99500-87J03-01E - MDMotors

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9 9 5 0 0 - 8 7 J 0 3 - 0 1 E
1
This manual contains an introductory description on
SUZUKI Outboard motor DF40/50 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.
GENERAL INFORMATION
PERIODIC MAINTENANCE
ENGINE CONTROL SYSTEM
ELECTRICAL
FUEL SYSTEM
POWER UNIT
MID UNIT
POWER TRIM AND TILT
LOWER UNIT
WIRE / HOSE ROUTING
DF40QH/DF50QH
DF40/DF50 “Y” (’00) MODEL
DF40/DF50(W) “K1” (’01)
MODEL
Marine & Power Products Division
GROUP INDEX
!
Apprentice machanics 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.
FOREWORD
1
2
3
4
5
6
7
8
9
10
• 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.
COPYRIGHT SUZUKI MOTOR CORPORATION 2002
11
12
13
2
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 you wish
to 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 bolt (1)
2Washer (1)
3Key (1)
4 Flywheel (1)
5CKP sensor assy (1)
6Screw (6)
7CMP sensor (1)
8Bolt (1)
1
2
3
4
56
7 8
Crankshaft
" 200 N.m
(20.0 kg-m, 144.5 lb.-ft.)
#
$
NOTE:
Clean flywheel and crankshaft mating
surfaces with cleaning solvent.
3
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.
Apply THREAD LOCK “1342”.
Apply THREAD LOCK SUPER
“1333B”.
Measure in DC voltage range.
Measure in resistance range.
Measure in continuity test range.
Use peak voltmeter
“Stevens CD-77”.
Use special tool.
Torque control required.
Data beside it indicates specified
torque.
Apply oil. Use engine oil unless
otherwise specified.
Apply SUZUKI OUTBOARD
MOTOR GEAR OIL.
Apply SUZUKI SUPER GREASE “A”.
Apply SUZUKI WATER
RESISTANT GREASE.
Apply SUZUKI BOND “1104”.
Apply SUZUKI BOND “1207B”.
Apply SUZUKI SILICONE SEAL.
SYMBOL DEFINITION SYMBOL DEFINITION
"
#
%
&
'
(
)
*
$
+
,
-
.
/
0
4
GENERAL INFORMATION
1
WARNING/CAUTION/NOTE__________________________________ 1-1
GENERAL PRECAUTIONS __________________________________ 1-1
IDENTIFICATION NUMBER LOCATION ________________________ 1-3
FUEL AND OIL ____________________________________________ 1-3
GASOLINE RECOMMENDATION .................................................................. 1-3
ENGINE OIL..................................................................................................... 1-3
ENGINE BREAK-IN ________________________________________ 1-4
PROPELLERS ____________________________________________ 1-5
SPECIFICATIONS _________________________________________ 1-6
SERVICE DATA____________________________________________ 1-8
TIGHTENING TORQUE _____________________________________ 1-15
SPECIAL TOOLS __________________________________________ 1-17
MATERIALS REQUIRED ____________________________________ 1-20
CONTENTS
5
1-1 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
well-ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or
shortly after engine operation.
• Oil can be hazardous. Children and 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.
!
6
GENERAL INFORMATION 1-2
• 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.
"
7
1-3 GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL PRE-FIX SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of motor are
stamped on a plate attached to the clamp bracket.
Example
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
"
If leaded gasoline is used, engine damage may result. Use only unleaded gasoline.
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.
MODEL
PRE-FIX SERIAL NUMBER
DF 50
0 5 0 0 1 F – X X X X X X
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss
on the cylinder block .
8
GENERAL INFORMATION 1-4
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 (3000 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 planning.
2. NEXT 1 HOUR
Operate the engine in-gear at less than 3/4 (three-quarter) throttle (4000 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.
9
1-5 GENERAL INFORMATION
PROPELLERS
An outboard motor is designed to develop its rated power
within a specified engine speed range. The maximum rated
power delivered by the DF40 / 50 T models is shown below.
Blade × Diam. (in.) × Pitch (in.)
3 × 11- 1/2 × 9 (S900)
3 × 11- 1/2 × 10 (S1000)
3 × 11- 1/2 × 11 (S1100)
3 × 11- 5/8 × 12 (S1200)
3 × 11- 1/2 × 13 (S1301, SS1300)
3 × 11- 3/8 × 14 (S1400, SS1400)
3 × 11- 1/4 × 15 (S1500)
3 × 11- 1/8 × 16 (S1600, SS1600)
3 × 11 × 17 (S1700)
If the standard propeller fails to meet the above requirement,
use another pitch propeller to hold the engine speed within
the range specified above.
Propeller selection chart
Recommended full
throttle speed range
DF40 5200-5800 r / min
DF50 5900-6500 r / min
10
GENERAL INFORMATION 1-6
SPECIFICATIONS
Item Unit
Data
DF40T DF50T
DIMENSIONS & WEIGHT
Overall length (front to back) mm (in) 756 (29.8)
Overall width (side to side) mm (in) 382 (15.0)
Overall height S mm (in) 1263 (49.7)
L mm (in) 1390 (54.7)
Weight
(without engine oil)
S kg (Ibs) 106 (234)
L kg (Ibs) 109 (240)
Transom height S mm (in. type) 401 (15)
L mm (in. type) 528 (20)
PERFORMANCE
Maximum output kW (PS) 29.4 (40)
Recommended operating range r/min
Idle speed r/min
36.8 (50)
5200 – 5800 5900 – 6500
850 ± 50 (in-gear: approx. 850)
POWERHEAD
Engine type 4-stroke DOHC
Number of cylinders 3
Bore mm (in) 71.0 (2.80)
Stroke mm (in) 68.6 (2.70)
Total displacement cm3 (cu in) 815 (49.7)
Compression ratio : 1 10
Spark plug NGK DCPR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Remote control
PRE-FIX 04001F 05001F
11
1-7 GENERAL INFORMATION
Item Unit
Data
DF40T DF50T
FUEL & OIL
Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 ( 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 10W-40
Engine oil amounts
L (US/Imp. qt)
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
R + M
ml (US/Imp. oz)
Gear oil
Gearcase oil capacity
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
610 (20.6/21.5)
BRACKET
Trim angle PTT system
Number of trim position PTT system
Maximum tilt angle degree 73°
LOWER UNIT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 25 (2.27)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in.) × Pitch (in.)
These specifications are subject to change without notice.
S : Aluminum propeller
SS : Stainless steel propeller
3 × 11-1/2 × 9 (S900)
3 × 11-1/2 × 10 (S1000)
3 × 11-1/2 × 11 (S1100)
3 × 11-5/8 × 12 (S1200)
3 × 11-1/2 × 13 (S1301, SS1300)
3 × 11-3/8 × 14 (S1400, SS1400)
3 × 11-1/4 × 15 (S1500)
3 × 11-1/8 × 16 (S1600, SS1600)
3 × 11 × 17 (S1700)
12
GENERAL INFORMATION 1-8
SERVICE DATA
POWERHEAD
Recommended operating range r/min 5200 – 5800
Idle speed 850 ± 50 (in-gear: approx.850)r/min
5900 – 6500
**Cylinder compression 1300 – 1600 (13 – 16, 185 – 228)kPa (kg/cm2, psi)
**Cylinder compression max.
difference between any two
cylinders
100 (1.0, 14)
kPa (kg/cm2, psi)
**Engine oil pressure 300 – 380 (3.0 – 3.8, 43 – 54) at 4000 r/min
(at normal operating temp.)
kPa (kg/cm2, psi)
Engine oil
Engine oil amounts
L (US/Imp. qt)
Thermostat operating
temperature
48 – 52 (118 – 126)°C (°F)
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
** Figures shown are guidelines only, not absolute service limits.
Item Unit
Data
DF40T DF50T
13
1-9 GENERAL INFORMATION
Item Unit
Data
DF40T DF50T
ENGINE OIL PUMP
0.31 (0.012)mm (in)LimitRadial clearance
0.15 (0.006)mm (in)LimitSide clearance
CYLINDER HEAD / CAMSHAFT
0.05 (0.002)mm (in)Limit
Cam height mm (in) 37.530–37.690 (1.4776–1.4839) 38.230–38.390 (1.5051–1.5114)
Cylinder head distortion
0.10 (0.004)mm (in)LimitManifold seating
faces distortion
STD
Limit mm (in) 37.430 (1.4736) 38.130 (1.5012)
IN
mm (in) 37.740–37.900 (1.4858–1.4921) 37.740–37.900 (1.4858–1.4921)STD
Limit mm (in) 37.640 (1.4819) 37.640 (1.4819)
EX
0.045 – 0.087 (0.0018 – 0.0034)mm (in)Camshaft journal oil
clearance
STD
Limit 0.120 (0.0047)mm (in)
Camshaft
journal
(housing)
inside diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
23.000 – 23.021 (0.9055 – 0.9063)
23.171 (0.9122)
Camshaft
journal outside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
22.934 – 22.955 (0.9029 – 0.9037)
22.784 (0.8970)
0.10 (0.004)mm (in)LimitCamshaft runout
Cylinder head bore
to tappet clearance
0.025 – 0.062 (0.0010 – 0.0024)mm (in)STD
0.150 (0.0059)mm (in)Limit
Tappet outer
diameter 26.959 – 26.975 (1.0614 – 1.0620)mm (in)STD
27.000 – 27.021 (1.0630 – 1.0638)mm (in)STDCylinder head bore
14
GENERAL INFORMATION 1-10
VALVE / VALVE GUIDE
24.6 (0.97)mm (in)IN
Tappet clearance
(Cold engine
condition)
mm (in)
Valve diameter
STD
STD mm (in)
mm (in)STD
Limit mm (in)
0.045 – 0.072 (0.0018 – 0.0028)mm (in)STD
Limit 0.090 (0.0035)mm (in)
IN,EX mm (in)STD 5.500 – 5.512 (0.2165 – 0.2170)
Item Unit
Data
DF40T DF50T
21.5 (0.85)mm (in)EX
IN
EX
0.18 – 0.24 (0.007 – 0.009)
0.18 – 0.24 (0.007 – 0.009)
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
IN
EX
Valve guide to
valve stem
clearance
Valve guide inside
diameter
Valve seat angle IN
EX
30°, 45°
15°, 45°
IN,EX mm (in)STD 11.0 (0.43)Valve guide
protrusion
Valve stem
outside diameter
mm (in)STD
STD mm (in)
IN
EX
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
IN,EX mm (in)Limit 3.20 (0.126)Valve stem end
length
Valve stem end
deflection
mm (in)Limit
Limit mm (in)
IN
EX
0.14 (0.006)
0.18 (0.007)
IN,EX mm (in)Limit 0.05 (0.002)Valve stem runout
IN,EX mm (in)Limit 0.08 (0.003)Valve head radial
runout
Valve head
thickness
mm (in)STD
Limit mm (in)
IN
1.0 (0.04)
0.7 (0.03)
mm (in)STD
Limit mm (in)
EX
1.15 (0.045)
0.5 (0.02)
Valve seat
contact width
mm (in)STD
STD mm (in)
IN
EX
1.80 – 2.20 (0.071 – 0.087)
1.65 – 2.05 (0.065 – 0.081)
Valve spring free
length
33.1 (1.30)mm (in)STD
31.8 (1.25)mm (in)Limit
Valve spring tension 97 – 113 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in)N (kg, Ibs)STD
89 (8.9, 19.6) for 28.5 mm (1.12 in)N (kg, Ibs)Limit
Valve spring
sequareness 2.0 (0.08)mm (in)Limit
degree
degree
15
1-11 GENERAL INFORMATION
CYLINDER / PISTON / PISTON RING
0.060 (0.0024)mm (in)Limit
Piston ring
end gap
mm (in) 0.10 – 0.25 (0.004 – 0.010)
Cylinder distortion
Piston to cylinder
clearance
STD
Limit mm (in) 0.70 (0.028)
1st
mm (in) 0.25 – 0.40 (0.010 – 0.016)STD
Limit mm (in) 1.00 (0.039)
2nd
Item Unit
Data
DF40T DF50T
mm (in) 0.020 – 0.040 (0.0008 – 0.0016)STD
Limit mm (in) 0.100 (0.0039)
71.000 – 71.020 (2.7953 – 2.7961)mm (in)STDCylinder bore
50 (2.0) from cylinder top surfacemm (in)Cylinder measuring position
70.970 – 70.990 (2.7941 – 2.7949)mm (in)STDPiston skirt diameter
19 (0.7) from piston skirt endmm (in)Piston measuring position
0.100 (0.0039)mm (in)LimitCylinder bore wear
Piston ring
free end gap
mm (in) Approx. 7.5 (0.30)STD
Limit mm (in) 6.0 (0.24)
1st
mm (in) Approx. 11.0 (0.43)STD
Limit mm (in) 8.8 (0.35)
2nd
Piston ring
groove width
mm (in) 1.01 – 1.03 (0.040 – 0.041)1st
mm (in) 1.01 – 1.03 (0.040 – 0.041)
mm (in) 1.51 – 1.53 (0.059 – 0.060)
2nd
Oil
Piston ring to
groove
clearance
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
1st
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
2nd
Piston ring
thickness
mm (in) 0.97 – 0.99 (0.038 – 0.039)STD
STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
1st
2nd
Pin clearance in
piston pin hole
mm (in) 0.006 – 0.018 (0.0002 – 0.0007)STD
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
mm (in) 17.996 – 18.000 (0.7085 – 0.7087)STD
Limit mm (in) 17.980 (0.7079)
Piston pin hole
diameter
mm (in) 18.006 – 18.014 (0.7089 – 0.7092)STD
Limit mm (in) 18.040 (0.7102)
Pin clearance in
conrod small end
mm (in) 0.003 – 0.015 (0.0001 – 0.0006)STD
Limit mm (in) 0.050 (0.0020)
Conrod small end
bore
mm (in) 18.003 – 18.011 (0.7088 – 0.7091)STD
STD
STD
STD
16
GENERAL INFORMATION 1-12
Item Unit
Data
DF40T DF50T
CRANKSHAFT / CONROD
LOWER UNIT
Design specification thickness for shim & washer
Pinion gear back-up shim mm (in) 1.0 (0.04)
Forward gear back-up shim mm (in) 1.0 (0.04)
Forward gear thrust washer mm (in) 2.0 (0.08)
Reverse gear thrust washer mm (in) 2.0 (0.08)
Reverse gear back-up shim mm (in) 1.0 (0.04)
Conrod small end
inside diameter
Conrod big end oil
clearance
Conrod big end
inside diameter
Crank pin outside
diameter
Crank pin outside
diameter difference
(out of round and taper)
Conrod bearing
thickness
Conrod big end side
clearance
Conrod big end width
Crank pin width
Crankshaft center
journal runout
Crankshaft journal
oil clearance
Crankcase bearing
holder inside diameter
Crankshaft journal
outside diameter
Crankshaft journal
outside diameter
difference
(out of round and taper)
Crankshaft bearing
thickness
Crankshaft thrust
play
Crankshaft thrust
bearing thickness
18.003 – 18.011 (0.7088 – 0.7091)
0.020 – 0.040 (0.0008 – 0.0016)
0.065 (0.0026)
41.000 – 41.018 (1.6142 – 1.6149)
37.982 – 38.000 (1.4954 – 1.4961)
0.010 (0.0004)
1.486 – 1.502 (0.0585 – 0.0591)
0.100 – 0.250 (0.0039 – 0.0098)
0.350 (0.0138)
21.950 – 22.000 (0.8642 – 0.8661)
22.100 – 22.200 (0.8700 – 0.8740)
0.04 (0.002)
0.020 – 0.040 (0.0008 – 0.0016)
0.065 (0.0026)
49.000 – 49.018 (1.9291 – 1.9298)
44.982 – 45.000 (1.7709 – 1.7717)
0.010 (0.0004)
1.999 – 2.015 (0.0787 – 0.0793)
0.11 – 0.31 (0.004 – 0.012)
0.35 (0.014)
2.470 – 2.520 (0.0972 – 0.0992)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
mm (in)
STD
STD
Limit
STD
STD
Limit
STD
STD
Limit
STD
STD
Limit
STD
Limit
STD
STD
Limit
STD
STD
Limit
STD
17
1-13 GENERAL INFORMATION
ELECTRICAL
BTDC 0° – BTDC 32°Degrees at r/minIgnition timing
6500r/minOver revolution limiter
Item Unit
Data
DF40T DF50T
Ω at 20°CCKP sensor resistance
Ω at 20°CCMP sensor resistance
Ω at 20°CIgnition coil resistance Primary
k Ω at 20°CSecondary
Ω at 20°CBattery charge coil resistance
WattBattery charge coil output (12V)
NGKStandard spark plug Type
mm (in)Gap 0.8 – 0.9 (0.031 – 0.035)
AFuse amp. rating
Main fuse : 30
Fuel pump fuse : 15
Ah (kC)
Recommended battery
capacity (12V)
70 (252) or larger
Ω at 20°CFuel injector resistance
Ω at 20°CIAC valve resistance
k Ω at 25°C
IAT sensor/Cylinder temp. sensor
/ Ex-mani. temp. sensor
(Thermistor characteristic)
Ω at 20°CECM main relay resistance
Ω at 20°CStarter motor relay resistance
Ω at 20°CPTT motor relay resistance
1.8 – 2.3
80 – 120
3.5 – 5.1
3.0 – 4.5
STARTER MOTOR
30Sec.Max. continuous time of use
0.9kWMotor output
17.0 (0.67)mm (in)STDBrush length
10.0 (0.39)mm (in)Limit
0.5 – 0.8 (0.02 – 0.03)mm (in)STDCommutator
undercut 0.2 (0.01)mm (in)Limit
33.0 (1.30)mm (in)STDCommutator
outside diameter 32.0 (1.26)mm (in)Limit
0.05 (0.002)mm (in)STD
0.40 (0.016)mm (in)Limit
Pinion to ring gear gap 3.0 – 5.0 (0.12 – 0.20)STD mm (in)
Commutator outside
diameter difference
168 – 252
——
1.9 – 2.5
8.1 – 11.1
DCPR 6E
BTDC 0° – BTDC 25°
7000
0.56 – 0.84
216
11.0 – 16.5
21.5 – 32.3
18
GENERAL INFORMATION 1-14
SELF-DIAGNOSTIC SYSTEM INDICATION
When the abnormality occurs in a signal from sensor, switch etc., the “CHECK ENGINE” lamp on the
monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
PRIORITY
*
FAILED ITEM CODE LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM
ACTIVATING
1 MAP sensor 1 3 – 4
on off
YES
2 CKP sensor 4 – 2
on off
NO
3
IAC valve/By-pass air
screw adjustment 3 – 1
on off
NO
4 CMP sensor 2 – 4
on off
YES
5 CTP switch 2 – 2
on off
NO
6 Cylinder temp. sensor 1 – 4
on off
YES
7 IAT sensor 2 – 3
on off
YES
8
MAP sensor 2
(Sensor hose)
3 – 2
on off
NO
9 1 – 1
on off
NO
Rectifier & regulator
(Over-charging)
* If more than two items fail at once, the self-diagnostic indication appears according to priority order.
The indication repeats three times.
PTT MOTOR
9.8 (0.39)mm (in)STDBrush length
4.8 (0.19)mm (in)Limit
mm (in)STDCommutator outside
diameter mm (in)Limit
10 1 – 5
on off
YES
Exhaust manifold temp.
sensor
22.0 (0.87)
21.0 (0.83)
19
1-15 GENERAL INFORMATION
TIGHTENING TORQUE
Tightening Torque – Important Fasteners
ITEM
THREAD
DIAMETER
TIGHTENING TORQUE
kg-mN . m Ib.-ft.
Cylinder head cover bolt 6 mm 10 1.0 7.0
Cylinder head bolt 10 mm
Crankcase bolt 8 mm 25 2.5 18.0
Conrod cap nut 8 mm 35 3.5 25.5
Camshaft housing bolt 10 1.0 7.0
Camshaft timing sprocket bolt 10 1.0 7.0
Timing chain guide bolt 10 1.0 7.0
11 1.1 8.0
8 mm 23 2.3 16.5
Oil pressure switch 13 1.3 9.5
Intake manifold fuel main gallery 6 mm 10 1.0 7.0
35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 200 20.0 144.5
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt/nut 8 mm 23 2.3 16.5
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 10 mm 40 4.0 29.0
Upper mount cover bolt 8 mm 23 2.3 16.5
Lower mount nut 12 mm 60 6.0 43.5
12 mm 40 4.0 29.0
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Water pump case nut 6 mm 8 0.8 6.0
Gearcase bolt 8 mm 23 2.3 16.5
Propeller shaft bearing housing bolt 8 mm 17 1.7 12.5
Pinion nut 50 5.0 36.0
Propeller nut 18 mm 55 5.5 40.0
3-way joint bolt
Upper/lower plug
Front
Rear
10 mm 53 5.3 38.5
6 mm
60 6.0 43.5
Intake manifold bolt / nut
6 mm
6 mm
6 mm
12 mm
20
GENERAL INFORMATION 1-16
Tightening torque – general bolt
NOTE:
These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners”
table.
TYPE OF BOLT
THREAD
DIAMETER
TIGHTENING TORQUE
kg-mN . m Ib.-ft.
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
10 mm 22 – 35 2.3 – 3.5 16.0 – 25.5
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5
5 mm 3 – 6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5
(Conventional or “4” marked bolt)
(Stainless steel bolt)
(7 marked or marked bolt)
21
1-17 GENERAL INFORMATION
SPECIAL TOOLS
1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
17. 18. 19. 20.
21. 22. 23.
(A) 09900-06107
(B) 09900-06108
Snap ring pliers
09900-20205
Micrometer (0 – 25 mm)
09900-20701
Magnetic stand
09900-26006
Engine tachometer
(1) 09912-58442
Fuel pressure gauge
(2) 09912-58432
Fuel pressure hose
(3) 09912-58490
3-way joint & hose
09900-00410
Hexagon wrench set
09900-20101 (150 mm)
09900-20102 (200 mm)
Vernier calipers
09900-20508
Cylinder gauge set
(40 – 80 mm)
09900-20803
Thickness gauge
09900-28403
Hydrometer
09900-00411
Hexagon socket
(included in 09900-00410)
09900-20202
Micrometer (25 – 50 mm)
09900-20605
Dial calipers (10 – 34 mm)
09900-21304
Steel “V” block set
09921-29510
Driveshaft holder
09913-50121
Oil seal remover
09900-00413 (5 mm)
09900-00414 (6 mm)
Hexagon bit
(included in 09900-00410)
09900-20203
Micrometer (50 – 75 mm)
09900-20602
Dial gauge
09900-22302
(0.051 – 0.125 mm)
09900-22301
(0.025 – 0.076 mm)
Plastigauge
09919-16010
Deep socket wrench
09914-79410
Test wheel
(A)
(B)
(1)
(2)
(3)
22
GENERAL INFORMATION 1-18
24. 25. 26. 27.
28. 29. 31.
32. 33. 34. 35.
37. 38. 39.
40.
30.
41. 43.
46.
09915-47340
Oil filter wrench
09916-10911
Valve lapper
09916-54910
Handle (N-505)
09916-34550
Valve guide reamer
(φ 5.5 mm)
09916-14910
Valve lifter attachment
09917-87010
Valve guide installer
attachment
09915-64512
Compression gauge
09915-63210
Adaptor
09916-14510
Valve lifter
09916-20630
Valve seat cutter
(Neway 126)
09916-34542
Valve guide reamer handle
09916-57330
Valve guide installer
09915-77310
Oil pressure gauge
09916-24450
Solid pilot (N-100-5.52)
09916-20620
Valve seat cutter
(Neway 122)
09916-37320
Valve guide reamer
(φ 10.5 mm)
09916-77310
Piston ring compressor
09915-78211
Oil pressure gauge adapter
09916-24440
Handle adaptor
(N-503-1)
09916-44310
Valve guide remover
45.
36.
09916-20610
Valve seat cutter
(Neway 121)
09917-47011
Vacuum pump gauge
42.
09916-67010
Tappet holder
44.
09916-84511
Tweezers
47.
(A) 09922-59410
Propeller shaft housing
installer
(B) 09922-59420
Housing installer handle
(A) (B)
23
1-19 GENERAL INFORMATION
49. 50.
53. 54.
57. 58.
61. 62.
65. 66.
68. 69.
09930-30161
Propeller shaft remover
09930-48720
Flywheel holder
09930-89910
4-pin connector test cord
09930-99320
Digital tester
09944-08711
PTT cylinder cap tool
Pinion bearing
installer and remover
(A) 09951-59910
Pinion bearing installer
shaft
(B) 01500-08403
Bolt
(C) 09951-39914
Pinion bearing plate
(D) 09951-19431
Attachment
09930-30104
Sliding hammer
09930-76420
Timing light
09930-89920
6-pin connector test cord
09932-79910
Diagnostic harness
09950-69512
Gearcase oil leakage tester
(A) 18213-74F00
O2 sensor
(B) 18498-99E70
Protector
48.
09922-89810
Shift lock pin remover
52.
09930-39420
Rotor remover bolt
51.
09930-39411
Flywheel rotor remover
55.
56.
09930-89240
4-pin connector test cord
09930-89260
Injector test cord A
59.
60.
09930-89930
8-pin connector test cord
09930-89940
12-pin connector test cord
63.
64.
09940-44121
Air pressure gauge
09940-44130
Attachment
67.
09951-09511
Gear adjusting gauge
(A)
(B) (D)
(C)
(A)
(B)
70.
09930-88720
H.T cord adapter
24
GENERAL INFORMATION 1-20
72. 73 .
99954-53873*
Stevens CD-77
Peak reading voltmeter
99954-53883*
Gear oil filler
MATERIALS REQUIRED
SUZUKI OUTBOARD
MOTOR GEAR OIL
99000-22540
(400 ml × 24 pcs.)
*99000-25030
99000-25010
(500 g)
* 99104-33140
99000-31140
(100 g)
99000-25160
(250 g)
99000-32050
(50 g)
99000-31120
(50 g)
API : SE, SF, SG, SH, SJ
SAE : 10W-40
SUZUKI SUPER
GREASE “A”
WATER RESISTANT
GREASE
SUZUKI SILICONE
SEAL
SUZUKI BOND “1207B” THREAD LOCK “1342” 4-Stroke Motor Oil
NOTE:
* Marked part No. is in U.S. market only.
NOTE:
* Marked part No. is in U.S. market only.
71.
99954-53008-820*
Digital voltmeter
25
PERIODIC MAINTENANCE SCHEDULE _______________________ 2-1
PERIODIC MAINTENANCE CHART .............................................................. 2-1
MAINTENANCE AND TUNE-UP PROCEDURES _________________ 2-2
ENGINE OIL / ENGINE OIL FILTER ............................................................... 2-2
GEAR OIL ........................................................................................................ 2-5
LUBRICATION ................................................................................................. 2-6
SPARK PLUG .................................................................................................. 2-7
TAPPET CLEARANCE .................................................................................... 2-8
IDLE SPEED .................................................................................................... 2-14
IGNITION TIMING ............................................................................................ 2-15
BREATHER AND FUEL LINE ......................................................................... 2-16
LOW PRESSURE FUEL FILTER .................................................................... 2-16
HIGH PRESSURE FUEL FILTER ................................................................... 2-17
WATER PUMP / WATER PUMP IMPELLER................................................... 2-17
PROPELLER / NUT / COTTER PIN ................................................................ 2-17
ANODES AND BONDING WIRES .................................................................. 2-18
BATTERY ......................................................................................................... 2-19
BOLT AND NUTS ............................................................................................ 2-20
FUEL MIXTURE CHECK (O2 FEEDBACK) .................................................... 2-21
OIL PRESSURE ___________________________________________ 2-26
CYLINDER COMPRESSION _________________________________ 2-28
2
PERIODIC MAINTENANCE
CONTENTS
26
2-1 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
Item to be serviced
Initial 20 hrs.
or 1 month
Every 50 hrs.
or 3 months
Every 100 hrs.
or 6 months
Every 200 hrs.
or 12 months
Spark plug I R
Breather Hose & Fuel line
I II I
Replace every 2 years
Engine oil R RR
Gear oil R RR
Lubrication I II
Anodes & Bonding wires I II
Battery I II
Fuel mixture check
(O2 feedback)
Perform every 2 years.
Engine oil filter
Low pressure fuel filter
Replace every 400 hours or 2 years.
High pressure fuel filter Replace every 1000 hours.
Ignition timing I
Idle Speed II
Tappet clearance I
Water pump I
Propeller nut & pin I II
Bolt & Nuts T TT
RR
Water pump impeller R
I
— —





——
— ——












I II—
27
PERIODIC MAINTENANCE 2-2
MAINTENANCE AND TUNE-UP PROCEDURES
(2) Remove the motor cover.
(3) Remove the oil level dipstick and wipe it clean.
(4) Insert it fully into the dipstick hole, then remove it to check
oil level.
This section describes the servicing procedures for each of the
periodic maintenance requirements.
ENGINE OIL / ENGINE OIL FILTER
ENGINE OIL LEVEL CHECK
Inspect oil level before every use.
(1) Place the outboard motor upright on a level surface.
1
(5) Oil level should be between the full level line (Max.) and
low level line (Min.)
If the level is low, add recommended oil to full level line.
Recommended oil :
• 4 stroke motor oil
• API classification SE, SF, SG, SH, SJ.
• Viscosity rating SAE 10 W-40.
Full level
line
Low level
line
1Oil level dipstick
2Oil filler cap
2
28
2-3 PERIODIC MAINTENANCE
ENGINE OIL CHANGE / ENGINE OIL FILTER
REPLACEMENT
ENGINE OIL
Change initially after 20 hours (1 month) and every
100 hours (6 months) thereafter.
ENGINE OIL FILTER
Replace initially after 20 hours (1 month) and every
200 hours (12 months) thereafter.
NOTE:
• Engine oil should be changed while the engine is warm.
• When replacing the engine oil filter, change engine oil at the
same time.
1. Place the outboard motor upright on a level surface.
2. Remove the oil filler cap.
3. Place a container under the engine oil drain plug.
4. Remove the engine oil drain plug and gasket to drain engine oil.
!
"
5. ENGINE OIL FILTER REPLACEMENT
NOTE:
For engine oil change only, go to step 6.
To replace the engine oil filter :
(1) Remove the PORT side lower cover. (See page 7-1)
(2) Using oil filter wrench, loosen the oil filter.
09915-47340 : Oil filter wrench
NOTE:
Before fitting new oil filter, be sure to oil O-ring.
1Oil filler cap
1
1Oil drain plug 2Gasket
1
2
29
PERIODIC MAINTENANCE 2-4
(3) Screw new filter on by hand until the filter O-ring contacts the Mounting surface.
(4) Tighten the filter 3/4 turn from the point of contact with
the mounting surface using an oil filter wrench.
Engine oil filter : 14 N . m (1.4 kg-m, 10.0 lb.-ft.),
3/4 turn.
(5) Install the PORT side lower cover.
6. Install the gasket and the oil drain plug.
Tighten the engine oil drain plug to the specified torque.
Engine oil drain plug : 13N . m (1.3 kg-m, 9.5 lb.-ft.)
#
Do not re-use gasket. Always replace with a new gasket.
7. Pour recommended engine oil into the oil filler opening, then
install the oil filler cap.
Engine oil amounts
Oil change only : 2.2L (2.3 / 1.9 US / Imp. qt)
Oil filter change : 2.4L (2.5 / 2.1 US / Imp. qt)
8. Start the engine and allow it to run for several minutes at
idle speed.
Check oil filter for oil leakage.
Turn off the engine and wait for approx. two minutes, then
re-check the engine oil level.
$
$
Full level
line
Low level
line
30
2-5 PERIODIC MAINTENANCE
GEAR OIL
Change initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.
(1) Place the outboard motor upright on a level surface.
(2) Place a container under the lower unit.
(3) Remove the lower gear oil drain plug before the gear oil
level plug and drain the gear oil.
1
2
1 Oil level plug
2 Oil drain plug
(4) Fill with the recommended gear oil through the oil drain hole
until oil just starts to flow out from the oil level hole.
Gear oil amount : 610 ml ( 20.6 / 21.5 US / Imp. oz)
Recommended oil :
Suzuki Outboard Motor Gear Oil or SAE # 90
Hypoid gear oil
(5) Install the oil level plug before removing the oil filler tube
from the drain hole.
(6) Install the oil drain plug.
#
Do not re-use gaskets. Always use a new gasket.
NOTE:
To avoid insufficient injection of gear oil, check the oil gear 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.
31
PERIODIC MAINTENANCE 2-6
LUBRICATION
Inspect every 50 hours (3 months).
Apply Suzuki Water Resistant Grease to the following points.
99000-25160 : Water Resistant Grease%
Swivel bracket
Steering bracket
Propeller shaft
Throttle/Shift linkage
32
2-7 PERIODIC MAINTENANCE
Gap
SPARK PLUG
• Inspect every 100 hours (6 months).
• Replace every 200 hours (12 months).
Standard spark plug : NGK DCPR6E
#
Only resistor (R) type spark plugs must be used with
this engine. Using a non-resistor spark pligs will cause
ignition and fuel injection system malfunctions.
CARBON DEPOSIT
Check for a carbon deposit on the spark plug bases.
If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool.
SPARK PLUG GAP
Use a thickness gauge to measure for correct spark plug gap.
Adjust to within the specified range if the gap is out of specification.
Spark plug gap : 0.8 – 0.9 mm (0.031 – 0.035 in.)
09900-20803 : Thickness gauge
CONDITION OF ELECTRODE
Check the electrode for a worn or burnt condition.
If it is extremely worn or burnt, replace the spark plug.
Also, be sure to replace the plug if it has a broken insulator,
damaged thread, etc.
#
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.
Spark plug : 18 N . m (1.8 kg-m, 13.0 lb.-ft.)
!
$
33
PERIODIC MAINTENANCE 2-8
10
2
3
4
7
12
6
8 9
1
11
5
TAPPET CLEARANCE
Inspect initially after 20 hours (1 month) and every 200
hours (12 months) thereafter
The tappet clearance specification is the same for both intake
and exhaust valves.
Too small a tappet clearance may reduce engine power, too
large a tappet clearance increases valve noise and hastens
valve and seat wear.
When the tappets are set to the specified clearance, the engine
will run without excessive noise from the valve mechanism and
will deliver full power. In this engine, the tappet clearance is
increased or decreased by replacing the shim disc, made of a
special wear resistant material, fitted to the top of the tappet.
The shim discs are easy to remove and refit.
Tappet clearance adjustment must be checked and adjusted:
• at the time of periodic inspection
• when the valve mechanism is serviced
• when the camshafts are disturbed by removing them for inspection
CHECKING AND ADJUSTING TAPPET CLEARANCE
(1) Remove following parts :
• Engine side lower cover (see page 7-1)
• Flywheel cover
• Ignition coils
• Spark plugs
(2) Disconnect camshaft sensor lead 1.
(3) Remove fuel hose (intake and outlet)2.3 from low fuel
pump.
(4) Remove the twelve bolts securing the cylinder head cover
4 to the cylinder head and remove cylinder head cover.
34
2-9 PERIODIC MAINTENANCE
(5) Rotate crankshaft clockwise to bring cam nose vertical to
shim surface.
(6) Measure tappet clearances by inserting thickness gauge
between cam and shim surface.
Tappet clearance (cold engine condition) :
IN. : 0.18 – 0.24 mm (0.007 – 0.009 in.)
EX. : 0.18 – 0.24 mm (0.007 – 0.009 in.)
09900-20803 : Thickness gauge
#
Rotate crankshaft clockwise to prevent water pump
impeller damage.
NOTE:
• Rotate crankshaft and measure clearance for each tappet
respectively by bringing cam nose vertical to shim surface.
• All tappet clearances can be measured during two turns of
crankshaft.
(7) If out of specification, adjust tappet clearance by changing
shim.
90°
!
!
35
PERIODIC MAINTENANCE 2-10
(2) Rotate crankshaft to open (lift up) the valve and then remove camshaft housing bolts where the shim to be replaced.
(3) Install special tool with camshaft housing bolts as shown in
figure.
09916-67010 : Tappet holder
NOTE:
Index mark “IN” on the tappet holder is for intake side, while
“EX” is for exhaust side.
(4) Rotate top of cam 90 degree clockwise and remove shim
from cut-away at tappet.
(Two tappets can be adjusted at the same time)
#
• Do not put your finger between camshaft and tappet
while the tappet is being held with the tappet holder.
• Use a magnet to remove and install shim.
• When installing shim, identification mark on the shim
must face towards tappet side.
(5) After removing shim, measure thickness of original shim and
determine correct thickness of shim for proper tappet clearance as calculated by the following formula.
09900-20205 : Micrometer
A = B + (C – 0.20 mm)
A : Correct thickness of shim for proper tappet
clearance (mm)
B : Thickness of original shim (mm)
C : Original tappet clearance (mm)
1
2
!
1 Camshaft housing bolt
2 Plug hole
1 Magnet
2 Shim
1
2
1 Removed shim
1
!
!
1 Cut section of tappet
2 Plug hole
3 Shim
1
2
3
ADJUSTMENT
Tappet clearances are adjusted by replacing tappet shim.
(1) Close valve and turn tappet cut-away toward inside as shown
in figure.
2-11 PERIODIC MAINTENANCE
(6) Install shim. Identification number must face towards tappet.
(7) Rotate crankshaft to be open (lift up) valve.
(8) Remove tappet holder 1 and tighten camshaft housing bolts
to the specified torque.
Camshaft housing bolt :
10 N . m (1.0 kg-m, 7.0 lb.- ft.)
(9) Recheck tappet clearance.
NOTE:
After completing tappet clearance adjustment and securing
camshaft housing bolts, inspect tappet clearance again.
Thickness
(mm)I.D No.
218 2.18 246 2.46 274 2.74
220 2.20 248 2.48 276 2.76
222 2.22 250 2.50 278 2.78
224 2.24 252 2.52 280 2.80
226 2.26 254 2.54 282 2.82
228 2.28 256 2.56 284 2.84
230 2.30 258 2.58 286 2.86
232 2.32 260 2.60 288 2.88
234 2.34 262 2.62 290 2.90
236 2.36 264 2.64 292 2.92
238 2.38 266 2.66 294 2.94
240 2.40 268 2.68 296 2.96
242 2.42 270 2.70 298 2.98
244 2.44 272 2.72 300 3.00
1 Special tool
2 Tappet
3 Camshaft
1
2
3
!
Thickness
(mm)I.D No.
Thickness
(mm)I.D No.
$
2.50 mm
250
I.D No.
PERIODIC MAINTENANCE 2-12
INSTALLATION
After checking and adjusting all tappet clearances, install the
cylinder head cover. Installation is reverse order of removal.
(See page 6-8)
$ Cylinder head cover bolts :
10 N . m (1.0 kg-m, 7.0 lb.-ft.)
2-13 PERIODIC MAINTENANCE
21
8
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21
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28
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0
PERIODIC MAINTENANCE 2-14
IDLE SPEED
Inspect initially after 20 hours (1 month) and every 200
hours (12 months) thereafter.
NOTE:
• Before checking idle speed, the engine should be allowed to
warm up.
• Check and / or adjust idle speed after engine speed has stabilized.
!
(3) Start engine.
(4) Attach engine tachometer to the special tool.
09900-26006 : Engine tachometer
(5) Check engine speed.
Idle speed (in neutral gear) : 800 – 900 r / min
ADJUSTMENT :
If the idle speed is out of specification, adjust it as follows :
(6) Remove IAC hose from silencer case.
(7) To stop the air flow from the IAC passage, pinch the IAC
valve hose closed.
(8) Adjust the engine speed to approx. 800 r / min. by turning
the by-pass air screw.
Turning air screw clockwise :
Engine speed will decrease.
Turning air screw counterclockwise :
Engine speed will increase.
(1) Remove bolt and No.1 ignition coil.
(2) Connect special tool (H . T cord with plug cap adapter) between No.1 ignition coil and spark plug.
09930-88720 : H . T cord with plug cap adapter!
2-15 PERIODIC MAINTENANCE
NOTE:
The idling / trolling speed of 800 – 900 r / min. is controlled by
the IAC ( idle air control ) system.
If the engine speed does not return to specification, the IAC
passage (including the IAC hose and silencer) may be clogged
or the IAC system may not operating correctly.
See the “IDLE AIR CONTROL SYSTEM” section, 3-20.
NOTE:
Trolling speed (in-gear idle speed) is the same as idle speed.
(10) Reinstall parts removed earlier.
IGNITION TIMING
Inspect every 200 hours (12 months)
NOTE:
Before checking the ignition timing, make sure idle speed is
adjusted within the specification.
(1) Start the engine.
(2) Attach the timing light cord to the No.1 ignition coil primary
wire .
09930-76420 : Timing light
(3) Check the ignition timing while operating the engine at 1000
r / min.
Ignition timing : Approx. BTDC 7° at 1000 r / min.
!
(9) Release pinch, allowing air to the IAC valve, and recheck if
engine speed is stable at 800 – 900 r / min.
PERIODIC MAINTENANCE 2-16
BREATHER AND FUEL LINE
• Inspect initially after 20 hours (1 month) and every
50 hours (3 months) thereafter.
• Replace every 2 year.
If leakage, cracks, swelling or other damage is found, replace
the breather line and / or fuel line.
LOW PRESSURE FUEL FILTER
• Inspect every 50 hours (3 months).
• Replace every 400 hours or 2 years.
If water accumulation, sediment, leakage, cracks, or other damage is found, replace the fuel filter.
2-17 PERIODIC MAINTENANCE
HIGH PRESSURE FUEL FILTER
Replace every 1000 hours.
SUZUKI recommends that the high pressure fuel filter be replaced every 1000 operating hours.
WATER PUMP / WATER PUMP IMPELLER
WATER PUMP
Inspect every 200 hours (12 months).
Inspect case and under panel.
Replace If wear, cracks, distortion or corrosion is found.
WATER PUMP IMPELLER
Replace every 200 hours (12 months).
Inspect water pump impeller.
Replace if vanes are cut, torn or worn.
PROPELLER / NUT / COTTER PIN
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.
• Inspect the propeller for bent ,chipped or broken blades.
Replace propeller if damage noticeably affects operation.
• Inspect propeller splines. Replace propeller if splines are
worn or damaged.
• Inspect propeller bush for slippage.
Replace if necessary.
• Make sure the propeller nut and cotter pin are installed securely.
PERIODIC MAINTENANCE 2-18
ANODES AND BONDING WIRES
Inspect every 50 hours (3 months).
ANODES
If 2/3 of the zinc anode has corroded away, replace the anode.
#
Never paint the anode.
NOTE:
The anode securing bolt should be covered with Suzuki Silicone Seal.
99000-31120 : Suzuki Silicone Seal&
BONDING WIRES
• If breakage or other damage is found on the wire, replace the
wire.
• If rust, corrosion, or other damage is found on terminal, clean
with cleaning solvent or replace the wire.
NOTE:
The insulation washer must be installed between the terminal
and the motor body.
Anode &
Insulation washer
Bonding wire terminal
2-19 PERIODIC MAINTENANCE
BATTERY
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 the battery, disconnect
the negative (black) cable. Be careful not to cause a
short circuit by allowing metal objects to contact the
battery posts and the motor at the same time.
• Wear approved eye protection.
Recommended battery :
12 V 70 Ah (252 kC) or larger
CONNECTING BATTERY
Upon completion of connection, 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.
PERIODIC MAINTENANCE 2-20
BATTERY SOLUTION LEVEL CHECK
Battery solution level should be between the UPPER level and
LOWER level.
If the level is low, add distilled water only.
#
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.
BATTERY SOLUTION GRAVITY CHECK
Measure the gravity of battery solution using a hydrometer.
Battery solution gravity : 1.28 at 20°C
09900-28403 : Hydrometer
BOLT AND NUTS
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter
Check that all bolt and nuts listed below are tightened to their
specified torque.
!
ITEM
TIGHTENING TORQUE
N . m kg-m lb.-ft.
Cylinder head cover bolt 10 1.0 7.0
Intake manifold bolt / nut 11 1.1 8.0
23 2.3 16.5
6 mm
8 mm
Flywheel bolt
ECM ground bolt
Power unit mount bolt
Clamp bracket shaft nut 43 4.3 31.0
Gearcase bolt
Propeller nut 55 5.5 40.0
200 20.0 144.5
10 1.0 7.0
23 2.3 16.5
50 5.0 36.0
8 mm
10 mm
23 2.3 16.5
THREAD
DIAMETER
6 mm
6 mm
16 mm
22 mm
8 mm
18 mm
2-21 PERIODIC MAINTENANCE
FUEL MIXTURE CHECK (O2 FEEDBACK)
Perform every 2 years.
#
Before performing a fuel mixture check (O2 feedback),
the outboard motor must be checked to be sure that
it is free of any trouble codes or operational problems.
NOTE:
See “O2 FEEDBACK SYSTEM” section on page 3-32 before
starting O2 feedback operation.
There are two methods available for performing the O2 feedback operation :
(a) Using a personal computer and the Suzuki Diagnostic System software.
(Suzuki recommends using this method as it is possible to
monitor the feedback condition.)
(b) Using the diagnostic harness without a personal computer.
Refer to the “ Suzuki Diagnostic System operation manual” for
the “a” method procedure.
The “b” method procedure is as follows :
'
To prevent any sudden boat movement, the boat must
be securely moored to the dock while the test wheel
equipped engine is running in gear during the feedback test procedure.
1. Remove propeller and install a test wheel.
09914-79410 : Test wheel!
PERIODIC MAINTENANCE 2-22
2. Remove grommet 1 and stbd.lower side cover.
(See page 7-1)
3. Remove plug 2 from oil pump case and install the O2 sensor 3 and protector sleeve 4.
18213-74F00 : O2 sensor
18498-99E40 : Protector sleeve
#
The O2 sensor used for the feedback test procedure
must be in proper working order and installed securely.
If either sensor or installation is improper, the O2 feedback operation will be performed incorrectly and
could possibly result in engine operating problems.
NOTE:
• The O2 sensor is NOT WATERPROOF.
Cover O2 sensor with the protector sleeve to protect from water
spray.
• Cut off the protector (P/N 18498-99E40) to a length of 20 –
30 cm (7.8 – 11.8 in.). The O2 sensor must be completely
covered as shown.
4. Connect the diagnostic harness to both O2 sensor and engine harness connectors.
09932-79910 : Diagnostic harness
!
!
4
2-23 PERIODIC MAINTENANCE
5. Install stbd.side lower cover.
NOTE:
Route the diagnostic harness through clearance between remote control cable holder plate and side cover.
6. Make sure none of the six diagnostic harness single lead
wire connectors (located next to the diagnostic adapter plug)
are connected.
7. Install motor cover.
8. Warm up the engine until it is stable at idle speed, then shift
into forward.
NOTE:
The O2 feedback operation must be performed under engine
load.
Do not perform the O2 feedback operation using warm-up
lever without first shifting into forward gear.
9. Connect one of the diagnostic harnesses single Black lead
wires and the single Red lead wire together.
NOTE:
If engine stalls when doing step “9”, raise engine speed to slightly
higher than trolling before repeating step “9”.
Red
Black
PERIODIC MAINTENANCE 2-24
10. Adjust engine speed to 2500±100 r/min (ZONE 1) and hold
for a minimum of 20 seconds.
• If buzzer sounds for approx.3 seconds, the feedback operation at this ZONE was successfully finished.
Go to next step (ZONE 2).
• If no buzzer sounds within approx.2 minutes, the feedback operation at this ZONE failed.
Ignore this ZONE and proceed to next step (ZONE 2).
11. Repeat the procedure in step “10” at 3500±100 r/min (ZONE
2).
12. Repeat the procedure in step “10” at 4500±100r/min (ZONE
3).
13. If the feedback operation at any ZONE failed, repeat the
feedback operation at that ZONE.
14. Return the throttle to a full closed position only after the
feedback operation at all ZONEs has been successfully
finished.
NOTE:
Do not close throttle fully for more than 10 seconds while feedback operation is being performed.
This will cause the O2 feedback operation to finish with incomplete data.
15. Approximately 10 seconds after closing the throttle, the
buzzer will sound as follows:
• If the total feedback operation was successfully finished,
a series of short (0.5 sec.) buzzer sounds will be heard.
• If the total feedback operation failed, a series of long (3
sec.) buzzer sounds will be heard.
2-25 PERIODIC MAINTENANCE
16. When finished with the O2 feedback operation, disconnect
the diagnostic harness Black and Red lead wires.
17. If retrying feedback operation , repeat procedure used in
steps “6” and “9” through “16”.
NOTE:
Repeat the O2 feedback operation with a new O2 sensor if :
• The total feedback operation finished without returning the
throttle to a fully closing position.
• The total feedback operation failed repeatedly.
#
The O2 sensor is only used when performing the O2
feedback operation.
After O2 feedback operation is completed the original
plug must be installed in the oil pump case.
18. Assembly is reverse order of disassembly.
Red
Black
PERIODIC MAINTENANCE 2-26
If oil pressure is lower or higher than specification, the following
causes may be considered.
(See page 6-66 for oil passage locations)
Low oil pressure
• Clogged oil filter
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure
regulator
• Damage O-ring
• Combination of above items.
OIL PRESSURE
Oil pressure ( at normal operating temp. ):
300 - 380 kPa (3.0 - 3.8 kg/cm2, 43 - 54 psi.)
at 4000 r / min.
NOTE:
The figure shown above is a guideline only, not an absolute
service limit.
High oil pressure
• Using an engine oil of too
high viscosity
• Clogged oil passage
• Clogged oil pressure regulator
• Combination of above items
TEST PROCEDURE
(1) Check the engine oil level.
(2) Remove the PORT side lower cover.
(3) Remove the plug1 for oil pressure service port.
!
(4) Install the oil pressure gauge in place of service port.
09915-77310 : Oil pressure gauge
09915-78211 : Oil pressure gauge adapter
1
!
2-27 PERIODIC MAINTENANCE
(7) Attach engine tachometer to the special tool.
09900-26006 : Engine tachometer
(8) Start the engine and warm up engine as follow :
Summer : 5 min. at 2000 r / min.
Winter : 10 min. at 2000 r / min.
(9) After warming up, shift into forward gear and increase the
engine speed to 4000 r / min. then compare the pressure
indicated on the gauge to specifications.
(10) After testing, reinstall parts removed earlier. (plug, side
lower cover, etc.)
!
(5) Remove bolt and No.1 ignition coil.
(6) Connect special tool (H . T cord with plug cap adapter) between No.1 ignition coil and spark plug.
09930-88720 : H . T cord with plug cap adapter!
PERIODIC MAINTENANCE 2-28
'
Disconnect the safety lanyard from the emergency stop
switch prior to cranking the engine.
This will prevent any residual fuel discharged from the
cylinders being ignited by a spark discharge from the
ignition coil.
CYLINDER COMPRESSION
Cylinder compression :
Standard : 1300 – 1600 kPa (13 - 16 kg / cm2,
185 – 228 psi.)
Max. difference between any two cylinders :
100kPa (1.0 kg / cm2, 14 psi.)
NOTE:
Figures shown are guidelines only, not absolute service limits.
Low compression pressure can indicate one or more of the following :
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head gasket
TEST PROCEDURE
(1) Start engine and allow to warm up, then shut engine off.
(2) Remove the STBD / PORT engine side lower cover.
(3) Remove all spark plugs.
(4) Install the compression gauge into the plug hole.
09915-64512 : Compression gauge
09915-63210 : Compression gauge adaptor
(5) Disconnect the safety lanyard (switch plate) from the emergency stop switch.
(6) Disconnect the remote control throttle cable from the throttle
lever.
(7) Move and hold the throttle lever in the full-open position.
(8) While cranking the engine with the starter motor, note the
maximum compression pressure reading on the gauge for
each cylinder.
(9) Reinstall parts removed earlier. ( spark plug, side lower
cover, etc.)
!
ENGINE CONTROL SYSTEM STRUCTURE ____________________ 3-1
SYSTEM STRUCTURE 1 ................................................................................ 3-1
SYSTEM STRUCTURE 2 ................................................................................ 3-2
WIRING DIAGRAM FOR ENGINE CONTROL ............................................... 3-3
COMPONENTS FOR SYSTEM CONTROL ______________________ 3-4
ENGINE CONTROL MODULE (ECM) ............................................................ 3-4
ECM CONNECTORS / TERMINALS LAYOUT ............................................... 3-5
ECM INTERNAL STRUCTURE ....................................................................... 3-6
SENSOR AND SWITCH .................................................................................. 3-7
IGNITION SYSTEM ________________________________________ 3-11
IGNITION CONTROL SYSTEM ...................................................................... 3-11
ELECTRONIC FUEL INJECTION SYSTEM _____________________ 3-13
FUEL INJECTION CONTROL SYSTEM......................................................... 3-13
FUEL DELIVERY SYSTEM COMPONENTS .................................................. 3-15
FUEL PUMP CONTROL SYSTEM ................................................................. 3-18
AIR INTAKE COMPONENTS .......................................................................... 3-19
IDLE AIR CONTROL SYSTEM ....................................................................... 3-20
CAUTION SYSTEM ________________________________________ 3-22
OVER-REVOLUTION CAUTION SYSTEM ..................................................... 3-22
LOW OIL PRESSURE CAUTION SYSTEM.................................................... 3-23
OVERHEAT CAUTION .................................................................................... 3-24
LOW BATTERY VOLTAGE CAUTION SYSTEM ............................................. 3-25
SELF-DIAGNOSTIC SYSTEM ________________________________ 3-26
PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC
SYSTEM OPERATION .................................................................................... 3-26
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION ................... 3-28
FAIL-SAFE SYSTEM _______________________________________ 3-29
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM ............................ 3-29
OPERATING HOUR INDICATION SYSTEM _____________________ 3-30
START-IN-GEAR PROTECTION SYSTEM ______________________ 3-31
O2FEEDBACK SYSTEM_____________________________________ 3-32
INSPECTION _____________________________________________ 3-33
PRECAUTION ON SYSTEM INSPECTION .................................................... 3-33
INSPECTION FOR ECM CIRCUIT VOLTAGE ................................................ 3-33
INSPECTION FOR RESISTANCE .................................................................. 3-35
OTHER INSPECTION ...................................................................................... 3-36
TROUBLESHOOTING ______________________________________ 3-41
REMOVAL / INSTALLATION _________________________________ 3-47
FLYWHEEL / CKP SENSOR / CMP SENSOR ............................................... 3-47
OIL PRESSURE SWITCH ............................................................................... 3-50
3
ENGINE CONTROL SYSTEM
CONTENTS
3-1 ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM STRUCTURE
The DF40 / DF50 models employ an integrated control system which performs the control functions for fuel
injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine control module).
SYSTEM STRUCTURE 1
[Abbreviation]
ECM (Engine control module)
CKP (Crankshaft position)
CMP (Camshaft position)
MAP (Manifold absolute pressure)
IAT (Intake air temperature)
CTP (Closed throttle position)
IAC (Idle air control)
INPUT
(sensor / switch)
CONTROL
(ECM)
OUTPUT
(actuator etc.)
Fuel injection control system
IAT sensor
Cylinder temp. sensor
Exhaust manifold
temp. sensor
CTP switch
Neutral switch
O2 sensor (optional)
MAP sensor
CMP sensor
CKP sensor
Ignition control system
Idle air control system
Fuel pump control system
Caution system
Self-diagnostic system
Fail-safe system
Operating hour indication
system
Start-in-gear protection
system
O2 feedback system
Ignition coil
IAC valve
High pressure fuel
pump
Caution buzzer
Monitor-tachometer
Fuel injector
Starter motor
Oil pressure switch
ENGINE CONTROL SYSTEM 3-2
F
ue l t
an k P
rim
er b ul b Lo w p re ss ur e fu el f ilt
er Lo w p re ss ur e fu el p um p E
va po ra tio
n ho se F
ue l v ap or se pa ra to r F
ue l pr es su re re gu la to r B
re at he r h os e H
ig h pr es su re fu el pu m p H
ig h pr es su re fu el fil
te r C
M
P
se ns or D
el iv er y ga lle
ry F
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T
P
s w itc
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ypa ss ai r sc re w S
ile
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b od y IA
T
s en so r N
eu tr al sw itc
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C
v al ve M
A
P
s en so r C
K
P
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lte
rn at or (B
at te ry c ha rg e co il)
R
ec tif
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re gu la to r B
at te ry Ig ni tio
n sw itc
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C
M
m ai n re la y E
ng in e co nt ro l m
od ul e C
K
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K
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s en so r *O
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xh au st m an ifo
ld te m p. se ns or Ig ni tio
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yl in de r te m p. se ns or *
: O
2
S
en so r m us t be in st al le d w he n pe rfo
rm in g “O
2
fe ed ba ck o pe ra tio
n” o nl y. SYSTEM STRUCTURE 2
O
il pr es su re sw itc
h 3-3 ENGINE CONTROL SYSTEM
WIRING DIAGRAM FOR ENGINE CONTROL
Alternator
Battery
charge
coil
Spark plug
No.1
Cyl.
No.2
Cyl.
No.3
Cyl.
Ignition
coil
Fuel injector
No.1 Cyl.
No.2 Cyl.
No.3 Cyl.
CMP sensor
No.3
No.2
No.1
CKP
sensor
15A Fuse
FP
High press.
fuel pump
IAT sensor
Cyl. temp.
sensor
Ex-mani
temp.sensor
MAP sensor
CTP sw.
Oil press. sw.MonitortachometerBattery
M Neutral sw.
Bz Buzzer
Neutral
sw.
Remo-con box
Ignition sw.
30A
fuse
To PTT sw.
ECM
main
relay
Rectifier &
regulator
ENGINE
CONTROL
MODULE
Communication
connector
Stop
sw.
IAC valve
1
2
3
4
5
6
7
8
1
2
3
4
5
6
1
2
3
5
6
7
4 8
9
10
11
12
1
2
3
5
6
7
4 8
9
10
11
12
1
2
3
4
A4
A7
A8
E2
E4
E3
E1
B1
D1
D6
D3
C9
D2
D7
D8
D4
C2
C5
C3
C4
C6
C12
C7
D11
C8
C1
B2
D5
D9
D12
C11
C10
B5
B4
A
5
A
1
A
3
A
2
A
6
B
3
B
6
A
B
C
D
E
OIL
TEMP
C/E
REV
Gr Gr Gr Gr Gr Gr Gr Gr Gr Gr
Gr Gr O GBl
R
R
P
B
B B B B
B
B
B
G
W
O O
W W W
W
W
Gr Bl Br Br Gr Bl W
R
Y/B
G/W
G/Y
Bl/B
Bl/W
Y/G
Br Bl/R
P/B
B
O/Y
G/Y
R/Y
Bl/Y
B/G
B/R
Lg/R
V/W
Lg/W
Lg/B
B/W
B/W
P
B/W
R/W
W/B
R/B
O/G
R/W
B/Y
O/B
B/W
B/W
Y/G Y/G
Gr Br W
O
F
F
O
N
S
TA
R
T
P
U
S
H
Gr ENGINE CONTROL SYSTEM 3-4
COMPONENTS FOR SYSTEM CONTROL
ENGINE CONTROL MODULE (ECM)
The ECM sends signals to control the actuators based on the information inputs from each sensor / switch.
Major controls are as follows:
NAME OF CONTROL DESCRIPTION
Fuel injection control
NOTE:
The information related to the Caution system, Self-Diagnostic System, Operating hour indication system
and O2 feedback system are retained in ECM memory.
• Controls fuel injection amount and timing.
Ignition control • Controls ignition timing.
Idle air control • Controls idling/trolling speed by adjusting intake air amount through IAC
valve.
Fuel pump control • Controls high pressure fuel pump drive.
Caution system control • Informs operator of abnormal engine condition.
• Controls engine speed.
Self-diagnostic system
control
• Informs operator of sensor / switch malfunction.
Fail-safe system control • Allows operation during sensor/ switch malfunction.
Operating hour indication
system control
• Informs operator of total operating time in units of 50 hours.
Start-in-gear
protection system control
• Prevents engine start when shift is positioned in forward or reverse.
O2 feedback system
control
• Controls and performs O2 feedback operation using optional O2 sensor.
3-5 ENGINE CONTROL SYSTEM
ECM CONNECTORS / TERMINALS LAYOUT
ECM CIRCUITS
TERMI-
NAL
WIRE
COLOR
CIRCUIT
A1 Bl No.2 Ignition (–)
A2 B Ground for power source
A3 G No.3 Ignition (–)
A4 O/B No.1 Fuel injector (–)
A5 O No.1 Ignition (–)
A6 B Ground for power source
A7 B/Y No.2 Fuel injector (–)
A8 R/W No.3 Fuel injector (–)
B1 B/W Fuel pump (–)
B2 P/B Ground for ECM main relay
B3 B Ground for ECM
B4 B/R IAC valve solenoid (–)
B5 Gr ECM power source
B6 B Ground for ECM
C1 Bl/R Emergency stop switch
C2 Y/B Tachometer
C3 G/W CHECK ENGINE lamp
C4 G/Y TEMP lamp
C5 P REV-LIMIT lamp
C6 Bl/B OIL lamp
C7 Bl/W Buzzer
C8 Br Neutral switch
C9 V/W Ex-manifold temperature sensor
C10 Bl/Y PC communication
C11 R/Y PC communication
C12 O Buzzer cancel
TERMI-
NAL
WIRE
COLOR
CIRCUIT
D1 B/W Ground for sensors
D2 R Power source for MAP sensor
D3 Lg/W Cylinder temperature sensor
D4 Bl Oil pressure switch
D5 B/G O2 feed-back / PC communication
D6 Lg/B IAT sensor
D7 W MAP sensor
D8 Lg/R CTP switch
D9 G/Y PC communication
D10 — —
D11 Y/G Engine start switch (signal)
D12 O/Y PC communication
E1 R/W CKP sensor No.3
E2 O/G CMP sensor
E3 W/B CKP sensor No.2
E4 R/B CKP sensor No.1
A B C D E
ENGINE CONTROL SYSTEM 3-6
A
8
B
5
B
2
B
6
B
3
D
2
D
7
D
6
D
3
D
8
D
5
D
1
F N
R
D
4
E
4
E
3
E
1
E
2
C
1
C
8
C
9
C
12 D
11
5V
12
V
P
U
S
H
S
T
O
FF
O
N
IN
O
U
T
A
4
A
7
B
1
F
/P
B
4
C
7
C
6
C
5
C
4
C
3
C
2
A
5
A
1
A
3
A
2
A
6
B
Z
In je ct or N
o. 3
In je ct or N
o. 1
In je ct or N
o. 2
F
ue l p
um p IA
C
v al ve Ig ni tio
n sw .
M
A
P
se ns or N
eu tra
l sw .
E
x, m an i, se ns or IA
T
s en so r C
T
P
s w itc
h O
il pr es su re s w itc
h C
K
P
s en so r N
o. 1 C
K
P
se ns or N
o. 3
C
K
P
s en so r N
o. 2
C
M
P
se ns or E
m er ge nc y st op s w itc
h R
ec tif
ie r &
r eg ul at or F
ly w he el C
yl .te
m p. se ns or 12
V
B
at te ry B
uz ze r C
an ce l sw .
E
C
M
m ai n re la y P
ow er S
ou rc e ci rc ui t C
P
U
E
C
M
B
uz ze r O
il la m p T
E
M
P
la m p Ta ch om et er Ig n. c oi l #
1
Ig n. c oi l #
2
Ig n. c oi l #
3
C
H
E
C
K
E
N
G
IN
E
la m p R
E
V-
LI
M
IT
la m p ECM INTERNAL STRUCTURE
3-7 ENGINE CONTROL SYSTEM
SENSOR AND SWITCH
CKP (Crankshaft Position) SENSOR
There are three (3) CKP sensors installed below the flywheel
rotor.
When the reluctor bar on the flywheel passes the sensors, a
signal (voltage pulse) is generated and sent to the ECM.
This is the fundamental signal used to judge the engine speed
and crankshaft angle.
CMP (Camshaft Position) SENSOR
A CMP sensor mounted on the cylinder head cover and a
reluctor bar pressed onto the end of the intake camshaft are
used to detect piston position. The signal from this sensor is
received by the ECM which uses it to determine sequential fuel
injection control.
The CMP sensor contains a “Hall Effect” semiconductor and a
magnet. The semiconductor generates a voltage in proportion
to the line of magnetic force passed through it. When the single
trigger vane on the camshaft reluctor aligns with the sensor’
internal magnet, a large amount of magnetic force is generated
allowing a high voltage to pass through the semiconductor. When
the trigger vane moves away from the sensor, no magnetic force
is generated and low voltage passes through the semiconductor.
These generated voltages are rectified to create “ON” (high
voltage) & “OFF” (low voltage) signals for ECM. The “ON” voltage signal indicates the position of #1 piston. The position of #2
and #3 pistons, “OFF” signal, follow in firing sequence order
based on the now established position of #1 piston.
“Hall Effect”
semiconductor
Camshaft
Trigger vane
Magnet
CMP sensor High voltage
Low voltage
ENGINE CONTROL SYSTEM 3-8
IAT (Intake Air Temperature) SENSOR
The IAT sensor is installed on the bottom of the air silencer and
used to detect the intake air temperature.
This sensor is the same type as the cylinder temperature sensor, and inputs a signal to the ECM as a voltage value.
This input signal is used to compensate the fuel injection time
duration.
MAP (Manifold Absolute Pressure) SENSOR
The MAP sensor is installed on the intake manifold and used to
detect the intake manifold pressure. It also detects the barometric pressure before starting the engine. This sensor inputs
the intake manifold pressure to the ECM as a voltage value.
This input signal is used as the fundamental signal to determine the fuel injection time duration, ignition timing, etc.
CYLINDER TEMPERATURE SENSOR
The cylinder temperature sensor is installed on the cylinder (top
side) and used to detect the cylinder temperature.
This is a thermistor type sensor (resistance of which changes
depending on the temperature) and inputs a signal to the ECM
as a voltage value. This input signal is used to compensate the
fuel injection time duration, ignition timing, etc.
This sensor is also used to detect engine over-heat as the ECM
detects both the temperature and temperature change gradient
(temperature rise Vs time).
R
es is ta nc e (kΩ)
(°C)Temperature
EXHAUST MANIFOLD TEMPERATURE SENSOR
The exhaust manifold temperature sensor is installed on the
exhaust manifold and used to detect the exhaust manifold temperature. This sensor is the same type as the cylinder temperature sensor, and inputs a signal to the ECM as a voltage value.
This input signal is used to detect engine over-heat.
3-9 ENGINE CONTROL SYSTEM
NEUTRAL SWITCH
The neutral switch is installed on the cylinder block (PORT side)
and used to detect the shift position.
This switch is “ON” in neutral and “OFF” in forward or reverse.
The ECM detects shift position and performs the following controls :
• Fuel injection is not performed when the shift is in forward or
reverse at the time of engine start.
(Start-in-gear protection. See page 3-31)
• When the shift is in neutral, fuel injection is controlled so that
the engine speed does not exceed 3000 r/min.
• When the shift is in neutral, if the engine speed exceeds 1200
r/min, the ignition timing is fixed at BTDC 9°.
• For two seconds after shifting into forward or reverse from
neutral, the IAC valve is controlled so that intake air increases
to prevent unstable engine idle or stalling.
ECM MAIN RELAY
The ECM main relay is installed in the electric parts holder.
When energized by the turning ignition switch ON, it forms the
circuit which supplies battery voltage to the ECM, injector, ignition coil, IAC valve, CMP sensor and high pressure fuel pump.
CTP (Closed Throttle Position) SWITCH
The CTP switch is installed on the top of throttle body and used
to detect whether the throttle is fully closed or not.
This switch inputs the signal to the ECM. The ECM detects the
throttle position and determines the control modes for various
control system (idle air control, ignition timing control, etc.).
ENGINE CONTROL SYSTEM 3-10
O2 SENSOR (Optional item)
The O2 sensor is installed in the exhaust manifold only when
the O2 feedback operation is performed.
This sensor is a zirconia element (platinum plated) the output
voltage of which changes depending on the oxygen concentration. The voltage change reflects the concentration of the oxygen in the exhaust gas and is used to perform the O2 feedback
operation.
The terminal voltage change (0 – 1 V) is dependent on the concentration of oxygen in the exhaust gas.
This detected voltage value therefore represents the oxygen
concentration. The terminal voltage decreases when the oxygen concentration is high, and increases when it is low.
NOTE:
As the zirconia element is not conductive below 250°C, the O2
sensor will not function properly until the engine is at normal
operating temperature.
NOTE:
Zirconia element
The zirconia element produces a potential difference (voltage)
when there is a difference in the oxygen concentration of the
gases which contact the two sides of the element.
Since the inner surface of the zirconia element (inside the sensor) is exposed to atmospheric air and the outer surface exposed to the exhaust gas, there is a difference in oxygen concentration on each side and thus a difference in the potential
generated.
Zirconia element
Housing
3-11 ENGINE CONTROL SYSTEM
IGNITION CONTROL SYSTEM
OUTLINE
Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM.
Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition
coils.
IGNITION SYSTEM
The ignition system used by the DF40/DF50 is a fully transistorized, electronic microcomputer timing advanced type.
On this system, power is totally supplied from the battery with the ECM controlling all ignition timing functions.
The ignition system is composed of the ignition coil, spark plug and components for system control (ECM,
sensor,switch etc.)
When the ignition switch is “ON”, battery voltage (12V) is applied to the circuit as shown in the illustration.
At the calculated time of ignition, the transistor in the ECM turns “OFF”, breaking the ground circuit.
In this way, a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated.
Basic sensors
Compensating sensors
Others
Spark plug
MAP sensor :
Informs ECM of intake manifold pressure.
CKP sensor :
Informs ECM of engine speed and crankshaft angle.
Cylinder temperature sensor :
Informs ECM of cylinder temperature.
CTP switch :
Informs ECM of throttle position (open / closed).
Ignition switch :
Informs ECM of “START” signal.
Ignition timing is determined by
a digital map designed in relation to intake manifold pressure and engine speed.
ECM
Signal
Ign.coil
Signal
Ign.coil
Signal
Ign.coil
(Voltage)
Spark timing
12V
A terminal voltage (Time)
Sensor/switch
signal input
ECM
CPU
ECM
main
relay
Ignition
switch
Battery
30A fuse
Rectifier &
regulator
Battery
charge
coil
Ignition
coil
Spark
plug
Ignition timing compensation.
Multi-point sequential timing
CMP sensor :
Informs ECM of camshaft angle.
ENGINE CONTROL SYSTEM 3-12
CONTROL MODE
WHEN CRANKING :
The ignition timing is fixed at BTDC 7° until the engine starts.
WHEN IDLING / TROLLING :
The ignition timing is controlled to within the range of BTDC 5° to 13° to provide stable engine operation at the
specified idling / trolling speed.
When the shift lever is in neutral, if engine speed exceeds 1200 r / min , ignition timing remains fixed at BTDC
9°.
WHEN RUNNING (NORMAL OPERATION) :
The ignition timing ranges between BTDC 0° – 32° (DF40) or 25° (DF50), depending on current engine
operating conditions.
WHEN DECELERATING :
When the throttle valve is closed suddenly, turning the CTP switch “ON”, ignition timing is delayed for a
programmed duration to prevent engine stalling or unstable running.
IGNITION TIMING CHART
The following chart is an example for ignition at BTDC30°.
SPECIFICATION
Ignition system Full-transistorized ignition
Advance Electronic microcomputer control
Ignition timing DF 40 : BTDC 0° – 32°, DF 50 : BTDC 0° – 25°
Firing order 1 – 3 – 2
CKP Sensor Signal 1
CKP Sensor Signal 2
CKP Sensor Signal 3
CMP Sensor Signal
#1 Ignition Signal
#3 Ignition Signal
#2 Ignition Signal
In.: Intake, Cm.: Compression, Ep.: Explosion Ex.: Exhaust
BTDC 65° on #1 exhaust stroke
120° 120° 120° 60°
30°
30°
ON
OFF
Spark timing
TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
In. Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex.
Cm.In.Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. E
Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. In.
3-13 ENGINE CONTROL SYSTEM
ELECTRONIC FUEL INJECTION SYSTEM
The fuel injection system used by the DF40/50 is a speed-density, multi-point, sequential, electronic fuel
injection type.
The fuel injection system is composed of the fuel line components, air intake components , and components
for system control (ECM,sensors, switches, etc.).
FUEL INJECTION CONTROL SYSTEM
OUTLINE
The sensors monitor current engine condition and send signals to the ECM. Based on these signals, the ECM
determines the optimum fuel injection time duration (fuel amount) and fuel injection timing (multi- point sequential timing) and controls the injector operating signals accordingly.
Fuel injection start timing is set at BTDC 545° on exhaust stroke constant.
Basic sensors
Compensating sensors
Injector
MAP sensor :
Informs ECM of intake manifold pressure.
CKP sensor :
Informs ECM of engine speed and crankshaft angle.
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
Fuel injection time duration
(amount) is determined by
a digital map designed in
relation to intake manifold
pressure and engine speed.
ECM
Fuel amount compensation
Others
CMP sensor:
Informs ECM of camshaft angle.
CTP switch:
Informs ECM of throttle position (open / closed).
IAT sensor:
Informs ECM of intake air temperature.
MAP sensor:
Informs ECM of barometric pressure at time of engine starting.
Battery voltage:
Multi-point sequential timing
Signal Signal Signal
Battery
charge
coil
Rectifier &
regulator
Battery
Ignition
switch
30A fuse
ECM
main
relay
ECM
CPU Sensor/switch
signal input
Injector A terminal voltage
(Time)
12V
(Voltage)
Injection time
duration
Neutral switch:
Informs ECM of shift position (neutral or not).
ENGINE CONTROL SYSTEM 3-14
CONTROL MODE
BEFORE START :
When the ignition switch is turned “ON”, the ECM receives a MAP sensor signal, indicating the static barometric pressure of the intake manifold, which is used to compensate the fuel injection map for altitude.
WHEN CRANKING :
Fuel is simultaneously injected to all cylinders every time any piston is positioned at compression stroke.
AFTER START (FAST-IDLE FUNCTION):
The fuel injection amount is controlled to increase until the timer, set according to cylinder temperature at the
time of engine start, expires.
WHEN IDLING / TROLLING :
The fuel injection amount is controlled to maintain a stable engine speed at the specified idle / trolling rpm.
WHEN ACCELERATING :
The fuel injection amount is controlled to increase.
WHEN DECELERATING :
The fuel injection amount is controlled to decrease.
The fuel injection is also cut off on very rapid engine deceleration.
FUEL INJECTION TIMING CHART
CKP Sensor Signal 1
CKP Sensor Signal 2
CKP Sensor Signal 3
CMP Sensor Signal
#1 Injection Signal
#3 Injection Signal
#2 Injection Signal
In.: Intake, Cm.: Compression, Ep.: Explosion Ex.: Exhaust
BTDC 65° on #1 exhaust stroke
120° 120° 120° 60°
30°
ON
OFF
Injection time duration
TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
In. Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex.
Cm.In.Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. Ep.
Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. In.
120°
BTDC 545° on #1
exhaust stroke
3-15 ENGINE CONTROL SYSTEM
FUEL DELIVERY SYSTEM COMPONENTS
The fuel delivery system is composed of the low pressure line components (fuel tank, filter , pump etc.), fuel
vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the
fuel vapor separator), fuel injector and hoses.
Fuel is supplied through the primer bulb, low pressure fuel filter, and low pressure pump to the fuel vapor
separator.
Fuel flow from the fuel vapor separator is pressurized by the high pressure fuel pump and supplied through
the high pressure fuel filter and fuel delivery gallery to the fuel injectors.
The pressure regulator maintains fuel pressure in the feed line between the high pressure fuel pump and fuel
injector.
This pressure , maintained at a constant level, is higher than the pressure in the vapor separator chamber.
When fuel feed line pressure exceeds vapor separator chamber pressure by more than approx. 255 kPa
(2.55 kg/cm2, 36.3 psi.), the valve in the fuel pressure regulator will open and return the excess fuel to the
vapor separator chamber.
Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals supplied
from the ECM.
Exhaust
manifold
Fuel injector
Throttle body
Intake
manifold
Silencer
Fuel tank
Primer bulb
Low pressure
fuel filter
Low pressure
fuel pump
Evaporation
hose
Fuel
vapor
separator
Fuel
pressure
regulator
High
pressure
fuel pump
Breather
hose
High
pressure
fuel
filter
Delivery
gallery
ENGINE CONTROL SYSTEM 3-16
FUEL VAPOR SEPARATOR
The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator
chamber.
As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump.
The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel
returned from the fuel pressure regulator.
This vapor is routed through the evaporation hose connecting the vapor separator cover to the air inlet cover
over the flywheel.
HIGH PRESSURE FUEL PUMP
The high pressure fuel pump is an “integral” type in which the pump mechanism is located within the fuel
vapor separator.
To supply the optimum fuel amount, the pump is driven by the duty cycle signal from ECM.
Fuel outlet
Evaporation
Fuel inlet
Water inlet
(For cooling Fuel)
Water outlet Fuel drain
Fuel return
Fuel pressure
regulator
Suction
filter
High pressure
fuel pump
Float
Needle valve
Valve seat
3-17 ENGINE CONTROL SYSTEM
FUEL PRESSURE REGULATOR
The fuel pressure regulator is located in vapor separator.
The regulator’ function in the system is to maintain a constant fuel pressure relative to the injector while the
engine is operating.
The regulator diaphragm chamber is open to the vapor separator chamber to keep the pressure balanced.
Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in vapor separator
chamber by approx. 255 kPa (2.55 kg/cm2, 36.3 psi.).
By-pass fuel is returned back to the fuel vapor separator chamber.
FUEL INJECTOR
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the
solenoid coil is energized pulling up the plunger.
This opens the injector needle valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel
injected is determined by the amount of time (duration) the valve
is open.
Solenoid coil
Filter
Fuel inlet
Needle valve
Plunger
Fuel inlet
Filter
VALVE CLOSED
(below 255 kPa)
VALVE OPENED
(over 255 kPa)
from Delivery linefrom Delivery line
To Vapor separator
chamber
(Fuel return)
ENGINE CONTROL SYSTEM 3-18
FUEL PUMP CONTROL SYSTEM
OUTLINE
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated ON/ OFF
signal, at a specified rate (1000 times a second).
Based on engine speed and battery voltage, the ECM determines the optimum duty (repeating “ON” time rate
within a cycle) and sends this signal to the fuel pump.
CONTROL MODE
BEFORE START :
For 3 seconds after ignition switch is turned “ON”, the pump is controlled to operate at 100% duty in order to
initially pressurize the high pressure line.
WHEN CRANKING :
The pump is controlled to operate at 100% duty.
WHEN RUNNING (NORMAL OPERATION) :
The pump is controlled to operate at 80 – 90% duty based on the current engine speed and battery voltage.
CKP sensor :
Informs ECM of engine speed.
Battery voltage :
Ignition switch :
Informs ECM of “START” signal.
ECM
Fuel pump
Signal FP
ECM
CPU
Sensor / switch
signal input
FP
Fuel pump
15A
fuse
Ignition
switch
Battery
30A fuse
Rectifier &
regulator
Battery
charge
coil
ECM
main
relay
Duty cycle signal for fuel pump
(example : 80% duty)
“ON” time
1 cycle time
× 100 = duty (%)
OFF
ON
0.8 ms
Time
1 ms (1cycle)
3-19 ENGINE CONTROL SYSTEM
AIR INTAKE COMPONENTS
Air, after entering through the silencer, passes through the throttle body and flows into the surge tank where
it is then distributed to the cylinder intake manifold.
Intake manifold pressure, monitored by the MAP sensor, is an indirect measure of the intake air amount.
When the throttle is fully closed, the main supply of intake manifold air necessary to sustain engine idle
passes through the by-pass air passage.
To maintain engine idle speed at specification, the ECM controlled IAC valve supplies a regulated amount of
additional air through the IAC (idle air control) passage.
THROTTLE BODY
The throttle body assembly consists of the main bore, throttle
valve, by-pass air passage, IAC passages, by-pass air screw
and CTP switch.
The throttle body adjusts the intake air amount with the throttle
valve which is connected to the throttle / linkage lever.
The CTP (closed throttle position) switch installed on the top of
throttle body informs of throttle valve position.
NOTE:
Do not try to adjust or remove any of the throttle body component parts (CTP switch, throttle valve, throttle / linkage lever,
etc.).
These components have been factory adjusted to precise specifications.
AIR FLOW
(Plunger)
IAC valve
Through passage
in flywheel cover
Silencer
IAC valve silencer
Flame arrester
By-pass air
passage
By-pass air
screw
Throttle body
Intake manifold
IAC passage
MAP sensor
Gas filter
(Surge tank)
ENGINE CONTROL SYSTEM 3-20
BY-PASS AIR SCREW / PASSAGE
Since the throttle valve is almost fully closed when idling/ trolling, the main flow of air necessary to maintain idling / trolling
speed passes through the by-pass air passage.
The by-pass air adjustment screw controls the flow of air through
the passage and provides a means of partially adjusting the
total amount of air necessary for idling / trolling.
NOTE:
See page 2-14 for the by-pass air screw adjustment procedure.
IAC VALVE / PASSAGE
The IAC valve is a solenoid plunger type mounted on the electrical parts holder.
Its purpose is to control the amount of intake air flowing from
the IAC passage.
The IAC valve is driven by the duty cycle signal from the ECM.
IDLE AIR CONTROL SYSTEM
OUTLINE
The ECM controls the duty cycle signal of the IAC valve to regulate a portion of the intake air flow to the intake
manifold.
This system is used for the following purposes:
• To keep idling / trolling at the specified speed.
• To improve driveability when decelerating.
(Dash-pot effect)
• To improve engine starting and warm-up performance.
(Fast-idle function)
The sensors / switch shown below monitor current engine condition and send signals to the ECM. Based on
these signals, the ECM determines the optimum duty cycle (repeating “ON” time rate within a cycle).
A repeating ON/OFF signal at a specified rate (10 times a second) is then sent to the IAC valve.
CKP sensor :
Informs ECM of engine speed.
ECM
Signal
IAC valve
MAP sensor :
Informs ECM of intake manifold pressure.
CTP switch :
Informs ECM of throttle position (open/closed).
Cylinder temp. sensor :
Informs ECM of cylinder temperature.
3-21 ENGINE CONTROL SYSTEM
CONTROL MODE
BEFORE START:
The IAC valve is always closed when engine is not running. (0% duty)
WHEN CRANKING :
The IAC valve is controlled to operate at 100% duty.
AFTER START ( FAST-IDLE FUNCTION ) :
The IAC valve is controlled to operate at 100% duty until the timer, which was set according to cylinder
temperature at cranking, expires.
WHEN IDLING / TROLLING :
The IAC valve is controlled so that the engine speed is stable at the idling / trolling speed specified.
During this period, the IAC valve has a duty cycle of approx. 20% but will vary slightly as idling / trolling
conditions change.
WHEN RUNNING ( NORMAL OPERATION ) :
The IAC valve is controlled to operate at 20 – 100% duty, which depends on the current engine conditions.
WHEN DECELERATING ( DASH-POT EFFECT):
When the throttle valve is suddenly returned to full close and the CTP switch signal changes to “ON”, the IAC
valve operates at a controlled gradual return to idle / troll operating duty to prevent engine stalling or unstable
running.
NOTE:
Due to the limited intake air flow from the IAC passage and in order to effectively use both the “Dash-pot
effect” and “Fast-idle function”, the by-pass air screw must be adjusted to provide IAC valve operation at 20 ±
5% duty at the engine idling / trolling specification.
See page 2-14 for the by-pass air screw adjustment procedure.
ECM
CPU
Sensor / switch
signal input
IAC valve
Ignition
switch
Battery
30A fuse
Rectifier &
regulator
Battery
charge
coil
ECM
main
relay
Duty cycle signal for IAC valve
(example : 20% duty)
“ON” time
1 cycle time
× 100 = duty (%)
20 ms
Time
100 ms (1cycle)
OFF
ON
ENGINE CONTROL SYSTEM 3-22
CAUTION SYSTEM
The following four caution systems alert the operator when an
abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
• OVERHEAT CAUTION
• LOW BATTERY VOLTAGE CAUTION
CAUTION
TYPE
CAUTION
LAMP
CAUTION
BUZZER
OVER-REV
LIMITER
(3000 r/ min)
Over-revolution Yes 1 No Yes
Low oil pressure Yes 2(1) Yes Yes
Overheat Yes 3(1) Yes Yes
Yes 4 Yes NoLow battery voltage
1 “REV LIMIT” lamp
2 “OIL” lamp
3 “TEMP” lamp
4 “CHECK ENGINE” lamp
MONITOR-TACHOMETER
1
23
4
OVER-REVOLUTION CAUTION SYSTEM
CONDITION:
When the engine speed exceeds 6500 r/min(DF40) or 7000 r/min (DF50), the ECM initiates an intermittent
fuel injection signal to provide a 6500 r/min or 7000 r/min maximum. (Over-revolution limiter)
ACTION:
RESET :
Close throttle to reduce engine speed below approx. 3000 r/min for one second.
Engine speed Automatically reduced to approx. 3000 r/min by intermittent fuel injection signal.
Caution lamp “REV-LIMIT” lamp lights continuously.
Caution buzzer No buzzer sounds.
3-23 ENGINE CONTROL SYSTEM
LOW OIL PRESSURE CAUTION SYSTEM
CONDITION :
Immediate activation of system when the oil pressure switch turns “ON” due to an engine oil pressure drop
below 100 kPa ( 1.0 kg / cm2, 14 psi.).
ACTION :
Engine speed Automatically reduced to approx. 3000 r/min by intermittent fuel injection signal if the
system is activated at 3000 r/min or higher.
Caution lamp “ OIL ” lamp lights continuously.
“ REV-LIMIT ” lamp lights continuously during engine speed rev-limiter activation.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.
RESET :
Stop engine and check engine oil level. Refill engine oil to the correct level if below the low oil mark.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity.
• Malfunctioning oil pressure switch.
• Clogged oil strainer or oil filter.
• Worn oil pump relief valve.
• Oil leakage from the oil passage.
• Excessive wear / damage of oil pump
NOTE:
The low oil pressure caution system is reset when the oil pressure is restored to over 1.0kg/cm2 with approx.
3000 r/min or less engine speed operation.
However, the engine must be stopped and checked immediately once the system is activated.
ENGINE CONTROL SYSTEM 3-24
OVERHEAT CAUTION SYSTEM
CONDITION 1 (Maximum temperature)
Immediate activation of system when :
• Cylinder temperature reaches 121°C
• Exhaust manifold temperature reaches 121°C
CONDITION 2 (Temp. rise Vs Time)
Immediate activation of system when :
• The average temperature difference during three consecutive 10 second measurement periods of the cylinder temperature sensor at engine speeds of 500 r/min or higher exceeds the limits as shown below.
• The average temperature difference during three consecutive 10 second measurement periods of the exhaust manifold temperature sensor at engine speeds of 500 r/min or higher exceeds the limits shown
below.
ACTION :
Engine speed Automatically reduced to approx. 3000 r/min by intermittent fuel injection signal if the
system is activated at 3000 r/min or higher.
Caution lamp “TEMP” lamp lights continuously.
“REV- LIMIT” lamp lights continuously during engine speed limiter activation.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.
Temperature range Temperature difference
60 °C ~ 94 °C 1.6 °C
95 °C ~ 0.9 °C
Temperature range Temperature difference
80 °C ~ 94 °C 14.4 °C
95 °C ~ 1.4 °C
RESET :
Close throttle to reduce engine speed below approx. 3000 r/min.
When cylinder temperature drops below the limits as shown below, the system resets. However, the system
may be activated again unless the cause for overheat (such as insufficient water) is removed.
Caution cause Reset temperature
Condition 1
(Maximum temperature) Approx. 65 °C
Approx. 70 °C
Condition 2
(Temperature rise Vs Time)
3-25 ENGINE CONTROL SYSTEM
LOW BATTERY VOLTAGE CAUTION SYSTEM
CONDITION :
System is activated when battery voltage decreases to less than 9 volts for 30 seconds.
ACTION:
Engine speed No engine speed limiter is activated.
Caution lamp “CHECK ENGINE” lamp lights continuously.
Caution buzzer Sounds in a series of long (1.5 sec.) beeps.
RESET:
This caution system is automatically reset when battery voltage increases to more than 9 volts. Refrain from
using electrical equipment requiring high amperage such as hydraulic trim tabs, hydraulic jack plate, etc.
after this caution is activated.
ENGINE CONTROL SYSTEM 3-26
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from sensor, switch, etc.
When the system is activated, the “CHECK ENGINE” lamp
flashes (lights intermittently) according to each code pattern
along with a buzzer sound.
When engine is running, the buzzer sounds a series of short
(0.2 sec.) beeps.
When engine is not running, the buzzer sounds according to
each code pattern, but not simultaneous with the lamp flash.
The buzzer sound, activated by the self-diagnostic system, can
be temporally canceled by pushing the ignition key in.
PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC SYSTEM OPERA-
TION
PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN FAIL-SAFE SYSTEM
ACTIVATING
1 MAP sensor 1 3 – 4
on off
YES
2 CKP sensor 4 – 2
on off
NO [NOTE1]
3
IAC valve/By-pass air
screw adjustment 3 – 1
on off
NO
4 CMP sensor 2 – 4
on off
YES
5 CTP switch 2 – 2
on off
NO
6 Cylinder temp. sensor 1 – 4
on off
YES
7 IAT sensor 2 – 3
on off
YES
8
MAP sensor 2
(Sensor hose)
3 – 2
on off
NO
9 1 – 1
on off
NO
Rectifier & regulator
(Over-charging) [NOTE 2]
10 1 – 5
on off
YES
Exhaust manifold
temp. sensor
MONITOR-TACHOMETER
“CHECK ENGINE” lamp
3-27 ENGINE CONTROL SYSTEM
NOTE:
• If more than two items fail at once, the self- diagnostic indication appears according to priority order. The
indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch “ON”.
• After correcting failed item, the self-diagnostic indication appears until the ECM receives the proper signal
with the engine running.
• For cylinder temp. sensor, exhaust manifold temp. sensor or IAT sensor the self-diagnostic indication will be
canceled after corrective action by turning the ignition switch “ON”.
(The ECM will require 10 – 20 seconds after turning the ignition switch “ON” to cancel the self-diagnostic
indication.)
NOTE 1:
• No spark or injection signal will be supplied to the cylinder corresponding to the faild CKP sensor.
• If two or more CKP sensors have failed at the same time, the engine will stop.
NOTE 2 :
The self-diagnostic indication may be canceled by turning ignition switch “ON” because the ECM detects only
battery voltage, not charging output. Under this condition the buzzer will not sound a 1-1 code.
However, if the rectifier & regulator have failed, the self-diagnostic indication will again appear after starting
the engine.
ENGINE CONTROL SYSTEM 3-28
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION
NOTE 1:
This condition will be caused by IAC valve failure or incorrect by-pass air screw adjustment. If IAC valve is
always closed or by-pass air is too low, the ECM controls the IAC valve duty to increase to maintain the idling/
trolling speed specified.
Conversely, if IAC valve is always opened or by -pass air is too high, the ECM controls the IAC valve duty to
decrease to maintain the idling / trolling speed specified.
NOTE 2:
This condition will be caused by disconnected, kinked or clogged MAP sensor hose or clogged inlet manifold
gas filter.
MAP sensor 1 • No signal (With engine running)
• Receiving an out of range “37 – 860 mmHg (0.20 – 4.53V)”
signal ( With engine running )
CKP sensor • No signal from any CKP sensors while receiving 8 signals from other
CKP sensors.
• No signal from any CKP sensors while receiving 6 signals from CMP
sensor.
IAC valve / By-pass air screw • IAC valve operates at 90% duty or higher when CTP switch is “ON”
adjustment [NOTE 1]
CMP sensor • No signal while receiving 12 signals from CKP sensors
CTP switch • Receiving “ON” signal when engine speed is 2500 r/ min or higher
and intake manifold pressure is 300 mmHg or higher.
Cylinder temp. sensor • No signal
• Receiving an out of range “– 46 to +170 °C (0.10 – 4.63V)” signal
IAT sensor • No signal
• Receiving an out of range “– 46 to +169 °C ( 0.04 – 4.46V)” signal
MAP sensor 2 • Receiving unchanging signal regardless engine speed change
(Sensor hose) [NOTE 2]
Rectifier & regulator • Receiving 16 volts or higher signal
(Over-charging )
Exhaust manifold temp, sensor • No signal
• Receiving an out of range “– 46 to +170 °C (0.10 – 4.63V)” signal
FAILED ITEM CONDITION
3-29 ENGINE CONTROL SYSTEM
FAIL-SAFE SYSTEM
The fail-safe system is closely related to the self-diagnostic system.
When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a preprogrammed value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM
NOTE:
There is no back-up system for the ECM itself. The engine will stop if it has failed.
NOTE 1:
This value will change according to the current engine speed.
MAP sensor 1 • 319 – 475 mmHg (Correspond to approx. 750 – 4000 r/min) [NOTE 1]
CMP sensor • Fuel Injection:
1 simultaneous injection for all cylinders per 2 crankshaft rotations
• Ignition Timing:
Fixed at BTDC 5° ignition timing
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Exhaust manifold 60 °C (140 °F)
temp. sensor
FAILED ITEM PRE-PROGRAMMED VALUE
ENGINE CONTROL SYSTEM 3-30
OPERATING HOUR INDICATION SYS-
TEM
When the ignition switch is initially turned “ON” (from “OFF”),
the ECM tests the caution system by turning on all four lamps
in the monitor-tachometer and sounding the caution buzzer for
an initial two seconds.
For the next three seconds, the ECM indicates the total operating hours, in units of 50 hours, using a combination of the tachometer needle and three lamps (except for “CHECK ENGINE”
lamp).
NOTE:
The total operating hours displayed are those of actual engine
operation, not ignition switch “ON” time.
CHART OF TOTAL OPERATING HOURS INDICATION
TOTAL OPERATING
HOURS
MONITOR-TACHOMETER INDICATION
“REV-LIMIT”
lamp1
“OIL”
lamp2
“TEMP”
lamp3
Needle
indication
0 (h)– off off off 0 rpm
50 (h)– flash off off 0 rpm
100 (h)– on off off 1000 rpm
150 (h)– flash off off 1000 rpm
200 (h)– on off off 2000 rpm
250 (h)– flash off off 2000 rpm
300 (h)– on off off 4000 rpm
350 (h)– flash flash off 0 rpm
400 (h)– on on off 1000 rpm
450 (h)– flash flash off 1000 rpm
500 (h)– on on off 2000 rpm
550 (h)– flash flash off 2000 rpm
600 (h)– on on off 4000 rpm
650 (h)– flash flash flash 0 rpm
700 (h)– on on on 1000 rpm
750 (h)– flash flash flash 1000 rpm
800 (h)– on on on 2000 rpm
850 (h)– flash flash flash 2000 rpm
900 (h)– on on on 4000 rpm
950 (h)– flash off flash 0 rpm
1000 (h)– on off on 1000 rpm
1050 (h)– flash off flash 1000 rpm
1100 (h)– on off on 2000 rpm
1150 (h)– flash off flash 2000 rpm
1200 (h)– on off on 4000 rpm
1 “REV LIMIT” lamp
2 “OIL” lamp
3 “TEMP” lamp
MONITOR-TACHOMETER
1
23
3-31 ENGINE CONTROL SYSTEM
START- IN- GEAR PROTECTION SYSTEM
A switch to detect neutral gear position is located on the cylinder block (PORT side) and operated by the
clutch control arm.
This ON / OFF type switch is “ON” in neutral and “OFF” in forward or reverse.
On starting the engine, the ECM detects the shift position using the neutral switch. When the neutral switch is
“OFF”, the ECM does not send a signal for injector operation.
This neutral switch is also used to regulate the starter motor circuit. The engine will not start, even by emergency rope, with the shift in the forward or reverse position.
Battery
charge
coil
Rectifier &
regulator
30A fuse
Battery
ECM
12V power supply
1 Neutral switch
2 Neutral switch
3 Ignition switch
4 Starter motor
5 Starter motor relay
6 ECM main relay
1
2
3
Remo-con box
OFF
ON
START
4
5
6
SHIFT POSITION NEUTRAL
SWITCH
OPERATION
Fuel injector Ignition Fuel pump Starter motor
Neutral ON Yes Yes Yes Yes
Forward / Reverse OFF No Yes Yes No
ENGINE CONTROL SYSTEM 3-32
O2 FEEDBACK SYSTEM
After extended usage, the engine components may become deteriorated or worn out.
This might make the A / F (air / fuel mixture ratio) incorrect which could affect exhaust emissions. To correct
the A/F, an O2 sensor is temporally installed to the exhaust manifold. This sensor is used to measure the
concentration of oxygen in the exhaust gas at engine speeds of 2500, 3500 and 4500 r/ min.
The ECM uses the input data from the O2 sensor to correct the compensation coefficient of the fuel injection
duration map within the ECM itself.
NOTE:
See the “FUEL MIXTURE CHECK (O2 FEEDBACK)” section on page 2-21 for the O2 feedback operation
procedure.
O2 sensor :
Informs ECM of concentration of oxygen in exhaust gas.
ECM Feedback
3-33 ENGINE CONTROL SYSTEM
INSPECTION
PRECAUTION ON SYSTEM INSPECTION
!
To prevent an unexpected engine start, perform the following before proceeding with any CRANKING tests.
• When performing tests not related to fuel injector operation :
• Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation :
• Relieve fuel pressure in line. (See page 5-2.)
• Disconnect high pressure fuel pump wire connector located on fuel vapor separator.
"
• Always turn ignition switch “OFF” and disconnect battery cables when wires are being disconnected or connected.
• Hold and pull connector pieces when disconnecting. Do not pull wires.
NOTE:
• The self-diagnostic code memory in ECM will remain even if battery is disconnected.
• As each terminal voltage is affected by battery voltage, use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires/cables are securely connected.
INSPECTION FOR ECM CIRCUIT VOLTAGE
"
ECM cannot be bench checked. It is strictly prohibited
to connect any tester (voltmeter or ohmmeter) to an
ECM separated from the engine wiring harness.
09930-89910 : 4-pin test cord – 1
09930-89920 : 6-pin test cord – 2
09930-89930 : 8-pin test cord – 3
09930-89940 : 12-pin test cord – 4
09930-99320 : Digital tester
Tester range : # V (DC voltage)
(1) Connect the test cord 1,2,3 or 4 between ECM and wire
harness as shown.
(2) Turn ignition switch ON.
(3) Connect the tester probe - (Black) to body ground, and
measure voltage according to the “CIRCUIT VOLTAGE
TABLE”.
$
%
ECM
EDCBA
1423
ENGINE CONTROL SYSTEM 3-34
CIRCUIT VOLTAGE TABLE
TER-
MINAL
WIRE COLOR
ENGINE TEST CORD
CIRCUIT
STANDARD
VOLTAGE CONDITION / REMARKS
A1 Bl No.2 Ignition (–)Bl Approx. 12V Ignition switch ON
A2 B G —
A3 G B/W Approx. 12V
A4 O/B B/R Approx. 12V
A5 O O Approx. 12V
A6 B B —
A7 B/Y B/Y Approx. 12V
A8 R/W Lg Approx. 12V
B1 B/W R/W Approx. 0V
Approx. 12V
B2 P/B P/B —
B3 B G —
B4 B/R O/B Approx. 12V
B5 Gr Gr Approx. 12V
B6 B B —
C1 Bl/R B/W Approx. 5V
Approx. 0V
C2 Y/B R —
C3 G/W Lg/W —
C4 G/Y Bl —
C5 P B/G —
C6 Bl/B Lg/B —
C7 Bl/W W —
C8 Br Lg/R Approx. 0V
Approx. 5V
C9 V/W G/Y 0.10 – 4.63V
C10 Bl/Y B/R —
C11 R/Y Y/G —
C12 O O/Y Approx. 12V
Approx. 0V
D1 B/W B/W —
D2 R R Approx. 5V
D3 Lg/W Lg/W 0.10 – 4.63V
D4 Bl Bl Approx. 5V
Approx. 0V
D5 B/G B/G —
D6 Lg/B Lg/B 0.04 – 4.46V
D7 W W 0.20 – 4.53V
D8 Lg/R Lg/R Approx. 5V
Approx. 0V
D9 G/Y G/Y —
D10 B/R —
D11 Y/G Y/G 6 – 12V
Approx. 0V
D12 O/Y O/Y —
E1 R/W B —
E2 O/G O/G Approx. 0.3V or 5V
E3 W/B W/B —
E4 R/B R/B —

Ground for power source
No.3 Ignition (–)
No.1 Fuel injector (–)
No.1 Ignition (–)
Ground for power source
No.2 Fuel injector (–)
No.3 Fuel injector (–)
Fuel pump (–)
Ground for ECM main relay
Ground for ECM
IAC valve solenoid (–)
ECM power source
Ground for ECM
Emergency stop switch
Tachometer
CHECK ENGINE lamp
TEMP lamp
REV-LIMIT lamp
OIL lamp
Buzzer
Neutral switch
Ex-manifold temperature sensor
PC communication
PC communication
Buzzer cancel
Ground for sensors
Power source for MAP sensor
Cylinder temperature sensor
Oil pressure switch
O2 feedback/PC communication
IAT sensor
MAP sensor
CTP switch
PC communication

Engine start switch (signal)
PC communication
CKP sensor No.3
CMP sensor
CKP sensor No.2
CKP sensor No.1

Ignition switch ON
Ignition switch ON
Ignition switch ON

Ignition switch ON
Ignition switch ON
For 3 sec. after ignition switch ON
While engine cranking
Other than above (Ignition switch ON)


Ignition switch ON
Ignition switch ON

Ignition switch ON, plate IN
Ignition switch ON, plate OUT






Ignition switch ON, shift into NEUTRAL
Ignition switch ON, shift into FORWARD or REVERSE
Ignition switch ON


Ignition switch ON, key pushed
Ignition switch ON, key not pushed

Ignition switch ON
Ignition switch ON
While engine running
Other than above (Ignition switch ON)

Ignition switch ON
Ignition switch ON
Ignition switch ON, throttle not fully closed
Ignition switch ON, throttle fully closed


While engine cranking
Other than above (Ignition switch ON)


Ignition switch ON


A B C D E
3-35 ENGINE CONTROL SYSTEM
INSPECTION FOR RESISTANCE
09930-99320 : Digital tester
Tester range : Ω (Resistance)
NOTE:
Make sure ignition switch is always OFF when measuring resistance.
(1) Disconnect battery cables from battery.
(2) Disconnect all wires from ECM.
(3) Connect the tester probes to terminal of wire harness side,
and measure resistance according to the “RESISTANCE
TABLE”.
RESISTANCE TABLE
ITEM
TERMINAL FOR TESTER
PROBE CONNECTION
STANDARD RESISTANCE
(at 20°C)
CKP sensor No.1 E4 (R/B) to D1 (B/W)
CKP sensor No.2 E3 (W/B) to D1 (B/W)
CKP sensor No.3 E1 (R/W) to D1 (B/W)
Ignition coil No.1 (Primary) A5 (O) to B5 (Gr)
Ignition coil No.2 (Primary) A1 (Bl) to B5 (Gr)
Ignition coil No.3 (Primary) A3 (G) to B5 (Gr)
Ignition coil No.1 (Secondary) B5 (Gr) to No.1 spark plug cap
Ignition coil No.2 (Secondary) B5 (Gr) to No.2 spark plug cap
Ignition coil No.3 (Secondary)
Fuel injector No.1
Fuel injector No.2
Fuel injector No.3
IAC valve
Cylinder temperature sensor
Ex-mani. temperature sensor C9 (V/W) to D1 (B/W)
ECM main relay B2 (P/B) to TerminalA [NOTE1]
Starter motor relay D11 (Y/G) to Ground
A4 (O/B) to B5 (Gr)
A7 (B/Y) to B5 (Gr)
B4 (B/R) to B5 (Gr)
A8 (R/W) to B5 (Gr)
B5 (Gr) to No.3 spark plug cap
D3 (Lg/W) to D1 (B/W)
D6 (Lg/B) to D1 (B/W)
168 – 252 Ω
1.9 – 2.5 Ω
8.1 – 11.1 kΩ
21.5 – 32.3 Ω
0°C ( 32°F) : 5.3 – 6.6 kΩ
25°C ( 77°F) : 1.8 – 2.3 kΩ
50°C (122°F) : 0.73 – 0.96 kΩ
75°C (135°F) : 0.33 – 0.45 kΩ
(Thermistor characteristic)
80 – 120 Ω
3.5 – 5.1 Ω
1 2 3
4 5 6
1 2 3 4
5 6 7 8
1 2 3 4
5 6 7 8
9 10 11 12
D (Black)
1 2 3 4
5 6 7 8
9 10 11 12
1 2
3 4
A
B
C (White)
E
$
&
IAT sensor
11.0 – 16.5 Ω
ENGINE CONTROL SYSTEM 3-36
"Click"
Gr B/Y
OTHER INSPECTION
FUEL INJECTOR OPERATING SOUND (CRANKING)
(1) Touch a sound scope or long blade screw driver to fuel injector body as shown.
(2) Crank engine and check for injector operating sound.
Injector operating sound : “Click”
FUEL INJECTOR OPERATING SOUND (INDIVIDUAL)
(1) Disconnect fuel injector wire, and connect the test cord.
09930-89260 : Injector test cord A
(2) Connect Gray wire to body ground.
(3) Momentarily touch Black/Yellow wire to starter motor relay
right terminal (connected to battery positive (+) terminal),
and check for injector operating sound.
Injector operating sound : “Click”
"
Connecting fuel injector to battery positive for more
than a few seconds may cause injector overheating and
possible injector solenoid failure.
NOTE1:
Disconnect remote control wire harness, and connect tester
probe to terminal A (Gray wire).
Starter
motor
relay
ECM
EDCBA
$
FUEL INJECTOR OPERATING SIGNAL
09930-89930 : 8-pin test cord
Peak voltmeter Stevens CD-77
Tester range : NEG50
$
'
(1) Connect the test cord as shown, then turn ignition switch
ON.
(2) Connect the tester probe- (Black) to starter motor relay
right terminal (connected to battery positive (+) terminal)
as shown.
3-37 ENGINE CONTROL SYSTEM
FUEL PUMP 3 SEC. OPERATING SOUND
Turn ignition switch ON and check for fuel pump operating
sound.
Fuel pump operating sound :
Sounds for approx. 3 seconds only
NOTE:
Fuel pump operating sound is low because pump is in fuel vapor separator. If you cannot hear clearly, use a sound scope or
long blade screw driver.
IGNITION COIL OPERATING SIGNAL
09930-89930 : 8-pin test cord
Peak voltmeter Stevens CD-77
Tester range : NEG50
(1) Connect the test cords as shown, then turn ignition switch
ON.
(2) Connect the tester probe - (Black) to starter motor relay
right terminal (connected to battery positive (+) terminal)
as shown.
(3) Connect the tester probe + (Red) to each terminal.
Ignition coil Terminal
Engine
Wire color
Test cord
No.1 A5 O O
No.2 A1 Bl Bl
No.3 A3 G B/W
(4) Crank engine and measure voltage.
Ignition coil operating signal : 6 – 10 V
Injector Terminal
Engine
Wire color
Test cord
No.1 A4 O/B B/R
No.2 A7 B/Y B/Y
No.3 A8 R/W Lg
(4) Crank engine and measure voltage.
Fuel injector operating signal : 6 – 10 V
(Voltage)
12V
(Time)
A
B
APeak voltage reading (NEG)
B 0V level for peak voltmeter
Starter
motor
relay
ECM
EDCBA
(Voltage)
12V
(Time)
A
B
APeak voltage reading (NEG)
B 0V level for peak voltmeter
(3) Connect the tester probe + (Red) to each terminal.
$
'
ENGINE CONTROL SYSTEM 3-38
CMP SENSOR SIGNAL
09930-89910 : 4-pin test cord
09930-99320 : Digital tester
Tester range : # V (DC voltage)
(1) Rremote CMP sensor from engine. (See page 3-48)
(2) Connect the test cord as shown, then turn ignition switch
ON.
(3) Connect the tester probe (+) (Red) to terminal.
Terminal
Wire color
Test cord
E2 O/G
Engine
O/G
(4) Connect the tester probe (–) (Black) to body ground.
(5) Measure voltage when steel tip of a screwdriver is brought
near and then pulled away from sensor tip A.
CMP sensor signal : Approx. 0.3 V or 5 V
NOTE:
Two signal voltages mentioned above (0.3 V or 5 V) will change
by repeating movement of screwdriver.
$
%
ECM
A B C D E
DC V
3-39 ENGINE CONTROL SYSTEM
MAP SENSOR OUTPUT VOLTAGE CHANGE
($ 09917-47011 : Vaccum pump gauge
09930-89940 : 12-pin test cord
09930-99320 : Digital tester
Tester range : (# V (DC voltage)
(1) Disconnect MAP sensor hose from gas filter (surge tank)
side.
(2) Connect the gauge to MAP sensor hose end as shown.
(3) While applying negative pressure to MAP sensor, measure
“D7” terminal voltage. (See page 3-33 and 3-34 for procedure.)
MAP sensor output voltage change :
Negative pressure
kPa (kg/cm2, mm Hg)
“D7” terminal
voltage (V)
0
(0, 0)
40
(0.4, 300)
80
(0.8, 600)
4.00 2.42 0.84
(at 1013 hPa barometric pressure)
CTP SWITCH
($ 09930-99320 : Digital tester
() Tester range : (* (Continuity)
(1) Disconnect CTP switch wire.
(2) Check continuity between CTP switch terminal and body
ground.
CTP switch function :
Throttle position Continuity
Fully closed
(switch contact in) Yes
Not fully closed
(switch contact out) No
%
ENGINE CONTROL SYSTEM 3-40
OIL PRESSURE SWITCH
09940-44121 : Air pressure gauge
: Air pump
09930-99320 : Digital tester
Tester range : *( (Continuity)
(1) Remove oil pressure switch. (See page 3-50.)
(2) Connect the gauge and pump as shown.
(3) While applying pressure to oil pressure switch, check continuity.
Oil pressure switch function :
ECM MAIN RELAY
09930-99320 : Digital tester
Tester range : *((Continuity)
(1) Disconnect ECM main relay from wire.
(2) Check continuity between terminal 1 and 2 each time 12V
is applied. Connect positive (+) side to terminal 4, and negative (–) side to terminal 3.
ECM main relay function :
12 V power Continuity
Applied Yes
Not applied No
"
Be careful not to touch 12 V power supply wires to each
other or with other terminals.
Oil pressure
switch
ECM main relay
12V
1
2 4
3
$
)
Pressure
kPa (kg/cm2)
Continuity
Less than
70 – 130 (0.7 – 1.3)
Yes
70 – 130 (0.7 – 1.3)
or over
No $
)
3-41 ENGINE CONTROL SYSTEM
TROUBLESHOOTING
!
Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION”
section on page 3-33.
In this section, troubleshooting procedures are based on the assumption that “low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.
NOTE:
For troubleshooting of “Starter motor will not run”, see page 4-7.
CHART1 : SELF-DIAGNOSTIC CODE “3-4”
START
< Ignition switch “ON” >
Check “D2” terminal voltage.
Is result OK? (See page 3-34.)
< Ignition switch “ON” >
Check “D7” terminal voltage.
Is result OK? (See page 3-34.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
YES
ECM failure
NO
MAP sensor failure
NO
CHART2 : SELF-DIAGNOSTIC CODE “4-2”
START
< Ignition switch “OFF” >
Check CKP sensor resistance.
Is result OK? (See page 3-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CKP sensor failure
NO
NOTE:
• It will be possible to start engine if one CKP sensor has
failed.
• No spark or injection signal will be supplied to the cylinder
corresponding to the faild CKP sensor.
ENGINE CONTROL SYSTEM 3-42
CHART3 : SELF-DIAGNOSTIC CODE “3-1”
START
< Ignition switch “OFF” >
Check IAC valve resistance.
Is result OK? (See page 3-35.)
< Ignition switch “ON” >
Check “B4” terminal voltage.
Is result OK? (See page 3-33.)
Possible cause :
• Incorrect by-pass air screw adjustment
• IAC valve failure (mechanical)
• IAC passage failure (clogged hose/silencer,
etc.)
• ECM failure
• Wire continuity/connection failure
YES
YES
IAC valve failure
NO
ECM failure
NO
CHART4 : SELF-DIAGNOSTIC CODE “2-4”
START
< Ignition switch “ON”, cranking >
Check CMP sensor signal.
Is result OK? (See page 3-38.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CMP sensor failure
NO
NOTE:
It will be possible to start engine if CMP sensor has failed.
CHART5 : SELF-DIAGNOSTIC CODE “2-2”
START
< Ignition switch “ON” >
Check “D8” terminal voltage.
Is result OK? (See page 3-34.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CTP switch failure
NO
NOTE1:
In this case, CTP switch will be in “always ON” condition.
(“D8” terminal voltage will be 0V always regardless throttle
position.)
[NOTE1]
3-43 ENGINE CONTROL SYSTEM
CHART6 : SELF-DIAGNOSTIC CODE “1-4”
START
< Ignition switch “OFF” >
Check cylinder temp. sensor resistance.
Is result OK? (See page 3-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
NO
CHART 7 : SELF-DIAGNOSTIC CODE “2-3”
START
< Ignition switch “OFF” >
Check IAT sensor resistance.
Is result OK? (See page 3-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
IAT sensor failure
NO
CHART8 : SELF-DIAGNOSTIC CODE “3-2”
START
< Individual check >
Check MAP sensor hose is in good
condition/connection.
Is result OK?
< Ignition switch “ON” >
Check MAP sensor output voltage
change.
Is result OK? (See page 3-39.)
YES
YES
MAP sensor hose failure
NO
MAP sensor failure
NO
Cylinder temp. sensor failure
Possible cause :
• Gas filter failure (clogged, etc.)
• ECM failure
• Wire continuity/connection failure
ENGINE CONTROL SYSTEM 3-44
CHART9 : SELF-DIAGNOSTIC CODE “1-1”
START
< Individual check >
Check rectifier & regulator resistance.
[NOTE1]
Is result OK? (See page 4-3.)
< Engine running >
Check “B5” terminal voltage at idle
speed. (See page 3-34.)
Is result 16 V or over?
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
NO
Rectifier & regulator failure
NO
YES
NOTE:
This self-diagnostic code indication may be canceled by turning ignition switch ON because ECM detects
battery voltage.
NOTE1:
It is difficult to check rectifier & regulator completely. Before replacing with new one, check if its ground point
has good electrical contact.
START
< Ignition switch “OFF” >
Check exhaust manifold temp. sensor
resistance.
Is result OK? (See page 3-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
Exhaust manifold temp. sensor failure
NO
CHART10 : SELF-DIAGNOSTIC CODE “1-5”
3-45 ENGINE CONTROL SYSTEM
CHART11 : ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY
AFTER STARTING)
Before starting this troubleshooting, make sure that :
• There is no self-diagnostic code indication.
• Emergency stop switch plate is set in place.
• 15A fuse is good.
START
< Ignition switch “ON” >
Check “B5” terminal
voltage.
Is result OK?
(See page 3-34.)
< Cranking >
Check injector operating
sound.
Is result OK?
(See page 3-36.)
NO
< Ignition switch “OFF” >
Check fuel injector
resistance.
Is result OK?
(See page 3-35.)
YES
< Ignition switch “ON” >
Check “A7, A8 and A4
terminal voltage.
Is result OK?
(See page 3-34.)
YES
< Cranking >
Check fuel injector
operating signal.
Is result OK?
(See page 3-36.)
YES
Fuel injector failure
< Ignition switch “ON” >
Check “B1” terminal
voltage for 3 sec. after
switch ON.
Is result OK?
(See page 3-34.)
Possible cause :
Failure of high pressure
fuel system components.
(See page 3-46.)
NO ECM main relay failure
YES < Ignition switch “ON” >
Check “C1” terminal
voltage
Is result OK?
(See page 3-34.)
YES
YES < Cranking >
Check ignition spark using
timing light
(P/no. 09930-76420).
Is there light flashing?
< Ignition switch “OFF” >
• Check ignition primary
coil resistance.
(See page 3-35.)
• Check ignition secondary
coil resistance.
(See page 3-35.)
Are results OK?
Power supply wire (Gr)
failure
ECM failure
Fuel pump failure
NO
< Ignition switch “ON” >
Check fuel pump 3 sec.
operating sound.
Is result OK?
(See page 3-37.)
YES
< Cranking >
Check “B1” terminal
voltage.
Is result OK?
(See page 3-34.)
Emergency stop switch
failure
Spark plug failure
< Individual check >
Check if spark plug is in
good condition.
Is result OK?
NO
Ignition coil failure
< Ignition switch “ON” >
Check “A1, A3 and A5”
terminal voltage.
Is result OK?
(See page 3-34.)
YES
< Cranking >
Check ignition coil operating signal.
Is result OK?
(See page 3-37.)
< Cranking >
Check “D11” terminal
voltage.
Is result OK?
(See page 3-34.)
NO
Engine start signal wire
(Y/G) failure
NO
NO
NO
YES
YES
NO
YES
NO
YES
NO
YES
NO
NO YES
NO
YES
NO
ENGINE CONTROL SYSTEM 3-46
CHART12 : UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL)
Before starting this troubleshooting, make sure that :
• There is no self-diagnostic code indication.
START
< Ignition switch “ON” >
Check “C8” terminal voltage.
Is result OK? (See page 3-34.)
YES
< Ignition switch “ON” >
Check “D8” terminal voltage.
Is result OK? (See page 3-34.)
YES
< Individual check >
Check neutral switch function.
Is result OK? (See page 4-9.)
NO YES
NO (Always 0 V)
Neutral switch failure ECM failure
(Always 5 V)
[NOTE1] YES
< Individual check >
Check CTP switch function.
Is result OK? (See page 3-39.)
NO
CTP switch failure
[NOTE2]
Possible cause :
• Incorrect by-pass air screw adjustment [NOTE3]
• IAC valve failure [NOTE3]
• IAC passage failure (clogged hose / silencer, etc.) [NOTE3]
• Spark plug failure
• Ignition coil failure
• ECM failure
• Wire continuity / connection failure
• Failure of high pressure fuel system components :
• Fuel injector (clog, stuck valve, etc.)
• Fuel pressure regulator (incorrect regulated pressure, etc.)
• Fuel pump (clogged suction filter, leakage in tank, etc.)
• Fuel filter (clog, etc.)
• Hose (clog, kink, leakage, etc.)
NOTE1:
If neutral switch has failed (while engine running), engine will tend to stall when shifting into gear.
If neutral switch has failed as “always ON”, engine speed is limited to 3000 r/min by intermittent fuel injection
and ignition timing is fixed at BTDC9 °.
If neutral switch has failed as “always OFF”, engine cannot be cranked.
NOTE2:
If CTP switch has failed, engine will tend to stall when decelerating.
NOTE3:
• The self-diagnostic code “3-1” may not be indicated because IAC valve condition depends on ECM control.
(See page 3-28.)
• If IAC valve has failed, “Fast-idle function (warm-up mode)” won’t operate.
NO (Always 0 V)
(Always 5 V)
3-47 ENGINE CONTROL SYSTEM
REMOVAL / INSTALLATION
FLYWHEEL / CKP SENSOR / CMP SENSOR
1 Flywheel bolt (1)
2Washer (1)
3Key (1)
4 Flywheel (1)
5CKP sensor assy (1)
6Screw (6)
7CMP sensor (1)
8Bolt (1)
1
2
3
4
5
6
7
8
NOTE:
Clean flywheel and crankshaft mating
surfaces with cleaning solvent.
Crankshaft
+ 200 N.m
(20.0 kg-m, 144.5 lb.-ft.)
,
-
ENGINE CONTROL SYSTEM 3-48
REMOVAL
Prior to removing Flywheel :
• Disconnect battery cables from battery.
1. Remove flywheel cover.
2. Loosen flywheel bolt 2 – 3 turns.
09930-48720 : Flywheel holder
NOTE:
Do not remove flywheel bolt at this time.
This bolt prevents damage to the crankshaft when using flywheel remover tools.
3. Using special tools, loosen flywheel from crankshaft.
09930-39411 : Flywheel remover
09930-39420 : Flywheel remover bolt
4. Remove flywheel bolt 1, washer 2, flywheel 3 and key
4.
5. Remove screws 5 and CKP sensors 6, then disconnect
CKP sensor connector.
$
$
1
2
3
4
6
5 6
6. Disconnect CMP sensor connector.
Remove bolt 7 and CMP sensor 8.
3-49 ENGINE CONTROL SYSTEM
Flywheel
• Clean flywheel and crankshaft mating surfaces with cleaning
solvent.
• Apply engine oil lightly to flywheel bolt before installing.
• Tighten flywheel bolt to specified torque.
09930-48720 : Flywheel holder
Flywheel bolt : 200 N . m (20.0 kg-m, 144.5 lb.- ft.)
$
+
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
CKP sensors
Apply Thread Lock 1342 to the sensor mounting screws.
99000-32050 : Thread Lock 1342ENGINE CONTROL SYSTEM 3-50
OIL PRESSURE SWITCH
REMOVAL
Remove flywheel cover.
Loosen screw and disconnect blue lead wire from switch.
Remove oil pressure switch from cylinder block.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Before installing oil pressure switch, wrap screw threads with
sealing tape then tighten switch to specified torque.
NOTE:
Cut off any excess sealing tape from switch threads before installation.
Oil pressure switch : 13 N . m (1.3kg-m, 9.5 lb.-ft.)
• Start engine and check oil pressure switch for oil leakage.
Reseal switch if oil leakage is found.
+
1. Sealing tape
1
BATTERY CHARGING SYSTEM ______________________________ 4-1
OUTLINE .......................................................................................................... 4-1
INSPECTION ................................................................................................... 4-2
REMOVAL / INSTALLATION ........................................................................... 4-4
ELECTRIC STARTER SYSTEM_______________________________ 4-6
OUTLINE .......................................................................................................... 4-6
TROUBLESHOOTING ..................................................................................... 4-7
INSPECTION ................................................................................................... 4-8
STARTER MOTOR........................................................................................... 4-11
MONITOR-TACHOMETER ___________________________________ 4-17
INSPECTION ................................................................................................... 4-17
4
ELECTRICAL
CONTENTS
4-1 ELECTRICAL
BATTERY CHARGING SYSTEM
OUTLINE
The battery charging system circuit is illustrated below.
It is composed of the BATTERY CHARGE COIL, RECTIFIER
& REGULATOR and BATTERY.
The three phase AC current generated from battery charge coil
is converted by the rectifier & regulator into regulated DC current which is used to charge the battery.
OUTPUT
REGULATED
VOLTAGE
216 W
14.5 – 15.5 V
Battery charge coil
Alternator
(Magneto)
HIC
Rectifier & regulator
Battery (12V)
To Starter motor
Starter
motor
relay
30A Fuse
To PTT switch
To ECM main relay
To Ignition switch
B
Y Y Y
W
W
W
R
+-
W
W
W
ELECTRICAL 4-2
INSPECTION
BATTERY CHARGE COIL
Measure battery charge coil resistance.
09930-99320 : Digital tester
Tester range : Ω (Resistance)
1. Disconnect battery charge coil leads from rectifier & regulator.
2. Measure resistance between leads in the combinations
shown.
Battery charge coil resistance :
!
If measurement exceeds specification, replace battery charge
coil.
FUSE CASE / FUSE
09930-99320 : Digital tester
Tester range : (Continuity)
Fuse
1. Remove the fuse from fuse case.
2. Inspect fuse and replace with a new 30-amp fuse if needed.
Fuse case
1. Disconnect all wires of fuse case.
2. Check continuity between White lead wire with plate terminal and the other two white lead wires.
Tester range : (Continuity)
If no continuity is indicated, replace fuse case.
Terminal for tester probe
connection
Resistance
White 1 to White 2
White 2 to White 3
White 3 to White 1
0.56 – 0.84 Ω
!
W1
W2W3
"
#
#
4-3 ELECTRICAL
7.5 – 11.5
RECTIFIER & REGULATOR
09930-99320 : Digital tester
Tester range : Ω (Resistance)
1. Disconnect all lead wires of rectifier & regulator.
2. Measure resistance between leads in the combinations
shown.
NOTE:
The values given below are for a SUZUKI digital tester.
As thyristors, diodes, etc. are used inside this rectifier & regulator, the resistance values will differ when an ohmmeter other
than SUZUKI digital tester is used.
Rectifier & regulator resistance :
If measurement exceeds specification, replace rectifier & regulator.
!
Tester probe + (Red)
Te st er p ro b e ---- -
(
B
la ck )
Black White Yellow 1 Yellow 2 Yellow 3
Black
White
Yellow 1
Yellow 2
Yellow 3
B
W
Y1
Y3Y2
"
9 – 14
0.F
Unit : MΩ
6 – 9
6 – 9
6 – 9
0.F
0.F
0.F
0.F
0.F
0.F
7 – 11
0.F 0.F
8 – 13
0.F 0.F
0.F
0.F
0.F : Infinity
ELECTRICAL 4-4
REMOVAL / INSTALLATION
REMOVAL
Prior to removing electrical parts :
• Disconnect battery cables from battery.
Battery charge coil
• Remove flywheel. (See page 3-48.)
• Remove three screws securing the battery charge coil.
• Disconnect battery charge coil lead wire connector from rectifier & regulator.
Rectifier & regulator
• Remove two bolts securing the Rectifier & regulator.
• Disconnect lead wire connectors.
1 Bolt (1)
2 Washer (1)
3 Key (1)
4 Flywheel (1)
5 Battery charge coil (1)
6 Screw (3)
7 Rectifier & regulator (1)
8 Bolt (2)
9 Fuse case (1)
0 30A fuse (1)
$1 200 N . m
(20.0 kg-m, 144.5 Ib.-ft.)
2
3
4
5
6
7
8 9
0
%
&
System construction
4-5 ELECTRICAL
Fuse case
• Disconnect fuse case lead wires from engine wiring harness
and starter motor relay terminal.
INSTALLATION
Installation is reverse order of removal with special attention to
the following step.
• Battery charge coil
• Apply Thread Lock 1342 to the coil securing screws.
99000-32050 : Thread Lock 1342
• Wire routing
• Check wire routing. (See page 10-1 to 10-4)
%
ELECTRICAL 4-6
ELECTRIC STARTER SYSTEM
OUTLINE
The circuit of the electric starter system is illustrated below.
This circuit is mainly composed of Battery, Starter motor, Relay, Neutral switches and Ignition switch.
To ECM
main relay To Rectifier
& regulator
30A Fuse
To ECM
Neutral switch
Neutral switch
Remote control box
Ignition
switch
Battery
-+
Starter motorM
B
W
Br GND
BATT
START
O
F
F
O
N
ST
A
R
T
F
R
E
E
P
U
S
H
BrBr
W
W
W
W
W
R
B
R
B
W
Br Br Y/G
Y/G
Y/G
4-7 ELECTRICAL
TROUBLESHOOTING
NOTE:
Before troubleshooting the electric starter system, make sure of the following :
• Battery is fully charged.
• All cables / wires are securely connected.
• Shift is in “NEUTRAL” position.
Circuit check schematic
Check starter motor.
(See page 4-14.)
Sub cable
1+- 3
Starter motor
GND
Ignition switch
Neutral switch
ST
BAT
GND
GNDNeutral
switch
30A Fuse
GND
GND
Battery
Starter motor relay
2
Starter motor will not run.
Check for relay “click” sound when turning
ignition switch to “START”.
Is there “click” sound?
Measure voltage at terminal2 with ignition
switch at “START”. It must be above 12 V.
Is result OK?
Measure voltage at terminal3 with ignition
switch at “START”. It must be above 12 V.
Is result OK?
Starter motor failure Sub cable failure
Measure voltage at
terminal1. It must be
above 12V.
Is result OK?
Check 30A fuse and
fuse case.
(See page 4-2.)
Is result OK?
Check ignition switch
function.
(See page 4-8.)
Is result OK?
Check function of
both neutral switches.
(See page 4-9.)
Is result OK?
Check starter motor
relay.
(See page 4-10.)
Starter motor relay
failure
Battery cable
failure
30A fuse or
fuse case failure
Ignition switch
failure
Neutral switch
failure
YES
YES
YES NO
YES
YES
YES
NO
NO
NO
NO
NO
NO
ELECTRICAL 4-8
INSPECTION
IGNITION SWITCH
09930-99320 : Digital tester
Tester range : (Continuity)
1. Disconnect the ignition switch from remo-con box wiring
harness.
2. Check continuity between wiring leads at the key positions
shown in the chart.
!
If out of specification, replace ignition switch.
Key
Position
1 OFF
Switch Lead Wires
Black Green White Gray Brown Orange
2 ON
3 START
4 FREE
5PUSH
: Continuity
Black
Green
White
Gray
Orange
Brown
1 (OFF)
2 (ON)
3 (START)
4 (FREE) 5 (PUSH)
PUSH
#
4-9 ELECTRICAL
NEUTRAL SWITCH
Check for continuity / infinity of the neutral switch.
09930-99320 : Digital tester
Tester range : (Continuity)
Neutral switch in remo-con box
1. Disconnect neutral switch lead wire from ignition switch and
remo-con box wiring lead.
2. Check continuity / infinity between switch brown wire leads
while operating remo-con handle.
If out of specification, replace neutral switch.
Shift position Tester indicates
Neutral Continuity
Forward Infinity
Reverse Infinity
Neutral switch on cylinder block
1. Disconnect neutral switch lead wires.
2. Check continuity / infinity between Yellow / Green and Brown
lead wires while operating remo-con handle.
If out of specification, replace neutral switch.
NOTE:
After installing neutral switch, check for proper correct function
by operating remo-con handle.
Shift position Tester indicates
Neutral Continuity
Forward Infinity
Reverse Infinity
REVERSE FORWARD
Brown
Brown
!
#
ELECTRICAL 4-10
STARTER MOTOR RELAY
Two methods can be used to test starter motor relay.
09930-99320 : Digital tester
Method 1
1. Disconnect all cables / lead wires from starter motor relay.
2. Measure resistance between relay wiring leads.
Tester range : Ω (Resistance)
Starter motor relay solenoid coil resistance :
3.5 – 5.1 Ω
If measurement exceeds specification, replace starter motor
relay.
Method 2
Connect the wiring leads of the relay to battery (12V) and check
relay operation.
Tester range : (Continuity)
1. Disconnect all cables / wires from starter motor relay.
2. Connect Yellow /Green wire to positive+ terminal, and Black
wire to negative- terminal of battery.
When 12V applied : Continuity between relay
terminal 1 and 2.
3. Disconnect wiring leads from battery.
No voltage applied : No continuity between
relay terminal 1 and 2.
If out of specification, replace starter motor relay.
Tester probe connection
Red + Black Yellow / Green Black
!
B
Y/G
1
2
BY/G
+ -
12V Battery
"
#
4-11 ELECTRICAL
STARTER MOTOR
REMOVAL
Prior to removing starter motor :
• Disconnect battery cables from battery.
1. Remove four bolts and flywheel cover.
2. Remove bolt 1 and silencer case 2.
3. Disconnect lead wire connector from IAT (Intake air temperature) sensor.
4. Remove bolt and negative - battery cable 3.
5. Remove starter motor sub cable 4.
6. Remove two bolts 5 and starter motor band 6.
7. Remove two bolts 7 and starter motor 8.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Install starter motor and tighten starter motor mounting bolts
securely.
Starter motor mounting bolt :
23 N . m (2.3 kg-m, 16.5 Ib.-ft.)
$
ELECTRICAL 4-12
DISASSEMBLY
NOTE:
For correct assembly, scribe an alignment mark on the front
cover, stator and rear cover.
1 Stopper ring
2 Pinion stopper (1)
3 Spring (1)
4 Pinion (1)
5 Bolt (2)
6 Front cover (1)
7 Washer
8 Washer
9 Stator (1)
0 Armature (1)
A Washer
B Rear cover (1)
C Nut (1)
D Washer (1)
E Washer (1)
F Screw
G Brush holder
HBrush
IBrush spring
1
2
3
4
6
7
8
0
A
9
B
C D
E
F
5
G
H
I
'
'
'
4-13 ELECTRICAL
Push down the pinion stopper 2, remove stopper ring 1.
Remove pinion stopper 2, spring 3, and pinion 4.
(
Wear safety grasses when disassembling
and assembling stopper ring.
NOTE:
Using a screw-driver, pry off the stopper ring.
Remove two bolts 5.
Remove following parts :
• Front cover 6
• Washer 7,8
• Stator 9
• Armature 0
• Washer A
• Rear cover B
Remove the nut C, washer D and E from rear cover B.
Remove two screws F and brush holder assembly G (with
brush H and brush spring I).
1
2
3
4
6
7
8
0
A
9
5
B
CD
E
F
H
G
I
B
ELECTRICAL 4-14
INSPECTION & SERVICING
Pinion
Inspect pinion.
Replace pinion if damaged or worn.
Armature and Commutator
Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grade emery paper
A.
Measure commutator outside diameter.
09900-20101 : Vernier calipers
Commutator outside diameter:
Standard : 33.0mm (1.30 in.)
Service limit : 32.0mm (1.26 in.)
If measurement exceeds service limit, replace armature.
Check that mica (insulator) between the segments is undercut
to specified depth.
Commutator undercut:
Standard : 0.5 – 0.8mm (0.02 – 0.03 in.)
Service limit : 0.2 mm (0.01in.)
If measurement exceeds service limit, cut to specified depth.
NOTE:
Remove all particles of mica and metal using compressed air.
(
Wear safety grasses when using compressed air.
!
A
SEGMENT
MICA
1
1. undercut
4-15 ELECTRICAL
Armature core
Commutator
Shaft
Check for continuity between the commutator and the armature core / shaft.
Replace armature if continuity is indicated.
Check for continuity between the adjacent commutator segments.
Replace armature if no continuity is indicated.
09930-99320 : Digital tester
Tester range : (Continuity)
BRUSHES
Check the length of each brush.
09900-20101 : Vernier calipers
Brush length:
Standard : 17.0 mm (0.67 in.)
Service limit : 10.0 mm (0.39 in.)
If brushes are worn down to the service limit, they must be replaced.
BRUSH HOLDER
Check brush holder continuity.
09930-99320 : Digital tester
Tester range : (Continuity)
Brush holder continuity :
!
!
!
Tester probe connection Continuity
Brush holder positive + to Brush holder
negative - No
Brush holder positive + to Base plate
(ground) No
Brush
+
-
Base plate
#
#
ELECTRICAL 4-16
'
'
'
ASSEMBLY
Assembly is reverse of disassembly with special attention to
following steps.
)
When installing armature, exercise care to avoid breaking brushes.
Apply grease to armature shaft and shaft holes.
99000-25010 : Suzuki Super Grease “A”
Align front cover, stator and rear cover with alignment lines
scribed earlier and assemble starter.
(
Wear safety grasses when disassembling and reassembling stopper ring.
Install pinion , spring , pinion stopper and stopper ring.
NOTE:
Make sure stopper ring 1 fit tightly in pinion stopper 2 and
armature shaft 3.
'
1
2
3
4-17 ELECTRICAL
MONITOR-TACHOMETER
INSPECTION
MONITOR LAMP CHECK
(1) Connect the test cord as shown.
09930-89240 : 4-pin test cord
NOTE:
This check can be performed without the test cord (P/no. 0993089240). If it is not available, directly connect battery to terminal
of meter.
(2) Apply 12V power to meter. Connect Gray wire to positive
(+) terminal, and Black wire to negative (–) terminal of battery.
(3) Check if lamp lights when connecting battery to test cord
terminal as shown.
Monitor lamp check:
If out of specification, replace monitor-tachometer.
Battery terminal
Terminal for
battery connection
Test cord Meter
Lighting lamp
Negative (–) Bl G/W Lamp 1
Negative (–) W G/Y Lamp 2
Negative (–) Y Bl/B Lamp 3
Positive (+) R P Lamp 4
1
2 3
4
B Gr
12V
Battery
P G/W
G/YBl/B
1 “CHECK ENGINE”
2TEMP “ ”
3OIL “ ”
4REV “LIMIT”
12V
Battery
12V
Battery
Bl W
Y
R
!
PRECAUTION ON FUEL SYSTEM SERVICE ____________________ 5-1
GENERAL PRECAUTION ............................................................................... 5-1
FUEL PRESSURE RELIEF PROCEDURE ..................................................... 5-2
FUEL LINE _______________________________________________ 5-3
REMOVAL / INSTALLATION ........................................................................... 5-3
FUEL LEAKAGE CHECK PROCEDURE ....................................................... 5-3
FUEL HOSE CONNECTION ........................................................................... 5-4
FUEL PRESSURE INSPECTION .................................................................... 5-5
FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP _____ 5-7
REMOVAL / INSTALLATION ........................................................................... 5-7
DISASSEMBLY ................................................................................................ 5-8
INSPECTION ................................................................................................... 5-9
ASSEMBLY ...................................................................................................... 5-11
FUEL INJECTOR __________________________________________ 5-12
INSPECTION ................................................................................................... 5-12
REMOVAL ........................................................................................................ 5-12
INSTALLATION................................................................................................ 5-13
LOW PRESSURE FUEL PUMP _______________________________ 5-14
REMOVAL / INSTALLATION ........................................................................... 5-14
DISASSEMBLY / REASSEMBLY .................................................................... 5-15
INSPECTION ................................................................................................... 5-16
FUEL TANK_______________________________________________ 5-17
DISASSEMBLY / REASSEMBLY .................................................................... 5-17
INSPECTION ................................................................................................... 5-18
FUEL SYSTEM
CONTENTS
5
5-1 FUEL SYSTEM
GENERAL PRECAUTION
!
Gasoline is extremely flammable and toxic. Always observe the following precautions when working around
gasoline or servicing the fuel system.
• Disconnect battery cables except when battery power
is required for servicing / inspection.
• Keep the working area well ventilated and 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.
• Keep a fully charged CO2 fire extinguisher and readily
available for use.
• Always use appropriate safety equipment and wear
safety glasses when working around pressurized fuel
system.
• To avoid potential fire hazards, do not allow fuel to
spill on hot engine parts or on operating electrical
components.
• Wipe up fuel spills immediately.
!
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.
PRECAUTION ON FUEL SYSTEM SERVICE
5-2FUEL SYSTEM
FUEL PRESSURE RELIEF PROCEDURE
After making sure that engine is cold, relieve fuel pressure as
follows.
1. Turn OFF ignition switch.
2. Disconnect high pressure fuel pump lead wire connector at
high pressure fuel pump.
3. Disconnect the ignition coil primary lead wire connector from
all ignition coils.
4. Crank the engine 5 – 10 times (3 seconds each time) to
dissipate fuel pressure in lines.
5. Make sure fuel pressure has been removed by pinching high
pressure fuel hose with finger tips (line should feel soft without pressure).
6. Upon completion of servicing, connect ignition coil primary
wire and fuel pump wire.
5-3 FUEL SYSTEM
FUEL LINE
REMOVAL / INSTALLATION
Pay special attention to the following steps when removing or
installing fuel hoses.
!
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 clamps, position tabs to avoid
contact with other parts.
• Be sure hoses do not contact rods, levers or other
components with engine either operating or at rest.
• Extreme care should be taken not to cut, abrade or
cause any other damage to hoses.
• Use care not to excessively compress hoses when
tightening clamps.
NOTE:
• Check fuel hose routing. (See page 10-7 and 10-9)
• Check for fuel leakage.
OFF
ON
FUEL LEAKAGE CHECK PROCEDURE
After performing any fuel system service, always be sure there
is not fuel leakage by checking as follows.
1. Squeeze fuel primer bulb until you feel resistance.
2. Turn ignition switch “ON” for 3 seconds(to operate fuel
pump), then turn it “OFF”.
Repeat this (ON and OFF) procedure 3 or 4 times to pressurize the fuel system.
3. Once pressurized, check all connections and components
for any signs of leakage.
5-4FUEL SYSTEM
FUEL HOSE CONNECTION
Note that fuel hose connection varies with each type of pipe. Be
sure to connect and clamp each hose correctly by referring to
the figure.
• For type “A” (short barbed end) pipe, hose must completely
cover pipe.
Clamp (Clip)
Hose
Joint piep
3 – 7 mm
(0.1 – 0.3 in)
3 – 7 mm
(0.1 – 0.3 in.)
20 – 30 mm
(0.8 – 1.2 in.)
3 – 7 mm (0.1 – 0.3 in.)
3 – 7 mm
(0.1 – 0.3 in.)
20 – 30 mm
(0.8 – 1.2 in.)
• For type “B” (bent end) pipe, hose must cover straight part of
pipe by 20 – 30mm (0.8 – 1.2in.).
• For type “C” pipe, hose must fit up against flanged part of
pipe.
• For type “D” pipe, hose must cover pipe by 20 – 30mm (0.8 –
1.2 in.).
“A”
“B”
“C”
“D”
5-5 FUEL SYSTEM
"
A small amount of fuel may be released when the fuel
feed hose is disconnected.
Place container under the fuel feed hose or 3-way pipe
with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in
an approved container.
3. Squeeze fuel primer bulb until you feel resistance.
Turn ignition switch “ON” for 3 seconds (to operate fuel
pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system and then check fuel pressure.
4. Measure fuel pressure in line at cranking or idle speed operation.
Fuel pressure : Approx. 255 kPa
(2.55 kg/cm2, 36.3 psi.)
5. Stop engine and wait 5 minutes.
6. Check residual fuel pressure in line.
Residual fuel pressure:
200 kPa (2.0 kg/cm2 , 28.4 psi) or higher
#
OFF
ON
FUEL PRESSURE INSPECTION
1. Relieve fuel pressure in fuel feed line. (See page 5-2)
2. Connect special tools (pressure gauge, pressure hose &
pressure joint) between fuel feed hose and 3-way joint pipe
as shown in figure.
Clamp hose securely to ensure no leaks occur during checking.
09912-58442 : Pressure gauge – a
09912-58432 : Fuel pressure hose – b
09912-58490 : Fuel pressure joint – c
1. High pressure fuel filter
2. Fuel delivery gallery
3. 3-way pipe
1
2
3
c a b "
As fuel feed line is still under high fuel pressure, make
sure to release fuel pressure according to following
procedures.
• Place container under joint to catch fuel.
• Cover joint with rag and loosen joint nut slowly to
gradually release fuel pressure. 1
1 Joint nut
5-6FUEL SYSTEM
7. After checking fuel pressure, remove fuel pressure gauge.
8. Reconnect fuel line.
9. With engine not running and ignition switch “ON”, check fuel
system for leaks.
5-7 FUEL SYSTEM
REMOVAL / INSTALLATION
Removal
!
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.
• Remove intake manifold assembly.
(See page 6-1)
• Remove three bolts and fuel vapor separator assembly from
intake manifold.
Installation
Installation is reverse order of removal.
See page 6-2 for installation of intake manifold assembly.
FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP
5-8FUEL SYSTEM
DISASSEMBLY
Remove five screws 1.
Remove separator cover 2 with high pressure fuel pump from
separator case 3.
NOTE:
Separator cover and case are a set.
Make sure paint marks on both items are matched when assembling.
Remove float pin 4 and float 5.
Remove needle valve 6, screw, plate and valve seat 7.
Remove plate 8.
Remove screw and fuel pressure regulator 9 from separator
case.
5-9 FUEL SYSTEM
INSPECTION
NOTE:
If cracks, excessive wear or other damage is found on any component, replace component.
Needle valve / Valve seat
Check needle valve and valve seat.
If grooved or damaged, replace valve and seat.
If dirt is found, clean.
Remove screw and pump bracket 0.
Remove high pressure fuel pump A from separator cover and
then disconnect pump lead wire connector.
Float
Check float.
If cracked or damaged, replace float.
5-10FUEL SYSTEM
Fuel pressure regulator
Check fuel pressure regulator operation.
: Hand air pump 1
09940-44120 : Air pressure gauge 2
09940-44130 : Attachment 3
09912-58490 : Hose 4
1. Connect special tools to inlet side of regulator as shown.
2. Pump air into regulator using pump 1 until air is released
through outlet side.
3. Note pressure on gauge when air is released.
Regulator operating pressure :
240 – 270 kPa (2.4 – 2.7 kg/cm2, 34.1 – 38.4 psi.)
If measurement exceeds specification, replace regulator.
#
1
2
3 4
Filter
Check pump suction filter.
If clogged or damaged, clean or replace filter.
5-11 FUEL SYSTEM
Separator cover / Separator case
Apply Suzuki Bond evenly to only the outside mating surface of
separator cover as shown.
99000-31140 : Suzuki Bond 1207B
NOTE:
• Clean mating surfaces before applying bond.
• Do not apply bond to o-ring, groove and inside mating surface.
Install separator case and tighten screws securely.
NOTE:
Separator cover and case are a set.
Make sure paint marks on both items are matched when assembling.
"
ASSEMBLY
Assembly is reverse order of disassembly paying special attention to the following steps.
Float / Float pin
Install float and float pin.
NOTE:
After assembling, check for smooth and free float movement.
Fuel pressure regulator
Install fuel pressure regulator and tighten screw securely.
NOTE:
Apply fuel to O-ring before installing regulator.
5-12FUEL SYSTEM
FUEL INJECTOR
INSPECTION
1. Using sound scope or equivelent, check operating sound of
fuel injector when engine is running or cranking.
The injector operating sound cycle should vary according
to engine speed.
If no sound or an unusual sound is heard, check injector
circuit (wire or connector) or injector.
2. Disconnect lead wire connector from fuel injector.
3. Connect digital tester between terminals of injector and
check resistance.
09930-99320 : Digital tester
Tester range : Ω (Resistance)
Fuel injector resistance : 11.0 – 16.5 Ω
If out of specification, replace fuel injector.
4. Connect lead wire connector to fuel injector securely.
#
$
REMOVAL
1. Relieve fuel pressure according to procedure described on
page 5-2.
2. Disconnect lead wire connectors from each injector.
3. Remove the screw securing the fuel injector stopper.
4. Remove fuel injector stopper and fuel injector.
"
A small amount of fuel may be released when the fuel
injector is removed from intake manifold.
Place a shop cloth under fuel injector before removal
to absorb any fuel released.
Dispose of fuel soaked cloth in appropriate container.
5-13 FUEL SYSTEM
INSTALLATION
1. Use care when installing to prevent any O-ring damage.
2. Always replace injector cushion with new.
Assemble cushion to fuel injector.
3. Apply thin coat of fuel to injector O-rings before installing
injector into intake manifold.
4. Install injector stopper and tighten stopper screw securely.
5. Connect lead wire connector to injector securely.
6. Turn ignition switch “ON” for 3 seconds (to operate fuel
pump), then turn it “OFF”.
Repeat this (ON and OFF) procedure 3 or 4 times to pressurize the fuel system.
Check for fuel leaks around fuel injector.
1 Cushion 3 O-ring
2 Injector 4 O-ring
5-14FUEL SYSTEM
LOW PRESSURE FUEL PUMP
REMOVAL / INSTALLATION
REMOVAL
1. Disconnect inlet hose 1 and outlet hose 2 from low pressure fuel pump.
2. Remove two bolts 3.
3. Remove fuel pump 4 and O-ring 5.
"
• Before installing fuel pump, rotate the crankshaft to
bring No.1 (top cylinder) piston to Top Dead Center
on compression stroke.
• Discard O-rings after removal. always use new O-ring
to ensure proper sealing.
Low pressure fuel pump bolt :
10 N . m (1.0 kg-m, 7.0 lb.-ft.)
%
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
5-15 FUEL SYSTEM
DISASSEMBLY / REASSEMBLY
DISASSEMBLY
NOTE:
For correct assembly, scribe an alignment mark on each part of
fuel pump.
Remove six screws 1 and remove in sequence the outer plate
2, diaphragm 3 and valve body 4.
Turn piston 6 until pin 5 comes out through cutaway of pump
body 0.
Remove following parts :
• Pin 5
• Piston 6
• Spring 7
• Diaphragm 8
• Spring 9
ASSEMBLY
Assembly is reverse order of disassembly with special attention the following steps.
NOTE:
After connecting diaphragm rod 8 to piston 6 with pin 5, align
the six diaphragm holes to pump body holes by turning piston 6 and diaphragm8 together. Turning them together prevents the pin from coming out through pump body0 cutaway.
1
6
5
7
0
9
8
4
3
2
5-16FUEL SYSTEM
INSPECTION
Diaphragm
Inspect all diaphragms. If distortion, tears, or other damage is
found, replace diaphragms.
Check-valves
Inspect the fuel pump check valves. If tears, distortion or damage is found, replace fuel pump.
Pump body
Inspect each fuel pump body and outer plate.
If cracks, nicks, distortion or damage is found, replace fuel pump.
5-17 FUEL SYSTEM
FUEL TANK
DISASSEMBLY / REASSEMBLY
When disassembly or reassembling fuel tank, refer to the construction diagram below.
Plastic tank Steel tank
K
2
1
E
D
C
B
A
0
9
8
6
5
I
H
H
J
H
H
G
F
1 Fuel hose assy (1)
2–(a), Connector
2–(b), Connector
[3 Clip (4)]
[4 Primer bulb (1)]
5 Tank cap (1)
6 Gasket (1)
7 Connector plug (1)
8 Outlet (1)
9 Filter (1)
0 O-ring (1)
A Fuel tank (1)
1 Tank cap (1)
2 Gasket (1)
3 Screw (4)
4 Gasket (4)
5 Connector plug (1)
6 Gasket (1)
7 Fuel gauge assy (1)
[8 Cover (1)]
[9 Gasket (1)]
[0 Lens (1)]
[A Gasket (1)]
[B Screw (2)]
[C Float (1)]
[D Push nut (1)]
[E Gasket (1)]
F Fuel hose assy (1)
[G Connector (1)]
[H Clip (4)]
[I Connector (1)]
[J Primer bulb (1)]
[K Fuel tank (1)]
1 2–(a)
3
3
4
3
3
2–(b)
5
7
8
9
0
6
A
3
4
7
5-18FUEL SYSTEM
INSPECTION
Fuel connector
Inspect fuel connector. If leakage,deterioration or other damage is found, replace fuel connector.
Fuel primer bulb
Inspect fuel primer bulb. If cracks, leakage, or deterioration is
found, replace primer bulb.
If check valve function is defective, replace primer bulb.
Fuel hose
Inspect fuel hose. If cuts, cracks, leakage, tears or deterioration
is found, replace fuel hose.
Fuel tank
Inspect fuel tank. if cracks, leakage or deterioration is found,
replace fuel tank.
If water or other contamination is found, drain and clean fuel
tank.
Tank cap
Check that the fuel tank vent opens and relieves internal tank
pressure properly.
Replace tank cap if vent is suspect.
1. Connector 2. Connector plug
2
1
2
1
INTAKE MANIFOLD ASSEMBLY _____________________________ 6-1
REMOVAL ........................................................................................................ 6-1
INSTALLATION ................................................................................................ 6-2
POWER UNIT _____________________________________________ 6-3
REMOVAL ........................................................................................................ 6-3
INSTALLATION ................................................................................................ 6-7
OIL PUMP / CASE _________________________________________ 6-10
REMOVAL ........................................................................................................ 6-10
DISASSEMBLY ................................................................................................ 6-10
INSPECTION ................................................................................................... 6-11
MEASURING PUMP COMPONENTS ............................................................ 6-11
ASSEMBLY ...................................................................................................... 6-12
INSTALLATION ................................................................................................ 6-12
TIMING CHAIN / TENSIONER ________________________________ 6-15
REMOVAL ........................................................................................................ 6-15
INSPECTION ................................................................................................... 6-17
INSTALLATION ................................................................................................ 6-18
CYLINDER HEAD ASSEMBLY _______________________________ 6-21
REMOVAL ........................................................................................................ 6-21
INSTALLATION ................................................................................................ 6-21
DISASSEMBLY ................................................................................................ 6-24
INSPECTION / SERVICING ............................................................................ 6-25
REASSEMBLY ................................................................................................. 6-38
CYLINDER / CRANKSHAFT / PISTON _________________________ 6-40
DISASSEMBLY ................................................................................................ 6-40
INSPECTION / SERVICING ............................................................................ 6-43
REASSEMBLY ................................................................................................. 6-57
THERMOSTAT ____________________________________________ 6-64
REMOVAL / INSPECTION / INSTALLATION ................................................. 6-64
OPERATION ______________________________________________ 6-65
WATER COOLING SYSTEM ........................................................................... 6-65
ENGINE LUBRICATION SYSTEM .................................................................. 6-66
POWER UNIT
CONTENTS
6
6-1 POWER UNIT
INTAKE MANIFOLD ASSEMBLY
REMOVAL
Before removing intake manifold :
• Relieve fuel pressure. (See page 5-2)
• Disconnect battery cables from battery.
• Remove both side covers. (See page 7-1)
1. Remove flywheel cover and breather hose.
Remove evaporation hose from flywheel cover.
2. Remove silencer case 1 and disconnect lead wire connector 2 from IAT sensor.
3. Disconnect lead wire connector 3 from CTP switch.
4. Remove throttle rod 4 from throttle body.
5. Remove bolts and side cover holder 5.
6. Remove water inlet hose 6 and outlet hose 7 from vapor
separator.
7. Place a suitable container under the vapor separator, then
disconnect fuel return hose 8 from vapor separator.
8. Disconnect MAP sensor lead wire connector 9 at MAP sensor.
Disconnect low pressure fuel inlet hose 0 from vapor separator.
9. Disconnect high pressure fuel outlet hose A from vapor
separator.
Disconnect high pressure fuel pump lead wire connector B
at high pressure fuel pump.
POWER UNIT 6-2
10. Remove two bolts and high pressure fuel filter C.
11. Disconnect lead wire connectors D from all fuel injectors.
12. Remove four (4) bolts and Throttle body E.
Remove IAC valve hose F from Throttle body.
13. Remove bolts and nuts, and then remove intake manifold
assembly G.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
!
Do not re-use gasket once removed. Always use a new
gasket.
• Apply the bond to both mating surfaces of the intake manifold
gasket.
" 99000-31140 : Suzuki Bond 1207B
• Tighten bolts and nuts securely.
# Intake manifold bolt & nut :
6 mm 11N . m (1.1 kg-m, 8.0 lb.-ft.)
8 mm 23N . m (2.3 kg-m, 16.5 lb.-ft.)
• Check to ensure that all removed parts are back in place.
Checking
• Check fuel and water hose routing. (See page 10-7 to 10-9)
• Check wire routing (See page 10-1 to 10-6)
• Check for fuel leakage. (See page 5-3)
• Check for water leakage.
6-3 POWER UNIT
POWER UNIT
REMOVAL
Before removing power unit :
• Drain engine oil.
• Remove intake manifold assembly. (See page 6-1)
Remove two bolts and low pressure fuel pump 1.
Disconnect ignition coil connectors.
Remove the bolt securing the ignition coil 2.
Remove all ignition coils 2 and spark plugs.
Disconnect CMP sensor connector 3.
Remove the twelve (12) cylinder head cover bolts, and then
remove cylinder head cover 4.
Remove starter motor. (See page 4-11)
Remove flywheel. (See page 3-48)
09930-48720 : Flywheel holder
09930-39411 : Flywheel remover
09930-39420 : Flywheel remover bolt
$
POWER UNIT 6-4
Remove battery charge coil 1. (See page 4-4)
Disconnect CKP sensor connector and remove sensors 2.
Disconnect cylinder temperature sensor connector and remove
sensor 3.
Remove two bolts and rectifier & regulator.
Remove bolt and low pressure fuel filter bracket.
Disconnect water hose 4 from thermostat cover and engine
holder.
Disconnect exhaust manifold temperature sensor connector and
remove sensor 5.
Loosen screw and disconnect oil pressure switch lead wire 6.
Disconnect neutral switch lead connector wire 7.
Disconnect all engine wiring harness connectors from ECM,
then remove ECM 8.
Disconnect the PTT motor cable wire leads (G, Bl) from the
PTT relays.
Remove positive (+) battery cable from starter motor relay.
ECM
6-5 POWER UNIT
Remove four bolts and electric part holder.
Remove IAC valve silencer.
Disconnect clutch rod from shift rod by loosening lock nut and
turnbuckle.
Remove throttle control lever 1 and clutch control lever 2.
Remove bolt and neutral switch 3 with bracket.
Remove two bolts 1 securing front panel bracket 2.
Remove screw 3 and clutch lever shaft 4.
Remove clutch rod arm 5 from crankcase .
Remove pin 6 and side cover seal 7.
Remove oil level dipstick 8.
POWER UNIT 6-6
Remove eight bolts and nut.
Lift up and remove power unit from engine holder.
6-7 POWER UNIT
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
!
Do not re-use gasket and o-ring.
Always replace with new parts.
POWER UNIT
Install dowel pins 1, gasket 2 and O-ring 3.
Apply Suzuki Water Resistant Grease to driveshaft splines.
99000-25160 : Suzuki Water Resistant Grease
Lower the power unit onto engine holder.
NOTE:
Rotate crankshaft to aid alignment of driveshaft and crankshaft
splines.
Apply Suzuki Silicone Seal to power unit mounting bolts and
tighten bolts and nut to specified torque.
99000-31120 : Suzuki Silicone Seal
Power unit mounting bolt and nut :
8 mm 23 N . m ( 2.3kg-m, 16.5 lb.-ft. )
10 mm 50 N . m ( 5.0kg-m, 36.0 lb.-ft.)
FLYWHEEL
Install battery charge coil. (See page 4-5)
Install CKP sensors. (See page 3-49)
%
&
#
POWER UNIT 6-8
Install flywheel and tighten flywheel bolt to specified torque.
(See page 3-49)
09930-48720 : Flywheel holder
Flywheel bolt : 200 N . m (20.0 kg-m, 144.5 lb.-ft.)
CYLINDER HEAD COVER
NOTE:
Before installing cylinder head cover, check tappet clearance.
(See page 2-8)
Apply Suzuki Bond to area as shown in figure.
" 99000-31140 : Suzuki Bond No. 1207B
!
Do not re-use gasket and o-ring once removed.
Always use new parts.
NOTE:
Be sure to check all parts for wear or any damage before installation and replace any found defective.
Install cylinder head cover to cylinder head and tighten cover
bolts to specified torque.
Cylinder head cover bolt :
10 N . m (1.0kg-m, 7.0 lb.-ft.)
NOTE:
Use care when installing cylinder head cover.
Be certain cylinder head cover gasket and O-rings remain in
their correct position.
Apply Thread Lock 1342 to the screws securing clutch shaft
arms to the clutch shaft.
' 99000-32050 Thread Lock 1342
#
#
$
6-9 POWER UNIT
INTAKE MANIFOLD
Install intake manifold assembly.
(See page 6-2)
FINAL ASSEMBLY CHECK
Perform the following checks to ensure proper and safe operation of the repaired unit.
• All parts removed have been returned to their original positions .
• Lower unit gear engagement is properly adjusted.
(See page 9-22)
• Fuel and water hose routing match’s service manual illustration. (See page 10-7 to 10-9)
• Wire routing match’s service manual illustration.
(See page 10-2 to 10-6)
• No fuel leakage is evident when fuel system is pressurized.
(See page 5-3)
• No water leakage is evident during final test running.
POWER UNIT 6-10
OIL PUMP / CASE
REMOVAL
1. Remove the power unit.
(see page 6-3 to 6-6)
2. Remove the two (2) bolts securing the under oil seal housing to oil pump case, then remove the under oil seal housing.
3. Remove the seven (7) bolts securing the oil pump case to
cylinder block, then remove oil pump case with oil pump.
DISASSEMBLY
1. Remove the screws securing oil pump rotor plate to the oil
pump case, then remove the oil pump rotor plate.
2. Take out inner rotor and outer rotor.
Rotor plate
1
2
1. Outer rotor 2. Inner rotor
6-11 POWER UNIT
INSPECTION
Oil seal
Check oil seal lip for wear or other damage.
Replace as necessary.
MEASURING PUMP COMPONENTS
Radial clearance
Using a feeler gauge, measure radial clearance between outer
rotor and case.
Radial clearance :
Service limit : 0.31 mm (0.012 in.)
If measurement is not within specifications, replace the outer
rotor and/or case.
Side clearance
Using straightedge and feeler gauge, measure side clearance.
Side clearance
Service limit : 0.15 mm (0.006 in.)
If measurement is not within specifications, replace the outer
rotor and/or pump case.
Oil pump components
Check outer and inner rotors, rotor plate and oil pump case for
excessive wear or damage.
Replace as necessary.
1
2
1. Outer rotor 2. Inner rotor
1. Outer rotor 2. Inner rotor
$
1
2
$
POWER UNIT 6-12
ASSEMBLY
(1) Wash, clean and then dry all disassembled parts.
(2) Apply thin coat of engine oil to inner and outer rotors, oil
seal lip and inside surfaces of oil pump case and plate.
(3) Install outer and inner rotor to pump case.
(4) Install outer plate.
Tighten six (6) screws securely.
After mounting the outer plate, check to be sure that each
rotor turns smoothly by hand.
INSTALLATION
Installation is reverse of removal with special attention to following steps.
1. Check for proper timing chain installation.
(see page 6-20)
2. Install two (2) dowel pins to cylinder block.
Before fitting the pump case, oil the oil seal lip.
1
2
1. Outer rotor 2. Inner rotor
1
1
1. Dowel pin
6-13 POWER UNIT
3. Apply sealant to areas as shown in figure.
99000-31140 : Suzuki Bond 1207B
4. Apply a continuous bead of sealant to oil pump case mating
surface as shown in figure.
99000-31140 : Suzuki Bond 1207B
5. Install oil pump case to cylinder block and tighten seven (7)
bolts securely.
NOTE:
• When installing oil pump case be sure position of oil pump
inner rotor matchs with crankshaft.
• Tighten bolts in the indicated order.
Sealant
Sealant
!
!
!
!
POWER UNIT 6-14
8. Install under oil seal housing and tighten bolts.
6. Install dowel pin and gasket to oil pump case.
7. Apply grease to oil seal lip.
99000-25160 : Water Resistant Grease&
6-15 POWER UNIT
TIMING CHAIN / TENSIONER
REMOVAL
Prior to this service work :
• remove the power unit. (see page 6-3 to 6-6)
• remove the oil pump case. (see page 6-10)
1. Turn the crankshaft in its normal running direction (R direction) until No.1 cylinder reaches top dead center.
NOTE :
To bring No.1 cylinder top dead center, align mark S on the
crankshaft with mark a on the crank case.
!
When timing chain has been removed, never turn crankshaft or camshaft.
2. Remove the bolts and timing chain tensioner link 5.
3. Remove the bolts and tensioner adjuster 6.
4. Remove the bolts and timing chain guide No.1 3.
1 Crankshaft / timing sprocket
2 Timing chain
3 Timing chain guide No.1
4 Timing chain tensioner
5 Timing chain tensioner link
6 Timing chain tensioner adjuster
7 Timing chain guide No.2
8 Exhaust camshaft w/timing sprocket
9 Intake camshaft and timing sprocket
1
2
3
9
7
8
5
4
a: Match mark on crank case
S: Match mark on crank shaft
R: Engine normal running direction
a S
6
R
POWER UNIT 6-16
NOTE:
Hold camshaft by placing a wrench on the hexagon area of the
camshaft.
7. Remove the three(3) bolts securing the intake timing sprocket
to camshaft.
8. Remove the intake timing sprocket, dowel pin and timing
chain.
5. Remove the bolt and timing chain tensioner 4.
6. Remove the bolts and timing chain guide No.2 7.
6-17 POWER UNIT
Tensioner adjuster
Inspect tensioner adjuster for smooth operation.
Replace if faulty.
Timing chain tensioner / chain guide
Check shoe for wear or damage.
Timing sprocket
Check teeth of sprocket for wear or damage.
1. Latch
2. Tooth surface
1 2
INSPECTION
NOTE:
If any component is worn excessively, cracked, defective or
damaged in any way, it must be replaced.
Timing chain
Inspect timing chain.
Replace if worn or damaged.
POWER UNIT 6-18
INSTALLATION
Installation is reverse of removal with special attention to following steps.
(1) Align crankshaft timing mark S with timing mark a on
crankcase as shown in figure by turning crankshaft.
(2) Install dowel pin 1 in intake camshaft.
Then turn the camshaft to position the dowel pin at the top,
as shown in figure.
Check that mark e on exhaust camshaft timing sprocket
aligns with timing mark b on cylinder head as shown in
figure.
(3) Install timing chain by aligning blue plate of timing chain
and arrow on exhaust camshaft timing sprocket as shown
in figure.
Install timing chain by aligning yellow plate of timing chain
and crankshaft timing mark S as shown in figure.
(4) Bring blue plate of timing chain into alignment with arrow
mark on intake camshaft timing sprocket, then install intake
cam timing sprocket to intake camshaft.
Tighten sprocket bolts to specified torque.
(# Camshaft timing sprocket bolt :
10 N . m (1.0 kg-m, 7.0 lb.-ft.)
1
b e S
a NOTE:
Hold the camshaft by placing a wrench on the hexagon area of
the shaft.
Blue plate
Yellow plate
S
Arrow
mark
( )
6-19 POWER UNIT
(8) With latch of tensioner adjuster returned and plunger pushed
back into body, insert stopper into latch and body.
After inserting stopper, check to make sure that plunger will
not come out.
(5) Install timing chain guide No.2 1.
(6) Insert spacer into chain tensioner.
Install chain tensioner 2 as shown in figure.
Apply oil to chain tensioner.
(7) Install timing chain guide No.1 3.
(9) Install timing chain tensioner adjuster 4.
Apply engine oil to timing chain.
1
1. Plunger
2. Latch
3. Body
4. Stopper
2
4
3
1 2
POWER UNIT 6-20
(10) Install timing chain tensioner link 5.
(11) Pull out stopper from adjuster.
(12) Turn crankshaft normal running direction 2 revolutions and
check that match marks are aligned as shown in figure.
(13) Install oil pump case.
(See page 6-12)
(14) Install under oil seal housing.
(See page 6-14)
1
2
1. Match mark (slit) on camshaft sprocket
2. Match mark (rib) on cylinder head
3. Match mark on crank shaft
4. Match mark on crankcase
4
3
6-21 POWER UNIT
CYLINDER HEAD ASSEMBLY
(Cylinder head / valve / camshaft)
REMOVAL
Prior to removing cylinder head :
• Remove the power unit.
(see page 6-3 to 6-6)
• Remove the timing chain.
(see page 6-15 to 6-16)
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
!
Do not re-use gasket. Always use a new gasket.
3. Loosen ten (10) cylinder head bolts in the order indicated in
figure and remove them.
4. Remove cylinder head assembly and head gasket.
NOTE:
Use a special tool (10mm deep socket wrench) when loosening the cylinder head bolts.
09919-16010 : Deep socket wrench (10 mm)
1. Remove the bolts securing the camshaft housing to cylinder head, then remove each camshaft housing.
NOTE:
For ease of assembly, note position of each individual camshaft
housing.
2. Remove intake and exhaust camshafts.
1. Insert the dowel pins and place a new cylinder head gasket
into position on the cylinder.
$
19 7 2
5
41086
3
POWER UNIT 6-22
4. Apply engine oil around tappets and install.
5. Install tappet shims.
6. Apply engine oil to the surface of each camshaft lobe and
journal, then install them as shown in figure.
NOTE:
Before installing camshafts, turn crankshaft until No.1 cylinder
reaches top dead center. (see page 6-15)
1
2
3
1. Dowel pin hole
2. Match mark (slit)
3. Match mark (rib)
NOTE:
Use special tool (10mm deep socket wrench) when tighten the
cylinder head bolt.
09919-16010 : Deep socket wrench (10 mm)$
#
2. Position cylinder head on cylinder.
3. Apply engine oil to cylinder head bolts and tighten them
gradually as follows.
(a) Tighten all bolts to 30 N . m (3.0 kg-m, 21.5 lb.-ft.) according to numerical order in figure.
(b) Loosen all bolts to 0 N . m (0 kg-m, 0 lb.-ft.) according to
reverse order in figure.
(c) Again tighten all bolts to 30 N . m (3.0 kg-m, 21.5 lb.-ft.)
according to numerical order in figure.
(d) Finally tighten all bolts to specified torque according to
numerical order in figure.
Cylinder head bolt : 60 N . m (6.0 kg-m, 43.5 lb.-ft.)
102 4 9
6
7135
8
6-23 POWER UNIT
7. Install camshaft housing pins as shown in figure.
8. Check position of camshaft housing.
• Embossed marks are provided on each camshaft housing
indicating position and direction of installation.
Install housings as indicated by these marks.
9. Apply engine oil to housing bolts.
10. Lightly seat all housing bolts at first.
Following numerical order in figure, tighten bolts to 1/3 of
specified torque, then 2/3 of specified torque and finally to
full specified torque.
Camshaft housing bolt : 10 N . m (1.0 kg-m, 7.0 lb.-ft.)
11. Install timing chain. (see page 6-18)
12. Adjust tappet clearance. (see page 2-8)
I : Intake side
E : Exhaust side
Position from flywheel
magneto side
Pointing to flywheel
magneto side
#
13
16
6 5 2 10
11
12
9
4387
17
14
15
1
Pin
POWER UNIT 6-24
DISASSEMBLY
1. Remove tappets with shims.
2. Using valve lifter and attachment, remove valve cotters 1
while compressing valve spring.
09916-14510 : Valve lifter
09916-14910 : Attachment
09916-84511 : Tweezers
3. Remove valve spring retainer 2, valve spring 3 and valve
4.
4. Remove valve stem seal 5 and valve spring seat 6.
NOTE:
Reassemble each valve and valve spring in their original positions.
$
$
$
$
$
1
1 2 3 5 6 4
1
5
6
$
6-25 POWER UNIT
CYLINDER HEAD
Remove all carbon from combustion chambers.
NOTE:
• Do not use any sharp edged tool to scrape carbon off cylinder head or its components.
• Be careful not to scuff or nick metal surfaces when decarboning.
Check cylinder head for cracks in intake and exhaust ports,
combustion chambers, and head surface.
Valve seat
Check valve seat, if cracks or other damage is found, replace
cylinder head.
Cylinder head distortion
Using a straightedge and thickness gauge, measure cylinder
head distortion (gasket surface) at a total of six (6) locations as
shown.
09900-20803 : Thickness gauge
Cylinder head distortion
Service limit : 0.05 mm (0.002 in.)
If measurement exceeds service limit, resurface or replace cylinder head.
NOTE:
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.
INSPECTION / SERVICING
NOTE:
If cracks, excessive wear or other damage is found on any component, replace component.
$
$
POWER UNIT 6-26
Manifold seating faces distortion
Using a straightedge and thickness gauge, check cylinder head
to manifold seating faces.
Manifold seating faces distortion
Service limit : 0.10 mm (0.004 in.)
If measurement exceeds service limit, resurface or replace cylinder head.
Water jackets
Check water jackets. If clogged or obstructed, clean water jackets.
CAMSHAFT
Cam face
Inspect cam face for scratches and wear.
Cam wear
Using micrometer, measure cam height H.
09900-20202 : Micrometer
Cam height
Standard:
DF40 IN 37.530 – 37.690 mm (1.4776 – 1.4839 in.)
EX 37.740 – 37.900 mm (1.4858 – 1.4921 in.)
DF50 IN 38.230 – 38.390 mm (1.5051 – 1.5114 in.)
EX 37.740 – 37.900 mm (1.4858 – 1.4921 in.)
Service limit
DF40 IN 37.430 mm (1.4736 in.)
EX 37.640 mm (1.4819 in.)
DF50 IN 38.130 mm (1.5012 in.)
EX 37.640 mm (1.4819 in.)
If measurement exceeds service limit, replace camshaft.
H
$
$
6-27 POWER UNIT
Camshaft identification
DF40 and DF50 camshafts differ as indicated below.
CAMSHAFT JOURNAL
Check camshaft journals and camshaft housing for pitting,
scratches, wear or damage.
If any of the above conditions are found, replace camshaft or
cylinder head with housing.
NOTE:
Camshaft housing and cylinder head must be replaced as a
set.
Model Identification Groove
No groove
DF50 Groove
DF40
Camshaft runout
Position camshaft between two “V” blocks and measure runout
using a dial gauge.
09900-20602 : Dial gauge
09900-21304 : “V” block set
09900-20701 : Magnetic stand
Camshaft runout
Service limit : 0.10 mm (0.004 in.)
If measurement exceeds service limit, replace camshaft.
$
IN EX
1 Groove
POWER UNIT 6-28
Camshaft journal oil clearance
Check journal oil clearance using Plastigauge as follows.
1. Clean housing and camshaft journals.
2. Install camshaft to cylinder head.
3. Place Plastigauge across the full width of camshaft journal
(parallel to camshaft).
09900-22302 : Plastigauge
4. Install camshaft housing. Tighten housing bolts in 3 steps
(1/3 of specification, 2/3 of specification, full torque specification) in the indicated order.
Camshaft housing bolt : 10 N . m (1.0 kg-m, 7.0 lb.-ft.)
NOTE:
Do not rotate camshaft while Plastigauge is installed.
5. Remove camshaft housing.
6. Using scale on Plastigauge envelope, measure Plastigauge
at its widest point.
Camshaft journal oil clearance
Standard : 0.045 – 0.087 mm (0.0018 – 0.0034 in.)
Service limit : 0.120 mm (0.0047 in.)
1. Plastigauge
2. Scale
1 2
$
#
Camshaft journal outside diameter
Standard : 22.934 – 22.955 mm (0.9029 – 0.9037 in.)
Service limit : 22.784 mm (0.8970 in.)
If journal oil clearance exceeds the service limit, measure camshaft journal (outside dia.) and camshaft housing (inner dia.).
Based on measurements, replace camshaft and / or cylinder
head with camshaft housing.
09900-20205 : Micrometer$
13
16
6 5 2 10
11
12
9
4387
17
14
15
1
yy yy 6-29 POWER UNIT
Camshaft journal (housing) inside diameter
Standard : 23.000 – 23.021 mm (0.9055 – 0.9063 in.)
Service limit : 23.171 mm (0.9122 in.)
TAPPET / TAPPET SHIM
Wear of tappet and shim
Check tappet and shim for pitting,scratches, or damage.
If any above conditions are found, replace component.
Measure cylinder head bore and tappet outside diameter to
determine cylinder head to tappet clearance.
09900-20202 : Micrometer
If measurement exceeds service limit, replace tappet or cylinder head.
Cylinder head bore to tappet clearance
Standard : 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
Service limit : 0.150 mm (0.0059 in.)
Tappet outer diameter
Standard : 26.959 – 26.975 mm (1.0614 – 1.0620 in.)
Cylinder head bore
Standard : 27.000 – 27.021 mm (1.0630 – 1.0638 in.)
$
POWER UNIT 6-30
Valve stem outside diameter
Using micrometer, measure valve stem outside diameter.
Valve stem outside diameter
Standard:
IN 5.465 – 5.480 mm (0.2152 – 0.2157 in.)
EX 5.440 – 5.455 mm (0.2142 – 0.2148 in.)
Valve guide inside diameter
Using a small bore gauge, measure valve guide inside diameter.
Valve guide inside diameter
Standard :
IN 5.500 – 5.512 mm (0.2165 – 0.2170 in.)
EX 5.500 – 5.512 mm (0.2165 – 0.2170 in.)
Valve guide to valve stem clearance
Valve guide to valve stem clearance
Standard :
IN 0.020 – 0.047 mm (0.0008 – 0.0019 in.)
EX 0.045 – 0.072 mm (0.0018 – 0.0028 in.)
Service limit :
IN 0.070 mm (0.0028 in.)
EX 0.090 mm (0.0035 in.)
If measurement exceeds service limit, replace valve and / or
valve guide.
NOTE:
For valve guide replacement, see “VALVE GUIDE REPLACEMENT” section on page 6-35.
$
VALVE / VALVE GUIDE
Valve guide to valve stem clearance
Using a micrometer and bore gauge, take diameter readings
on valve stems and guides to check guide to stem clearance.
Be sure to take readings at more than one place along the length
of each stem and guide.
09900-20205 : Micrometer$
6-31 POWER UNIT
Valve stem end deflection
If unable to measure valve guide inside diameter, check “Valve
stem end deflection”.
09900-20602 : Dial gauge
09900-20701 : Magnetic stand
Measure valve stem end deflection as follows :
(1) Install valve into valve guide.
(2) Position valve head at approx. 5mm away from valve seat.
(3) Move stem end in the direction “X – Y”, and measure deflection.
Valve stem end deflection
Service limit :
IN 0.14 mm (0.006 in.)
EX 0.18 mm (0.007 in.)
If measurement exceeds service limit, replace valve.
If measurement still exceeds service limit with new valve, replace valve guide.
!
X
Y
1
Valve stem end length
Inspect valve stem end face for pitting and wear.
If pitting or wear is found, valve stem end may be resurfaced.
Use caution when resurfacing, do not grind away stem end
chamfer.
When chamfer has been worn away, replace valve.
09900-20101 : Vernier calipers
Valve stem end length 1
Service limit : 3.20 mm (0.126 in.)
!
POWER UNIT 6-32
Valve stem runout
Measure valve stem runout.
09900-20602 : Dial gauge
09900-20701 : Magnetic stand
09900-21304 : “V” block set
Valve stem runout
Service limit : 0.05 mm (0.002 in.)
If measurement exceeds service limit, replace valve.
Valve head radial runout
Measure valve head radial runout.
09900-20602 : Dial gauge
09900-20701 : Magnetic stand
09900-21304 : “V” block set
Valve head radial runout
service limit : 0.08 mm (0.003 in.)
If measurement exceeds service limit, replace valve.
Valve head thickness
Measure thickness T of valve head.
09900-20101 : Vernier calipers
Valve head thickness
Standard :
IN 1.0 mm (0.04 in.)
EX 1.15 mm (0.045 in.)
Service limit :
IN 0.7 mm (0.03 in.)
EX 0.5 mm (0.02 in.)
If measurement exceeds service limit, replace valve.
45° T
!
!
!
6-33 POWER UNIT
Valve seat contact width
Measure valve seat contact width as follows :
(1) Remove all carbon from valve and seat.
(2) Coat valve seat evenly with Prussian blue
(or equivalent)
(3) Install valve into valve guide.
(4) Put valve lapper on valve.
09916-10911 : Valve lapper
(5) Rotate valve while gently tapping valve contact area against
seat.
(6) Continuously pattern on valve seating face with Prussian
blue.
(7) Measure valve seat contact width A.
09900-20101 : Vernier calipers
Valve seat contact width A
Standard :
IN 1.80 – 2.20 mm (0.071 – 0.087 in.)
EX 1.65 – 2.05 mm (0.065 – 0.081 in.)
If measurement exceeds specification, repair valve seat.
NOTE:
For valve seat repair, see “Valve seat servicing” section on page
6-34.
A
!
!
POWER UNIT 6-34
VALVE SEAT SERVICING
If valve seat contact width is out of specification, reface valve
seat as follows :
• Valve seat angle
Intake side : 30°, 45°
Exhaust side : 15°, 45°
09916-20620 : Valve seat cutter (NEWAY122) 45°
09916-20610 : Valve seat cutter (NEWAY121) 15°
09916-20630 : Valve seat cutter (NEWAY 126) 30°
09916-24440 : Handle adaptor (N-503-1)
09916-24450 : Solid pilot (N-100-5.52)
09916-54910 : Handle (N-505)
NOTE:
Turn cutter clockwise, never counterclockwise.
(1) Remove all carbon from valve and valve seat.
(2) Using 45° angle cutter, reface valve seat.
(3) Check valve seat contact width A.
See the “Valve seat contact width” section on page 6-33.
(4) If width A is too high (or wide), reface valve seat using small
angle cutter (Intake side : 30°, Exhaust side : 15°).
If width A is too low (or narrow), reface valve seat using
45° angle cutter.
(5) Clean up any burrs using 45° angle cutter very lightly.
"
Grind seat areas minimally only.
Do not grind more than necessary.
(6) Lap valve on seat in two steps, first with coarse grit lapping
compound applied to face and the second with fine grit
compound.
(7) Recheck valve seat contact width A.
IN EX
30°
45°
15°
45°
A
• Too high (wide)
• Too low (narrow)
A
!
6-35 POWER UNIT
NOTE:
Clean and assemble cylinder head and valve components.
Fill intake and exhaust ports with solvent to check for leaks between valve seat and valve.
If any leaks occur , inspect valve seat and face for burrs or other
things that could prevent valve from sealing.
(1) Using valve guide remover, drive valve guide out from combustion chamber side towards valve spring side.
09916-44310 : Valve guide remover
NOTE:
Do not reuse valve guide once it has been removed.
Always use a new valve guide (oversize) when assembling.
(2) Ream valve guide hole with φ10.5 mm reamer to true hole
and remove burrs.
09916-37320 : Valve guide reamer (φ10.5mm)
09916-34542 : Reamer handle
NOTE:
Turn reamer clockwise, never counterclockwise.
!
!
!
VALVE GUIDE REPLACEMENT
"
Be careful not to damage cylinder head when replacing valve guide.
!
!
POWER UNIT 6-36
09916-57330 : Valve guide installer handle A
09917-87010 : Valve guide installer attachment B
Valve guide protrusion H
standard :
IN & EX 11.0 mm (0.43 in.)
(4) Ream valve guide bore with φ5.5mm reamer.
09916-34550 : Valve guide reamer (φ5.5mm)
09916-34542 : Reamer handle
NOTE:
Clean and oil valve guide bore after reaming.
!
!
!
!
A
BH
(3) Install valve guide to cylinder head.
• Heat cylinder head to a temperature of 80 – 100°C (176 –
212°F ).
Apply heat uniformly so that head will not be distorted.
• Use special tools to drive new valve guide into hole.
Drive in new valve guide until special tool (valve guide
installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion H.
!
!
6-37 POWER UNIT
Valve spring squareness
Use a square and surface plate to check each spring for squareness
(clearance between end of valve spring and square).
09900-20101 : Vernier calipers
Valve spring squareness
Service limit :
IN & EX 2.0 mm (0.08 in.)
If measurement exceeds service limit, replace valve spring.
VALVE SPRING
Valve spring free length
Check spring strength by measuring free length.
09900-20101 : Vernier calipers
Valve spring free length
Standard :
IN & EX 33.1 mm (1.30 in.)
Service limit :
IN & EX 31.8 mm (1.25 in.)
If lower than service limit, replace valve spring.
Valve spring preload
Measure valve spring preload.
09900-20101 : Vernier calipers
Valve spring preload
Standard :
IN & EX 97 – 113 N (9.7 – 11.3 kg , 21.4 – 24.9 lbs.)
for 28.5 mm (1.12 in.)
Service limit :
IN & EX 89 N (8.9 kg, 19.6 lbs.)
for 28.5mm (1.12 in.)
If lower than service limit, replace valve spring.
!
!
!
POWER UNIT 6-38
1
2
65
4
3
REASSEMBLY
Reassemble in reverse order of disassembly paying special
attention to the following steps.
VALVE
Install valve spring seat 1 to cylinder head.
After applying engine oil to stem seal 2 and spindle of special
tool ( Installer attachment ), fit stem seal to spindle.
Then, pushing special tool by hand, install stem seal to valve
guide.
Check to be sure that seal is properly fixed to valve guide.
09917-87010 : Installer attachment A
09916-57330 : Installer handle B
"
Do not reuse stem seal once removed.
Always install new seal.
Apply engine oil to stem seal, valve guide bore and valve stem.
Install valve 3 to valve guide.
NOTE:
Reassemble each valve and valve spring to their original position.
!
!A
B
2
#
!
Install valve spring 4, and valve retainer 5.
NOTE:
Set valve spring in place with narrow spiral area facing valve
seat.
1. Large-pitch
2. Small-pitch
3. Valve spring
retainer side
4. Valve spring
seat side
1
3
2
4
6-39 POWER UNIT
Hold valve spring compressed with special tool and install valve
cotters 6.
Make sure valve cotters are properly seated in groove A.
09916-14510 : Valve lifter
09916-14910 : Attachment
09916-84511 : Tweezers
!
!
!
!
!
A
6
6
!
POWER UNIT 6-40
Remove the five (5) bolts securing the upper oil seal housing to
cylinder, then remove the oil seal housing.
Remove oil filter.
09915-47340 : Oil filter wrench
Remove oil pressure switch.
CYLINDER / CRANKSHAFT / PISTON
DISASSEMBLY
Before performing service work in this section :
• Remove power unit (see page 6-3 to 6-6)
• Remove timing chain (see page 6-15 to 6-16)
• Remove cylinder head (see page 6-21)
!
Remove eight (8) bolts 1.
Remove eight (8) bolts 2.
Remove crankcase from cylinder block.
6-41 POWER UNIT
Remove all conrod cap nuts 1 and conrod caps 2.
NOTE:
For proper assembly, mark cylinder number on all pistons,
conrods, and conrod caps, using quick drying paint.
NOTE:
To prevent damage to crank pin and cylinder walls, install a
piece of hose over threads of rod bolts.
Remove crankshaft.
Mark cylinder number on pistons using quick dry paint.
Push piston (with conrod) out through the top of cylinder bore.
NOTE:
• To prevent damage to piston rings, decarbon top of cylinder
bore wall before removing piston.
• Reassemble each conrod cap to its original position after
removing piston from bore.
Guide hose
POWER UNIT 6-42
Remove two compression rings (top and 2 nd) and oil ring from
piston.
Mark cylinder number on conrod using quick dry paint.
Remove piston pin circlips as shown.
1
1. Piston pin circlip
Remove piston pin from conrod.
NOTE:
Reassemble each piston, piston pin and conrod in their original
combination and position.
6-43 POWER UNIT
INSPECTION / SERVICING
NOTE:
If cracks, excessive wear or other damage is found on any component, replace component.
CYLINDER
• Cylinder distortion
Using a straightedge and thickness gauge, measure cylinder
distortion (gasketed surface) at a total of six (6) locations as
shown.
09900-20803 : Thickness gauge
Cylinder distortion
Service limit : 0.060 mm (0.0024 in.)
If measurement exceeds service limit, resurface or replace
cylinder.
NOTE:
Cylinder can be resurfaced, using a surface plate and # 400 grit
wet sand paper.
Use a figure eight sanding pattern when resurfacing.
• Water jackets
Check water jackets.
If clog or obstruction is found, clean water jacket.
• Cylinder bore
Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear.
If cylinder bore is very rough or deeply scratched, or ridged,
rebore cylinder and use oversize piston.
!
!
POWER UNIT 6-44
PISTON TO CYLINDER CLEARANCE
(1) Measure the piston diameter at a point 19mm (0.748 in.)
above the piston skirt at a right angle to the piston pin bore.
09900-20203 : Micrometer
Piston skirt diameter
Standard : 70.970 – 70.990 mm (2.7941 – 2.7949 in.)
(2) Measure the cylinder bore at 50mm (1.969 in.) below the
cylinder head gasket surface at a right angle to the crankshaft pin.
09900-20508 : Cylinder gauge set
Cylinder bore
Standard : 71.000 – 71.020 mm (2.7953 – 2.7961 in.)
!
19 mm
!
!
50 mm
!
!
!
1. 50 mm (1.96 in.)
2. 90 mm (3.54 in.)
1
2
• Cylinder bore wear (difference)
Using cylinder gauge, measure cylinder bore in both axial
(vertical line, following crankshaft) and transverse (horizontal
line across crankshaft) directions at two positions as shown
in figure.
09900-20508 : Cylinder gauge set
Check for following :
• Difference between measurements at the two positions
(taper).
• Difference between axial and transverse measurement (outof-round).
Cylinder bore wear (difference)
Service limit : 0.10 mm (0.039 in.)
If measurement exceeds service limit, rebore or replace cylinder.
6-45 POWER UNIT
NOTE:
Oversize oil ring rails have no I.D. mark to distinguish size.
Oil ring outer diameter must be measured to determine size.
(3) Calculate the piston / cylinder clearance
(Clearance equals difference between piston diameter
and cylinder bore measurements).
Piston to cylinder clearance
Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.)
Service limit : 0.100 mm (0.0039 in.)
If clearance exceeds service limit, replace piston and / or
cylinder or rebore cylinder.
• Piston
Oversize I.D. mark
0.50 mm 0.50
• 1st & 2nd Piston ring
Oversize
I.D. mark
1st ring 2nd ring
N50 2N500.50 mm
• Oil ring
Oversize I.D. mark
0.50 mm Blue paint
I.D. mark
0.50
I.D. mark
1st, 2nd ring
I.D. mark
Oil ring spacer
Identification of oversize piston / piston ring
Oversize piston / piston ring are marked as shown below.
POWER UNIT 6-46
PISTON
• Inspect piston for faults, cracks or other damage.
Damaged or faulty piston(s) should be replaced.
• Piston ring to groove clearance
Before checking, piston grooves must be clean, dry and free
of carbon.
Fit piston ring into piston groove, and measure clearance between ring and ring groove using thickness gauge.
09900-20803 : Thickness gauge
Piston ring to groove clearance
Standard:
1 st 0.02 – 0.06 mm (0.001 – 0.002 in.)
2 nd 0.02 – 0.06 mm (0.001 – 0.002 in.)
Service limit :
1 st 0.10 mm (0.004 in.)
2 nd 0.10 mm (0.004 in.)
If measurement exceeds service limit, replace piston and /
or piston ring.
Piston ring groove width
Standard :
1 st 1.01 – 1.03 mm (0.040 – 0.041 in.)
2 nd 1.01 – 1.03 mm (0.040 – 0.041 in.)
Oil 1.51 – 1.53 mm (0.059 – 0.060 in.)
Piston ring thickness
Standard :
1 st 0.97 – 0.99 mm (0.038 – 0.039 in.)
2 nd 0.97 – 0.99 mm (0.038 – 0.039 in.)
Piston ring
!
!
6-47 POWER UNIT
PISTON RING
Piston ring end gap
Measure piston ring end gap with piston ring in the lowest position of cylinder bore.
09900-20803: Thickness gauge
Piston ring end gap
Standard:
1 st 0.10 – 0.25 mm (0.004 – 0.010 in.)
2 nd 0.25 – 0.40 mm (0.010 – 0.016 in.)
Service limit :
1 st 0.70 mm (0.028 in.)
2 nd 1.00 mm (0.039 in.)
If measurement exceeds service limit, replace piston ring.
Piston ring free end gap
Measure piston ring free end gap using vernier calipers.
09900-20101 : Vernier calipers
Piston ring free end gap
Standard :
1 st Approx. 7.5 mm (0.30 in.)
2 nd Approx. 11.0 mm (0.43 in.)
Service limit :
1 st 6.0 mm (0.24 in.)
2 nd 8.8 mm (0.35 in.)
If measurement exceeds service limit, replace piston ring.
Cylinder
Piston ring
!
!
!
POWER UNIT 6-48
PISTON PIN
Check piston pin, conrod small end bore and piston pin hole for
wear or damage.
If badly worn or damaged, replace component.
Piston pin clearance
• Check the piston pin clearance in the conrod small end.
Replace the conrod if its small end is badly worn or damaged
or if clearance exceeds service limit.
09900-20205 : Micrometer
09900-20605 : Dial calipers
Piston pin outside diameter
Standard : 17.996 – 18.000 mm (0.7085 – 0.7087 in.)
Service limit : 17.980 mm (0.7079 in.)
Piston pin hole diameter
Standard : 18.006 – 18.014 mm (0.7089 – 0.7092 in.)
Service limit : 18.040 mm (0.7102 in.)
Conrod small end bore
Standard : 18.003 – 18.011 mm (0.7088 – 0.7091 in.)
Pin clearance in piston pin hole
Standard : 0.006 – 0.018 mm (0.0002 - 0.0007 in.)
Service limit : 0.040 mm (0.0016 in.)
Pin clearance in conrod small end
Standard : 0.003 – 0.015 mm (0.0001 – 0.0006 in.)
Service limit : 0.050 mm (0.0020 in.)
!
6-49 POWER UNIT
CONROD BIG END SIDE CLEARANCE
Measure conrod big end side clearance with conrod installed
on crank pin as shown.
09900-20803 : Thickness gauge
Conrod big end side clearance
Standard : 0.100 – 0.250 mm (0.0039 – 0.0098 in.)
Service limit : 0.350 mm (0.0138 in.)
If measurement exceeds service limit, replace conrod and /or
crankshaft.
Conrod big end width
Standard : 21.950 – 22.000 mm (0.8642 – 0.8661 in.)
Crank pin width
Standard : 22.100 – 22.200 mm (0.8700 – 0.8740 in.)
CRANK PIN
Inspect crank pin for uneven wear or damage.
Measure crank pin for out - of - round or taper with micrometer.
If crank pin is damaged, out - of - round or taper is out of service limit, replace crankshaft.
09900-20202 : Micrometer
Out - of - round : A – B
Taper : a – b
Out-of-round and taper
Service limit : 0.010mm (0.0004 in.)
Crank pin diameter
Standard : 37.982 – 38.000 mm (1.4954 – 1.4961 in.)
!
A
B
a b
!
!
POWER UNIT 6-50
CONROD BEARING
Inspect bearing shell for proper contact pattern and signs of
fusion, pitting, burning or flaking.
Bearing shells found in defective condition must be replaced.
Conrod big end oil clearance
Check conrod big end oil clearance as follows :
(1) Clean surface of conrod, conrod cap, conrod bearing, and
crank pin.
(2) Install conrod bearing onto conrod and conrod cap.
NOTE:
• Reassemble each bearing and conrod cap to their original
position.
• Do not apply oil to bearing.
(3) Place a piece of Plastigauge on crank pin parallel to crankshaft. Avoiding placing Plastigauge over oil hole.
09900-22301 : Plastigauge
(4) Install conrod cap (with bearing) to conrod with the arrow
mark on cap toward flywheel side.
!
$
(5) Apply engine oil to conrod bolts and tighten nut in two steps.
Conrod cap nut :
1 st step 18 N . m (1.8 kg-m, 13.0 lb.-ft.)
2 nd step 35 N . m (3.5 kg-m, 25.5 lb.-ft.)
NOTE:
Do not rotate conrod with Plastigauge in place.
6-51 POWER UNIT
(6) Remove conrod and conrod cap from crank pin.
(7) Using scale on Plastigauge envelope, measure Plastigauge
width at its widest point.
Conrod big end oil clearance
Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.)
Service limit : 0.065 mm (0.0026 in.)
If measurement exceeds service limit, replace conrod bearing.
CRANKSHAFT
Crankshaft center journal runout
Using a dial gauge, measure runout at center journal.
09900-20602 : Dial gauge
09900-20701 : Magnetic stand
Crankshaft center journal runout
Service limit : 0.04 mm (0.0016 in.)
If measurement exceeds service limit, replace crankshaft.
Crankshaft thrust play
Measure thrust play with crankshaft, thrust bearing, journal
bearing and crankcase/cylinder block assembled in a normal
manner.
Tighten crankcase bolts to specified torque.
Crankcase bolt :
8 mm 25 N . m (2.5 kg-m, 18.0 Ib.-ft.)
10 mm 53 N . m (5.3 kg-m, 38.5 Ib.-ft.)
Use a dial gauge to read displacement in axial (thrust) direction of crankshaft.
Crankshaft thrust play
Standard : 0.11 – 0.31 mm (0.004 – 0.012 in.)
Service limit : 0.35 mm (0.014 in.)
!
$
POWER UNIT 6-52
If measurement exceeds service limit, replace crankshaft
thrust bearing.
Crankshaft thrust bearing thickness
Standard : 2.470 – 2.520 mm (0.0972 – 0.0992 in.)
Out - of - round and taper (uneven wear) of journals
An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or
both).
This difference, if any, is determined by taking micrometer
readings.
If any journal is badly damaged or if measurements exceed
service limit, replace crankshaft.
09900-20202 : Micrometer
Out - of - round : A – B
Taper : a – b
Out - of - round and taper
Service limit : 0.010 mm (0.0004 in.)
Crankshaft journal outside diameter
Standard : 44.982 – 45.000 mm (1.7709 – 1.7717 in.)
1
1. Thrust bearing
A
B
a b
!
6-53 POWER UNIT
CRANKSHAFT JOURNAL OIL CLEARANCE
Check clearance using Plastigauge according to the following
procedure.
NOTE:
Assemble each bearing in its original position before checking
clearance.
(1) Clean surface of bearing holder (crankcase, and cylinder),
bearing, and main bearing journal.
(2) Install main bearing to cylinder and crankcase.
NOTE:
• Align the tab a of bearing with notch in cylinder and crankcase.
• Do not apply engine oil to bearing.
• Install the bearing half with oil hole / groove to cylinder side.
(3) Install crankshaft to cylinder.
(4) Place a piece of Plastigauge across full width of bearing
(parallel to crankshaft) on journal.
Do not place Plastigauge over oil hole.
09900-22301 : Plastigauge
NOTE:
Do not rotate crankshaft while Plastigauge is installed.
Plastigauge
CRANKSHAFT MAIN BEARING
Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper and lower
halves.
Always replace both bearing halves, never replace only one
half of a bearing set.
!
POWER UNIT 6-54
(6) Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three(3) steps following the order indicated below.
Crankcase bolt:
1st step 8 mm 5 N . m (0.5 kg-m, 3.5 lb.-ft.)
10 mm 11 N . m (1.1 kg-m, 8.0 lb.-ft.)
2nd step 8 mm 20 N . m (2.0 kg-m, 14.5 lb.-ft.)
10 mm 43 N . m (4.3 kg-m, 31.0 lb.-ft.)
Final step 8 mm 25 N . m (2.5 kg-m, 18.0 lb.-ft.)
10 mm 53 N . m (5.3 kg-m, 38.5 lb.-ft.)
NOTE:
Crankcase must be torqued to specification in order to assure
proper compression of Plastigauge and accurate reading of
clearance.
(7) Remove crankcase from cylinder.
(8) Using scale on Plastigauge envelope, measure Plastigauge
width at its widest point.
Crankshaft journal oil clearance
Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.)
Service limit : 0.065 mm (0.0026 in.)
If measurement exceeds service limit, replace crankshaft main
bearing.
NOTE:
For bearing replacement, see the “SELECTION OF MAIN
BEARING” section on page 6-55.
Scale
Plastigauge
(5) Assemble crankcase to cylinder.
$
Tightening order
8
16
12
4
9
1
13
5 6
14
10
2
11
3
15
7
6-55 POWER UNIT
SELECTION OF MAIN BEARING
Whenever a bearing requires replacement, select a new bearing according to following procedure.
(1) First check journal diameter.
As shown in figure, upper (flywheel side) crank web of No.1
cylinder has four (4) stamped code numerals.
The numerals (1 , 2 & 3) represent the journal diameters
shown below.
(2) Next, check bearing holder inside diameter without bearing.
As shown in figure, the STBD side of cylinder block has four
(4) stamped codes letters.
The letters (A, B & C) represent the bearing holder inside
diameters shown below.
Numeral stamped Journal diameter
1
44.994 – 45.000 mm
(1.7714 – 1.7717 in.)
2 44.988 – 44.994 mm
(1.7712 – 1.7714 in.)
3
44.982 – 44.988 mm
(1.7709 – 1.7712 in.)
Code
Crank bearing holder inside
diameter ( w / o bearing )
A
49.000 – 49.006 mm
(1.9291 – 1.9294 in.)
B
49.006 – 49.012 mm
(1.9294 – 1.9296 in.)
C
49.012 – 49.018 mm
(1.9296 – 1.9298 in.)
Flywheel
side
No.2 Journal code
No.1 Journal code
No.3 Journal code
No.4 Journal code
Flywheel
side
No.1 Holder code
No.2 Holder code
No.3 Holder code
No.4 Holder code
POWER UNIT 6-56
(3) There are five (5) main bearings available, each of differing thickness.
To distinguish them, a color mark is painted at the position
indicated in figure.
Each color represents the following thickness measured at
the center of the bearing.
Color mark Bearing thickness
Green
1.999 – 2.003 mm
(0.0787 – 0.0789 in.)
Black
2.002 – 2.006 mm
(0.0788 – 0.0790 in.)
No Color mark
2.005 – 2.009 mm
(0.0789 – 0.0790 in.)
(4) Select crankshaft main bearing referring the below table.
Yellow
2.008 – 2.012 mm
(0.0790 – 0.0792 in.)
Blue
2.011 – 2.015 mm
(0.0792 – 0.0793 in.)
Numeral stamped on crank web
( journal outside diameter )
1 2 3
ACode stamped
on cylinder block
(Bearing holder
inside diameter)
Green Black No Color
B Black No Color Yellow
C No Color Yellow Blue
Color mark
NOTE:
Measure crankshaft journal oil clearance again after installing
new bearings selected. (see page 6-53)
OIL SEAL
Inspect condition. If cracked, cut or damaged, replace.
6-57 POWER UNIT
REASSEMBLY
Assembly is reverse order of disassembly paying special attention to the following steps.
"
If original components are not replaced, each piston,
piston pin and conrod is to be assembled and installed
in its original order and position.
PISTON TO CONROD
Apply engine oil to piston pin 2, piston pin bore and conrod 3.
Fit conrod 3 to piston 1 as shown in figure and insert piston
pin 2 through piston and conrod.
Install piston pin circlips 4.
NOTE:
• Make sure conrod is installed in the direction shown.
• Circlip should be installed with gap facing either up or down
as shown in figure.
• Always use new piston pin circlip.
Up mark “O”
Flywheel
side
Oil hole
Circlip
or 1
3
1
4
2
4
3#
POWER UNIT 6-58
1st ring and 2nd ring
• Apply engine oil to piston ring.
• Install 2nd ring and 1st ring to piston.
NOTE:
• 1st ring differs from 2nd ring in shape and color of surface
contacting cylinder wall.
Distinguish 1st ring from 2nd ring by referring to figure.
• As indicated in figure, 1st and 2nd ring are marked, “N” or
“2N” .
When installing these piston rings, the marked side of each
ring must face towards top of piston.
Ring gap direction
Position rings so that their gaps are staggered at approximately 90 degree angles as shown.
1 1st ring 3 2nd ring
2 Oil ring lower side rail 4 Oil ring upper side rail
"
Failure to stagger piston ring gaps may result in crankcase oil dilution.
1. 1st ring
2. 2nd ring
3. Oil ring
Mark
“N”
“2N”
1st ring
2nd ring
Up mark “O”
12
3 4
2
1
2
Incorrect
Correct
PISTON RING TO PISTON
Oil ring
• Apply engine oil to piston rings.
• Install spacer 1 first, then side rails 2 to piston.
"
When installing spacer, do not allow ends to overlap in
groove.
1
2
3
2nd ring
1st ring
6-59 POWER UNIT
PISTON TO CYLINDER
Install conrod bearing to conrod and conrod cap.
"
• Assemble each conrod bearing to its original position.
• Do not apply oil between conrod and bearing or between bearing cap and bearing.
Apply engine oil to piston and cylinder walls.
Insert piston and conrod assembly into cylinder bore from cylinder head side using special tool.
09916-77310 : Piston ring compressor
NOTE:
Position the “circle” mark on piston head to flywheel side.
!
!
POWER UNIT 6-60
CRANKSHAFT TO CYLINDER
Install crankshaft main bearings in cylinder and crankcase.
Apply engine oil to bearings.
"
• Assemble each bearing to its original position.
• Assemble main bearing half containing oil groove /
hole to cylinder block.
Assemble the half without oil groove to crankcase.
• Do not apply oil between crank bearing holder and
crank main bearing.
NOTE:
Align bearing tab a with notch in cylinder and crankcase.
Thrust bearing
Apply engine oil to thrust bearing and install in cylinder block
between the No.2 and No.3 cylinders.
Oil groove sides of thrust bearing must face towards crank webs.
Crankshaft
Apply engine oil to crank pin and crankshaft main journal and
install crankshaft in cylinder.
1. Thrust bearing
2. Oil groove
1
6-61 POWER UNIT
CRANKCASE TO CYLINDER
Clean mating surface of cylinder and crankcase.
Apply SUZUKI BOND to mating surface of crankcase as shown.
"
Apply bond to mating surface only.
Do not allow bond to contact surface of bearing.
CONROD CAP
Apply engine oil to crank pin and conrod bearing.
Install conrod cap (with bearing) to conrod with arrow mark on
cap toward flywheel side.
"
Reassemble each conrod cap to its original position.
Apply engine oil to conrod bolts.
Tighten conrod cap nuts in two steps.
Conrod cap nut :
1st step 18 N . m ( 1.8 kg-m, 13.0 lb.-ft.)
2nd step 35 N . m ( 3.5 kg-m, 25.5 lb.-ft.)
% 99000-31140 : Suzuki Bond 1207B
Apply Bond to marked line
$
Install four (4) dowel pins 1.
%
%
POWER UNIT 6-62
Install crankcase to cylinder.
Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three (3) steps following the order
indicated below.
NOTE:
After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
Crankcase bolt
1st step 8 mm 5 N . m (0.5 kg-m, 3.5 lb.-ft.)
10 mm 11 N . m (1.1 kg-m, 8.0 lb.-ft.)
2nd step 8 mm 20 N . m (2.0 kg-m, 14.5 lb.-ft.)
10 mm 43 N . m (4.3 kg-m, 31.0 lb.-ft.)
Final step 8 mm 25 N . m (2.5 kg-m, 18.0 lb.-ft.)
10 mm 53 N . m (5.3 kg-m, 38.5 lb.-ft.)
UPPER OIL SEAL HOUSING
Apply engine oil to lip area of upper oil seal.
Install upper oil seal housing and secure with bolts.
$
Tightening order
8
16
12
4
9
1
13
5 6
14
10
2
11
3
15
7
6-63 POWER UNIT
CYLINDER HEAD
Install cylinder head. (see page 6-21 to 6-23)
TIMING CHAIN
Install timing chain. (see page 6-18 to 6-20)
OIL PUMP CASE
Install oil pump case. (see page 6-12 to 6-14)
POWER UNIT
Install power unit. (see page 6-7 to 6-9)
POWER UNIT 6-64
THERMOSTAT
REMOVAL
• Disconnect water hose 1 from thermostat cover.
• Remove the four (4) bolts 2 securing the thermostat cover,
then remove the cover 3 and thermostat 4.
INSPECTION
• If salt deposits, corrosion, wear or other damage is found,
clean or replace.
• Thermostat operation
Check thermostat opening temperature as follows :
• Insert a length of thread between thermostat valve / body
and suspend thermostat in a container filled with water.
• Place thermometer in container and heat water.
Observe water temperature when thermostat valve opens
and releases thread.
Thermostat operating temperature
Standard : 48 – 52 °C (118 – 126 °F)
Thermometer
Heater
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Assemble thermostat 1, gasket 2 and thermostat cover 3
to cylinder head block and secure with bolts.
$ Thermostat cover bolt : 10 N.m (1.0 kgf-m, 7.0 Ib.-ft.)
6-65 POWER UNIT
OPERATION
WATER COOLING SYSTEM
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil
pan water pressure valve, power unit water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic from below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion buildup or component damage.
Component inspection Refer to page
Water pump / Impeller ........................... 9-9
Water tube............................................. 7-5
Thermostat ............................................ 6-64
Water pressure valve ............................ 7-5
Cylinder head........................................ 6-26
Cylinder block ....................................... 6-43
ENGINE HOLDER
OIL PUMP CASE
CYLINDER
THERMOSTAT
OIL PANOIL PAN
WATER TUBE
ENGINE HOLDER
PROPELLER
EXHAUST OUTLET
DRIVESHAFT
HOUSING
CYLINDER HEAD
EXHAUST
WATER JACKET
VAPOR
SEPARATOR
SUB-WATER
INTAKE
PRESSURE
VALVE
PILOT
WATER HOLE
WATER PUMP
When open
WATER INTAKE
WATER
POWER UNIT 6-66
No.4 CRANKSHAFT
MAIN JOURNAL
No.3 CRANKSHAFT
MAIN JOURNAL
No.2 CRANKSHAFT
MAIN JOURNAL
No.1 CRANKSHAFT
MAIN JOURNALNo.1 CYLINDER
WALL
No.2 CYLINDER
WALL
OIL PRESSURE
SWITCH
No.4 CAMSHAFT
HOUSING
No.1 CRANK PIN
No.2 CRANK PIN
No.1 PISTON
No.2 PISTON
No.3 CYLINDER
WALL
No.3 PISTON No.3 CRANK PIN
OIL FILTER
OIL PUMP
PRESSURE
REGULATOR
OIL STRAINER
OIL PAN
No.1 CAMSHAFT
JOURNAL (IN)
No.2 CAMSHAFT
JOURNAL (IN)
No.3 CAMSHAFT
JOURNAL (IN)
No.1 CAMSHAFT
JOURNAL (EX)
No.2 CAMSHAFT
JOURNAL (EX)
No.3 CAMSHAFT
JOURNAL (EX)
No.1
CAM FACE
No.3
CAM FACE
No.2
CAM FACE
No.3
CAM FACE
No.1
CAM FACE
No.2
CAM FACE
ENGINE LUBRICATION SYSTEM
A crankshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.
Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before
entering the main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at
a constant level.
From the main gallery, oil flow is directed through either drilled internal passages or by splash method to
those surfaces requiring lubrication.
ENGINE OIL LUBRICATION CHART
MID UNIT
CONTENTS
ENGINE SIDE COVER ______________________________________ 7-1
REMOVAL ........................................................................................................ 7-1
INSTALLATION................................................................................................ 7-1
DRIVESHAFT HOUSING AND OIL PAN ________________________ 7-2
REMOVAL ........................................................................................................ 7-2
INSPECTION ................................................................................................... 7-4
ASSEMBLY ...................................................................................................... 7-6
SWIVEL BRACKET, STEERING BRACKET AND
CLAMP BRACKET _________________________________________ 7-12
REMOVAL ........................................................................................................ 7-12
INSPECTION ................................................................................................... 7-14
REASSEMBLY ................................................................................................. 7-15
7
7-1 MID UNIT
3 4
2
1
ENGINE SIDE COVER
REMOVAL
Remove snap pin 1, washer 2, pin 3 and fastener 4.
Remove side cover seal 5.
Remove five screws 6 and PORT side cover 7.
Disconnect PTT switch lead connector.
Remove three screws 8 and STBD side cover 9.
INSTALLATION
Installation is reverse order of removal.
5
6
7
9
8
MID UNIT 7-2
DRIVESHAFT HOUSING AND OIL PAN
REMOVAL
Remove power unit. (See pages 6-3 to 6-6)
Remove lower unit. (See pages 9-1)
Remove screw and bonding wire from driveshaft housing.
Unscrew the lower mount cover bolts 1 and remove PORT/
STBD lower mount covers 2.
Remove two lower mount nuts 3.
Remove two upper mount nuts 4 and washers.
Remove driveshaft housing with oil pan.
7-3 MID UNIT
Remove bolts 5 and upper mount cover 6.
Note the different length and placement of the bolts.
Remove upper mount assembly 7.
Remove lower mount assembly 8.
Remove three bolts 9 and engine holder 0.
Remove bolts A and oil strainer B.
Remove six bolts C and oil pan D.
MID UNIT 7-4
Remove bolt E and water tube F.
Remove bolts G, water pressure valve cover H, pressure valve
I and valve case J.
INSPECTION
NOTE:
If any component is found to be excessively worn, cracked,
defective or damaged in any way, it must be replaced.
Mid unit component
Check oil pan, driveshaft housing, engine holder and mount
covers.
If cracks, defects or other damage is found, replace it.
7-5 MID UNIT
Mount
Check upper and lower mount.
If excessive wear, corrosion, or other damage is found, replace
mount.
Water tube
Check water tube.
If a clog or obstruction is found, clean water tube.
If cracks, corrosion or other damage is found, replace water
tube.
Check water tube grommet.
If excessive wear or other damage is found, replace grommet.
Oil seal
Check driveshaft upper oil seal for leakage or damage.
If cracks, cuts or other damage is found, replace seal.
NOTE:
Install oil seal with lip (spring side) facing downward.
Water pressure valve
If salt deposits, corrosion, wear, or other damage is found, clean
or replace.
MID UNIT 7-6
ASSEMBLY
Assembly is reverse order of removal with special attention to
the following steps.
1Engine holder
2 Gasket
3 Pin
4 O-ring
5Oil seal
6Upper thrust mount
7Upper mount
8Upper mount cover, STBD
9Upper mount cover, PORT
0Upper thrust stopper
AUpper mount bolt
BMount cover bolt
CMount cover bolt
D Nut
E Washer
F Washer
G Washer
H O-ring
IOil strainer
J Bolt
J
I
H
1
5
3
4
2
A
G
0
7
F
E
D
8
9
B
C
6
! 23 N.m ( 2.3 kg-m, 16.6 lb.ft.)
"
! 40 N.m
( 4.0 kg-m, 30 lb.ft.)
7-7 MID UNIT
K Gasket
LOil pan
MWater indicator tube
N Cover
O O-ring
PStud bolt
Q Bolt
R Bolt
S Bolt
T Washer
U Nut
V Gasket
W Plug
X Pin
YExhaust pipe
ZDriveshaft housing
[ Bolt
Pin
]Bonding wire
^ Screw
a Insulation washer
b Bolt
c Lower mount cover
d Nut
e Washer
f Lower mount
g Damper
h Lower mount bolt
i Lower thrust mount
j Lower mount bracket
k Washer
l Nut
m Gasket
nWater pressure valve case
oWater pressure valve
p Grommet
q Cover
r Bolt
sWater tube
t Bolt
K
L
T
U
P
X
M
O
N
m n o p q r t s de f h k l a b c ^
]
^
j i
! 40 N.m
( 4.0 kg-m, 29.0 lb.ft.)
R
Q
V
W
S
[ \
Y
Z
#
! 60 N.m
( 6.0 kg-m, 43.5 lb.ft.)
! 13 N.m
( 1.3 kg-m, 9.5 lb.ft.)
g MID UNIT 7-8
OIL PAN TO DRIVESHAFT HOUSING
Install water tube 1, then tighten bolt 2.
Place the gasket 3, water pressure valve case 4, pressure
valve 5, and water tube grommet 6 into position.
Install pressure valve cover 7, then securely tighten the four
(4) valve cover bolts 8.
Install two dowel pins 9 to driveshaft housing 0.
Apply sealant to mating surfaces of driveshaft housing and oil
pan.
99000-31120 : Suzuki Silicone Seal
Install oil pan A to driveshaft housing, then tighten six (6) bolts
B securely.
#
7-9 MID UNIT
ENGINE HOLDER TO OIL PAN
Install O-ring 1 and oil strainer 2 to engine holder 3, then
tighten bolts 4 securely.
Install dowel pin 5 and gasket 6 to oil pan.
Install engine holder 3 to oil pan, then gently tighten it temporarily with engine holder bolts 7.
NOTE:
When installing power unit, tighten engine holder bolts to specified torque.
(See page 7-11)
UPPER AND LOWER MOUNT
Upper mount and mount cover
Install upper mount.
Install upper mount cover with the lettered mark “FRONT” facing forward. Tighten bolt, pre-coated with thread lock, to specified torque.
99000-32050 : Thread lock “1342”
Upper mount cover bolt :
23 N . m (2.3 kg-m, 16.5 lb.-ft.)
!
$
%
Do not re-use gasket. Always assemble with a new gasket.
F
R
O
N
T
MID UNIT 7-10
Lower mount
Assemble these items in the following sequence :
place washer 1, stopper 2 and lower mount 3 on lower mount
bolt 4.
Tighten lower mount rear nut, pre-coated with thread lock, to
specified torque.
99000-32050 : Thread Lock “1342”
Lower mount (rear) nut :
40 N . m (4.0 kg-m, 29.0 lb.-ft.)
Place lower mount into driveshaft housing.
Install lower mount cover to driveshaft housing.
At this time only lightly tighten the bolts to temporarily hold it in
place.
DRIVESHAFT HOUSING / OIL PAN
Install driveshaft housing / oil pan to steering bracket.
NOTE:
When installing the driveshaft housing / oil pan assembly, be
sure lower mount hex head bolt properly fits into the lower mount
bracket groove.
Install upper mount nuts. Tighten nuts, pre-coated with thread
lock, to specified torque.
99000-32050 : Thread Lock “1342”
Upper mount nut : 40 N . m (4.0 kg-m, 30.0 lb.-ft.)
Tighten lower mount cover bolts securely.
!
$
!
$
7-11 MID UNIT
Install lower mount front nuts. Tighten nuts, pre-coated with
thread lock, to specified torque.
99000-32050 : Thread Lock “1342”
Lower mount front nut :
60 N . m (6.0 kg-m, 43.5 lb.-ft.)
BONDING WIRE
Reattach bonding wire to driveshaft housing.
Tighten screw securely.
NOTE:
Insulation washer must be installed between the bonding wire
terminal and housing.
POWER UNIT
Install power unit. (See page 6-7 to 6-9)
Tighten power unit mounting bolts and engine holder bolts to
specified torque.
Power unit mounting bolt & Engine holder bolt :
8 mm 23 N . m (2.3 kg-m, 16.5 lb.-ft.)
10 mm 50 N . m (5.0 kg-m, 36.0 lb.-ft.)
!
!
$
11
5
1
3
7
9
8
6
2
4
10
12
Tightening order
MID UNIT 7-12
SWIVEL BRACKET, STEERING
BRACKET AND CLAMP BRACKET
REMOVAL
Remove driveshaft housing / oil pan.
(See page 7-2)
Remove circlip 1.
Remove lower mount bracket 2, shim 3, and washer 4 from
the steering shaft.
Remove steering adjuster bolt 5, washer 6, adjuster cover 7
and spring 8.
Lift steering bracket 9 upward to remove from swivel bracket.
Remove washer 0, upper bush A, and steering adjuster B
from bracket.
Remove swivel bracket seal C and lower bush D.
7-13 MID UNIT
Remove circlip E and push out tilt cylinder upper rod F.
Remove nut 1 from clamp bracket shaft.
Remove tilt cylinder lower shaft nut 2 and lower shaft bolt 4.
Remove tilt pin 5.
Slide STBD clamp bracket 6 off clamp bracket shaft.
Remove the PTT unit assembly.
1
2
4
5
6
Remove bonding wire 7 from PORT clamp bracket.
Pull PORT clamp bracket 8 outward to remove clamp bracket
and bracket shaft 9 from swivel bracket 0.
Remove bushings from each side of swivel bracket.
PTT unit
MID UNIT 7-14
INSPECTION
NOTE:
If any component is found to be excessively worn, cracked,
defective or damaged in any way, it must be replaced.
BUSHINGS
Check all bushings.
If excessive wear or other damage is found, replace bushing.
If bushing fit is loose when installing, replace bushing.
OIL SEAL
Check swivel bracket seal.
If excessive wear or other damage is found, replace seal.
CLAMP BRACKET SHAFT
Check clamp bracket shaft.
If clamp bracket shaft is bend or twisted, replace shaft.
BRACKET
Check clamp brackets, steering bracket and swivel bracket.
If cracks or other damage is found, replace bracket (s).
7-15 MID UNIT
REASSEMBLY
Reassembly is reverse order of removal with special attention
to the following steps.
1Clamp bracket STBD
2Clamp bracket PORT
3Clamp bracket shaft
4 Nut
5 Tilt lock pin
6 Nut
7 Anode
8 Bolt
9 Tilt cylinder lower bolt
0 Bush
A Tilt cylinder lower shaft
B Washer
C Nut
DSteering bracket
E Washer
F Bush
GSwivel bracket
H Bush
IGrease nipple
JBonding wire
K Washer
L Screw
MOil seal
N Shim
O Lower mount bracket
P Circlip
Q Tilt lock spring assy
R Bush
S Tilt lock lever. PORT
T Tilt lock lever. STBD
U Pin
VSteering adjuster
W Spring
X Cover
Y Washer
Z Bolt
1
4
C
B
7
8
A
0
0
9
6
5
2
3
F
E
E
D
J
K
L
P
X
Y
Z
W
V
O
N
M
E
S
R
U
F
H
Q
I
H
T
R
G
! 43 N.m
(4.3 kg-m, 31.0 lb.-ft.)
"
"
"
"
"
"
"
"
"
MID UNIT 7-16
CLAMP BRACKET
Insert PORT and STBD bushings 2 into the swivel bracket 1.
Install clamp bracket 3, 4 and clamp bracket shaft 5 to swivel
bracket 1.
Install clamp bracket shaft nut 6. Leave nut loose for easier
installation of PTT unit.
99000-25160 : Suzuki Water Resistant Grease
NOTE:
Before installing clamp bracket to swivel bracket, apply grease
to clamp bracket shaft and bushings.
Install PTT unit assembly, lower shaft and bushings in position
between clamp brackets.
(See “INSTALLATION” in POWER TRIM & TILT section for PTT
unit installation.)
"
6
3
2
1
2
4
5
! 43 N.m (4.3 kg-m, 31.0 lb.-ft.)
"
"
"
Tighten clamp bracket shaft nut 6 to specified torque.
Clamp bracket shaft nut :
43 N . m (4.3 kg-m, 31.0 lb.-ft.)
!
7-17 MID UNIT
STEERING BRACKET
Apply Water Resistant Grease to steering bracket shaft.
99000-25160 : Suzuki Water Resistant Grease
NOTE:
Apply grease to bushings, oil seal lip and pilot shaft portion of
steering bracket.
Install upper bushing 1, steering adjuster 2 and washer 3 to
swivel bracket.
NOTE:
Be certain that steering adjuster 2 is placed between upper
bushing 1 and swivel bracket casing.
Install lower bushing 4 and swivel bracket seal 5 to swivel
bracket.
NOTE:
Install seal 5 with lip (spring side) facing downward.
Install steering bracket 6 to swivel bracket.
LOWER MOUNT BRACKET
Install washer 7 and shim 8, and then slide the lower mount
bracket 9 upward on the splines until it contacts the shim.
Install circlip 0 to retain bracket.
"
Seal lip
0
9
8
7
5
4
6
2
3
3
1
"
"
"
"
"
MID UNIT 7-18
BONDING WIRE
Reattach bonding wire to clamp bracket and swivel bracket, then
tighten screw securely.
NOTE:
The insulation washer must be installed between the bonding
wire terminal and bracket.
LUBRICATION
After completing reassembly of the mid unit, apply grease
through each grease nipple.
99000-25160 : Suzuki Water Resistant Grease"
POWER TRIM AND TILT
SYSTEM WIRING DIAGRAM _________________________________ 8-1
SERVICE PROCEDURE ____________________________________ 8-2
OIL LEVEL ....................................................................................................... 8-2
AIR BLEEDING................................................................................................ 8-2
POWER TRIM AND TILT UNIT ________________________________ 8-3
REMOVAL ........................................................................................................ 8-3
DISASSEMBLY ................................................................................................ 8-4
CLEANING AND INSPECTING ...................................................................... 8-6
REASSEMBLY ................................................................................................. 8-8
PTT MOTOR .................................................................................................... 8-10
INSTALLATION................................................................................................ 8-14
PTT MOTOR RELAY _______________________________________ 8-16
PTT SWITCH _____________________________________________ 8-17
OPERATION ______________________________________________ 8-18
COMPONENTS................................................................................................ 8-18
PRINCIPLES OF OPERATION ....................................................................... 8-19
CONTENTS
8
8-1 POWER TRIM AND TILT
SYSTEM WIRING DIAGRAM
PTT switch
UP DN
Lbl P
W tube
Gr Gr To ignition switch
Remote control box
P
Lbl
PP
PTT relay
(DOWN)
W
G
W
Bl PTT relay (UP)
B
PTT motor
Starting
motor relay
Battery
Y/G
LblLbl
P
Lbl
W/R
UP
DN
PTT switch
POWER TRIM AND TILT 8-2
SERVICE PROCEDURE
OIL LEVEL
To check the oil level :
1. The motor should be raised to a full-tilt position.
2. Lower the manual tilt lock lever 1.
3. Remove the oil filler plug 2.
4. If oil can be seen at filler plug level, the unit is full.
5. If oil level is low, refill with the recommended oil.
Recommended oil :
Dexron automatic transmission fluid or equivalent
!
To ensure consistent pump operation, do not mix different types of oil.
6. Reinstall oil filler plug.
AIR BLEEDING
1. Open manual release valve before performing air bleeding.
2. Manually raise and lower engine (full up to full down) 5-6
times.
3. Check oil level, topping off if necessary.
4. Reinstall oil filler plug.
8-3 POWER TRIM AND TILT
POWER TRIM AND TILT UNIT
REMOVAL
Tilt engine fully up and lower the manual tilt lock levers 1.
"
During the following procedures, firmly secure the
engine and support its weight. (see right)
Remove the tilt rod snap ring 2 and push tilt cylinder upper
shaft pin 3 out.
Lower tilt rod to full down position and disconnect the battery
cable.
Disconnect the PTT motor cable wire leads (G, Bl) from the
PTT relays.
Remove the PTT motor cable from engine lower cover.
Remove the two STBD motor mounting bolts 4.
Loosen the clamp bracket shaft nut 5.
NOTE:
Complete removal of the clamp bracket shaft nut is not required.
Nut should be loosened as far as the end of the shaft threads
only to facilitate removal of the PTT unit.
POWER TRIM AND TILT 8-4
Remove the tilt pin 6.
Loosen the PTT cylinder lower shaft nut 7 and remove the
lower shaft bolt 8.
Slide the STBD clamp bracket fully outward to the right hand
side.
Remove the PTT unit from between the clamp brackets.
DISASSEMBLY
NOTE:
Before disassembly, wash the PTT body with a stiff bristle brush
and hot, soapy water to remove sand or dirt and dry the PTT
body with compressed air.
Connect the PTT motor cable leads (G, Bl) to battery and operate PTT motor until tilt piston rod is at maximum stroke.
(full-tilt up position)
Place the lower mounting eye of the PTT cylinder in a vise.
Tighten the vise only enough to secure the PTT unit, do not
over tighten.
NOTE:
To prevent damage to the PTT cylinder use wood blocks, vise
jaw protectors, etc., between the vise jaws and PTT component before tightening vise.
Using special tool, unscrew the PTT cylinder head.
09944-08711 : PTT cylinder cap tool#
8-5 POWER TRIM AND TILT
Pull the tilt rod / piston assembly 1 out of the cylinder body.
Remove the free piston from the cylinder body 2.
Remove the PTT motor.
Note the position of drive joint 3 and O-ring 4, before removing them.
(see page 8-10)
Unscrew the fill plug and drain PTT oil into suitable container.
Remove the manual release valve snap ring 5, then unscrew
the manual release valve 6.
Remove the seal washer 7.
Remove the main check valve 8 and spool valve 9.
POWER TRIM AND TILT 8-6
Disassembly of tilt rod / piston assembly
Unscrew the piston retaining nut from the bottom of the tilt rod
and remove the washer.
Carefully retain and account for four shock valves, each composed of a spring, rod and ball.
Remove the piston assembly and PTT cylinder head from the
tilt rod by sliding them down and off the rod end.
CLEANING AND INSPECTING
Thoroughly wash all metal components with cleaning solvent
and dry them with compressed air.
Arrange all components on a clean sheet of paper.
NOTE:
Do not lay PTT components out on a rag, as dirt or lint may be
transferred to these items which may cause possible system
operating problems.
Inspect tilt rod, replace if damaged or bent.
Inspect the surface of tilt rod for scores, grooves or roughness.
Slight roughness may be removed with fine emery paper.
A badly scored or grooved rod must be replaced.
8-7 POWER TRIM AND TILT
Inspect the PTT cap seal and O-ring.
Replace if cuts, nicks, or excessive wear is found.
NOTE:
It is recommended that the O-ring always be replaced once the
tilt cylinder has been disassembled.
Inspect the shock valves (spring, rod and ball).
Replace if there are any signs of rust or pitting.
Inspect the cylinder bore for evidence of a rough or grooved
surface.
Light honing may rectify slight surface roughness or scarring,
but a deeply scarred surface will require replacement of the tilt
cylinder.
Inspect all O-ring (manual release valve and main check valve).
Replace if nicked or cut.
POWER TRIM AND TILT 8-8
REASSEMBLY
Assembly is reverse of disassembly with special attention to
following steps.
!
• Do not reuse O-rings after removal, always use new
O-rings.
• Lubricate all components and O-rings with PTT fluid
before assembly.
• Do not reuse PTT fluid, always refill with new fluid.
MAIN CHECK VALVE
Oil and install spool valve 1 and main check valve 2.
Tighten the main check valve 2 to specified torque.
Main check valve plug : 20 N . m
(2.0 kg-m, 14.5 lb.-ft.)
MANUAL RELEASE VALVE
Oil and install the seal washer 1 and manual release valve 2.
Tighten the valve to specified torque.
Install snap ring 3.
Manual release valve : 1.7 N . m
(0.17 kg-m, 1.2 lb.-ft.)
$
$
TILT ROD
When tightening the piston retaining nut on the tilt rod piston,
apply Thread lock 1342 to the threads.
Tighten the nut to specified torque.
99000-32050 : Thread Lock 1342
Piston retaining nut : 100 N . m (10.0 kg-m, 72.5 lb.-ft.)$
%
8-9 POWER TRIM AND TILT
Installing tilt rod / piston
Pour 100 ml of PTT fluid into cylinder.
Insert the free piston into cylinder and push it down to the bottom of the cylinder.
Pour PTT fluid into the cylinder until it is topped off.
Insert the tilt rod / piston into cylinder and thread the tilt cylinder head by hand until fully seated.
Tighten the cylinder head to specified torque using special tool.
Tilt cylinder head : 45 N . m (4.5 kg-m, 32.5 lb.-ft.)
09944-08711 : PTT cylinder cap tool
PTT MOTOR
See the PTT Motor Installation section on page 8-13.
AIR BLEEDING
See the AIR BLEEDING section on page 8-2.
#
$
Cylinder
Free piston
Top OFF
POWER TRIM AND TILT 8-10
PTT MOTOR
Removal
Remove the four (4) screws securing the PTT motor to the pump
& reservoir.
Detach the PTT motor from pump & reservoir.
Note the position of drive joint 1 and O-ring 2 and remove
them.
PTT motor Disassembly
For correct assembly, scribe an alignment mark on the field
case and brush holder.
Remove the three (3) screws securing the field case to the brush
holder.
Using a soft face hammer, gently tap the field case from side to
side to unseat it from the brush holder.
Slide the field case upward and away from the brush holder.
Note the position of the O-ring encircling the brush holder.
Slide the armature free of the brushes.
1. Screw
2. Field case
3. Armature
4. O-ring
5. Brush holder1
2
3
4
5
8-11 POWER TRIM AND TILT
Inspection
Armature and Commutator
Check for continuity between the commutator and the armature
core / shaft.
Replace armature if continuity is indicated.
09930-99320 : Digital tester
Tester range : (Continuity)
Check continuity between the adjacent commutator segments.
Replace armature if no continuity is indicated.
Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grade emery paper.
Measure commutator outside diameter.
09900-20101 : Vernier calipers
Commutator outside diameter :
Standard 22 mm (0.87 in.)
Service limit 21 mm (0.83 in.)
If measurement exceeds service limit, replace armature.
Ensure that the mica (insulator) between the segments is undercut to specified depth.
Commutator undercut :
Standard 0.5 – 0.8 mm (0.02 – 0.03 in.)
Service limit 0.2 mm (0.008 in.)
If undercut is less than service limit, cut to specified depth.
NOTE:
Remove all particles of mica and metal using compressed air.
"
Wear safety grasses when using compressed air.
#
&
#
SEGMENT
MICA
1
1 Commutator undercut
#
#
POWER TRIM AND TILT 8-12
Brushes
Check the length of each brush.
09900-20101 : Vernier calipers
Brush length :
Standard 9.8 mm (0.39 in.)
Service limit 4.8 mm (0.19 in.)
If brushes are worn down to the service limit, they must be replaced .
O-ring
Inspect the O-ring between the PTT motor and pump & reservoir. Replace if cuts, nicks or tears are found.
#
Assembly
Assembly is reverse of disassembly with special attention to
following steps.
When installing the armature, exercise care not to break the
brushes.
!
When installing armature, exercise care to avoid breaking brushes.
8-13 POWER TRIM AND TILT
PTT Motor Installation
Installation is reverse of removal with special attention to following steps.
• Ensure that the drive joint 1 is aligned and firmly inserted
into the gear pump assembly.
• Fit O-ring 2 to pump & reservoir.
• Check the level of PTT fluid contained in the pump & reservoir. If level is low, add recommended PTT fluid until level
with mating surface of PTT motor.
• Ensure that the faces of the PTT motor and pump unit are
free of dirt or debris.
When attaching the PTT motor to the pump & reservoir, ensure that the tip of armature shaft fits firmly into the drive
joint.
• Tighten the four (4) screws to specified torque.
PTT motor screw : 6 N . m (0.6 kg-m, 4.5 lb.-ft.)$
POWER TRIM AND TILT 8-14
INSTALLATION
Installation is reverse of removal with special attention to following steps.
Lower tilt rod full down position.
Apply Water Resistant Grease to the tilt cylinder lower shaft 1
and lower shaft bushes 2.
Install lower shaft and bushes into position in the lower eyelet.
99000-25160 : Water Resistant Grease
Place the PTT unit in position between the clamp brackets.
Tighten the clamp bracket shaft nut to specified torque.
Clamp bracket shaft nut :
43 N . m (4.3 kg-m, 31.0 lb.-ft.)
Slide the PTT cylinder lower shaft bolt through the clamp bracket
and lower shaft, then secure with the nut.
Apply Water Resistant Grease to tilt rod upper bushes 3, then
install bushs in tilt rod.
Operate the PTT motor to extend the PTT rod upward.
Align the tilt rod with the hole in the swivel bracket as the tilt rod
extends.
99000-25160 : Water Resistant Grease
'
'
$
8-15 POWER TRIM AND TILT
Apply Water Resistant Grease to the PTT rod upper shaft 4,
then insert the shaft through the swivel bracket and tilt rod.
99000-25160 : Water Resistant Grease
Secure the upper shaft with the snap ring 5.
Route the PTT motor cable in through the lower cover and connect the terminals to the PTT relays.
(Cable routing–see the WIRE / HOSE ROUTING section on
page 10-2 to 10-6.)
'
POWER TRIM AND TILT 8-16
PTT MOTOR RELAY
Two methods can be used to test PTT relays.
Method 1.
Measure resistance between wiring leads of the relay.
09930-99320 : Digital tester
Tester range : Ω (Resistance)
Method 2.
Connect the wiring leads of the relay to battery (12V) and check
relay operation.
09930-99320 : Digital tester
Tester range : (Continuity)
When there is continuity between terminals 1↔2↔3, the
unit is considered to be without defect.
With Black lead wire connected to the battery negative (–) terminal and Light blue or Pink lead wires are connected to battery positive (+) terminal there should be continuity between
2↔3↔4.
With the lead wires disconnected from the battery there should
be no continuity between 3↔4.
The relay is considered to be without defect if continuity test
results are as stated above.
PTT relay solenoid coil resistance :
Standard 3.0 – 4.5 Ω
Tester probe connection
Red (+) Black (–)
UP Light Blue Black
DOWN Pink Black
#
(
#
&
B Lbl(P)
Lbl(P)
B
CONT
1
2
34
CONT
Lbl(P)
B
12V BAT.
1
2
34
8-17 POWER TRIM AND TILT
PTT SWITCH
Test continuity between the wires at each of the three switch
positions.
09930-99320 : Digital tester
Tester range : (Continuity)
#
&
Tester probe connection Tester
indicatesRed (+) Black (–)
“DN” side
depressed Pink
Gray
(White/Red)
Continuity
“UP” side
depressed Light Blue Continuity
not
depressed
Pink
Infinity
Gray
(White/Red)
Gray
(White/Red)Light Blue
LBI
Gr P
P
(W/R)
Lbl
POWER TRIM AND TILT 8-18
OPERATION
The power trim and tilt system is operated by a “rocker” type switch (protected by a rubber thumb pad) on top
of the remote control box handle.
When the switch is depressed, power is delivered to the electric motor via the relevant relay. The relay with the
Blue wire connected to the PTT pump is for trim/ tilt “up”, while the relay with the Green wire is for trim/tilt
“down”.
COMPONENTS
Oil reservoir
Tilt rod
PTT cylinder
Piston
Free piston
Gear pump
Check valveB
PTT motor
Check valveA
“DOWN” relief
valve
Spool valve
“DOWN” pressure
main check valve
Manual release valve
“UP” relief valve
“UP” pressure main check valve
8-19 POWER TRIM AND TILT
PRINCIPLES OF OPERATION
TRIM/TILT “UP” CIRCUIT
The electric motor is operating in a clockwise direction. Check valve A will open, allowing oil to flow from the
reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the left, opening the “down”
pressure main check valve and returning oil from the upper cylinder chamber (plus oil from the reservoir) to
the pump. Pressure built up by the pump will then open the “up” pressure main check valve and oil will enter
the lower cylinder chamber.
When trim motor stops, both the “DOWN” pressure main check valve and the “up” pressure main check valve
will close to retain tilt/trim position.
When full trim/tilt “up” position is attained, sustained operation of the “up” relay will have no effect, as pump oil
flow will be returned to the reservoir through the “up” relief valve.
Oil reservoir
Upper cylinder chamber
Tilt rod
Piston
PTT motor
Check valveA
Gear pump
Spool valve
“DOWN” pressure main check valve
“UP” relief valve
“UP” pressure main check valve
Lower
cylinder
chamber
POWER TRIM AND TILT 8-20
TRIM/TILT “DOWN” CIRCUIT
The electric motor is operating in a counterclockwise direction. Check valve B will open, allowing oil to flow
from the reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the right, thereby
opening the “up” pressure main check valve. Oil from the lower cylinder chamber will go through the “up”
pressure main check valve to the pump.
Pressure built up by the pump will open the “down” pressure main check valve and oil will enter the upper
cylinder chamber. The piston will retract (move inward), which will tilt the outboard down. Oil in the lower
cylinder chamber is returned to the pump through the “up” pressure main check valve.
When full “down” position is reached, continued operation of the “down” relay will have no effect, as pump oil
flow will be returned to the reservoir through the “down” relief valve.
Oil reservoir
Upper cylinder chamber
Tilt rod
Piston
Check valveB
“DOWN” relief valve
Gear pump
Spool valve
“DOWN” pressure main check valve
“UP” pressure main check valve
Lower
cylinder
chamber
8-21 POWER TRIM AND TILT
SHOCK ABSORBER CIRCUIT
( ) Shock valve
Should the lower unit strike an underwater object whilst in motion, the piston will rise abruptly, creating a
sudden high impact pressure in the upper cylinder chamber. The shock valve will then open, allowing oil
to flow into the area between the tilt ram piston and the free piston, thereby dampening (absorbing) the
impact.
( ) Return valve
When the point of impact has passed, propeller thrust and motor weight will force the tilt ram piston back
downwards. The oil from between the ram piston and the free piston is then expelled through the return
valve before flowing into the upper cylinder chamber.
Shock valve
Free piston
Return valve
Piston
Upper cylinder chamber
Tilt rod
POWER TRIM AND TILT 8-22
MANUAL RELEASE CIRCUIT (MANUAL VALVE)
Operation:Turn manual valve maximum two (2) full turns counterclockwise.
When the manual valve is loosened, oil will flow unimpeded (without resistance) through the internal pump
tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position,
the manual valve must be closed again.
Upper cylinder
chamber
Tilt rod
Piston
Lower
cylinder
chamber
“UP” pressure main check valve
Manual release valve
: Tilt up
: Tilt down
8-23 POWER TRIM AND TILT
THERMAL VALVE
The PTT system incorporates a thermal valve for protection of the internal components, should excessive
downward force be exerted on the lower unit with the motor in a tilted position, or (in the case of an impact in
reverse gear), the outboard clamp/swivel brackets and the boat transom.
Should the propeller strike an underwater object whilst in reverse gear, a build up of pressure will be induced
in the lower cylinder chamber, whereby the outboard mounting bracket and/or the boat transom may sustain
damage. To prevent this, the thermal valve will open to relieve the oil pressure, thereby softening the impact.
Internal PTT circuits are protected, as the thermal valve will open to reduce oil pressure (caused by either hot
climate or abnormally heavy usage).
Tilt rod
Piston
Lower
cylinder
chamber
Thermal valve
LOWER UNIT
CONTENTS
REMOVAL & DISASSEMBLY ________________________________ 9-1
PINION BEARING _________________________________________ 9-5
INSPECTION _____________________________________________ 9-7
PROPELLER.................................................................................................... 9-7
GEARCASE ..................................................................................................... 9-7
GEAR ............................................................................................................... 9-8
PROPELLER SHAFT COMPONENTS ........................................................... 9-8
PROPELLER SHAFT BEARING HOUSING .................................................. 9-8
SHIFT ROD AND SHIFT CAM ........................................................................ 9-9
WATER PUMP AND RELATED ITEMS .......................................................... 9-9
DRIVESHAFT BEARING HOUSING .............................................................. 9-10
DRIVESHAFT .................................................................................................. 9-11
ASSEMBLY & INSTALLATION _______________________________ 9-12
TRIM TAB ________________________________________________ 9-22
LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT ___________ 9-23
9
9-1 LOWER UNIT
REMOVAL & DISASSEMBLY
!
Always disconnect the battery cable, before removing
lower unit.
To separate the clutch rod from the shift rod, loosen the clutch
rod lock nut 1, then unscrew the turnbuckle 2.
Remove six(6) bolts 3 and separate gearcase 4 from driveshaft
housing.
Place a drain pan under the oil drain plug.
Remove oil drain plug first 6 then oil level plug 5 and allow
gear oil to drain.
Remove cotter pin 7 from propeller nut and remove propeller
nut 8.
Remove washer 9, spacer 0, propeller A and stopper B from
the propeller shaft.
7
8
9
0
A
B
!
To prevent injury from propeller blades, wear gloves
and place a block of wood between the anti - cavitation
plate and the propeller blade tips to lock the propeller
in place.
LOWER UNIT 9-2
Loosen the four(4) nuts 1, then remove the water pump case
2, impeller 3, and pump under plate 4.
Keep the impeller key 5 for reuse and discard the plate gasket.
Remove the two (2) bolts 1 securing the propeller shaft bearing housing to the gearcase.
Using special tools, draw out the propeller shaft bearing housing.
Remove the propeller shaft and bearing housing assembly.
09930-30104 : A Sliding hammer
09930-30161 : B Propeller shaft remover
Hold the pinion nut securely, then fit special tool to the driveshaft
and loosen the pinion nut.
09921-29510 : Driveshaft holder "
"
A
B
"
"
9-3 LOWER UNIT
To separate the bearing housing from the gearcase, use two
(2) 8mm bolts A as screw jacks, by alternately turning each
one equally.
This will keep the housing level as it pushed off the gearcase.
Remove the pinion gear 1.
Remove the forward gear 2 (with thrust washer 5, back-up
shim 4 and bearing 3)
Lift out driveshaft 1, driveshaft bearing housing 2 and shift
rod assembly 3.
Account for the seal 4 on the driveshaft bearing housing.
Remove the detent ball 1, spring 2 and plate 3.
Remove driveshaft 2 from driveshaft bearing housing 1 and
take off shim 3, thrust washer 4 and thrust bearing 5.
Pull out the spring pin 6, then remove the preload spring 7.
A
3 1
2
Shift cam
LOWER UNIT 9-4
Remove the spring collar 1 and two driveshaft thrust washers
2 from the gear case.
Disassembly of propeller shaft components
Slide propeller shaft away from reverse gear 3 and bearing
housing assembly 1.
Account for the reverse gear back-up shim 2 and reverse gear
thrust washer 4.
To disassemble propeller shaft components, refer to the following :
(a) Pull the push rod 6 out of the propeller shaft.
(b) Remove the spring 7 from the clutch dog shifter.
Slide the shift rod out of the shift rod guide.
Separate the shift cam 2 from the shift rod 3 by driving out
the spring pin 1.
Remove the lower shift rod guide 5 by driving out the spring
pin 4.
Remove the snap ring 6 and push shift rod guide 7 out of
bearing housing.
9-5 LOWER UNIT
(d) Remove the clutch dog shifter 9, push pin 0, and return
spring A from propeller shaft.
PINION BEARING
Removal & Installation Tools
09951-59910 : Shaft (removal & installation) 1
09951-39914 : plate 2
01500-08403 : Bolt 3
09951-19431 : Attachment 4
09930-30104 : Sliding hammer 5
REMOVAL
1. Remove the water pump stud bolts a.
1
2
3 4
5
(c) Use special tool to push the dog pin 8 out of the clutch dog
shifter.
09922-89810 : Shift pin remover
"
8
"
"
a LOWER UNIT 9-6
#
Before installing bearing, ensure that inside of gear
case is clean and free of debris.
7. Set the installer shaft 1, plate 2, attachment 4 and pinion
bearing as shown.
8. Place the installer shaft (with pinion bearing on end of installer) into the gearcase.
9. Secure the plate 2 by tightening the bolts 3.
10. Thread the sliding hammer 5 into the top of the installer
shaft.
11. Drive the bearing down into position by gently striking the
installer shaft until the coupler touches the plate.
2
4
5
1
3
198 m
m (7.79 in)
Pinion bearing
5
1
4
Pinion bearing
Wood block
2. Place the attachment 4 inside the pinion bearing.
3. Insert the removal shaft 1 into attachment.
4. Thread sliding hammer 5 into top of removal shaft.
5. Put wood block under pinion bearing.
6. Drive the pinion bearing out by striking top of shaft with sliding hammer.
#
When removing the pinion bearing, use care to avoid
damaging the gearcase.
INSTALLATION
9-7 LOWER UNIT
INSPECTION
NOTE:
If any component is worn excessively, cracked, defective or
damaged in any way, it must be replaced.
NOTE:
Thoroughly wash all metal components with cleaning solvent
and dry with compressed air.
!
Wear safety grasses when using compressed air.
PROPELLER
• Inspect the propeller for bent, chipped or broken blades.
Replace or repair propeller if in damaged condition.
• Inspect propeller bush splines. Replace or repair propeller if
splines are worn or damaged.
• Inspect propeller bush for deterioration or slipping.
Replace if necessary.
GEARCASE
• Inspect the gearcase. Replace if cracked or damaged.
• Visually check the pinion bearing. Replace if pitted, noisy or
rough.
NOTE:
If removal and replacement are required, see the “PINION
BEARING” section on page 9-5.
LOWER UNIT 9-8
GEAR
• Inspect forward, reverse and pinion gear teeth and engaging
dogs.
Replace gears if damaged or worn.
• Inspect forward gear bearing. Replace bearing if pitted, noisy
or rough.
PROPELLER SHAFT COMPONENTS
• Inspect push rod, replace if worn, broken, or tip is flattened.
• Inspect clutch dog shifter. Replace if chipped, worn or damaged.
• Inspect dog pin. Replace if bent or worn.
• Inspect propeller shaft / splines. Replace if worn, twisted or
damaged.
PROPELLER SHAFT BEARING HOUSING
• Inspect housing. Replace if cracked or damaged.
• Inspect reverse gear bearing. Replace bearing if pitted, noisy
or rough.
• Inspect bearing. Replace bearing if pitted, noisy or rough.
• Check condition of oil seal and O-ring.
Replace the seals if nicked, cut or worn.
( L )
• Check clutch return spring by measuring its free length.
If free length is not within specifications, replace the return
spring.
Clutch return spring free length (L)
Standard : 62 mm (2.44 in.)
Service limit : 60 mm (2.36 in.)
9-9 LOWER UNIT
Replacing propeller shaft oil seal
1. Extract the seals with oil seal remover.
09913-50121 : Oil seal remover
2. Apply Water Resistant Grease to the inner circumference of
the housing.
SHIFT ROD AND SHIFT CAM
• Inspect the “stepped” surfaces of the shift cam.
Replace if chipped, damaged or excessively worn.
• Inspect shift rod guide. Replace if pitted, stiff or corroded.
• Inspect O-ring. Replace if nicked, cut or torn.
• Inspect shift rod boot. Replace if cracked or damaged.
3. Using an oil seal installer, drive the two oil seals (one at a
time ) into the propeller shaft bearing housing.
The lipped portion of the seal must face towards the propeller.
Apply Water Resistant Grease to the seal lips.
WATER PUMP AND RELATED ITEMS
• Inspect impeller. Replace if vanes are cut, torn or worn.
• Inspect pump case. Replace if cracked, distorted or corroded.
• Inspect under panel. Replace if cracked, distorted or corroded.
"
LOWER UNIT 9-10
DRIVESHAFT BEARING HOUSING
• Inspect housing. Replace if cracked or damaged.
• Inspect bearing. Replace if pitted, noisy or rough.
• Check condition of oil seals. Replace if nicked, cut or worn.
Replacing driveshaft oil seal
1. Using bearing remover, draw the driveshaft bearing out of
the driveshaft housing.
09923-74510 : Bearing remover
2. With the oil seal remover, draw the two oil seals out of the
driveshaft bearing housing.
09913-50121 : Oil seal remover
3. Apply Water Resistant Grease to the inner circumference of
the driveshaft bearing housing.
99000-25160 : Water Resistant Grease
4. Grease the inner lips of the seal.
With the lips facing away from driveshaft bearing, place seal
in position and drive it into the bearing housing.
5. Place the driveshaft bearing in position and drive it into the
bearing housing.
$
"
"
Direction of
water pump case
9-11 LOWER UNIT
DRIVESHAFT
Inspect driveshaft / splines. Replace if worn, twisted or damaged.
Inspect driveshaft bearing, replace if pitted, noisy or rough.
LOWER UNIT 9-12
G
F
1
2
3
4
5
6
7
8
9
A
0
B
CD
E
H
I
L
N
Q
R
S
T
U
V
W
X
Y
Z
[
Y
Z
\
] ^
a 23 N . m
(2.3 kg-m, 16.6 lb.-ft.)
%
&
&
&
$
$
$
$
'
J
K
M
O
P
ASSEMBLY & INSTALLATION
Assembly & Installation are reverse of disassembly with special attention to following steps.
1 Dust boot
2 Shift rod guide
3 O-ring
4 O-ring
5 Circlip
6 Shift rod
7 Pin
8 Magnet set
9 Pin
0 Shift rod lower guide
A Pin
B Shift cam
C Ball
D Spring
E Notch plate
F Nut
G Turnbuckle
H Grommet
I Water pump case
J Nut
K Lock washer
L Water pump impeller
M Key
N Pump case under panel
O Gasket
P Stud bolt
Q Driveshaft bearing housing
R Stud bolt
S Oil seal
T Bearing
U Seal ring
V Pin
W Pin
X Gear case
Y Screw
Z Water filter
[ Bolt w/washer
Screw
] Sub water filter
^ Bolt
a Trim tab
Oil seal
9-13 LOWER UNIT
m n m n13 N
. m
(1.3 kg-m,
9.5 lb.-ft.)
%
13 N . m
(1.3 kg-m, 9.5 lb.-ft.)
%
b c d e f g h i j k lm n o X
p q r s t u v w x y z {
| }
~ ;
:
,
/
.
+
*
<
>
?
$
$
$
$
$
'
'
'
' '
'
50 N . m
(5.0 kg-m,
36.5 lb.-ft.)
%
(
55 N . m
(5.5 kg-m,
40.0 lb.-ft.)
%
j Spring collar
k Pinion gear
l Pinion nut
m Plug
n Gasket
o Pinion bearing
p F, gear bearing
q Shim
r Forward gear
s Thrust washer
t Push rod
u Push pin
v Clutch dog shifter
w Dog pin
x Dog spring
y Return spring
z Propeller shaft
{ Thrust washer
| Reverse gear
} Shim
~ O-ring
; Bearing
: Propeller shaft bearing housing
, Bearing
. Oil seal
/ Bolt
+ Stopper
* Propeller
< Propeller Bush
> Spacer
? Washer
„ Nut
… Pin
'
17 N . m
(1.7 kg-m,
12.5 lb.-ft.)
%
b Shim
c Washer
d Bearing
e Driveshaft
f Spring pin
g Pre-load spring
h Washer
i Washer
LOWER UNIT 9-14
#
• 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 9-23)
SHIFT CAM AND SHIFT ROD
Apply Water Resistant Grease to the shift rod guide O-ring 2,
3 and the inside of the dust boot 4.
Slide complete dust boot 4 and shift rod guide 1 into the drive
shaft bearing housing, then secure it with the snap ring 5.
Attach lower shift rod guide 7 to shift rod 6, then secure it with
the pin 8.
Attach shift cam 9 to shift rod, then insert pin 0.
Slide the shift rod through shift rod guide.
Drive shaft
bearing
housing.
$
4
1
2
3
5
6
8
0 9
7
9-15 LOWER UNIT
DETENT BALL
Insert the plate 1, spring 2 and detent ball 3 into gearcase.
FORWARD GEAR
Place the forward gear bearing 3 and back-up shim 2 in position, then install forward gear 1.
99000-22540 : Suzuki Outboard Motor Gear Oil
DRIVESHAFT THRUST WASHERS
Install the two driveshaft thrust washers 1, 2.
The lower washer( with the tab) is located as shown.
DRIVESHAFT SPRING COLLAR
Install the collar 3 on top of the two thrust washers.
PINION GEAR
Place pinion gear in gearcase.
'
1 3
2
Shift cam
2
3
1
'
LOWER UNIT 9-16
DRIVESHAFT
Slide on the pre-load spring 1 and secure it with the pin 2.
Assemble the thrust bearing 3, washer 4 and pinion shim 5
to the driveshaft.
Lower the driveshaft assembly down into the gearcase until the
bottom of shaft protrudes through center of pinion.
DRIVESHAFT BEARING HOUSING
Apply Water Resistant Grease to the driveshaft oil seal.
99000-25160 : Water Resistant Grease
Install the gearcase seal ring 1 into the groove on the driveshaft
bearing housing.
Apply Suzuki Silicone Seal to gearcase and driveshaft bearing
housing surfaces.
99000-31120 : Suzuki Silicone Seal
Install complete housing and shift rod assembly on gearcase.
NOTE:
Be sure the stepped section A of shift cam faces towards propeller shaft.
Also be sure the rear side of the shift cam (with detent notch ) is
positioned over the detent ball 2 in the gearcase.
$
&
Shift cam
2
A
9-17 LOWER UNIT
PINION NUT
Apply Thread Lock 1342 to the threads of the pinion nut before
threading it onto the driveshaft.
Tighten nut to the specified torque.
Pinion nut : 50 N . m (5.0 kg-m, 36.2 lb.-ft.)
99000-32050 : Thread Lock 1342
09921-29510 : Drive shaft holder
CHECKING DRIVESHAFT THRUST PLAY
Before installing reverse gear, driveshaft thrust play should
checked.
(See the “GEARS-SHIMMING AND ADJUSTMENT / CHECKING DRIVESHAFT THRUST PLAY” section on page 9-26)
09951-09511 : Gear adjusting gauge
PROPELLER SHAFT
Slide the clutch dog shifter 2 onto the propeller shaft 1.
NOTE:
For correct installation the side of the clutch dog shifter which
must face towards forward gear is marked with the letter “F”.
Insert the return spring 3 , push pin 4 and push rod 5 into
propeller shaft.
Align the holes in the shifter dog and push pin. Depress the
push rod and slide the dog pin 6 through both dog and push
pin.
Install the dog pin retaining spring 7, ensuring that it fits snuggly
into the groove on the dog shifter.
(
"
"
%
"
"F"
LOWER UNIT 9-18
PROPELLER SHAFT / BEARING HOUSING
Assemble the propeller shaft in the following sequence :
forward thrust washer 5, reverse thrust washer 1, reverse gear
2, reverse gear back-up shim 3 and propeller shaft housing
4.
99000-25160 : Water Resistant Grease
99000-22540 : Suzuki Outboard Motor Gear Oil
Using special tools, install the propeller shaft and housing assembly in the gear case.
09922-59410 : Propeller shaft housing installer
09922-59420 : Housing Installer Handle
When the housing is fully seated, tighten both retaining bolts to
the specified torque.
Bearing housing bolt : 17 N . m (1.7 kg-m, 12.5 lb.-ft.)
RECHECKING DRIVESHAFT THRUST PLAY
Recheck the driveshaft thrust play.
This should not be less than previously checked. If less, reduce
the number / thickness of reverse gear back-up shims.
09951-09511 : Gear adjusting gauge
$
'
"
%
"
$
"
%
9-19 LOWER UNIT
CHECKING PROPELLER SHAFT THRUST PLAY
See the “GEARS - SHIMMING AND ADJUSTMENT / CHECK-
ING PROPELLER SHAFT THRUST PLAY” section on page 927.
LEAKAGE CHECK
To check for oil seal or o-ring leakage, use oil leakage tester.
Before leakage check, temporarily fasten the driveshaft bearing housing to gearcase using two bolts and nuts (placed through
the two diagonally opposite gearcase mounting holes).
Apply the specified pressure through the oil level hole and rotate the drive and propeller shafts.
If pressure does not fall, sealing performance is correct.
09950-69512 : Oil leakage tester
: Air pump
Leakage test pressure : 100 kPa (1.0 kg/cm2, 14.2 psi)
NOTE:
Apply low initial pressure of 0.2 – 0.4 kg / cm2, (2.8 – 5.7 psi)
first, then apply specified pressure.
#
Do not exceed pressure of 110 kPa (1.1kg/cm2, 15.6 psi)
or damage to oil seals will result.
"
"
LOWER UNIT 9-20
WATER PUMP ( Impeller & Case )
Place the under panel gasket 1 and under panel 2 into position.
Insert the key 3 in the driveshaft and slide the impeller 4 onto
driveshaft, ensuring that key and keyway are aligned.
Install the pump case 5 while rotating driveshaft clockwise to
flex the impeller vanes in the correct direction.
Securely tighten the four (4) pump case nuts to the specified
torque.
Pump case nut : 8 N . m (0.8 kg-m, 6.0 lb.-ft.)
PROPELLER INSTALLATION
Install propeller stopper 1 onto propeller shaft, then slide on
the propeller 2.
Fit spacer 3, washer 4 and nut 5, then tighten nut to specified torque.
Push cotter pin 6 through nut and shaft, then bend to secure.
99000-25160 : Water Resistant Grease
Propeller nut : 55 N . m (5.5 kg-m, 40.0 lb.-ft.)
$
1
2
3
4
5
6
%
%
9-21 LOWER UNIT
LOWER UNIT INSTALLATION
Insert dowel pins 1.
Coat the driveshaft splines with Water Resistant Grease.
Apply a light coat of Suzuki Silicone Seal to mating surfaces of
gearcase and driveshaft housing.
Slide the lower unit 2 into place, making sure that the top of
the driveshaft engages properly with the crankshaft and that
water tube locates in the water pump case outlet.
Apply Suzuki Silicone Seal to the retaining bolts 3 and tighten
them to specified torque.
99000-25160 : Water Resistant Grease
99000-31120 : Suzuki Silicone Seal
Gearcase bolt : 23 N . m (2.3 kg-m, 16.5 lb.-ft.)
NOTE:
Apply Suzuki Silicone Seal to the six (6) gearcase bolts.
GEAR OIL
Fill the gearcase with specified gear oil.
(See the “PERIODIC MAINTENANCE / GEAR OIL” section on
page 2-5.)
99000-22540 : Suzuki Outboard Motor Gear Oil
$
&
'
%
LOWER UNIT 9-22
CLUTCH ADJUSTMENT
Connect clutch rod to shift rod as shown.
#
Make sure that chamfered edge of the turnbuckle faces
downward to seat against the lower nut when tightened.
Adjustment step :
1. Shift the clutch lever from Neutral through Forward and Reverse 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 clockwise until
both gears engage with the same amount of clutch lever
travel.
• If Reverse gear engages earlier than Forward, the turnbuckle should be rotated counterclockwise.
TRIM TAB
Adjusting
The trim tab counteracts or minimizes propeller torque “pull” felt
through the steering system.
• To compensate for a veer to starboard, set trailing edge of tab
to the right (as viewed from behind).
• To compensate for a veer to port, set trailing edge of tab to
the left.
With a properly adjusted trim tab, steering will be neutral meaning there should be no tendency for the steering to “pull” to either port or starboard.
2. Lock the lower nut securely against the turnbuckle when
clutch lever adjustment is correct.
Chamfered
edge
9-23 LOWER UNIT
LOWER UNIT GEARS- SHIMMING AND
ADJUSTMENT
If 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
FORWARD GEAR / PINION GEAR
Step to prior to adjustment
1. Correctly assemble driveshaft bearing housing, driveshaft,
forward gear, pinion gear and related components (see page
9-14 to 9-17).
NOTE:
When installing forward gear back-up shim, choose shim thinner than design specification for calculating adjustment.
2. Tighten pinion nut to specified torque.
Pinion nut : 50 N . m (5.0 kg-m, 36.0 lb.-ft.)
3. Temporarily fasten the driveshaft bearing housing to the
gearcase with two bolts and nuts.
Œ
Numerical
index / item
Available
thickness
(mm)
Design
specification
Thickness
(mm)
Pinion gear
back up shim 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 1.0
Forward gear
back up shim 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 1.0
Forward gear
thrust washer 2.0, 2.2 2.0
Reverse gear
thrust washer 1.8, 1.9, 2.0, 2.1, 2.2, 2.3 2.0
Reverse gear
back up shim 0.5, 0.6, 0.7, 0.8, 0.9, 1.0 1.0




Œ
• • • •
%
LOWER UNIT 9-24
"
Checking and adjusting tooth contact pattern
(Pinion and Forward gear )
Check tooth contact pattern by using the following procedure :
1. To assess tooth contact, apply a light coat of Prussian Blue
on the convex surface of forward gear.
2. Install propeller shaft and housing assembly (minus reverse
gear and internal components).
3. Push propeller shaft inward and hold in position.
4. Using driveshaft holder tool, rotate the driveshaft 5 - 6 times.
09921-29510 : Driveshaft holder
"
"
Adjusting gear backlash
1. Screw gear adjusting gauge into the oil drain hole.
09951-09511 : Gear adjusting gauge
#
When adjusting gauge, align the gauge rod end to contact the gear tooth at the convex side (heel end).
Make sure the rod does not contact the adjacent tooth.
Rod end alignment is as illustrated in the figure.
2. Hold the driveshaft by hand, then gently rock forward gear
back and forth by hand.
Read the backlash on the dial gauge.
Gear backlash : 0.1 – 0.2 mm (0.004 – 0.008 in.)
• If backlash is larger than specified, thickness of forward
gear back-up shim must be increased.
• If backlash is smaller, back-up shim thickness must be
decreased.
#
When measuring backlash, rotate forward gear back
and forth very gently.
Do not force the gear beyond the point where the forward and pinion gears make contact.
Excessive movement may also result in breakage of
the gauge rod.
9-25 LOWER UNIT
5. Carefully pull out propeller shaft and housing to check tooth
contact pattern.
Optimum tooth contact
The optimum tooth contact is shown at right.
A shim adjustment may be necessary to obtain this contact
pattern.
Concave side
Convex side
Heel
Tooth top
Tooth bottom
Tooth width
Toe
TOOTH
CONTACT
PATTERN
Optimum tooth contact
HEEL
Convex side
TOE
approx. 1/3 of
tooth width approx.
1 mm
Example(1)
Incorrect topside toe contact :
Correction measures :
• Decrease thickness of forward gear shim.
• Slightly increase pinion gear shim thickness.
#
Do not set tooth contact in this position (top side toe
contact). Damage and chipping of forward and pinion
gear may result.
Example(2)
Incorrect bottom side toe contact :
Correction measures :
• Increase thickness of forward gear shim.
• Slightly decrease pinion gear shim thickness.
#
Do not set tooth contact in this position (bottom side
toe contact). Chipping of pinion gear may result.
EXAMPLE OF INCORRECT
Top side toe contact
HEEL
TOE
EXAMPLE OF INCORRECT
Bottom side toe contact
HEEL
TOE
LOWER UNIT 9-26
CHECKING DRIVESHAFT THRUST PLAY
After obtaining optimum tooth contact, driveshaft thrust play
should be measured.
1. Affix gear adjusting gauge to driveshaft.
09951-09511 : Gear adjusting gauge
2. Slowly push driveshaft downward.
Read the maximum play. Designate this amount of play as
(A).
NOTE:
Driveshaft thrust play (A) must be known to adjust reverse gear
shim.
RECHECKING DRIVESHAFT THRUST PLAY
( Reverse gear back-up shim adjustment )
1. After adjusting forward gear tooth contact pattern, correctly
assemble propeller shaft, housing assembly, reverse gear
and related components (see page 9-17 to 9-18).
2. Screw sliding hammer assembly onto propeller shaft and
strike a few gentle outward taps.
09930-30161 : Propeller shaft remover – B
09930-30104 : Sliding hammer – A
3. Affix gear adjusting gauge to driveshaft.
09951-09511 : Gear adjusting gauge
4. Push shaft downward and read maximum play. Designate
this measurement as play (B).
5. Compare play (B) to play (A)( page 9-26).
6. Reverse gear back-up shim adjustment is correct if (B) is
equal to (A).
• If (B) is less than (A), reduce reverse gear back-up shim
thickness.
"
"
"
"
A
B
9-27 LOWER UNIT
CHECKING PROPELLER SHAFT THRUST PLAY
After adjusting all gear positions, measure the propeller shaft
thrust play. if not within the following specification, a shim adjustment is required.
Propeller shaft thrust play : 0.20 – 0.40 mm
(0.008 – 0.016 in.)
NOTE:
Maintain the forward gear thrust washer at standard thickness
(2.0 mm) and adjust only the reverse gear thrust washer with
shim.
Measurement step :
1. Assemble gear adjusting gauge to the propeller shaft.
09951-09511 : Gear adjusting gauge
2. Push propeller shaft inward.
3. Hold shaft in and set dial gauge pointer to zero.
4. Slowly pull shaft outward and read the maximum thrust play
on the dial.
• If measurement is more than specification, increase reverse gear thrust washer thickness.
• If measurement is less than specification, reduce reverse
gear thrust washer thickness.
"
"
WIRE / HOSE ROUTING
CONTENTS
WIRING DIAGRAM _________________________________________ 10-1
WIRE ROUTING ___________________________________________ 10-2
FUEL / WATER HOSE ROUTING _____________________________ 10-7
10
10-1 WIRE / HOSE ROUTING
WIRING DIAGRAM
DF40T / DF50T
WIRE / HOSE ROUTING 10-2
WIRE ROUTING
F
ix b at te ry c ha rg e co il le ad w ire
.
C
la m p 3
0A
F
us e C
om m un ic at io n co nn ec to r / c
ap P
T
T
m ot or r el ay (
U
P
)
P
T
T
m ot or c ab le P
T
T
r el ay p la te P
T
T
m ot or r el ay (
D
O
W
N
)
P
T
T
r el ay p la te B
at te ry c ab le S
ta rt er m ot or r el ay S
ta rt er m ot or s ub c ab le E
ng in e m ai n w iri
ng h ar ne ss R
ou te e ng in e m ai n w iri
ng h ar ne ss u nd er w at er h os e. R
ec tif
ie r &
r eg ul at or C
la m p F
ix r ec tif
ie r &
re gu la to r le ad w ire
C
la m p F
ix E
x. m an i. te m p. se ns or le ad w ire
.
E
xm an i. te m pe ra tu re s en so r E
C
M
E
C
M
m ai n re la y C
K
P
s en so r co nn ec to r 10-3 WIRE / HOSE ROUTING
C
la m p W
iri
ng h ar ne ss C
M
P
s en so r C
M
P
s en so r le ad w ire
F
ue l i
nj ec to r #1
F
ix in je ct or le ad w ire
an d fu el p um p le ad w ire
.
F
ue l i
nj ec to r #2
F
ue l i
nj ec to r #3
E
ng in e ha rn es s P
T
T
s w itc
h le ad c on ne ct or N
eu tr al s w itc
h G
as fi lte
r 3
N
m (0
.3
k gm 2
.0
Ib .-
ft.
)
.M
A
P
s en so r ho se /
P
ro te ct or ho se c lip
ho se c lip
M
A
P
s en so r O
il pr es su re s w itc
h C
la m p F
ix n eu tr al s w itc
h le ad w ire
N
eu tr al s w itc
h le ad w ire
c on ne ct or WIRE / HOSE ROUTING 10-4
E
xm an i. te m p. s en so r W
he n in st al lin
g se ns or , a
pp ly en gi ne o il to s en so r O
-r in g. R
ec tif
ie r &
r eg ul at or R
ec tif
ie r &
r eg ul at or le ad w ire
C
la m p F
ix e ac h le ad w ire
a nd h ar ne ss .
(C
K
P
s en so r le ad , C
yl in de r te m p. s en so r le ad , e
ng in e ha rn es s C
K
P
s en so r M
A
P
s en so r C
la m p F
ix C
K
P
s en so r le ad w ire
w ith
c la m p as s ho w n B
at te ry c ha rg e co il R
ou te C
K
P
s en so r le ad w ire
u nd er u pp er oi l s
ea l h
ou si ng S
ta rt er m ot or C
K
P
s en so r C
la m p F
ix le ad w ire
n ot to co nt ac t w
ith
fl yw he el .
E
le ct ric
p ar ts h ol de r co ve r E
le ct ric
p ar ts h ol de r E
ng in e ha rn es s C
K
P
s en so r C
yl in de r te m p. se ns or le ad w ire
co nn ec to r C
yl in de r te m p. s en so r W
he n in st al lin
g se ns or , a
pp ly en gi ne o il to s en so r O
-r in g. 10-5 WIRE / HOSE ROUTING
CTP switch
Battery cable
Battery cable
Battery cable
Route battery cable
on fuel hose
Wiring harness
IAT sensor
IAT sensor grommet
IAC valve
Starter motor sub cable
Tighten bolt with PTT relay ground
wire, battery cable ground wire and
harness ground wire.
Starter motor
Bolt
Ignition coil #1
Ignition coil #3
Ignition coil #2
Clamp
Clamp
Clamp
Clamp
CMP sensor
WIRE / HOSE ROUTING 10-6
P
T
T
s w itc
h F
ix P
T
T
c ab le a nd tr im s en de r le ad to c la m p br ac ke t. P
T
T
m ot or c ab le C
la m p Tr im s en de r ca bl e C
la m p Tr im s en de r B
in d th e tr im s en de r ca bl e an d P
T
T
m ot or c ab le .
P
T
T
a tta
ch m en t 10-7 WIRE / HOSE ROUTING
High pressure fuel filter
Evaporation hose / Protector
(Vapor separator to flywheel cover)
Fuel hose / Protector
(Low fuel pump to vapor separator)
Vapor separator
Fuel hose
(Vapor separator to H fuel filter).
Breather hose
Clamp
Clamp
Breather hose
Water return hose
Fuel hose / Protector
(Fuel filter to Low fuel pump)
Fuel filter
Water hose (Engine holder to 3-way)
Water hose (Engine holder to vapor separator)
Pilot water hole
Fuel hose / Protector
(fuel connector to fuel filter)
FUEL / WATER HOSE ROUTING
!
• Do not over-bend (kink) or twist hoses when installing.
• When installing hose clips, position tabs to avoid contact with other parts.
• Check that hoses do not contact rods and levers during either engine operation or standstill.
• Extreme care should be taken not to cut, abrade or cause any other damage on hoses.
• Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted.
WIRE / HOSE ROUTING 10-8
Lo w fu el p um p F
ue l f
ilt
er F
ue l h
os e / P
ro te ct or (f ue l f
ilt
er to lo w fu el p um p) 3-
w ay W
at er h os e (3
-w ay to p ilo
t w
at er h ol e) F
ue l h
os e / P
ro te ct or (3
-w ay to v ap or s ep ar at or )
3-
w ay jo in t C
la m p F
ue l h
os e (V
ap or s ep ar at or to H
fu el fi lte
r) F
ue l h
os e / P
ro te ct or (H
fi lte
r to 3
-w ay jo in t) .
.
H
ig h pr es su re fu el fi lte
r D
ra in h os e C
la m p W
at er h os e (E
ng in e ho ld er to v ap or s ep ar at or )
W
at er h os e (3
-w ay to v ap or s ep ar at or )
F
ue l h
os e / P
ro te ct or (3
-w ay jo in t t
o va po r se pa ra to r) Lo w fu el p um p C
la m p F
ue l h
os e / P
ro te ct or (L
ow fu el p um p to v ap or s ep ar at or )
F
ue l h
os e / P
ro te ct or (H
fu el fi lte
r to 3
-w ay jo in t) .
H
ig h pr es su re fu el fi lte
r C
la m p 10-9 WIRE / HOSE ROUTING
Fuel hose
(H fuel filter to vapor separator).
Fuel hose / Protector
(H fuel filter to 3-way joint).
Fuel hose / Protector
(H fuel filter to 3-way joint).
Fuel hose / Protector
(Vapor separator to
low fuel pump)
High pressure fuel filter
Clamp
3-way joint
Fuel hose / Protector
(3-way joint to vapor separator)
Vapor separator
Gas filter
IAC hose
IAC valve
IAC hose
IAC valve silencer
Throttle body
MAP sensor hose
MAP sensor
Clamp
3-way joint
Fuel hose / Protector
(3-way joint to vapor
separator) Clamp
Water hose
(Vapor separator to 3-way)
Water hose
(Engine holder to vapor separator)
Clamp
High pressure fuel filter
Evaporation hose
MAP sensor
DF40QH / DF50QH
11
CONTENTS
SPECIFICATIONS ________________________________________ 11- 1
SERVICE DATA __________________________________________ 11- 3
TIGHTENING TORQUE ____________________________________ 11- 9
WIRING DIAGRAM _______________________________________ 11-10
ENGINE CONTROL SYSTEM _______________________________ 11-11
Caution / Diagnostic System ................................................................ 11-11
Engine speed control during shifting ................................................... 11-12
Checking engine total operating hours ................................................ 11-12
MID UNIT _______________________________________________ 11-13
TILLER HANDLE ................................................................................. 11-13
REMOVAL ......................................................................................... 11-13
DISASSEMBLY.................................................................................. 11-14
ASSEMBLY ....................................................................................... 11-17
INSTALLATION.................................................................................. 11-18
TILT AID SYSTEM ................................................................................ 11-23
REMOVAL ......................................................................................... 11-23
INSPECTION ..................................................................................... 11-24
INSTALLATION.................................................................................. 11-25
11-1 DF40QH / DF50QH
SPECIFICATIONS
Item Unit
Data
DF40QH DF50QH
DIMENSIONS & WEIGHT
Overall length (front to back) mm (in) 852 (33.5)
Overall width (side to side) mm (in) 382 (15.0)
Overall height S mm (in) 1263 (49.7)
L mm (in) 1390 (54.7)
Weight
(without engine oil)
S kg (Ibs) 107 (236)
L kg (Ibs) 110 (243)
Transom height S mm (in. type) 401 (15)
L mm (in. type) 528 (20)
PERFORMANCE
Maximum output kW (PS) 29.4 (40)
Recommended operating range r/min
Idle speed r/min
36.8 (50)
5200 – 5800 5900 – 6500
850 ± 50 (in-gear: approx. 850)
POWERHEAD
Engine type 4-stroke DOHC
Number of cylinders 3
Bore mm (in) 71.0 (2.80)
Stroke mm (in) 68.6 (2.70)
Total displacement cm3 (cu in) 815 (49.7)
Compression ratio : 1 10
Spark plug NGK DCPR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Twist grip
PRE-FIX 04001F 05001F
DF40QH / DF50QH 11-2
Item Unit
Data
DF40QH DF50QH
FUEL & OIL
Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 ( 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 10W-40
Engine oil amounts
L (US/Imp. qt)
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
R + M
ml (US/Imp. oz)
Gear oil
Gearcase oil capacity
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
610 (20.6/21.5)
BRACKET
Trim angle Manual Trim and Gas Assisted Tilt System
Number of trim position 5
Maximum tilt angle degree 73°
LOWER UNIT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 25 (2.27)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in.) × Pitch (in.)
These specifications are subject to change without notice.
S : Aluminum propeller
SS : Stainless steel propeller
3 × 11-1/2 × 9 (S900)
3 × 11-1/2 × 10 (S1000)
3 × 11-1/2 × 11 (S1100)
3 × 11-5/8 × 12 (S1200)
3 × 11-1/2 × 13 (S1301, SS1300)
3 × 11-3/8 × 14 (S1400, SS1400)
3 × 11-1/4 × 15 (S1500)
3 × 11-1/8 × 16 (S1600, SS1600)
3 × 11 × 17 (S1700)
Adjustable
11-3 DF40QH / DF50QH
SERVICE DATA
POWERHEAD
Recommended operating range r/min 5200 – 5800
Idle speed 850 ± 50 (in-gear: approx.850)r/min
5900 – 6500
**Cylinder compression 1300 – 1600 (13 – 16, 185 – 228)kPa (kg/cm2, psi)
**Cylinder compression max.
difference between any two
cylinders
100 (1.0, 14)
kPa (kg/cm2, psi)
**Engine oil pressure 300 – 380 (3.0 – 3.8, 43 – 54) at 4000 r/min
(at normal operating temp.)
kPa (kg/cm2, psi)
Engine oil
Engine oil amounts
L (US/Imp. qt)
Thermostat operating
temperature
48 – 52 (118 – 126)°C (°F)
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
** Figures shown are guidelines only, not absolute service limits.
Item Unit
Data
DF40QH DF50QH
DF40QH / DF50QH 11-4
Item Unit
Data
DF40QH DF50QH
ENGINE OIL PUMP
0.31 (0.012)mm (in)LimitRadial clearance
0.15 (0.006)mm (in)LimitSide clearance
CYLINDER HEAD / CAMSHAFT
0.05 (0.002)mm (in)Limit
Cam height mm (in) 37.530–37.690 (1.4776–1.4839) 38.230–38.390 (1.5051–1.5114)
Cylinder head distortion
0.10 (0.004)mm (in)LimitManifold seating
faces distortion
STD
Limit mm (in) 37.430 (1.4736) 38.130 (1.5012)
IN
mm (in) 37.740–37.900 (1.4858–1.4921) 37.740–37.900 (1.4858–1.4921)STD
Limit mm (in) 37.640 (1.4819) 37.640 (1.4819)
EX
0.045 – 0.087 (0.0018 – 0.0034)mm (in)Camshaft journal oil
clearance
STD
Limit 0.120 (0.0047)mm (in)
Camshaft
journal
(housing)
inside diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
23.000 – 23.021 (0.9055 – 0.9063)
23.171 (0.9122)
Camshaft
journal outside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
22.934 – 22.955 (0.9029 – 0.9037)
22.784 (0.8970)
0.10 (0.004)mm (in)LimitCamshaft runout
Cylinder head bore
to tappet clearance
0.025 – 0.062 (0.0010 – 0.0024)mm (in)STD
0.150 (0.0059)mm (in)Limit
Tappet outer
diameter 26.959 – 26.975 (1.0614 – 1.0620)mm (in)STD
27.000 – 27.021 (1.0630 – 1.0638)mm (in)STDCylinder head bore
11-5 DF40QH / DF50QH
VALVE / VALVE GUIDE
24.6 (0.97)mm (in)IN
Tappet clearance
(Cold engine
condition)
mm (in)
Valve diameter
STD
STD mm (in)
mm (in)STD
Limit mm (in)
0.045 – 0.072 (0.0018 – 0.0028)mm (in)STD
Limit 0.090 (0.0035)mm (in)
IN,EX mm (in)STD 5.500 – 5.512 (0.2165 – 0.2170)
Item Unit
Data
DF40QH DF50QH
21.5 (0.85)mm (in)EX
IN
EX
0.18 – 0.24 (0.007 – 0.009)
0.18 – 0.24 (0.007 – 0.009)
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
IN
EX
Valve guide to
valve stem
clearance
Valve guide inside
diameter
Valve seat
angle
IN
EX
30°, 45°
15°, 45°
IN,EX mm (in)STD 11.0 (0.43)Valve guide
protrusion
Valve stem
outside diameter
mm (in)STD
STD mm (in)
IN
EX
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
IN,EX mm (in)Limit 3.20 (0.126)Valve stem end
length
Valve stem end
deflection
mm (in)Limit
Limit mm (in)
IN
EX
0.14 (0.006)
0.18 (0.007)
IN,EX mm (in)Limit 0.05 (0.002)Valve stem runout
IN,EX mm (in)Limit 0.08 (0.003)Valve head radial
runout
Valve head
thickness
mm (in)STD
Limit mm (in)
IN
1.0 (0.04)
0.7 (0.03)
mm (in)STD
Limit mm (in)
EX
1.15 (0.045)
0.5 (0.02)
Valve seat
contact width
mm (in)STD
STD mm (in)
IN
EX
1.80 – 2.20 (0.071 – 0.087)
1.65 – 2.05 (0.065 – 0.081)
Valve spring free
length
33.1 (1.30)mm (in)STD
31.8 (1.25)mm (in)Limit
Valve spring tension 97 – 113 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in)N (kg, Ibs)STD
89 (8.9, 19.6) for 28.5 mm (1.12 in)N (kg, Ibs)Limit
Valve spring
squareness 2.0 (0.08)mm (in)Limit
degree
degree
DF40QH / DF50QH 11-6
CYLINDER / PISTON / PISTON RING
0.060 (0.0024)mm (in)Limit
Piston ring
end gap
mm (in) 0.10 – 0.25 (0.004 – 0.010)
Cylinder distortion
Piston to cylinder
clearance
STD
Limit mm (in) 0.70 (0.028)
1st
mm (in) 0.25 – 0.40 (0.010 – 0.016)STD
Limit mm (in) 1.00 (0.039)
2nd
Item Unit
Data
DF40QH DF50QH
mm (in) 0.020 – 0.040 (0.0008 – 0.0016)STD
Limit mm (in) 0.100 (0.0039)
71.000 – 71.020 (2.7953 – 2.7961)mm (in)STDCylinder bore
50 (2.0) from cylinder top surfacemm (in)Cylinder measuring position
70.970 – 70.990 (2.7941 – 2.7949)mm (in)STDPiston skirt diameter
19 (0.7) from piston skirt endmm (in)Piston measuring position
0.100 (0.0039)mm (in)LimitCylinder bore wear
Piston ring
free end gap
mm (in) Approx. 7.5 (0.30)STD
Limit mm (in) 6.0 (0.24)
1st
mm (in) Approx. 11.0 (0.43)STD
Limit mm (in) 8.8 (0.35)
2nd
Piston ring
groove width
mm (in) 1.01 – 1.03 (0.040 – 0.041)1st
mm (in) 1.01 – 1.03 (0.040 – 0.041)
mm (in) 1.51 – 1.53 (0.059 – 0.060)
2nd
Oil
Piston ring to
groove
clearance
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
1st
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
2nd
Piston ring
thickness
mm (in) 0.97 – 0.99 (0.038 – 0.039)STD
STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
1st
2nd
Pin clearance in
piston pin hole
mm (in) 0.006 – 0.018 (0.0002 – 0.0007)STD
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
mm (in) 17.996 – 18.000 (0.7085 – 0.7087)STD
Limit mm (in) 17.980 (0.7079)
Piston pin hole
diameter
mm (in) 18.006 – 18.014 (0.7089 – 0.7092)STD
Limit mm (in) 18.040 (0.7102)
Pin clearance in
conrod small end
mm (in) 0.003 – 0.015 (0.0001 – 0.0006)STD
Limit mm (in) 0.05 (0.002)
Conrod small end
bore
mm (in) 18.003 – 18.011 (0.7088 – 0.7091)STD
STD
STD
STD
11-7 DF40QH / DF50QH
Item Unit
Data
DF40QH DF50QH
CRANKSHAFT / CONROD
Conrod big end oil
clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Conrod small end
inside diameter
18.003 – 18.011 (0.7088 – 0.7091)mm (in)STD
Conrod big end
inside diameter
41.000 – 41.018 (1.6142 – 1.6149)mm (in)STD
Crank pin outside
diameter
37.982 – 38.000 (1.4954 – 1.4961)mm (in)STD
Crank pin outside
diameter difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Conrod bearing
thickness
1.486 – 1.502 (0.0585 – 0.0591)mm (in)STD
Conrod big end side
clearance
0.100 – 0.250 (0.0039 – 0.0098)mm (in)STD
0.350 (0.0138)mm (in)Limit
21.950 – 22.000 (0.8642 – 0.8661)mm (in)STDConrod big end width
22.100 – 22.200 (0.8700 – 0.8740)mm (in)STDCrank pin width
Crankshaft journal
oil clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Crankshaft center
journal runout
0.04 (0.002)mm (in)Limit
Crankcase bearing
holder inside diameter
49.000 – 49.018 (1.9291 – 1.9298)mm (in)STD
Crankshaft journal
outside diameter
44.982 – 45.000 (1.7709 – 1.7717)mm (in)STD
Crankshaft journal
outside diameter
difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Crankshaft thrust
play
0.11 – 0.31 (0.004 – 0.012)mm (in)STD
0.35 (0.014)mm (in)Limit
Crankshaft thrust
bearing thickness
2.470 – 2.520 (0.0972 – 0.0992)mm (in)STD
Crankshaft bearing
thickness
1.999 – 2.015 (0.0787 – 0.0793)mm (in)STD
LOWER UNIT
Design specification thickness for shim & washer
Pinion gear back-up shim 1.0 (0.04)mm (in)
Forward gear back-up shim 1.0 (0.04)mm (in)
Forward gear thrust washer 2.0 (0.08)mm (in)
Reverse gear thrust washer 2.0 (0.08)mm (in)
Reverse gear back-up shim 1.0 (0.04)mm (in)
DF40QH / DF50QH 11-8
ELECTRICAL
BTDC 0° – BTDC 32°Degrees at r/minIgnition timing
6500r/minOver revolution limiter
Item Unit
Data
DF40QH DF50QH
Ω at 20°CCKP sensor resistance
Ω at 20°CCMP sensor resistance
Ω at 20°CIgnition coil resistance Primary
k Ω at 20°CSecondary
Ω at 20°CBattery charge coil resistance
WattBattery charge coil output (12V)
NGKStandard spark plug Type
mm (in)Gap 0.8 – 0.9 (0.031 – 0.035)
AFuse amp. rating
Main fuse : 30
Fuel pump fuse : 15
Ah (kC)
Recommended battery
capacity (12V)
70 (252) or larger
Ω at 20°CFuel injector resistance
Ω at 20°CIAC valve resistance
k Ω at 25°C
IAT sensor/Cylinder temp. sensor
/ Ex-mani. temp. sensor
(Thermistor characteristic)
Ω at 20°CECM main relay resistance
Ω at 20°CStarter motor relay resistance
1.8 – 2.3
80 – 120
3.5 – 5.1
STARTER MOTOR
30Sec.Max. continuous time of use
0.9kWMotor output
17.0 (0.67)mm (in)STDBrush length
10.0 (0.39)mm (in)Limit
0.5 – 0.8 (0.02 – 0.03)mm (in)STDCommutator
undercut 0.2 (0.01)mm (in)Limit
33.0 (1.30)mm (in)STDCommutator
outside diameter 32.0 (1.26)mm (in)Limit
0.05 (0.002)mm (in)STD
0.40 (0.016)mm (in)Limit
Pinion to ring gear gap 3.0 – 5.0 (0.12 – 0.20)STD mm (in)
Commutator outside
diameter difference
168 – 252
——
1.9 – 2.5
8.1 – 11.1
DCPR6E
BTDC 0° – BTDC 25°
7000
0.56 – 0.84
216
11.0 – 16.5
21.5 – 32.3
11-9 DF40QH / DF50QH
TIGHTENING TORQUE
Tightening Torque – Important Fasteners
ITEM
THREAD
DIAMETER
TIGHTENING TORQUE
kg-mN . m Ib.-ft.
Cylinder head cover bolt 6 mm 10 1.0 7.0
Cylinder head bolt 10 mm
Crankcase bolt 8 mm 25 2.5 18.0
Conrod cap nut 8 mm 35 3.5 25.5
Camshaft housing bolt 10 1.0 7.0
Camshaft timing sprocket bolt 10 1.0 7.0
Timing chain guide bolt 10 1.0 7.0
11 1.1 8.0
8 mm 23 2.3 16.5
Oil pressure switch 13 1.3 9.5
Intake manifold fuel main gallery 6 mm 10 1.0 7.0
35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 200 20.0 144.5
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt/nut 8 mm 23 2.3 16.5
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 10 mm 40 4.0 29.5
Upper mount cover bolt 8 mm 23 2.3 16.5
Lower mount nut 12 mm 60 6.0 43.5
12 mm 40 4.0 29.0
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Water pump case nut 6 mm 8 0.8 6.0
Gearcase bolt 8 mm 23 2.3 16.5
Propeller shaft bearing housing bolt 8 mm 17 1.7 12.5
Pinion nut 50 5.0 36.0
Propeller nut 18 mm 55 5.5 40.0
3-way joint bolt
Upper/lower plug
Front
Rear
10 mm 53 5.3 38.5
6 mm
60 6.0 43.5
Intake manifold bolt / nut
Tiller handle mounting bolt 10 mm 50 5.0 36.0
Tiller handle pivot bolt/nut 10 mm 45 4.5 32.5
6 mm
6 mm
6 mm
12 mm
DF40QH / DF50QH 11-10
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WIRING DIAGRAM
DF40QH/DF50QH
11-11 DF40QH / DF50QH
B
G
W
Gr Br O O
Ignition switch
from ECM
B
G
W
Gr Br Gr O
O
Gr Gr Ignition switch
from ECM
ENGINE CONTROL SYSTEM
The engine control systems such as ignition and fuel injection are basically the same as DF40/50T model specification
except for the following:
Caution / Diagnostic System
Caution and Diagnostic system operator alert signals are audio
only on QH models. Alerts will be signaled by a sound sequence from the caution buzzer contained in the tiller handle.
When any caution system is activated, the diagnostic code
buzzer sound sequence for that caution will be the same as
that of a T- specification model.
Refer to the illustration for the QH model buzzer sound sequence (ON/OFF pattern) of caution and diagnostic signals.
NOTE:
The buzzer cancellation feature found on T-specification Models is not available on QH models. Due to this features removal, the ignition switch and the function of the orange lead
extending from ECM to the ignition switch is different between
T and QH specifications.
QH models
T models
Buzzer ON/OFF pattern
A. Caution signal
ON
OFF
1.5 sec. 7 sec.
B. Diagnostic signals
ON
OFF
0.2 sec. 3 sec. 0.2 sec. 5 sec.
1.3 sec.
[EX] : Code 2–3
• When engine is at stop and Ign. Key is turned ON
• During engine operation
ON
OFF
0.2 sec.
4.8 sec.
1.5 sec. 7 sec.
1.3 sec.
4.8 sec.
0.2 sec.
DF40QH / DF50QH 11-12
Engine speed control during shifting
On QH-specification models, a special safety feature to control engine speed during shifting has been added. This feature fixes the upper limit of engine speed during shifting to a
preset value of 1500 r/min.
[ Operation ]
If the CTP switch is “OFF” and engine speed at the moment
of shifting (neutral switch turns “OFF” ) is above the rpm limit
of 1500 r/min, engine speed will automatically be lowered to
approximately 1500 r/min.
Once this feature is engaged, engine speed will be regulated
to remain at the fixed 1500 r/min limit until the feature is cancelled.
[ Cancellation ]
The engine speed control feature will be canceled if any one
of the following conditions is satisfied:
• Throttle is returned to and remains at full close (CTP switch
“ON”) for at least one second.
• Engine speed is lowered below the control speed (1500
r/min) and remains there for at least for two seconds.
Checking engine total operating hours
As a monitor-tachometer gauge is not supplied with QH models, engine total operating hours must be checked using SDS
and a personal computer or by temporarily connecting a DF
model monitor-tachometer.
11-13 DF40QH / DF50QH
MID UNIT
TILLER HANDLE
Functions
The tiller handle is equipped with the following centralized
component parts necessary for proper operation and handling.
1Ignition switch 2Emergency stop switch
3Shift lever 4Throttle control grip
5Throttle friction adjust knob
REMOVAL
1. Remove the rigging port grommet 1 from front panel.
Remove both lower side covers.
2. Remove snap pin 2, washer 3 and throttle cable connector 4 from throttle control arm.
Unthread connector from throttle cable.
3. Remove snap pin 5, washer 6 and shift cable connector 7 from clutch control lever.
Unthread connector from shift cable.
4. Remove cable stopper 8 from between cables.
5. Disconnect handle wire harness connector 9 from engine wiring harness.
8
3 4
5
1 2
DF40QH / DF50QH 11-14
6. Remove nut 0 and washer A.
Loosen and remove the handle pivot bolt B.
Remove tiller handle assembly.
Account for three washers and spring.
7. Remove the seals C and connector lock nuts D from
throttle / shift cables.
Slide rigging port grommet 1 off.
DISASSEMBLY
Remove six (6) screws 1 and take off tiller handle lower cover
2.
Disconnect emergency stop switch lead connector 3.
Remove E-ring 4 and throttle cable 5 from throttle link 8.
Remove shift cable 6 from clutch link 7 in the same manner.
Remove screw 9, handle grip 0.
11-15 DF40QH / DF50QH
Drive out handle rod stopper pin A, then pull out rod stopper
B, spring C and handle rod bush D.
Loosen handle grip adjuster E.
Remove screws F and handle rod plate G.
Remove the two screws H securing the throttle link I to tiller
handle housing, then remove throttle link I and handle rod
assembly J.
Remove the bolt K securing the shift lever.
Separate the shift lever L by installing 8mm bolt a in shift
lever as shown in figure.
Using a hammer, tap on bolt head until the shift lever separates, then remove 8mm bolt.
DF40QH / DF50QH 11-16
Remove the two bolts M securing the clutch link N to tiller
handle housing, then remove clutch link and spacer O.
11-17 DF40QH / DF50QH
9
11
10
32
31 1
2
14
13
12
15
20
21
19
2316
17
18
22
30
28
25
35
36
34 33
24
25 5
4
27
26
7
3
6
37
29
8
ASSEMBLY
Assembly is reverse order of disassembly.
When reassembling tiller handle, refer to the construction diagram below .
1.Tiller handle housing (1)
2.Handle grip (1)
3.Lower cover (1)
4.Screw (6)
5.Cable grommet (1)
6.Switch cover (1)
7.Emergency switch (1)
8.Lock plate (1)
9.Ignition switch (1)
10.Handle wire harness (1)
11.Handle wire grommet (1)
23.Screw (2)
24.Throttle cable (1)
25. E-ring (2)
26.Bolt (1)
27.Bush (1)
28.Shift cable (1)
29.Shift link (1)
30.Screw (2)
31.Bush (1)
32.Shift lever (1)
33.Buzzer (1)
12.Screw (1)
13.Washer (1)
14.Handle rod stopper (1)
15.Spring (1)
16.Bush (1)
17.Pin (1)
18.Handle rod (1)
19.Handle grip adjuster (1)
20.Plate (1)
21.Screw (2)
22.Throttle link (1)
34.Lock plate (1)
35.Guide plate (1)
36.Ball (1)
37.E-ring (1)
DF40QH / DF50QH 11-18
INSTALLATION
Installation is reverse order of removal with special attention
to the following steps.
Tiller handle assembly
• Install three (3) nylon bushes 1 into tiller handle mounting
hole and set tiller handle 2 on handle bracket.
• Place three (3) washers 3 and spring 4 into position.
Insert handle pivot bolt 5.
Coat pivot bolt threads with thread lock and tighten pivot
bolt to specified torque.
! Handle pivot bolt: 45 N.m (4.5 kg-m, 32.5 lb.-ft.)
" 99000-32050: Thread Lock 1342
• Install washer 6, nut 7 and tighten nut to specified torque.
! Handle pivot nut: 45 N.m (4.5 kg-m, 32.5 lb.-ft.)
Handle wire harness
Route the handle wire harness 1 as shown in figure.
Connect handle wire harness connector to engine wiring harness 2.
11-19 DF40QH / DF50QH
Throttle / Shift cable installation
• Installation
(1) Insert shift cable and throttle cable through the rigging
port grommet 1 as shown in figure.
Install the seals 2 and connector lock nut 3 on both
cables.
(2) Secure the shift cable 4 and throttle cable 6 in the cable
holder 5 by fitting groove on the cable into slots of holder.
(3) Push the cable stopper 7 into the clearance between
both cables until the stopper is fixed on the cable holder.
(4) Screw cable connector 8, 9 onto both cables.
DF40QH / DF50QH 11-20
• Adjustment
Shift cable to clutch control lever
(a) Place shift lever and clutch control lever a in the neutral position.
(b) Push the cable connector 8 and shift cable 4 in the direction shown by the arrow H to remove all
play in the cable.
(c) While pressing against the cable and connector, adjust the connector 8 to align with pivot pin 0 on
the clutch control lever.
(d) When aligned, press the connector 8 (flat side of connector towards the clutch control lever) over
the pivot pin 0.
(e) Install the washer A and snap pin B, then tighten the cable lock nut C against the connector to
maintain adjustment.
(f) Make sure that both forward and reverse gears can be engaged with the same angle of shift lever
travel from “NEUTRAL” position.
View X
x PIVOT PIN POSITION
Tiller handle
model
Remote control
model
D
11-21 DF40QH / DF50QH
Throttle cable to throttle control arm
(A) Set the throttle grip to the fully closed position.
(B) Make sure that the throttle lever is fully closed
(CTP switch G must be in “ON”, pushed-in, position).
(C) Push the cable connector 9 and throttle cable in the direction shown by the arrow H to remove all play in the
cable.
(D) While pressing against the cable and connector, adjust
the connector 9 to align with the pivot pin E on the throttle
control arm D.
(E) When aligned , press the connector 9 (flat side of connector towards the throttle control arm) over the pivot pin
E.
(F) Install the washer A and snap pin B, then tighten the
cable lock nut C against the connector to maintain adjustment.
#
Cable connectors must be threaded at least 13 mm
( 0.5 in.) onto cable.
DF40QH / DF50QH 11-22
Rigging port grommet
• Install both side lower covers and rigging port grommet 1.
• Push the cable seal tube 2 into the clearance between
shift / throttle cable 3/4 and rigging port grommet.
Harness/Cable routing
• Fix handle wire harness with clamp a as shown at right.
• Bind shift and throttle cable with spiral tube b as shown at
right.
a b 11-23 DF40QH / DF50QH
TILT AID SYSTEM
The DF40QH/50QH models are equipped with a tilt aid cylinder assembly located between the PORT and STBD clamp
brackets.
This mechanism helps decrease the manual effort required
to tilt the motor. The nitrogen gas sealed in the cylinder expands as the cylinder rod extends, thereby assisting the
manual tilting process.
$
This unit contains high pressure gas and it must not
be disassembled, punctured, incinerated or exposed
to heat.
REMOVAL
Tilt engine fully up and lower the manual tilt lock levers 1.
$
During the following procedure, firmly secure the
engine and support its weight. (see right)
Remove the snap ring 2 and push tilt cylinder upper shaft
pin 3 out.
1
1. Tilt aid cylinder assembly
DF40QH / DF50QH 11-24
Remove the two STBD motor mounting bolts 4.
Loosen the clamp bracket shaft nut 5.
NOTE:
Complete removal of the clamp bracket shaft nut is not required.
Nut should only be loosened as far as the end of the shaft
threads to facilitate removal of the tilt aid gas cylinder.
Remove the tilt pin 6.
Loosen the tilt aid gas cylinder lower shaft nut 7 and remove
the lower shaft bolt 8.
Slide the STBD clamp bracket 9 fully outward to the right
hand side.
Remove the tilt aid gas cylinder 0 from between the clamp
brackets.
INSPECTION
NOTE:
If any component is found to be excessively worn, cracked,
defective or damaged in any way, it must be replaced.
Tilt aid gas cylinder
Check tilt aid gas cylinder.
If cracks, defects or other damage is found, replace the cylinder assembly complete.
11-25 DF40QH / DF50QH
Bushings
Check all bushings.
If excessive wear or other damage is found, replace bushing.
If bushing fit is loose when installing, replace bushing.
1. Tilt aid gas cylinder
2. Release lever
3. Rubber, release lever
4. Cylinder upper shaft
5. Bush
6. Snap ring
7. Gas cylinder lower shaft
8. Bolt
9. Bush
10. Washer
11. Nut
12. Bolt
13. Nut
INSTALLATION
Installation is reverse order of removal with special attention
to following steps.
DF40QH / DF50QH 11-26
Release lever
Install release lever by aligning with punch mark a of release
lever and punch mark b of shaft as shown in figure.
Tighten lever bolt securely.
Tilt aid gas cylinder
Apply grease to each bush, cylinder lower shaft and cylinder
upper shaft.
Install bushes 1, 2 and cylinder lower shaft 3.
% 99000-25160 : Suzuki Water Resistant Grease
Place the tilt aid gas cylinder in position between the clamp
brackets.
Tighten clamp bracket shaft nut to specified torque.
! Clamp bracket shaft nut:
43 N.m (4.3 kg-m, 31.0 lb.-ft.)
Slide the cylinder lower shaft bolt through the clamp bracket
and lower shaft, then secure with the nut.
Align the cylinder upper eyelet with the hole in the swivel
bracket, then insert the upper shaft through the swivel bracket
and gas cylinder.
Secure the upper shaft with the snap ring.
1 Lower shaft bolt
2 Nut
1 Upper shaft
2 Snap ring
Release lever
CONTENTS
SPECIFICATIONS__________________________________________ 12-1
SERVICE DATA____________________________________________ 12-3
ENGINE CONTROL SYSTEM ________________________________ 12-9
ELECTRICAL _____________________________________________ 12-10
POWER UNIT _____________________________________________ 12-11
LOWER UNIT _____________________________________________ 12-12
WIRE/HOSE ROUTING _____________________________________ 12-13
DF40 / DF50 “Y” (’00) MODEL
12
12-1 DF40/DF50 “Y” (‘00) model
SPECIFICATIONS
Item Unit
Data
DF40T DF50T
DIMENSIONS & WEIGHT
Overall length (front to back) mm (in) 756 (29.8)
Overall width (side to side) mm (in) 382 (15.0)
Overall height S mm (in) 1263 (49.7)
L mm (in) 1390 (54.7)
Weight
(without engine oil)
S kg (Ibs) 106 (234)
L kg (Ibs) 109 (240)
Transom height S mm (in. type) 401 (15)
L mm (in. type) 528 (20)
PERFORMANCE
Maximum output kW (PS) 29.4 (40)
Recommended operating range r/min
Idle speed r/min
36.8 (50)
5200 – 5800 5900 – 6500
850 ± 50 (in-gear: approx. 850)
POWERHEAD
Engine type 4-stroke DOHC
Number of cylinders 3
Bore mm (in) 71.0 (2.80)
Stroke mm (in) 68.6 (2.70)
Total displacement cm3 (cu in) 815 (49.7)
Compression ratio : 1 10
Spark plug NGK DCPR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Remote control
PRE-FIX 04001F 05001F
DF40QH DF50QH
852 (33.5)
382 (15.0)
1263 (49.7)
1390 (54.7)
107 (236)
110 (243)
401 (15)
528 (20)
852 (33.5)
382 (15.0)
1263 (49.7)
1390 (54.7)
107 (236)
110 (243)
401 (15)
528 (20)
756 (29.8)
382 (15.0)
1263 (49.7)
1390 (54.7)
106 (234)
109 (240)
401 (15)
528 (20)
Twist grip Remote control Twist grip
DF40/DF50 “Y” (‘00) model 12-2
Item Unit
Data
DF40T DF50T
FUEL & OIL
Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 ( 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 10W-40
Engine oil amounts
L (US/Imp. qt)
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
R + M
ml (US/Imp. oz)
Gear oil
Gearcase oil capacity
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
610 (20.6/21.5)
BRACKET
Trim angle
PTT system
Number of trim position PTT system
Maximum tilt angle degree 73°
LOWER UNIT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 25 (2.27)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in.) × Pitch (in.)
These specifications are subject to change without notice.
S : Aluminum propeller
SS : Stainless steel propeller
3 × 11-1/2 × 9 (S900)
3 × 11-1/2 × 10 (S1000)
3 × 11-1/2 × 11 (S1100)
3 × 11-5/8 × 12 (S1200)
3 × 11-1/2 × 13 (S1301, SS1300)
3 × 11-3/8 × 14 (S1400, SS1400)
3 × 11-1/4 × 15 (S1500)
3 × 11-1/8 × 16 (S1600, SS1600)
3 × 11 × 17 (S1700)
Adjustable
DF40QH DF50QH
Manual trim and gas
assisted tilt system
Manual trim and gas
assisted tilt system
PTT system
5 PTT system 5
12-3 DF40/DF50 “Y” (‘00) model
SERVICE DATA
POWERHEAD
Recommended operating range r/min 5200 – 5800
Idle speed 850 ± 50 (in-gear: approx.850)r/min
5900 – 6500
**Cylinder compression 1300 – 1600 (13 – 16, 185 – 228)kPa (kg/cm2, psi)
**Cylinder compression max.
difference between any other
cylinders
100 (1.0, 14)kPa (kg/cm2, psi)
**Engine oil pressure 300 – 380 (3.0 – 3.8, 43 – 54) at 4000 r/min
(at normal operating temp.)
kPa (kg/cm2, psi)
Engine oil
Engine oil amounts
L (US/Imp. qt)
Thermostat operating
temperature
48 – 52 (118 – 126), *58 – 62 (136 – 144)°C (°F)
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
* For serial no. DF40-031586 and later models, DF50-031526 and later models.
** Figures shown are guidelines only, not absolute service limits.
Item Unit
Data
DF40T/40QH DF50T/50QH
ENGINE OIL PUMP
0.31 (0.012)mm (in)LimitRadial clearance
0.15 (0.006)mm (in)LimitSide clearance
CYLINDER HEAD/CAMSHAFT
0.05 (0.002)mm (in)Limit
Cam height mm (in) 37.530–37.690 (1.4776–1.4839) 38.230–38.390 (1.5051–1.5114)
Cylinder head distortion
0.10 (0.004)mm (in)LimitManifold seating faces
distortion
STD
Limit mm (in) 37.430 (1.4736) 38.130 (1.5012)
IN
mm (in) 37.740–37.900 (1.4858–1.4921) 37.740–37.900 (1.4858–1.4921)STD
Limit mm (in) 37.640 (1.4819) 37.640 (1.4819)
EX
0.045 – 0.087 (0.0018 – 0.0034)mm (in)Camshaft journal oil
clearance
STD
Limit 0.120 (0.0047)mm (in)
Camshaft
journal (housing) inside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
23.000 – 23.021 (0.9055 – 0.9063)
23.171 (0.9122)
Camshaft
journal outside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
22.934 – 22.955 (0.9029 – 0.9037)
22.784 (0.8970)
0.10 (0.004)mm (in)LimitCamshaft runout
Cylinder head bore to
tappet clearance
0.025 – 0.062 (0.0010 – 0.0024)mm (in)STD
0.150 (0.0059)mm (in)Limit
Tappet outer diameter 26.959 – 26.975 (1.0614 – 1.0620)mm (in)STD
27.000 – 27.021 (1.0630 – 1.0638)mm (in)STDCylinder head bore
DF40/DF50 “Y” (‘00) model 12-4
VALVE / VALVE GUIDE
24.6 (0.97)mm (in)IN
Tappet clearance
(Cold engine
condition)
mm (in)
Valve diameter
STD
STD mm (in)
mm (in)STD
Limit mm (in)
0.045 – 0.072 (0.0018 – 0.0028)mm (in)STD
Limit 0.090 (0.0035)mm (in)
IN,EX mm (in)STD 5.500 – 5.512 (0.2165 – 0.2170)
Item Unit
Data
DF40T/40QH DF50T/50QH
21.5 (0.85)mm (in)EX
IN
EX
0.18 – 0.24 (0.007 – 0.009)
0.18 – 0.24 (0.007 – 0.009)
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
IN
EX
Valve guide to
valve stem
clearance
Valve guide inside
diameter
Valve seat
angle
IN
EX
30°, 45°
15°, 45°
IN,EX mm (in)STD 11.0 (0.43)Valve guide
protrusion
Valve stem
outside diameter
mm (in)STD
STD mm (in)
IN
EX
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
IN,EX mm (in)Limit 3.20 (0.126)Valve stem end
length
Valve stem end
deflection
mm (in)Limit
Limit mm (in)
IN
EX
0.14 (0.006)
0.18 (0.007)
IN,EX mm (in)Limit 0.05 (0.002)Valve stem runout
IN,EX mm (in)Limit 0.08 (0.003)Valve head radial
runout
Valve head
thickness
mm (in)STD
Limit mm (in)
IN
1.0 (0.04)
0.7 (0.03)
mm (in)STD
Limit mm (in)
EX
1.15 (0.045)
0.5 (0.02)
Valve seat
contact width
mm (in)STD
STD mm (in)
IN
EX
1.80 – 2.20 (0.071 – 0.087)
1.65 – 2.05 (0.065 – 0.081)
Valve spring free
length
33.1 (1.30)mm (in)STD
31.8 (1.25)mm (in)Limit
Valve spring tension 97 – 113 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in)N (kg, Ibs)STD
89 (8.9, 19.6) for 28.5 mm (1.12 in)N (kg, Ibs)Limit
Valve spring
squareness 2.0 (0.08)mm (in)Limit
degree
degree
12-5 DF40/DF50 “Y” (‘00) model
CYLINDER/PISTON/PISTON RING
0.060 (0.0024)mm (in)Limit
Piston ring
end gap
mm (in) 0.10 – 0.25 (0.004 – 0.010)
Cylinder distortion
Piston to cylinder
clearance
STD
Limit mm (in) 0.70 (0.028)
1st
mm (in) 0.25 – 0.40 (0.010 – 0.016)STD
Limit mm (in) 1.00 (0.039)
2nd
Item Unit
Data
DF40T/40QH DF50T/50QH
mm (in) 0.020 – 0.040 (0.0008 – 0.0016)STD
Limit mm (in) 0.100 (0.0039)
71.000 – 71.020 (2.7953 – 2.7961)mm (in)STDCylinder bore
50 (2.0) from cylinder top surfacemm (in)Cylinder measuring position
70.970 – 70.990 (2.7941 – 2.7949)mm (in)STDPiston skirt diameter
19 (0.7) from piston skirt endmm (in)Piston measuring position
0.100 (0.0039)mm (in)LimitCylinder bore wear
Piston ring
free end gap
mm (in) Approx. 7.5 (0.30)STD
Limit mm (in) 6.0 (0.24)
1st
mm (in) Approx. 11.0 (0.43)STD
Limit mm (in) 8.8 (0.35)
2nd
Piston ring
groove width
mm (in) 1.01 – 1.03 (0.040 – 0.041)1st
mm (in) 1.01 – 1.03 (0.040 – 0.041)
mm (in)
1.51 – 1.53 (0.059 – 0.060)
*2.01 – 2.03 (0.079 – 0.080)
2nd
Oil
Piston ring to
groove
clearance
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
1st
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
2nd
Piston ring
thickness
mm (in) 0.97 – 0.99 (0.038 – 0.039)STD
STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
1st
2nd
Pin clearance in
piston pin hole
mm (in) 0.006 – 0.018 (0.0002 – 0.0007)STD
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
mm (in) 17.996 – 18.000 (0.7085 – 0.7087)STD
Limit mm (in) 17.980 (0.7079)
Piston pin hole
diameter
mm (in) 18.006 – 18.014 (0.7089 – 0.7092)STD
Limit mm (in) 18.040 (0.7102)
Pin clearance in
conrod small end
mm (in) 0.003 – 0.015 (0.0001 – 0.0006)STD
Limit mm (in) 0.050 (0.0020)
Conrod small end
bore
mm (in) 18.003 – 18.011 (0.7088 – 0.7091)STD
STD
STD
STD
* For serial no. DF40-031716 and later models, DF50-031700 and later models.
DF40/DF50 “Y” (‘00) model 12-6
Item Unit
Data
DF40T/40QH DF50T/50QH
CRANKSHAFT / CONROD
Conrod big end oil
clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Conrod small end
inside diameter
18.003 – 18.011 (0.7088 – 0.7091)mm (in)STD
Conrod big end
inside diameter
41.000 – 41.018 (1.6142 – 1.6149)mm (in)STD
Crank pin outside
diameter
37.982 – 38.000 (1.4954 – 1.4961)mm (in)STD
Crank pin outside
diameter difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Conrod bearing
thickness
1.486 – 1.502 (0.0585 – 0.0591)mm (in)STD
Conrod big end side
clearance
0.100 – 0.250 (0.0039 – 0.0098)mm (in)STD
0.350 (0.0138)mm (in)Limit
21.950 – 22.000 (0.8642 – 0.8661)mm (in)STDConrod big end width
22.100 – 22.200 (0.8700 – 0.8740)mm (in)STDCrank pin width
Crankshaft journal
oil clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Crankshaft center
journal runout
0.04 (0.002)mm (in)Limit
Crankcase bearing
holder inside diameter
49.000 – 49.018 (1.9291 – 1.9298)mm (in)STD
Crankshaft journal
outside diameter
44.982 – 45.000 (1.7709 – 1.7717)mm (in)STD
Crankshaft journal
outside diameter
difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Crankshaft thrust
play
0.11 – 0.31 (0.004 – 0.012)mm (in)STD
0.35 (0.014)mm (in)Limit
Crankshaft thrust
bearing thickness
2.470 – 2.520 (0.0972 – 0.0992)mm (in)STD
Crankshaft bearing
thickness
1.999 – 2.015 (0.0787 – 0.0793)mm (in)STD
LOWER UNIT
Design specification thickness for shim & washer
Pinion gear back-up shim 1.0 (0.04)mm (in)
Forward gear back-up shim 1.0 (0.04)mm (in)
Forward gear thrust washer 2.0 (0.08)mm (in)
Reverse gear thrust washer 2.0 (0.08)mm (in)
Reverse gear back-up shim 1.0 (0.04)mm (in)
12-7 DF40/DF50 “Y” (‘00) model
ELECTRICAL
BTDC 0° – BTDC 32°Degrees at r/minIgnition timing
6500r/minOver revolution limiter
Item Unit
Data
DF40T/40QH DF50T/50QH
Ω at 20°CCKP sensor resistance
Ω at 20°CCMP sensor resistance
Ω at 20°CIgnition coil resistance Primary
k Ω at 20°CSecondary
Ω at 20°CBattery charge coil resistance
WattBattery charge coil output (12V)
NGKStandard spark plug Type
mm (in)Gap 0.8 – 0.9 (0.031 – 0.035)
AFuse amp. rating
Main fuse : 30
Fuel pump fuse : 15
Ah (kC)
Recommended battery
capacity (12V)
70 (252) or larger
Ω at 20°CFuel injector resistance
Ω at 20°CIAC valve resistance
k Ω at 25°C
IAT sensor/Cylinder temp. sensor
/ Ex-mani. temp. sensor
(Thermistor characteristic)
Ω at 20°CECM main relay resistance
Ω at 20°CStarter motor relay resistance
1.8 – 2.3
80 – 120
3.5 – 5.1
STARTER MOTOR
30Sec.Max. continuous time of use
0.9kWMotor output
17.0 (0.67)mm (in)STDBrush length
10.0 (0.39)mm (in)Limit
0.5 – 0.8 (0.02 – 0.03)mm (in)STDCommutator
undercut 0.2 (0.01)mm (in)Limit
33.0 (1.30)mm (in)STDCommutator
outside diameter 32.0 (1.26)mm (in)Limit
0.05 (0.002)mm (in)STD
0.40 (0.016)mm (in)Limit
Pinion to ring gear gap 3.0 – 5.0 (0.12 – 0.20)STD mm (in)
Commutator outside
diameter difference
168 – 252
——
1.9 – 2.5
8.1 – 11.1
DCPR6E
BTDC 0° – BTDC 25°
7000
0.56 – 0.84
216
11.0 – 16.5
21.5 – 32.3
PTT MOTOR
9.8 (0.39)mm (in)STDBrush length
4.8 (0.19)mm (in)Limit
22.0 (0.87)mm (in)STDCommutator
outside diameter 21.0 (0.83)mm (in)Limit
Ω at 20°CPTT motor relay resistance 3.0 – 4.5
DF40/DF50 “Y” (‘00) model 12-8
PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM
ACTIVATING
1 MAP sensor 1 34 YES
2 CKP sensor 42 NO
3 IAC valve/By-pass air screw adjustment 31 NO
4 CMP sensor 24 YES
5 CTP switch 22 NO
6 Cylinder temp. sensor 14 YES
7 IAT sensor 23 YES
8 MAP sensor 2 (Sensor hose) 32 NO
9 Rectifier & regulator (Over-charging) 11 NO
10 Exhaust manifold temp. sensor 15 YES
on off
on off
on off
on off
on off
on off
on off
on off
on off
on off
SELF-DIAGNOSTIC SYSTEM INDICATION
When the abnormality occurs in a signal from sensor, switch etc., the “CHECK ENGINE” lamp on the
monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
NOTE:
• If more than two items fail at once, the self-diagnostic indication appears according to priority order.
The indication repeats three times.
• On the tiller handle (QH) model, alerts is signaled by a sound from the caution buzzer contained in the
tiller handle.
12-9 DF40/DF50 “Y” (‘00) model
TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
TDC TDC TDC TDC TDC TDC
120˚ 120˚ 120˚ 120˚ 60˚
BTDC 65˚ on #1 exhaust stroke
BTDC 420˚ on #1
exhaust stroke
30˚
Injection time duration
ON
OFF
CKP Sensor Signal 1
CKP Sensor Signal 2
CKP Sensor Signal 3
CMP Sensor Signal
#1 Injection Signal
#3 Injection Signal
#2 Injection Signal
In. Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex.
Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. In.
Ex. In. Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm. Ep.
In. : Intake, Cm. : Compression, Ep. : Explosion, Ex. : Exhaust
ENGINE CONTROL SYSTEM
ENGINE CONTROL MODULE
The fuel injection timing has been modified from the “Y” (‘00) model.
The fuel injection will be started at BTDC 420° on exhaust stroke as shown in the chart below.
FUEL INJECTION TIMING CHART
DF40/DF50 “Y” (‘00) model 12-10
Water return hose Water return hose
Rectifier & regulator
Rectifier & regulator
EARLY LATE
ELECTRICAL
RECTIFIER & REGULATOR
The location of the rectifier & regulator has been modified from the cylinder head to the cylinder block.
In relation to this modification;
• Bosses have been added to facilitate mounting of the rectifier & regulator to the cylinder block.
• Water return hose has been modified in shape.
This modification has been carried out from the “Y” (‘00) model.
12-11 DF40/DF50 “Y” (‘00) model
Ê1.0 mm Hole
3-way joint
Filter
Opened to
atmosphere
Ê1.5 mm Hole
EARLY LATE
EARLY Ê 1.5 mm Hole
LATE Ê 1.0 mm Hole
8 - Ê 1.710 - Ê 1.2
18
˚
18
˚
18
˚
18˚
18
˚
18
˚
18
˚
18˚
1.
5
+
0
.0
1
+
0
.0
3
0.
75
2.
0
+
0
.0
1
+
0
.0
3
1
EARLY LATE
POWER UNIT
PISTON / PISTON RNG
Number of diameter of the piston oil holes and thickness of oil ring have been modified.
This modification has been carried out from the middle of “Y” (‘00) model. Refer to the page 12-5.
EVAPORATION HOSE / FUEL VAPOR SEPARATOR
The evaporation hose and related items have been modified. In reration to this modification, the hose
nipple on the fuel vapor separator has been modified also.
This modification has been carred out from the middle of “Y” (‘00) model.
THERMOSTAT
The thermostat has been modified in specification of operating temperature from 50 ±2°C to 60 ±2°C.
This modification has been carried out from the middle of “Y” (‘00) model. Refer to the page 12-3.
DF40/DF50 “Y” (‘00) model 12-12
LOWER UNIT
GEARCASE
The gearcase has been modified in shape as follows:
• Modified the shape of the part above the cavitation plate.
• Modified the shape of the splash plate to make common use with “S” transom size.
• Aligned the height of the oil level plug and flashing plug.
• Modified the shape of the skeg end.
• Chamfied the edge.
• Added rib behind the shift cam.
This modification has been carried out from the “Y” (‘00) model.
12-13 DF40/DF50 “Y” (‘00) model
C
la m p F
ix E
xm an i. te m p. s en so r le ad w ire
a nd re ct ifi
er &
r eg ul at or le ad w ire
to ge th er .
E
xm an i. te m p. s en so r C
la m p
F
ix r ec tif
ie r &
r eg ul at or le ad w ire
on to w at er h os e w ith
c la m p.
P
os iti
on c la m p en d in w ar d (e ng in e si de )
no t t
o co nt ac t w
ith
m ot or co ve r. E
ng in e si de R
ec tif
ie r &
r eg ul at or E
ng in e w iri
ng h ar ne ss R
ou te e ng in e w iri
ng h ar ne ss u nd er w at er h os e. E
C
M
m ai n re la y C
K
P
s en so r co nn ec to r S
ta rt er m ot or s ub c ab le S
ta rt er m ot or r el ay B
at te ry c ab le +
P
T
T
r el ay p la te P
T
T
m ot or r el ay (
D
O
W
N
)
P
T
T
m ot or c ab le P
T
T
m ot or r el ay (
U
P
)
P
T
T
r el ay p la te C
om m un ic at io n co nn ec to r / C
ap 30
A
F
us e C
la m p F
ix b at te ry c ha rg e co il le ad w ire
.
WIRE / HOSE ROUTING
WIRE ROUTING
DF40/DF50 “Y” (‘00) model 12-14
C
yl in de r te m p. s en so r A
pp ly e ng in e oi l t
o O
-r in g w he n in st al lin
g se ns or .
C
K
P
s en so r #2
(
W
/B
)
C
yl in de r te m p. s en so r le ad w ire
c on ne ct or E
ng in e w iri
ng ha rn es s E
le ct ric
p ar ts h ol de r E
le ct ric
p ar ts h ol de r co ve r C
la m p F
ix le ad w ire
n ot to c on ta ct w ith
fly
w he el .
C
K
P
s en so r #1
(
R
/B
)
S
ta rt er m ot or R
ou te C
K
P
s en so r le ad w ire
u nd er up pe r oi l s
ea l h
ou si ng .
B
at te ry c ha rg e co il C
la m p F
ix C
K
P
s en so r le ad w ire
w ith
c la m p as s ho w n. M
A
P
s en so r C
K
P
s en so r #3
(
R
/W
)
C
la m p F
ix C
K
P
s en so r le ad w ire
, C
yl in de r te m p. se ns or le ad w ire
a nd e ng in e w iri
ng ha rn es s. R
ec tif
ie r &
r eg ul at or E
xm an i. te m p. s en so r A
pp ly e ng in e oi l t
o O
-r in g w he n in st al lin
g se ns or .
12-15 DF40/DF50 “Y” (‘00) model
Clamp
Breather hose
Water return hose
Fuel hose / Protector
(Fuel filter to L. fuel pump)
Fuel filter
Water hose
(3-way joint to Pilot water hole)
Pilot water hole
Water hose (Engine holder to Vapor separator)
Water hose (Engine holder to 3-way joint)
Clamp
Fuel hose / Protector
(Fuel connector to Fuel filter)
FUEL / WATER HOSE ROUTING
!
• Do not over-bend (kink) or twist hoses when installing.
• When installing hose clips, position tabs to avoid contact with other parts.
• Check that hoses do not contact rods and levers during either engine operation or standstill.
• Extreme care should be taken not to cut, abrade or cause any other damage on hoses.
• Care should be taken not to cause hoses to be compressed excessively by any clamp
when fitted.
DF40/DF50 “Y” (‘00) model 12-16
F
ue l h
os e (L
. f
ue l p
um p to V
ap or s ep ar at or )
E
va po la tio
n ho se (V
ap or s ep ar at or to 3
-w ay jo in t) 3-
w ay jo in t E
va po la tio
n ho se (3
-w ay jo in t t
o F
ilt
er )
E
va po la tio
n ho se (3
-w ay jo in t t
o F
ly w he el c ov er )
C
la m p B
re at he r ho se H
ig h pr es su re fu el fi lte
r F
ue l h
os e (V
ap or s ep ar at or to H
. f
ue l f
ilt
er )
F
ue l v
ap or s ep ar at or 12-17 DF40/DF50 “Y” (‘00) model
F
ue l v
ap or s ep ar at or dr ai n ho se E
va po ra tio
n ho se (F
ilt
er to A
tm os ph er e) F
ilt
er E
va po ra tio
n ho se (3
-w ay jo in t F
ilt
er )
W
at er h os e (E
ng in e ho ld er to V
ap or s ep ar at or )
W
at er h os e (3
-w ay jo in t t
o V
ap or s ep ar at or )
F
ue l h
os e / P
ro te ct or (F
ue l j
oi nt p ip e to V
ap or s ep ar at or )
F
ue l j
oi nt p ip e Lo w p re ss ur e fu el p um p F
ue l h
os e / P
ro te ct or (L
. f
ue l p
um p to V
ap or s ep ar at or )
F
ue l h
os e / P
ro te ct or (H
. f
ue l f
ilt
er to 3
-w ay jo in t) 3-
w ay jo in t E
va po ra tio
n ho se H
ig h pr es su re fu el fi lte
r F
ue l h
os e (V
ap or s ep ar at or to H
. f
ue l f
ilt
er )
W
at er h os e (3
-w ay jo in t t
o P
ilo
t w
at er h ol e) DF40 / DF50(W) “K1” (’01) MODEL
13
CONTENTS
GENERAL INFORMATION___________________________________ 13-1
SPECIFICATIONS ______________________________________ 13-1
SERVICE DATA ________________________________________ 13-3
TIGHTENING TORQUE __________________________________ 13-9
SPECIAL TOOLS _______________________________________ 13-11
MATERIALS REQUIRED _________________________________ 13-14
PERIODIC MAINTENANCE __________________________________ 13-15
MAINTENANCE AND TUNE-UP PROCEDURES ______________ 13-15
ENGINE CONTROL SYSTEM ________________________________ 13-20
ENGINE CONTROL SYSTEM STRUCTURE _________________ 13-20
IGNITION SYSTEM _____________________________________ 13-25
ELECTRONIC FUEL INJECTION SYSTEM __________________ 13-26
SELF-DIAGNOSTIC SYSTEM _____________________________ 13-27
FAIL-SAFE SYSTEM ____________________________________ 13-29
OPERATING HOUR INDICATION SYSTEM __________________ 13-30
OIL CHANGE REMINDER SYSTEM________________________ 13-31
INSPECTION __________________________________________ 13-33
TROUBLESHOOTING ___________________________________ 13-41
REMOVAL/INSTALLATION _______________________________ 13-47
ELECTRICAL _____________________________________________ 13-48
ELECTRIC STARTER SYSTEM ___________________________ 13-48
MID UNIT_________________________________________________ 13-54
TILT AID SYSTEM ______________________________________ 13-54
POWER TRIM AND TILT _____________________________________ 13-57
POWER TRIM AND TILT UNIT ____________________________ 13-58
WIRE/HOSE ROUTING _____________________________________ 13-68
WIRING DIAGRAM _____________________________________ 13-68
WIRE ROUTING________________________________________ 13-70
13-1 DF40/DF50 “K1” (‘01) model
GENERAL INFORMATION
SPECIFICATIONS
Item Unit
Data
DF40T DF50(W)T
DIMENSIONS & WEIGHT
Overall length (front to back) mm (in) 756 (29.8)
Overall width (side to side) mm (in) 382 (15.0)
Overall height S mm (in) 1263 (49.7)
L mm (in) 1390 (54.7)
Weight
(without engine oil)
S kg (Ibs) 106 (234)
L kg (Ibs) 109 (240)
Transom height S mm (in. type) 401 (15)
L mm (in. type) 528 (20)
PERFORMANCE
Maximum output kW (PS) 29.4 (40)
Recommended operating range r/min
Idle speed r/min
36.8 (50)
5200 – 5800 5900 – 6500
850 ± 50 (in-gear: approx. 850)
POWERHEAD
Engine type 4-stroke DOHC
Number of cylinders 3
Bore mm (in) 71.0 (2.80)
Stroke mm (in) 68.6 (2.70)
Total displacement cm3 (cu in) 815 (49.7)
Compression ratio : 1 10
Spark plug NGK DCPR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Remote control
PRE-FIX 04001F 05001F
DF40QH DF50(W)QH
852 (33.5)
382 (15.0)

1390 (54.7)

110 (243)

528 (20)
852 (33.5)
382 (15.0)

1390 (54.7)

110 (243)

528 (20)
756 (29.8)
382 (15.0)
1263 (49.7)
1390 (54.7)
106 (234)
109 (240)
401 (15)
528 (20)
Twist grip ´ Twist grip
UL kg (Ibs) —
UL mm (in. type) —


113 (249)
655 (25)
112 (247)
655 (25)
UL mm (in) — — 1517 (59.7)1517 (59.7)
DF40/DF50 “K1” (‘01) model 13-2
Item Unit
Data
DF40T DF50(W)T
FUEL & OIL
Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 ( 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 10W-40
Engine oil amounts
L (US/Imp. qt)
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
R + M
ml (US/Imp. oz)
Gear oil
Gearcase oil capacity
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
610 (20.6/21.5)
BRACKET
Trim angle
PTT system
Number of trim position PTT system
Maximum tilt angle degree 73°
LOWER UNIT
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 11 : 25 (2.27)
Drive line impact protection Spline drive rubber hub
Propeller Blade × Diam. (in) × Pitch (in)
These specifications are subject to change without notice.
S : Aluminum propeller
SS : Stainless steel propeller
3 × 11-1/2 × 9 (S900)
3 × 11-1/2 × 10 (S1000)
3 × 11-1/2 × 11 (S1100)
3 × 11-5/8 × 12 (S1200)
3 × 11-1/2 × 13 (S1301, SS1300)
3 × 11-3/8 × 14 (S1400, SS1400)
3 × 11-1/4 × 15 (S1500)
3 × 11-1/8 × 16 (S1600, SS1600)
3 × 11 × 17 (S1700)
Adjustable
DF40QH DF50(W)QH
Manual trim and gas
assisted tilt system
Manual trim and gas
assisted tilt system
PTT system
5 PTT system 5
13-3 DF40/DF50 “K1” (‘01) model
SERVICE DATA
POWERHEAD
Recommended operating range r/min 5200 – 5800
Idle speed 850 ± 50 (in-gear: approx.850)r/min
5900 – 6500
*Cylinder compression 1300 – 1600 (13 – 16, 185 – 228)kPa (kg/cm2, psi)
*Cylinder compression max.
difference between any other
cylinders
100 (1.0, 14)
kPa (kg/cm2, psi)
*Engine oil pressure 300 – 380 (3.0 – 3.8, 43 – 54) at 4000 r/min
(at normal operating temp.)
kPa (kg/cm2, psi)
Engine oil
Engine oil amounts
L (US/Imp. qt)
Thermostat operating
temperature
58 – 62 (136 – 144)°C (°F)
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
2.2 (2.3/1.9) : Oil change only
2.4 (2.5/2.1) : Oil filter change
* Figures shown are guidelines only, not absolute service limits.
Item Unit
Data
DF40T/40QH DF50(W)T/50(W)QH
ENGINE OIL PUMP
0.31 (0.012)mm (in)LimitRadial clearance
0.15 (0.006)mm (in)LimitSide clearance
CYLINDER HEAD/CAMSHAFT
0.05 (0.002)mm (in)Limit
Cam height mm (in) 37.530–37.690 (1.4776–1.4839) 38.230–38.390 (1.5051–1.5114)
Cylinder head distortion
0.10 (0.004)mm (in)LimitManifold seating faces
distortion
STD
Limit mm (in) 37.430 (1.4736) 38.130 (1.5012)
IN
mm (in) 37.740–37.900 (1.4858–1.4921) 37.740–37.900 (1.4858–1.4921)STD
Limit mm (in) 37.640 (1.4819) 37.640 (1.4819)
EX
0.045 – 0.087 (0.0018 – 0.0034)mm (in)Camshaft journal oil
clearance
STD
Limit 0.120 (0.0047)mm (in)
Camshaft
journal (housing) inside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
23.000 – 23.021 (0.9055 – 0.9063)
23.171 (0.9122)
Camshaft
journal outside
diameter
Top,
2nd,
3rd,
4th
mm (in)STD
Limit mm (in)
22.934 – 22.955 (0.9029 – 0.9037)
22.784 (0.8970)
0.10 (0.004)mm (in)LimitCamshaft runout
Cylinder head bore to
tappet clearance
0.025 – 0.062 (0.0010 – 0.0024)mm (in)STD
0.150 (0.0059)mm (in)Limit
Tappet outer diameter 26.959 – 26.975 (1.0614 – 1.0620)mm (in)STD
27.000 – 27.021 (1.0630 – 1.0638)mm (in)STDCylinder head bore
DF40/DF50 “K1” (‘01) model 13-4
VALVE / VALVE GUIDE
24.6 (0.97)mm (in)IN
Tappet clearance
(Cold engine
condition)
mm (in)
Valve diameter
STD
STD mm (in)
mm (in)STD
Limit mm (in)
0.045 – 0.072 (0.0018 – 0.0028)mm (in)STD
Limit 0.090 (0.0035)mm (in)
IN,EX mm (in)STD 5.500 – 5.512 (0.2165 – 0.2170)
Item Unit
Data
DF40T/40QH DF50(W)T/50(W)QH
21.5 (0.85)mm (in)EX
IN
EX
0.18 – 0.24 (0.007 – 0.009)
0.18 – 0.24 (0.007 – 0.009)
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
IN
EX
Valve guide to
valve stem
clearance
Valve guide inside
diameter
Valve seat
angle
IN
EX
30°, 45°
15°, 45°
IN,EX mm (in)STD 11.0 (0.43)Valve guide
protrusion
Valve stem
outside diameter
mm (in)STD
STD mm (in)
IN
EX
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
IN,EX mm (in)Limit 3.20 (0.126)Valve stem end
length
Valve stem end
deflection
mm (in)Limit
Limit mm (in)
IN
EX
0.14 (0.006)
0.18 (0.007)
IN,EX mm (in)Limit 0.05 (0.002)Valve stem runout
IN,EX mm (in)Limit 0.08 (0.003)Valve head radial
runout
Valve head
thickness
mm (in)STD
Limit mm (in)
IN
1.0 (0.04)
0.7 (0.03)
mm (in)STD
Limit mm (in)
EX
1.15 (0.045)
0.5 (0.02)
Valve seat
contact width
mm (in)STD
STD mm (in)
IN
EX
1.80 – 2.20 (0.071 – 0.087)
1.65 – 2.05 (0.065 – 0.081)
Valve spring free
length
33.1 (1.30)mm (in)STD
31.8 (1.25)mm (in)Limit
Valve spring tension 97 – 113 (9.7–11.3, 21.4–24.9) for 28.5 mm (1.12 in)N (kg, Ibs)STD
89 (8.9, 19.6) for 28.5 mm (1.12 in)N (kg, Ibs)Limit
Valve spring
squareness 2.0 (0.08)mm (in)Limit
degree
degree
13-5 DF40/DF50 “K1” (‘01) model
CYLINDER/PISTON/PISTON RING
0.060 (0.0024)mm (in)Limit
Piston ring
end gap
mm (in) 0.10 – 0.25 (0.004 – 0.010)
Cylinder distortion
Piston to cylinder
clearance
STD
Limit mm (in) 0.70 (0.028)
1st
mm (in) 0.25 – 0.40 (0.010 – 0.016)STD
Limit mm (in) 1.00 (0.039)
2nd
Item Unit
Data
DF40T/40QH DF50(W)T/50(W)QH
mm (in) 0.020 – 0.040 (0.0008 – 0.0016)STD
Limit mm (in) 0.100 (0.0039)
71.000 – 71.020 (2.7953 – 2.7961)mm (in)STDCylinder bore
50 (2.0) from cylinder top surfacemm (in)Cylinder measuring position
70.970 – 70.990 (2.7941 – 2.7949)mm (in)STDPiston skirt diameter
19 (0.7) from piston skirt endmm (in)Piston measuring position
0.100 (0.0039)mm (in)LimitCylinder bore wear
Piston ring
free end gap
mm (in) Approx. 7.5 (0.30)STD
Limit mm (in) 6.0 (0.24)
1st
mm (in) Approx. 11.0 (0.43)STD
Limit mm (in) 8.8 (0.35)
2nd
Piston ring
groove width
mm (in) 1.01 – 1.03 (0.040 – 0.041)1st
mm (in) 1.01 – 1.03 (0.040 – 0.041)
mm (in) 2.01 – 2.03 (0.079 – 0.080)
2nd
Oil
Piston ring to
groove
clearance
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
1st
mm (in) 0.02 – 0.06 (0.001 – 0.002)STD
Limit mm (in) 0.10 (0.004)
2nd
Piston ring
thickness
mm (in) 0.97 – 0.99 (0.038 – 0.039)STD
STD mm (in) 0.97 – 0.99 (0.038 – 0.039)
1st
2nd
Pin clearance in
piston pin hole
mm (in) 0.006 – 0.018 (0.0002 – 0.0007)STD
Limit mm (in) 0.040 (0.0016)
Piston pin outside
diameter
mm (in) 17.996 – 18.000 (0.7085 – 0.7087)STD
Limit mm (in) 17.980 (0.7079)
Piston pin hole
diameter
mm (in) 18.006 – 18.014 (0.7089 – 0.7092)STD
Limit mm (in) 18.040 (0.7102)
Pin clearance in
conrod small end
mm (in) 0.003 – 0.015 (0.0001 – 0.0006)STD
Limit mm (in) 0.050 (0.0020)
Conrod small end
bore
mm (in) 18.003 – 18.011 (0.7088 – 0.7091)STD
STD
STD
STD
DF40/DF50 “K1” (‘01) model 13-6
Item Unit
Data
DF40T/40QH DF50(W)T/50(W)QH
CRANKSHAFT / CONROD
Conrod big end oil
clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Conrod small end
inside diameter
18.003 – 18.011 (0.7088 – 0.7091)mm (in)STD
Conrod big end
inside diameter
41.000 – 41.018 (1.6142 – 1.6149)mm (in)STD
Crank pin outside
diameter
37.982 – 38.000 (1.4954 – 1.4961)mm (in)STD
Crank pin outside
diameter difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Conrod bearing
thickness
1.486 – 1.502 (0.0585 – 0.0591)mm (in)STD
Conrod big end side
clearance
0.100 – 0.250 (0.0039 – 0.0098)mm (in)STD
0.350 (0.0138)mm (in)Limit
21.950 – 22.000 (0.8642 – 0.8661)mm (in)STDConrod big end width
22.100 – 22.200 (0.8700 – 0.8740)mm (in)STDCrank pin width
Crankshaft journal
oil clearance
0.020 – 0.040 (0.0008 – 0.0016)mm (in)STD
0.065 (0.0026)mm (in)Limit
Crankshaft center
journal runout
0.04 (0.002)mm (in)Limit
Crankcase bearing
holder inside diameter
49.000 – 49.018 (1.9291 – 1.9298)mm (in)STD
Crankshaft journal
outside diameter
44.982 – 45.000 (1.7709 – 1.7717)mm (in)STD
Crankshaft journal
outside diameter
difference
(out of round and taper)
0.010 (0.0004)mm (in)Limit
Crankshaft thrust
play
0.11 – 0.31 (0.004 – 0.012)mm (in)STD
0.35 (0.014)mm (in)Limit
Crankshaft thrust
bearing thickness
2.470 – 2.520 (0.0972 – 0.0992)mm (in)STD
Crankshaft bearing
thickness
1.999 – 2.015 (0.0787 – 0.0793)mm (in)STD
LOWER UNIT
Design specification thickness for shim & washer
Pinion gear back-up shim 1.0 (0.04)mm (in)
Forward gear back-up shim 1.0 (0.04)mm (in)
Forward gear thrust washer 2.0 (0.08)mm (in)
Reverse gear thrust washer 2.0 (0.08)mm (in)
Reverse gear back-up shim 1.0 (0.04)mm (in)
13-7 DF40/DF50 “K1” (‘01) model
ELECTRICAL
ATDC 1° – BTDC 27°Degrees at r/minIgnition timing
6500r/minOver revolution limiter
Item Unit
Data
DF40T/40QH DF50(W)T/50(W)QH
Ω at 20°CCKP sensor resistance
Ω at 20°CCMP sensor resistance
Ω at 20°CIgnition coil resistance Primary
k Ω at 20°CSecondary
Ω at 20°CBattery charge coil resistance
WattBattery charge coil output (12V)
NGKStandard spark plug Type
mm (in)Gap 0.8 – 0.9 (0.031 – 0.035)
AFuse amp. rating Main fuse : 30
Ah (kC)
Recommended battery
capacity (12V)
70 (252) or larger
Ω at 20°CFuel injector resistance
Ω at 20°CIAC valve resistance
k Ω at 25°C
IAT sensor/Cylinder temp. sensor
/ Ex-mani. temp. sensor
(Thermistor characteristic)
Ω at 20°CECM main relay resistance
Ω at 20°CStarter motor relay resistance
1.8 – 2.3
80 – 120
3.5 – 5.1
STARTER MOTOR
30Sec.Max. continuous time of use
0.9kWMotor output
17.0 (0.67)mm (in)STDBrush length
10.0 (0.39)mm (in)Limit
0.5 – 0.8 (0.02 – 0.03)mm (in)STDCommutator
undercut 0.2 (0.01)mm (in)Limit
33.0 (1.30)mm (in)STDCommutator
outside diameter 32.0 (1.26)mm (in)Limit
0.05 (0.002)mm (in)STD
0.40 (0.016)mm (in)Limit
Pinion to ring gear gap 3.0 – 5.0 (0.12 – 0.20)STD mm (in)
Commutator outside
diameter difference
168 – 252
——
1.9 – 2.5
8.1 – 11.1
DCPR6E
ATDC 1° – BTDC 24°
7000
0.56 – 0.84
216
11.0 – 16.5
21.5 – 32.3
PTT MOTOR
9.8 (0.39)mm (in)STDBrush length
4.8 (0.19)mm (in)Limit
22.0 (0.87)mm (in)STDCommutator
outside diameter 21.0 (0.83)mm (in)Limit
Ω at 20°CPTT motor relay resistance 3.0 – 4.5
DF40/DF50 “K1” (‘01) model 13-8
PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM
ACTIVATING
1 MAP sensor 1 3-4 YES
2 CKP sensor 4-2 YES
3 IAC valve/By-pass air screw adjustment 3-1 NO
4 CMP sensor 2-4 YES
5 CTP switch 2-2 NO
6 Cylinder temp. sensor 1-4 YES
7 IAT sensor 2-3 YES
8 MAP sensor 2 (Sensor hose) 3-2 NO
9 Rectifier & regulator (Over-charging) 1-1 NO
10 Exhaust manifold temp. sensor 1-5 YES
11 Fuel injector (Open circuit) 4-3 NO
on off
on off
on off
on off
on off
on off
on off
on off
on off
on off
on off
SELF-DIAGNOSTIC SYSTEM INDICATION
When the abnormality occurs in a signal from sensor, switch etc., the “CHECK ENGINE” lamp on the monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
NOTE:
• If more than two items fail at once, the self-diagnostic indication appears according to priority order. The
indication repeats three times.
• On the tiller handle (QH) model, alerts is signaled by a sound from the caution buzzer contained in the
tiller handle.
13-9 DF40/DF50 “K1” (‘01) model
TIGHTENING TORQUE
Tightening Torque – Important Fasteners
ITEM
THREAD
DIAMETER
TIGHTENING TORQUE
kg-mN . m Ib.-ft.
Cylinder head cover bolt 6 mm 10 1.0 7.0
Cylinder head bolt 10 mm
Crankcase bolt 8 mm 25 2.5 18.0
Conrod cap nut 8 mm 35 3.5 25.5
Camshaft housing bolt 10 1.0 7.0
Camshaft timing sprocket bolt 10 1.0 7.0
Timing chain guide bolt 10 1.0 7.0
11 1.1 8.0
8 mm 23 2.3 16.5
Oil pressure switch 13 1.3 9.5
Intake manifold fuel main gallery 6 mm 10 1.0 7.0
35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 190 19.0 137.5
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil filter 14 1.4 10.0
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt/nut 8 mm 23 2.3 16.5
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Upper mount nut 10 mm 40 4.0 29.0
Upper mount cover bolt 8 mm 23 2.3 16.5
Lower mount nut 12 mm 60 6.0 43.5
12 mm 40 4.0 29.0
Clamp bracket shaft nut 22 mm 43 4.3 31.0
Water pump case nut 6 mm 8 0.8 6.0
Gearcase bolt 8 mm 23 2.3 16.5
Propeller shaft bearing housing bolt 8 mm 17 1.7 12.5
Pinion nut 50 5.0 36.0
Propeller nut 18 mm 55 5.5 40.0
3-way joint bolt
Upper/lower plug
Front
Rear
10 mm 53 5.3 38.5
6 mm
60 6.0 43.5
Intake manifold bolt / nut
6 mm
6 mm
6 mm
12 mm
DF40/DF50 “K1” (‘01) model 13-10
Tightening torque – general bolt
NOTE:
These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners”
table.
TYPE OF BOLT
THREAD
DIAMETER
TIGHTENING TORQUE
kg-mN . m Ib.-ft.
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5
10 mm 22 – 35 2.3 – 3.5 16.0 – 25.5
5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5
10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5
5 mm 3 – 6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0
10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5
(Conventional or “4” marked bolt)
(Stainless steel bolt)
(7 marked or marked bolt)
13-11 DF40/DF50 “K1” (‘01) model
(1)
(2)
(3)
SPECIAL TOOLS
1. 2. 3. 4.
5. 6. 7. 8.
9. 10. 11. 12.
13. 14. 15. 16.
17. 18. 19. 20.
21. 22. 23.
(A) 09900-06107
(B) 09900-06108
Snap ring pliers
09900-20205
Micrometer (0 – 25 mm)
09900-20701
Magnetic stand
09900-26006
Engine tachometer
(1) 09912-58442
Fuel pressure gauge
(2) 09912-58432
Fuel pressure hose
(3) 09912-58490
3-way joint & hose
09900-00410
Hexagon wrench set
09900-20101 (150 mm)
09900-20102 (200 mm)
Vernier calipers
09900-20508
Cylinder gauge set
(40 – 80 mm)
09900-20803
Thickness gauge
09900-28403
Hydrometer
09900-00411
Hexagon socket
(included in 09900-00410)
09900-20202
Micrometer (25 – 50 mm)
09900-20605
Dial calipers (10 – 34 mm)
09900-21304
Steel “V” block set
09921-29510
Driveshaft holder
09913-50121
Oil seal remover
09900-00413 (5 mm)
09900-00414 (6 mm)
Hexagon bit
(included in 09900-00410)
09900-20203
Micrometer (50 – 75 mm)
09900-20602
Dial gauge
09900-22302
(0.051 – 0.125 mm)
09900-22301
(0.025 – 0.076 mm)
Plastigauge
09919-16010
Deep socket wrench
09914-79410
Test wheel
(A)
(B)
DF40/DF50 “K1” (‘01) model 13-12
47.
(A) 09922-59410
Propeller shaft housing
installer
(B) 09922-59420
Housing installer handle
(A) (B)
24. 25. 26. 27.
28. 29. 31.
32. 33. 34. 35.
37. 38. 39.
40.
30.
41. 43.
46.
09915-47340
Oil filter wrench
09916-10911
Valve lapper
09916-54910
Handle (N-505)
09916-34550
Valve guide reamer
(φ 5.5 mm)
09916-14910
Valve lifter attachment
09917-87010
Valve guide installer
attachment
09915-64512
Compression gauge
09915-63210
Adaptor
09916-14510
Valve lifter
09916-20630
Valve seat cutter
(Neway 126)
09916-34542
Valve guide reamer handle
09916-57330
Valve guide installer
09915-77310
Oil pressure gauge
09916-24450
Solid pilot (N-100-5.52)
09916-20620
Valve seat cutter
(Neway 122)
09916-37320
Valve guide reamer
(φ 10.5 mm)
09916-77310
Piston ring compressor
09915-78211
Oil pressure gauge adapter
09916-24440
Handle adaptor
(N-503-1)
09916-44310
Valve guide remover
45.
36.
09916-20610
Valve seat cutter
(Neway 121)
09917-47011
Vacuum pump gauge
42.
09916-67010
Tappet holder
44.
09916-84511
Tweezers
13-13 DF40/DF50 “K1” (‘01) model
52.
09930-39420
Rotor remover bolt
49. 50.
53. 54.
57. 58.
61. 62.
65. 66.
68. 69.
09930-30161
Propeller shaft remover
09930-48720
Flywheel holder
09930-89950
44-pin connector test cord
09932-89910
Adapter
Pinion bearing
installer and remover
(A) 09951-59910
Pinion bearing installer
shaft
(B) 01500-08403
Bolt
(C) 09951-39914
Pinion bearing plate
(D) 09951-19431
Attachment
09930-30104
Sliding hammer
09930-76420
Timing light
09930-99320
Digital tester
09950-69512
Gearcase oil leakage tester
(A) 18213-74F00
O2 sensor
(B) 18498-99E70
Protector
48.
09922-89810
Shift lock pin remover
51.
09930-39411
Flywheel rotor remover
55.
56.
09930-89240
4-pin connector test cord
09930-89260
Injector test cord A
59.
60.
09932-69930-01E
SDS software ver. 3.00
09932-79910
Diagnostic harness
63.
64.
09940-44121
Air pressure gauge
09940-44130
Attachment
67.
09951-09511
Gear adjusting gauge
(A)
(B) (D)
(C)
(A)
(B)
70.
09930-88720
H.T cord adapter
DF40/DF50 “K1” (‘01) model 13-14
72. 73 .
99954-53873*
Stevens CD-77
Peak reading voltmeter
99954-53883*
Gear oil filler
MATERIALS REQUIRED
SUZUKI OUTBOARD
MOTOR GEAR OIL
99000-22540
(400 ml × 24 pcs.)
*99000-25030
99000-25010
(500 g)
* 99104-33140
99000-31140
(100 g)
99000-25160
(250 g)
99000-32050 (TB1342, 50 g)
09900-32020 (TB1333B, 50 g)
99000-31120
(50 g)
API : SE, SF, SG, SH, SJ
SAE : 10W-40
SUZUKI SUPER
GREASE “A”
WATER RESISTANT
GREASE
SUZUKI SILICONE
SEAL
SUZUKI BOND “1207B” THREAD LOCK “1342”
THREAD LOCK “1333B”
4-Stroke Motor Oil
NOTE:
* Marked part No. is in U.S. market only.
NOTE:
* Marked part No. is in U.S. market only.
71.
99954-53008-820*
Digital voltmeter
13-15 DF40/DF50 “K1” (‘01) model
BOLT AND NUTS
Inspect initially after 20 hours (1 month) and every 100
hours (6 months) thereafter.
Check that all bolt and nuts listed below are tightened to their
specified torque.
ITEM
TIGHTENING TORQUE
N.m kg-m lb-ft
Cylinder head cover bolt 10 1.0 7.0
Intake manifold bolt / nut 11 1.1 8.0
23 2.3 16.5
6 mm
8 mm
Flywheel bolt
ECM ground bolt
Power unit mount bolt
Clamp bracket shaft nut 43 4.3 31.0
Gearcase bolt
Propeller nut 55 5.5 40.0
190 19.0 137.5
10 1.0 7.0
23 2.3 16.5
50 5.0 36.0
8 mm
10 mm
23 2.3 16.5
THREAD
DIAMETER
6 mm
6 mm
16 mm
22 mm
8 mm
18 mm
PERIODIC MAINTENANCE
MAINTENANCE AND TUNE-UP PROCEDURES
The following items have been modified from “K1” (‘01) model.
• Checking for tightening torque of the lower mount nut (front) has been added in the “BOLT AND NUT”
section.
• Servicing procedure for the “FUEL MIXTURE CHECK (O2 FEEDBACK)” has been modified to the method
by using the Suzuki Diagnostic System (SDS) software with a personal computer. It is no longer possible to
perform the O2 feedback operation by using the diagnostic cable (P/N. 09932-79910) only.
Lower mount nut (Front) 60 6.0 43.512 mm
DF40/DF50 “K1” (‘01) model 13-16
FUEL MIXTURE CHECK (O2 FEEDBACK)
Perform every 2 years.
!
Before performing a fuel mixture check (O2 feedback),
the outboard motor must be checked to be sure that it
is free of any trouble codes or operational problems.
NOTE:
See “O2 FEEDBACK SYSTEM” section on page 3-32 before starting O2 feedback operation.
To perform the O2 feedback, use the SDS software with a personal computer.
Procedure
"
To prevent any sudden boat movement, the boat must
be securely moored to the dock while the test wheel
equipped engine is running in gear during the feedback
test procedure.
1. Remove propeller and install a test wheel.
# 09914-79410 : Test wheel
3. Remove plug 2 from oil pump case and install the O2 sensor
3 and protector sleeve 4.
# 18213-74F00 : O2 sensor
18498-99E70 : Protector sleeve
2. Remove grommet 1 and stbd. lower side cover.
13-17 DF40/DF50 “K1” (‘01) model
!
The O2 sensor used for the feedback test procedure
must be in proper working order and installed securely.
If either sensor or installation is improper, the O2 feedback operation will be performed incorrectly and could
possibly result in engine operating problems.
NOTE:
• The O2 sensor is NOT WATERPROOF.
Cover O2 sensor with the protector sleeve to protect from water
spray.
• Cut off the protector (P/N 18498-99E40) to a length of 20 – 30
cm (7.8 – 11.8 in.). The O2 sensor must be completely covered
as shown.
4. Connect the diagnostic harness to both O2 sensor and engine harness connectors.
# 09932-79910 : Diagnostic harness
5. Connect the adapter to the diagnostic harness.
# 09932-89910 : Adapter
6. Install stbd. side lower cover.
NOTE:
Route the diagnostic harness through clearance between remote
control cable holder plate and side cover.
7. Install motor cover.
8. Connect the diagnostic harness (with the adapter) to the personal computer.
9. Start and warm-up the engine for at least 5 minutes at around
2,000 r/min.
NOTE:
Before starting the SDS program, read and follow the “SDS Operation Manual” which comes supplied with each unit of the SDS
software.
4
DF40/DF50 “K1” (‘01) model 13-18
10. After starting the SDS program, select “O2 Feedback” on the
“Main Menu” screen and Fig. A appears. (STAND-BY mode)
# 09932-69930-01E : SDS software (required installation on to personal computer)
: Battery-powered personal computer
Zone RPM for DF40/50
ZONE1 2,500±100 rpm
ZONE2 3,500±100 rpm
ZONE3 4,500±100 rpm
12. Adjust engine speed at the ZONE1 rpm and press the [Enter]
key, then Fig. B appears. (ACTION mode) Hold the engine
speed specified for a minimum of 20 seconds.
• If buzzer sounds for approx. 3 seconds, the feedback
operation at this zone was successfully finished. Also
the “Compensation Factor” data will be changed. Go to next
step.
• If no buzzer sounds within approx. 2 minutes, the feedback
operation at this zone failed. Ignore this zone and proceed
to next step.
NOTE:
• Do not close throttle fully for more than 10 seconds while
feedback operation is being performed. This will cause the
O2 feedback operation to finish with incomplete data.
• Do not allow the engine to be stable at an unnecessary speed
range (other than the zone rpm) for more than 10 seconds.
This will cause the O2 feedback operation to be done with an
incorrect data for that speed range.
13. Repeat the procedure in step “5” at the ZONE2 rpm.
14. Repeat the procedure in step “5” at the ZONE3 rpm.
15. If the feedback operation at any zone failed, repeat the feedback operation at that zone.
Fig. A
Fig. B
11. Shift into forward gear.
NOTE:
The O2 feedback operation must be performed under engine
load. Do not perform the O2 feedback operation using warmup lever (or throttle control grip) without first shifting into forward gear.
13-19 DF40/DF50 “K1” (‘01) model
16. Return throttle to a full closed position only after the O2 feedback operation at all zones has been successfully finished.
17. Approximately 10 seconds after closing the throttle, the buzzer
will sound as follows:
• If the total feedback operation was successfully finished, a
series of short (0.5 sec.) buzzer sounds will be heard.
Also “FIN. OK” is displayed. (Fig. C)
• If the total feedback operation failed, a series of long (3
sec.) buzzer sounds will be heard. Also “FIN. NG” is displayed. (Fig. D)
18. If retrying feedback operation, repeat procedure used in step
“12” through “16”.
NOTE:
Following causes may be considered if the total feedback operation failed:
• There was no feedback operation at any zone before returning throttle to a full closed position.
• There was the feedback operation with an abnormal compensation factor (coefficient).
NOTE:
Repeat the O2 feedback operation with a new O2 sensor if:
• The total feedback operation finished without returning throttle
to a full closed position.
• The total feedback operation failed repeatedly.
!
The O2 sensor is only used when performing the O2
feedback operation.
After O2 feedback operation is completed the original
plug must be installed in the original position.
Fig. C
Fig. D
DF40/DF50 “K1” (‘01) model 13-20
ENGINE CONTROL SYSTEM
Main modifications from “K1” (‘01) model are as follows:
• For more accurate control, ECM, CKP sensor, flywheel magneto etc. have been modified.
• Ignition timing and fuel injection timing controls have been modified.
• The total operating hours indication system has been modified.
• An oil change reminder system has been added.
• Self-diagnostic system for fuel injector circuit has been added.
ENGINE CONTROL SYSTEM STRUCTURE
SYSTEM STRUCTURE
13-21 DF40/DF50 “K1” (‘01) model
WIRING DIAGRAM FOR ENGINE CONTROL
DF40/DF50 “K1” (‘01) model 13-22
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22
23 24 25 26 27 28 29 30 31 32 33 34 35
36 37 38 39 40 41 42 43 44
44-pin connector (Box type)
44-pin connector (Solid type)
24-pin connector (White) 24-pin connector (Black)

TERMI- WIRE CIRCUIT
NAL COLOR
1 – –
2 Bl/R Emergency stop switch
3 O Buzzer cancel
4 Y/B Tachometer
5 Br Neutral switch, Engine start signal
6 – –
7 V/W Ex-manifold temperature sensor
8 – –
9 Lg/W Cylinder temperature sensor
10 B Ground for ECM
11 B/W Ground for sensor
12 Bl/B OIL lamp
13 P/B Ground for ECM main relay
14 – –
15 R/B CKP sensor
16 O/Y PC communication
17 G/Y TEMP lamp
18 B/R IAC valve solenoid (–)
19 – –
20 B Ground for power souce
21 – –
22 G No.3 Ignition (–)
ECM CIRCUIT
TERMI- WIRE CIRCUIT
NAL COLOR
23 Bl Oil pressure switch
24 Lg/R CTP switch
25 P REV-LIMIT lamp
26 G/W CHECK ENGINE lamp
27 Bl/W Buzzer
28 – –
29 W MAP sensor
30 Gr ECM power source
31 Lg/B IAT sensor
32 B Ground for ECM
33 O/G CMP sensor
34 B/G O2 feedback
35 R Power source for MAP sensor
36 Y PC communication
37 B/W Fuel pump (–)
38 R/W No.3 Fuel injector (–)
39 B/Y No.2 Fuel injector (–)
40 O/B No.1 Fuel injector (–)
41 – –
42 B Ground for power source
43 Bl No.2 Ignition (–)
44 O No.1 Ignition (–)
NOTE: “WIRE COLOR” shows the wire color of engine wire harness side.
ECM TERMINAL LAYOUT / TEST CORD
Terminal layout on the ECM is the same as the “❉” marked terminal in the illustration of the 44-pin test cord
(special tool P/N. 09930-89950) below.
13-23 DF40/DF50 “K1” (‘01) model
ECM INTERNAL STRUCTURE
DF40/DF50 “K1” (‘01) model 13-24
Trigger vane
Reluctor bar (34 pieces)
SENSOR AND RELATED COMPONENTS
For more accurate control and simplification of structure, CKP
sensor and related components have been modified.
CKP SENSOR
Number of pickup coil of CKP sensor assy has been modified
from 3 pieces to 1 piece.
FLYWHEEL MAGNETO
Number of reluctor bar (trigger vane) on the flywheel magneto
has been modified from 1 piece to 34 pieces.
CMP SENSOR / INTAKE CAMSHAFT
The CMP sensor on the “K1” (‘01) model is the same as the one
on the previous year models, number of trigger vane on the sensing rotor installed to the intake camshaft, however, has been
modified from 1 piece to 4 pieces.
13-25 DF40/DF50 “K1” (‘01) model
In. Cm. Ep. Ex. In. Cm. Ep. Ex. In.
TDC TDC TDC TDC
Ex. In. Cm. Ep. Ex. In. Cm. Ep.
TDC TDCTDC TDC
Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm.
TDC TDCTDCTDC
Spark timing24˚
10˚
120˚ 120˚ 120˚
4-signals/720˚
34-signals/360˚
CKP sensor
signal
CMP sensor
signal
#1 Ignition
signal
#3 Ignition
signal
#2 Ignition
signal
In. : Intake, Cm. : Compression, Ep. : Explosion, Ex. : Exhaust, TDC : Top Dead Center
ON
OFF
IGNITION SYSTEM
IGNITION TIMING CHART
• The following chart shows example for ignition at BTDC24°.
• The ignition timing is varied by the condition of engine running.
• Angles indicated in the following chart show CRANKSHAFT angle.
CONTROL MODE
WHEN CRANKING :
The ignition timing is fixed at BTDC 7° until the engine starts.
WHEN IDLING / TROLLING :
The ignition timing is controlled to within the range of ATDC 1° to BTDC 17° to provide stable engine operation at the specified idling / trolling speed.
When the shift lever is in neutral, if engine speed exceeds 1200 r / min , ignition timing remains fixed at BTDC 9°.
WHEN RUNNING (NORMAL OPERATION) :
The ignition timing ranges between BTDC 0° – 27° (DF40) or 24° (DF50), depending on current engine
operating conditions.
WHEN DECELERATING :
When the throttle valve is closed suddenly, turning the CTP switch “ON”, ignition timing is delayed for a
programmed duration to prevent engine stalling or unstable running.
SPECIFICATION
Ignition system Full-transistorized ignition
Advance Electronic microcomputer control
Ignition timing DF 40 : ATDC 1° – BTDC 27°, DF 50 : ATDC 1° – BTDC 24°
Firing order 1 – 3 – 2
DF40/DF50 “K1” (‘01) model 13-26
ELECTRONIC FUEL INJECTION SYSTEM
FUEL INJECTION TIMING CHART
• Fuel injection start timing is set at BTDC 425° on exhaust stroke.
• The fuel injection time duration (amount) is varied by the condition of engine running.
• Angles indicated in the following chart show CRANKSHAFT angle.
CONTROL MODE
BEFORE START :
When the ignition switch is turned “ON”, the ECM receives a MAP sensor signal, indicating the static barometric pressure of the intake manifold, which is used to compensate the fuel injection map for altitude.
WHEN CRANKING :
Fuel is simultaneously injected to all cylinders every time any piston is positioned at compression stroke.
AFTER START (FAST-IDLE FUNCTION):
The fuel injection amount is controlled to increase until the timer, set according to cylinder temperature at the
time of engine start, expires.
WHEN IDLING / TROLLING :
The fuel injection amount is controlled to maintain a stable engine speed at the specified idle / trolling rpm.
WHEN ACCELERATING :
The fuel injection amount is controlled to increase.
WHEN DECELERATING :
The fuel injection amount is controlled to decrease.
The fuel injection is also cut off on very rapid engine deceleration.
In. Cm. Ep. Ex. In. Cm. Ep. Ex. In.
TDC TDC TDC TDC
Ex. In. Cm. Ep. Ex. In. Cm. Ep.
TDC TDCTDC TDC
Cm. Ep. Ex. In. Cm. Ep. Ex. In. Cm.
TDC TDCTDCTDC
10˚
120˚ 120˚ 120˚
4-signals/720˚
34-signals/360˚
Injection time durationBTDC 425˚ on exhaust stroke
CKP sensor
signal
CMP sensor
signal
#1 Injection
signal
#3 Injection
signal
#2 Injection
signal
In. : Intake, Cm. : Compression, Ep. : Explosion, Ex. : Exhaust, TDC : Top Dead Center
ON
OFF
13-27 DF40/DF50 “K1” (‘01) model
SELF-DIAGNOSTIC SYSTEM
PRIORITY / CODE / PATTERN FOR SELF-DIAGNOSTIC SYSTEM OPERA-
TION
PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM
ACTIVATING
1 MAP sensor 1 3 – 4
on off
YES
2 CKP sensor 4 – 2
on off
YES
3
IAC valve/By-pass air
screw adjustment 3 – 1
on off
NO
4 CMP sensor 2 – 4
on off
YES
5 CTP switch 2 – 2
on off
NO
6 Cylinder temp. sensor 1 – 4
on off
YES
7 IAT sensor 2 – 3
on off
YES
8
MAP sensor 2
(Sensor hose)
3 – 2
on off
NO
9 1 – 1
on off
NO
Rectifier & regulator
(Over-charging) [NOTE 1]
10 1 – 5
on off
YES
Exhaust manifold
temp. sensor
11 4 – 3
on off
NO
Fuel injector
(Open circuit)
NOTE:
• If more than two items fail at once, the self- diagnostic indication appears according to priority order. The
indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch “ON”.
• After correcting failed item, the self-diagnostic indication appears until the ECM receives the proper signal
with the engine running.
• For cylinder temp. sensor, exhaust manifold temp. sensor or IAT sensor the self-diagnostic indication will be
canceled after corrective action by turning the ignition switch “ON”.
(The ECM will require 10 – 20 seconds after turning the ignition switch “ON” to cancel the self-diagnostic
indication.)
NOTE 1 :
The self-diagnostic indication may be canceled by turning ignition switch “ON” because the ECM detects only
battery voltage, not charging output. Under this condition the buzzer will not sound a 1-1 code.
However, if the rectifier & regulator have failed, the self-diagnostic indication will again appear after starting
the engine.
DF40/DF50 “K1” (‘01) model 13-28
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION
NOTE 1:
This condition will be caused by IAC valve failure or incorrect by-pass air screw adjustment. If IAC valve is
always closed or by-pass air is too low, the ECM controls the IAC valve duty to increase to maintain the idling/
trolling speed specified.
Conversely, if IAC valve is always opened or by -pass air is too high, the ECM controls the IAC valve duty to
decrease to maintain the idling / trolling speed specified.
NOTE 2:
This condition will be caused by disconnected, kinked or clogged MAP sensor hose or clogged inlet manifold
gas filter.
MAP sensor 1 • No signal (With engine running)
• Receiving an out of range “37 – 860 mmHg (0.20 – 4.53V)”
signal ( With engine running )
CKP sensor • No signal from CKP sensor while receiving 3 signals from CMP sensor.
IAC valve / By-pass air screw • IAC valve operates at 90% duty or higher when CTP switch is “ON”
adjustment [NOTE 1]
CMP sensor • No signal from CMP sensor while receiving 544 signals from CKP sensor.
(Corresponded to 16 turns of crankshaft)
CTP switch • Receiving “ON” signal when engine speed is 2500 r/ min or higher and
intake manifold pressure is 300 mmHg or higher.
Cylinder temp. sensor • No signal
• Receiving an out of range “– 46 to +170 °C (0.10 – 4.63 V)” signal
IAT sensor • No signal
• Receiving an out of range “– 46 to +169 °C ( 0.04 – 4.46V)” signal
MAP sensor 2 • Receiving unchanging signal regardless engine speed change
(Sensor hose) [NOTE 2]
Rectifier & regulator • Receiving 16 volts or higher signal
(Over-charging )
Exhaust manifold temp, sensor • No signal
• Receiving an out of range “– 46 to +170 °C (0.10 – 4.63V)” signal
Fuel injector • No signal
FAILED ITEM CONDITION
13-29 DF40/DF50 “K1” (‘01) model
FAIL-SAFE SYSTEM
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM
NOTE:
There is no back-up system for the ECM itself. The engine will stop if it has failed.
NOTE 1:
This value will change according to the current engine speed.
MAP sensor 1 • 319 – 475 mmHg (Correspond to approx. 750 – 4000 r/min) [NOTE1]
CKP sensor Based on signals from CMP sensor:
• Ignition timing fixed at BTDC 5°
• Normal sequential fuel injection
CMP sensor Based on signals from CKP sensor:
(a) Failed while engine running
• Ignition timing fixed at BTDC 5°
• Normal sequential fuel injection
(b) Failed prior to engine start
• Ignition timing fixed at BTDC 5°
• 1 simultaneous injection for all cylinders per 2 crankshaft rotations
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Exhaust manifold
60 °C (140 °F)temp. sensor
FAILED ITEM PRE-PROGRAMMED VALUE
DF40/DF50 “K1” (‘01) model 13-30
Total MONITOR-TACHOMETER
operating Needle 1 REV-LIMIT
hours indication lamp 2 flashing *
0h-(49h) No No
50h- 500rpm No
60h- 600rpm No
: : :
: : :
540h- 5400rpm No
550h- 500rpm 1 time
560h- 600rpm 1 time
: : :
: : :
1040h- 5400rpm 1 time
1050h- 500rpm 2 times
: : :
: : :
1540h- 5400rpm 2 times
1550h- 500rpm 3 times
: : :
: : :
2030h- 5300rpm 3 times
2040h or over 5400rpm 3 times
*: One flashing is corresponded to 500 hours.
OPERATING HOUR INDICATION SYSTEM
(For remote control model)
After 2-seconds indicator check, monitor-tachometer will indicate the total motor operating hours by means of
the “REV-LIMIT” lamp flashing and needle indicating as shown on the chart below.
NOTE:
The total operating hours displayed are those of actual engine operation, not ignition switch “ON” time.
CHART OF TOTAL OPERATING HOURS INDICATION
MONITOR-TACHOMETER
13-31 DF40/DF50 “K1” (‘01) model
OIL CHANGE REMINDER SYSTEM
This system informs the operator of the time for replacing ENGINE OIL on the basis of the recommended
maintenance schedule.
When the total motor operating hours have reached the preprogrammed hours;
• On the tiller handle model, the buzzer will begin a series of double beeps for approx. 1 minute.
• On the remote control model, the “OIL” lamp will flash, and the buzzer will begin a series of double
beeps if engine is not running (but ignition switch is ON).
The above mentioned indication will repeat until canceling system activation.
INDICATION OF SYSTEM ACTIVATION
0.3 sec
5 sec
0.3 sec0.3 sec
NOTE:
On the tiller handle model, the buzzer for system activation will first begin to sound when the engine is
stopped (but ignition switch is ON) after reaching the preprogrammed hours.
0.3 sec
0.3 sec
Buzzer OIL lamp
Tiller Handle Model
Remote Control Model
DF40/DF50 “K1” (‘01) model 13-32
Action
Starting operation
CancellationIndication
(*1) (*4)
CancellationIndication
CancellationIndication
CancellationIndication
Repeat
(*2) (*4)
(*3) (*4)
(*3) (*4)
FLOWCHART OF SYSTEM ACTIVATION AND CANCELLATION
NOTE:
This system will activate up to 2100 hour’s operation.
*1 : Lapse of initial 20 hour’s operation
*2 : Lapse of 80 hour’s operation
*3 : Lapse of 100 hour’s operation
*4 : When performing cancellation before system activation
CANCELLATION
Procedure
1. Turn the ignition key to the “ON” position.
2. Pull out the emergency stop switch plate 1.
3. Pull up the emergency stop switch knob 2 three times in seven
seconds. A short beep will be heard if the cancellation is successfully finished.
4. Turn the ignition key to the “OFF” position.
5. Set the plate 1 in the original position.
NOTE:
• Canceling of the system activation is possible regardless of
whether or not the engine oil has been replaced. Once the
system has operated, however, Suzuki strongly recommends
that the engine oil be replaced before canceling the system
activation.
• Even if the engine oil has been replaced with the system not
operating, it is still necessary to perform the cancellation.
13-33 DF40/DF50 “K1” (‘01) model
ECM
INSPECTION
PRECAUTION ON SYSTEM INSPECTION
"
To prevent an unexpected engine start, perform the following before proceeding with any CRANKING tests.
• When performing tests not related to fuel injector operation :
• Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation :
• Relieve fuel pressure in line.
• Disconnect high pressure fuel pump wire connector located on fuel vapor separator.
!
• Always turn ignition switch “OFF” and disconnect battery cables when wires are being disconnected or connected.
• Hold and pull connector pieces when disconnecting. Do not pull wires.
NOTE:
• The self-diagnostic code memory in ECM will remain even if battery is disconnected.
• As each terminal voltage is affected by battery voltage, use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires/cables are securely connected.
• For the test cord terminal numbers and layout, refer to the “ECM TERMINAL LAYOUT/TEST CORD” section
on page 13-22.
INSPECTION FOR ECM CIRCUIT VOLTAGE
!
ECM cannot be bench checked. It is strictly prohibited to
connect any tester (voltmeter or ohmmeter) to an ECM
separated from the engine wiring harness.
09930-89950 : 44-pin test cord
Tester range : $ V (DC voltage)
(1) Connect the test cord between ECM and wire harness as
shown.
(2) Turn ignition switch ON.
(3) Connect the tester probe - (Black) to body ground, and measure voltage according to the “CIRCUIT VOLTAGE TABLE”.
#
%
DF40/DF50 “K1” (‘01) model 13-34
CIRCUIT VOLTAGE TABLE
TERMINAL CIRCUIT STANDARD CONDITION / REMARKS
NUMBER VOLTAGE
1 – – –
2 Emergency stop switch Approx. 5V Ignition switch ON, plate IN
Approx. 0V Ignition switch ON, plate OUT
3 Buzzer cancel Approx. 12V Ignition switch ON, key pushed
Approx. 0V Ignition switch ON, key not pushed
4 Tachometer – –
5 Neutral switch / Engine start signal Approx. 0V Ignition switch ON, shift into NEUTRAL
Approx. 2.5V Ignition swich ON, shift into FORWARD or REVERSE
6 – 12V While engine cranking
6 – – –
7 EX-manifold temperature sensor 0.10 – 4.63V Ignition switch ON
8 – – –
9 Cylinder temperature sensor 0.10 – 4.63V Ignition switch ON
10 Ground for ECM – –
11 Ground for sensors – –
12 OIL lamp – –
13 Ground for ECM main relay – –
14 – – –
15 CKP sensor – –
16 PC communication – –
17 TEMP lamp – –
18 IAC valve solenoid (–) Approx. 12V Ignition switch ON
19 – – –
20 Ground for power source – –
21 – – –
22 No. 3 Ignition (–) Approx. 12V Ignition switch ON
23 Oil pressure switch Approx. 5V While engine running
Approx. 0V Other than above (Ignition switch ON)
24 CTP switch Approx. 5V Ignition switch ON, throttle not fully closed
Approx. 0V Ignition switch ON, throttle fully closed
25 REV-LIMIT lamp – –
26 CHECK ENGINE lamp – –
27 Buzzer – –
28 – – –
29 MAP sensor 0.20 – 4.53V Ignition switch ON
30 ECM power source Approx. 12V Ignition switch ON
31 IAT sensor 0.04 – 4.46V Ignition switch ON
32 Ground for ECM – –
33 CMP sensor Approx. 0.3V or 5V Ignition switch ON
34 O2 feedback / PC communication – –
35 Power source for MAP sensor Approx. 5V Ignition switch ON
36 PC communication – –
37 Fuel pump (–) Approx. 0V For 3 sec. after ignition switch ON
While engine running
Approx. 12V Other than above (Ignition switch ON)
38 No. 3 Fuel injector (–) Approx. 12V Ignition switch ON
39 No. 2 Fuel injector (–) Approx. 12V Ignition switch ON
40 No. 1 Fuel injector (–) Approx. 12V Ignition switch ON
41 – – –
42 Ground for power source – –
43 No. 2 Ignition (–) Approx. 12V Ignition switch ON
44 No. 1 Ignition (–) Approx. 12V Ignition switch ON
13-35 DF40/DF50 “K1” (‘01) model
22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
44 43 42 41 40 39 38 37 36 35 34 33 32 31 30 29 28 27 26 25 24 23
INSPECTION FOR RESISTANCE
09930-99320 : Digital tester
Tester range : Ω (Resistance)
NOTE:
Make sure ignition switch is always OFF when measuring resistance.
(1) Disconnect battery cables from battery.
(2) Disconnect wire harness from ECM.
(3) Connect the tester probes to terminal of wire harness side,
and measure resistance according to the “RESISTANCE
TABLE”.
TERMINAL LAYOUT OF WIRE HARNESS CONNECTOR
RESISTANCE TABLE
ITEM
TERMINAL NO. FOR TESTER
PROBE CONNECTION
STANDARD RESISTANCE
(at 20°C)
CKP sensor 15 to 11
Ignition coil No.1 (Primary) 44 to 30
Ignition coil No.2 (Primary) 43 to 30
Ignition coil No.3 (Primary) 22 to 30
Ignition coil No.1 (Secondary) 30 to No.1 spark plug cap
Ignition coil No.2 (Secondary) 30 to No.2 spark plug cap
Ignition coil No.3 (Secondary)
Fuel injector No.1
Fuel injector No.2
Fuel injector No.3
IAC valve
Cylinder temperature sensor
Ex-mani. temperature sensor 7 to 11
ECM main relay 13 to Terminal A [NOTE 1]
Starter motor relay 5 to GND [NOTE 2]
40 to 30
39 to 30
18 to 30
38 to 30
30 to No.3 spark plug cap
9 to 11
31 to 11
168 – 252 Ω
1.9 – 2.5 Ω
8.1 – 11.1 kΩ
21.5 – 32.3 Ω
0°C ( 32°F) : 5.3 – 6.6 kΩ
25°C ( 77°F) : 1.8 – 2.3 kΩ
50°C (122°F) : 0.73 – 0.96 kΩ
75°C (135°F) : 0.33 – 0.45 kΩ
(Thermistor characteristic)
80 – 120 Ω
3.5 – 5.1 Ω
#
&
IAT sensor
11.0 – 16.5 Ω
DF40/DF50 “K1” (‘01) model 13-36
ECM
Starter
motor
relay
"Click"
Gr B/Y
OTHER INSPECTION
FUEL INJECTOR OPERATING SOUND (CRANKING)
(1) Touch a sound scope or long blade screw driver to fuel injector body as shown.
(2) Crank engine and check for injector operating sound.
Injector operating sound : “Click”
FUEL INJECTOR OPERATING SOUND (INDIVIDUAL)
(1) Disconnect fuel injector wire, and connect the test cord.
09930-89260 : Injector test cord A
(2) Connect Gray wire to body ground.
(3) Momentarily touch Black/Yellow wire to starter motor relay right
terminal (connected to battery positive (+) terminal), and check
for injector operating sound.
Injector operating sound : “Click”
!
Connecting fuel injector to battery positive for more than
a few seconds may cause injector overheating and possible injector solenoid failure.
NOTE 1:
Disconnect remote control wire harness, and connect tester probe
to terminal A (Gray wire).
NOTE 2:
Measure resistance with shift in NEUTRAL position.
#
(1) Connect the test cord as shown, then turn ignition switch ON.
(2) Connect the tester probe- (Black) to starter motor relay right
terminal (connected to battery positive (+) terminal) as shown.
FUEL INJECTOR OPERATING SIGNAL
09930-89950 : 44-pin test cord
Peak voltmeter Stevens CD-77
Tester range : NEG50
#
'
13-37 DF40/DF50 “K1” (‘01) model
ECM
Starter
motor
relay
FUEL PUMP 3 SEC. OPERATING SOUND
Turn ignition switch ON and check for fuel pump operating sound.
Fuel pump operating sound :
Sounds for approx. 3 seconds only
NOTE:
Fuel pump operating sound is low because pump is in fuel vapor
separator. If you cannot hear clearly, use a sound scope or long
blade screw driver.
IGNITION COIL OPERATING SIGNAL
09930-89950 : 44-pin test cord
Peak voltmeter Stevens CD-77
Tester range : NEG50
(1) Connect the test cords as shown, then turn ignition switch
ON.
(2) Connect the tester probe - (Black) to starter motor relay right
terminal (connected to battery positive (+) terminal) as shown.
(3) Connect the tester probe + (Red) to each terminal.
Ignition coil Terminal No.
No.1 44
No.2 43
No.3 22
(4) Crank engine and measure voltage.
Ignition coil operating signal : 6 – 10 V
Injector Terminal No.
No.1 40
No.2 39
No.3 38
(4) Crank engine and measure voltage.
Fuel injector operating signal : 6 – 10 V
(Voltage)
12V
(Time)
A
B
APeak voltage reading (NEG)
B 0V level for peak voltmeter
(Voltage)
12V
(Time)
A
B
APeak voltage reading (NEG)
B 0V level for peak voltmeter
(3) Connect the tester probe + (Red) to each terminal.
#
'
DF40/DF50 “K1” (‘01) model 13-38
CMP SENSOR SIGNAL
09930-89950 : 44-pin test cord
09930-99320 : Digital tester
Tester range : $ V (DC voltage)
(1) Rremote CMP sensor from engine. (See page 3-48)
(2) Connect the test cord as shown, then turn ignition switch
ON.
(3) Connect the tester probe (+) (Red) to terminal “33”.
(4) Connect the tester probe (–) (Black) to body ground.
(5) Measure voltage when steel tip of a screwdriver is brought
near and then pulled away from sensor tip A.
CMP sensor signal : Approx. 0.3 V or 5 V
NOTE:
Two signal voltages mentioned above (0.3 V or 5 V) will change
by repeating movement of screwdriver.
#
%
ECM
13-39 DF40/DF50 “K1” (‘01) model
MAP SENSOR OUTPUT VOLTAGE CHANGE
(#09917-47011 : Vaccum pump gauge
09930-89950 : 44-pin test cord
09930-99320 : Digital tester
Tester range : ($ V (DC voltage)
(1) Disconnect MAP sensor hose from gas filter (surge tank) side.
(2) Connect the gauge to MAP sensor hose end as shown.
(3) While applying negative pressure to MAP sensor, measure
“29” terminal voltage. (See page 13-33 and 13-34 for procedure.)
MAP sensor output voltage change :
Negative pressure
kPa (kg/cm2, mmHg)
“29” terminal
voltage (V)
0
(0, 0)
40
(0.4, 300)
80
(0.8, 600)
4.00 2.42 0.84
(at 1013 hPa barometric pressure)
CTP SWITCH
(#09930-99320 : Digital tester
()Tester range : (* (Continuity)
(1) Disconnect CTP switch wire.
(2) Check continuity between CTP switch terminal and body
ground.
CTP switch function :
Throttle position Continuity
Fully closed
(switch contact in) Yes
Not fully closed
(switch contact out) No
%
DF40/DF50 “K1” (‘01) model 13-40
OIL PRESSURE SWITCH
09940-44121 : Air pressure gauge
09930-99320 : Digital tester
: Air pump
Tester range : *((Continuity)
(1) Remove oil pressure switch.
(2) Connect the gauge and pump as shown.
(3) While applying pressure to oil pressure switch, check continuity.
Oil pressure switch function :
ECM MAIN RELAY
09930-99320 : Digital tester
Tester range : *((Continuity)
(1) Disconnect ECM main relay from wire.
(2) Check continuity between terminal 1 and 2 each time 12V
is applied. Connect positive (+) side to terminal 4, and negative (–) side to terminal 3.
ECM main relay function :
12 V power Continuity
Applied Yes
Not applied No
!
Be careful not to touch 12 V power supply wires to each
other or with other terminals.
ECM main relay
12V
1
2 4
3
#
)
Pressure
kPa (kg/cm2)
Continuity
Less than
70 – 130 (0.7 – 1.3)
Yes
70 – 130 (0.7 – 1.3)
or over
No #
)
13-41 DF40/DF50 “K1” (‘01) model
TROUBLESHOOTING
"
Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION”
section on page 13-33.
In this section, troubleshooting procedures are based on the assumption that “low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.
NOTE:
For troubleshooting of “Starter motor will not run”, see page 4-7 in Service Manual P/N. 99500-87J0•-01E.
CHART1 : SELF-DIAGNOSTIC CODE “3-4”
START
< Ignition switch “ON” >
Check “35” terminal voltage.
Is result OK? (See page 13-34.)
< Ignition switch “ON” >
Check “29” terminal voltage.
Is result OK? (See page 13-34.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
YES
ECM failure
NO
MAP sensor failure
NO
CHART2 : SELF-DIAGNOSTIC CODE “4-2”
START
< Ignition switch “OFF” >
Check CKP sensor resistance.
Is result OK? (See page 13-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CKP sensor failure
NO
NOTE:
• It will be possible to start engine if CKP sensor has failed.
DF40/DF50 “K1” (‘01) model 13-42
CHART3 : SELF-DIAGNOSTIC CODE “3-1”
START
< Ignition switch “OFF” >
Check IAC valve resistance.
Is result OK? (See page 13-35.)
< Ignition switch “ON” >
Check “18” terminal voltage.
Is result OK? (See page 13-34.)
Possible cause :
• Incorrect by-pass air screw adjustment
• IAC valve failure (mechanical)
• IAC passage failure (clogged hose/silencer,
etc.)
• ECM failure
• Wire continuity/connection failure
YES
YES
IAC valve failure
NO
ECM failure
NO
CHART4 : SELF-DIAGNOSTIC CODE “2-4”
START
< Ignition switch “ON” / Cranking >
Check CMP sensor signal.
Is result OK? (See page 13-38.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CMP sensor failure
NO
NOTE:
It will be possible to start engine if CMP sensor has failed.
CHART5 : SELF-DIAGNOSTIC CODE “2-2”
START
< Ignition switch “ON” >
Check “24” terminal voltage.
Is result OK? (See page 13-34.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
CTP switch failure
NO
NOTE1:
In this case, CTP switch will be in “always ON” condition.
(“24” terminal voltage will be 0V always regardless throttle
position.)
[NOTE1]
13-43 DF40/DF50 “K1” (‘01) model
CHART6 : SELF-DIAGNOSTIC CODE “1-4”
START
< Ignition switch “OFF” >
Check cylinder temp. sensor resistance.
Is result OK? (See page 13-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
NO
CHART 7 : SELF-DIAGNOSTIC CODE “2-3”
START
< Ignition switch “OFF” >
Check IAT sensor resistance.
Is result OK? (See page 13-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
IAT sensor failure
NO
CHART8 : SELF-DIAGNOSTIC CODE “3-2”
START
< Individual check >
Check MAP sensor hose is in good
condition/connection.
Is result OK?
< Ignition switch “ON” >
Check MAP sensor output voltage
change.
Is result OK? (See page 13-39.)
YES
YES
MAP sensor hose failure
NO
MAP sensor failure
NO
Cylinder temp. sensor failure
Possible cause :
• Gas filter failure (clogged, etc.)
• ECM failure
• Wire continuity/connection failure
DF40/DF50 “K1” (‘01) model 13-44
CHART9 : SELF-DIAGNOSTIC CODE “1-1”
START
< Individual check >
Check rectifier & regulator resistance.
[NOTE1]
Is result OK?
< Engine running >
Check “30” terminal voltage at idle
speed. (See page 13-34.)
Is result 16 V or over?
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
NO
Rectifier & regulator failure
NO
YES
NOTE:
This self-diagnostic code indication may be canceled by turning ignition switch ON because ECM detects
battery voltage.
NOTE1:
It is difficult to check rectifier & regulator completely. Before replacing with new one, check if its ground point
has good electrical contact.
START
< Ignition switch “OFF” >
Check exhaust manifold temp. sensor
resistance.
Is result OK? (See page 13-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
Exhaust manifold temp. sensor failure
NO
CHART10 : SELF-DIAGNOSTIC CODE “1-5”
START
< Ignition switch “OFF” >
Check fuel injector resistance.
Is result OK? (See page 13-35.)
Possible cause :
• ECM failure
• Wire continuity/connection failure
YES
Fuel injector failure
NO
CHART11 : SELF-DIAGNOSTIC CODE “4-3”
13-45 DF40/DF50 “K1” (‘01) model
CHART12 : ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY
AFTER STARTING)
Before starting this troubleshooting, make sure that :
• There is no self-diagnostic code indication.
• Emergency stop switch plate is set in place.
START
< Ignition switch “ON” >
Check “30” terminal
voltage.
Is result OK?
(See page 13-34.)
< Cranking >
Check injector operating
sound.
Is result OK?
(See page 13-36.)
NO
< Ignition switch “OFF” >
Check fuel injector
resistance.
Is result OK?
(See page 13-35.)
YES
< Ignition switch “ON” >
Check “40, 39 and 38”
terminal voltage.
Is result OK?
(See page 13-34.)
YES
< Cranking >
Check fuel injector
operating signal.
Is result OK?
(See page 13-36.)
YES
Fuel injector failure
< Ignition switch “ON” >
Check “37” terminal
voltage for 3 sec. after
switch ON.
Is result OK?
(See page 13-34.)
Possible cause :
Failure of high pressure
fuel system components.
NO ECM main relay failure
YES < Ignition switch “ON” >
Check “2” terminal voltage
Is result OK?
(See page 13-34.)
YES
YES < Cranking >
Check ignition spark using
timing light.
(P/no. 09930-76420).
Is there light flashing?
< Ignition switch “OFF” >
• Check ignition primary
coil resistance.
(See page 13-35.)
• Check ignition secondary
coil resistance.
(See page 13-35.)
Are results OK?
Power supply wire (Gr)
failure
ECM failure
Fuel pump failure
NO
< Ignition switch “ON” >
Check fuel pump 3 sec.
operating sound.
Is result OK?
(See page 13-37.)
YES
< Cranking >
Check “37” terminal
voltage.
Is result OK?
(See page 13-34.)
Emergency stop switch
failure
Spark plug failure
< Individual check >
Check if spark plug is in
good condition.
Is result OK?
NO
Ignition coil failure
< Ignition switch “ON” >
Check “44, 43 and 22”
terminal voltage.
Is result OK?
(See page 13-34.)
YES
< Cranking >
Check ignition coil operating signal.
Is result OK?
(See page 13-37.)
NO
NO
NO
YES
YES
NO
NO
YES
NO
YES
NO
NO YES
NO
YES
NO
DF40/DF50 “K1” (‘01) model 13-46
CHART13 : UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL)
Before starting this troubleshooting, make sure that :
• There is no self-diagnostic code indication.
START
< Ignition switch “ON” >
Check “5” terminal voltage.
Is result OK? (See page 13-34.)
YES
< Ignition switch “ON” >
Check “24” terminal voltage.
Is result OK? (See page 13-34.)
YES
< Individual check >
Check neutral switch function.
Is result OK?
NO YES
NO (Always 0 V)
Neutral switch failure ECM failure
(Always 5 V)
[NOTE1] YES
< Individual check >
Check CTP switch function.
Is result OK? (See page 13-39.)
NO
CTP switch failure
[NOTE2]
Possible cause :
• Incorrect by-pass air screw adjustment [NOTE3]
• IAC valve failure [NOTE3]
• IAC passage failure (clogged hose / silencer, etc.) [NOTE3]
• Spark plug failure
• Ignition coil failure
• ECM failure
• Wire continuity / connection failure
• Failure of high pressure fuel system components :
• Fuel injector (clog, stuck valve, etc.)
• Fuel pressure regulator (incorrect regulated pressure, etc.)
• Fuel pump (clogged suction filter, leakage in tank, etc.)
• Fuel filter (clog, etc.)
• Hose (clog, kink, leakage, etc.)
NOTE1:
If neutral switch has failed (while engine running), engine will tend to stall when shifting into gear.
If neutral switch has failed as “always ON”, engine speed is limited to 3000 r/min by intermittent fuel injection
and ignition timing is fixed at BTDC9 °.
If neutral switch has failed as “always OFF”, engine cannot be cranked.
NOTE2:
If CTP switch has failed, engine will tend to stall when decelerating.
NOTE3:
• The self-diagnostic code “3-1” may not be indicated because IAC valve condition depends on ECM control.
(See page 13-28.)
• If IAC valve has failed, “Fast-idle function (warm-up mode)” won’t operate.
NO (Always 0 V)
(Always 5 V)
13-47 DF40/DF50 “K1” (‘01) model
+
1
2
3
4
5
9
6
0
7
8
o @ 190 N·m
(19.0 kg-m, 137.5 lb-ft)
NOTE:
Check air gap between CKP
sensor and reluctor bar on
flywheel magneto.
Air gap : 0.75 mm (0.030 in)
NOTE:
Clean flywheel and crankshaft mating
surfaces with cleaning solvent.
Crankshaft
REMOVAL / INSTALLATION
FLYWHEEL / CKP SENSOR / CMP SENSOR
1 Flywheel bolt (1)
2Washer (1)
3Key (1)
4 Flywheel magneto (1)
5CKP sensor (1)
6Screw (2)
7CMP sensor (1)
8Bolt (1)
9Clamp (1)
0Clamp (1)
# 09930-48720 : Flywheel holder
09930-39411 : Flywheel remover
09930-39420 : Flywheel remover bolt
DF40/DF50 “K1” (‘01) model 13-48
ELECTRICAL
ELECTRIC STARTER SYSTEM
STARTER MOTOR
REMOVAL
Prior to removing starter motor:
• Disconnect battery cables from battery.
Remove three bolts, two fastening bands and flywheel cover.
Remove bolt and silencer cover.
Disconnect lead wire connector from IAT sensor.
Remove nut and IAC valve from electric parts holder.
Remove starter motor sub cable.
Remove four bolts, motor band and starter motor assy.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Install starter motor and tighten starter motor mounting bolts
securely.
, Starter motor mounting bolt :
23 N·m (2.3 kg-m, 16.5 lb-ft)
13-49 DF40/DF50 “K1” (‘01) model
DISASSEMBLY
NOTE:
For correct assembly, scribe an alignment mark on the front cover,
stator and rear cover.
Remove nut 1 on + terminal.
Remove two screws 2 and sub rear cover 3.
Remove circrip 4, washer 5 and 6.
NOTE:
When installing, set thicker washer 6 to circrip side.
Remove two bolts 7.
DF40/DF50 “K1” (‘01) model 13-50
Remove rear cover 8 and brush holder 9.
Remove washers 0 from armature shaft.
Remove front cover A and stator B.
Push down pinion stopper C, remove stopper ring D.
Remove pinion stopper C, spring E, pinion F and cover G.
"
Wear safety grasses when disassembling and assembling stopper ring.
NOTE:
Using a screw-driver, pry off the stopper ring.
13-51 DF40/DF50 “K1” (‘01) model
INSPECTION & SERVICING
Pinion
Inspect pinion.
Replace pinion if damaged or worn.
Armature and Commutator
Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grade emery paper
A.
Measure commutator outside diameter.
09900-20101 : Vernier calipers
Commutator outside diameter:
Standard : 33.0mm (1.30 in)
Service limit : 32.0mm (1.26 in)
If measurement exceeds service limit, replace armature.
Check that mica (insulator) between the segments is undercut
to specified depth.
Commutator undercut:
Standard : 0.5 – 0.8mm (0.02 – 0.03 in)
Service limit : 0.2 mm (0.01in)
If measurement exceeds service limit, cut to specified depth.
NOTE:
Remove all particles of mica and metal using compressed air.
"
Wear safety grasses when using compressed air.
#
A
SEGMENT
MICA
1
1. undercut
DF40/DF50 “K1” (‘01) model 13-52
Armature core
Commutator
Shaft
Check for continuity between the commutator and the armature core / shaft.
Replace armature if continuity is indicated.
Check for continuity between the adjacent commutator segments.
Replace armature if no continuity is indicated.
09930-99320 : Digital tester
Tester range : (Continuity)
BRUSHES
Check the length of each brush.
09900-20101 : Vernier calipers
Brush length:
Standard : 17.0 mm (0.67 in)
Service limit : 10.0 mm (0.39 in)
If brushes are worn down to the service limit, they must be replaced.
BRUSH HOLDER
Check brush holder continuity.
09930-99320 : Digital tester
Tester range : (Continuity)
Brush holder continuity :
#
#
#
Tester probe connection Continuity
Brush holder positive + to Brush holder
negative - No
Brush holder positive + to Base plate
(ground) No
Brush
+
-
Base plate
)
)
13-53 DF40/DF50 “K1” (‘01) model
v v v @ 4.0 N·m (0.4 kg-m, 2.9 lb-ft)
ASSEMBLY
Assembly is reverse of disassembly with special attention to following steps.
!
When installing armature, exercise care to avoid breaking brushes.
Apply grease to armature shaft and shaft holes.
- 99000-25010 : Suzuki Super Grease “A”
Align front cover, stator and rear cover with alignment lines scribed
earlier and assemble starter.
, Bolt D: 4.0 N·m (0.4 kg-m, 2.9 lb-ft)
1. Front cover (1)
2. Stopper ring (1)
3. Pinion stopper (1)
4. Spring (1)
5. Pinion (1)
6. Cover (1)
7. Armature (1)
8. Washer (2)
9. Stator (1)
10. Brush (1)
11. Brush spring (2)
12. Brush holder (1)
13. Rear cover (1)
14. Bolt (2)
15. Washer (1)
16. Washer (1)
17. Circrip (1)
18. Sub rear cover (1)
19. Screw (2)
DF40/DF50 “K1” (‘01) model 13-54
MID UNIT
TILT AID SYSTEM
"
This unit contains high pressure gas and it must not be
disassembled, punctured, incinerated or exposed to
heat.
REMOVAL
Tilt engine fully up and lower the manual tilt lock levers 1.
"
During the following procedure, firmly secure the engine
and support its weight. (see right)
Remove the snap ring 2 and push tilt cylinder upper shaft pin 3
out.
Remove the two STBD motor mounting bolts 4.
Loosen the clamp bracket shaft nut 5.
NOTE:
Complete removal of the clamp bracket shaft nut is not required.
Nut should only be loosened as far as the end of the shaft threads
to facilitate removal of the tilt aid gas cylinder.
13-55 DF40/DF50 “K1” (‘01) model
Remove the both lower shaft bolts 8.
Slide the STBD clamp bracket 9 fully outward to the right hand
side.
Remove the tilt aid gas cylinder 0 from between the clamp brackets.
INSPECTION
NOTE:
If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced.
Tilt aid gas cylinder
Check tilt aid gas cylinder.
If cracks, defects or other damage is found, replace the cylinder
assembly complete.
Bush
Check all bush.
If excessive wear or other damage is found, replace bush.
If bush fit is loose when installing, replace bush.
DF40/DF50 “K1” (‘01) model 13-56
l l h @
@h INSTALLATION
Installation is reverse order of remove with special attention to
following steps.
• Install release lever 1, bolt 2 and lock nut 3 as shown. Tighten
the bolt 2 first, then the lock nut 3.
• Apply grease to the cylinder lower shaft, cylinder upper shaft
and bushes.
. 99000-25160 : Suzuki Washer Resistant Grease
• Tighten the clamp bracket shaft nut to specified torque.
, Clamp bracket shaft nut : 43 N·m (4.3 kg-m, 31.0 lb-ft)
• Tighten the lower shaft bolts, pre-coated with thread lock, to
specified torque.
+ 99000-32050 : Thread Lock “1342”
, Lower shaft bolt : 23 N.m (2.3 kg-m, 16.5 lb-ft)
1. Release lever (1)
2. Spacer (1)
3. Spacer (1)
4. Tilt aid gas cylinder (1)
5. Lower shaft (1)
6. Upper shaft (1)
7. Bush (2)
8. Bush (1)
9. Bolt (1)
10. Bolt (2)
11. Nut (1)
12. Washer (2)
13. Snap ring (2)
13-57 DF40/DF50 “K1” (‘01) model
POWER TRIM AND TILT
OIL LEVEL
To check the oil level :
1. The motor should be raised to a full-tilt position.
2. Lower the manual tilt lock lever 1.
3. Remove the oil filler plug 2.
4. If oil can be seen at filler plug level, the unit is full.
5. If oil level is low, refill with the recommended oil.
Recommended oil :
Dexron automatic transmission fluid or equivalent
!
To ensure consistent pump operation, do not mix different types of oil.
6. Reinstall oil filler plug.
AIR BLEEDING
1. Make sure the manual release valve A is closed securely
before performing air bleeding.
, Manual release valve : 1.7 N·m (0.17 kg-m, 1.2 lb-ft)
2. Using PTT switch, raise and lower engine (full up to full down)
5-6 times.
3. Check oil level, topping off if necessary.
4. Reinstall oil filler plug.
DF40/DF50 “K1” (‘01) model 13-58
POWER TRIM AND TILT UNIT
REMOVAL
Tilt engine fully up and lower the manual tilt lock levers 1.
"
During the following procedures, firmly secure the engine and support its weight. (see right)
Remove the tilt rod snap ring 2 and push tilt cylinder upper shaft
pin 3 out.
Lower tilt rod to full down position and disconnect the battery
cable.
Disconnect the PTT motor cable wire leads (G, Bl) from the PTT
relays.
Remove the PTT motor cable from engine lower cover.
Remove the two STBD motor mounting bolts 4.
Loosen the clamp bracket shaft nut 5.
NOTE:
Complete removal of the clamp bracket shaft nut is not required.
Nut should be loosened as far as the end of the shaft threads
only to facilitate removal of the PTT unit.
13-59 DF40/DF50 “K1” (‘01) model
Remove the both lower shaft bolts 6.
Slide the STBD clamp bracket fully outward to the right hand
side.
Remove the PTT unit from between the clamp brackets.
DISASSEMBLY
NOTE:
Before disassembly, wash the PTT body with a stiff bristle brush
and hot, soapy water to remove sand or dirt and dry the PTT
body with compressed air.
Connect the PTT motor cable leads (G, Bl) to battery and operate PTT motor until tilt piston rod is at maximum stroke.
(full-tilt up position)
Place the lower mounting eye of the PTT cylinder in a vise. Tighten
the vise only enough to secure the PTT unit, do not over tighten.
NOTE:
To prevent damage to the PTT cylinder use wood blocks, vise jaw
protectors, etc., between the vise jaws and PTT component before tightening vise.
Check all bush.
If excessive wear or other damage is found, replace bush.
If bush fit is loose when installing, replace bush.
DF40/DF50 “K1” (‘01) model 13-60
Remove the PTT motor.
Note the position of drive joint 3 and O-ring 4, before removing
them.
(See page 13-63)
Unscrew the fill plug and drain PTT oil into suitable container.
Remove the manual release valve snap ring 5, then unscrew
the manual release valve 6.
Remove the seal washer 7.
PUMP ASSY
Remove the drive joint 1 and filter 2.
Remove three bolts 3 and pump assy.
Remove the check valve 4, down-blow valve 5 and O-ring 6.
13-61 DF40/DF50 “K1” (‘01) model
Remove the tilt rod joint.
Remove four bolts and cylinder housing.
!
When removing the cylinder housing, exercise care to
avoid damaging the rip of oil seal.
CLEANING AND INSPECTING
Thoroughly wash all metal components with cleaning solvent and
dry them with compressed air.
Arrange all components on a clean sheet of paper.
NOTE:
Do not lay PTT components out on a rag, as dirt or lint may be
transferred to these items which may cause possible system operating problems.
Inspect manual release valve, down-blow valve, seal and O-ring.
Replace if cuts, nicks, excessive wear or other damages are found.
DF40/DF50 “K1” (‘01) model 13-62
REASSEMBLY
Assembly is reverse of disassembly with special attention to following steps.
!
• Do not reuse O-rings after removal, always use new
O-rings.
• Lubricate all components and O-rings with PTT fluid
before assembly.
• Do not reuse PTT fluid, always refill with new fluid.
CYLINDER HOUSING
Install the the cylinder housing .
Tighten four bolts.
!
When installing the the cylinder housing, exercise care
to avoid damaging the rip of oil seal.
MANUAL RELEASE VALVE
Oil and install the seal washer and manual release valve.
Tighten the valve to specified torque.
Install snap ring.
, Manual release valve : 1.7 N.m (0.17 kg-m, 1.2 lb-ft)
PUMP ASSY
Install the check valve and down-blow valve.
TILT ROD JOINT
Apply Thread Lock 1333B to the thread part of tilt rod joint.
/ 99000-32020 Thread Lock 1333B
Tighten the tilt rod joint to specified torque.
, Piston rod joint : 40 N.m (4.0 kg-m, 30.0 lb-ft)
13-63 DF40/DF50 “K1” (‘01) model
1. Screw
2. Field case
3. Armature
4. O-ring
5. Brush holder1
2
3
4
5
Install the pump assy.
Tighten three bolts to specified torque.
, Pump securing bolt : 5 N.m (0.5 kg-m, 3.6 lb-ft)
PTT MOTOR
See the PTT MOTOR-installation section on page 13-66.
AIR BLEEDING
See the AIR BLEEDING section on page 13-57.
PTT MOTOR
Removal
Remove the four screws securing the PTT motor to the pump &
reservoir.
Detach the PTT motor from pump & reservoir.
Note the position of drive joint 1 and O-ring 2 and remove them.
Disassembly
For correct assembly, scribe an alignment mark on the field case
and brush holder.
Remove the three screws securing the field case to the brush
holder.
Using a soft face hammer, gently tap the field case from side to
side to unseat it from the brush holder.
Slide the field case upward and away from the brush holder.
Note the position of the O-ring encircling the brush holder.
Slide the armature free of the brushes.
DF40/DF50 “K1” (‘01) model 13-64
Inspection
• Armature and commutator
Check for continuity between the commutator and the armature
core / shaft.
Replace armature if continuity is indicated.
09930-99320 : Digital tester
Tester range : (Continuity)
Check continuity between the adjacent commutator segments.
Replace armature if no continuity is indicated.
Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grade emery paper.
Measure commutator outside diameter.
09900-20101 : Vernier calipers
Commutator outside diameter :
Standard 22.0 mm (0.87 in)
Service limit 21.0 mm (0.83 in)
If measurement exceeds service limit, replace armature.
Ensure that the mica (insulator) between the segments is undercut to specified depth.
Commutator undercut :
Standard 0.5 – 0.8 mm (0.02 – 0.03 in)
Service limit 0.2 mm (0.01 in)
If undercut is less than service limit, cut to specified depth.
NOTE:
Remove all particles of mica and metal using compressed air.
"
Wear safety grasses when using compressed air.
#
)
#
SEGMENT
MICA
1
1 Commutator undercut
#
#
13-65 DF40/DF50 “K1” (‘01) model
• Brushes
Check the length of each brush.
09900-20101 : Vernier calipers
Brush length :
Standard 9.8 mm (0.39 in)
Service limit 4.8 mm (0.19 in)
If brushes are worn down to the service limit, they must be replaced .
• O-ring
Inspect the O-ring between the PTT motor and pump & reservoir.
Replace if cuts, nicks or tears are found.
#
Assembly
Assembly is reverse of disassembly with special attention to following steps.
!
When installing the armature, exercise care to avoid
breaking brushes.
DF40/DF50 “K1” (‘01) model 13-66
Installation
Installation is reverse of removal with special attention to following steps.
• Ensure that the drive joint 1 is aligned and firmly inserted into
the gear pump assembly.
• Fit O-ring 2 to pump & reservoir.
• Check the level of PTT fluid contained in the pump & reservoir.
If level is low, add recommended PTT fluid until level with mating surface of PTT motor.
• Ensure that the faces of the PTT motor and pump unit are free
of dirt or debris.
When attaching the PTT motor to the pump & reservoir, ensure
that the tip of armature shaft fits firmly into the drive joint.
• Tighten the four screws to specified torque.
, PTT motor screw : 4.5 N.m (0.45 kg-m, 3.3 lb-ft)
13-67 DF40/DF50 “K1” (‘01) model
10
3
3
2
9
7
8
5
1
4
6
6
8
7
l l h@ h@ INSTALLATION
Installation is reverse of removal with special attention to following steps.
• Apply grease to the cylinder lower shaft, cylinder upper shaft
and bushes.
. 99000-25160 : Water Resistant Grease
• Lower tilt rod full down position.
Place the PTT unit in position between the clamp brackets.
Tighten the clamp bracket shaft nut to specified torque.
, Clamp bracket shaft nut :
43 N.m (4.3 kg-m, 31.0 lb-ft)
• Tighten the lower shaft bolts, pre-coated with thread lock, to
specified torque.
+ 99000-32050 : Thread Lock “1342”
, Lower shaft bolt : 23 N.m (2.3 kg-m, 16.5 lb-ft)
1. PTT unit (1)
2. Upper shaft (1)
3. Bush (2)
4. Lower shaft (1)
5. Spacer (1)
6. Bush (2)
7. Bolt (2)
8. Washer (2)
9. Snap ring (2)
DF40/DF50 “K1” (‘01) model 13-68
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WIRING DIAGRAM
DF40QH / DF50QH / DF50WQH
13-69 DF40/DF50 “K1” (‘01) model
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R/W
O
V/W
P/B
O/Y
Y
R
Lg/B
Bl/B
P
O
Y/B
Bl/W
Br Lg/W
B
B
B/W
B/Y
G
Bl Lg/W
W
Gr W/R
P/B
G
G
P
W/R
Lbl
P
Lbl
B
l B
l B W W
G
B W
P L
b L
b l P L
b L
b l P G
r G
r P
P L
g L
g B
l B
l B
l B
l B
r B
r O
B
r B
r G
r G
r B
r B
r Gr Gr
B
B
G W
Gr W
Lbl Lbl
P P
B O
G
/Y
G
/Y
G
/W
G
/W
P G
r G
r G
r G
r G
r G
r P
W R
L
b L
b l B
Gr G
r G
r L
b L
b l P W Y
B R G
r G
r Y
B
B
G
r G
r G
r G
r G
r G
r B
B
BR
/G
R
/G B
R
/G
R
/G B
G
r G
r B
G
r G
r B
G
r G
r BR
/G
R
/G B G
r G
r B
G
r G
r B
R
/G
R
/G BR
/G
R
/G B
B
R/G
B
R/G
R/G R/G
W/R
B
l B W W
G
B W
P L
b l P L
b l P G
r P
PP
L
b L
b l B OB O L
b l L
b L
b l L
b l W Y G
r G
r BW Y G
r B
O O B
r B
r G B
l B
l B
r G B
l P L
g O BO B
P G
r G
rP G
r O BO B
B
l B
l B
r O
B
r G
r B
r B
B
G W
B O
G
/Y
G
/W
B
l/B
B
l/B P
B
l/B P
P G
r P G
r G
r O
r O
r B P G
r O B
P G
r G
rP L
g G
r G
r P
W R
L
b l B
G
r L
b l P W Y
B R G
r Y
B
B
G
r G
r G
r B
B
G
r G
r YG
r Y
B
G
r G
r YG
r Y
R
/G B
R
/G B
G
r B
G
r B
G
r BR
/G B G
r B
G
r B
R
/G BR
/G B
O
r O
r BO B
DF40T / DF50T / DF50WT
DF40/DF50 “K1” (‘01) model 13-70
"Q
H
"
M
O
D
E
L
In st al l h
ol de r co ve r to ho ld er h oo k se cu re ly .
E
C
M
m ai n re la y C
la m p E
xh au st m an ifo
ld te m p. s en so r R
ec tif
ie r &
r eg ul at or E
ng in e w iri
ng h ar ne ss E
le ct ric
p ar ts h ol de r co ve r S
ta rt er m ot or s ub c ab le P
T
T
m ot or c ab le S
ta rt er m ot or r el ay B
at te ry c ab le P
T
T
r el ay p la te P
T
T
m ot or r el ay (
D
O
W
N
)
P
T
T
m ot or r el ay (
U
P
)
C
om m un ic at io n co nn ec to r / c
ap 30
A
F
us e WIRE ROUTING
13-71 DF40/DF50 “K1” (‘01) model
M
A
P
s en so r M
A
P
s en so r ho se /
P
ro te ct or G
as fi lte
r 3N
·m
(
0.
3
kg -m , 2
.0
lb -f t) N
eu tr al s w itc
h P
T
T
s w itc
h le ad c on ne ct or F
ue l i
nj ec to r #3
F
ue l i
nj ec to r #2
F
ue l i
nj ec to r #1
C
la m p C
la m p C
la m p C
lip
F
ix in je ct or le ad w ire
.
F
ix fu el p um p le ad w ire
a nd fu el h os e. F
ix n eu tr al s w itc
h le ad w ire
.
O
il pr es su re s w itc
h DF40/DF50 “K1” (‘01) model 13-72
C
yl in de r te m p. s en so r E
xh au st m an ifo
ld te m p. s en so r E
le ct ric
p ar ts h ol de r co ve r E
le ct ric
p ar ts h ol de r C
K
P
s en so r C
la m p C
la m p C
la m p C
la m p C
la m p C
la m p R
ec tif
ie r &
r eg ul at or S
ta rt er m ot or B
at te ry c ha rg e co il M
A
P
s en so r br ac ke t M
A
P
s en so r A
pp ly e ng in e oi l t
o O
-r in g w he n in st al lin
g se ns or .
A
pp ly e ng in e oi l t
o O
-r in g w he n in st al lin
g se ns or .
F
ix le ad w ire
n ot to c on ta ct w ith
fl yw he el m ag ne to .
F
ix le ad w ire
n ot to c on ta ct w ith
fl yw he el m ag ne to .
F
ix le ad w ire
s no t t
o co nt ac t w
ith
fl yw he el m ag ne to .
F
ix e ng in e w iri
ng ha rn es s no t t
o co nt ac t w ith
o il fil
le r ca p. F
ix e ng in e w iri
ng h ar ne ss n ot to c on ta ct w ith
h os e cr ip .
A
fte
r in st al lin
g fly
w he el m ag ne to a nd se cu rin
g nu t w
ith
s pe ci fie
d to rq ue ,
ch ec k ai r ga p be tw ee n C
K
P
s en so r an d re lu ct or b ar s on fl yw he el m ag ne to .
A
ir ga p : 0
.7
5
m m (
0.
03
0
in )
13-73 DF40/DF50 “K1” (‘01) model
Clamp
Clamp
Clamp
Clamp
CMP sensor
Ignition coil #3
Ignition coil #2
Ignition coil #1
Clip
Position clip tabs
inward (engine side)
Starter motor
Starter motor sub cable
Grommet
IAT sensor
Engine wiring harness
Battery cable
IAC valve
CTP switch
Battery cable
Route battery cable on fuel hose.
Tighten bolt with PTT relay
ground wire, battery cable
ground wire and harness
ground wire.
DF40/DF50 “K1” (‘01) model 13-74
Trim sender cable
Grommet
Trim sender
Trim sender cable
PTT motor cable
Clamp
Clamp
Bind trim sender cable and
PTT motor cable.
Prepared by
Marine & Power Products Division
1st Ed.October, 1998
4th Ed. March, 2002
Manual No.99500-87J03-01E
Printed in Japan
420
Printed in Japan TK
X, Y, K1

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