General Information - Maritime Propulsion

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Transcript

GROUP INDEX
GENERAL INFORMATION 1
PERIODIC MAINTENANCE 2
IGNITION AND ELECTRICAL 3
FUEL SYSTEM 4
RECOIL STARTER 5
POWER UNIT 6
MID UNIT 7
LOWER UNIT 8
ROUTING AND DIAGRAM 9
12
© COPYRIGHT SUZUKI MOTOR CORPORATION 2002 Marine & Power Products Division
FOREWORD
This manual contains an introductory description on
SUZUKI Outboard motor DF9.9/15 and procedures
for the inspection, service and overhaul of its main
components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor. Read and refer to
the other sections in this manual for information
regarding proper inspection and service procedures.
This manual will help you better understand this outboard motor so that you may provide your customers with optimum and quick service.
!
NOTE:
This manual is compiled based on 2003 (K3) model.
* This manual has been prepared using the latest information available at the time of publication.
If a modification has been made since then,
differences may exist between the content of
this manual and the actual outboard motor.
* Illustrations in this manual are used to show
the basic principles of operation and work
procedures and may not represent the actual
outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI outboard
motors.
Persons without such knowledge and skills
should not attempt to service an outboard
engine by relying on this manual only.
Instead, please contact your nearby authorized SUZUKI outboard motor dealer.
Apprentice mechanics or do-it-yourself
mechanics that don’t have the proper tools
and equipment may not be able to properly
perform the services described in this manual. Improper repair may result in injury to
the mechanic and may render the engine
unsafe for the boat operator and passengers.
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page in a
GROUP INDEX. Select the section needed for reference.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. The first page of each section lists a table of contents to easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other service information such as the tightening torque, lubrication and locking agent points.
Example:
1 Flywheel nut (1)
2 Washer (1)
3 Flywheel (1)
4 Flywheel key (1)
5 Bolt (2)
6 Pulser coil (1)
7 Bolt (4)
8 Condenser charge coil (1)
9 Battery charge coil (1)
0 Bolt (1)
A Bolt (2)
B Stator base (1)
C Dowel pin (2)
80 N·m
8.0 kgf-m
58.5 lb-ft
NOTE:
Clean the flywheel and the
crankshaft mating surfaces
with cleaning solvent.
NOTE:
Route the coil wires through
slots of the stator base.
( )
SYMBOL
Listed in the table below are the symbols indicating instructions and other important information necessary
for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout
this manual. Refer back to this table if you are not sure of any symbol(s) meanings.
SYMBOL DEFINITION SYMBOL DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply the THREAD LOCK “1342”.
Apply the oil. Use the engine oil unless
otherwise specified.
Apply the THREAD LOCK SUPER
“1333B”.
Apply the SUZUKI OUTBOARD
MOTOR GEAR OIL.
Measure in resistance range.
Apply the SUZUKI SUPER GREASE “A”. Measure in continuity test range.
Apply the SUZUKI WATER RESISTANT
GREASE.
Use peak voltmeter “Stevens CD-77”.
Apply the SUZUKI BOND “1207B”. Use special tool.
Apply the SUZUKI SILICONE SEAL.
1
GENERAL INFORMATION 1-1
CONTENTS
GENERAL INFORMATION
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
IDENTIFICATION NUMBER LOCATION ......................................................1- 4
FUEL AND OIL ..............................................................................................1- 5
GASOLINE RECOMMENDATION .........................................................1- 5
ENGINE OIL ...........................................................................................1- 5
ENGINE BREAK-IN .......................................................................................1- 6
WARM-UP RECOMMENDATION ..........................................................1- 6
THROTTLE RECOMMENDATION .........................................................1- 6
PROPELLERS ...............................................................................................1- 7
SPECIFICATIONS .........................................................................................1- 8
SERVICE DATA .............................................................................................1-10
TIGHTENING TORQUE .................................................................................1-17
SPECIAL TOOLS ..........................................................................................1-19
MATERIALS REQUIRED ..............................................................................1-22
1-2 GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
Indicates a potential hazard that could result in motor damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all
potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical safety
principles.
GENERAL PRECAUTIONS
!
* Proper service and repair procedures are important for the safety of the service mechanic and
the safety and reliability of the outboard motor.
* To avoid eye injury, always wear protective goggles when filing metals, working on a grinder,
or doing other work, which could cause flying material particles.
* When 2 or more persons work together, pay attention to the safety of each other.
* When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented
outdoors.
* When testing an outboard motor in the water and on a boat, ensure that the necessary safety
equipment is on board. Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope,
etc.
* When working with toxic or flammable materials, make sure that the area you work in is wellventilated 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 pets may be harmed from contact with oil. Keep new and
used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve
shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet
with oil. Recycle or properly dispose of used oil.
* After servicing fuel, oil/engine cooling system and exhaust system, check all lines and fittings
related to the system for leaks.
* Carefully adhere to the battery handling instructions laid out by the battery supplier.
GENERAL INFORMATION 1-3
"
* If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
* When removing parts that are to be reused, keep them arranged in an orderly manner so that
they may be reinstalled in the proper order and orientation.
* Be sure to use special tools when instructed.
* Make sure that all parts used in assembly are clean and also lubricated when specified.
* When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type.
* When removing the battery, disconnect the negative cable first and then the positive cable.
When reconnecting the battery, connect the positive cable first and then the negative cable.
* When performing service to electrical parts, if the service procedures do not require using
battery power, disconnect the negative cable at the battery.
* Tighten cylinder head and case 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 over material from the mating
surfaces.
* Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger
than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is
completely seated in its groove and securely fitted.
* Use a torque wrench to tighten fasteners to the torque values when specified.
Remove grease or oil from screw/bolt threads unless a lubricant is specified.
* After assembly, check parts for tightness and operation.
* To protect the environment, do not unlawfully dispose of used motor oil, other fluids and batteries.
* To protect the Earth’s natural resources, properly dispose of used motor parts.
1-4 GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL, PRE-FIX, SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of the motor are
stamped on a plate attached to the clamp bracket.
Example
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss on
the cylinder block.
Model
Pre-fix Serial number
GENERAL INFORMATION 1-5
FUEL AND OIL
GASOLINE RECOMMENDATION
Suzuki highly recommends that you use alcohol-free unleaded
gasoline with a minimum pump octane rating of 87 (R+M /2
method) or 91 (Research method). However, blends of
unleaded gasoline and alcohol with equivalent octane content
may be used.
Allowable maximum blend of a single additive (not combination):
5% Methanol, 10% Ethanol, 15% MTBE
"
ENGINE OIL
Use only oils that are rated SE, SF, SG, SH or SJ under the API
(American Petroleum Institute) classification system.
The viscosity rating should be SAE 10W-40.
If an SAE 10W-40 motor oil is not available, select an alternative
according to the chart at right.
If leaded gasoline is used, engine damage may result.
Use only unleaded gasoline.
1-6 GENERAL INFORMATION
ENGINE BREAK-IN
The first 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 starting.
THROTTLE RECOMMENDATION
NOTE:
Avoid maintaining a constant engine speed for an extended
period at any time during the engine break-in by varying the
throttle position occasionally.
1. FIRST 2 HOURS
For first 15 minutes, operate the engine in-gear at idling
speed.
During the remaining 1 hour and 45 minutes, operate the
engine in-gear at less than 1/2 (half) throttle (3 000 r/min).
NOTE:
The throttle may be briefly opened beyond the recommended
setting to plane the boat, but must be reduced to the recommended setting immediately after planing.
2. NEXT 1 HOUR
Operate the engine in-gear at less than 3/4 (three-quarter)
throttle (4 000 r/min).
3. LAST 7 HOURS
Operate the engine in-gear at desired engine speed.
However, do not operate continuously at full throttle for more
than 5 minutes.
GENERAL INFORMATION 1-7
PROPELLERS
An outboard motor is designed to develop its rated power within
a specified engine speed range. The maximum rated power
delivered by the DF9.9/15 models are shown below.
If the standard propeller fails to meet the above requirement,
use another pitch propeller to hold the engine speed within the
range specified above.
Propeller selection chart
"
Recommended full
throttle speed range
DF9.9 4 500 – 5 500 r/min
DF15 5 400 – 6 000 r/min
Blade × Diam. (in) × Pitch (in)
3 × 9# × 7
3 × 9# × 8
3 × 9# × 9
3 × 9# × 10
3 × 9# × 11
Installing a propeller with pitch either too high or too
low will cause incorrect maximum engine speed,
which may result in severe damage to the motor.
1-8 GENERAL INFORMATION
SPECIFICATIONS
DIMENSIONS & WEIGHT
PERFORMANCE
POWER HEAD
Item Unit
Date
DF9.9/9.9A DF9.9E/9.9AE DF9.9R/9.9AR DF15/15A DF15E/15AE DF15R/15AR
Overall length
(front to back)
mm (in) 1 005 (39.6)
Overall width
(side to side)
mm (in) 320 (12.6)
Overall heigth S mm (in) 1 095 (43.1)
L mm (in) 1 220 (48.0)
Weight
S
kg (lbs)
44.0
(97.0)
47.5
(104.7)
46.5
(102.5)
44.0
(97.0)
47.5
(104.7)
46.5
(102.5)
L
kg (lbs)
45.0
(99.2)
48.5
(106.9)
47.5
(104.7)
45.0
(99.2)
48.5
(106.9)
47.5
(104.7)
Transom height
[Trim position: 3]
S mm (in. type) 427 (15)
L mm (in. type) 554 (20)
Maximum output kW (PS) 7.3 (9.9) 11.0 (15)
Recommended operating
range
r/min 4 500 – 5 500 5 400 – 6 000
Idle speed r/min 1 100 ± 50
In-gear idle speed r/min Approx. 1 000
Engine type 4-stroke SOHC
Number of cylinders 2
Bore mm (in) 58.0 (2.28)
Stroke mm (in) 57.0 (2.24)
Total displacement cm3 (cu. in) 302 (18.4)
Compression ratio 9.0
Spark plug NGK DCPR6E
Intake system Carburetor
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual Electric Manual Electric
Choke system Manual Electric Manual Electric
Throttle control
Twist grip
Remote
control
Twist grip
Remote
control
Ignition system SUZUKI PEI (Digital CDI)
GENERAL INFORMATION 1-9
FUEL & OIL
BRACKET
LOWER UNIT
These specifications are subject to change without notice.
Item Unit
Date
DF9.9/9.9A DF9.9E/9.9AE DF9.9R/9.9AR DF15/15A DF15E/15AE DF15R/15AR
Fuel Suzuki highly recommends that you use alcohol-free unleaded
gasoline with a minimum pump octane rating of 87 (R+M /2
method) or 91 (Research method). However, blends of unleaded
gasoline and alcohol with equivalent octane content may be used.
Engine oil API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
Engine oil amounts
L (US/lmp. qt)
1.0 (1.1/0.9): Oil change only
1.1 (1.2/1.0): Oil filter change
Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
Gearcase oil amounts ml (US/lmp. qt) 170 (5.7/6.0)
Trim angle Degrees 4 – 20
Number of trim position 5
Maximum tilt angle Degrees 74
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12 : 23 (1.917)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in) × Pitch (in)
3 × 9# × 7
3 × 9# × 8
3 × 9# × 9
3 × 9# × 10
3 × 9# × 11
1-10 GENERAL INFORMATION
SERVICE DATA
POWERHEAD
* Figures shown are guidelines only, not absolute service limit.
CYLINDER HEAD/CAMSHAFT
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Recommended operation
range
r/min 4 500 – 5 500 5 400 – 6 000
Idle speed r/min 1 100 ± 50 (in-gear: approx. 1 000)
Cylinder compression*
(with decompression system)
kPa
(kg/cm2, psi)
Approx. 400 (4.0, 57) with recoil starting
Oil pressure*
[Oil temp. at 60 °C (140 °F)]
kPa
(kg/cm2, psi)
Min. 200 (2.0, 28)
Max. 500 (5.0, 71)
at 3 000 r/min
Engine oil API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
Engine oil amount
L (US/lpm. qt))
1.0 (1.1/0.9): Oil change only
1.1 (1.2/1.0): Oil filter change
Thermostat operating
temperature
°C (°F) 58 – 62 (136 – 144)
Cylinder head distortion Limit mm (in) 0.05 (0.002)
Cam height
IN
STD mm (in)
22.259 – 22.319
(0.8763 – 0.8787)
23.471 – 23.531
(0.9241 – 0.9264)
Limit mm (in) 22.100 (0.8701) 23.320 (0.9181)
EX
STD mm (in)
22.257 – 22.317
(0.8763 – 0.8786)
23.471 – 23.531
(0.9241 – 0.9264)
Limit mm (in) 22.100 (0.8701) 23.230 (0.9181)
Camshaft journal oil
clearance
STD mm (in) 0.020 – 0.062 (0.0008 – 0.0024)
Limit mm (in) 0.100 (0.0039)
Camshaft
holder inside
diameter
Upper STD mm (in) 25.000 – 25.021 (0.9843 – 0.9851)
Lower STD mm (in) 23.000 – 23.021 (0.9055 – 0.9063)
Camshaft
journal outside diameter
Upper STD mm (in) 24.959 – 24.980 (0.9826 – 0.9835)
Lower STD mm (in) 22.959 – 22.980 (0.9039 – 0.9047)
Rocker arm shaft to
rocker arm clearance
STD mm (in) 0.016 – 0.045 (0.0006 – 0.0018)
Limit mm (in) 0.060 (0.0024)
Rocker arm inside
diameter STD mm (in)
13.000 – 13.018
(0.5118 – 0.5125)
Rocker arm shaft
outside diameter STD mm (in)
12.973 – 12.984
(0.5107 – 0.5112)
GENERAL INFORMATION 1-11
VALVE/VALVE GUIDE
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Valve diameter
IN STD mm (in) 26 (1.0)
EX STD mm (in) 22 (0.9)
Valve clearance
(when cold)
IN STD mm (in) 0.08 – 0.12 (0.003 – 0.005)
EX STD mm (in) 0.13 – 0.17 (0.005 – 0.007)
Valve guide
to valve stem
clearance
IN
STD mm (in) 0.010 – 0.037 (0.0004 – 0.0015)
Limit mm (in) 0.070 (0.0028)
EX
STD mm (in) 0.035 – 0.062 (0.0014 – 0.0024)
Limit mm (in) 0.090 (0.0035)
Valve guide
inside diameter
IN STD mm (in) 5.500 – 5.512 (0.2165 – 0.2170)
EX STD mm (in) 5.500 – 5.512 (0.2165 – 0.2170)
Valve guide
outside
diameter
IN STD mm (in) 5.475 – 5.490 (0.2156 – 0.2161)
EX STD mm (in) 5.450 – 5.465 (0.2146 – 0.2152)
Valve stem
end length
IN Limit mm (in) 2.2 (0.09)
EX Limit mm (in) 2.2 (0.09)
Valve stem
deflection
IN Limit mm (in) 0.16 (0.006)
EX Limit mm (in) 0.16 (0.006)
Valve stem
runout
IN Limit mm (in) 0.05 (0.02)
EX Limit mm (in) 0.05 (0.02)
Valve head
radial runout
IN Limit mm (in) 0.03 (0.001)
EX Limit mm (in) 0.03 (0.001)
Valve head
thickness
IN Limit mm (in) 0.5 (0.02)
EX Limit mm (in) 0.5 (0.02)
Valve seat
width
IN STD mm (in) 0.9 – 1.1 (0.035 – 0.043)
EX STD mm (in) 0.9 – 1.1 (0.035 – 0.043)
Valve spring free
length
STD mm (in) 32.52 (1.280)
Limit mm (in) 32.40 (1.276)
Valve spring tension STD N (kg, lbs) 90 (9.0, 19.8) for 28.5 mm (1.12 in)
Limit N (kg, lbs) 76 (7.6, 16.8) for 28.5 mm (1.12 in)
1-12 GENERAL INFORMATION
CYLINDER/PISTON/PISTON RING
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Cylinder distortion Limit mm (in) 0.05 (0.002)
Piston to cylinder
clearance
STD mm (in) 0.0276 – 0.0425 (0.0011 – 0.0017)
Limit mm (in) 0.100 (0.0039)
Cylinder bore STD mm (in) 58.000 – 58.015 (2.2835 – 2.2841)
Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface
Piston skirt diameter STD mm (in) 57.965 – 57.980 (2.2821 – 2.2827)
Piston measuring position mm (in) 15 (0.6) from piston skirt end
Wear on cylinder
bore
Limit mm (in) 0.055 (0.0022)
Piston ring
end gap 1st
STD mm (in) 0.10 – 0.25 (0.004 – 0.010)
Limit mm (in) 0.50 (0.020)
2nd
STD mm (in) 0.10 – 0.25 (0.004 – 0.010)
Limit mm (in) 0.50 (0.020)
Piston ring
free end gap 1st
STD mm (in) Approx. 5.8 (0.23)
Limit mm (in) 4.6 (0.18)
2nd
STD mm (in) Approx. 7.4 (0.29)
Limit mm (in) 5.9 (0.23)
Piston ring to
groove clearance
1st
STD mm (in) 0.02 – 0.06 (0.001 – 0.002)
Limit mm (in) 0.10 (0.004)
2nd
STD mm (in) 0.02 – 0.06 (0.001 – 0.002)
Limit mm (in) 0.10 (0.004)
Piston ring to
groove width
1st mm (in) 1.21 – 1.23 (0.0476 – 0.0484)
2nd mm (in) 1.21 – 1.23 (0.0476 – 0.0484)
Oil mm (in) 2.51 – 2.53 (0.0988 – 0.0996)
Piston ring
thickness
1st STD mm (in) 1.17 – 1.19 (0.0461 – 0.469)
2nd STD mm (in) 1.17 – 1.19 (0.0461 – 0.469)
Piston pin oil clearance
STD mm (in) 0.002 – 0.013 (0.0001 – 0.0005)
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
STD mm (in) 13.995 – 14.000 (0.5510 – 0.5512)
Limit mm (in) 13.980 (0.5504)
Piston pin hole diameter
STD mm (in) 14.002 – 14.008 (0.5513 – 0.5515)
Limit mm (in) 14.030 (0.5524)
GENERAL INFORMATION 1-13
CRANKSHAFT/CONROD
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Conrod small end
inside diameter
STD mm (in) 14.006 – 14.014 (0.5514 – 0.5517)
Limit mm (in) 14.040 (0.5528)
Conrod big end
oil clearance
STD mm (in) 0.025 – 0.043 (0.0010 – 0.0017)
Limit mm (in) 0.063 (0.0025)
Conrod big end
inside diameter
STD mm (in) 29.016 – 29.034 (1.1424 – 1.1431)
Crank pin outside diameter
STD mm (in) 28.982 – 29.000 (1.1410 – 1.1417)
Crank pin outside diameter
difference
Limit mm (in) 0.010 (0.0004)
Conrod big end
side clearance
STD mm (in) 0.10 – 0.20 (0.004 – 0.008)
Limit mm (in) 0.60 (0.024)
Conrod big end
width
STD mm (in) 19.95 – 20.00 (0.785 – 0.787)
Crank pin width STD mm (in) 20.10 – 20.15 (0.791 – 0.793)
Crankshaft
thrust clearance
Limit mm (in) 0.60 (0.024)
Crankshaft
length
STD mm (in) 126.8 – 126.9 (4.992 – 4.996)
Crankcase
length
STD mm (in) 127.0 – 127.1 (5.000 – 5.004)
Crankshaft bearing oil clearance
STD mm (in) 0.020 – 0.044 (0.0008 – 0.0017)
Limit mm (in) 0.060 (0.0024)
Crankshaft bearing holder inside
diameter
STD mm (in) 35.000 – 35.016 (1.3780 – 0.3986)
Crankshaft journal outside
diameter
STD mm (in) 31.984 – 32.000 (1.2592 – 1.2598)
Crankshaft journal outside
diameter difference
Limit mm (in) 0.010 (0.0004)
Bearing thickness
STD mm (in) 1.486 – 1.498 (0.0585 – 0.0590)
1-14 GENERAL INFORMATION
LOWER UNIT
Preliminary gear shim & thrust washer
Initial selection-shim adjustment may be required.
CARBURETOR
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Gearcase oil amount ml
(US/lmp.oz)
170 (5.7/6.0)
Gear ratio 1.917 (23/12)
Pinion back up shim mm (in) 1.0 (0.039)
Forward back up shim mm (in) 1.0 (0.039)
Reverse back up shim mm (in) 1.0 (0.039)
Forward thrust washer mm (in) 1.5 (0.06)
Reverse thrust washer mm (in) 1.5 (0.06)
Type MIKUNI B22TI-15 B26TI-20
I.D. mark 93E40 93E21 93E50 93E31
Main jet # 92.5 86.3 123.8 118.8
Pilot jet # 60 52.5 47.5 42.5
Pilot screw Turns open PRE-SET PRE-SET PRE-SET PRE-SET
Float height mm 17.6 ± 1 17.6 ± 1 17.6 ± 1 17.6 ± 1
NOTE:
Hold carburetor vertical (bore up) and slowly rotate to an inverted horizontal position until float
adjustment tab contacts inlet needle valve. Holding carburetor in this position, measure with vernier caliper from the float to the mating surface of the carburetor body, gasket removed, at 180°
from the needle valve.
GENERAL INFORMATION 1-15
ELECTRICAL
STARTER MOTOR (only for Electric start model)
Item Unit
Date
DF9.9 (E)/9.9R DF9.9A (E)/9.9AR DF15 (E)/15R DF15A (E)/15AR
Ignition timing Degree
at r/min
BTDC 5° at 1 300
BTDC 35° at 3 500
BTDC 5° at 1 300
BTDC 30° at 3 500
Over revolution limiter r/min Approx. 6 500
Condenser charge coil
resistance
Ω at 20° 244 – 364 (G – B/R)
Pulser coil resistance Ω at 20° 155 – 233 (R/B – B)
Ignition coil
resistance
(without spark
plug cap)
Primary Ω at 20° 0.2 – 0.4 (O – B)
Secondary kΩ at 20° 6.4 – 9.6 (H.T. cord – H.T. cord)
Spark plug cap resistance kΩ at 20° 8 – 12
Battery charge coil resistance
Ω at 20° 0.2 – 0.4 (R – Y)
Battery charge coil output
(12V)
Watt 80 (120......with option coil)
Standard spark
plug
Type NGK DCPR6E
Gap mm (in) 0.8 – 0.9 (0.031 – 0.035)
Fuse amp rating A 25: Electric start model
Recommended battery
capacity (12V)
Ah (kC) 35 (126) or over: Electric start model
Chock solenoid coil resistance
Ω at 20 °C 2.8 – 4.2 (O – B): Remote control model
Starter motor relay coil
resistance
Ω at 20 °C 3.5 – 5.1 (Y/G – B): Remote control model
Max. continuous time of use Sec. 30
Motor output kW 0.6
Brush length STD mm (in) 12.5 (0.49)
Limit mm (in) 9.0 (0.35)
Commutator undercut
STD mm (in) 0.5 – 0.8 (0.02 – 0.03)
Limit mm (in) 0.2 (0.01)
Commutator outside
diameter
STD mm (in) 30 (1.2)
Limit mm (in) 29 (1.1)
Difference between
max/min diameter of
commutator
STD mm (in) 0.05 (0.002)
Limit mm (in) 0.40 (0.016)
Pinion/ring gear gap mm (in) 3.0 – 5.0 (0.12 – 0.20)
1-16 GENERAL INFORMATION
PEAK VOLTAGE
Requirements for peak voltage measurement
• Remove all spark plugs to eliminate the variables at cranking speed.
• Crank with recoil starter.
• Use a STEVENS peak voltage tester, Model CD-77.
Testing sequence
Tester probe
connection Peak voltage Tester range Remarks
+ (Red) - (Black)
CDI output
Orange Black 144 V or over NEG 500
With ignition coil
connected
Condenser charge coil
output
Green Black/Red 144 V or over POS 500
With CDI unit
disconnectedPluser coil output
Red/Black
Black
(Ground)
2.2 V or over SEN 5
Battery charge coil output
Red Yellow 3.5 V or over POS 50
With rectifier
disconnected
GENERAL INFORMATION 1-17
TIGHTENING TORQUE
Tightening torque – Important fasteners
ITEM
THREAD
DIAM.
TIGHTENING TORQUE
N·m kgf-m lb-ft
Cylinder head cover bolt 6 mm 10 1.0 7.0
Cylinder head bolt 8 mm 28 2.8 20.0
Crankcase bolt 6 mm 14 1.4 10.0
8 mm 25 2.5 18.0
Conrod cap bolt 7 mm 12 1.2 8.5
Oil pump bolt 6 mm 14 1.4 10.0
Oil pump gallery bolt 6 mm 14 1.4 10.0
Intake manifold bolt 8 mm 23 2.3 16.5
Carburetor mounting bolt 6 mm 10 1.0 7.0
Fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Valve adjusting lock nut 5 mm 10 1.0 7.0
Timing pulley nut 26 mm 50 5.0 36.0
Flywheel nut 14 mm 80 8.0 58.5
Spark plug — 17 1.7 12.5
Power unit mounting bolt and nut 8 mm 23 2.3 16.5
Driveshaft housing bolt 8 mm 23 2.3 16.5
Oil pressure switch — 13 1.3 9.5
Oil regulator 14 mm 27 2.7 19.5
Camshaft pulley bolt 6 mm 10 1.0 7.0
Engine oil drain plug 12 mm 13 1.3 9.5
Upper mount bolt 8 mm 23 2.3 16.5
Upper mount bracket bolt 8 mm 23 2.3 16.5
Lower mount cover bolt 8 mm 23 2.3 16.5
Lower mount bolt 8 mm 23 2.3 16.5
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Tilt lock arm bolt 10 mm 25 2.5 18.0
Handle pivot bolt 10 mm 6 0.6 4.5
Handle pivot nut 10 mm 23 2.3 16.5
Water pump case bolt 8 mm 8 0.8 6.0
Gearcase bolt 8 mm 23 2.3 16.5
Propeller nut 12 mm 18 1.8 13.0
Propeller shaft bearing housing bolt 6 mm 8 0.8 6.0
1-18 GENERAL INFORMATION
Tightening torque – General bolt
NOTE:
These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners”
table.
TYPE OF BOLT
THREAD
DIAMETER
TIGHTENING TORQUE
N·m kgf-m lb-ft
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
(Conventional or “4” marked bolt) 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
(Stainless steel bolt) 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5
5 mm 3 – 6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
(7 marked or marked bolt) 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5
GENERAL INFORMATION 1-19
SPECIAL TOOLS
1. 2. 3. 4. 5.
09900-00410
Hexagon wrench set
09900-06108
Snap ring pliers
09900-20101 (150 mm)
09900-20102 (200 mm)
Vernier calipers
09900-20202
Micrometer
(25 – 50 mm)
09900-20203
Micrometer
(50 – 75 mm)
6. 7. 8. 9. 10.
09900-20205
Micrometer
(0 – 25 mm)
09900-20508
Cylinder gauge set
(40 – 80 mm)
09900-20602
Dial gauge
09900-20605
Dial calipers
(10 – 34 mm)
09900-20701
Magnetic stand
11. 12. 13. 14. 15.
09900-20803
Thickness gauge
09900-21304
Steel “V” block set
09900-22301
Plastigauge
(0.025 – 0.076 mm)
09900-26006
Engine tachometer
09900-28403
Hydrometer
16. 17. 18. 19. 20.
09911-49310
Crankshaft holder
09913-50121
Oil seal remover
09915-63210
Compression gauge
adapter
09915-64512
Compression gauge
09915-77311
Oil pressure gauge
1-20 GENERAL INFORMATION
21. 22. 23. 24. 25.
09915-78211
Oil pressure gauge
adapter
09916-10911
Valve lapper
09916-14510
Valve lifter
09916-14521
Valve lifter attachment
09916-20610
Valve seat cutter (15°)
(N-121)
26. 27. 28. 29. 30.
09916-20620
Valve seat cutter (45°)
(N-122)
09916-24440
Handle adapter
(N-503-1)
09916-24450
Solid pilot
(N-100-5.52)
09916-34542
Valve guide reamer
handle
09916-34550
Valve guide reamer
($ 5.5 mm)
31. 32. 33. 34. 35.
09916-38210
Valve guide reamer
($ 11 mm)
09916-44910
Valve guide
remover/installer
09916-54910
Handle (N-505)
09916-77310
Piston ring compressor
09916-84511
Tweezers
36. 37. 38. 39. 40.
09917-14910
Valve adjuster driver
09930-30104
Sliding hammer
09930-39210
Flywheel remover
attachment bolt
09930-39411
Flywheel remover
09930-39520
Flywheel holder
GENERAL INFORMATION 1-21
NOTE:
* Marked part No. is in U.S. market only.
41. 42. 43. 44. 45.
09930-76420
Timing light
09930-99320
Digital tester
09940-44121
Air pressure gauge
09950-59320
Propeller shaft
remover
09950-69512
Gearcase oil leakage
tester
46. 47. 48. 49.
09951-09511
Gear adjusting
gauge
Pinion bearing installer and remover
09951-59910 Pinion bearing installer shaft
A
09951-49910 Pinion bearing remover shaft B
09951-69910 Bearing C
01500-08403 Bolt D
09951-39914 Pinion bearing plate E
09951-19311 Attachment F
09951-79311 Spacer G
09951-29910 Nut H
99954-53008-820*
Digital voltmeter
99954-53873*
Stevens CD-77
Peak reading voltmeter
50.
99954-53883*
Gear oil filler
1-22 GENERAL INFORMATION
MATERIALS REQUIRED
NOTE:
* Marked part No. is in U.S. market only.
SUZUKI OUTBOARD
MOTOR GEAR OIL
SUZUKI SUPER
GREASE “A”
WATER RESISTANT
GREASE
SUZUKI SILICONE
SEAL
SUZUKI BOND
“1207B”
99000-22540
(400 ml × 24 pcs.)
99000-25030*
99000-25010
(500 g)
99000-25160
(250 g)
99000-31120
(50 g)
99104-33140*
99000-31140
(100 g)
THREAD LOCK
“1342”
THREAD LOCK
SUPER “1333B”
4-Stroke Motor Oil
99000-32050
(50 g)
99000-32020
(50 g)
API: SE, SF, SG, SH, SJ
SAE: 10W-40
2
6
PERIODIC MAINTENANCE 2-1
CONTENTS
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 3
ENGINE OIL ...........................................................................................2- 3
ENGINE OIL FILTER ..............................................................................2- 4
GEAR OIL ...............................................................................................2- 5
LUBRICATION .......................................................................................2- 6
SPARK PLUG ........................................................................................2- 7
VALVE CLEARANCE ............................................................................2- 8
TIMING BELT .........................................................................................2-10
IDLE SPEED ...........................................................................................2-13
CARBURETOR ......................................................................................2-13
IGNITION TIMING ..................................................................................2-14
BREATHER AND FUEL LINE ................................................................2-14
FUEL FILTER .........................................................................................2-14
WATER PUMP/WATER PUMP IMPELLER ...........................................2-15
PROPELLER NUT AND PIN ..................................................................2-15
ANODES AND BONDING WIRES .........................................................2-15
BATTERY ...............................................................................................2-17
BOLTS AND NUTS ................................................................................2-18
2-2 PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motor operating at peak performance and economy.
Maintenance intervals should be judged by number of hours or months, whichever comes first.
NOTE:
More frequent servicing should be performed on outboard motors that are used under severe conditions.
PERIODIC MAINTENANCE CHART
I: Inspect and clean, adjust, lubricate or replace, if necessary T: Tighten R: Replace
Interval Initial 20 hrs.
or 1 month
Every 200 hrs.
or 12 months
Every 100 hrs.
or 6 months
Every 50 hrs.
or 3 months
Refer to
pageItem to be serviced
Spark plug — — I R 2-7
Breather and fuel line
I I I I
2-14
Replace every 2 years.
Engine oil R — R R 2-3
Gear oil R — R R 2-5
Lubrication — I I I 2-6
Anodes and bounding
wire
— I I I 2-15
Battery — I I I 2-17
Bolts and nuts T — T T 2-18
Engine oil filter R — — R 2-4
Fuel filter
— I I I
2-14
Replace every 400 hours or 2 years.
Valve clearance I — — I 2-8
Timing belt
— — — I
2-10
Replace every 4 years.
Carburetor I — I I 2-13
Propeller nut and pin I — I I 2-15
Water pump — — — I 2-15
Water pump impeller — — — R 2-15
Idle speed I — — I 2-13
Ignition timing — — — I 2-14
PERIODIC MAINTENANCE 2-3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes the servicing procedures for each of the
periodic maintenance requirements.
ENGINE OIL
NOTE:
Engine oil should be changed while the engine is warm.
1. Place the outboard motor upright on a level surface.
2. Remove the motor cover.
3. Remove the oil filler cap
1.
4. Place an oil pan, then drain oil by removing the oil drain plug
2 and the gasket.
5. Install the gasket and the oil drain plug.
Tighten the engine oil drain plug.
! Engine oil drain plug: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
"
Change initially after 20 hours (1 month) and every
100 hours (6 months) thereafter.
Do not re-use the gasket once removed. Always use a
new gasket.
2-4 PERIODIC MAINTENANCE
6. Pour the recommended engine oil, then install the oil filler
cap.
Necessary amount of engine oil:
Oil change only: 1.0 L (1.1/0.9 US/Imp. qt)
Oil filter change:1.1 L (1.2/1.0 US/Imp. qt)
Recommended oil:
* 4 stroke motor oil
* API classification SE, SF, SG, SH, SJ
* Viscosity rating SAE 10W-40
7. Start the engine and allow it to run for several minutes at the
idle speed.
Turn off the engine and wait for approx. two minutes.
8. Remove the oil level dipstick
3 and wipe it clean.
9. Insert the dipstick fully into the dipstick hole, then pull it out.
10. Oil level should be between the full level hole (Max.) and the
low level hole (Min.)
If the level is low, add the recommended oil to the full level
hole.
ENGINE OIL FILTER
NOTE:
When replacing the engine oil filter, change the engine oil at the
same time. (For oil change, see pages 2-3 and 2-4.)
Necessary amount of engine oil:
Oil filter change: 1.1 L (1.2/1.0 US/Imp. qt)
1. Remove the motor cover.
2. Remove the side covers.
3. Remove the three bolts securing the oil filter cap.
4. Remove the oil filter 1.
Full level line
Low level line
Replace initially after 20 hours (1 month) and every
200 hours (12 months) thereafter.
PERIODIC MAINTENANCE 2-5
5. Assembly is reverse order of disassembly.
"
GEAR OIL
1. Place the outboard motor upright on a level surface.
2. Place a container under the lower unit.
3. Remove the gear oil drain plug
2 before the gear oil level
plug 1 and drain the gear oil.
4. Fill with the recommended gear oil through the oil drain hole
until the oil just starts to flow out from the oil level hole.
Gear oil amount: 170 ml (5.7/6.0 US/Imp. oz)
Recommended oil:
SUZUKI OUTBOARD MOTOR GEAR OIL or
SAE #90 HYPOID GEAR OIL
5. Install the oil level plug before removing the oil filler tube
from the drain hole.
6. Install the oil drain plug.
"
NOTE:
To avoid insufficient injection of the gear oil, check the gear oil
level 10 minutes after doing the procedure in the step 6. If the oil
level is low, slowly inject the gear oil up to the correct level.
Do not re-use the O-rings removed. Always use a new
O-ring.
Change initially after 20 hours (1 month) and every
100 hours (6 months) thereafter.
Do not re-use the gasket once removed. Always use a
new gasket.
2-6 PERIODIC MAINTENANCE
LUBRICATION
Apply the water resistant grease to the following points.
# 99000-25160: SUZUKI WATER RESESTANT GREASE
Inspect every 50 hours (3 months).
Carburetor linkage
NSI cable
Propeller shaft
Steering bracket
Clamp screw
Swivel bracket
PERIODIC MAINTENANCE 2-7
SPARK PLUG
Standard spark plug: NGK DCPR6E
"
CARBON DEPOSIT
Inspect for a carbon deposit on the spark plug bases.
If carbon is present, remove carbon with a spark plug cleaning
machine or by carefully using a pointed tool.
SPARK PLUG GAP
Measure for the spark plug gap using the thickness gauge.
Adjust to within the specified range if the gap is out of the specification.
Spark plug gap: 0.8 – 0.9 mm (0.031 – 0.035 in)
$ 09900-20803: Thickness gauge
CONDITION OF ELECTRODE/INSULATOR
Check the electrode and insulator condition.
If the electrode is extremely worn or burnt, replace the spark
plug.
If the spark plug has a broken insulator, damaged threads, etc.,
replace the spark plug.
"
! Spark plug: 17 N·m (1.7 kgf-m, 12.5 lb-ft)
* Inspect every 100 hours (6 months).
* Replace every 200 hours (12 months).
Only resistor (R) type spark plugs must be used with
this engine. Using a non-resistor spark plug will cause
ignition system malfunctions.
Confirm the thread size and reach when replacing the
plug. If the reach is too short, carbon will be deposited
on the threaded portion of the plug hole resulting in
possible engine damage.
2-8 PERIODIC MAINTENANCE
VALVE CLEARANCE
1. Remove the following parts:
* Motor cover
* Side covers
* Recoil starter
* Spark plugs
2. Disconnect the fuel hoses
1 from the fuel pump 2.
3. Remove the six bolts and the cylinder head cover 3.
4. Rotate the flywheel clockwise to bring each piston to the Top
Dead Center (TDC) on a compression stroke. Align each
PUNCH mark on the cam pulley with the INDEX mark on the
cylinder head block.
"
NOTE:
* The piston must be at its TDC position on a compression
stroke to check or adjust the valve clearance.
* The valve clearance specification is for COLD engine condition.
* The valve clearance specification is different for the intake (IN)
valves and the exhaust (EX) valves.
5. Insert the thickness gauge between the valve stem end and
the valve adjusting screw on the rocker arm.
$ 09900-20803: Thickness gauge
Valve clearance (when cold):
IN. 0.08 – 0.12 mm (0.003 – 0.005 in)
EX. 0.13 – 0.17 mm (0.005 – 0.007 in)
If the measurement is out of the specification, adjust the valve
clearance.
Inspect initially after 20 hours (1 month) and every
200 hours (12 months) thereafter.
PUNCH mark TDC cylinder number
1 No. 1 cylinder
2 No. 2 cylinder
Rotate the crankshaft in the normal running direction
only (clockwise) to prevent water pump impeller damage.
PERIODIC MAINTENANCE 2-9
ADJUSTMENT
6. Loosen the valve adjusting lock nut
4.
7. Turn the valve adjusting screw using the valve adjuster
driver to bring the valve clearance to within the specification.
$ 09900-20803: Thickness gauge
09917-14910: Valve adjustment driver
8. Tighten the valve adjusting lock nut while holding the valve
adjusting screw.
! Valve adjusting lock nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
9. Recheck the valve clearance.
10. Tighten the cylinder head cover bolts to the specified torque.
! Cylinder head cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
"
Do not re-use the gasket once removed. Always use a
new gasket.
2-10 PERIODIC MAINTENANCE
TIMING BELT
If wear, crack or other damage is found, replace the timing belt.
1. Remove the motor cover.
2. Remove the recoil starter.
3. Remove the side covers.
4. Remove the spark plugs.
5. Remove the flywheel
1. (See page 3-9.)
$ 09930-39520: Flywheel holder
09930-39411: Flywheel remover
09930-39210: Flywheel remover attachment bolt
6. Remove the battery charge coil 2 and condenser charge
coil 3.
7. Remove the startor 4.
* Inspect every 200 hours (12 months).
* Replace every 4 years.
PERIODIC MAINTENANCE 2-11
8. Rotate the crankshaft to align the HOLLOW mark on the
washer with the INDEX mark on the cylinder block.
$ 09911-49310: Crankshaft holder
"
"
9. Remove the timing belt from the cam pulley first, then from
the timing pulley.
"
10. Install the timing belt on the timing pulley first, then the cam
pulley.
"
"
Rotate the crankshaft in the normal running direction
(clockwise) to prevent water pump impeller damage.
Do not rotate the cam pulley with timing belt installed.
Do not rotate the crankshaft or the cam pulley before
installing the belt; the following must be checked:
* The PUNCH mark on the timing pulley aligns with the
INDEX mark on the cylinder block.
* The PUNCH mark “1” on the cam pulley aligns with
the INDEX mark on the cylinder head block.
If the timing pulley or the cam pulley is rotated with
the timing belt removed or installed but misaligned,
this may cause the valves to become bent.
If the alignment marks are not correctly matched,
loosen the valve adjusting lock nuts and the valve
adjusting screws fully to prevent valve damage.
Then align the marks correctly by rotating the cam
pulley clockwise.
Always keep the timing belt away from any grease and
oil.
If the timing belt must be installed with the arrow mark
on the timing belt toward the direction of rotation.
2-12 PERIODIC MAINTENANCE
11. Make sure that either of the PUNCH mark “1” on the cam
pulley aligns with the INDEX mark on the cylinder head block
when the HOLLOW mark on the washer aligns with the
INDEX mark on the cylinder clock.
12. Install the following parts.
* Condenser charge coil (See page 3-10.)
* Battery charge coil (See page 3-10.)
* Flywheel (See page 3-10.)
* Spark plugs
* Recoil starter
* Motor cover
PERIODIC MAINTENANCE 2-13
IDLE SPEED
Checking
1. Check the link mechanism and the carburetor throttle valves
for smooth operation.
2. Attach the tachometer cord to the spark plug high-tension
cord.
$ 09900-26006: Engine tachometer
3. Start and warm up the engine.
NOTE:
Check and/or adjust the idle speed after the engine speed has
stabilized.
4. Check the idle speed.
Idle speed (in neutral gear): 1 050 – 1 150 r/min
Adjustment
If the idle speed is out of the specification, adjust the speed as
follows:
Turn the throttle stop screw.
* Turning clockwise: The engine speed becomes higher.
* Turning counterclockwise: The engine speed becomes lower.
CARBURETOR
If crack or other damage is found on carburetor body, lever, rod
connector, inlet manifold or silencer, replace.
Inspect initially after 20 hours (1 month) and every
200 hours (12 months) thereafter.
Inspect initially after 20 hours (1 month) and every
100 hours (6 months) thereafter.
2-14 PERIODIC MAINTENANCE
IGNITION TIMING
NOTE:
Before checking the ignition timing, make sure that the idle
speed is adjusted within the specification.
1. Start and warm up the engine.
2. Attach the timing light to the No. 1 spark plug high-tension
cord.
$ 09930-76420: Timing light
09900-26006: Engine tachometer
3. Check the ignition timing while operating the engine at idling
speed.
Ignition timing: Approx. BTDC 5° at 1 100 r/min
BREATHER AND FUEL LINE
If leakage, cracks, swelling or other damage is found, replace
the breather line and/or the fuel line.
FUEL FILTER
If water accumulation, sediment, leakage, crack or other damage is found, replace the fuel filter.
Inspect every 200 hours (12 months).
* Inspect initially after 20 hours (1 month) and every
50 hours (3 months) thereafter.
* Replace every 2 years.
* Inspect every 50 hours (3 months).
* Replace every 400 hours or 2 years.
PERIODIC MAINTENANCE 2-15
WATER PUMP/WATER PUMP IMPELLER
If excessive wear, crack, distortion or corrosion is found on the
pump case or the under panel, replace.
"
PROPELLER NUT AND PIN
Make sure that the propeller nut and the pin are installed
securely.
If excessive wear, breakage or other damage is found on the
propeller, the propeller bush or the propeller shaft, replace.
ANODES AND BONDING WIRES
ANODES
If 2/3 of the anode has corroded away, replace the anode.
"
NOTE:
The anode securing bolt should be covered with the SUZUKI
SILICONE SEAL.
% 99000-31120: SUZUKI SILICONE SEAL
WATER PUMP
Inspect every 200 hours (12 months).
WATER PUMP IMPELLER
Replace every 200 hours (12 months).
Do not re-use the gasket once removed. Always use a
new gasket.
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.
Inspect every 50 hours (3 months).
Never paint the anode.
Anode
2-16 PERIODIC MAINTENANCE
BONDING WIRES
If breakage or other damage is found, replace the wire.
If rust or corrosion is found on the wire terminal, clean it with solvent.
PERIODIC MAINTENANCE 2-17
BATTERY
&
Recommended battery:
12 V 35 AH (126 kC) or larger battery
CONNECTING BATTERY
Upon completion of the connection, lightly apply grease to the
battery terminals.
How to connect:
1. Connect the positive (+) terminal first.
2. Connect the negative (–) terminal second.
How to disconnect:
1. Disconnect the negative (–) terminal first.
2. Disconnect the positive (+) terminal second.
"
Inspect every 50 hours (3 months).
* Never expose battery to open flame or electric spark
as batteries generate gas which is flammable and
explosive.
* Battery 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 battery, disconnect the
negative (black) cable. Be careful not to cause a
short circuit by allowing metal objects to contact battery posts and motor at the same time.
* Wear approved eye protection.
If the battery leads are incorrectly connected, the electrical system could be damage.
2-18 PERIODIC MAINTENANCE
BATTERY SOLUTION LEVEL CHECK
The battery solution level should be between the UPPER and
LOWER level.
If the level is low, add distilled water only.
"
BATTERY SOLUTION SPECIFIC GRAVITY CHECK
Measure the gravity of the battery solution by using the hydrometer.
$ 09900-28403: Hydrometer
Battery solution specific gravity: 1.28 at 20 °C
BOLTS AND NUTS
Check that all bolts and nuts listed below are tightened to their
specified torque.
Once the battery has been initially serviced, NEVER
add diluted sulfuric acid, or you will damage the battery. Follow the battery manufacture’s instructions for
specific maintenance procedures.
Tighten initially after 20 hours (1 month) and every
100 hours (6 months) thereafter.
ITEM
THREAD
DIAMETER
TIGHTENING TORQUE
N·m kgf-m lb-ft
Cylinder head cover bolt 6 mm 10 1.0 7.0
Cylinder head bolt 8 mm 28 2.8 20.0
Intake manifold bolt 8 mm 23 2.3 16.5
Carburetor mounting bolt 6 mm 10 1.0 7.0
Flywheel nut 14 mm 80 8.0 58.5
Power unit mounting bolt/nut 8 mm 23 2.3 16.5
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Gearcase bolt 8 mm 23 2.3 16.5
Propeller nut 12 mm 18 1.8 13.0
IGNITION AND ELECTRICAL 3-1
IGNITION AND ELECTRICAL
3
CONTENTS
IGNITION SYSTEM........................................................................................3- 2
PRINCIPLES OF OPERATION ...............................................................3- 2
TROUBLESHOOTING ............................................................................3- 3
INSPECTION ...........................................................................................3- 4
REMOVAL/INSTALLATION....................................................................3- 8
CAUTION SYSTEM .......................................................................................3-11
OVER-REVOLUTION CAUTION SYSTEM.............................................3-11
LOW OIL PRESSURE CAUTION SYSTEM............................................3-12
INSPECTION ...........................................................................................3-13
REMOVAL AND INSTALLATION...........................................................3-14
BATTERY CHARGING SYSTEM ..................................................................3-15
OUTLINE .................................................................................................3-15
INSPECTION ...........................................................................................3-16
ELECTRIC STARTER SYSTEM....................................................................3-18
OUTLINE .................................................................................................3-18
TROUBLESHOOTING ............................................................................3-19
INSPECTION ...........................................................................................3-21
STARTER MOTOR..................................................................................3-23
3-2 IGNITION AND ELECTRICAL
IGNITION SYSTEM
PRINCIPLES OF OPERATION
A digital CDI (condenser discharge ignition) system is employed on the DF9.9/DF15.
The condenser built in the CDI unit stores the electrical energy generated by the exciter coil.
The electrical energy stored in the condenser is released to the ignition coil primary windings by the ignition
timing signal calculated by the CDI microcomputer from the pulse coil signals.
SPECIFICATION
Ignition type CDI
Advance Electronic microcomputer control
Ignition timing BTDC 5° – 35°: DF9.9
BTDC 5° – 30°: DF9.9A/DF15/DF15A
1 Power source circuit 1
2 Power source circuit 2
3 Base signal circuit 1
4 Base signal circuit 2
5 Hardware ignition signal circuit
6 Software ignition signal circuit
Stop switch
Exciter coil
Pulser coil
Caution lamp
Ignition coil
Neutral switch
Oil pressure switch
CPU
SCR
IGNITION AND ELECTRICAL 3-3
TROUBLESHOOTING
Perform the following ignition system tests when the engine is hard to start in order to determine if the cause
is in the ignition or another system.
START
Check the spark condition.
Check if the spark plug is in good condition.
(See page 2-7.)
Check the spark plug cap for any evidence
of the high-tension leak.
Disconnect the engine stop switch lead wire
(Blue/Red).
Check the ignition coil resistance.
(See page 3-6.)
[Primary: 0.2 – 0.4 Ω]
[Secondary: 6.4 – 9.6 kΩ]
Check the spark plug cap resistance.
(See page 3-7.)
[Cap resistance: 8 – 12 kΩ)]
Check the condencer charge coil resistance.
(See page 3-4.)
[Coil resistance: 244 – 364 Ω]
Check the pulser coil resistance.
(See page 3-5.)
[Coil resistance: 155 – 233 Ω]
Check the CDI unit. (See page 3-6.)
OK
OK
OK
OK
OK
OK
No or weak sparks
No or weak sparks
Check the ignition timing by using
the timing light.
[BTDC 5˚ at 1 100 r/min]
The cause will not be in the ignition
system.
Not good
Not good
Not good
Sparks
Out of spec.
Out of spec.
Out of spec.
Out of spec.
Out of spec.
Replace the spark plug with a new one.
Check and/or replace the engine stop
switch. (See page 3-7.)
Replace the ignition coil.
Replace the spark plug cap.
Replace the condenser change coil.
Replace the pulser coil.
Replace the CDI unit.
3-4 IGNITION AND ELECTRICAL
INSPECTION
!
CONDENSER CHARGE COIL OUTPUT
" Peak Voltmeter Stevens CD-77
Tester selector: POS 500
1. Disconnect the condenser charge coil lead wire connector.
2. Connect the test probe to the coil lead wires as shown.
3. Remove the all spark plugs.
4. Crank with the recoil starter, then measure voltage.
Condenser charge coil output: 144 V or over
If the measurement is out of the specification, replace the condenser charge coil.
CONDENSER CHARGE COIL RESISTANCE
# 09930-99320: Digital tester
$ Tester selector: Ω
1. Disconnect the condenser charge coil lead wire connector.
2. Connect the test probe to the coil lead wires as shown.
Condenser charge coil resistance: 244 – 364 Ω
If the measurement is out of the specification, replace the condenser charge coil.
Always disconnect the battery before commencing resistance test.
Tester probe connection
+ (Red) - (Black)
Green Black/Red
G
B/R
Condenser
charge coil
Tester probe connection
Probe Other probe
Green Black/Red
G
B/R
Condenser
charge coil
IGNITION AND ELECTRICAL 3-5
PULSER COIL OUTPUT
" Peak Voltmeter Stevens CD-77
Tester selector: SEN 5
1. Disconnect the pulser coil lead wires.
2. Connect the test probe to the coil lead wires as shown.
3. Remove all spark plugs.
4. Crank with the recoil starter, then measure voltage.
Pulser coil output: 2.2 V or over
If the measurement is out of the specification, replace the pulser
coil.
PULSER COIL RESISTANCE
# 09930-99320: Digital tester
$ Tester selector: Ω
1. Disconnect the pulser coil lead wires.
2. Connect the test probe to the coil lead wires as shown.
Pulser coil resistance: 155 – 233 Ω
If the measurement is out of the specification, replace the pulser
coil.
Tester probe connection
+ (Red) - (Black)
Red/Black Black (Ground)
B R/B
Tester probe connection
Probe Other probe
Red/Black Black (Ground)
B R/B
3-6 IGNITION AND ELECTRICAL
IGNITION COIL RESISTANCE
# 09930-99320: Digital tester
$ Tester selector: Ω
Primary side
1. Disconnect the ignition coil lead wires.
2. Connect the test probe to the coil lead wires as shown.
Primary coil resistance: 0.2 – 0.4 Ω
If the measurement is out of the specification, replace the ignition coil.
Secondary side
1. Remove the spark plug cap from the high-tension cord.
2. Connect the test probe to the high-tension cords as shown.
Secondary coil resistance: 6.4 – 9.6 6kΩ
If the measurement is out of the specification, replace the ignition coil.
CDI UNIT OUTPUT
" Peak Voltmeter Stevens CD-77
Tester selector: NEG 500
1. Disconnect the CDI unit lead wires.
NOTE:
With the ignition coil connected.
2. Connect the test probe to the CDI unit lead wires as shown.
3. Remove all spark plugs.
4. Crank with the recoil starter, then measure voltage.
CDI unit output: 144 V or over
If the measurement is out of the specification, replace the CDI
unit.
Tester probe connection
Probe Other probe
Orange Black
Tester probe connection
Probe Other probe
High-tension cord Other High-tension cord
Tester probe connection
+ (Red) - (Black)
Orange Black
O B
B O
To the
ignition coil
IGNITION AND ELECTRICAL 3-7
SPARK PLUG CAP
# 09930-99320: Digital tester
$ Tester range: Ω (Resistance)
Measure the spark plug cap resistance.
Spark plug cap resistance: 8 – 12 kΩ
If the measurement is out of the specification, replace the spark
plug cap.
ENGINE STOP SWITCH CONTINUITY
# 09930-99320: Digital tester
% Tester range: & (Continuity)
Inspect the continuity of the engine stop switch.
Spark plug cap resistance
If the result is out of the specification, replace the engine stop
switch.
Tester probe connection
Probe Other probe
Cap end Other cap end
Tester probe connection
Probe Other probe
Blue/Red Black
Switch condition Continuity
Lock plate IN No
Lock plate OUT Yes
Lock plate IN & button depressed Yes
Button
Lock plate
Bl/R
B
3-8 IGNITION AND ELECTRICAL
REMOVAL/INSTALLATION
REMOVAL
1. Remove the motor cover.
2. Remove the CDI unit and the recoil starter.
3. Remove the side cover. (See page 7-2.)
Before removing electrical parts:
* Disconnect the battery cables from the battery.
( )
1 Flywheel nut (1)
2 Washer (1)
3 Flywheel (1)
4 Flywheel key (1)
5 Bolt (2)
6 Pulser coil (1)
7 Bolt (4)
8 Condenser charge coil (1)
9 Battery charge coil (1)
0 Bolt (1)
A Bolt (2)
B Stator base (1)
C Dowel pin (2)
80 N·m
8.0 kgf-m
58.5 lb-ft
NOTE:
Clean the flywheel and the
crankshaft mating surfaces
with cleaning solvent.
NOTE:
Route the coil wires through
slots of the stator base.
IGNITION AND ELECTRICAL 3-9
4. Remove the flywheel nut using the special tool.
# 09930-39520: Flywheel holder
09930-39411: Flywheel remover
09930-39210: Flywheel remover attachment bolt
NOTE:
Use the flywheel holder and shaft of flywheel remover.
'
5. Remove the flywheel using the special tool.
# 09930-39411: Flywheel remover
09930-39210: Flywheel remover attachment bolt
6. Remove the pulser coil
1.
7. Remove the condenser charge coil 2.
When installing a special tool for mounting or
demounting the flywheel, do not thrust in the bolt for
fixing the flywheel more than 10 mm into the flywheel.
If may cause the bolt to come into contact with the coil
(condenser charge coil, battery charge coil) to damage the coil.
Nut
WasherBolt
Flywheel holder
Coil
Less Than 10 mm
3-10 IGNITION AND ELECTRICAL
INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
Wire routing
Flywheel
• Clean the flywheel and crankshaft mating surfaces with cleaning solvent.
• Tighten the flywheel nut to the specified torque.
# 09930-39520: Flywheel holder
09930-39411: Flywheel remover
09930-39210: Flywheel remover attachment bolt
( Flywheel nut: 80 N·m (8.0 kgf-m, 58.5 lb-ft)
Pulser
• Install the pulser coil with a gap of 0.8 mm (0.03 in) between
the pulser coil and flywheel.
# 09930-20803: Thickness gauge
CDI unit
• Install the CDI unit as shown.
Condenser
charge coil
Battery charge
coil
Pulser coil
Fix leads
with tube
To CDI
unit
Rectifier (For electric
starter model)
Yellow
Condenser
charge coil
Route wires through
slots of stator base
Screw
Stator base
Battery
charge coil
Install the CDI unit on the starboard
side hole.
CDI unit
IGNITION AND ELECTRICAL 3-11
CAUTION SYSTEM
LAMP CHECK/BUZZER CHECK
Two (2) seconds after starting engine:
• The caution lamp turns on.
• The caution buzzer sounds. (Remote control models)
The following two caution systems alert the operator when an
abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
*: Remote control model only
OVER-REVOLUTION CAUTION SYSTEM
CONDITION:
When the engine speed exceeds 6 500 r/min, the CDI initiates intermittent ignition signals to provide a maximum engine speed of 6 500 r/min (Over-revolution limiter).
ACTION:
• If the operator decreases engine speed to less than approximately 6 200 r/min within 10 seconds, the
over-revolution caution control will be cancelled.
• If the engine is operated at a speed above 6 500 r/min for more than 10 seconds, the engine speed will be
automatically controlled by ignition interruption and lowered to approximately 3 000 r/min.
To cancel the over-revolution caution control, close the throttle to reduce the engine speed below approximately 2 500 r/min for one second.
CAUTION TYPE
CAUTION
LAMP
CAUTION
BUZZER (*)
OVER-REV
LIMITER
Over-revolution No No Yes
Low oil pressure Yes Yes Yes
Caution lamp (Tiller handle model)
Caution lamp (Remote control model)
3-12 IGNITION AND ELECTRICAL
LOW OIL PRESSURE CAUTION SYSTEM
CONDITION:
Immediate activation of the system when the oil pressure switch turns “ON” due to an engine oil pressure
drop below 15 kPa (0.15 kg/cm2, 2 psi).
ACTION:
• The caution lamp is on.
• The caution buzzer sounds. (For remote control model only.)
• The engine speed automatically reduced to approx. 2 000 r/min by intermittent fuel injection and ignition
signals if the system is activated at 2 000 r/min or higher.
RESET:
• Stop the engine and check the engine oil level. Refill the engine oil to the correct level.
• The low oil pressure caution system is reset when the oil pressure is restored to over 15 kPa (0.15 kg/cm2,
2 psi) with approx. 1 500 r/min for 1.5 seconds.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity
• Malfunctioning oil pressure switch
• Clogged oil filter
• Worn oil pump relief valve
• Oil leakage from oil passage
• Excessive wear/damage of oil pump
CDI unit
LED output
circuit
Caution lamp
Magneto
Condenser charge coil
Oil pressure switch
15 kPa
(0.15 kg/cm2, 2 psi)
P P B
G G
B/R B/R
BI BI
IGNITION AND ELECTRICAL 3-13
INSPECTION
Oil pressure switch
# 09940-44121: Air pressure gauge
09930-99320: Digital tester
: Air pump
% Tester range: & (Continuity)
1. Remove the oil pressure switch
1. (See page 3-14.)
2. Connect the gauge and an air pump as shown.
3. While applying pressure to the oil pressure switch, inspect
continuity.
Oil pressure switch function:
If the measurement is out of the specification, replace the oil
pressure switch.
Caution lamp
Check for illumination of the caution lamp.
1. Disconnect the lamp lead wires from the engine harness.
2. Connect the test cord as shown.
3. For the tests using 1.5 V power source (or battery), connect
the lamp lead wire to the 1.5 V power source (or battery) as
shown below.
'
Pink lead wire → Battery (+)
Black lead wire → Battery (–)
When 1.5 V applied → Lamp ON
If the measurement is out of the specification, replace the caution
lamp.
Pressure
kPa (kg/cm2, psi)
Continuity
Less than approx. 15 (0.15, 2) Yes
Approx. 15 (0.15, 2) or over No
Air pump
Oil pressure
switch
Do not use the battery larger than 2 V.
Pink
Black
Black
Pink
1.5 V
Battery
3-14 IGNITION AND ELECTRICAL
REMOVAL AND INSTALLATION
OIL PRESSURE SWITCH
Removal
1. Remove the side cover. (See page 7-2.)
2. Remove the oil level gauge guide
1.
3. Remove the CDI unit 2 and the recoil starter asssembly 3.
4. Loosen the bolt and disconnect the switch wire (Blue).
5. Remove the oil pressure switch from the cylinder block.
Installation
Installation is reverse order of removal with special attention to
the following steps.
( Oil pressure switch: 13 N·m (1.3 kgf-m, 9.5 lb-ft)
NOTE:
Prior to installation, wrap the oil pressure switch thread with
sealing tape. If the sealing tape edge is bulged out from the
thread, cut off the excess. 1 Sealing tape
IGNITION AND ELECTRICAL 3-15
BATTERY CHARGING SYSTEM
OUTLINE
The battery charging system circuit is illustrated below.
It is composed of the battery charge coil, the rectifier & regulator and the battery.
The AC current generated form the battery charge coil is converted by the rectifier into regulated DC current
which is used to charge the battery.
Manual start model
Electric start model Electric start model (with option coil)
MAGNETO
BATTERY
CHARGE COIL
R
RR
YY
WW
B RECTIFIER &
REGULATOR
Y
R
Y
12 V 80 W
12 V 120 W (with the option coil)
Option
F
us e 20
A
W
B
W
Y-Tube
R-Tube
B
W
RECTIFIER &
REGULATOR
Option
BATTERY
Fuse 25A
Starter motor
relay
W/R
R
W/R
WWW
Y/G
B
B B
B
Y
R
RR
Y Y
Y
B
BB
12 V 80 W
12 V 120 W
(with the option coil)
MAGNETO
BATTERY
CHARGE COIL
RECTIFIER
BATTERY
Starter motor
relay
Fuse 25A
12 V 80 W
B
B
B
B
B
B
Y Y
R
R
Y
Y/G
W/R
W/R
W W W
B
3-16 IGNITION AND ELECTRICAL
INSPECTION
BATTERY CHARGE COIL OUTPUT
" Peak Voltmeter Stevens CD-77
Tester selector: POS 50
1. Disconnect the rectifier.
2. Remove all spark plugs.
3. Crank with the recoil starter.
Coil output: Red – Yellow 3.5 V or over
If the measurement is out of the specification, replace the battery charge coil.
BATTERY CHARGE COIL RESISTANCE
# 09930-99320: Digital tester
$ Tester selector: Ω
1. Disconnect the battery charge coil wires from the rectifier.
Coil resistance: Red – Yellow 0.2 – 0.4 Ω
If the measurement is out of the specification, replace the battery charge coil.
Tester probe connection
+ (Red) - (Black)
Red Yellow Y
R
Battery charge coil
Tester probe connection
Probe Other probe
Red Yellow
Y
R
Battery charge coil
IGNITION AND ELECTRICAL 3-17
RECTIFIER
# 09930-99320: Digital tester
$ Tester selector: Ω
1. Disconnect all wires of the rectifier.
2. Measure resistance between the terminals for all combinations.
NOTE:
The values given below are for the SUZUKI digital tester.
As thyristors, diodes, etc. are used inside this rectifier, the resistance values will differ when an ohmmeter other than the
SUZUKI digital tester is used.
Rectifier resistance:
FUSE CASE/FUSE
# 09930-99320: Digital tester
% Tester range: & (Continuity)
Fuse
1. Remove the fuse from the fuse case.
2. Inspect the fuse and replace with a new 25-amp fuse if
needed.
Fuse case
1. Disconnect all wires of the fuse case.
2. Check continuity between White/Red lead wire with the plate
terminal and the other two lead wires.
% Tester range: & (Continuity)
If no continuity is indicated, replace fuse case.
Tester probe
+ (Red)
T
es te r p ro be -
(
B
la ck )
Black White Yellow Red
Black ∞ ∞ ∞
White ∞ 4 – 7 MΩ 3 – 6 MΩ
Yellow 4 – 7 MΩ ∞ ∞
Red 4 – 7 MΩ ∞ ∞
Red
Yellow
Black
White
3-18 IGNITION AND ELECTRICAL
ELECTRIC STARTER SYSTEM
OUTLINE
The electric starter system circuit is illustrated below. It is mainly composed of the battery, starter motor,
relay, neutral switches and ignition switch.
For Remote control model
For Electric start model
Ignition
switch
Remote control box
BrSTART Br
BATT
P
U
S
H
F
R
E
E
O
N
O
F
F
W
GND B
Br W/RW
B
To rectifier
To CDI
Starter motor relay
Neutral switch
Starter motor
25A Fuse
Battery
W/R
W/R
Y/G
Y/G
Br B
BR
RBr
Engine start switch
Br W/R
To CDI
Starter motor relay
Neutral switch
Starter motor
25A Fuse
W/R
W/R
Y/G
Y/G
Br B
B
R
RBr
To rectifier Battery
IGNITION AND ELECTRICAL 3-19
TROUBLESHOOTING
NOTE:
Before troubleshooting for the electric starter system, make sure of the following:
• Battery is fully charged.
• All cables/wires are securely connected.
• Shift is in “NEUTRAL” position.
ELECTRIC START MODEL
Circuit check schematic
Starter motor relay
GND
Starter motor
Sub cable
W/R
Battery
Fuse
To Rectifier Starter switch
W
Br Neutral switch
W/R
Y/G
W/R
GNDGND
Starter motor
Check for relay “click” sound when the
starter button depressed. (See page 3-22.)
Is there “click” sound?
Measure voltage at the terminal 2 with
the starter button depressed. It must be
avobe 12 V.
Is result OK?
Measure voltage at the terminal 3 with
the starter button depressed. It must be
avobe 12 V.
Is result OK?
Starter motor failure Sub cable failure
YES
YES NO
YES
Measure voltage at the terminal
1. It must be above 12 V.
Is result OK?
Check the 25 A fuse and fuse
case. (See page 3-17.)
Is result OK?
Check the starter switch function.
(See page 3-21.)
Is result OK?
Check the function of neutral
switch. (See page 3-22.)
Is result OK?
Starter motor relay failure
Starter motor will not run.
Check the starter
motor.
(See page 3-25.)
Check the starter motor relay.
(See page 3-22.)
Battery cable
failure
25 A fuse or
fuse case
failure
Starter switch
failurer
Neutral switch
failurer
NO
NO
YES
YES
YES
YES
NO
NO
NO
NO
3-20 IGNITION AND ELECTRICAL
REMOTE CONTROL MODEL
Circuit check schematic
Starter motor relay
Starter motor
Ignition switch
GND
BB
WW
Br Battery
W/R
Fuse
Neutral
switch
Y/G
Sub cable
GND
GND
GND
W/R
W/R
Br Br GND
BAT
ST
Check for relay “click” sound when turning
the ignition switch to “START”.
(See page 3-22.)
Is there “click” sound?
Measure voltage at the terminal 2 with
the ignition switch at “START”. It must be
avobe 12 V.
Is result OK?
Measure voltage at the terminal 3 with
the ignition switch at “START”. It must be
avobe 12 V.
Is result OK?
Starter motor failure Sub cable failure
YES
YES NO
YES
Measure voltage at the terminal
1. It must be above 12 V.
Is result OK?
Check the 25 A fuse and fuse
case. (See page 3-17.)
Is result OK?
Check the ignition switch function.
(See page 3-21.)
Is result OK?
Check the function of neutral
switch. (See page 3-22.)
Is result OK?
Starter motor relay failure
Starter motor will not run.
Check the starter
motor.
(See page 3-25.)
Check the starter motor relay.
(See page 3-22.)
Battery cable
failure
25 A fuse or
fuse case
failure
Starter switch
failurer
Neutral switch
failurer
NO
NO
YES
YES
YES
YES
NO
NO
NO
NO
IGNITION AND ELECTRICAL 3-21
INSPECTION
IGNITION SWITCH (Remote control model)
# 09930-99320: Digital tester
% Tester range: & (Continuity)
1. Disconnect the ignition switch from the remo-con box wiring
harness.
2. Check continuity between the wiring leads at the key positions shown in the chart.
If out of the specification, replace the ignition switch.
STARTER SWITCH (Electric start model)
# 09930-99320: Digital tester
% Tester range: & (Continuity)
1. Disconnect the starter switch lead wire.
2. Check continuity between the wiring leads under the condition shown below.
If out of the specification, replace the starter switch.
Tester probe connection
Continuity
Probe Other probe
Starter button
not depressed
White/Red Brown
No Starter button
depressed
Yes
Black
Green
White
Gray
Brown
Orange
4 (FREE) 5 (PUSH)
1 (OFF) 2 (ON)
3 (START)
PUSH
1 OFF
2 ON
3 START
4 FREE
5 PUSH
Key
Position
Switch Lead Wires
Black Green White Gray Brown Orange
: Continuity
W/R
Br Depressed
Not depressed
3-22 IGNITION AND ELECTRICAL
NEUTRAL SWITCH
# 09930-99320: Digital tester
% Tester range: & (Continuity)
1. Disconnect the neutral switch wire.
2. Inspect continuity between the Yellow/Green wire and the
Brown wire while operating the shift lever or the remo-con
handle.
Neutral switch function:
If the result is out of the specification, replace the neutral switch.
STARTER MOTOR RELAY
# 09930-99320: Digital tester
Disconnect all cables/wires from the starter motor relay.
Resistance check
$ Tester selector: Ω (Resistance)
Measure resistance between the Yellow/Green wire and the
Black wire.
Starter motor relay resistance: 3.5 – 5.1 Ω
If the resistance is out of the specification, replace the starter
motor relay.
Function check
% Tester range: & (Continuity)
Inspect continuity between the terminal
1 and 2 with momently
applying 12 V power. Connect the Yellow/Green wire to the positive + terminal, and the Black wire to the negative - terminal
of the battery.
Starter motor relay function:
If the result is out of the specification, replace the starter motor
relay.
Shift position Continuity
Neutral Yes
Forward No
Reverse No
Forward
Neutral
Reverse
B
Y/G
12 V power Continuity
Applied Yes
Not applied No
BY/G
12 V Battery
IGNITION AND ELECTRICAL 3-23
STARTER MOTOR
REMOVAL
1. Remove the motor cover.
2. Remove the side covers. (See page 7-2.)
3. Remove the recoil starter.
4. Disconnect the starter cable
1.
5. Disconnect the starter sub cable 2.
6. Remove two bolts and the starter motor assy.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
DISASSEMBLY
Before removing electrical motor:
* Disconnect the battery cables from the battery.
1 Stopper ring
2 Pinion stopper (1)
3 Spring (1)
4 Pinion (1)
5 Front cover (1)
6 Washer (1)
7 Shim (1)
8 Washer
9 Stator (1)
0 Armature (1)
A Washer
B Bolt (2)
C Washer (2)
D Washer (2)
E Nut (1)
F Washer (1)
G Washer (1)
H Brush holder (1)
I Screw (2)
J Brush (1)
K Brush (1)
L Brush spring (2)
M Rear cover (1)
3-24 IGNITION AND ELECTRICAL
1. Remove the nut
1 on the + terminal.
2. Remove two bolts 2.
3. Remove the rear cover 3, the stator 4, the washer 5 and
the armature 6 (with the front cover).
4. Remove brush holder assembly 7, bush 8 and the O-ring
9 from the rear cover.
5. Push down the pinion stopper 0, remove the stopper ring
A.
6. Remove the pinion stopper 0, spring B and pinion C.
!
NOTE:
Using a screw-driver, pry off the stopper ring.
Wear the safety glasses when disassembling and
assembling the stopper ring.
IGNITION AND ELECTRICAL 3-25
INSPECTION & SERVICING
Pinion
Inspect the pinion.
If excessive wear or other damage is found, replace the pinion.
Armature and Commutator
1. Inspect the commutator surface.
If the surface is gummy or dirty, clean with 400 grade emery
paper
A.
2. Measure the commutator outside diameter.
# 09900-20101: Venier calipers
Commutator outside diameter:
Standard : 30.0 mm (1.18 in)
Service limit : 29.0 mm (1.14 in)
If the measurement exceeds the service limit, replace the armature.
3. Check that the mica (insulator) 1 between the segments 2
is undercut 3 to the specified depth.
Commutator undercut:
Standard : 0.5 – 0.8 mm (0.02 – 0.03 in)
Service limit : 0.2 mm (0.01 in)
If the measurement exceeds the service limit, cut to the specified depth.
NOTE:
Remove all particles of mica and metal using compressed air.
!
Wear the safety glasses when using compressed air.
3-26 IGNITION AND ELECTRICAL
4. Inspect continuity of the armature coil.
# 09930-99320: Digital tester
% Tester range: & (Continuity)
Armature coil continuity:
If the result is out of the specification, replace the armature.
Brushes
Measure length of each brush.
# 09900-20101: Venier calipers
Brush length:
Standard : 12.5 mm (0.49 in)
Service limit : 9.0 mm (0.35 in)
If the measurement exceeds the service limit, replace the brush.
Brush Holder
Inspect continuity of the brush holder.
# 09930-99320: Digital tester
% Tester range: & (Continuity)
Brush holder continuity:
If the result is out of the specification, replace the brush holder.
Tester probe connection Continuity
Between commutator segments Yes
Commutator
4 to Armature core 5 No
Commutator 4 to Shaft 6 No
Brush
Tester probe connection Continuity
Brush holder positive + to Brush
holder negative No Brush holder positive + to Base
plate 1 (ground)
No IGNITION AND ELECTRICAL 3-27
ASSEMBLY
Assembly is reverse of disassembly with special attention to the
following steps.
'
• Apply the grease to the armature shaft and shaft holes.
) 99000-25010: SUZUKI SUPER GREASE “A”
!
• Install the pinion, spring, pinion stopper and stopper rings.
NOTE:
Make sure that the stopper rings
1 tightly fit in the pinion stopper 2 and armature shaft 3.
• Align the notch in the cover (Front & Rear) with the tab on the
stator when assembling.
• Tighten the through bolts.
( Through bolt: 4.0 N·m (0.4 kgf-m, 2.9 lb-ft)
When installing armature, exercise care to avoid
breaking brushes.
Wear the safety glasses when disassembling and
reassembling the stopper ring.
FUEL SYSTEM 4-1
4
FUEL SYSTEM
CONTENTS
PRECAUTION ON FUEL SYSTEM SERVICE ..............................................4- 2
GENERAL PRECAUTION.......................................................................4- 2
FUEL LINE.....................................................................................................4- 2
REMOVAL/INSTALLATION....................................................................4- 2
FUEL LEAKAGE CHECK PROCEDURE ...............................................4- 2
FUEL HOSE CONNECTION ...................................................................4- 3
CARBURETOR..............................................................................................4- 4
REMOVAL ...............................................................................................4- 4
INSTALLATION.......................................................................................4- 5
DISASSEMBLY .......................................................................................4- 6
CLEANING & INSPECTION....................................................................4- 7
OPERATION............................................................................................4-10
ACCELERATOR PUMP SYSTEM ..........................................................4-11
THROTTLE CONTROL .................................................................................4-12
FUEL PUMP...................................................................................................4-14
REMOVAL/INSTALLATION....................................................................4-14
DISASSEMBLY/REASSEMBLY .............................................................4-15
INSPECTION ...........................................................................................4-16
FUEL TANK ...................................................................................................4-17
DISASSEMBLY/REASSEMBLY .............................................................4-17
INSPECTION ...........................................................................................4-18
4-2 FUEL SYSTEM
PRECAUTION ON FUEL SYSTEM SERVICE
GENERAL PRECAUTION
!
!
FUEL LINE
REMOVAL/INSTALLATION
Remove or install the fuel hoses with special attention to the following steps.
"
NOTE:
* Check the fuel hose routing. (See page 9-11.)
* Check for fuel leakage.
FUEL LEAKAGE CHECK PROCEDURE
After performing any fuel system service, always be sure that
there is no fuel leakage by checking as follows.
1. Squeeze the fuel primer bulb until you feel resistance.
2. Once pressurized, check all connections and components
for any signs of leakage.
Gasoline is extremely flammable and toxic. Always observe the following precautions when
working around gasoline or servicing the fuel system.
* Disconnect battery cables except using battery power for servicing/inspection.
* Keep the working area well ventilated, away from open flame (such as gas heater) or sparks.
* Do not smoke or allow anyone else to smoke near the working areas. Post a “NO SMOKING”
sign.
* Have a CO2 fire extinguisher to be ready for use.
* Always use appropriate safety equipment and wear the safety glasses when working around
pressurized fuel systems.
* 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.
The components after the high pressure fuel pump remain pressurized at all times.
To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components.
* Do not over-bend (kink) or twist hoses when installing.
* When installing hose clips, position tabs to avoid contact with other parts.
* Be sure that hoses do not contact rods, levers or other components with engine either operating or at rest.
* Extreme care should be taken not to cut, abrade or cause any other damage to hoses.
* Use care not to excessively compress hoses when tightening clamps.
FUEL SYSTEM 4-3
FUEL HOSE CONNECTION
Note that the fuel hose connection varies with each type of the
pipe. Be sure to connect and clamp each hose correctly by referring to the following figure.
• For the type “A” (short barbed end) pipe, hose should completely cover the pipe.
• For the type “B” (bent end) pipe, hose should cover straight
part of the pipe by 20 – 30 mm (0.8 – 1.2 in).
• For the type “C” pipe, hose should fit up against flanged part
of the pipe.
• For the type “D” pipe, hose should cover the pipe by 20 –
30 mm (0.8 – 1.2 in).
Clamp (Clip)
Hose
Joint pipe
3 – 7 mm
(0.1 – 0.3 in)
20 – 30 mm
(0.8 – 1.2 in)
3 – 7 mm
(0.1 – 0.3 in)
3 – 7 mm (0.1 – 0.3 in)
20 – 30 mm
(0.8 – 1.2 in)
3 – 7 mm
(0.1 – 0.3 in)
“A”
“B”
“C”
“D”
4-4 FUEL SYSTEM
CARBURETOR
!
REMOVAL
1. Remove the motor cover.
2. Remove the side covers. (See page 7-2.)
3. Remove the choke knob
1.
4. Disconnect the breather hose 2 from the cylinder head
cover.
5. Disconnect the fuel hose 3 from the fuel pump.
6. Remove the clamp 4.
7. Remove the fuel hose from the clamp 5.
8. Remove the two bolts 6.
Remove the silencer and the carburetor.
Before servicing for the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in
the previous section.
FUEL SYSTEM 4-5
INSTALLATION
Installation is the reverse order of removal with special attention
to the following steps.
"
• Install the carburetor gasket
1, the carburetor 2 and the
silencer 3, then tighten the carburetor mounting bolts to the
specified torque.
# Carburetor mounting bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
FINAL ASSEMBLY CHECK
Perform the following checks to ensure proper and safe operation.
• All parts removed have been returned to their original positions.
• No fuel leakage is evident when fuel system is pressurized.
(See page 4-2.)
• Apply the THREAD LOCK to the choke lever and install the
choke knob.
$ 99000-32050: THREAD LOCK “1342”
Do not re-use the gaskets, as sealing abilities will be
insufficient. Air leakage will induce a lean air/fuel mix
which will result in severe engine damage.
4-6 FUEL SYSTEM
DISASSEMBLY
When disassembling the carburetor, refer to the construction
diagram.
1 Screw
2 Pilot jet
3 Adjuster
4 Screw
5 Main air jet
6 Main jet
7 Main nozzle
8 Main nozzle cap
9 Needle valve assy
0 Plate
A Screw
B Float chamber gasket
C Float
D Cap
E Cap
F Holder guide
G O-ring
H Plunger
I Spring
J Adjuster
K Float chamber
L Hose
M Screw
Remove the float pin from the right side to the left side. (See the
figure.)
NOTE:
* Only for the pilot screw covered type carburetor:
Do not remove the cover and the pilot screw.
Pin
Pin
FUEL SYSTEM 4-7
CLEANING & INSPECTION
Clean thoroughly with cleaning solvent and compressed air
before inspection.
!
"
NOTE:
Wire or small drill bits must not be used to clean carburetor orifices and jet.
CARBURETOR BODY
Inspect the carburetor body. If cracks or other damage are found
on any component, replace it.
Clean the carburetor body so that there is no obstruction.
JET, NOZZLE
Inspect the jet and nozzle. If cracks or other damage are found
on the jet and nozzle, replace them.
Clean the jet and nozzle thoroughly so that there is no obstruction.
NEEDLE VALVE ASSEMBLY
Inspect the needle valve assembly.
If broken tips or wear are found on the needle valve assembly,
replace it.
Wear the safety glasses when using compressed air to
expel solvent, carburetor cleaner, etc.
Do not place any rubber, plastic and non-metallic
parts in cleaning solvent, as severe damage or deterioration will result.
4-8 FUEL SYSTEM
FLOAT
Inspect the float.
If cracks or other damage are found on the float, replace it.
REASSEMBLY
Reassembly is reverse order of disassembly with special attention to the following steps.
FLOAT
Install the float and the float pin.
"
NOTE:
After installing float, inspect for smooth movement of the float.
CHECKING FLOAT HEIGHT
Remove the float chamber gasket and measure the float height.
NOTE:
Make sure that the float weight is not applied to the needle
valve.
% 09900-20101: Vernier calipers
Float height
H: 17.6 ± 1 mm
SETTING FLOAT HEIGHT
To correct specification, bend only the adjustment tab 1.
"
Install the float pin from the left side to the right side.
(See the figure.)
Pin
Pin
When adjusting tab, do not bend to the point that it
applies pressure to the needle and the seat.
FUEL SYSTEM 4-9
ADJUSTING ACCELERATION PUMP LEVER GAP
Adjust gap
A between the acceleration pump lever and the
pump plunger rod by turning the adjust screw B.
NOTE:
In normal use, adjustment of the acceleration pump lever is
unnecessary as it has been adjusted at factory.
Gap A
(at the throttle valve fully closed)
0 – 0.5 mm
4-10 FUEL SYSTEM
OPERATION
Fuel inlet joint
Float valve seat
Float valve
Float pin
Float
FUEL
Float system
Pilot air jet
Pilot jet
Pilot screw
Idle port
Throttle valve
Bypass port
AIR
FUEL
FUEL + AIR (MIXTURE)
Main Metering system
Main air jet
Venturi
Main nozzle
Main jet
Throttle valve
AIR
FUEL
FUEL + AIR (MIXTURE)
Idle system
FUEL SYSTEM 4-11
ACCELERATOR PUMP SYSTEM
The DF9.9/15 models are equipped with an accelerator pump system. This system is composed of an accelerator pump on each carburetor with brass tubes connecting the pump to the fuel output nozzles on each
carburetor.
A normal engine characteristic during hard acceleration is hesitation caused by an imbalance in the fuel/air
ratio. This is due to the rapid rate of increase in intake air volume when the throttle is opened quickly with the
air velocity and fuel flow rate following at a slower rate of increase. The accelerator pump system overcomes
this characteristic.
Accelerator pump operation
The accelerator pump system’s function is to provide a balanced fuel/air ratio during acceleration only by
adding a specific volume of fuel to richen the mixture. When the throttle is opened, the accelerator pump
lever
1 pushes down on the pump rod 2 and plunger 3. As the plunger pushes against the fuel, the inlet
passage check ball closes and fuel is pushed out of the pump body, through the brass tube and outlet nozzle 4, spraying into carburetor bore.
4-12 FUEL SYSTEM
THROTTLE CONTROL
1. Turn the throttle stop screw
1 counterclockwise until no longer contacts the throttle lever 2.
2. Adjust the throttle rod 3 length to 86 mm (3.39 in) measuring between the centers of the two connector
holes.
3. Press fit the rod 3 onto the ball pivot on the throttle drum 4 and the throttle arm 5.
4. Turn the drum 4 clockwise, then check if the clearance “X” (between the drum and the stopper A) is 0 –
1 mm when the lever 2 just contacts with the stopper B.
If not, adjust the rod 3 setting.
86 mm (3.39 in)
X
FUEL SYSTEM 4-13
5. Fully close the throttle control grip (for tiller handle model).
Position the control handle into “Neutral” (for remote control model).
6. Secure the throttle cable
6 in the holder 7 by fitting groove on the cable into a slot on the holder, then
install the bracket 8 to fix the cable by the screw 9 as shown.
7. Thread the connector 0 onto the cable 6.
8. Turn the drum 4 counterclockwise until the clearance “Y” exists.
9. While pushing cable end as shown by arrow C, adjust the connector 0 until the center of connector
aligns with the center of ball pivot on the drum 4.
10. When aligned, press fit the connector onto the ball pivot and tighten the lock nut A.
11. Make sure the lever 2 contacts the stopper B with the throttle control fully opened.
Also make sure the clearance “Y” exists with the throttle control fully closed. If not, adjust the connector
0 again.
Y
Tiller handle model
Remote control model
4-14 FUEL SYSTEM
FUEL PUMP
REMOVAL/INSTALLATION
!
REMOVAL
1. Disconnect the inlet hose
1 and the outlet hose 2 from the
fuel pump.
2. Remove the two bolts 3.
3. Remove the fuel pump 4 and the O-ring 5.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
"
# Fuel pump bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
Before servicing for the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in
the previous section.
* Before installing the fuel pump, rotate the crankshaft
to bring the No. 1 (top cylinder) piston to Top Dead
Center on a compression stroke.
* Do not re-use the O-ring once removed. Always use
a new O-ring.
FUEL SYSTEM 4-15
DISASSEMBLY/REASSEMBLY
DISASSEMBLY
Remove the six screws
1 and remove in sequence the outer
plate 2, the gasket 3 and the valve body 4.
Turn the piston 5 until the pin 6 comes out through cutaway of
the pump body 7.
Remove the following parts:
• Piston 5
• Pin 6
• Pump body 7
• Spring 8
• Diaphragm 9
• Spring 0
"
Do not re-use the diaphragm set once removed.
Always use a new diaphragm set.
4-16 FUEL SYSTEM
ASSEMBLY
Assembly is reverse order of disassembly with special attention
to the following steps.
"
When connecting the diaphragm set to the piston with the pin,
align the punch mark on the piston and the convex of the diaphragm.
Align the convex marks on the pump body, the diaphragm, the
valve body, the gasket and the outer plate when assembling.
INSPECTION
Check-valves
Inspect the fuel pump check valves. If tears, distortion or damage is found, replace the fuel pump.
Pump body
Inspect the fuel pump body and the outer plate.
If cracks, nicks, distortion or damage is found, replace the fuel
pump.
Do not re-use the diaphragm set once removed.
Always use a new diaphragm set.
FUEL SYSTEM 4-17
FUEL TANK
DISASSEMBLY/REASSEMBLY
When disassembling or reassembling the fuel tank, refer to the construction diagram below.
Steel tank Plastic tank
1 Nut (1)
2 Washer (1)
3 Fuel plug (1)
4 Fuel hose assy (1)
5 Fuel connector (1)
6 Clip (4)
7 Squeeze pump (1)
8 Fuel connector (1)
9 Fuel gauge assy (1)
0 Gauge cover (1)
A Gasket (1)
B Lens (1)
C Lens gasket (1)
D Screw (4)
E Float (1)
F Push nut (1)
G Gasket
H Screw (4)
I Washer (4)
J Connector gasket (1)
K Fuel connector (1)
L Tank cap assy (1)
M Tank cap gasket (1)
N Fuel tank set
1 Nut (1)
2 Washer (1)
3 Fuel plug (1)
4 Fuel hose assy (1)
5 Socket (2)
6 Clip (4)
7 Squeeze pump (1)
8 Fuel tank assy (1)
9 Fuel connector plug (1)
0 Outlet (1)
A Outlet filter (1)
B O-ring (1)
C Fuel tank cap
D Fuel tank cap gasket
4-18 FUEL SYSTEM
INSPECTION
Fuel connector
Inspect the fuel connector
1 and the connector plug 2. If leakage, deterioration or other damage is found, replace the connector and/or the plug.
Fuel primer bulb
Inspect the fuel primer bulb. If crack, leakage or deterioration is
found, replace the bulb.
If the check valve function is defective, replace the bulb.
Fuel hose
Inspect the fuel hoses. If cut, crack, leakage, abrasion, tear or
deterioration is found, replace the hoses.
Fuel tank
Inspect the fuel tank. If crack, leakage or deterioration is found,
replace the tank.
If water or other contamination is found, drain and clean the
tank.
Tank cap
Check that the fuel tank vent opens and relieves internal tank
pressure properly.
If vent is suspect, replace the tank cap.
RECOIL STARTER 5-1
5
RECOIL STARTER
CONTENTS
REMOVAL .....................................................................................................5- 2
DISASSEMBLY .............................................................................................5- 3
INSPECTION .................................................................................................5- 5
REASSEMBLY ..............................................................................................5- 6
INSTALLATION .............................................................................................5- 8
NEUTRAL START INTERLOCK (NSI) ..........................................................5- 9
INSTALLATION/ADJUSTMENT .............................................................5- 9
5-2 RECOIL STARTER
+
REMOVAL
1. Remove the CDI unit
1.
2. Loosen the lock nuts 2 and remove the NSI cable 3 from
the cable bracket 4.
3. Remove the NSI cable from the clutch notch lever 5.
4. Loosen and remove the four (4) bolts securing the recoil
starter.
5. Remove the recoil starter assembly.
RECOIL STARTER 5-3
DISASSEMBLY
!
1. Guide the rope into notch
A in the reel and turn the reel 1
clockwise to release the coiled tension in the recoil spring.
2. Remove the bolt 2, then remove the friction plate 3 with
the friction spring 4.
3. Remove the reel.
4. Remove the screw 5 first, and then take off the ratchet
(pawl) 6, the ratchet guide 7 and the return spring 8.
Because of the coiled tension in the recoil spring,
wear the safety glasses and hand protection when
winding or unwinding this component.
5-4 RECOIL STARTER
5. Remove the rope.
6. Remove the recoil spring
9.
NOTE:
Do not remove the recoil spring unless replacement is necessary. It should be visually inspected in its assembled position.
7. Remove the NSI cable 0 and the spring A.
Remove the cotter pin B, the washer C and the stopper
arm D.
8. Remove the reel stopper spring E and the reel stopper F.
RECOIL STARTER 5-5
INSPECTION
NOTE:
If any parts is worn excessively, cracked, defective or damaged
in any way, it must be replaced.
• Inspect the ratchet (pawl), the stopper arm and all springs.
If there is any defect such as excessive wear or damage,
replace it.
• Inspect the reel and the recoil case.
If any cracks or damage is found on them, replace it.
• Inspect the recoil rope.
If the recoil rope is worn or damaged, replace it.
• Inspect the recoil spring.
If there is any cracks, deformation or excessive curve on the
recoil spring, replace it.
5-6 RECOIL STARTER
REASSEMBLY
Reassembly is in the reverse order of disassembly with special
attention to the following reassembling steps.
• Install the stopper spring as shown figure.
1 NSI cable (1)
2 NSI set
3 Cotter pin (1)
4 Washer (1)
5 Stopper arm (1)
6 Spring (1)
7 Reel stopper (1)
8 Bolt (1)
9 Bolt (3)
0 Recoil case (1)
A Rope guide (1)
B Grip (1)
C Screw (1)
D Recoil spring (1)
E Reel (1)
F Rope (1)
G Ratchet set
H Friction spring (1)
I Friction plate (1)
J Bolt (1)
K Ratchet (1)
L Ratchet guide (1)
M Return spring (1)
RECOIL STARTER 5-7
• Install the NSI set and the NSI cable.
Apply the grease to the NSI cable.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
• Secure the outer end of the recoil spring on the groove in the
recoil case and wind spring inward towards the center of the
case in a counterclockwise direction.
!
• Install the ratchet set.
• Install the reel on the recoil case.
NOTE:
* Apply the grease to the reel as shown figure.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
* Align groove in the reel with bent end of the spring.
• Install the friction plate
1 (with the friction spring 2) and
secure it with the bolt 3.
Apply the THREAD LOCK to the thread of the bolt.
# 99000-32050: THREAD LOCK “1342”
NOTE:
Twist friction plate slightly to align holes in the plate with the
square lugs A on the center boss.
Because of the coiled tension in the recoil spring,
wear the safety glasses and hand protection when
winding or unwinding this components.
5-8 RECOIL STARTER
• After assembling, guide the rope into notch in the reel and
rotate the reel approximately 5 turns counterclockwise until
the spring is tensioned.
INSTALLATION
Installation is in the reverse order of removal with special attention to the following.
• Check to ensure that all removed parts are back in place.
• Check the neutral start interlock function.
RECOIL STARTER 5-9
NEUTRAL START INTERLOCK (NSI)
INSTALLATION/ADJUSTMENT
1. Shift into “NEUTRAL” position.
2. Install the NSI cable in the recoil starter, the clutch notch
lever
1, the stopper arm 2 and the cable bracket 3.
3. Turn the adjustment nut 4 to align the slot on the stopper
arm 2 with the punch mark 5 on the recoil starter case.
4. Pull the recoil starter and make sure that the starter does not
work when the shift lever is in “FORWARD” and “REVERSE”
position.
5. Tighten the lock nuts 6.
6. Apply SUZUKI WATER RESISTANT GREASE to the inner
cable, the cable end and the cam.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
!
If the NSI cable is removed or left without correct
adjustment, there is a high risk of losing one’s balance and/or being thrown overboard if the motor
starts in gear.
POWER UNIT 6-1
6
POWER UNIT
CONTENTS
POWER UNIT ................................................................................................6- 2
REMOVAL ...............................................................................................6- 2
INSTALLATION.......................................................................................6- 4
CYLINDER HEAD ASSY ...............................................................................6- 6
REMOVAL AND DISASSEMBLY ...........................................................6- 6
INSPECTION/SERVICING ......................................................................6- 9
REASSEMBLY AND INSTALLATION....................................................6-18
CYLINDER/CRANKSHAFT/PISTON.............................................................6-23
DISASSEMBLY .......................................................................................6-23
INSPECTION/SEVICING.........................................................................6-27
CONROD SELECTION ...........................................................................6-34
REASSEMBLY ........................................................................................6-38
OPERATION ..................................................................................................6-44
WATER COOLING SYSTEM ..................................................................6-44
ENGINE LUBRICATION SYSTEM..........................................................6-45
CRANKCASE VENTILATION SYSTEM .................................................6-47
EXHAUST SYSTEM ................................................................................6-48
6-2 POWER UNIT
POWER UNIT
REMOVAL
1. Remove the motor cover.
2. Remove the side covers. (See page 7-2.)
3. Remove the recoil starter. (See page 5-2.)
4. Disconnect the water hose
1 from the thermostat cover.
5. Disconnect the fuel hose 2 from the fuel pump.
6. Remove the screw 3 and the throttle cable holder plate 4.
7. Unthread the connector 5 from the throttle drum 6.
Detach the throttle cable from the throttle cable holder 7.
8. Loosen the nut 8 and remove the choke knob 9.
Remove the choke lever from the instrument panel 0.
Before removing the power unit:
* Disconnect the battery cable from the battery.
* Drain the engine oil.
POWER UNIT 6-3
9. Remove the starter motor sub cable
A from the starter
motor relay B.
10. Remove the battery cables C from the starter motor and the
starter motor relay B.
11. Disconnect the lead wires (White/Red, Brown, Blue/Red,
Black, Pink).
12. Remove the bolt D and the ground lead wires.
13. Remove the two bolts E and the starter motor. (Push the
starter motor toward the up side.)
14. Remove the screw F and the clutch lever shaft G.
15. Disconnect the clutch rod arm H.
6-4 POWER UNIT
16. Remove the six bolts and the two nuts.
17. Remove the power unit.
18. Remove the oil hose
I.
INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
!
POWER UNIT
1. Set the two dowel pins and the gasket.
2. Apply the grease to the drive shaft splines.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
Do not re-use the gasket once removed. Always use a
new gasket.
POWER UNIT 6-5
3. Apply the bond to the cylinder block and the cylinder head as
shown.
# 99000-31140: SUZUKI BOND “1207B”
4. Install the power unit.
NOTE:
Rotate the crankshaft to aid alignment of the drive shaft and the
crankshaft splines.
5. Apply the seal to the bolts and the nuts.
$ 99000-31120: SUZUKI SILICONE SEAL
6. Tighten the six bolts and the two nuts.
% Power unit mounting bolt and nut:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
CLUTCH LEVER SHAFT
• Apply the grease to the clutch rod arm, the clutch notch plate
and the clutch rod.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
FINAL ASSEMBLY CHECK
Perform the following checks in order to ensure proper and safe
operation of the repaired unit.
• All parts removed have been returned to the original positions.
• Lower unit gear engagement is properly adjusted.
• Fuel hose routing matches the service manual illustration.
(See page 9-11.)
• Wire routing matches the service manual illustration. (See
page 9-2 to 9-4.)
• No fuel leakage is evident.
• No water leakage is evident during final test running.
6-6 POWER UNIT
CYLINDER HEAD ASSY
REMOVAL AND DISASSEMBLY
1. Remove the power unit. (See page 6-2 to 6-4.)
2. Remove the spark plugs and the fuel pump.
3. Remove the flywheel nut.
& 09930-39520: Flywheel holder
09930-39411: Flywheel rotor remover
09930-39210: Flywheel remover attachment bolt
4. Remove the flywheel.
& 09930-39411: Flywheel rotor remover
09930-39210: Flywheel remover attachment bolt
5. Remove the cylinder head cover.
6. Loosen all valves adjusting the lock nuts.
Loosen all valves adjusting the screws fully.
& 09917-14910: Valve adjuster driver
!
To prevent valve damage, loosen the valve adjusting
lock nuts and the valve adjusting screws fully before
removing the timing belt.
POWER UNIT 6-7
7. Remove the timing belt.
8. Remove the two bolts and the intake manifold
1 with the
carburetor assembly.
9. Remove the eight bolts.
Remove the cylinder head assy and the gasket.
10. Remove the bolt and the cam pulley 2.
Remove the key 3 from the camshaft.
11. Remove the four bolts.
Remove the oil pump 4 and the oil gallery block 5.
6-8 POWER UNIT
12. Remove the rocker arm shaft
6.
NOTE:
Install the 8 mm bolt A into the lower end of the rocker arm shaft
and pull out the rocker arm shaft.
13. Remove the washer 7, the wave washer 8, the rocker
arms 9 and the spring 0.
NOTE:
Reassemble each rocker arm to the original position.
14. Remove the camshaft A.
15. Remove the valve cotters B while compressing the valve
spring.
16. Remove the valve spring retainer C, the valve spring D and
the valve E.
& 09916-14510: Valve lifter
09916-14521: Attachment
09916-84511: Tweezers
NOTE:
Reassemble each valve and the valve spring to their original
positions.
POWER UNIT 6-9
17. Remove the valve stem seal
F and the valve spring seat.
18. Remove the oil seal using the special tool.
& 09913-50121: Oil seal remover
19. Turn the shaft H until the pin I comes out through hole of
the oil galley block J.
INSPECTION/SERVICING
NOTE:
If crack, excessive wear or other damage is found on any component, replace.
CYLINDER HEAD
1. Remove all carbon from the combustion chamber.
NOTE:
* Do not use any sharp edged tool to scrape carbon off the cylinder head or the head components.
* Be careful not to scuff or nick the metal surfaces when decarboning.
6-10 POWER UNIT
2. Inspect the intake ports, the exhaust ports, the combustion
chambers and the head surface.
If crack or other damage is found, replace the cylinder head.
Valve seat
Check the valve seat.
If crack or other damage is found, replace the cylinder head.
Cylinder head distortion
Measure the cylinder head distortion (gasketed surface) at a
total of 6 locations as shown.
& 09900-20803: Thickness gauge
Straight gauge
Service limit: 0.05 mm (0.002 in)
If the measurement exceeds the service limit, resurface or
replace the cylinder head.
NOTE:
The cylinder head can be resurfaced, using a surface plate and
#400 grit wet sandpaper. Move the cylinder head in a figure
eight pattern when sanding.
Water jackets
Inspect the water jackets.
If clog or obstruction is found, clean the water jacket.
POWER UNIT 6-11
CAMSHAFT
Cam height
Measure the cam height
H.
& 09900-20202: Micrometer
Standard:
DF9.9 IN 22.259 – 22.319 mm (0.8763 – 0.8787 in)
EX 22.257 – 22.317 mm (0.8763 – 0.8786 in)
DF15 IN & EX
23.471 – 23.531 mm (0.9241 – 0.9264 in)
Service limit:
DF9.9 IN & EX 22.100 mm (0.8701 in)
DF15 IN & EX 23.320 mm (0.9181 in)
If the measurement exceeds the service limit, replace the camshaft.
Camshaft identification
DF9.9 : 00 – Electric start model
DF9.9 : 40 – Manual start model
DF15 : 10 – Electric start model
DF15 : 50 – Manual start model
Camshaft journal oil clearance
Standard: 0.020 – 0.062 mm (0.0008 – 0.0024 in)
Service limit: 0.100 mm (0.0039 in)
If the measurement exceeds the service limit, replace the camshaft and/or cylinder head.
To check the clearance, measure the following items:
• Camshaft journal outside diameter (2 locations)
• Camshaft holder inside diameter (2 locations)
& 09900-20202: Micrometer
09900-20605: Dial calipers
Camshaft journal outside diameter
Standard:
Upper side 24.959 – 24.980 mm (0.9826 – 0.9835 in)
Lower side 22.959 – 22.980 mm (0.9039 – 0.9047 in)
Camshaft holder inside diameter
Standard:
Upper side 25.000 – 25.021 mm (0.9843 – 0.9851 in)
Lower side 23.000 – 23.021 mm (0.9055 – 0.9063 in)
6-12 POWER UNIT
Decompression parts (For manual starter model)
Inspect the decompression parts in the camshaft.
If abnormal movement is found, replace the camshaft.
ROCKER ARM/SHAFT
Rocker arm wear
Inspect the arm-riding face and tip of the adjusting screw.
If excessive wear is found, replace the rocker arm and/or adjusting screw.
Rocker arm shaft to rocker arm clearance
Standard: 0.006 – 0.035 mm (0.0002 – 0.0014 in)
Service limit: 0.060 mm (0.0024 in)
If the measurement exceeds the service limit, replace the rocker
arm and/or rocker arm shaft.
To check the clearance, measure the following items:
• Rocker arm shaft outside diameter
• Rocker arm inside diameter
& 09900-20205: Micrometer
09900-20605: Dial calipers
Rocker arm shaft outside diameter
Standard: 12.973 – 12.984 mm (0.5107 – 0.5112 in)
Rocker arm inside diameter
Standard: 13.000 – 13.018 mm (0.5118 – 0.5125 in)
POWER UNIT 6-13
VALVE/VALVE GUIDE
Valve guide to valve stem clearance
Standard: IN 0.010 – 0.037 mm (0.0004 – 0.0015 in)
EX 0.035 – 0.062 mm (0.0014 – 0.0024 in)
Service limit: IN 0.070 mm (0.0028 in)
EX 0.090 mm (0.0035 in)
If the measurement exceeds the service limit, replace the valve
and/or valve guide.
To check the clearance, measure the following items:
• Valve stem outside diameter
• Valve guide inside diameter
& 09900-20205: Micrometer
Small bore gauge or dial calipers
Valve stem outside diameter
Standard: IN 5.475 – 5.490 mm (0.2156 – 0.2161 in)
EX 5.450 – 5.465 mm (0.2146 – 0.2152 in)
Valve guide inside diameter
Standard: IN & EX 5.500 – 5.512 mm (0.2165 – 0.2170 in)
If you are unable to measure the valve guide inside diameter,
measure the “Valve stem deflection”.
Valve stem deflection
Measure the valve stem deflection as follows:
1. Install the valve into the valve guide.
2. Position the valve head at approx. 10 mm away from the
valve seat.
3. Move the stem in the direction “X – Y”, and measure the
deflection.
& 09900-20602: Dial gauge
09900-20701: Magnetic stand
Service limit: IN & EX 0.16 mm (0.006 in)
Valve guide
X
Y
6-14 POWER UNIT
If the measurement exceeds the service limit, replace the valve.
If the measurement still exceeds the service limit with a new
valve, replace the valve guide.
NOTE:
For the valve guide replacement, see the “VALVE GUIDE
REPLACEMENT” section on page 6-15.
Valve stem end length
Measure the valve stem end length
1.
& 09900-20102: Vernier calipers
Service limit: IN & EX 2.2 mm (0.09 in)
If the measurement exceeds the service limit, replace the valve.
Valve stem runout
Measure the valve stem runout.
& 09900-20602: Dial gauge
09900-20701: Magnetic stand
09900-21304: Steel “V” block set
Service limit: IN & EX 0.05 mm (0.002 in)
If the measurement exceeds the service limit, replace the valve.
Valve head radial runout
Measure the valve head radial runout.
& 09900-20602: Dial gauge
09900-20701: Magnetic stand
09900-21304: Steel “V” block set
Service limit: IN & EX 0.03 mm (0.0012 in)
If the measurement exceeds the service limit, replace the valve.
Valve head thickness
Measure the valve head thickness T.
& 09900-20102: Vernier Calipers
Service limit: IN & EX 0.5 mm (0.02 in)
If the measurement exceeds the service limit, replace the valve.
45˚
POWER UNIT 6-15
Valve seating contact width
Measure the valve seating contact width
A as follows:
1. Coat the valve seat evenly with Prussian blue (or equivalent).
2. Install the valve into the valve guide.
3. Put the valve lapper on the valve.
& 09916-10911: Valve lapper
4. Rotate the valve while gently tapping the valve contact area
against the seat.
5. Continuously pattern on the valve seating face with Prussian
blue.
6. Measure the valve seating contact width A.
& 09900-20102: Vernier calipers
Standard: IN & EX 0.9 – 1.1 mm (0.035 – 0.043 in)
If the measurement is out of the specification, service the valve
seat.
NOTE:
For the valve seat servicing, see the “VALVE SEAT SERVICING” section on page 6-16.
VALVE GUIDE REPLACEMENT
!
1. Drive the valve guide out toward the valve spring side.
& 09916-44910: Valve guide remover/installer
2. Refinish the valve guide hole.
& 09916-38210: Valve guide reamer (' 11 mm)
09916-34542: Valve guide reamer handle
NOTE:
Turn the reamer clockwise, never counterclockwise.
Be careful not to damage the cylinder head when
replacing the valve guide.
6-16 POWER UNIT
3. Drive the valve guide in from the valve spring side to the
specified height.
& 09916-44910: Valve guide/Remover installer
4. Measure the valve guide protrusion
H.
& 09900-20102: Vernier calipers
Valve guide protrusion:
Standard: IN & EX 10.0 ± 0.5 mm (0.39 ± 0.02 in)
5. Refinish the valve guide bore.
& 09916-34550: Valve guide reamer (' 5.5 mm)
09916-34542: Valve guide reamer handle
NOTE:
Clean and oil the valve guide bore after reaming.
VALVE SEAT SERVICING
If the valve seating contact width is out of the specification,
reface the valve seat as follows:
& 09916-20610: Valve seat cutter 15° (N-121)
09916-20620: Valve seat cutter 45° (N-122)
09916-24440: Handle adapter (N-503-1)
09916-24450: Solid pilot (N-100-5.52)
09916-54910: Handle (N-505)
NOTE:
Turn the cutter clockwise, never counterclockwise.
1. Insert the 45° cutter and reface the valve seat.
2. Measure the valve seating contact width A. See the “Valve
seating contact width” section on page 6-15.
3. If the width A is too high (or wide), reface the valve seat
using the 15° cutter.
If the width A is too low (or narrow), reface the valve seat
using the 45° cutter.
4. Clean up any burrs using the 45° cutter very lightly.
45˚ 15˚
Valve seat
Too low (narrow)Too high (wide)
POWER UNIT 6-17
!
5. Recheck the valve seat contact width
A.
!
NOTE:
Clean and assemble the cylinder head and valve components.
Fill the intake and exhaust ports with solvent to check for leaks
between the valve seat and valve. If any leaks occur, inspect the
valve seat and the face for burrs or other things that could prevent the valve from sealing.
VALVE SPRING
Valve spring free length
Measure the spring free length.
& 09900-20102: Vernier calipers
Standard: 32.52 mm (1.280 in)
Service limit: 32.40 mm (1.276 in)
If the measurement is lower than the service limit, replace the
valve spring.
Valve spring tension
Measure the valve spring tension.
& 09900-20102: Vernier caliper
Standard: 9 kg (19.8 lbs) for 28.5 mm (1.12 in)
Service limit: 7.6 kg (16.8 lbs) for 28.5 mm (1.12 in)
If the measurement is lower than the service limit, replace the
valve spring.
Grind the seat areas minimally only.
Do not grind more than necessary.
Do not use lapping compound after the final cut is
made. The finished valve seat should have a velvety
smooth finish and not a highly polished or shiny finish. This will provide a soft surface for the final seating of the valve which will occur during the first few
seconds of engine operation.
6-18 POWER UNIT
OIL SEAL
Inspect condition.
If cracked, cut or damaged, replace oil seal.
REASSEMBLY AND INSTALLATION
Reassembly is reverse order of disassembly with the special
attention to the following steps:
OIL SEAL
Press the oil seal with the spring/lipped side facing inward.
!
VALVE
1. Install the valve spring seat
1.
2. Apply the engine oil to the valve stem seal 2.
3. Install the valve stem seal onto the valve guide by pushing
with the finger tip.
!
4. Apply the engine oil to the stem seal, the valve guide bore
and the valve stem.
5. Install the valve 3, the valve spring 4 and the valve retainer
5.
NOTE:
* Reassemble each valve and valve spring to their original position.
* Set the valve spring in place with the narrow spiral area facing
the valve spring seat.
6. Install the valve cotters 6 while compressing the valve
spring by the tool.
& 09916-14510: Valve lifter
09916-14521: Attachment
09916-84511: Tweezers
Do not re-use the seal once removed. Always install a
new oil seal.
Do not re-use the valve stem seal once removed.
Always use a new valve stem seal.
wide
narrow
POWER UNIT 6-19
7. Make sure the valve cotters seat in the groove
A properly.
CAMSHAFT
1. Apply the engine oil to the camshaft and all holder journals.
2. Install the camshaft.
ROCKER ARM/SHAFT
1. Apply the engine oil to the rocker arms 1 and the rocker arm
shafts 2.
2. Install the rocker arms, the rocker arm springs 3, the
washer 4, the wave washer 5 and the rocker arm shaft 2.
NOTE:
* Reassemble each rocker arm to its original position.
* Install the rocker arm shaft with its threaded end down.
OIL PUMP
1. Align the pin on the oil pump shaft with the recess in the
camshaft.
6-20 POWER UNIT
2. Install the oil pump gallery block and the oil pump.
% Oil pump bolt: 14 N·m (1.4 kgf-m, 10.0 lb-ft)
CAMSHAFT PULLEY
1. Install the key and the camshaft pulley.
% Camshaft pulley bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
CYLINDER HEAD ASSY
!
1. Apply the bond to the cylinder head block as shown.
# 99000-31140: SUZUKI BOND “1207B”
2. Install the gasket and the two dowel pins.
3. Install the cylinder head to the cylinder block.
4. Apply the engine oil lightly to six cylinder head bolts.
NOTE:
Do not apply the engine oil to the two cylinder head bolts
A.
5. Tighten the bolts to the specified torque according to the
numerical order in the figure.
% Cylinder head bolt: 28 N·m (2.8 kgf-m, 20.0 lb-ft)
Do not re-use the gasket once removed. Always use a
new gasket.
POWER UNIT 6-21
TIMING BELT AND VALVE CLEARANCE
Timing belt
1. Rotate the camshaft clockwise to align the PUNCH mark “1”
on the cam pulley with the INDEX mark on the cylinder head
block.
2. Rotate the crankshaft to align the HOLLOW mark on the lock
washer with the INDEX mark on the cylinder block.
3. Install the timing belt.
!
4. Make sure that either of the PUNCH mark “1” on the cam
pulley aligns with the INDEX mark on the cylinder head block
when the HOLLOW mark on the lock washer aligns with the
INDEX mark on the cylinder block.
Valve clearance
IN: 0.08 – 0.12 mm (0.003 – 0.005 in)
EX: 0.13 – 0.17 mm (0.005 – 0.007 in)
& 09900-20803: Thickness gauge
09917-14910: Valve adjuster driver
% Valve adjusting lock nut: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
* Always keep the timing belt away from any grease
and oil.
* If the timing belt must be installed with the arrow
mark on the timing belt toward the direction of rotation.
6-22 POWER UNIT
5. Adjust the valve clearance on the No. 1 (Top) cylinder.
6. Rotate the crankshaft clockwise to align the PUNCH mark
“2” on the cam pulley with the INDEX mark on the cylinder
head block.
!
7. Adjust the valve clearance on the No. 2 (Bottom) cylinder.
CYLINDER HEAD COVER
• Install the cylinder head cover.
% Cylinder head cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
FLYWHEEL
• Install the flywheel. (See page 3-10.)
% Flywheel bolt: 80 N·m (8.0 kgf-m, 58.5 lb-ft)
& 09930-39520: Flywheel holder
Rotate the crankshaft in the normal running direction
(clockwise) to prevent water pump impeller damage.
POWER UNIT 6-23
CYLINDER/CRANKSHAFT/PISTON
DISASSEMBLY
1. Remove the clamp
1 and fuel hose 2.
Remove the throttle drum 3 and the throttle control lever 4.
2. Remove the pulser coil 5 and the ignition coil 6.
3. Remove the CDI unit 7.
4. Remove the starter relay 8.
Before disassembling:
* Remove the power unit. (See page 6-2 to 6-4.)
* Remove the cylinder head assy. (See page 6-6.)
6-24 POWER UNIT
5. Remove the oil pressure switch
9 and the neutral switch 0.
6. Remove the clutch notch lever A (with the clutch notch
plate), the ball B and the spring C.
NOTE:
Note the clutch notch ball B.
7. Remove the oil filter cap D and the oil filter E.
8. Remove the side cover cushion, the screw and the side
cover holder F.
9. Remove the battery charge coil G and the condenser
charge coil H.
POWER UNIT 6-25
10. Remove the stator base
I.
Remove the timing belt J.
11. Remove the timing pulley nut K.
& 09911-49310: Crankshaft holder
Remove the lock washer L, the upper guide M, the timing
pulley N, the key O and the lower guide P.
12. Remove the starter motor bracket Q.
13. Remove the thermostat cover R and the thermostat S.
14. Remove the oil pressure regulator T.
6-26 POWER UNIT
15. Remove the six M6-bolts
E.
16. Remove the four M8-bolts F.
17. Remove the crankcase from the cylinder block.
18. Remove the conrod cap bolts and the conrod caps.
NOTE:
For proper assembly, mark the cylinder number on all conrod
caps using quick dry paint.
19. Remove the crankshaft.
20. Remove the oil seals G from the crankshaft.
21. Remove the pistons with the conrod.
NOTE:
* For proper assembly, mark cylinder number on all conrods
and pistons using quick dry paint.
* To prevent damage to the piston rings, decarbon from the cylinder bore wall before removing the piston.
POWER UNIT 6-27
22. Remove the circlips
H.
23. Remove the piston pin I, the piston and the conrod.
24. Remove all piston rings.
NOTE:
Install the 1st ring to the piston with its original direction.
There is no I.D. mark on the standard size 1st ring.
INSPECTION/SEVICING
NOTE:
If excessive wear, cracks, defective or other damage is found on
any component, replace component.
CYLINDER/PISTON
Cylinder distortion
Measure the cylinder distortion (gasketed surface) at a total of 6
locations as shown.
& 09900-20803: Thickness gauge
Straight gauge
Service limit: 0.05 mm (0.002 in)
If the measurement exceeds the service limit, resurface or
replace the cylinder.
NOTE:
The cylinder can be resurfaced, using a surface plate and #400
grit wet sandpaper. Move the cylinder in a figure eight pattern
when sanding.
Water jacket
Check the water jackets.
If clog or obstruction is found, clean the water jacket.
6-28 POWER UNIT
Cylinder bore wear (difference)
Measure the cylinder bore in the thrust and axial directions at
the three positions
A, B and C as shown.
Check for the followings:
• Difference of the measurements at two positions (Taper)
• Difference between the thrust and axial measurement
(Out-of-round)
& 09900-20508: Cylinder gauge set
Service limit: 0.055 mm (0.0022 in)
If the measurement exceeds the service limit, rebore or replace
the cylinder.
Piston to cylinder clearance
Standard: 0.0276 – 0.0425 mm (0.0008 – 0.0016 in)
Service limit: 0.100 mm (0.0039 in)
If the measurement exceeds the service limit, replace the piston
and/or the cylinder or rebore the cylinder.
To check the clearance, measure the following items:
• Cylinder bore at 50 mm elevation from the gasketed surface
• Piston skirt diameter at 15 mm elevation from the skirt end
& 09900-20508: Cylinder gauge set
09900-20203: Micrometer
Cylinder bore
Standard: 58.000 – 58.015 mm (2.2835 – 2.2841 in)
Piston skirt diameter
Standard: 57.965 – 57.980 mm (2.2821 – 2.2827 in)
NOTE:
For this check, measure the cylinder bore and the piston skirt
diameter in the direction that makes a right angle with the crankshaft (piston pin).
50 mm
(2.0 in)
15 mm
(0.6 in)
POWER UNIT 6-29
Identification of oversize piston/piston ring
Piston
1st & 2nd ring
Oil ring
NOTE:
For the oil ring side rail, measure the outer diameter of the rail to
distinguish because there is no I.D. mark.
Piston ring to groove clearance
Measure the clearance after decarboning.
& 09900-20803: Thickness gauge
Standard: 1st & 2nd 0.02 – 0.06 mm (0.0008 – 0.0024 in)
Service limit: 1st & 2nd 0.10 mm (0.004 in)
If the measurement exceeds the service limit, replace the piston
and/or piston ring.
& 09900-20102: Vernier calipers
09900-20205: Micrometer
Piston ring groove width
Standard:
1st & 2nd 1.21 – 1.23 mm (0.0476 – 0.0484 in)
Oil 2.51 – 2.53 mm (0.0988 – 0.0996 in)
Piston ring thickness
Standard: 1st & 2nd 1.17 – 1.19 mm (0.0461 – 0.0469 in)
Oversize I.D. mark
0.50 mm (0.020 in) 0.50
I.D. mark
Oversize I.D. mark
0.50 mm (0.020 in) 50
I.D. mark
1st, 2nd ring
Oversize I.D. mark
0.50 mm (0.020 in) Red paint
I.D. mark
1st, 2nd ring
6-30 POWER UNIT
Piston ring end gap
Measure the piston ring end gap with the piston ring in the lowest position of the cylinder bore.
& 09900-20803: Thickness gauge
Standard: 1st & 2nd 0.10 – 0.25 mm (0.004 – 0.010 in)
Service limit: 1st & 2nd 0.50 mm (0.020 in)
If the measurement exceeds the service limit, replace the piston
ring.
Piston ring free end gap
Measure the piston ring free end gap.
& 09900-20102: Vernier calipers
Standard: 1st Approx. 5.8 mm (0.23 in)
2nd Approx. 7.4 mm (0.29 in)
Service limit: 1st 4.6 mm (0.18 in)
2nd 5.9 mm (0.23 in)
If the measurement is lower than the service limit, replace the
piston ring.
Piston pin oil clearance
Check for the followings:
• The piston pin and the piston pin hole are free from excessive
wear and damage.
• The piston pin can move smoothly in the piston pin hole with
oil.
If the result is not the above conditions, replace the piston pin
and/or piston.
Standard: 0.002 – 0.013 mm (0.00008 – 0.00051 in)
Service limit: 0.040 mm (0.0016 in)
If the measurement exceeds the service limit, replace the piston
pin and/or piston.
To check the clearance, measure the following items:
• Piston pin outside diameter in the thrust and axial directions
• Piston pin hole diameter in the thrust and axial directions
& 09900-20205: Micrometer
09900-20605: Dial calipers
POWER UNIT 6-31
Piston pin outside diameter
Standard: 13.995 – 14.000 mm (0.5510 – 0.5512 in)
Service limit: 13.980 mm (0.5504 in)
Piston pin hole diameter
Standard: 14.002 – 14.008 mm (0.5513 – 0.5515 in)
Service limit: 14.030 mm (0.5524 in)
Conrod small end inside diameter
Measure the conrod small end inside diameter.
& 09900-20605: Dial calipers
Standard: 14.006 – 14.014 mm (0.5514 – 0.5517 in)
Service limit: 14.040 mm (0.5528 in)
If the measurement is out of the specification, replace the conrod.
NOTE:
The piston pin is press-fitted into the conrod small end hole.
There must be a negative clearance between two items.
CONROD/CRANKSHAFT/CRANKCASE
Conrod big end side clearance
Measure the conrod big end side clearance with the conrod
installed on the crank pin as shown.
& 09900-20803: Thickness gauge
Standard: 0.10 – 0.20 mm (0.004 – 0.008 in)
Service limit: 0.60 mm (0.024 in)
If the measurement exceeds the service limit, replace the conrod and/or crankshaft.
& 09900-20205: Micrometer
09900-20605: Dial calipers
Conrod big end width
Standard: 19.95 – 20.00 mm (0.785 – 0.787 in)
Crank pin width
Standard: 20.10 – 20.15 mm (0.791 – 0.793 in)
6-32 POWER UNIT
Crank pin outside diameter/difference
Measure the crank pin outside diameter in the thrust and axial
directions at two positions as shown.
Check for the followings:
• Difference of the measurements at two positions (Taper)
• Difference between the thrust and axial measurement
(Out-of-round)
& 09900-20202: Micrometer
Service limit: 0.010 mm (0.0004 in)
If the measurement exceeds the service limit, replace the crankshaft.
Crank pin outside diameter:
Standard: 28.982 – 29.000 mm (1.1410 – 1.1417 in)
Conrod big end inside diameter
Measure the conrod big end inside diameter as follows.
1. Clean the surface of the conrod and the conrod cap.
2. Install the conrod cap to the conrod.
3. Apply the engine oil to the conrod bolts and tighten the bolts
to the specified torque.
% Conrod cap bolt: 12 N·m (1.2 kgf-m, 8.5 lb-ft)
4. Measure the conrod big end inside diameter.
& 09900-20605: Dial calipers
Conrod big end inside diameter
Standard: 29.016 – 29.034 mm (1.1424 – 1.1431 in)
Conrod big end oil clearance
Standard: 0.025 – 0.043 mm (0.0010 – 0.0017 in)
Service limit: 0.063 mm (0.0025 in)
If the measurement exceeds the service limit, replace the conrod assembly and/or crankshaft.
POWER UNIT 6-33
Measure the conrod big end oil clearance as follows:
1. Clean the surface of the conrod, the conrod cap and the
crank pin.
2. Place a piece of the plastigauge on the crank pin with parallel to the crankshaft, avoiding the oil hole.
& 09900-22301: Plastigauge
3. Install the conrod cap.
4. Apply the engine oil to the conrod bolts and tighten the bolts
to the specified torque.
% Conrod cap bolt: 12 N·m (1.2 kgf-m, 8.5 lb-ft)
NOTE:
Do not rotate the conrod with the plastigauge in place.
5. Remove the conrod and conrod cap from the crank pin.
6. Measure the compressed plastigauge width at its widest
point.
Crankshaft and conrod combination
CONROD BIG END INSIDE DIAMETER CODE
The code is stamped on the conrod as shown.
Standard:
CRANK PIN OUTSIDE DIAMETER CODE
The codes are stamped on the bottom of the crankshaft middle
web.
Standard:
1 Top crank pin O.D. code 2 2nd crank pin O.D. code
Code Conrod big end inside diameter
1 29.025 – 29.034 mm (1.1427 – 1.1430 in)
2 29.016 – 29.025 mm (1.1424 – 1.1427 in)
Code Crank pin outside diameter
1 28.991 – 29.000 mm (1.1414 – 1.1417 in)
2 28.982 – 28.991 mm (1.1389 – 1.1414 in)
6-34 POWER UNIT
CONROD SELECTION
Select the conrod referring the below table.
Conrod selection table
NOTE:
Assemble the crankshaft and the conrod of the same code.
CRANKSHAFT THRUST CLEARANCE
Measure the crankshaft thrust clearance.
& 09900-20803: Thickness gauge
Crankshaft thrust clearance
Service limit: 0.6 mm (0.024 in)
If the measurement exceeds the service limit, replace crankshaft
and/or crankcase.
Crankshaft journal outside diameter/difference
Measure the crankshaft journal outside diameter in the thrust
and axial directions at two positions as shown.
Check for the followings:
• Difference of the measurements at two positions (Taper)
• Difference between the thrust and axial measurement
(Out-of-round)
& 09900-20202: Micrometer
Service limit: 0.010 mm (0.0004 in)
If the measurement exceeds the service limit, replace the crankshaft.
Crankshaft journal outside diameter:
Standard: 31.984 – 32.000 mm (1.2592 – 1.2598 in)
Crankshaft bearing condition
If pitting, flaking, burn or excessive wear is found, replace the
bearing.
Crankshaft bearing oil clearance
Standard: 0.020 – 0.044 mm (0.0008 – 0.0017 in)
Service limit: 0.060 mm (0.0024 in)
If the measurement exceeds the service limit, replace the crankshaft bearing.
Item
Conrod big end inside diam.
Code 1 2
Crank pin
outside diam.
1 OK NG
2 NG OK
POWER UNIT 6-35
Measure the crankshaft bearing oil clearance as follows:
1. Clean the surface of the bearing holder (the crankcase and
the cylinder), the bearing and the crankshaft bearing journal.
2. Install the crankshaft bearing to the cylinder and the crankcase.
NOTE:
* Reassemble each bearing to its original position.
* Align the tab
a of the bearing with the notch in the cylinder
and the crankcase.
* Do not apply the oil to the bearing.
3. Install the crankshaft to the cylinder.
4. Place a piece of the plastigauge on the journal with parallel
to the crankshaft, avoiding the oil hole.
& 09900-22301: Plastigauge
5. Install the crankcase (with the bearing) to the cylinder.
6. Apply the engine oil to the crankcase bolts and tighten the
bolts to the specified torque in the indicated order.
% Crankcase bolt:
6 mm 14 N·m (1.4 kgf-m, 10.0 lb-ft)
8 mm 25 N·m (2.5 kgf-m, 18.0 lb-ft)
NOTE:
* The crankcase should be torqued to the specification in order
to assure proper compression of the plastigauge and accurate
reading of the clearance.
* Do not rotate the crankshaft with the plastigauge in place.
6-36 POWER UNIT
7. Remove the crankcase from the cylinder.
8. Measure the compressed plastigauge width at its widest
point.
NOTE:
For bearing replacement, see the “CRANKSHAFT/CRANKCASE COMBINATION” section.
CRANKSHAFT/CRANKCASE COMBINATION
Crankshaft journal outside diameter code
The codes are stamped on the upper (flywheel side) and lower
web of the crankshaft as shown.
Standard:
1 Top side O.D. code 2 Lower side O.D. code
Crankcase bearing holder inside diameter code
The codes are stamped on the port side of the cylinder block as
shown.
Standard:
1 Top side I.D. code 2 Lower side I.D. code
Crankshaft bearing thickness code
The codes are painted on the side of the bearing as shown.
Standard:
Code Crankshaft journal outside diameter
A 31.992 – 32.000 mm (1.2595 – 1.2598 in)
B 31.984 – 31.992 mm (1.2592 – 1.2595 in)
Code Crankcase bearing holder inside diameter
A 35.008 – 35.016 mm (1.3783 – 1.3786 in)
B 35.000 – 35.008 mm (1.3780 – 1.3783 in)
Code Crankshaft bearing thickness
Green 1.486 – 1.490 mm (0.0585 – 0.0587 in)
Black 1.490 – 1.494 mm (0.0587 – 0.0588 in)
Brown 1.494 – 1.498 mm (0.0588 – 0.0590 in)
Yellow 1.498 – 1.502 mm (0.0590 – 0.0591 in)
POWER UNIT 6-37
Crankshaft bearing selection
Select the crankshaft bearing referring the below table.
Bearing selection table
NOTE:
Remeasure the crankshaft bearing oil clearance using the new
bearings selected. (See page 6-34.)
OIL SEAL
If crack, cut or other damage is found, replace.
THERMOSTAT
If deposited salt, corrosion, wear or other damage is found,
clean or replace.
Thermostat operation
Check the thermostat opening temperature as follows:
1. Insert a length of thread between the thermostat valve/body
and suspend the thermostat in a container filled with water.
2. Place the thermometer in the container and heat water.
Observe water temperature when the thermostat valve
opens and releases the thread.
Thermostat operating temperature:
Standard: 58 – 62 °C (136 – 144 °F)
Item
Crankshaft journal outside diameter
Code A B
Crankcase
bearing
holder inside
diameter
A Black Brown
B Green Black
6-38 POWER UNIT
REASSEMBLY
Reassembly is reverse order of disassembly with the special
attention to the following steps:
!
PISTON TO CONROD
1. Apply the engine oil to the piston pin
2, piston pin bore and
the conrod 3.
2. Fit the conrod to the piston 1 as shown in the figure and
insert the piston pin through the piston and the conrod.
3. Install the piston pin circlips 4.
NOTE:
* Make sure that the conrod is installed in the direction shown in
the figure.
1 Up mark
2 I.D. mark
3 Circlip
* Install the circlips with a gap facing either up or down as
shown in the figure.
PISTON RING TO PISTON
Oil ring
1. Apply the engine oil to the piston rings.
2. Install the spacer 1 first, then the side rails 2 to the piston.
!
* If the original components are not replaced, each
piston, piston pin and conrod is to be assembled and
installed in the original order and position.
* Do not re-use the gasket, oil seal, O-ring and circlip
once removed. Always use new parts.
or When installing the spacer, do not allow its two ends
to overlap in the groove.
INCORRECT
CORRECT
POWER UNIT 6-39
1st ring and 2nd ring
1. Apply the engine oil to the piston rings.
2. Install the 2nd ring and the 1st ring to the piston.
!
Ring gap direction
Position the rings so that their gaps are stagged at approximately 90 degree angles as shown.
1 1st ring
2 Oil ring lower side rail
3 2nd ring
4 Oil ring upper side rail
PISTON TO CYLINDER
1. Apply the engine oil to the piston and the cylinder bore wall.
2. Insert the piston (with conrod) to the cylinder from the head
side using the special tool.
& 09916-77310: Piston ring compressor
NOTE:
Position the CIRCLE mark on the piston head to the flywheel
side.
* Install the 2nd ring to the piston with the “R” mark
toward the piston head side.
* Install the 1st ring to the piston with its original
direction.
There is no I.D. mark on the standard size 1st ring.
1st ring
2nd ring
1st ring
2nd ring
Mark “O”
6-40 POWER UNIT
CRANKSHAFT TO CYLINDER
1. Install the crankshaft bearings to the cylinder and the crankcase.
2. Apply the engine oil to the bearings.
!
NOTE:
Align the tab
a of the bearing with the notch in the cylinder and
crankcase.
3. Clean the oil seal fitting surface of the cylinder.
Apply the bond to the oil seal fitting surface of the cylinder as
shown.
# 99000-31140: SUZUKI BOND “1207B”
A – Oil seal fitting surface (Apply the bond.)
B – Groove for the oil seal rib (Do not apply the bond.)
4. Apply the engine oil to the lip area of the oil seals.
5. Install the oil seals to the crankshaft.
!
NOTE:
Install the oil seals with its spring/lipped side facing inward.
* Reassemble each bearing to its original position.
* Do not apply the oil to the back of the bearing.
– marked area
– marked area
Do not re-use the seal once removed. Always use a
new seal.
POWER UNIT 6-41
6. Apply the engine oil to the crank journal, the crank pin and
the conrod.
7. Install the crankshaft to the cylinder.
NOTE:
When installing the crankshaft to the cylinder, be sure to fit the
oil seal tabs in the grooves of the cylinder.
8. Apply the engine oil to the conrod cap.
9. Install the conrod cap to the cylinder.
!
10. Apply the engine oil to the conrod cap bolts.
11. Tighten the bolts to the specified torque.
% Conrod cap bolt: 12 N·m (1.2 kgf-m, 8.5 lb-ft)
CRANKCASE TO CYLINDER
1. Clean the mating surface of the cylinder and the crankcase.
2. Apply the bond to the mating surface of the crankcase as
shown.
# 99000-31140: SUZUKI BOND “1207B”
!
A – Fitting surface of the oil seal (Apply the bond.)
B – Groove for the oil seal rib (Do not apply the bond.)
C – Mating surface of the crankshaft (Apply the bond.)
3. Install the two dowel pins.
Reassemble each conrod cap to its original position.
Apply the bond to the mating surface avoiding the
bearing with bond.
– marked area
– marked area
– marked area
6-42 POWER UNIT
4. Install the crankcase (with the bearing) to the cylinder.
5. Apply the engine oil lightly to the crankcase bolts.
6. Tighten the ten bolts of the specified torque according to the
numerical order as shown.
% Crankcase bolt:
6 mm 14 N·m (1.4 kgf-m, 10.0 lb-ft)
8 mm 25 N·m (2.5 kgf-m, 18.0 lb-ft)
TIMING PULLEY
1. Install the lower guide
1.
2. Install the key.
3. Install the timing pulley 2 and the upper guide 3 with the
direction as shown.
4. Install the lock washer 4 with the direction as shown.
5. Apply the THREAD LOCK to the timing pulley nut 5.
( 99000-32050: THREAD LOCK “1342”
6. Install the timing pulley nut 5.
Tighten the timing pulley nut 5 to the specified torque using
the special tool.
& 09911-49310: Crankshaft holder
% Timing pulley nut: 50 N·m (5.0 kgf-m, 36.0 lb-ft)
POWER UNIT 6-43
7. Bend the lock washer
4.
THERMOSTAT
Install the thermostat and the cover by three bolts.
% Thermostat cover bolt: 10 N·m (1.0 kgf-m, 7.0 lb-ft)
OIL PRESSURE REGULATOR
Install the oil pressure regulator to the specified torque.
% Oil pressure regulator: 27 N·m (2.7 kgf-m, 19.5 lb-ft)
ENGINE OIL FILTER
Install the engine oil filter. (Refer to page 2-4.)
CLUTCH NOTCH LEVER
Apply the grease to the clutch notch spring and the ball.
" 99000-25160: SUZUKI WATER RESISTANT GREASE
Apply the THREAD LOCK to the clutch notch plate screw.
( 99000-32050: THREAD LOCK “1342”
OIL PRESSURE SWITCH
Install the oil pressure switch. (Refer to page 3-14.)
6-44 POWER UNIT
OPERATION
WATER COOLING SYSTEM
The water cooling system consists of the water pump (in the lower unit), the water tube (between the lower
unit and the power unit) and the thermostat (in the cylinder). This system cools both the power unit and the
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 damage.
Component inspection Refer to page
Water pump/Impeller........................................................... 8-10
Water tube .......................................................................... 7-9
Thermostat.......................................................................... 6-37
Cylinder head...................................................................... 6-10
Cylinder block ..................................................................... 6-27
COOLING SYSTEM SCHEMATIC
When OPEN
Air vent hole
Water
Exhaust gas
Exhaust tube
THERMOSTATCYLINDER HEAD
CYLINDER
WATER TUBE
WATER PUMP
WATER INLET
PILOT WATER HOLE WATER DRAIN HOSE
DRIVESHAFT HOUSING
WATER PASSAGE
IN OIL PAN
WATER PASSAGE
IN OIL PAN
PROPELLER
EXHAUST OUTLET
WATER
POWER UNIT 6-45
ENGINE LUBRICATION SYSTEM
Engine oil stored in the oil pan is pumped up by the trochoid type pump.
ENGINE OIL LUBRICATION CHART
CRANKSHAFT UPPER
BEARING
OIL PRESSURE
SWITCH
CAMSHAFT
UPPER JOURNAL
ROCKER ARM
SHAFT AND
ROCKER ARM
CAM FACES
OIL FILTER
CAM SHAFT
LOWER JOURNAL
OIL PUMP
OIL HOSE
OIL REGULATOR
CRANKSHAFT LOWER
BEARING
No. 1
CRANK PIN
No. 1
CYLINDER WALL
No. 1
PISTON PIN
No. 2
CYLINDER WALL
No. 2
PISTON PIN
No. 2
CRANK PIN
OIL PAN
M
A
I
N
G
A
L
L
E
R
Y
6-46 POWER UNIT
OIL PASSAGE LOCATION
To CAMSHAFT
UPPER JOURNAL
To CAMSHAFT
LOWER JOURNALFrom OIL PUMP
OIL PRESSURE SWITCH
To CRANKSHAFT
UPPER BEARING
To OIL PUMP
OIL PUMP
OIL HOSE
OIL
RELIEF
To #2 CRANK
PIN
To #1 CRANK
PIN
CRANKSHAFT
LOWER BEARING
CRANKSHAFT
UPPER BEARING
OIL REGULATOR
MAIN GALLERY
OIL
FILTER
OIL FILTER
To CAMSHAFT
UPPER JOURNAL
To OIL PUMP
From OIL PUMP
OIL HOSE
OIL RELIEF
To CRANKSHAFT
LOWER BEARING
From
OIL PAN
POWER UNIT 6-47
CRANKCASE VENTILATION SYSTEM
The blow-by vapors which is generated inside the crankcase is separated into the liquid and vapors components inside the space which is bounded by the head cover and the head cover gasket. Only the resulting
vapors component is sent via the breather hose to the silencer. After this, it is mixed with fresh air, and the
resulting mixture is drawn into the combustion chamber to improve combustion efficiency.
Cylinder
head cover
Cylinder
head cover
gasket
Cylinder
head
Combustion
chamber
Crankcase
Breather
hose
Carburetor
Silencer
BLOW-BY VAPORS
FRESH AIR
6-48 POWER UNIT
EXHAUST SYSTEM
A prop-hub exhaust system has been adopted. This is basically the same as the exhaust system which is
employed in the two-stroke engines. A three-stage baffle chamber is located in the exhaust release circuit to
reduce noise while trolling.
1 Main exhaust passage
2 1st baffle chamber
3 2nd baffle chamber
4 Driveshaft housing
MID UNIT 7-1
7
MID UNIT
CONTENTS
ENGINE SIDE COVER ..................................................................................7- 2
REMOVAL ...............................................................................................7- 2
INSTALLATION.......................................................................................7- 3
TILLER HANDLE...........................................................................................7- 4
REMOVAL/DISASSEMBLY ....................................................................7- 4
REASSEMBLY/INSTALLATION.............................................................7- 5
DRIVESHAFT HOUSING AND OIL PAN ......................................................7- 7
REMOVAL ...............................................................................................7- 7
INSPECTION ...........................................................................................7- 9
REASSEMBLY ........................................................................................7-10
SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET .......7-13
REMOVAL/DISASSEMBLY ....................................................................7-13
INSPECTION ...........................................................................................7-15
REASSEMBLY ........................................................................................7-16
7-2 MID UNIT
ENGINE SIDE COVER
REMOVAL
1. Remove the snap pin, the washer, the pin and the fastener
1.
Remove the screw 2.
2. Remove the side cover rubber 3.
3. Remove the three side cover bolts.
4. Remove the bolt 4 from the clutch lever 5.
5. Remove the connector 6 and the clutch lever link 7.
6. Remove the two screws and the engine side cover.
7. Disconnect the water hose 8.
MID UNIT 7-3
INSTALLATION
Installation is revers order of removal.
Apply the THREAD LOCK to the clutch lever bolt.
! 99000-32050: THREAD LOCK “1342”
Tighten the clutch lever bolt to the specified torque.
" Clutch lever bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft)
1 Side cover rubber (1)
2 Screw (2)
3 Nut (2)
4 Plug (1)
5 Remocon cable grommet (1)
6 Side cover (Starboard) (1)
7 Side cover (Port) (1)
8 Side cover plug (1)
9 Bolt (1)
0 Bolt (2)
A Fastener (1)
B Pin (1)
C Washer (1)
D Snap pin (1)
E Screw (1)
F Nut (1)
G Protector (2)
H Screw (4)
I Protector (2)
J Side cover seal (1)
7-4 MID UNIT
TILLER HANDLE
REMOVAL/DISASSEMBLY
REMOVAL
1. Remove the side cover.
2. Remove the screw
1 and the throttle cable holder plate 2.
3. Unthread the connector 3 from the throttle drum 4.
Detach the throttle cable from the throttle cable holder 5.
4. Remove the emergency/stop switch 6, the tiller handle
stopper 7 and the clamp 8.
5. Remove the handle grip.
6. Pull out the pin 9 and remove the inner grip 0.
7. Remove the handle grip adjuster A and the slider B.
8. Detach the throttle cable C from the tiller handle.
9. Remove the connector D, the boot E and the grommet F.
Remove the throttle cable.
MID UNIT 7-5
10. Remove the tiller handle nut
G.
11. Remove the tiller handle bolt H and the tiller handle.
REASSEMBLY/INSTALLATION
REASSEMBLY
Assembly is revers order of disassembly.
When reassembling the tiller handle, refer to the construction diagram below.
1 Grommet (1)
2 Throttle cable (1)
3 Pin (1)
4 Tube (1)
5 Cap (1)
6 Tiller handle nut (1)
7 Washer (1)
8 Spring (1)
9 Washer (1)
0 Tiller handle bolt (1)
A Tiller handle (1)
B Slider (1)
C Handle rod support (1)
D Screw (2)
E Stopper (1)
F Bolt (1)
G Handle grip adjuster (1)
H Handle grip assy (1)
I Inner grip (1)
J Handle grip (1)
K Cap (1)
L Bolt (1)
M Washer (1)
N Spacer (1)
23 N·m
(2.3 kgf-m, 16.5 Ib-ft)
6 N·m
(0.6 kgf-m, 4.5 Ib-ft)
23 N·m
(2.3 kgf-m, 16.5 Ib-ft)
7-6 MID UNIT
INSTALLATION
Installation is reverse order of removal with the special attention
to the following steps.
Tiller handle assembly
• Apply the grease to the tiller handle bolt and tighten the bolt to
the specified torque.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
" Handle pivot bolt: 6 N·m (0.6 kgf-m, 4.5 lb-ft)
• Tighten the tiller handle nut to the specified torque.
" Handle pivot nut: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
EMERGENCY/STOP SWITCH WIRE ROUTING
• Adjust the throttle control. (See page 4-11 and 4-12.)
Clamp:
Fix the emergency/stop switch
and the throttle cable with clamp.
Throttle cable
Emergency/stop switch
Emergency/stop
switch wire
Handle Stopper
Route the emergency/stop
switch wire under the
handle stopper.
Route the emergency/stop
switch wire under the
throttle cable.
MID UNIT 7-7
DRIVESHAFT HOUSING AND OIL PAN
REMOVAL
1. Remove the power unit. (See page 6-2 to 6-4.)
2. Remove the lower unit. (See page 8-2.)
3. Remove the screw and the bonding wire from the swivel
bracket.
4. Remove the two bolts and the lower mount cover
1. (Both
sides)
5. Remove the screw and the bonding wire from the lower
mount cover. (STBD side)
6. Remove two bolts and the driveshaft housing (with the oil
pan).
$
7. Remove the oil level gauge guide 2 and the water hose 3.
During the removing the upper mount bolts, the driveshaft housing must be firmly secured.
7-8 MID UNIT
8. Remove the six bolts and the oil pan from the driveshaft
housing.
9. Remove the four bolts and the upper mounts
4.
10. Remove the four bolts and the lower mount 5.
11. Remove the water tube 6.
MID UNIT 7-9
INSPECTION
NOTE:
If excessive wear, cracks, defective or other damage is found on
any component, replace component.
OIL PAN AND DRIVESHAFT HOUSING
Inspect the oil pan and the driveshaft housing.
If crack, defective or other damage is found, replace.
MOUNT
Inspect the upper mount and the lower mount.
If excessively wear, corrosion or other damage is found, replace.
OIL SEAL
Inspect the oil seal.
If crack, cut or other damage is found, replace.
WATER TUBE
Inspect the water tube.
If clog is found, clean.
If crack, corrosion or other damage is found, replace.
7-10 MID UNIT
REASSEMBLY
Reassembly is reverse order of removal with the special attention to the following steps.
1 Gasket (1)
2 Oil level gauge (1)
3 Oil level gauge guide (1)
4 Bolt (1)
5 O-ring (1)
6 Oil seal (2)
7 Bolt (6)
8 Plug (2)
9 Gasket (2)
0 Oil pan assy (1)
A Bolt (4)
B Upper mount (2)
C Bolt (2)
D Stud bolt (2)
E Nut (2)
F Knock pin (2)
G Bolt (6)
H Pipe (1)
I Driveshaft housing (1)
J Bolt (4)
K Lower mount (1)
L Bolt (2)
M Lower mount cover (STBD) (1)
N Pin (2)
O Lower mount cover (Port) (1)
P Washer (2)
Q Nut (2)
R Bonding wire (1)
S Screw (2)
T Bonding wire (1)
U Bolt (1)
V Grommet (2)
W Water tube (1)
23 N·m
2.3 kgf-m
16.5 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
MID UNIT 7-11
WATER TUBE UPPER GROMMET
• Apply the grease to the outer surface of the water tube upper
grommet
1.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
LOWER MOUNT
1. Install the lower mount with the lettered mark “UP” facing
upward.
2. Apply the THREAD LOCK to the lower mount bolts.
! 99000-32050: THREAD LOCK “1342”
3. Tighten the lower mount bolts to the specified torque.
" Lower mount bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
UPPER MOUNT
1. Apply the THREAD LOCK to the upper mount bolts.
! 99000-32050: THREAD LOCK “1342”
2. Tighten the upper mount bolts to the specified torque.
" Upper mount bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
OIL PAN AND DRIVESHAFT HOUSING
1. Install the two dowel pins to the driveshaft housing.
%
2. Install the oil pan to the driveshaft housing.
3. Tighten the driveshaft housing bolts to the specified torque.
" Driveshaft housing bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
Do not re-use the gasket once removed. Always use a
new gasket.
7-12 MID UNIT
OIL LEVEL GAUGE GUIDE
• Install the O-ring
1 to the oil level gauge guide and apply the
engine oil to the O-ring 1.
UPPER MOUNT BRACKET
1. Apply the THREAD LOCK to the upper mount bracket bolts.
! 99000-32050: THREAD LOCK “1342”
2. Tighten the upper mount bracket bolts to the specified
torque.
" Upper mount bracket bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
LOWER MOUNT COVER
When attaching the lower mount cover 1 to the steering shaft
2, ensure that the pin 3 into the hole 4 of the steering shaft.
1. Apply the THREAD LOCK to the lower mount cover bolts.
! 99000-32050: THREAD LOCK “1342”
2. Tighten the lower mount cover bolt to the specified torque.
" Lower mount cover bolt: 23 N·m (2.3 kgf-m, 16.5 lb-ft)
MID UNIT 7-13
SWIVEL BRACKET, STEERING
BRACKET AND CLAMP BRACKET
REMOVAL/DISASSEMBLY
1. Remove the driveshaft housing/oil pan. (See page 7-7.)
2. Remove two bolts.
Remove the handle bracket (with the handle) and the instrument panel assy.
3. Loosen the steering adjuster bolt.
4. Lift the steering bracket
1 upward to remove from the swivel
bracket.
5. Remove the washer 2 and the upper bushing 3.
6. Remove the O-ring 4 and the lower bushing 5.
7. Detach the steering adjuster 6.
7-14 MID UNIT
8. Remove the bonding wire
7.
9. Remove the nut 8.
10. Remove the nut 9 and the bolt 0.
Remove the spacer A.
11. Remove the tilt lock pin B.
12. Remove the port clamp bracket C.
13. Remove the clamp bracket shaft D and the STBD clamp
bracket E.
14. Remove the shallow drive arm spring F.
Remove the shallow drive arm pins G and the shallow drive
arm H.
15. Remove the springs I from the reverse lock arm J.
Remove the reverse lock arm pin K, the reverse lock arm
link L and the reverse lock arm J.
MID UNIT 7-15
INSPECTION
NOTE:
If excessive wear, cracks, defective or damage is found on any
component, replace component.
BUSHINGS
Inspect all bushings for excessive wear or other damage.
Replace if necessary.
If bushing fit is loose when installing, replace the bushing.
O-RING
Inspect swivel bracket O-ring for cuts, nicks, excessive wear or
other damage.
CLAMP BRACKET SHAFT
Inspect the clamp bracket shaft for bend, twist or other damage.
Replace if necessary.
BRACKET
Inspect the clamp brackets, the steering bracket and the swivel
bracket for excessive wear, cracks or other damage.
Replace if necessary.
7-16 MID UNIT
REASSEMBLY
Reassembly is reverse order of removal with the special attention to the following steps.
1 Clamp bracket shaft (1)
2 Bolt (1)
3 Clamp screw (2)
4 Pin (2)
5 Clamp plate (2)
6 Spacer (1)
7 Bolt (2)
8 Spring (1)
9 Rubber (1)
0 Tilt lock arm (1)
A Clamp bracket (STBD) (1)
B Screw (2)
C Bonding wire (1)
D Clamp bracket (Port) (1)
E Nut (1)
F Seal (1)
G Washer (1)
H Nut (1)
I Spring (1)
J Tilt lock pin (1)
K Steering bracket (1)
L Steering bracket attachment (1)
M Washer (2)
N Bolt (2)
O Swivel bracket (1)
O Steering adjuster (1)
Q Washer (1)
R Spring (1)
S Cover (1)
T Bolt (1)
U Bushing
V Bushing
W Spring (1)
X Rubber (1)
Y Release lever (1)
Z Release arm pin (1)
[ Release link (1)
Screw (1)
] Washer (2)
^ Bushing (2)
a O-ring (1)
b Nipple (3)
c Release lock arm (1)
d Cotter pin (2)
e Washer (2)
f Spring (2)
g Reverse lock arm link (1)
h Pin (1)
i Pin (1)
j Shallow drive (1)
k Spring (1)
l Pin (2)
m Washer (2)
n Cotter pin (2)
25 N·m
2.5 kgf-m
18.0 lb-ft( )
25 N·m
2.5 kgf-m
18.0 lb-ft( )
43 N·m
4.3 kgf-m
31.0 lb-ft( )
MID UNIT 7-17
SHALLOW DRIVE ARM SPRING
• Install the shallow drive arm spring as shown in the figure.
A Groove
CLAMP BRACKET AND SWIVEL BRACKET
Apply the grease to the clamp bracket shaft and the bushings.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
1. Install the tilt lock arm spring as shown in the figure.
Apply the THREAD LOCK to the tilt lock arm bolt 1 to the
specified torque.
! 99000-32050: THREAD LOCK “1342”
" Tilt lock arm bolt: 25 N·m (2.5 kgf-m, 18.0 lb-ft)
2. Install the release link 2 to the release lever 3.
Hang the spring end A on the release lever 3 and other
spring end B on groove of the swivel bracket.
3. Assemble the clamp bracket shaft 4, the STBD clamp
bracket 5, the bush 6 and the swivel bracket 7.
7-18 MID UNIT
4. Install the bush
8, the port clamp bracket 9 and the clamp
bracket shaft nut 0, then the nut to the specified torque.
" Clamp bracket shaft nut: 43 N·m (4.3 kgf-m, 31.0 lb-ft)
5. Reattach the bonding wires, then tighten the screw securely.
STEERING BRACKET
1. Install the steering adjuster 1 to the swivel bracket.
2. Apply the grease to the bushing.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
3. Install the upper bushing 2 and the washer 3 to the swivel
bracket.
4. Install the lower bushing 4 and the O-ring 5 to the swivel
bracket.
5. Apply the grease to the steering bracket shaft.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
NOTE:
Apply grease to the bushings, the O-ring and the pilot shaft portion of the steering bracket.
6. Install the steering bracket 6 to the swivel bracket.
MID UNIT 7-19
7. Apply the THREAD LOCK to the steering bracket attachment bolts
7 to the specified torque.
! 99000-32050: THREAD LOCK “1342”
" Steering bracket attachment bolt:
23 N·m (2.3 kgf-m, 16.5 lb-ft)
LUBRICATION
After completing reassembly of the mid unit, apply Water Resistant Grease through each grease nipple.
# 99000-25160: SUZUKI WATER RESISTANT GREASE
LOWER UNIT 8-1
8
LOWER UNIT
CONTENTS
REMOVAL & DISASSEMBLY.......................................................................8- 2
PINION BEARING .........................................................................................8- 6
INSPECTION .................................................................................................8- 8
PROPELLER ...........................................................................................8- 8
GEARCASE.............................................................................................8- 8
GEARS ....................................................................................................8- 8
PROPELLER SHAFT COMPONENTS ...................................................8- 9
PROPELLER SHAFT BEARING HOUSING...........................................8- 9
SHIFT ROD GUIDE HOUSING COMPONENTS.....................................8-10
WATER PUMP AND RELATED ITEMS..................................................8-10
WATER INLET HOUSING.......................................................................8-10
DRIVESHAFT ..........................................................................................8-11
ASSEMBLY & INSTALLATION ....................................................................8-12
LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT............................8-21
FOREWARD GEAR/PINION GEAR........................................................8-21
PINION GEAR/REVERSE GEAR............................................................8-23
CHECKING PROPELLER SHAFT THRUST PLAY................................8-24
8-2 LOWER UNIT
REMOVAL & DISASSEMBLY
!
1. Loosen the clutch rod lock nut
1.
To separate the clutch rod from the shift rod, unscrew the
turnbuckle 2.
2. Remove the four bolts and separate the gearcase from the
driveshaft housing.
3. Place a drain pan under the oil drain plug.
Remove the oil drain plug 3 first, then the oil level plug 4,
and allow gear oil to drain.
4. Remove the bolt and the zinc 5 (if necessary).
5. Remove the cotter pin 6 from the propeller shaft and
remove the propeller nut 7.
6. Remove the washer 8, the spacer 9, the propeller 0 and
the stopper A from the propeller shaft.
Before removing the lower unit, disconnect the battery
cable.
LOWER UNIT 8-3
!
7. Remove the four bolts then remove the water pump case
B
and the impeller C.
8. Remove the key D and the dowel pins E.
9. Remove the under panel F, under the panel gasket, the
water inlet housing G, the gasket H, the exhaust seal rubber I and the exhaust seal core J.
10. Remove the two bolts securing the propeller shaft bearing
housing K to the gearcase.
To prevent injury from the propeller blades, wear
gloves and place a block of wood between the
anti-cavitation plate and the propeller blade tips to
lock the propeller in place.
8-4 LOWER UNIT
11. Using the special tools, draw out propeller shaft and the
bearing housing assembly.
" 09930-30104: Sliding hammer
09950-59320: Propeller shaft remover
12. Remove the circlip from the driveshaft.
Lift out the driveshaft assy.
13. Remove the pinion gear
L, the pinion gear back up shim M,
the washer N, and the thrust bearing O.
14. Remove the forward gear P, the thrust washer Q and the
forward gear back-up shim R.
15. Remove the nut and the shaft rod assembly.
Disassembly of propeller shaft component
1. Separate the propeller shaft bearing housing 1, the propeller shaft 2 (with the clutch dog shifter), the reverse gear 3,
the reverse gear back up shim 4, the thrust washer 5, the
push rod 6 and the push pin 7.
LOWER UNIT 8-5
2. Remove the spring
8 from the clutch dog shifter.
3. Remove the dog pin 9.
4. Remove the clutch dog shifter 0, and the spring A.
Disassembly of shift rod components
1. Push the pin 1 and remove the clutch cam 2.
2. Remove the pin 3, the washer 4, the O-ring 5, the O-ring
6, the shift rod guide 7 and the boot 8.
8-6 LOWER UNIT
PINION BEARING
Removal/installation is in the following procedure.
Removal & Installation tools
" 09951-59910: Shaft (Installation)
1
09551-49910: Shaft (Removal) 2
09951-69910: Bearing 3
01500-08403: Bolt 4
09951-39914: Plate 5
09951-19311: Attachment 6
09951-79311: Spacer (Attachment) 7
09951-29910: Nut 8
09930-30104: Sliding hammer 9
REMOVAL
1. Set the plate 5 on the gearcase with the two bolts 4.
NOTE:
Using the two water pump bolt holes.
2. Set the shaft (removal) 2, the bearing 3, the attachment 6
and the nut 8 as shown.
3. To push the pinion bearings A out of the gearcase, turn the
lower nut B clockwise while holding the bolt C tightly.
#
Do not re-use the pinion bearing once removed.
Always use a new pinion bearing.
LOWER UNIT 8-7
INSTALLATION
#
1. Set the shaft installation
1, the plate 5, the spacer 7, the
attachment 6 and the pinion bearing A as shown in the figure.
2. Place the shaft 1 (with the pinion bearing A on the end of
the shaft) into the gearcase.
3. Secure the plate 5 by tightening the bolts 4.
4. Thread the sliding hammer 9 into the top of the shaft 1.
5. Drive the pinion bearing A down into position by gently striking the shaft 1 until the coupler touches the plate 5.
6. Repeat Nos. 4 – 8 to install the second bearing.
* Before installing the bearing, ensure that the inside
of the gearcase is clean and free of debris.
* Ensure that the bearing stamped mark faces upward.
8-8 LOWER UNIT
INSPECTION
NOTE:
Thoroughly wash all metal components with cleaning solvent
and dry with compressed air.
!
PROPELLER
• Inspect the propeller for bent, chipped or broken blades.
Replace or repair if necessary.
• Inspect the propeller bushing splines for wear or other damage. Replace if necessary.
• Inspect the propeller bushing for deterioration or slipping.
Replace if necessary.
GEARCASE
• Inspect the gearcase for cracks or other damage.
Replace if necessary.
• Inspect the pinion bearing for pitting, rough or other damage.
Replace if necessary.
NOTE:
If removal and replacement are required, see the “PINION
BEARING” section on page 8-6.
GEARS
• Inspect the forward gear, the reverse gear and the pinion gear
teeth and engaging dogs for excessive wear or other damage.
Replace if necessary.
• Inspect the thrust bearing and the forward gear bearing for pitting, rough or other damage. Replace if necessary.
Wear the safety grasses when using compressed air.
LOWER UNIT 8-9
PROPELLER SHAFT COMPONENTS
• Inspect the push rod and push rod pin for excessive wear or
other damage. Replace if necessary.
• Inspect the clutch dog shifter for excessive wear, chip or other
damage. Replace if necessary.
• Inspect the dog pin for bent or other damage. Replace if necessary.
• Inspect the propeller shaft/splines for wear, twist or other
damage. Replace if necessary.
• Measure the clutch return spring free length.
" 09900-20101: Vernier calipers
Clutch return spring free length (L)
Standard: 67 mm (2.6 in)
Service limit: 64 mm (2.5 in)
If the measurement exceeds the service limit, replace the clutch
return spring.
PROPELLER SHAFT BEARING HOUSING
• Inspect the housing for cracks or other damage. Replace if
necessary.
• Inspect the propeller shaft bearings and the reverse gear
bearing for pitting, rough or other damage. Replace if necessary.
• Inspect the oil seals and the O-ring for cuts, nicks or tears.
Replacing propeller shaft oil seal
1. Extract the oil seals
3 using the oil seal remover.
" 09913-50121: Oil seal remover
#
2. Apply the grease to the inner circumference of the housing.
3. Using an oil seal installer, drive two oil seals (one at a time)
into the housing.
The lipped portion of the seal should face toward the propeller.
Apply the grease to the seal lips.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
Do not re-use the oil seal once removed.
Always use a new oil seal.
Direction of
propeller
8-10 LOWER UNIT
SHIFT ROD GUIDE HOUSING COMPONENTS
• Inspect the “stepped” surfaces of the shift cam for excessive
wear, chip or other damage. Replace if necessary.
• Inspect the shift rod guide for excessive wear, pit, corrosion or
stiff. Replace if necessary.
• Inspect the O-ring for wear, cuts, nicks or tears.
• Inspect the boot for cracked or other damage
WATER PUMP AND RELATED ITEMS
• Inspect the impeller vanes for cuts, cracks, tears or excessive
wear. Replace if necessary.
• Inspect the pump case and the under panel for cracks, distortion or corrosion. Replace if necessary.
WATER INLET HOUSING
• Inspect the housing for cracks or other damage. Replace of
necessary.
• Inspect the oil seal for wear, cuts, nicks of tears.
Replacing oil seal
1. Extract the oil seal using the oil seal remover.
" 09913-50121: Oil seal remover
2. Apply the water resistant grease to the inner circumference
of the housing.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
LOWER UNIT 8-11
3. Using an oil seal installer, drive the oil seal into the housing.
The lipped portion of the seal should face toward the water
pump case.
Apply the grease to the seal lips.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
DRIVESHAFT
• Inspect the driveshaft/splines for wear, twist or other damage.
Replace if necessary.
• Inspect the driveshaft bearing for pitting, rough or other damage. Replace if necessary.
8-12 LOWER UNIT
ASSEMBLY & INSTALLATION
Assembly & installation are reverse order of removal & disassembly with the special attention to the following steps.
Circlip (2)
Bearing (1)
Drive shaft (1)
Washer (1)
Bearing (1)
Washer (1)
Shim (1)
Pinion gear (1)
Circlip (1)
Pinion bearing (2)
Knock pin (2)
Exhaust seal rubber (1)
Exhaust seal core (1)
Plug (3)
Gascket (3)
Zinc (1)
Bolt (1)
Bolt (4)
Gearcase (1)
Zinc (1)
Bolt (1)
Water filter (1)
Screw (1)
Bearing (1)
Shim (1)
Forward gear (1)
Thrust washer (1)
Push rod (1)
Push pin (1)
Clutch dog shifter (1)
Dog pin (1)
Dog spring (1)
Return spring (1)
Propeller shaft (1)
Washer (1)
Reverse gear (1)
Shim (1)
Bearing (1)
O-ring (1)
Propeller shaft bearing housing (1)
Oil seal (2)
Bolt (2)
Propeller bush stopper (1)
Propeller (1)
Propeller bush (1)
Spacer (1)
Washer (1)
Nut (1)
Cotter pin (1)
13 N·m
1.3 kgf-m
9.5 lb-ft( )
13 N·m
1.3 kgf-m
9.5 lb-ft( )
13 N·m
1.3 kgf-m
9.5 lb-ft( )
18 N·m
1.8 kgf-m
13.0 lb-ft( )
23 N·m
2.3 kgf-m
16.5 lb-ft( )
8 N·m
0.8 kgf-m
6.0 lb-ft( )
LOWER UNIT 8-13
#
Nut (1)
Turnbuckle (1)
Nut (1)
Washer (1)
Stud bolt (1)
Coller (1)
Shift rod (1)
Boot (1)
Shift rod guide (1)
O-ring (1)
O-ring (1)
Washer (1)
Spring pin (2)
Shift cam (1)
Bolt (4)
Bush (1)
Grommet (1)
Water pump case (1)
Impeller (1)
Key (1)
Dowel pin (2)
Under panel (1)
Gasket (1)
Water inlet housing (1)
Water inlet drain (1)
Oil seal (1)
Gasket (1)
Grommet
Bolt (1)
Water inlet tube (1)
Grommet (1)
8 N·m
0.8 kgf-m
6.0 lb-ft( )
* Make sure that all parts used in assembly are clean
and lubricated.
* After assembly, check parts for tightness and
smoothness of operation.
* Before final assembly, be absolutely certain that all
gear contact, shim adjustments and tolerances are
correct.
Failure to correctly adjust these areas will result in
lower unit damage. (See the “GEARS SHIMMING
AND ADJUSTMENT” section on page 8-21.)
8-14 LOWER UNIT
SHIFT ROD/SHIFT CAM ASSEMBLY
• Apply the grease to the inside of the boot
1, the O-ring 2
and the O-ring 3.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
• Install the shift rod guide 4 to the shift rod 5 as shown in the
figure.
• Fit the shift cam 6 to the shift rod as shown in the figure and
insert the spring pin 7.
• Install the shift rod/shift cam assembly to gearcase with the
face A of the cam facing toward the propeller side.
• Fit the shift rod guide 4 to gearcase as shown in the figure.
PROPELLER SHAFT/CLUTCH DOG ASSEMBLY
• Install the clutch dog shifter with “F” mark toward the forward
gear side.
• Fit the return spring 1 snugly in to the groove on the dog
shifter 2 so that the dog pin 3 does not come out.
LOWER UNIT 8-15
• Install the dog spring
4, ensuring that it fits snugly into the
groove on the clutch dog shifter.
FORWARD GEAR
Apply the gear oil to the forward gear and place the back-up
shim 1 in position, then install the forward gear.
% 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL
PINION GEAR AND DRIVE SHAFT
1. Apply the gear oil to the thrust bearing 4 and pinion gear 1.
% 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL
2. Place the pinion gear 1, the back-up shim 2, the washer 3
and the thrust bearing 4 in the gearcase.
3. Slide the driveshaft assembly down into the gearcase and
install the pinion gear on splines.
4. Install the circlip 5.
5. Check the backlash exists between the pinion gear and the
forward gear. (See the “FORWARD GEAR/PINION GEAR”
section on page 8-21 to 8-23.)
8-16 LOWER UNIT
PROPELLER SHAFT BEARING HOUSING
• Apply the grease to the oil seals and O-ring.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
• Apply gear oil to the bearings.
% 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL
• Assemble the propeller shaft in the following sequence.
* Propeller shaft housing
1
* Reverse gear back-up shim 2
* Reverse gear 3
* Reverse gear thrust washer 4
* Forward gear thrust washer 5
* Push pin 6
* Push rod 7
• Install the propeller shaft bearing housing assembly to gearcase with the arrow mark A of the housing toward the upside.
• When the housing is fully seated, tighten two bolts to the
specified torque.
& Bearing housing bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft)
• Check and adjust the shimming of the gears.
(See page 8-23.)
LOWER UNIT 8-17
WARTER INLET HOUSING
1. Apply the grease to the oil seal.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
2. Install the gasket
1, the water inlet tube 2 and the water
inlet drain 3 to the water inlet housing.
3. Install the exhaust seal core 5 and the rubber 6.
4. Install the water inlet housing assembly to the gearcase.
Place the water inlet tube 2 and drain 3 into position.
WATER PUMP
1. Place the dowel pins 1, the under panel gasket 2 and the
under panel 3 into the position.
2. Insert the key 4 in the driveshaft and slide the impeller 5
onto the driveshaft, ensuring that the key and keyway are
aligned.
3. Install the pump case 6 while rotating the driveshaft clockwise to flex the impeller vanes in correct direction.
4. Tighten the four pump case bolts 7 to the specified torque.
& Pump case bolt: 8 N·m (0.8 kgf-m, 6.0 lb-ft)
8-18 LOWER UNIT
LEAKAGE CHECK
Check for leakage of the oil seal and the O-ring when applying
air pressure inside of the gearcase.
" 09950-69512 : Oil leakage tester
: Hand air pump
Procedure
1. Install the oil leakage tester into the oil level hole.
2. Connect a hand air pump to the oil leakage tester.
3. While rotate the driveshaft and propeller shaft clockwise several times, apply specified pressure for leakage test.
NOTE:
Apply low initial pressure of 20 – 40 kPa, (0.2 – 0.4 kg/cm2, 2.8 –
5.7 psi) first, then apply specified pressure.
Leakage test pressure: 100 kPa (1.0 kgf/cm2, 14.2 psi)
#
4. Once stabilized, pressure should remain steady for at least
5 min.
If pressure does not fall, sealing performance is correct.
PROPELLER INSTALATION
1. Install the propeller stopper
1 onto the propeller shaft, then
slide on the propeller 2.
2. Fit the spacer 3, the washer 4 and the nut 5, then tighten
the nut to the specified torque.
& Propeller nut: 18 N·m (1.8 kgf-m, 13.0 lb-ft)
3. Push the cotter pin 6 through the nut and the shaft, then
bend to secure.
LOWER UNIT INSTALLATION
1. Install the gasket 1 and the two dowel pins 2.
Do not exceed pressure of 110 kPa (1.1kg/cm2,
15.6 psi) or damage to oil seals will result.
LOWER UNIT 8-19
2. Apply the grease to the driveshaft splines.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
3. Slide the gearcase into place, making sure that the top of the
driveshaft engages properly with the crankshaft and the
water tube locates in the water pump case outlet.
4. Apply the seal to the four gearcase bolts and tighten them to
the specified torque.
' 99000-31120: SUZUKI SILICONE SEAL
& Gearcase bolt: 23 N·m (2.3 kg-m, 16.5 lb-ft)
CLUTCH ADJUSTMENT
1. Install the hose
1 on the clutch rod.
2. Connect the clutch rod to the shift rod as shown.
#
Adjustment step:
1. Shift the clutch lever from Neutral N through Forward F and
Reverse R to check that proper engagement of both gears
is at an equal angle from Neutral.
• If Forward gear engages earlier (at a smaller angle) than
Reverse, the turnbuckle should be rotated counterclockwise until both gears engage with the same amount of
clutch lever travel.
Make sure that chambered edge A of the turnbuckle
faces upward to seat against the upper nut when tightened.
8-20 LOWER UNIT
• If Reverse gear engages earlier than Forward, the turnbuckle should be rotated clockwise.
2. Lock the upper nut securely against the turnbuckle when
clutch lever adjustment is correct.
GEAR OIL
Fill the gearcase with the specified gear oil.
See the “PERUIODIC MAINTENANCE/GEAR OIL” section on
page 2-5.
Necessary amount of gear oil:
170 ml (5.7/6.0 US/lmp.oz)
% 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL
LOWER UNIT 8-21
LOWER UNIT GEARS- SHIMMING AND
ADJUSTMENT
If the lower unit has been rebuilt or has had components
replaced, shimming for correct gear contact and backlash will
have to be adjusted to ensure smooth, reliable operation of
gears.
Shim/Washer & Mounting position
FOREWARD GEAR/PINION GEAR
Step to prior to adjustment
Correctly assemble the forward gear, the pinion gear, the driveshaft and related components. (See page 8-15 to 8-16.)
NOTE:
When installing the forward gear back-up shim, choose shim
thinner than design specification for calculating adjustment.
Adjusting gear backlash
Check a slight amount of backlash exists between the pinion
gear and the forward gear by slightly rotating the driveshaft or
the forward gear by hand.
• If backlash is larger than the specified, thickness of the forward gear back-up shim must be increased.
• If backlash is smaller, the forward gear back-up shim thickness must be decreased.
Numerical
index/item
Available
thickness
(mm)
Design
specification
thickness
(mm)
1
Pinion gear back up
shim
0.7, 0.8, 0.9, 1.0,
1.1, 1.2, 1.3
1.0
2
Forward gear back
up shim
0.7, 0.8, 0.9, 1.0,
1.1, 1.2, 1.3
1.0
3
Forward gear thrust
washer
1.5 1.5
4
Reverse gear thrust
washer
1.1, 1.2, 1.3, 1.4,
1.5, 1.6, 1.7, 1.8,
1.9
1.5
5
Reverse gear back
up shim
0.7, 0.8, 0.9, 1.0,
1.1, 1.2, 1.3
1.0
8-22 LOWER UNIT
Checking and adjusting tooth contact pattern
(Pinion and forward gear)
1. To assess the tooth contact, apply a light coat of Prussian
Blue on the convex surface of the forward gear.
2. Install the propeller shaft and the housing assembly (minus
the reverse gear and the internal components).
& Propeller shaft bearing housing bolt:
8 N·m (0.8 kgf-m, 6.0 lb-ft)
3. Push the propeller shaft inward and hold in the position.
4. Rotate the driveshaft clockwise 5 – 6 times by hand.
5. Carefully pull out the propeller shaft and the housing to
check the tooth contact pattern.
Concave side
Convex side
Heel
Tooth top
Tooth bottom
Toe
TOOTH
CONTACT
PATTERN
Tooth width
LOWER UNIT 8-23
Optimum tooth contact
The optimum tooth contact is shown in the figure.
A shim adjustment may be necessary to obtain the optimum
tooth contact pattern.
#
Example (1)
Incorrect topside toe contact:
Correction measures:
• Decrease the thickness of the forward gear back-up shim.
• Slightly increase the pinion gear back-up shim thickness.
#
Example (2)
Incorrect bottom side toe contact:
Correction measures:
• Increase the thickness of the forward gear back-up shim.
• Slightly decrease the pinion gear back-up shim thickness.
#
PINION GEAR/REVERSE GEAR
1. Check the amount of backlash between the pinion gear and
forward gear. (See page 8-21.)
2. Install the propeller shaft/bearing housing assembly to the
gearcase.
& Propeller shaft bearing housing bolt:
8 N·m (0.8 kgf-m, 6.0 lb-ft)
3. Check the amount of backlash by slightly rotating the driveshaft by hand.
4. Backlash should not be less than when checked step (1).
If backlash is less, reduce the reverse gear back-up shim
thickness.
The backlash of the gear should be checked when
increasing or decreasing the thickness of the shim to
adjust tooth contact.
Do not set tooth contact in the top side toe contact
position. Damage and chipping of the forward and pinion gear back-up may result.
Do not set tooth contact in the bottom side toe contact
position. Chipping of the pinion gear may result.
Optimum tooth contact
HEEL
Convex side
Approx. 1/3 of
tooth width
Approx.
1 mm
TOE
HEEL
TOE
EXAMPLE OF INCORRECT
Top side toe contact
Example (1)
EXAMPLE OF INCORRECT
Bottom side toe contact
HEEL
TOE
Example (2)
8-24 LOWER UNIT
CHECKING PROPELLER SHAFT THRUST
PLAY
After adjusting all gear positions, measure the propeller shaft
thrust play. If the measurement is not within the following specification, a shim adjustment is required.
Propeller shaft thrust play: 0.2 – 0.4 mm (0.01 – 0.02 in)
NOTE:
Maintain the forward gear thrust washer at the standard thickness (1.5 mm) and adjust only reverse gear thrust washer with
the shim.
1. Affix the gear adjusting gauge to the propeller shaft.
" 09951-09511: Gear adjusting gauge
2. Slowly push the propeller shaft inward.
3. Hold the shaft in and set the dial gauge pointer to zero.
4. Slowly pull the propeller shaft outward and read the maximum thrust play.
If the measurement is more than the specification, increase the
reverse gear thrust washer thickness.
If the measurement is less than the specification, reduce the
reverse gear thrust washer thickness.
ROUTING AND DIAGRAM 9-1
9
ROUTING AND DIAGRAM
CONTENTS
WIRING DIAGRAM........................................................................................9- 2
DF9.9/DF9.9A/DF15/DF15A (MANUAL STARTER MODEL).................9- 2
DF9.9E/DF9.9AE/DF15E/DF15AE (ELECTRIC STARTER MODEL).....9- 3
DF9.9R/DF9.9AR/DF15R/DF15AR (REMORT CONTROL MODEL) .....9- 4
WIRE ROUTING ............................................................................................9- 5
EXCEPT FOR REMOTE CONTROL MODEL.........................................9- 6
FOR REMOTE CONTROL MODEL ........................................................9- 6
TILLER HANDLE MODEL ......................................................................9-10
HOSE ROUTING............................................................................................9-11
9-2 ROUTING AND DIAGRAM
WIRING DIAGRAM
DF9.9/DF9.9A/DF15/DF15A (MANUAL STARTER MODEL)
W
IR
E
C
O
L
O
R
B
: B
la ck B
l : B
lu e B
r : B
ro w n G
: G
re en O
: O
ra ng e P
: P
in k R
: R
ed W
: W
hi te Y
: Y
el lo w B
/R
: B
la ck w ith
R
ed tr ac er B
I/R
: B
lu e w ith
R
ed tr ac er R
/B
: R
ed w ith
B
la ck tr ac er Y
/G
: Y
el lo w w ith
G
re en tr ac er ROUTING AND DIAGRAM 9-3
DF9.9E/DF9.9AE/DF15E/DF15AE (ELECTRIC STARTER MODEL)
W
IR
E
C
O
L
O
R
B
: B
la ck B
l : B
lu e B
r : B
ro w n G
: G
re en O
: O
ra ng e P
: P
in k R
: R
ed W
: W
hi te Y
: Y
el lo w B
/R
: B
la ck w ith
R
ed tr ac er B
I/R
: B
lu e w ith
R
ed tr ac er R
/B
: R
ed w ith
B
la ck tr ac er W
/R
: W
hi te w ith
R
ed tr ac er Y
/G
: Y
el lo w w ith
G
re en tr ac er 9-4 ROUTING AND DIAGRAM
DF9.9R/DF9.9AR/DF15R/DF15AR (REMORT CONTROL MODEL)
W
IR
E
C
O
L
O
R
B
: B
la ck B
l : B
lu e B
r : B
ro w n G
: G
re en G
r : G
ra y O
: O
ra ng e P
: P
in k R
: R
ed W
: W
hi te Y
: Y
el lo w B
/R
: B
la ck w ith
R
ed tr ac er B
I/R
: B
lu e w ith
R
ed tr ac er R
/B
: R
ed w ith
B
la ck tr ac er W
/R
: W
hi te w ith
R
ed tr ac er Y
/G
: Y
el lo w w ith
G
re en tr ac er ROUTING AND DIAGRAM 9-5
WIRE ROUTING
To C
D
I u
ni t To C
D
I u
ni t Y
/G
B
r S
ta rt er m ot or F
us e ca se C
la m p S
ta rt er m ot or su b ca bl e B
at te ry c ab le S
ta rt er m ot or r el ay N
eu tr al s w itc
h Tu be T
ig ht en th e C
D
I g
ro un d, th e pu ls er c oi l gr ou nd a nd th e oi l p
re ss ur e ca ut io n la m p gr ou nd w ire
to ge th er .
E
le ct ric
s ta rt m od el N
eu tr al s w itc
h le ad c on ne ct in g S
pa rk p lu g ca p Ig ni tio
n co il C
ap o ve r th e oi l p
re ss ur e sw itc
h. T
ig ht en th e re la y sc re w , t
he r el ay g ro un d w ire
an d th e re ct ifi
er g ro un d w ire
to ge th er .
C
la m p P
lu se r co il Tu be R
ec tif
ie r C
D
I u
ni t A
pp ly th e T
H
R
E
A
D
L
O
C
K

13
42
”.
F
ix th e sw itc
h w ire
s, th e ca bl es ,
th e sp ar e fu se w ith
th e tu be .
To s ta rt er m ot or re la y Y
/G
B
r B
r M
an ua l s
ta rt m od el S
cr ew :
O
il pr es su re s w itc
h: B
ol t: B
ol t: Tu be :
9-6 ROUTING AND DIAGRAM
EXCEPT FOR REMOTE CONTROL MODEL
FOR REMOTE CONTROL MODEL
Starter Cable
Routing the battery cable under
the throttle cable.
Condenser charge coil
Battery charge coil (option)
Pulser coil
Clamp
Starter motor
Battery charge coil
Wiring harness assy
Clamp
Starter cable
Route choke solenoid wire between the
cable holder and the starter motor bracket.
Condenser charge coil
Battery charge coil (option)
Choke solenoid assyPulser coil
Starter motor
Battery charge coil
ROUTING AND DIAGRAM 9-7
To the remocon harness
From the choke
Clamp
Choke solenoid wire
Fix the choke solenoid wire
with the clamp.
Starter cable
Starter cable
Starter sub cable
Fuse case assy
Starter motor
Clamp
Bolt
Spacer
30˚
Manual starter model
9-8 ROUTING AND DIAGRAM
Condenser charge coil
Battery charge coil
Pulser coil
Fix the leads with the tube.
Stator base
Condenser
charge coil
Yellow
To the CDI unit
RectifierBattery
charge coil
Screw
Route the wires through
the slots of the stator base.
Electric starter model
ROUTING AND DIAGRAM 9-9
Bolt Tube
Black
White
Rectifier & Regulator
Battery charge coil
Route the wires through
the slots of the stator base.
Install the CDI unit on the startboard side hole.
CDI unit
Manual/Electric start model with options
9-10 ROUTING AND DIAGRAM
TILLER HANDLE MODEL
* marked item: For electoric start model only.
Emergency/stop
switch
Throttle cable
Clamp:
Fix the emergency/stop switch
and the throttle cable with the
clamp.
Handle stopper:
Route the emergency/stop switch
wire under the handle stopper.
Grommet
Switch wire tube
Grommet:
Insert the switch wire tube ends
into the grommet.
Screw
Clamp
Switch wire tube
* Clamp:
Place the clamp connecting part
on back of the handle bracket.
* Start switch nut
Route the emergency/stop
switch wire under the throttle
cable.
Emergency/stop
switch wire
ROUTING AND DIAGRAM 9-11
HOSE ROUTING
Fuel pump
Fuel filter:
When installing the fuel filter, ensure
that the arrow mark points toward
the fuel pump.
Clamp
Clamp
Fuel hose
Fuel connector plug
Water inspection hose
Clip:
Set the clip as shown
direction.
Fuel pump
Fuel hose
Water hose
Clip:
Set the clip as shown
direction.
Thermostat cover
Clamp
Clip
Clamp
Carburetor drain hose
Do not touch the fuel hose protector
with the bolt.
Prepared by
Marine & Power Products Division
February, 2003
Manual No.99500-93E10-01E
Printed in Japan
204
Printed in Japan TK
K3

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