulation Chart 1F 2 Diagnostic Information and Procedures 1F 3 Powerhead Cooling...

Page 51: ...gnostic Information and Procedures 1I 3 Starter System Symptom Diagnosis 1I 3 Starter System Troubleshooting 1I 4 Service Instructions 1I 6 Starter Motor Removal and Installation 1I 6 Starter Motor Test 1I 7 Starter Motor Components 1I 9 Starter Motor Disassembly and Assembly 1I 10 Starter Motor Components Inspection and Servicing 1I 12 Ignition Switch Inspection 1I 16 Starter Motor Relay Inspecti...

Page 52: ...1 1 Precautions Power Head Precautions Precautions Precautions for Powerhead ZAJ6111000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 53: ...onnect the high pressure fuel pump wire connector located on the fuel vapor separator CAUTION Always turn the ignition switch OFF and disconnect the battery cables when wires are being disconnected or connected Hold and pull the connectors when disconnecting Do not pull the wires NOTE To troubleshoot the ECM and the engine control system consisting of sensors and actuators use the Suzuki Diagnosti...

Page 54: ...pump Caution Buzzer Monitor tachometer Starer motor relay Starter motor Fuel injection system Ignition system Idle air control system Fuel pump system Caution system Self diagnostic system Fail safe system Operating hour indication system Oil changing reminder system Start in gear protection system Starter motor relay control system Power trim and tilt relay INPUT sensor switch CONTROL ECM OUTPUT ...

Page 55: ...essure fuel pump 3 Cylinder temp sensor 12 ECM main relay 21 Battery 30 Fuel vapor separator 4 Spark plug 13 Ignition switch 22 Fuel injector 31 Float 5 Ignition coil 14 Fuse 30 amp 23 Air intake silencer 32 High pressure fuel pump 6 CMP sensor 15 Fuse 15 amp 24 Throttle body 33 Fuel pressure regulator 7 MAP sensor 16 Starter relay 25 Intake manifold 34 Water jacket 8 Throttle position sensor 17 N...

Page 56: ... Informs the operator of abnormal engine conditions Controls engine speed if activated Self diagnostic system control Informs the operator of sensor switch malfunction Fail safe system control Allows engine operation with a back up system during sensor switch malfunction Total operating hour indication system control Informs the operator of the total operating time Oil changing reminder system con...

Page 57: ...D GND 45 71 INJECTOR 3 47 72 60 70 58 48 42 54 41 44 57 69 66 43 55 56 PWR GND 51 24 36 12 35 15 2 65 64 50 40 33 32 6 TRIM GAUGE PWR GND 63 62 38 VB MONITOR STARTER RELAY CTRL START SW 23 PTT UP SW PTT DN SW 49 22 IPS IPS 27 3 10 7 20 8 11 16 25 MAIN RELAY RELAY UP PTT RELAY DN CMP SENSOR 1 SENSOR PWR 1 TPS SENSOR PWR 2 TRIM TILT SENSOR IAT SENSOR CYL TEMP SENSOR SENSOR GND OIL PRESSURE SW EMERGE...

Page 58: ...wer source for sensor 46 11 Bl Oil pressure switch 47 R W No 3 Fuel injector 12 Gr Power source for ECM 48 W Bl IAC valve 4 13 49 Y G Neutral switch 14 50 R B CKP sensor 15 B G Ignition key switch 51 B Ground for power 16 Bl R Emergency stop switch 52 17 53 18 54 Bl No 2 Ignition coil 19 55 P W Rev Limit lamp 20 Lg W Cylinder temp sensor 56 Y B Tachometer 21 57 G Y TEMP lamp 22 P PTT switch DN 58 ...

Page 59: ... Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed Over revolution limiter DF60 6 400 r min Action Reset Close the throttle to reduce the engine speed below approx 3 000 r min for one second A REV LIMIT lamp C TEMP lamp B OIL lamp D CHECK ENGINE lamp C B D A I9J011110004 02 Caution Type Caution Lamp Caution Buzzer Engine RPM Limited Over revolution Yes A No...

Page 60: ...is restored to over 100 kPa 1 0 kg cm2 14 psi at approx 1 000 r min or less engine speed operation The engine must be stopped and checked immediately once the system is activated Overheat Caution System Condition 1 Maximum temperature Immediate activation of the system when Cylinder temperature reaches 100 C 212 F Condition 2 Gradient temperature Temp rise vs Time Immediate activation of the syste...

Page 61: ...ipment requiring high amperage such as hydraulic trim tabs hydraulic jack plate etc after this caution is activated Condition 2 For the caution system to engage under this condition possibilities such as a deteriorated battery poor battery cable connection battery switch in the OFF position etc must be inspected To cancel the caution system activation for these conditions check all power source re...

Page 62: ...g the ignition key in Monitor Tachometer Priority Code Pattern for Self Diagnostic System Operation 0 OFF 1 ON A CHECK ENGINE lamp A I9J011110005 01 Priority Failed Item Code Lamp Flashing Pattern Fail Safe System Active 1 MAP sensor 1 3 4 Yes 2 Cylinder temp sensor 1 4 Yes 3 IAT sensor 2 3 Yes 4 CKP sensor 4 2 No 5 CMP sensor 2 4 No 6 Air intake system 2 2 Yes 7 MAP sensor 2 3 2 No 8 Fuel injecto...

Page 63: ...gine running Receiving an out of range 37 860 mmHg 1 45 33 85 inHg 0 2 4 5 V signal With the engine running Cylinder temp sensor No signal Receiving an out of range 46 to 170 C 114 8 338 F 0 10 4 6 V signal IAT sensor No signal Receiving an out of range 46 to 169 C 114 8 336 2 F 0 10 4 6 V signal CKP sensor During one crankshaft rotation 30 signals are not received by the ECM During cranking CMP s...

Page 64: ...l four lamps in the monitor tachometer and sounding the caution buzzer for an initial two seconds For the next three seconds the ECM indicates the total operating hours using a combination of the tachometer needle and REV LIMIT lamp flash NOTE The total operating hours displayed are those of the actual engine operation not the ignition switch ON time Monitor Tachometer Failed Item Pre Programmed V...

Page 65: ...Hours Monitor Tachometer Needle A Indication REV LIMIT Lamp B Flashing 0 h 49 h No No 50 h 500 r min 60 h 600 r min 540 h 5 400 r min 550 h 500 r min 1 time 560 h 600 r min 1 040 h 5 400 r min 1 050 h 500 r min 2 times 1 540 h 5 400 r min 1 550 h 500 r min 3 times 2 030 h 5 300 r min 2 040 h or over 5 400 r min 3 times ...

Page 66: ... three times in ten seconds A short beep will be heard if the cancellation is successful 4 Turn the ignition key to the OFF position 5 Set the emergency stop switch plate 1 into the original position NOTE Cancellation of the system is possible whether or not the engine oil has been replaced Once the system has been activated SUZUKI strongly recommends that the engine oil be replaced before canceli...

Page 67: ...n and Procedures ECM Power and Ground Circuit Check ZAJ6111104001 Wiring Diagram Circuit Description When the ignition switch is turned ON the main relay turns ON the contact point closes and the main power is supplied to the ECM BATT ECM IG GND 12 36 Gr W W R W B Gr B Gr B Bl B G 15 W 35 R B 1 3 4 2 5 6 IAJ611110004 01 1 Starter motor 3 30 amp fuse 5 ECM main relay 2 Battery cable 4 30 amp fuse 6...

Page 68: ...re open shorted or poor connection 4 1 Turn the ignition switch OFF 2 Connect the 36 pin test cord set between the ECM and the main wire harness 3 Turn the ignition switch ON 4 Measure the voltage between the No 36 terminal and body ground and the No 15 terminal and body ground Is the voltage 12 V Battery Voltage Go to step 5 Check the ignition switch Refer to Ignition Switch Inspection in Section...

Page 69: ...r lead wire continuity 3 Disconnect the MAP sensor connector at sensor 4 Check the continuity between R wire terminal and B W wire terminal Is it no continuity Go to step 2 R wire shorted to B W wire 2 1 With the ignition switch ON check the voltage at the R wire terminal of MAP sensor and ground Is the voltage approx 4 5 V Go to step 3 R wire open R wire shorted to ground circuit or poor connecti...

Page 70: ...Page 1C 12 Is it in good condition Substitute a known good ECM and recheck Faulty MAP sensor R wire shorted to W wire B W wire open poor B W wire connection poor W wire connection W wire open or poor MAP sensor connection If the wiring and connection is OK intermittent trouble or a faulty ECM may be the cause Step Action Yes No ...

Page 71: ...ion switch ON check the voltage at the Lg W wire terminal of the Cylinder Temp Sensor connector Is the voltage 4 V or more Go to step 2 Lg W wire shorted to the B W wire or ground circuit If the wiring is OK substitute a known good ECM and recheck 2 1 Check the Cylinder Temp Sensor Refer to Cylinder Temp Sensor Inspection in Section 1C Page 1C 8 Is it in good condition Poor Cylinder Temp Sensor co...

Page 72: ...ire continuity 3 Disconnect the IAT sensor connector at sensor 4 Check the continuity between Lg B wire terminal and B W wire terminal Is it no continuity Go to step 2 Lg B wire shorted to B W wire 2 1 With the ignition switch OFF disconnect the IAT sensor connector 2 With the ignition switch ON check the voltage at the Lg B wire terminal of the IAT sensor connector Is the voltage 4 V or more Go t...

Page 73: ...and Installation in Section 1C Page 1C 9 Is it in good condition Go to step 2 Incorrectly adjusted air gap 2 1 Check the CKP sensor resistance Refer to Resistance Check in Section 1C Page 1C 7 Is it in good condition Open wire between the CKP sensor and the ECM poor lead wire connection or sensor lead wires are shorted to each other If lead wire and connection are ok intermittent trouble or a faul...

Page 74: ...e CMP sensor connector CMP sensor voltage Terminal B Bl 10 14 V Terminal Y Bl 4 5 V Terminal B W 0 V Is the voltage satisfactory Go to step 5 Go to step 3 3 Was terminal Y Bl voltage in step 2 within specification Go to step 4 Y Bl wire open or shorted to ground power supply circuit If the wiring and connection is OK substitute a known good ECM and recheck 4 Was terminal B Bl voltage in step 2 wit...

Page 75: ...or Is the voltage approx 4 5 V Go to step 2 R wire open R wire shorted to ground circuit or poor wire connection If the wiring and connection is OK substitute a known good ECM and recheck 2 1 Check the TPS output voltage change Refer to TPS Inspection in Section 1C Page 1C 13 Is it in good condition Go to step 3 Faulty TPS R wire shorted to Br Y wire B W wire open poor B W wire connection poor Br ...

Page 76: ...the voltage approx 4 5 V Go to step 2 R wire open R wire shorted to ground circuit or poor wire connection If the wiring and connection is OK substitute a known good ECM and recheck 2 1 Check the MAP sensor output voltage change Refer to MAP Sensor Output Voltage Inspection in Section 1C Page 1C 12 Is it in good condition Go to step 3 Faulty MAP sensor 3 1 Check the TPS output voltage change Refer...

Page 77: ...and the wire harness of the fuel injector not making the operating sound Are all of the above OK Substitute a known good ECM and recheck Faulty injector or its circuit 3 1 With the ignition switch OFF disconnect the connector from the fuel injector 2 Check the voltage at Gr wire terminal with the ignition switch ON Is the voltage 12 V battery voltage Go to step 4 Power circuit open 4 1 Disconnect ...

Page 78: ...heck the TPS lead wire continuity 3 Disconnect the TPS connector at sensor 4 Check the continuity between Br Y wire terminal and R wire terminal Is it no continuity Go to step 2 R wire shorted to Br Y wire 2 1 With the ignition switch ON check the voltage at the R wire terminal of TPS and ground Is the voltage approx 4 5 V Go to step 3 R wire open R wire shorted to ground circuit or poor connectio...

Page 79: ...s it in good condition Substitute a known good ECM and recheck Faulty TPS R wire shorted to Br Y wire B W wire open poor B W wire connection poor Br Y wire connection Br Y wire open or poor TPS connection If the wiring and connection is OK intermittent trouble or a faulty ECM may be the cause Step Action Yes No ...

Page 80: ...lty Rectifier Regulator 2 1 With the engine running check charging voltage at idle speed Is the result 16 V or higher Faulty Rectifier Regulator Faulty ECM or wire continuity connection failure 1 Oil pressure switch ECM Bl C P U 1 I9J011110063 01 Step Action Yes No 1 1 With the ignition switch OFF remove the oil pressure switch wire 2 With the ignition switch ON check the voltage between the oil p...

Page 81: ...e open R wire shorted to ground circuit or poor wire connection If the wire and connection is OK substitute a known good ECM and recheck 2 1 Check the trim sensor output voltage change Refer to Trim Sensor Inspection in Section 1C Page 1C 14 Is it in good condition Poor trim sensor connection intermittent trouble or a faulty ECM R wire shorted to W Y wire B W wire open poor B W wire connection poo...

Page 82: ... stall Clogged MAP sensor vacuum passage Check the vacuum passage Malfunctioning TPS Check the TPS sensor Faulty IAC system Check the IAC system Fuel pressure out of specification Check the fuel pressure Faulty injector or its circuit Check the injector and its circuit Poor performance of the IAT sensor TPS or MAP sensor Check each sensor Faulty ECM Replace Faulty spark plug Replace Faulty ignitio...

Page 83: ...min approx 0 30 Is result OK IAC system is in good condition Go to step 2 2 1 Disconnect the IAC connector at the IAC valve with ignition switch OFF 2 Check the resistance between following terminals IAC 1 terminal B terminal IAC 2 terminal B terminal IAC 3 terminal A terminal IAC 4 terminal A terminal Is the resistance 25 34 Ω for each test Proceed to Unstable Idling Trolling in Troubleshooting W...

Page 84: ...engine wiring harness Special tool 09930 88730 36 pin test cord set 09930 99320 Digital tester Tester knob indication Voltage 1 Turn the ignition switch OFF 2 Connect the 36 pin test cord set between the ECM and wire harness as shown in figure 3 Turn the ignition switch ON 4 Connect the tester probe Black to body ground and measure the voltage according to the Circuit Voltage Table Page 1A 33 37 5...

Page 85: ...J011110017 02 A Black connector B Gray connector Terminal Wire color Circuit Standard Voltage Condition Remarks 1 2 G Starter relay control Approx 0 5 V Ignition switch ON Cranking Approx 12 V Ignition switch ON Normal 3 P W PTT relay DN Approx 0 V PTT switch DN free Approx 12 V PTT switch DN Push 4 5 6 Br Y Throttle position sensor Approx 3 8 V Ignition switch ON Throttle WOT Approx 0 7 V Ignitio...

Page 86: ...ition switch ON 37 38 Y PC communication line B 39 40 Y Bl CMP sensor Approx 0 3 V or 5 V Ignition switch ON 41 Gr Y No 3 Ignition coil Approx 0 V Ignition switch ON 42 O No 1 Ignition coil Approx 0 V Ignition switch ON 43 Y Trim gauge 44 Bl W Buzzer 45 O B No 1 Fuel injector Approx 12 V Ignition switch ON 46 47 R W No 3 Fuel injector Approx 12 V Ignition switch ON 48 W Bl IAC valve 4 Approx 12 V ...

Page 87: ...ion replace ECM main relay Tester knob indication Resistance Ω ECM Main relay solenoid coil resistance Standard 145 190 Ω 65 Br Starter switch Approx 2 5 V Ignition switch ON Approx 12 V Ignition switch START position 66 Bl B OIL lamp 67 68 69 G W CHECK ENGINE lamp 70 R Y IAC Valve 2 Approx 12 V or 0 V Ignition switch ON 71 B Br No 2 Fuel injector Approx 12 V Ignition switch ON 72 B R High pressur...

Page 88: ...le There are 30 reluctor bars They are located 10 degrees apart except at three positions where they are 30 degrees apart During one crankshaft rotation 30 signals are input to the ECM Failure symptom Without the CKP sensor signal input the ECM does not output the ignition and fuel injection signals CMP Sensor The CMP sensor is mounted on the cylinder head cover and the trigger vanes are pressed o...

Page 89: ...e camshaft rotation two rotations of crankshaft Failure symptom Without the CMP sensor signal input the ECM does not output the ignition and fuel injection signals ECM cylinder identification The cylinders are identified by a calculation of two signals one from the CKP sensor and one from the CMP sensor The ECM measures the time interval of the signals inputted from the CKP sensor When the ECM det...

Page 90: ...ensors MAP sensor TPS IAT sensor are combined into one unit that is installed on top of the throttle body IAT sensor is used to detect the intake air temperature It is a thermistor type sensor and inputs a signal to the ECM as a voltage value This signal is used to compensate the fuel injection duration MAP Sensor Three sensors MAP sensor TPS IAT sensor are combined into one unit that is installed...

Page 91: ...llowing control based on the neutral switch signal When the shift lever is in neutral fuel injection is controlled to prevent engine speed from exceeding 3 000 r min After shifting into forward or reverse from neutral the IAC valve is controlled to increase intake air to prevent unstable engine idle or stalling When the shift lever is in forward or reverse at the time of engine start the ECM will ...

Page 92: ...FF position and the UP or DOWN button of the PTT switch pressed the main relay turns ON to supply 12 V power to the ECM which then performs the on off control of the PTT motor relay Cranking Switch Signal The ECM detects if the engine is being started by the position of ignition switch When the ignition key is turned to ST position a voltage 12 V signal is input to the ECM The ECM in turn sets the...

Page 93: ...s the voltage in the engine control system circuit If a short occurs in this circuit the ECM 30 amp fuse will blow causing the engine control system to be inoperative If an open occurs in this circuit the cranking system will not function Emergency Stop Switch When the cord from the plate of the switch is secured to the operator the plate will be pulled off if the operator is suddenly thrown overb...

Page 94: ...4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 1 2 3 I9J011130006 04 1 Engine main wire harness 2 Black connector 3 Gray connector Circuit Terminal for Tester Probe Connection Standard Resistance at 20 C CKP sensor 50 R B to 25 B W 168 252 Ω Fuel...

Page 95: ...uting Refer to Wiring Harness Routing Diagram in Section 4A Page 4A 4 Cylinder Temp Sensor Inspection ZAJ6111306003 1 Remove the cylinder temperature sensor Refer to Cylinder Temp Sensor Removal and Installation Page 1C 8 2 Immerse temperature sensing part of cylinder temp sensor in water 3 Measure resistance between sensor terminals while heating water gradually 4 If measured resistance does not ...

Page 96: ...e position sensor as follows 1 Turn the ignition key to ON position 2 Disconnect connector of the MAP throttle IAT sensor at sensor side 3 The calibration is completed when the diagnostic cord of the throttle position sensor failure is displayed NOTE When calibration is completed the failure history of the MAP sensor IAT sensor and the throttle position sensor is automatically memorized in the ECM...

Page 97: ... drop as temperature goes up 1 Disconnect wire harness connector at ECM 2 Connect tester probes to No 8 terminal and No 25 terminal wire harness side and measure resistance Special tool 09930 99320 Digital tester Tester knob indication Resistance Ω IAT sensor resistance temperature 1 8 2 3 kΩ 25 C 77 F 3 If out of specification check wire harnesses for open and short If wire harnesses are in good ...

Page 98: ... 36 pin test cord set between ECM and wire harness as shown in figure Special tool A 09930 88730 36 pin test cord set 5 Connect the tester probe Red to No 40 terminal 6 Connect the tester probe Black to No 25 terminal or to body ground Special tool 09930 99320 Digital tester Tester knob indication DC Voltage 36 pin test cord White connector 36 pin test cord Black connector 1 IAJ611130022 01 2 IAJ6...

Page 99: ...orward Gradually increase engine speed to 3 000 rpm then measure the voltage change at 32 terminal sensor output Special tool 09930 99320 Digital tester Tester knob indication DC Voltage MAP sensor output voltage change Fully closed throttle Approx 1 4 V 258 mmHg 1 000 rpm Approx 1 5 V 290 mmHg 2 000 rpm Approx 2 V 407 mmHg 3 000 rpm Approx 3 V 604 mmHg 5 If sensor voltage change is out of the spe...

Page 100: ... valve turns to open and returns to closed 7 If the valve does not turn check the wiring harness for continuity between ECM and IAC valve and connector contact condition 8 Reinstall IAC valve Refer to IAC Valve Removal and Installation Page 1C 12 TPS Inspection ZAJ6111306016 1 Turn ignition switch OFF 2 Connect the 36 pin test cord set between ECM and wire harness as shown in figure Special tool A...

Page 101: ...top of the throttle body Never loosen the screws securing TPS TPS position has been adjusted the factory and must not be changed 7 If out of specification check wire harnesses for open and short If wire harnesses are in good condition replace the throttle body and recheck Trim Sensor Inspection ZAJ6111306018 1 Turn ignition switch OFF 2 Connect 3 pin test cord between trim sensor and wire harness ...

Page 102: ...heck Emergency Stop Switch Inspection ZAJ6111306021 1 Disconnect the emergency stop switch lead wire 2 Check the continuity infinity between the wiring leads under the condition shown below Special tool A 09930 99320 Digital tester Tester knob indication Continuity 3 If out of specification replace the switch Trim Tilt position Output voltage Full trim down Approx 0 9 V Full tilt up Approx 4 0 V B...

Page 103: ...The double overhead camshaft is mounted over the cylinder head it is driven from crankshaft through timing chain and no pushed rods are provided in the valve train system Cylinder Number Cylinder number is as mentioned in figure Diagnostic Information and Procedures Cylinder Compression Check ZAJ6111404001 Refer to Cylinder Compression Pressure Check in Section 0B Page 0B 21 Oil Pressure Check ZAJ...

Page 104: ...ation is reverse order of removal Cylinder Head Cover Removal and Installation ZAJ6111406003 Removal Before removing cylinder head cover disconnect battery cables from battery 1 Remove both lower side covers Refer to Lower Side Cover Removal and Installation in Section 2A Page 2A 3 2 Loosen the clamp securing breather hose 1 then remove the breather hose from cylinder head cover 3 Remove the bolts...

Page 105: ... remove the cylinder head cover Installation Installation is reverse order of removal with special attention to the following steps Clean sealing surface on cylinder head and cover Remove oil old sealant and dust from sealing surfaces After cleaning apply sealant to cylinder head sealing surface area as shown in figure Sealant 99000 31140 SUZUKI Bond 1207B 100 g Install new cylinder head cover gas...

Page 106: ...Installation in Section 1I Page 1I 6 2 Remove the breather hose 1 from silencer case 2 Installation Installation is reverse order of removal Install the silencer case and starter motor Refer to Starter Motor Removal and Installation in Section 1I Page 1I 6 Electric Parts Holder Removal and Installation ZAJ6111406005 Removal Before removing electric parts holder disconnect battery cables from batte...

Page 107: ...the lead wire connectors for the cylinder temp sensor 6 high pressure fuel pump 7 and disconnect them from main harness Remove the bolt 8 securing harness clamp plate 8 Disconnect the MAP throttle position IAT sensor lead wire connector 9 at sensor 9 Loosen the screw 10 and disconnect blue lead wire 11 from oil pressure switch Remove the screw securing the harness clamp plate 12 2 IAJ611140047 01 ...

Page 108: ...e electric parts holder refer to following a Remove the nut 18 positive battery cable 19 and positive lead wire 20 from magnetic switch 21 of starter motor b Disconnect the red lead wire 22 from magnetic switch S terminal c Remove the bolt 23 securing negative battery cable 24 Pull battery cable out of electric parts holder d Cut the cable tie 25 securing main harness 13 14 IAJ611140053 01 15 16 I...

Page 109: ...the fuse box 28 from electric parts holder then remove the nut 29 and PTT motor relay positive lead wire 30 h Disconnect the PTT relay lead wire connector 31 Remove the PTT relay 32 i Remove the capacitor 33 joint connectors 34 from electric parts holder j Pull the main harness out of electric parts holder 26 IAJ611140060 01 27 28 IAJ611140061 01 30 29 IAJ611140063 01 32 31 IAJ611140062 01 34 33 I...

Page 110: ...ustration Refer to Wiring Harness Routing Diagram in Section 4A Page 4A 4 and Fuel Hose Routing in Section 4B Page 4B 1 Upper Oil Seal Housing Removal and Installation ZAJ6111406031 Removal 1 Remove the battery charge coil 1 Refer to Battery Charge Coil Removal and Installation in Section 1K Page 1K 5 2 Remove the bolts securing hose clamps 2 3 Remove the screws and CKP sensor 3 4 Remove the seven...

Page 111: ... oil seal housing 3 and secure with bolts Tightening torque Upper oil seal housing bolt 6 mm a 11 N m 1 1 kgf m 8 0 lbf ft Install the battery charge coil Refer to Battery Charge Coil Removal and Installation in Section 1K Page 1K 5 Intake Manifold and Throttle Body Components ZAJ6111406006 1 1 2 IAJ611140071 01 3 a IAJ611140072 01 1 2 3 5 6 7 8 4 9 IAJ611140002 02 1 Intake manifold assembly 4 Bra...

Page 112: ...ody to intake manifold then detach the throttle body 6 Disconnect the MAP throttle position IAT sensor lead wire connector 6 at sensor Installation Installation is reverse order of removal with special attention to the following steps CAUTION Do not reuse gaskets always replace with new one Clean mating surface and install the seal ring 1 Install the throttle body 2 then securely tighten the four ...

Page 113: ...ottle lever and throttle valve moves smoothly Replace throttle body if necessary Intake Manifold Removal and Installation ZAJ6111406007 Removal 1 Relieve fuel pressure Refer to Fuel Pressure Relief Procedure in Section 1G Page 1G 15 2 Disconnect battery cables from battery 3 Remove both lower side covers Refer to Lower Side Cover Removal and Installation in Section 2A Page 2A 3 4 Remove the ring g...

Page 114: ... To remove the intake manifold refer to following a Disconnect the high pressure fuel pump lead wire connector 7 at fuel pump b Disconnect the evaporation hose 8 from fuel vapor separator 9 c Disconnect the fuel cooler water inlet hose 10 and outlet hose 11 from the fuel vapor separator 9 4 IAJ611140083 02 5 IAJ611140084 01 6 1 IAJ611140085 01 2 3 4 5 6 7 8 9 IAJ611140086 01 7 IAJ611140087 01 8 9 ...

Page 115: ...sembly 2 then tighten bolts and nuts securely Tightening torque Intake manifold bolt nut a 23 N m 2 3 kgf m 16 5 lbf ft Install fuel injectors and fuel delivery pipe Refer to Fuel Injector Removal and Installation in Section 1G Page 1G 24 Install the throttle body Refer to Throttle Body Removal and Installation Page 1D 10 Perform the following final assembly checks to ensure proper and safe operat...

Page 116: ... 09930 39420 Flywheel remover bolts 5 Remove the battery charge coil 2 Refer to Battery Charge Coil Removal and Installation in Section 1K Page 1K 5 6 Remove the starter motor 3 Refer to Starter Motor Removal and Installation in Section 1I Page 1I 6 7 Remove the bolts and rectifier regulator 4 Refer to Rectifier Regulator Removal and Installation in Section 1K Page 1K 6 8 Remove the throttle body ...

Page 117: ...move the electric parts holder 10 Refer to Electric Parts Holder Removal and Installation Page 1D 4 13 Remove the five bolts and upper oil seal housing 11 14 Remove the two bolts securing front panel 12 15 Disconnect the water return hose 13 then remove the thermostat cover 14 and thermostat 16 Loosen and remove the cylinder temperature sensor 15 6 IAJ611140099 01 7 7 8 8 IAJ611140100 01 9 IAJ6111...

Page 118: ...20 Remove the bolt 21 throttle lever 22 and clutch control lever 23 21 Remove the screws and neutral switch 24 if necessary 22 Remove the two bolts and clutch lever holder 25 with clutch shaft 26 23 Remove the side cover seal 27 24 Remove the bolt and oil level dipstick tube 28 16 IAJ611140107 01 17 18 IAJ611140108 01 20 19 19 IAJ611140109 01 21 22 23 IAJ611140110 01 24 25 26 IAJ611140111 01 27 IA...

Page 119: ... unit Install dowel pins 1 gasket 2 and seal ring 3 Apply water resistant grease to driveshaft splines Grease 99000 25161 SUZUKI Water Resistant Grease 250 g Install the engine holder seal 4 NOTE Install seal 4 with lip facing upward NOTE Before installing power unit apply sealant to the four hatched areas shown in the illustration at below Sealant 99000 31140 SUZUKI Bond 1207B 100 g 29 29 29 IAJ6...

Page 120: ...KI Silicone Seal 50 g Tightening torque Power unit mounting bolt 8 mm a 23 N m 2 3 kgf m 16 5 lbf ft Power unit mounting bolt 10 mm b 50 N m 5 0 kgf m 36 0 lbf ft Thermostat Assemble thermostat 1 and thermostat cover 2 to cylinder block and secure with bolts Refer to Thermostat Removal and Installation in Section 1F Page 1F 3 Upper oil seal housing Apply engine oil to upper oil seal lip a b IAJ611...

Page 121: ... Battery Charge Coil Removal and Installation in Section 1K Page 1K 5 Install flywheel 3 and tighten flywheel bolts to specified torque Refer to Flywheel Removal and Installation in Section 1K Page 1K 4 Tightening torque Flywheel bolt a 166 N m 16 6 kgf m 120 lbf ft Special tool A 09930 48720 Flywheel holder Cylinder head cover Install cylinder head cover 1 Refer to Cylinder Head Cover Removal and...

Page 122: ... 1D 10 Perform the following final assembly checks to ensure proper and safe operation All parts removed have been returned to their original positions Fuel and water hose routing matches service manual illustration Refer to Fuel Hose Routing in Section 4B Page 4B 1 and Water Hose Routing in Section 4B Page 4B 4 Wire routing matches service manual illustration Refer to Wiring Harness Routing Diagr...

Page 123: ... 3 17 5 6 4 8 9 11 12 10 7 1 IAJ611140133 02 1 Timing chain 6 Spacer 11 Bolt 16 Bolt 2 Bolt 7 Chain tensioner 12 Exhaust camshaft sprocket 17 Crankshaft 3 Chain guide 8 Bolt 13 Dowel pin 65 N m 6 5 kgf m 47 0 lbf ft 4 Bolt 9 Chain tensioner link 14 Intake camshaft sprocket Apply oil 5 Washer 10 Tensioner adjuster 15 Washer ...

Page 124: ...ankshaft with mark B on the crankcase or position the keyway on crankshaft for fixing flywheel to 12 o clock position toward cylinder head CAUTION When timing chain has been removed never turn crankshaft or camshaft 3 Remove the bolts 1 and timing chain tensioner link 2 4 Remove the bolts 3 and chain tensioner adjuster 4 5 Remove the bolts 5 and timing chain guide 6 6 Remove the bolt 7 and timing ...

Page 125: ...n in figure 2 Check that match mark C on exhaust camshaft timing sprocket aligns with match mark D on cylinder head as shown in figure 3 Fit the dowel pin 1 onto IN camshaft Then turn the camshaft to position the dowel pin at the bottom as shown in figure 4 Install timing chain by aligning blue plate F of timing chain and match mark E on exhaust camshaft timing sprocket as shown in figure Install ...

Page 126: ...en tighten bolt 6 securely Apply engine oil to chain tensioner 7 Install timing chain guide 7 then tighten bolt securely 8 With latch of tensioner adjuster 8 pushed in and plunger pushed back into body insert stopper into latch and body After inserting stopper check to make sure that plunger will not come out 9 Install timing chain tensioner adjuster 8 then tighten bolts 9 to specified torque Tigh...

Page 127: ... mark B on crankcase Keyway of flywheel on crankshaft should be positioned to 12 o clock position toward cylinder head Match mark C on exhaust camshaft timing sprocket is aligned with match mark D on cylinder head Engraved line I on intake camshaft timing sprocket is aligned with cylinder head cover mating face J 15 Install oil pump Refer to Oil Pump Removal and Installation in Section 1E Page 1E ...

Page 128: ...r shoe for wear or damage If excessive wear or other damage is found replace it Check chain guide shoe for wear or damage If excessive wear or other damage is found replace it Camshaft Timing Sprocket Check teeth of sprocket for wear or damage If excessive wear or other damage is found replace it Camshaft Tappet and shim Removal and Installation ZAJ6111406014 Removal 1 Remove the oil pump Refer to...

Page 129: ... thickness for each individual cylinder valve position Installation 1 Apply engine oil around tappets and install them 2 Install tappet shims 3 Apply engine oil to surface of each camshaft lobe and journal then install them NOTE Before installing camshafts align crankshaft match mark A with match mark B on crankcase Install IN camshaft so that dowel pin hole C on the camshaft is position as shown ...

Page 130: ...f m 8 0 lbf ft 9 Install timing chain Refer to Timing Chain Chain Tensioner and Camshaft Sprockets Removal and Installation Page 1D 22 10 Adjust tappet clearance 11 Install oil pump Refer to Oil Pump Removal and Installation in Section 1E Page 1E 3 Camshaft Tappet and Shim Inspection ZAJ6111406015 NOTE If any component is worn excessively cracked defective or damaged in any way it must be replaced...

Page 131: ...for pitting scratches wear or damage If any of the above conditions are found replace camshaft or cylinder head with housing NOTE Camshaft housing and cylinder head must be replaced as a set Camshaft Journal Oil Clearance Check journal oil clearance using Plastigauge as follows 1 Clean housing and camshaft journals 2 Install camshaft to cylinder head 3 Place Plastigauge across the full width of ca...

Page 132: ...ance Standard 0 045 0 087 mm 0 0018 0 0034 in Service limit 0 120 mm 0 0047 in If journal oil clearance exceeds the service limit measure camshaft journal outside dia and camshaft housing inner dia Based on measurements replace camshaft and or cylinder head with camshaft housing Camshaft journal outside diameter No 1 No 4 Standard 22 934 22 955 mm 0 9029 0 9037 in Camshaft journal housing inside d...

Page 133: ...er head to tappet clearance If clearance exceeds service limit replace tappet or cylinder head Special tool 09900 20202 Micrometer 25 50 mm 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 Cylinder head tappet bore Standard 27 000 27 021 mm 1 0630 1 0638 in I9J011140076 ...

Page 134: ... IAJ611140011 02 1 Intake valve 5 Valve stem seal 9 Tappet 59 N m 5 9 kgf m 42 7 lbf ft 2 Exhaust valve 6 Valve spring 10 Tappet shim 23 N m 2 3 kgf m 16 5 lbf ft 3 Valve guide 7 Valve spring retainer 11 Cylinder head bolt 10 mm Apply engine oil 4 Valve spring seat 8 Valve cotter 12 Cylinder head bolt 8 mm ...

Page 135: ...deep socket wrench when loosening cylinder head bolts Special tool A 09919 16010 Deep socket wrench 10 mm Installation Installation is in reverse order of removal paying special attention to the following steps CAUTION Do not reuse gasket Always use a new gasket 1 Insert the dowel pins 1 and place a new cylinder head gasket 2 into position on the cylinder NOTE Before installing cylinder head gaske...

Page 136: ...ighten all cylinder head bolts to specified torque according to sequence in figure Tightening torque Cylinder head bolt Final step 10 mm 59 N m 5 9 kgf m 42 7 lbf ft Cylinder head bolt Final step 8 mm 23 N m 2 3 kgf m 16 5 lbf ft 4 Install the IN and EX camshafts Refer to Camshaft Tappet and shim Removal and Installation Page 1D 26 5 Install the timing chain Refer to Timing Chain Chain Tensioner a...

Page 137: ...is properly fixed to valve guide CAUTION Do not reuse stem seal once removed Always install new seal Special tool A 09917 98221 Valve guide stem seal installer attachment B 09916 58210 Valve guide installer handle 3 Apply engine oil to stem seal valve guide bore and valve stem 4 Install valve 3 to valve guide NOTE Reassemble each valve and valve spring to their original position 5 Install valve sp...

Page 138: ...and Servicing ZAJ6111406019 NOTE If cracks excessive wear or other damage is found on any component replace component Cylinder Head Remove all carbon from combustion chambers NOTE Do not use any sharp edged tool to scrape carbon off cylinder head or its components Be careful not to scuff or nick metal surfaces when decarbonizing Check cylinder head for cracks in intake and exhaust ports combustion...

Page 139: ...pecial tool A 09900 20803 Thickness gauge Manifold seating faces distortion Service limit 0 10 mm 0 004 in Valve and Valve Guide Valve guide to valve stem clearance Using a micrometer and bore gauge take diameter readings on valve stems and guides to check guide to stem clearance Be sure to take readings at more than one place along the length of each stem and guide If measurement exceeds service ...

Page 140: ...ction as follows 1 Install valve into valve guide 2 Position valve head at approx 5 mm away from valve seat 3 Move valve head in the direction a b and measure deflection Special tool A 09900 20606 Dial gauge B 09900 20701 Magnetic stand Valve stem deflection Service limit IN 0 14 mm 0 006 in Service limit EX 0 18 mm 0 007 in Valve stem end Inspect valve stem end face for pitting and wear If pittin...

Page 141: ...N 0 7 mm 0 03 in Service limit EX 0 5 mm 0 02 in Valve seat contact width Measure valve seat contact width as follows 1 Remove all carbon from valve and seat 2 Coat valve seat evenly with Prussian blue or equivalent 3 Install valve into valve guide 4 Put valve lapper on valve Special tool A 09916 10911 Valve lapper 5 Rotate valve while gently tapping valve contact area against seat 6 Continue unti...

Page 142: ...e Too low narrow 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 4 Clean up any burrs using 45 angle cutter very lightly CAUTION Cut seat areas minimally only Do not cut more than necessary 5 Lap valve on seat in two steps first with coarse grit lapping compound applied ...

Page 143: ...r handle 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 After installing check valve guide protrusion a Special tool D 09916 58210 Valve guid...

Page 144: ...ace valve spring Special tool 09900 20101 Vernier calipers 150 mm Valve spring preload Standard IN EX 97 113 N 9 7 11 3 kg 21 4 24 9 lbs at 28 5 mm 1 12 in Service limit IN EX 89 N 8 9 kg 19 6 lbs at 28 5 mm 1 12 in Valve spring squareness Use a square and surface plate to check each spring for squareness clearance between end of valve spring and square If measurement exceeds service limit replace...

Page 145: ...r block 7 Conrod bearing 13 Dowel pin 15 N m 1 5 kgf m 10 8 lbf ft then plus turn in 65 degrees 2 Piston ring set 8 Conrod cap 14 Crankcase Apply engine oil 3 Piston 9 Conrod bolt 15 Bolt inside Apply Molybdenum oil solution 4 Piston pin 10 Oil seal 16 Bolt outside Do not reuse 5 Circlip 11 Crankshaft 46 N m 4 6 kgf m 33 3 lbf ft 6 Conrod 12 Crankshaft main bearing 25 N m 2 5 kgf m 18 0 lbf ft ...

Page 146: ...1D 22 Remove cylinder head Refer to Cylinder Head Removal and Installation Page 1D 33 2 Remove oil pressure switch 1 Remove oil filter 2 3 Remove eight bolts 3 Remove eight bolts 4 Remove crankcase 5 from cylinder block NOTE For proper assembly mark cylinder number on all pistons conrods and conrod caps using quick drying paint 4 Remove all conrod cap bolts 6 and conrod caps 7 CAUTION Never reuse ...

Page 147: ...s original position after removing piston from bore 7 Remove two compression rings top and 2nd and oil ring from piston Mark cylinder number on conrod using quick dry paint 8 Remove piston pin circlips 9 as shown 9 Remove piston pin from conrod NOTE Reassemble each piston piston pin and conrod in their original combination and position 10 Remove the bolts and exhaust cover 10 if necessary IAJ61114...

Page 148: ...pin circlips 4 NOTE 88L mark on conrod and up mark A on piston dome must face toward flywheel side Always use new piston pin circlip Install so that circlip end gap comes within such range as indicated by arrow End gap of the circlip should not be aligned with the cutaway in the piston pin bore Piston ring to piston 1 Install the oil ring Apply engine oil to piston rings Install spacer 1 first the...

Page 149: ...rings so gaps are staggered at approximately 90 degree angles as shown CAUTION Failure to stagger piston ring gaps may result in crankcase oil dilution Piston to cylinder 1 Install conrod bearing 1 to conrod 2 and cap 3 CAUTION Assemble each conrod bearing to it s original position Do not apply oil between conrod and bearing or between bearing cap and bearing 1R R 3 4 C IAJ611140192 01 3 3 4 4 IAJ...

Page 150: ...bearing to its original position Assemble main bearing half containing oil groove hole to cylinder block Assemble the main bearing half without oil groove to crankcase Do not apply molybdenum oil solution between crank bearing holder and crank main bearing NOTE Align bearing tab A with notch in cylinder and crankcase Crankshaft 1 Apply molybdenum oil solution to crank pin and crankshaft main journ...

Page 151: ...ng torque Conrod cap bolt 1st step 10 N m 1 0 kgf m 7 2 lbf ft b Tighten bolts 15 N m 1 5 kgf m 10 8 lbf ft of specified torque Tightening torque Conrod cap bolt 2nd step 15 N m 1 5 kgf m 10 8 lbf ft c Finally tighten bolts 65 degrees turn from the point of step b using an angular torque gauge Tightening torque Conrod cap bolt Final step 15 N m 1 5 kgf m 10 8 lbf ft then plus turn in 65 degrees NO...

Page 152: ...lowing the order shown in figure then tighten 8 mm 0 315 in thread diameter bolts Tightening torque Crankcase inside bolt 10 mm thread diameter 1st step 10 N m 1 0 kgf m 7 2 lbf ft Crankcase inside bolt 10 mm thread diameter 2nd step 37 N m 3 7 kgf m 26 8 lbf ft Crankcase inside bolt 10 mm thread diameter Final step 46 N m 4 6 kgf m 33 3 lbf ft Tightening torque Crankcase outside bolt 8 mm thread ...

Page 153: ... If cracks excessive wear or other damage is found on any component replace component Cylinder Distortion Using a straightedge and thickness gauge measure cylinder distortion gasket surface at a total of six locations as shown If measurement exceeds service limit resurface or replace cylinder Special tool A 09900 20803 Thickness gauge Cylinder distortion Service limit 0 06 mm 0 002 in Water Jacket...

Page 154: ...in above the piston skirt at a right angle to the piston pin bore Special tool A 09900 20203 Micrometer 50 75 mm Piston skirt diameter Standard 72 470 72 490 mm 2 8531 2 8539 in 2 Measure the cylinder bore at 50 mm 1 969 in below the cylinder head gasket surface at a right angle to the crankshaft pin NOTE Purchase a commercially available telescoping gauge 1 for this measurement Cylinder bore diam...

Page 155: ...ness gauge Piston ring to groove clearance Standard 1st 0 030 0 070 mm 0 0012 0 0028 in Standard 2nd 0 020 0 060 mm 0 0008 0 0024 in Service limit 1st 0 12 mm 0 005 in Service limit 2nd 0 10 mm 0 004 in Piston ring groove width Standard 1st 1 02 1 04 mm 0 040 0 041 in Standard 2nd 1 21 1 23 mm 0 048 0 048 in Standard Oil 2 01 2 03 mm 0 079 0 080 in Piston ring thickness Standard 1st 0 97 0 99 mm 0...

Page 156: ...the piston pin can move smoothly in the piston pin hole If improper condition is found replace the piston pin and or piston Piston pin clearance Check the piston pin clearance in the conrod small end Replace the conrod if its small end is badly worn or damaged or if clearance exceeds service limit Measure the following item Special tool A 09900 20205 Micrometer 0 25 mm B 09900 20605 Dial calipers ...

Page 157: ...ank Pin and Conrod Bearing Inspection ZAJ6111406024 Crank Pin Diameter Inspect crank pin for uneven wear or damage Measure crank pin for out of round a b or taper c d with micrometer If crank pin is damaged out of round a b or taper c d is out of service limit replace crankshaft Special tool A 09900 20202 Micrometer 25 50 mm Crank pin diameter Standard 37 982 38 000 mm 1 4954 1 4961 in Out of roun...

Page 158: ...bearing 3 Place a piece of Plastigauge on crank pin parallel to crankshaft Avoid placing Plastigauge over oil hole Special tool A 09900 22301 Plastigauge 0 025 0 076 mm 4 Install conrod cap with bearing to conrod with the embossed mark on cap toward flywheel side 5 Apply engine oil to conrod bolts Tighten conrod cap bolts in three steps as follows a Lightly seat all conrod bolts at first then tigh...

Page 159: ...election of Conrod Bearing ZAJ6111406025 NOTE If bearing is in malfunction or bearing clearance is not in specification select a new standard bearing according to the following procedure When replacing crankshaft conrod and its bearing due to any reason select a new standard bearing to be installed by referring to numbers stamped on conrod and its cap and numbers stamped on crank web No 2 1 Check ...

Page 160: ...d in four colors at the position indicated in the figure Each color indicates the following thickness at the center of bearing Size of conrod bearing thickness Stamped No Crank pin diameter 1 37 9940 38 0000 mm 1 4958 1 4961 in 2 37 9880 37 9939 mm 1 4956 1 4958 in 3 37 9820 37 9879 mm 1 4954 1 4956 in B No 1 Crank pin dia code D No 3 Crank pin dia code C No 2 Crank pin dia code C D B IAJ611140221...

Page 161: ... service limit replace crankshaft Special tool A 09900 20606 Dial gauge 09900 20701 Magnetic stand Crankshaft runout Service limit 0 04 mm 0 002 in Crankshaft Thrust Play 1 Measure thrust play with crankshaft journal bearing and crankcase cylinder block assembled in a normal manner Tighten crankcase bolts to specified torque Tightening torque Crankcase bolt Inside 10 mm 46 N m 4 6 kgf m 33 3 lbf f...

Page 162: ...t Main Bearing Visual Inspection Check bearings for pitting scratches wear or damage If any improper condition is found replace both upper and lower halves Always replace both bearing halves never replace only one half of a bearing set Crankshaft Journal Oil Clearance Check clearance using Plastigauge according to the following procedure NOTE Assemble each bearing in its original position before c...

Page 163: ...e inside bolt 10 mm thread diameter 2nd step 37 N m 3 7 kgf m 26 8 lbf ft Crankcase inside bolt 10 mm thread diameter Final step 46 N m 4 6 kgf m 33 3 lbf ft Tightening torque Crankcase outside bolt 8 mm thread diameter 1st step 6 N m 0 6 kgf m 4 3 lbf ft Crankcase outside bolt 8 mm thread diameter 2nd step 21 N m 2 1 kgf m 15 0 lbf ft Crankcase outside bolt 8 mm thread diameter Final step 25 N m ...

Page 164: ...in bearings available each of differing thickness To distinguish them a color mark is painted at the position indicated in figure Each color represents the following thickness measured at the center of the bearing 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 A No 1 Journal code C No 3 Journal code B No ...

Page 165: ...l seal housing Refer to Upper Oil Seal Housing Removal and Installation Page 1D 8 2 Extract oil seal with oil seal remover Special tool A 09913 50121 Oil seal remover 3 Apply water resistant grease to outer circumference of oil seal 4 Drive the oil seal into the upper oil seal housing NOTE Install the oil seal with the spring lipped side facing inward 5 Reassemble the upper oil seal housing Refer ...

Page 166: ...passages or by splash method to those surfaces requiring lubrication Schematic and Routing Diagram Engine Oil Lubrication Chart ZAJ6111502001 No 4 CRANKSHAFT MAIN JOURNAL No 3 CRANKSHAFT MAIN JOURNAL No 2 CRANKSHAFT MAIN JOURNAL No 1 CRANKSHAFT MAIN JOURNAL OIL PRESSURE SWITCH No 4 CAMSHAFT HOUSING No 1 CRANK PIN No 2 CRANK PIN No 1 PISTON No 2 PISTON No 3 PISTON No 3 CRANK PIN OIL FILTER OIL PUMP...

Page 167: ...tion in Section 1A Page 1A 7 Powerhead Lubrication System Diagnosis ZAJ6111504004 Condition Possible cause Correction Reference Item Low oil pressure Clogged oil filter Replace Leakage from oil passages Repair or replace Defective oil pump Replace Defective oil pressure regulator Replace Damaged O ring Replace Combination of above item Repair or replace High oil pressure Using an engine oil of too...

Page 168: ...l pins 1 and oil pump assembly 2 then tighten seven bolts securely NOTE When installing oil pump assembly be sure position of oil pump inner rotor matchs with crankshaft Tightening torque Oil pump a 11 N m 1 1 kgf m 8 lbf ft Pour approx 20 ml 0 7 oz of engine oil into pump case for initial lubrication Oil Pump Disassembly and Assembly ZAJ6111506002 Disassembly 1 Remove the eight screws 1 securing ...

Page 169: ...nd 5 Pour approx 20 ml 0 7 oz of engine oil into pump case for initial lubrication Inspection Oil Pump Component Parts ZAJ6111506003 NOTE If any repair is required on outer rotor inner rotor and oil pump case plate replace them as an oil pump assembly Oil Pump Component Parts Check outer and inner rotors rotor plate and oil pump case for excessive wear or damage Replace as necessary Measuring Radi...

Page 170: ...nect blue lead wire 2 from oil pressure switch 3 3 Remove oil pressure switch from cylinder block Installation Installation is reverse order of removal with special attention to the following steps Before installing oil pressure switch wrap screw threads with sealing tape 1 then tighten switch to specified torque NOTE Cut off any excess sealing tape from switch threads before installation Tighteni...

Page 171: ...tinuity Oil pressure switch continuity Engine running Infinity Engine stopped Continuity 4 If measurement exceeds specification replace oil pressure switch 5 Reinstall parts removed earlier Oil Strainer Removal and Installation ZAJ6111506006 Removal Refer to Engine Holder Oil Pan Driveshaft Housing Mounts Disassembly in Section 2A Page 2A 13 Installation Refer to Engine Holder Oil Pan Driveshaft H...

Page 172: ...e higher than normal is detected by a sensor an advance caution of overheat condition is provided Displacement Type Water Pump Description ZAJ6111601002 In this displacement type water pump the water pressure is increased by the change in volume between the impeller and the pump case As a result the increased water pressure enables the water pump to circulate the cooling water Water Pressure Valve...

Page 173: ...ools both the power unit and exhaust and is shown in schematic form below If overheating occurs the components of the cooling system must be inspected for blockage corrosion build up or component damage WATER Oil pan Driveshaft housing Oil pan Water jacket cover Pilot water hole Return hose Thermostat open Thermostat Cylinder block Cylinder head Pressure valve Engine holder Oil pan Water tube Wate...

Page 174: ...cover 2 to cylinder block and secure with the bolts 3 Tightening torque Thermostat cover bolt a 10 N m 1 0 kgf m 7 2 lbf ft Condition Possible cause Correction Reference Item Overheating powerhead Water inlet screen obstructed Clean Water passage obstructed Clean or replace Pump plate not sealing Check and repair Water pump impeller damage Replace Water pump housing and or plate worn Replace Water...

Page 175: ...ermostat in a container filled with water b Place thermometer in container and heat water Observe water temperature when thermostat valve opens and releases thread Thermostat operating temperature Standard 58 62 C 136 144 F 4 Install the thermostat Refer to Thermostat Removal and Installation Page 1F 3 Water Pressure Valve Removal and Installation ZAJ6111606003 Removal 1 Remove lower side cover Re...

Page 176: ... nicked cut or torn 3 Install the water pressure valve Refer to Water Pressure Valve Removal and Installation Page 1F 4 Water Pump Removal and Installation ZAJ6111606005 Refer to Water Pump Removal and Installation in Section 3A Page 3A 6 Water Pump Related Item Inspection ZAJ6111606006 Refer to Water Pump and Related Items Inspection in Section 3A Page 3A 8 Water Tube Removal and Installation ZAJ...

Page 177: ...ety equipment and wear safety glasses when working around a 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 Fuel components and fuel hoses after the high pressure fuel pump remain pressurized at all times To protect against fuel spray relieve fuel line pressure before discon...

Page 178: ...nes operating conditions and determines the fuel injection start timing In the injection timing chart below the injection end timing is set at 60 BTCD on the exhaust stroke Basic sensors MAP sensor Informs ECM of intake manifold pressure Compensating sensors Cylinder temperature sensor Informs ECM of cylinder temperature Others CMP sensor Informs ECM of camshaft angle Neutral switch Informs ECM of...

Page 179: ...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 Cm Compression Ep Explosion Ex Exhaust In Intake CKP sensor signal CMP sensor No 1 cylinder No 3 cylinder No...

Page 180: ...ne 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 295 kPa 2 95 kg cm2 42 psi the valve in the fuel pressure regulator will open and return the excess fuel to the vapor separator chamber Pressurized f...

Page 181: ...This vapor is routed through the evaporation hose to the atmosphere 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 the ECM 1 2 3 5 6 7 8 9 10 4 10 12 8 13 14 11 15 IAJ611170010 01 1 High pressure fuel pump 5 Float 9 Fuel ...

Page 182: ...e 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 valve and injects fuel Because the fuel pressure is kept constant the amount of fuel injected is determined by the amount of time duration...

Page 183: ... and sends this signal to the fuel pump Duty cycle signal for fuel pump example 80 duty CKP sensor Informs ECM of engine speed Ignition switch Informs ECM of START signal Cylinder temp sensor Informs ECM of cylinder temperature Battery voltage ECM Signal FP Fuel pump I9J011170006 01 1 Sensor switch signal input 5 30 A fuse 2 Fuel pump 6 Battery charge coil 3 ECM main relay 7 Rectifier Regulator 4 ...

Page 184: ...4 Air after entering through the silencer case passes through the throttle body and flows into the surge tank where it is then distributed to the intake manifold Intake manifold pressure monitored by the MAP sensor is an indirect measurement of the intake air amount When the throttle is fully closed the main supply of intake manifold air necessary to sustain engine idle passes through the by pass ...

Page 185: ...take manifold pressure NOTE Do not try to adjust or remove any of the throttle body component parts Sensor throttle valve throttle stop screw etc These components have been factory adjusted to precise specifications Idle Air Control System Description ZAJ6111701005 IAC Valve Passage The IAC valve is a stepper motor type mounted on the intake manifold Its purpose is to control the amount of intake ...

Page 186: ...ing necessary to achieve the target engine speed and outputs the signal for actuating the stepper motor inside the IAC valve The rotor of the stepper motor then turns in an amount equal to the steps of the signal supplied from the ECM moving the valve via a screw shaft ECM 60 IAC1 70 IAC2 58 IAC3 48 IAC4 Air flow IAC valve 12 V Gr W B R Y R G W Bl 1 2 3 4 I9J011170010 02 1 Valve pintle 2 Screw sha...

Page 187: ... to operate at a 0 90 open position dependent on current engine operating conditions When decelerating dash pot effect When the throttle valve is suddenly returned to fully closed and the throttle position sensor signal changes to fully closed the IAC valve is controlled to gradually return to an idle troll operating position to prevent engine stalling or unstable running NOTE Due to the limited i...

Page 188: ...erate the fuel pump then turn it OFF 7 Repeat this ON and OFF procedure 3 or 4 times to pressurize the fuel system and then check the fuel pressure 8 Check for any signs of fuel leakage WARNING When the engine is running keep your hands hair clothing etc away from the engine 9 Measure fuel pressure at cranking or idle speed operation If out of specification check each possibly defective parts high...

Page 189: ...ble idling trolling or engine tends to stall Neutral switch failure Replace Throttle position sensor failure Replace IAC control system failure Check idle air control system IAC passage clogged Clean ECM failure Replace Wire continuity connection failure Repair or replace Fuel injector s clogged Clean Fuel pressure regulator failure Check fuel pressure Replace if necessary High pressure fuel pump ...

Page 190: ...und with ignition switch turned ON Is voltage 10 14 V Go to step 4 Gray wire open or shorted If it is in good condition check ECM power source and ground circuit 4 Check Wire circuit Turn OFF ignition switch Disconnect connector from ECM Measure resistance between each O B B Br R W wire terminal of the fuel injector connector and body ground Is resistance infinity Go to step 5 O B B Br and or R W ...

Page 191: ...urized at all times To protect against fuel spray relieve the fuel line pressure before disconnecting or removing components CAUTION Do not over bend kink or twist hoses when installing When installing hose clamps position the tabs to avoid contact with other parts Be sure hoses do not contact rods levers or other components with engine either operating or at rest Extreme care should be taken not ...

Page 192: ...B bent end pipe hose must cover the straight part of pipe by 20 30 mm 0 8 1 2 in Type B For type C pipe hose must fit up against the flanged part of pipe Type C For type D pipe the hose must cover the pipe by 20 30 mm 0 8 1 2 in Type D High Pressure Fuel Pump Operating Sound Inspection ZAJ6111706006 1 Install the emergency stop switch lock plate into position 2 Shift into Neutral 3 Turn ignition s...

Page 193: ...on Installation is in the reverse order of removal with special attention to the following steps Install the fuel vapor separator then tighten the bolts securely Install the intake manifold assembly Refer to Intake Manifold Removal and Installation in Section 1D Page 1D 11 Check to ensure that all removed parts are back in place Check hose and wire routing Refer to Fuel Hose Routing in Section 4B ...

Page 194: ...Remove the fuel outlet filter 13 from separator cover 6 Remove the screw 14 and valve seat 15 7 Remove the fuel pressure regulator assembly 16 from separator cover Remove in sequence the large O ring 17 holder 18 O ring 19 and washer 20 8 IAJ611170026 01 IAJ611170027 01 9 10 11 12 IAJ611170028 01 13 IAJ611170029 01 14 15 IAJ611170030 01 16 IAJ611170032 01 20 17 18 19 IAJ611170031 01 ...

Page 195: ... Float pin Install the valve seat 1 then tighten screw 2 securely Install the needle valve 3 float 4 and float pin 5 then tighten screw 6 securely NOTE After assembling check for smooth and free float movement Checking float height Measure the float height Special tool 09900 20101 Vernier calipers 150 mm Float height a Standard 47 3 0 mm NOTE Make sure that the float weight is not applied to the n...

Page 196: ...6 to separator cover Separator cover Separator case 1 Install the seal ring 1 and then apply Suzuki Bond evenly to only the outside mating surface of the separator case as shown in figure Sealant 99000 31140 SUZUKI Bond 1207B 100 g NOTE Clean mating surfaces before applying bond Do not apply bond to seal ring groove or inside mating surface 2 Install the suction filter 2 spacer 3 and separator cas...

Page 197: ...r and fuel outlet filter for evidence of dirt and contamination If present replace or clean and check for presence of dirt in fuel tank Separator Cover and Case Inspect the separator cover and case Replace if cracked damaged or other abnormal conditions NOTE Separator cover and case are a set If any repair is required on the cover or case replace them as a fuel vapor separator assembly Fuel Pressu...

Page 198: ...e connector to the fuel injector securely Individual Fuel Injector Operating Sound Inspection ZAJ6111706011 1 Disconnect the ignition coil lead wire connectors from all of the ignition coils 2 Disconnect the fuel injector lead wire connector and connect the test cord Special tool A 09930 89260 Injector test cord A 3 Connect the Gray wire to body ground 4 Momentarily touch the Black Yellow wire to ...

Page 199: ... voltage If out of specification inspect the related parts as described in Fuel System Diagnostic Information Fuel Injection System Troubleshooting Refer to Fuel System Diagnosis Page 1G 13 and Fuel Injection System Troubleshooting Page 1G 14 Fuel injector operating signal Standard Approx 4 10 V or over 45 47 71 37 50 38 51 39 52 40 41 53 42 43 44 45 46 47 48 49 55 68 56 69 57 70 58 59 71 60 61 62...

Page 200: ...small container 3 Disconnect the three fuel injector connectors 2 4 Remove the two bolts 3 and the fuel delivery pipe 4 with the fuel injectors CAUTION A small amount of fuel may be released when the fuel injector is removed from delivery pipe Place a shop cloth under the fuel injector before removal to absorb any fuel released Dispose of the fuel soaked cloth in appropriate container 5 Remove the...

Page 201: ...oothly 4 Tighten the delivery pipe bolts 3 and make sure that the injectors rotate smoothly Tightening torque Fuel delivery pipe bolt a 11 N m 1 1 kgf m 8 0 lbf ft 5 Reconnect the fuel feed hose and fuel line securely 6 Connect the lead wire connector to the injectors securely 7 Make sure the emergency stop switch lock plate is in place Shift into Neutral position 8 Squeeze the fuel primer bulb un...

Page 202: ...teps CAUTION Before installing the fuel pump rotate the crankshaft to bring the No 1 top cylinder piston to Top Dead Center on the compression stroke Do not reuse O ring once removed Always use a new O ring Tightening torque Low pressure fuel pump bolt a 10 N m 1 0 kgf m 7 2 lbf ft Low Pressure Fuel Pump Inspection ZAJ6111706015 NOTE The low pressure fuel pump is a non repairable component Do not ...

Page 203: ...rcuit as shown in the illustration The ECM determines the optimum ignition timing and duration of current flowing through the ignition coil primary winding based on the signals received from various sensors The ECM interrupts the base current of the power transistor inside the ignition coil thereby controlling current flow ignition to the primary winding of the ignition coil In this way a mutual i...

Page 204: ...rs Ignition switch Informs ECM of START signal Cylinder temperature sensor Informs ECM of cylinder temperature Throttle position sensor Informs ECM of throttle opening angle Neutral switch Informs ECM of shift position and change IAT sensor Informs ECM of intake air temperature Compensating sensors ECM Ignition timing is determined by a digital map designed in relation to intake manifold pressure ...

Page 205: ...e operation at the specified idling trolling speed When Running Normal Operation The ignition timing ranges between 2 25 BTDC depending on engine operating conditions Cm Compression Ep Explosion Ex Exhaust In Intake CKP sensor signal CMP sensor signal No 1 Ignition signal No 3 Ignition signal No 2 Ignition signal No 1 cylinder No 3 cylinder No 2 cylinder TDC Cm E p Ex In Cm E p Ex In TDC Cm In TDC...

Page 206: ...f lead wire Connect securely Faulty spark plug s Replace Faulty ignition coil Replace Faulty CKP sensor Replace Faulty CMP sensor or sensor trigger vane of camshaft Replace Faulty ECM Replace Spark plug is wet or quickly becomes fouled with carbon Incorrect gasoline Change Incorrect spark plug Replace Spark plug quickly become fouled with oil or carbon Worn piston ring Replace Worn piston Replace ...

Page 207: ...Is result OK Go to step 6 Check ignition coil operating signal wire for open short and poor connection 6 Measure the battery voltage between input lead wire at ECM with the ignition switch in ON position Is result OK Go to step 7 Faulty ignition switch Faulty ECM main relay Broken wire harness or poor connection of related circuit connector 7 Check CKP sensor Refer to CKP Sensor Inspection in Sect...

Page 208: ...il with its mounting bolt 2 Connect the ignition coil connector 3 Connect the battery cables to battery Ignition Coil Inspection ZAJ6111806004 NOTE The ignition coil power transistor and high tension lead are an integral part of the coils internal circuit Using resistance measurements to check for a defect on either the primary or secondary coil is not possible Special tool 09930 99320 Digital tes...

Page 209: ... tester probe Red to each terminal one at a time to test each circuit 4 Connect the tester probe Black to No 51 terminal or to body ground 5 Crank the engine and measure the voltage If out of specification inspect the related parts Refer to Ignition System Symptom Diagnosis Page 1H 4 and Ignition System Troubleshooting Page 1H 5 Ignition coil operating signal Standard Approx 3 V or over CKP Sensor...

Page 210: ...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 16 G Y G Y G Br B B B GND OFF ON START W BATT Br START G R ECM Bl R W 1 2 10 3 4 5 6 7 9 8 11 12 13 ...

Page 211: ...at at the time of engine starting the system prohibits starter motor operation when the shift lever is IN gear Control by Neutral Switch A switch to detect Neutral gear position is located on the clutch lever holder and operated by the clutch control lever This ON OFF type switch is ON in Neutral and OFF in Forward or Reverse When attempting to start the engine the ECM detects the shift position u...

Page 212: ...shes inspection Motor not running Operating sound of magnetic switch heard Weak or shorted battery Replace or recharge battery Battery voltage too low due to battery deterioration Replace battery Loose or corroded battery connection Repair or retighten Burnt main contact point or poor contacting action of magnetic switch Replace magnetic switch Magnetic switch inspection Brushes are seating poorly...

Page 213: ...cables wires are securely connected Shift is in Neutral position Emergency stop switch lock plate is set in place Fuse is not blown Circuit Check Schematic 12 ECM 35 36 15 49 2 65 16 1 2 6 5 4 7 9 10 11 3 8 12 13 14 A IAJ611190006 01 1 Battery 5 Main relay 9 Ign switch START 13 START s w signal 2 Main fuse 6 Starter relay 10 Emergency switch 14 Magnetic switch 3 Fuse ECM 7 Neutral switch 11 Neutra...

Page 214: ...neutral switch Refer to Neutral Switch Inspection Page 1I 17 Is it in good condition Go to step 6 Replace neutral switch 6 1 Check the ignition switch Refer to Ignition Switch Inspection Page 1I 16 Is it in good condition Go to step 7 Replace ignition switch 7 1 Check the emergency stop switch Refer to Emergency Stop Switch Inspection in Section 1C Page 1C 15 Is it in good condition Go to step 8 R...

Page 215: ...r bolts 4 Remove nut 1 positive battery cable 2 and positive Red cable 3 from the magnetic switch 4 of starter motor 5 Remove the bolt 5 negative battery cable 6 and ground lead wire 7 6 Remove the two bolts 8 securing the starter motor 9 11 1 Measure voltage between No 65 terminal of ECM and body ground when turning ignition switch to START Is the voltage approx 8 12 V Go to step 12 Starter switc...

Page 216: ...owing steps Install the starter motor and tighten starter motor mounting bolts securely Tightening torque Starter motor mounting bolt a 23 N m 2 3 kgf m 16 5 lbf ft Check to ensure that all removed parts are back in place Starter Motor Test ZAJ6111906002 WARNING When performing the following test be sure to connect the battery and the starting motor with a lead wire of the same size as original eq...

Page 217: ...Plunger and Pinion Return Test Disconnect the negative lead from the switch motor body Check that the plunger and pinion return inward If the plunger and pinion don t return inward replace the magnetic switch No Load Performance Test CAUTION Before performing the following test secure the starter motor to the test bench 1 Connect a battery and ammeter to the starter motor as shown 2 Check that the...

Page 218: ...t 2 Bolt 10 Front housing 18 Center cover plate 26 Rubber ring 3 Magnetic switch 11 Screw 19 Internal gear 27 Stopper ring 4 Gasket 12 Through bolt 20 Planetary gear 28 Pinion stopper 5 Spring 13 Rear cover 21 Pinion shaft 7 N m 0 7 kgf m 5 1 lbf ft 6 Plunger 14 Thrust washer 22 Pinion 5 5 N m 0 55 kgf m 4 0 lbf ft 7 Torsion spring 15 Brush holder 23 E ring Apply grease 8 Rubber packing 16 Yoke 24...

Page 219: ... motor be sure to put match marks at three locations A B and C as shown in the figure to avoid any possible component alignment mistakes 1 Remove nut 1 from the magnetic switch then disconnect the connecting wire 2 2 Remove two bolts 3 securing the magnetic switch 3 Remove the magnetic switch 4 4 Remove screws 5 long through bolts 6 and the rear cover 7 5 Remove thrust washer 8 with a screwdriver ...

Page 220: ...es when disassembling and assembling the stopper ring NOTE Using a screw driver pry off the stopper ring 12 Push the pinion stopper 21 down then remove the stopper ring 22 Remove the pinion stopper and pinion 19 13 Remove the E ring 23 14 Remove the pinion shaft 20 washers 24 and rubber ring 25 from the center bracket 13 14 15 I9J011190014 01 20 16 17 18 19 I9J011190015 02 18 I9J011190016 01 22 21...

Page 221: ...mutator outside diameter If the measurement exceeds the service limit replace the armature Special tool A 09900 20101 Vernier calipers 150 mm Commutator outside diameter Standard 29 0 mm 1 14 in Service limit 28 0 mm 1 10 in Check that the mica insulator between the segments is undercut to specified depth If the measurement exceeds the service limit cut to the specified depth WARNING Wear safety g...

Page 222: ...brush 1 If brushes are worn down to the service limit they must be replaced Special tool A 09900 20101 Vernier calipers 150 mm Brush length Standard 16 0 mm 0 63 in Service limit 12 0 mm 0 47 in Brush Holder Check brush holder continuity Replace the brush holder if the tester doesn t show the below Special tool 09930 99320 Digital tester Tester knob indication Continuity Brush holder continuity B ...

Page 223: ...place if necessary Gear Inspect planetary gears and internal gear for wear damage or other abnormal conditions Replace if necessary Pinion Shaft Pinion Shaft Bushing Inspect the pinion shaft for wear damage or other abnormal conditions Replace if necessary Inspect the pinion shaft bushing for wear or other damage Replace if necessary Front Housing Inspect the front housing for wear damage or other...

Page 224: ...and M terminal 2 If no continuity exists the coil is open and should be replaced Special tool A 09930 99320 Digital tester Tester knob indication Continuity Hold in coil open circuit test Check for continuity across the magnetic switch S terminal 1 and coil case 4 If no continuity exists the coil is open and should be replaced Special tool A 09930 99320 Digital tester Tester knob indication Contin...

Page 225: ...1 Disconnect the ignition switch from remo con box wiring harness 2 Check continuity between wiring leads at the key positions shown in the chart 3 If out of specification replace the ignition switch Special tool 09930 99320 Digital tester Tester knob indication Continuity Starter Motor Relay Inspection ZAJ6111906007 Inspect the starter motor relay using the following procedures 1 Disconnect the s...

Page 226: ...er motor relay solenoid coil resistance Standard 145 190 Ω Neutral Switch Inspection ZAJ6111906008 Check for continuity infinity of the neutral switch Special tool A 09930 99320 Digital tester Tester knob indication Continuity Neutral switch in remo con box 1 Disconnect the neutral switch lead wire connector from the ignition switch 2 Check continuity infinity between the switch brown wire leads w...

Page 227: ...ecessary 2nd Check the wire harnesses for open and short circuits If the wire harnesses are in good condition replace the neutral switch and recheck NOTE After installing the neutral switch check for correct function by operating the remo con handle Emergency Stop Switch Inspection ZAJ6111906009 Refer to Emergency Stop Switch Inspection in Section 1C Page 1C 15 Shift position Tester indicates Neut...

Page 228: ...il is converted by the rectifier regulator into regulated DC current which is used to charge the battery Battery Charge coil Output Standard 12 V 19 A 228 W at 3 000 r min Regulated Voltage Standard 14 5 15 2 Volts M W W To ECM To Fuel injector To Ign coil To Fuel pump Other To ECM From Ign switch To Starter relay Gr P B W W Y Y R Y B 8 7 6 5 1 2 3 4 IAJ6111B0001 01 1 Alternator Magneto 4 Starter ...

Page 229: ...ernator Battery charge coil does not charge Open or short circuit lead wires Repair or replace Open or short circuit battery charge coil Replace Rectifier Regulator failure Replace Main fuse blown out Replace Poor or broken battery connection Repair or Replace Alternator Battery charge coil overcharge Rectifier Regulator failure Replace Poorly grounded rectifier regulator Repair or Retighten Unsta...

Page 230: ...t 8 Clamp 15 Wiring harness assembly 22 Battery cable 2 Washer 9 Electric parts holder 16 Fuse case upper cover 166 N m 16 6 kgf m 120 lbf ft 3 Flywheel 10 Rectifier Regulator 17 O ring Apply engine oil 4 Key 11 Bolt 18 Fuse 30 amp Apply SUZUKI Bond 1207B 5 Battery charge coil 12 Cushion 19 Main relay 6 Screw 13 Washer 20 Starter motor relay 7 Bolt 14 Bolt 21 Fuse ...

Page 231: ...l remover bolts 4 Remove the flywheel bolt 1 washer 2 flywheel 3 and key 4 Installation Installation is reverse order of removal with special attention to the following steps Clean flywheel and crankshaft mating surfaces with cleaning solvent Apply engine oil lightly to flywheel bolt before installing Tighten flywheel bolt to specified torque Special tool A 09930 48720 Flywheel holder Tightening t...

Page 232: ...emoval with special attention to the following steps Battery charge coil Apply suzuki bond No 1207B to the coil securing screws Sealant 99000 31140 SUZUKI Bond 1207B 100 g Install battery charge coil then tighten coil screws securely Wire routing Secure coil lead wire with lead wire clamp then check that coil lead wire is routed properly and away from hot or rotating parts For wire routing refer t...

Page 233: ...tery charge coil resistance Rectifier Regulator Removal and Installation ZAJ6111B06005 Removal CAUTION Prior to removing electrical parts disconnect battery cables from battery 1 Remove the ring gear cover Refer to Ring Gear Cover Removal and Installation in Section 1D Page 1D 2 2 Disconnect lead wire connector 1 from rectifier regulator 3 Remove the bolts 2 and rectifier regulator 3 Installation ...

Page 234: ...binations shown If measurement exceeds specification replace rectifier regulator NOTE The values given below are for a SUZUKI pocket tester As thyristors diodes etc are used inside this rectifier regulator the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used Special tool 09930 25002 Pocket tester Tester knob indication Resistance x 1 kΩ W Y1 Y2 Y3 B IAJ6111B00...

Page 235: ...he main fuse in the following procedures 1 Remove the main fuse from fuse box 2 Inspect continuity between both terminal of fuse If no continuity is indicated replace fuse Special tool 09930 99320 Digital tester Tester knob indication Continuity CONT I9J0111B0023 01 ...

Page 236: ...1K 9 Charging System ...

Page 237: ...wivel Steering Brackets Related Components Inspection 2A 27 Power Trim and Tilt 2B 1 Precautions 2B 1 Precaution for Power Trim and Tilt 2B 1 General Description 2B 1 Power Trim and Tilt Description 2B 1 Principles of Power Trim and Tilt Operation Description 2B 3 Schematic and Routing Diagram 2B 8 Power Trim and Tilt System Diagram 2B 8 Diagnostic Information and Procedures 2B 9 Diagnose PTT Syst...

Page 238: ...2 1 Precautions Mid Unit Precautions Precautions Precaution for Mid Unit ZAJ6112000001 Refer to General Precautions in Section 00 Page 00 1 ...

Page 239: ...onding wires as they perform an important function in the prevention of galvanic corrosion or build up of static charges Replace any damaged wire NOTE When dismantling housing and bracket inspect mountings and bolts for damage and wear Replace if necessary Check the condition of the zinc anodes on lower section of mid unit Replace if necessary ...

Page 240: ...Side cover rubber 8 Bolt 15 Bolt 22 Hook lever latch 2 Side cover seal 9 Washer 16 Rear hook lever 23 Bolt 3 Lower side cover STBD 10 Cushion 17 Washer Apply water resistance grease 4 Lower side cover PORT 11 Hook 18 Wave washer 3 N m 0 3 kgf m 2 0 lbf ft 5 Screw 12 Screw 19 Pin 6 Cushion 13 Engine cover hook shaft 20 Bush 7 Front panel 14 Engine cover hook 21 Cushion ...

Page 241: ...f removal with special attention to the following step Tighten side cover screws to specified torque Tightening torque Side cover screw 3 N m 0 3 kgf m 2 lbf ft Tiller Handle Removal and Installation TH model ZAJ6112106014 Removal Before removing tiller handle disconnect battery cables from battery 1 Remove the PORT lower side cover Refer to Lower Side Cover Removal and Installation Page 2A 3 2 Cu...

Page 242: ...from the engine harness 7 Remove the two bolts 14 securing tiller handle bracket 15 to steering bracket extension then remove the tiller handle assembly 16 8 Remove the nut 17 and washer 18 Loosen and remove the handle pivot bolt 19 Remove the tiller handle 20 from handle bracket Installation Installation is reverse order of removal with special attention to the following steps Tiller handle 1 Ins...

Page 243: ... kgf m 18 0 lbf ft 4 Install washer 5 nut 8 and tighten nut to specified torque Tightening torque Handle pivot nut b 45 N m 4 5 kgf m 32 0 lbf ft 5 Install the tiller handle and handle bracket assembly 9 to steering bracket extension 10 then tighten bolts 11 pre coated with thread lock to specified torque Thread lock cement 99000 32050 SUZUKI Thread Lock 1342 50 g Tightening torque Tiller handle m...

Page 244: ...ve all play from cable 3 Set the connector 2 onto the pivot pin A with the flat side of connector towards the lever 4 Install the washer 4 and snap pin 5 then tighten the cable lock nut 6 against the connector to maintain adjustment 5 Make sure that both forward and reverse gears can be engaged Throttle cable to throttle control lever 1 Set the throttle control grip to the fully closed position 2 ...

Page 245: ...he match mark pointer B on the throttle cam 9 align with the stopper 10 6 Return the throttle control grip to the fully closed position Check that the throttle control lever 1 is in fully closed position Also make sure that the tip of throttle stop screw 2 contacts the throttle lever stop 3 Harness routing 1 Connect the handle wire harness 1 to the engine side then install the connector to the con...

Page 246: ...met 21 Throttle shaft 37 Plate 53 Bolt 6 PTT switch 22 Plate 38 Ball 54 Extension 7 Screw 23 Screw 39 Shift cable 55 Spacer 8 Cap 24 Throttle tension adjuster 40 E ring 56 Bolt 9 Cover 25 Throttle arm assembly 41 Clamp bracket 25 N m 2 5 kgf m 18 0 lbf ft 10 Emergency stop switch 26 Screw 42 Bolt 45 N m 4 5 kgf m 32 0 lbf ft 11 Lock plate 27 Throttle cable 43 Shift lever 50 N m 5 0 kgf m 36 0 lbf ...

Page 247: ...ad wire connector 3 Remove the E ring 3 and throttle cable 4 from throttle arm 5 Remove the shift cable 6 from the shift gear assembly 7 in the same manner 4 Remove the screw 8 and handle grip 9 5 Drive out the handle rod stopper pin 10 then pull out rod stopper 11 spring 12 and handle rod bush 13 6 Loosen the handle grip adjuster 14 Remove the screws 15 and handle rod plate 16 2 1 1 IAJ011210022 ...

Page 248: ... lever as shown in figure Using a mallet tap on bolt head until the shift lever separates then remove 8 mm bolt 10 Remove the two bolts 25 securing the shift gear assembly 26 to tiller handle housing then remove shift gear assembly 26 and bush 27 11 Remove the lock plate 28 and ball 29 from shift gear assembly Assembly Assembly is reverse order of disassembly When reassembling tiller handle refer ...

Page 249: ...25 Oil strainer 2 Mount case cover 10 Bolt 18 Upper mount 26 Bolt 3 Gasket 11 Dowel pin 19 Washer 60 N m 6 0 kgf m 43 4 lbf ft 4 Bolt 12 Dowel pin 20 Nut 50 N m 5 0 kgf m 36 0 lbf ft 5 Bolt 13 Upper mount cover 21 Bolt Apply engine oil 6 Oil seal 14 Bolt 22 Water indicator Apply SUZUKI water resistant grease 7 Gasket 15 Upper mount Bolt 23 Bolt Apply SUZUKI thread lock 1342 8 Engine holder 16 Uppe...

Page 250: ...owel pin 23 Lower mount cushion 33 Grommet 4 Gasket 14 Bolt 24 Lower side mount 34 Grommet 5 Oil drain plug 15 Driveshaft housing 25 Lower mount 35 Water tube 6 Bolt 16 Lower mount bolt 26 Damper 36 Bolt 7 Bolt 17 Washer 27 Lower mount cover 13 N m 1 3 kgf m 9 5 lbf ft 8 Gasket 18 Lower mount bracket 28 Bolt 60 N m 6 0 kgf m 43 4 lbf ft 9 Water jacket cover 19 Lower thrust mount 29 Bush Transom X ...

Page 251: ...s securing harness clamp plates to engine holder then remove the engine wiring harness 2 Disconnect the fuel cooler water hose 3 from engine holder 5 Remove the four bolts 4 securing the STBD PORT lower mount covers then detach the mount covers 5 6 Unscrew and remove STBD PORT lower mount nuts 6 and washers 7 7 Remove the seven bolts and the mount case cover 8 8 Remove STBD PORT upper mount nuts 9...

Page 252: ...ve the three bolts and upper mount cover 18 12 Remove the upper mounts 19 upper thrust mount 20 upper mount bolts 21 and washers 22 13 Remove the bolt and water indicator union 23 and water hose 24 if necessary 14 Remove the seven bolts 25 and engine holder 26 IAJ611210039 01 IAJ611210040 01 11 10 12 13 14 15 16 17 IAJ611210041 01 18 IAJ611210042 01 20 22 22 21 21 19 19 IAJ611210043 01 24 23 IAJ61...

Page 253: ...05 Assembly is in reverse order of disassembly with special attention to the following steps Oil Pan to Driveshaft Housing Install water tube 1 with bushings then tighten bolt 2 Install two dowel pins 3 to driveshaft housing 4 Apply sealant to mating surfaces of driveshaft housing and oil pan Sealant 99000 31120 SUZUKI Silicone Seal 50 g Install the oil pan 5 to driveshaft housing 4 then tighten e...

Page 254: ...encer 5 to oil pan CAUTION Do not reuse gasket Always assemble with a new gasket Install engine holder 6 to oil pan 7 then securely tighten it with engine holder bolts 8 Upper Mount and Mount Cover Assemble these items in the following sequence Place the washers 1 upper mounts 2 upper thrust mount 3 on upper mount bolts 4 2 2 1 IAJ611210054 02 3 3 5 4 IAJ611210055 01 6 7 8 8 IAJ611210056 01 8 IAJ6...

Page 255: ...ng torque Upper mount cover bolt a 50 N m 5 0 kgf m 36 0 lbf ft Thread lock cement 99000 32050 SUZUKI Thread Lock 1342 50 g Lower Mount Bolt Nut Assemble these items in the following sequence Place the washer 1 side lower mount 2 lower mount 3 forward damper 4 cushion 5 side lower mount 6 and washer 7 on lower mount bolt 8 Place the lower mount and bolt assembly into position NOTE Install the lowe...

Page 256: ...to specified torque Tightening torque Lower mount nut b 60 N m 6 0 kgf m 43 4 lbf ft Thread lock cement 99000 32050 SUZUKI Thread Lock 1342 50 g Mount Case Cover Apply water resistant grease to oil seal 1 Grease 99000 25161 SUZUKI Water Resistant Grease 250 g Install the gasket 2 dowel pins 3 and mount case cover 4 then tighten seven cover bolts securely Lower Mount Cover Install lower mount cover...

Page 257: ... be excessively worn cracked defective or damaged in any way it must be replaced Engine Holder Inspect the engine holder Replace if cracked damaged or other abnormal conditions are noted Check water passage If clogged or obstructed clean water passage Mount Case Cover Inspect the mount case cover Replace the mount case cover if cracked damaged or other abnormal conditions are found Check condition...

Page 258: ...or other damage is found replace it Mount Check upper lower and thrust mounts If excessive wear corrosion or other damage is found replace mount Inspect mount cover Replace mount cover if cracked damaged or other abnormal conditions are found Water Tube Water Tube Grommet Check water tube If a clog or obstruction is found clean water tube If cracks corrosion or other damage is found replace water ...

Page 259: ... nipple 26 Arm 38 Screw 3 Clamp bracket shaft 15 Steering bracket 27 Link 39 Bolt 4 Bolt 16 Washer 28 Spring 40 Steering bracket attachment 5 Washer 17 Bush 29 Tilt lock lever PORT 41 Washer 6 Nut 18 Seal 30 Bracket 42 Nut 7 Anode 19 Washer 31 Screw 43 N m 4 3 kgf m 31 0 lbf ft 8 Bolt 20 Shim 32 Plate STBD Apply SUZUKI water resistance grease 9 Washer 21 Lower mount bracket 33 Plate PORT Apply SUZ...

Page 260: ...emove lower mount bracket 2 shims 3 and washer 4 from the steering shaft 5 Lift steering bracket 5 upward to remove from swivel bracket Remove washer 6 and upper bushing 7 6 Remove swivel bracket seal 8 and lower bushing 9 7 Remove bolt 10 and trim sensor assembly 11 Cut the cable tie securing sensor lead wire 8 Slide the lower trim sensor cam plate 12 off IAJ611210078 01 1 IAJ611210079 01 2 3 4 I...

Page 261: ...blade screw driver drive locking edge of lock washer 19 to clamp bracket side 14 Remove the two PORT motor mounting bolts 20 Remove the clamp bracket shaft nut 21 and washer 15 Slide PORT clamp bracket 22 off clamp bracket shaft 16 Remove the PTT unit 23 17 Remove the bolt 24 securing clamp bracket shaft to STBD clamp bracket 13 I9J011210089 01 14 15 IAJ611210084 01 16 16 17 IAJ611210085 01 18 18 ...

Page 262: ...nt Grease 250 g Insert PORT and STBD bushings 2 into the swivel bracket 1 Assemble STBD clamp bracket 3 washer 4 clamp bracket shaft 5 and swivel bracket 1 Apply Thread Lock 1342 to threads of shaft bolt 5 before threading it to STBD clamp bracket Install the shaft bolt 5 then tighten it securely Thread lock cement 99000 32050 SUZUKI Thread Lock 1342 50 g Install PTT unit and lower shaft assembly ...

Page 263: ...ensor cam 1 engaging its locating pin A with the clamp bracket shaft hole B Install the lower trim sensor cam plate 2 Install the trim sensor assembly 3 then secure it with bolts 4 Secure switch lead wire with cable tie Steering Bracket Apply water resistant grease to steering bracket shaft Grease 99000 25161 SUZUKI Water Resistant Grease 250 g NOTE Apply grease to bushings oil seal lip and pilot ...

Page 264: ...nding Wire Reattach bonding wire to swivel bracket and tighten screw securely Lubrication After completing reassembly of the mid unit apply grease through each grease nipple Grease 99000 25161 SUZUKI Water Resistant Grease 250 g 1 Upper bushing 6 Shim 2 Washer 7 Lower mount bracket 3 Lower bushing 8 Circlip 4 Swivel bracket seal A Seal lip 5 Steering bracket 1 2 3 5 6 7 8 4 A 2 IAJ611210099 01 1 2...

Page 265: ...replaced Bushings Check all bushings If excessive wear or other damage is found replace bushing If bushing fit is loose when installing replace bushing Oil Seal Check swivel bracket seal If excessive wear or other damage is found replace seal Clamp Bracket Shaft Check clamp bracket shaft If clamp bracket shaft is bent or twisted replace shaft Bracket Check clamp brackets steering bracket and swive...

Page 266: ...e tilted for beaching operating in shallow water or trailering Trim and tilt UP or DOWN is obtained by supplying power to a permanent magnet type motor This motor will rotate clockwise for UP or counterclockwise for DOWN according to power delivered via the PTT relay which is mounted on the electric part holder The PTT relay is controlled by the ECM The ON OFF signal for the PTT UP or DOWN is inpu...

Page 267: ...n 15 Down main valve 2 Tilt rod 9 Free piston 16 UP relief valve 3 Oil reservoir 10 Lower cylinder chamber 17 DOWN relief valve 4 Tilt cylinder Upper chamber 11 Manual release valve 18 Spool valve 5 Floating tube 12 Thermal valve 19 Down check valve 6 Trim cylinder upper chamber 13 2 way valve 20 Up check valve 7 Tilt piston 14 Gear pump 21 Upper main valve ...

Page 268: ...ump enters the spool valve 3 moving it to the right opening the Up check valve 4 and returning oil from the upper cylinder chamber plus oil from the reservoir to the pump Pressure built up by the pump will then open the Down check valve 5 and oil will enter the lower cylinder chamber This makes the piston rod push up and the engine tilt up When trim motor stops both the Down check valve and the Up...

Page 269: ...hamber will go through the Down check valve 4 to the pump Pressure built up by the pump will open the Up check valve 5 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 Down check valve 4 In the trim area the trim piston and floating tube are moving with the pisto...

Page 270: ...will then open allowing oil to flow into the area between the tilt ram piston 3 and the free piston 4 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 downward The oil from between the ram piston 3 and the free piston 4 is then expelled through the return valve 5 before flowing into the upp...

Page 271: ...terclockwise When the manual release valve 1 is 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 DN Tilt UP Tilt DOWN UP 1 IAJ611220013 01 ...

Page 272: ...l pressure will increase and the oil in PTT unit will expand High oil pressure in the upper cylinder chamber 1 caused by rising temperature will release the thermal valve 2 and make the oil flow to the reservoir to prevent damage to the PTT unit 1 2 IAJ611220006 01 ...

Page 273: ...B GND OFF ON START W BATT Br START P W Lbl W B G Lbl P W Gr P B W Gr P B R 36 3 27 23 22 12 35 Gr IGN W tube 10 11 7 3 6 4 1 5 2 P 8 9 IAJ611220007 02 1 PTT switch Remote control box 5 Ignition switch 9 ECM fuse 30 amp 2 PTT switch Side cover 6 Battery 10 PTT switch fuse 15 amp 3 PTT motor relay 7 Starter motor 11 Main fuse 30 amp 4 PTT motor 8 ECM main relay ...

Page 274: ...ch Replace Defective PTT relay Replace Open light blue lead wire circuit Repair or replace Defective ECM Replace Motor will not trim tilt down Defective PTT switch Replace Defective PTT relay Replace Open pink lead wire circuit Repair or replace Defective ECM Replace PTT motor operates but no motor trim tilt movement Low PTT fluid level Added PTT fluid Manual release valve leaking Ensure that valv...

Page 275: ...ic transmission fluid or equivalent 6 Reinstall oil filler plug Air Bleeding from PTT Unit ZAJ6112206002 1 Check that the manual release valve 1 is tightened to the specified torque CAUTION Do not over tighten manual release valve Tightening torque Manual release valve a 3 0 N m 0 3 kgf m 2 2 lbf ft Direction of rotation Counterclockwise Open Clockwise Close 2 Operate the PTT switch raising and lo...

Page 276: ...turn the throttle to the fully closed position Setting Trim Down Position Limit 1 Press the DOWN side of the PTT switch so that the full trim down position is obtained 2 Turn the ignition key to the ON position 3 Pull out the emergency stop switch lock plate 4 Make sure that remote control handle is in Neutral Check that the neutral switch is in the ON position 5 Top mount type Using the throttle ...

Page 277: ... the throttle to the fully closed position Setting Tilt Up Position Limit 1 Press the UP side of the PTT switch so that the optimum full tilt up position for the boat can be obtained 2 Turn the ignition key to the ON position 3 Pull out the emergency stop switch lock plate 4 Make sure that remote control handle is in Neutral Check that the neutral switch is in ON position 5 Top mount type Using th...

Page 278: ...ly secured and its weight fully supported See below 3 Remove the tilt rod snap ring 2 and push the tilt cylinder upper shaft pin 3 out To remove the tilt cylinder upper shaft pin pull up the manual tilt lever 4 Lower the tilt rod to the full down position and disconnect the battery cable 5 Disconnect the PTT motor cable wire connector from the PTT relay Cut the cable tie binding PTT motor cable an...

Page 279: ...l with special attention to the following steps Lower tilt rod to full down position Apply water resistant grease to the tilt cylinder lower shaft and lower shaft bushing Install the lower shaft bushing 1 and cylinder lower shaft 2 to PTT unit Install the spacer 3 to cylinder lower shaft Grease 99000 25161 SUZUKI Water Resistant Grease 250 g Place PTT unit in position then install clamp bracket Ti...

Page 280: ... the tilt rod extends Grease 99000 25161 SUZUKI Water Resistant Grease 250 g Apply water resistant grease to the PTT rod upper shaft 8 then insert the shaft through the swivel bracket and tilt rod Secure the upper shaft with the snap ring 9 Grease 99000 25161 SUZUKI Water Resistant Grease 250 g Route the PTT motor cable in through the lower cover and connect the PTT cable connector to the PTT rela...

Page 281: ... 01 1 Joint 9 Screw 17 Drive joint 25 Circlip 2 Tank 10 O ring 18 Filter 26 Anode 3 Plug 11 Armature 19 Gear pump 27 Bolt 4 O ring 12 Brush 20 Screw 45 N m 4 5 kgf m 32 5 lbf ft 5 Bolt 13 Spring 21 Down pressure valve Apply thread lock to the thread area 6 O ring 14 Brush holder 22 Up pressure valve 7 Manifold assembly 15 Screw 23 O ring 8 Field case 16 Oil seal 24 Manual valve ...

Page 282: ...vise 2 Connect the PTT cable extension to PTT motor cable connector Special tool A 09945 79310 PTT cable extension 3 Connect the PTT cable extension leads G Bl to battery and operate PTT motor until tilt rod is at maximum stroke full tilt up position Unscrew the filler plug and drain PTT oil into a suitable container 4 Remove the manual release valve snap ring 1 then unscrew the manual release val...

Page 283: ...12 Special tool B 09945 69010 PTT rod holder CAUTION When removing the reservoir exercise care to avoid damaging the rip of oil seal 10 Remove the four bolts securing the reservoir 13 then detach the reservoir from the PTT body 11 Remove the O ring 14 7 8 IAJ611220042 01 9 10 11 IAJ611220043 01 9 10 IAJ611220044 01 12 B IAJ611220045 01 13 IAJ611220046 01 13 14 IAJ611220047 01 ...

Page 284: ...amaging the rip of oil seal Apply PTT fluid to reservoir seal then install reservoir Tighten four bolts securely Tightening torque Reservoir bolt a 4 7 N m 0 47 kgf m 3 4 lbf ft Upper Eye Apply thread lock super 1333B to threads of upper eye before threading it onto tilt rod Thread lock cement 99000 32020 SUZUKI Thread Lock Super 1333B 50 g Tighten upper eye to specified torque Tightening torque U...

Page 285: ... installing the PTT unit on the outboard motor use the following procedure to bleed air from the system 1 Support the PTT unit in an upright position in a vise 2 Fill the reservoir with PTT fluid to the specified level then install oil filler plug 3 Tighten the manual release valve to the specified torque 4 Connect the PTT cable extension to the PTT motor cable connector Special tool A 09945 79310...

Page 286: ...er Trim and Tilt Unit Components Cleaning and Inspecting ZAJ6112206009 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 If excessive wear cracks defective or other damage is found on any component replace component Inspect PTT pump assembly for cracks nic...

Page 287: ... Installation Page 2B 13 NOTE Before removing PTT motor wash the PTT body with a stiff bristle brush and hot soapy water to remove sand or dirt Dry the PTT body with compressed air 2 Place the lower section of the PTT unit 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 etc between the ...

Page 288: ... torque PTT motor screw a 6 N m 0 6 kgf m 4 3 lbf ft Pour recommended PTT fluid into reservoir until specified level Perform the air bleeding procedure Refer to Power Trim and Tilt Unit Reassembly Page 2B 19 Power Trim and Tilt Motor Disassembly and Assembly ZAJ6112206011 Disassembly 1 For correct assembly scribe an alignment mark on the field case and brush holder 2 Remove the three screws 1 secu...

Page 289: ... if no continuity is indicated Inspect the commutator surface If surface is gummy or dirty clean with 400 grit emery paper 1 Measure commutator outside diameter If measurement exceeds service limit replace armature Special tool B 09900 20101 Vernier calipers 150 mm Commutator outside diameter Standard 22 0 mm 0 87 in Service limit 21 0 mm 0 83 in Ensure that the mica insulator between commutator s...

Page 290: ...elay from the electric parts holder Refer to Electric Parts Holder Removal and Installation in Section 1D Page 1D 4 2 Check the resistance between each two lead wires Special tool A 09930 99320 Digital tester Tester knob indication Resistance Ω PTT relay coil resistance Between P wire and B wire 25 37 Ω Between Lbl wire and B wire 25 37 Ω 3 Connect the R red wire to positive terminal and the B bla...

Page 291: ...nd or step 4 5 fails replace PTT motor relay 7 Install the PTT motor relay to the electric parts holder Refer to Electric Parts Holder Removal and Installation in Section 1D Page 1D 4 PTT Switch Inspection ZAJ6112206014 Test continuity between the switch lead wires at each of the three switch positions If out of specification replace PTT switch Special tool 09930 99320 Digital tester Tester knob i...

Page 292: ...2B 27 Power Trim and Tilt ...

Page 293: ... Propeller Removal and Installation 3A 4 Propeller Nut Cotter Pin Inspection 3A 5 Lower Unit Removal and Installation 3A 5 Water Pump Removal and Installation 3A 6 Water Pump and Related Items Inspection 3A 8 Lower Unit Disassembly 3A 8 Pinion Bearing Removal and Installation 3A 11 Lower Unit Related Items Inspection 3A 13 Propeller Shaft Oil Seal Replacement 3A 15 Driveshaft Oil Seal Replacement ...

Page 294: ...d accidentally Wear safety glasses if using compressed air CAUTION When draining lower unit gear oil check the following points Water ingress white milky appearance Overheating or burning black appearance charred smell Metal filings or deposits If reassembling with original components and gears do not omit or add any shims or thrust washers NOTE To simplify reassembly and to prevent confusion note...

Page 295: ...qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqLower Unit Right Hand Rotation Unit Diagnostic Information and Procedures Diagnose Lower Unit Malfunction ZAJ6113104001 Trouble Check Chart Condition Possible cause Correction Reference I...

Page 296: ... Driveshaft bearing housing 3 O ring 14 Spring 25 Nut 36 Oil seal 4 O ring 15 Plate 26 Stud bolt 37 Seal ring 5 Circlip 16 Gearcase 27 Water pump case 38 Sub water filter 6 Shift rod 17 Trim tab 28 Inner sleeve 39 Screw 7 Pin 18 Bolt 29 Key 10 N m 1 1 kgf m 7 2 lbf ft 8 Pin 19 Plug 30 Water pump impeller 23 N m 2 3 kgf m 16 6 lbf ft 9 Pin 20 Gasket 31 Sealing 8 N m 0 8 kgf m 6 0 lbf ft 10 Magnet 2...

Page 297: ...26 Propeller shaft bearing housing 37 Pin 5 Pinion bearing 16 Spring 27 Washer 45 N m 4 5 kgf m 32 5 lbf ft 6 Pinion gear 17 Dog spring 28 Bolt 23 N m 2 3 kgf m 16 6 lbf ft 7 Pinion nut 18 Clutch dog shifter 29 Bearing 55 N m 5 5 kgf m 40 lbf ft 8 Shim 19 Dog pin 30 Oil seal Apply SUZUKI Water Resistant Grease 9 Driveshaft bearing 20 Propeller shaft 31 Stopper Apply SUZUKI Outboard Motor Gear Oil ...

Page 298: ...ift to Neutral position 2 Remove cotter pin 1 from propeller nut and remove propeller nut 2 3 Remove washer 3 spacer 4 propeller 5 and stopper 6 from the propeller shaft Installation 1 Coat the propeller shaft splines liberally with Suzuki water resistant grease Grease 99000 25161 SUZUKI Water Resistant Grease 250 g 2 Install propeller stopper 1 onto propeller shaft then slide on the propeller 2 3...

Page 299: ...llation 1 Insert two dowel pins 1 2 Apply water resistant grease to driveshaft splines Grease 99000 25161 SUZUKI Water Resistant Grease 250 g 3 Apply a light coating of suzuki silicone seal to mating surfaces of gearcase and driveshaft housing Sealant 99000 31120 SUZUKI Silicone Seal 50 g 4 Slide the lower unit 2 into place ensuring that the top of driveshaft engages properly with crankshaft and t...

Page 300: ...il the connector contacts the lower nut 6 e With the clutch rod connector 4 securely held tighten the lower nut 6 firmly against the connector 7 Shift the clutch control lever to Forward and Reverse position from Neutral position to check proper gear engagement Water Pump Removal and Installation ZAJ6113106005 Removal 1 Remove the lower unit Refer to Lower Unit Removal and Installation Page 3A 5 2...

Page 301: ...gned 4 Place the seal ring 7 into groove of the pump case 6 CAUTION Do not reuse seal ring once removed Always use new ring NOTE Before installing water pump case assembly apply water resistant grease lightly on pump case inner sleeve and under panel for initial lubrication 5 Install the pump case assembly 8 while rotating driveshaft clockwise to flex the impeller vanes in the correct direction Se...

Page 302: ...o Lower Unit Removal and Installation Page 3A 5 2 Remove the propeller Refer to Propeller Removal and Installation Page 3A 4 3 Remove the water pump and related parts Refer to Lower Unit Removal and Installation Page 3A 5 and Water Pump Removal and Installation Page 3A 6 4 Place a drain pan under oil drain plug Remove oil drain plug 1 first then oil level plug 2 and allow gear oil to drain Inspect...

Page 303: ...h one equally This will keep the housing level as it pushed off the gearcase 9 Remove the pinion gear 6 Remove the forward gear 7 with thrust washer 8 back up shim 9 and bearing 10 10 Remove the nut 11 from shift rod Lift out driveshaft 12 driveshaft bearing housing 13 Account for the seal 14 on the driveshaft bearing housing 11 Lift out shift rod assembly 15 C 5 IAJ611310023 01 A A IAJ611310024 0...

Page 304: ...riveshaft collar 22 from driveshaft if necessary 15 Remove the snap ring 23 and push shift rod guide 24 out of bearing housing 16 Separate the shift cam 25 from the shift rod 26 by driving out the spring pin 27 Remove the lower shift rod guide 28 by driving out the spring pin 29 17 Remove the driveshaft spring housing 30 from the gear case 16 17 18 IAJ611310031 01 12 IAJ611310032 01 D IAJ611310033...

Page 305: ...ve the clutch dog shifter 37 push pin 39 and return spring 40 from propeller shaft Pinion Bearing Removal and Installation ZAJ6113106008 CAUTION When removing the pinion bearing use care to avoid damaging the gearcase Do not reuse pinion bearing once removed Always use a new pinion bearing Removal and Installation Tools To remove the pinion bearing from the gearcase use the following special tools...

Page 306: ... is clean and free of debris Ensure that the bearing stamped mark faces upward 1 Set the installer shaft A plate B attachment D and pinion bearing as shown in the figure 2 Place the installer shaft A with pinion bearing on end of installer shaft into the gearcase 3 Secure the plate B by tightening the bolt C 4 Thread the sliding hammer E into the top of the installer shaft A 5 Drive the pinion bea...

Page 307: ...on bearing removal and installation Gears Bearing Inspect forward reverse and pinion gear teeth and engaging dogs Replace gears if damaged worn or other abnormal conditions are noted Inspect propeller shaft forward bearing forward gear bearing Replace bearing if pitted noisy rough or other abnormal conditions are noted Propeller Shaft Components Inspect the push rod and push pin Replace if worn da...

Page 308: ...mal conditions are noted Shift Rod and Shift Cam Components Inspect the stepped surface of shift cam Replace if worn damaged or other abnormal conditions are noted Inspect shift rod guide Replace if cracked damaged or other abnormal conditions are noted Inspect O ring Replace if nicked cut torn swollen or other abnormal conditions are noted Inspect dust seal Replace if nicked cut worn or other abn...

Page 309: ... SUZUKI Water Resistant Grease 250 g 4 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 propeller Apply water resistant grease to the seal lips 5 Assemble the propeller shaft bearing housing Refer to Lower Unit Assembly Page 3A 16 Driveshaft Oil Seal Replacement ZAJ6113106011 1 Remove the...

Page 310: ...contact shim adjustments and tolerances are correct Failure to correctly adjust these areas will result in lower unit damage Refer to Lower Unit Gears Shimming and Adjustment Page 3A 22 Shift Cam and Shift Rod Attach lower shift rod guide 1 to shift rod 2 then secure it with the pin 3 Attach shift cam 4 to shift rod then insert pin 5 Insert the plate 6 spring 7 and detent ball 8 into gearcase Inst...

Page 311: ...l the bottom of shaft protrudes through center of pinion Driveshaft Bearing Housing Shift Rod Guide Apply water resistant grease to the shift rod guide O ring 1 2 and the inside of the dust seal 3 Slide complete dust seal 3 and shift rod guide 4 into the driveshaft bearing housing then secure it with the snap ring 5 Apply water resistant grease to the driveshaft oil seal 6 Grease 99000 25161 SUZUK...

Page 312: ...ly on gearcase Pinion Nut Apply thread lock 1342 to the threads of pinion nut 1 before threading it onto driveshaft Thread lock cement 99000 32050 SUZUKI Thread Lock 1342 50 g Tighten pinion nut to specified torque NOTE It is recommended the original pinion nut be used for the purposes of shimming during repair A new pinion nut should be used on final assembly Special tool A 09921 29511 Driveshaft...

Page 313: ...es in the shifter dog and push pin Depress the push rod and slide the dog pin 6 through both dog and push pin Install the dog pin retaining spring 7 ensuring that it fits snugly into the groove on the dog shifter Propeller Shaft Bearing Housing Place the forward thrust washer 1 and reverse thrust washer 2 on the propeller shaft Install back up shim 3 and reverse gear 4 to propeller shaft bearing h...

Page 314: ...veshaft Thrust Play Recheck the driveshaft thrust play This should not be less than previously checked If less reduce the number thickness of the reverse gear back up shims Refer to Lower Unit Gears Shimming and Adjustment Page 3A 22 Special tool A 09951 09530 Gear adjusting gauge Checking Propeller Shaft Thrust Play Check propeller shaft thrust play Refer to Lower Unit Gears Shimming and Adjustme...

Page 315: ...tall the propeller Refer to Propeller Removal and Installation Page 3A 4 Lower Unit Install the Lower Unit Refer to Lower Unit Removal and Installation Page 3A 5 Gear Oil Fill the gearcase with specified gear oil Refer to Gear Oil Change in Section 0B Page 0B 6 Trim Tab Adjustment ZAJ6113106013 The trim tab counteracts or minimizes propeller torque pull felt through the steering system If the stee...

Page 316: ...thickness mm Design specification thickness mm Pinion gear back up shim 0 50 0 55 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 1 00 1 0 Forward gear back up shim 0 50 0 60 0 70 0 80 0 90 1 3 Forward gear thrust washer 2 0 2 0 Propeller shaft reverse thrust washer 1 80 1 90 2 00 2 10 2 20 2 30 2 0 Reverse gear back up shim 0 50 0 60 0 70 0 80 0 90 1 00 1 0 1 2 3 5 4 IAJ611310086 01 1 Pinion gear back up...

Page 317: ... Temporarily fasten the driveshaft bearing housing to the gearcase with two bolts and nuts Checking driveshaft thrust play 1 Affix the gear adjusting gauge to driveshaft Special tool A 09951 09530 Gear adjusting gauge 2 To check driveshaft thrust play push the forward gear inward and hold it in this position Slowly push the driveshaft downward completely then slowly pull the driveshaft up and read...

Page 318: ...s Special tool A 09921 29511 Driveshaft holder 5 Carefully remove the propeller shaft and housing to check the tooth contact pattern Optimum tooth contact The optimum tooth contact is shown in the figure A shim adjustment may be necessary to obtain this contact pattern CAUTION The driveshaft thrust play should be checked when increasing or decreasing shim thickness to adjust tooth contact Optimum ...

Page 319: ... this position bottom side toe contact Chipping of the pinion gear may result Example of incorrect Rechecking driveshaft thrust play After obtaining optimum tooth contact driveshaft thrust play should be measured 1 Affix the gear adjusting gauge to the driveshaft Special tool A 09951 09530 Gear adjusting gauge 2 To check driveshaft thrust play push the forward gear inward and hold it in this posit...

Page 320: ... shim adjustment is correct if B is equal to A If B is less than A reduce reverse gear back up shim thickness Checking propeller shaft thrust play After adjusting all gear positions measure the propeller shaft thrust play If not within the following specification a shim adjustment is required NOTE Maintain the forward gear thrust washer at standard thickness 2 0 mm and use only the reverse gear th...

Page 321: ...ponent Location 4 1 Electrical Component Location 4 1 Wire Routing 4A 1 Schematic and Routing Diagram 4A 1 Wiring Diagram 4A 1 Wiring Harness Routing Diagram 4A 4 Fuel Water Hose Routing 4B 1 Precautions 4B 1 Precautions for Fuel Water Hose Routing 4B 1 Schematic and Routing Diagram 4B 1 Fuel Hose Routing 4B 1 Water Hose Routing 4B 4 ...

Page 322: ...ons Precautions Precautions for Wire Hose Routing ZAJ6114000001 Refer to General Precautions in Section 00 Page 00 1 Component Location Electrical Component Location ZAJ6114003001 Refer to Wiring Harness Routing Diagram in Section 4A Page 4A 4 ...

Page 323: ...Wire Routing 4A 1 Wire Hose Routing Wire Routing Schematic and Routing Diagram Wiring Diagram ZAJ6114102001 Refer to Wire Color Symbols in Section 0A Page 0A 2 ...

Page 324: ...W R Y V W W B W Bl W G W R W Y Y Bl Y G Light green with Black Light green with Red Light green with White Orange with Black Orange with White Orange with Yellow Pink with Blue Pink with White Red with Black Red with Green Red with White Red with Yellow Violet with White White with Black White with Blue White with Green White with Red White with Yellow Yellow with Blue Yellow with Green WIRE COLOR...

Page 325: ...Orange with Black Orange with White Orange with Yellow Pink with Blue Pink with White Red with Black Red with Green Red with White Red with Yellow Violet with White White with Black White with Blue White with Green White with Red White with Yellow Yellow with Blue Yellow with Green WIRE COLOR R B R B R G R G W B W B W Bl W Bl R Y R Y B R B R Y Bl Y Bl O O Bl Bl Gr Y Gr Y O B O B B Br B Br R W R W ...

Page 326: ...itch B terminal 5 Cap Pass the PTT relay lead wire and main harness red lead wire through the cap 11 Fuse box 4 5 N m 0 45 kgf m 3 3 lbf ft 6 Main harness Red 12 PTT relay lead wire Red 1 2 3 5 4 6 7 11 8 10 9 IAJ611410004 04 1 Battery charge coil 5 Oil pressure switch Cover the oil pressure switch with the cap 9 Harness bracket 2 Bolt Tighten bolt with the rectifier GND lead wire 6 Cylinder temp ...

Page 327: ... 2 Taping 4 Rigging port grommet B Outside B A 4 2 1 1 3 4 IAJ611410005 01 C B 10 A A 9 8 8 9 7 10 1 2 3 6 5 4 11 12 13 15 14 IAJ611410006 03 1 Flywheel 6 ECM 11 Washer A Taping 2 CKP sensor 7 Cable tie 12 Cushion B Inside 3 Fuse box 8 Trim sensor lead wire 13 Bolt C Outside 4 Electric parts holder 9 PTT cable 14 Harness bracket 5 Cushion 10 Grommet 15 Bolt ...

Page 328: ...ead wire 4 Battery cable 8 Main harness GND lead wire 12 Main harness GND lead wire Route the main harness lead wire under the fuel hose 3 a 2 1 6 6 7 4 5 8 11 9 10 12 IAJ611410008 02 1 Flywheel 6 Clamp 11 Clamp 2 Flywheel bolt 7 Neutral switch 12 Main harness Route the harness lead wire through the backside of fuel delivery pipe 3 Washer 8 Clamp Bind the neutral switch lead wire and water hose 16...

Page 329: ... bracket 3 No 2 Ign Coil 6 Joint connector 9 Bolt 1 2 3 1 4 5 7 6 8 12 14 13 10 11 15 9 IAJ611410010 02 1 PTT motor cable 6 Trim sensor lead wire 11 Lever 2 Bracket 7 Cable tie Fix the trim sensor lead wire at yellow taping position 12 Bolt 3 Clamp 8 Trim sensor assembly 13 Trim sensor 4 Clamp 9 Trim sensor cam 14 Screw 5 Cable tie 10 Sensor bracket 15 Plate ...

Page 330: ...g either engine operation or standstill Extreme care should be taken not to cut abrade or cause any other damage on hoses Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted Schematic and Routing Diagram Fuel Hose Routing ZAJ6114202001 8 1 2 2 3 5 6 7 9 4 IAJ611420001 01 1 Breather hose Protector 4 Fuel hose Fuel vapor separator to fuel delivery pipe 7 Fue...

Page 331: ...Low pressure fuel pump 3 Fuel hose Fuel vapor separator to fuel delivery pipe 6 Fuel delivery pipe 1 2 3 5 6 7 8 9 10 10 4 IAJ611420003 04 1 Fuel hose Low pressure fuel pump to fuel vapor separator 5 Evaporation hose hose protector 9 Clamp 2 Fuel hose Fuel vapor separator to fuel delivery pipe 6 Fuel vapor separator 10 Hose protector 3 Fuel delivery pipe 7 Water inlet hose Engine holder to fuel va...

Page 332: ...lder 2 Low pressure fuel pump 5 Filter bracket 3 Fuel hose guard 6 Fuel filter 1 2 3 5 6 7 4 IAJ611420004 03 7 1 2 6 3 5 4 6 2 IAJ611420005 02 1 Fuel filter 4 Hose protector 7 Hose clamp bracket 2 Fuel hose Connector to fuel filter 5 Clamp Clamp the hose at the yellow marking position on the hose 3 Clamp Clamp the hose at the yellow marking position on the hose 6 Hose protector ...

Page 333: ...114202002 1 2 3 IAJ611420006 03 1 Water return hose 2 Clip 3 Thermostat cover 1 2 3 3 5 4 IAJ611420007 01 1 Water inlet hose Engine holder to fuel vapor separator 3 Hose protector 5 Clamp 2 Water outlet hose Fuel vapor separator to engine holder 4 Clamp ...

Page 334: ... 5 Fuel Water Hose Routing 1 3 6 2 5 6 7 4 IAJ611420008 02 1 Water return hose 4 Water indicator hose 7 Bolt 2 Clip 5 Water indicator union 3 Water outlet hose Fuel vapor separator to engine holder 6 Clip ...

Page 335: ...Prepared by Marine Design Department December 2009 Manual No 99500 88L00 01E Printed in Japan 336 ...

Page 336: ...K10 ...

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