Page 1 99500-87J00-01E...
Page 2 FOREWORD GROUP INDEX This manual contains an introductory description on SUZUKI Outboard motor DF40/50 and procedures for the inspection, service and overhaul of its main GENERAL INFORMATION components. General knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION sec- tion to familiarize yourself with basic information concerning this motor.
Page 3: Component Parts And Important Item Illustrations
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.
Page 4 Apply THREAD LOCK SUPER otherwise specified. “1333B”. Apply SUZUKI OUTBOARD Measure in DC voltage range. MOTOR GEAR OIL. Apply SUZUKI SUPER GREASE “A”. Measure in resistance range. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”.
Page 5: Table Of Contents
GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE _________________________________ 1-1 GENERAL PRECAUTIONS _________________________________ 1-1 IDENTIFICATION NUMBER LOCATION _______________________ 1-3 FUEL AND OIL ___________________________________________ 1-3 GASOLINE RECOMMENDATION ..............ENGINE OIL ....................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...
Page 6: Warning/Caution/Note
1-1 GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the sym- bol 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.
Page 7 GENERAL INFORMATION • 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.
Page 8: Identification Number Location
. FUEL AND OIL GASOLINE RECOMMENDATION Suzuki highly recommends that you use alcohol - free un- leaded 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 con- tent may be used.
Page 9: Engine Break-In
GENERAL INFORMATION ENGINE BREAK-IN The first 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long-term durability.
Page 10: Propellers
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. DF40T 5200-5800 r / min Recommended full throttle speed range DF50T...
Page 11: Specifications
GENERAL INFORMATION SPECIFICATIONS Data Item Unit DF40T DF50T PRE-FIX 04001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in.) 756 (29.8) Overall width (side to side) mm (in.) 382 (15.0) Overall height mm (in.) 1263 (49.7) mm (in.) 1390 (54.7) Weight kg (Ib.)
Page 12 Engine oil amounts 2.2 (2.3/1.9) : Oil change only L (US/Imp. qt) 2.4 (2.5/2.1) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/Imp. oz) 610 (20.6/21.5) BRACKET Trim angle...
Page 13: Service Data
GENERAL INFORMATION SERVICE DATA Data Item Unit DF40T DF50T POWERHEAD r/min 5200 – 5800 Recommended operating range 5900 – 6500 Idle speed r/min 850 ± 50 (in-gear: approx.850±50) **Cylinder compression kPa (kg/cm . psi) 1300 – 1600 (13 – 16, 185 – 228) **Cylinder compression max.
Page 14 1-9 GENERAL INFORMATION Data Item Unit DF40T DF50T ENGINE OIL PUMP Limit mm (in.) 0.31 (0.0122 in.) Radial clearance Limit mm (in.) 0.15 (0.0059 in.) Side clearance CYLINDER HEAD / CAMSHAFT Limit mm (in.) 0.05 (0.002) Cylinder head distortion Manifold seating Limit mm (in.) 0.10 (0.004)
Page 15: General Information
GENERAL INFORMATION 1-10 Data Item Unit DF40T DF50T VALVE / VALVE GUIDE mm (in.) 24.6 (0.9685) Valve diameter mm (in.) 21.5 (0.8465) Tappet clearance 0.18 – 0.24 (0.007 – 0.009) mm (in.) (Cold engine 0.18 – 0.24 (0.007 – 0.009) mm (in.) condition) Valve seat...
Page 16 1-11 GENERAL INFORMATION Data Item Unit DF40T DF50T CYLINDER / PISTON / PISTON RING Limit mm (in.) 0.06 (0.0024) Cylinder distortion mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in.) 0.100 (0.0039) mm (in.) 71.000 –...
Page 17 GENERAL INFORMATION 1-12 Data Item Unit DF40T DF50T CRANKSHAFT / CONROD Conrod small end mm (in.) 18.003 – 18.011 (0.7088 – 0.7091) inside diameter mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance Limit mm (in.) 0.065 (0.0026) Conrod big end mm (in.)
Page 18: Starter Motor
1-13 GENERAL INFORMATION Data Item Unit DF40T DF50T ELECTRICAL Degrees at r/min Ignition timing BTDC 0° – BTDC 32° BTDC 0° – BTDC 25° r/min 6500 7000 Over revolution limiter 168 – 252 at 20°C CKP sensor resistance —— CMP sensor resistance at 20°C Primary 1.9 –...
Page 19: Self-Diagnostic System Indication
GENERAL INFORMATION 1-14 PTT MOTOR mm (in.) 9.8 (0.39) Brush length Limit mm (in.) 4.8 (0.19) mm (in.) 22.0 (0.87) Commutator outside diameter Limit mm (in.) 21.0 (0.83) 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 sound- ing.
Page 20: Tightening Torque
1-15 GENERAL INFORMATION TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib.-ft. Cylinder head cover bolt 6 mm Cylinder head bolt 43.4 10 mm Crankcase bolt 8 mm 18.1 10 mm 38.3 Conrod cap nut 8 mm 25.3...
Page 21 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. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N . m kg-m Ib.-ft. 5 mm 2 –...
Page 22: Special Tools
1-17 GENERAL INFORMATION SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) 09821-00004 09900-00410 Hexagon socket Hexagon bit Air pump Assy Hexagon wrench set (included in 09900-00410) (included in 09900-00410) (A) 09900-06107 09900-20101 (150 mm) (B) 09900-06108 09900-20102 (200 mm) 09900-20202 09900-20203 Snap ring pliers...
Page 23 GENERAL INFORMATION 1-18 09915-64510 Compression gauge 09915-47340 09915-63210 09915-77310 09915-78211 Oil filter wrench Adaptor Oil pressure gauge Oil pressure gauge adapter 09916-10910 09916-14510 09916-14910 09916-24450 Valve lapper Valve lifter Valve lifter attachment Solid pilot (N-100-5.52) 09916-24440 09916-20630 09916-20620 Handle adaptor 09916-24980 Valve seat cutter Valve seat cutter...
Page 24 1-19 GENERAL INFORMATION 09922-89810 09930-30161 09930-30102 09930-39411 Shift lock pin remover Propeller shaft remover Sliding hammer Flywheel rotor remover 09930-39420 09930-48720 09930-76420 09930-89240 Rotor remover bolt Flywheel holder Timing light 4-pin connector test cord 09930-89260 09930-89910 09930-89920 09930-89930 Injector test cord A 4-pin connector test cord 6-pin connector test cord 8-pin connector test cord...
Page 25: Materials Required
99000-25010 99000-25160 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1104” SUZUKI BOND “1207B” THREAD LOCK “1342” 4-Stroke Motor Oil * 99104-33140 99000-31030 99000-31140 99000-32050 API : SE, SF, SG, SH, SJ (100 g)
Page 26: Periodic Maintenance
PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE _______________________ 2-1 PERIODIC MAINTENANCE CHART .............. MAINTENANCE AND TUNE-UP PROCEDURES _________________ 2-2 ENGINE OIL / ENGINE OIL FILTER ............... GEAR OIL ......................LUBRICATION ....................SPARK PLUG ....................TAPPET CLEARANCE ..................2-14 IDLE SPEED ....................2-15 IGNITION TIMING ....................
Page 27: Periodic Maintenance Schedule
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.
Page 28: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE 2-2 MAINTENANCE AND TUNE-UP PROCEDURES 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. (2) Remove the motor cover.
Page 29: Engine Oil Change/Engine Oil Filterreplacement
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: •...
Page 30 PERIODIC MAINTENANCE 2-4 (3) Screw new filter on by hand until the filter O-ring con- tacts 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.
Page 31: Gear Oil
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.
Page 32: Lubrication
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 Throttle/Shift linkage Swivel bracket Steering bracket Propeller shaft...
Page 33: Spark Plug
2-7 PERIODIC MAINTENANCE SPARK PLUG • Inspect every 100 hours (6 months). • Replace every 200 hours (12 months). Standard spark plug : NGK DCPR6E CARBON DEPOSIT Check for a carbon deposit on the spark plug bases. If carbon is present, remove it with a spark plug cleaning ma- chine or by carefully using a pointed tool.
Page 34: Tappet Clearance
PERIODIC MAINTENANCE 2-8 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.
Page 35 2-9 PERIODIC MAINTENANCE (5) Rotate crankshaft clockwise to bring cam nose vertical to shim surface. 90° (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.
Page 36 PERIODIC MAINTENANCE 2-10 ADJUSTMENT Tappet clearances are adjusted by replacing tappet shim. (1) Close valve and turn tappet cut-away toward inside as shown in figure. Cut section of tappet Plug hole Shim (2) Rotate crankshaft to open (lift up) the valve and then re- move camshaft housing bolts where the shim to be re- placed.
Page 37 2-11 PERIODIC MAINTENANCE Thickness Thickness Thickness I.D No. I.D No. I.D No. (mm) (mm) (mm) 2.18 2.46 2.74 2.20 2.48 2.76 I.D No. 2.22 2.50 2.78 2.50 mm 2.24 2.52 2.80 2.26 2.54 2.82 2.28 2.56 2.84 2.30 2.58 2.86 2.32 2.60 2.88...
Page 38 PERIODIC MAINTENANCE 2-12 Reassembly After checking and adjusting all valves, reverse removal proce- dure for installation. • Install the cylinder head cover. (See page 6-8) NOTE: Examine cylinder head cover gasket for damage. Always replace gasket if sealing performance is suspect. •...
Page 39 TAPPET SHIM SELECTION CHART Shim I.D. 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 292 294 296 298 300 Present shim size (mm) Tappet...
Page 40: Idle Speed
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 sta- bilized.
Page 41: Ignition Timing
2-15 PERIODIC MAINTENANCE (9) Release pinch, allowing air to the IAC valve, and recheck if engine speed is stable at 800 – 900 r / min. NOTE: The idling / trolling speed of 800 – 900 r / min. is controlled by the IAC ( idle air control ) system.
Page 42: Breather And Fuel Line
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 •...
Page 43: High Pressure Fuel Filter
2-17 PERIODIC MAINTENANCE HIGH PRESSURE FUEL FILTER Replace every 1000 hours. SUZUKI recommends that the high pressure fuel filter be re- placed every 1000 operating hours. WATER PUMP / WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months).
Page 44: Anodes And Bonding Wires
If 2/3 of the zinc anode has corroded away, replace the anode. Anode Never paint the anode. NOTE: The anode securing bolt should be covered with Suzuki Sili- cone Seal. 99000-31120 : Suzuki Silicone Seal BONDING WIRES • If breakage or other damage is found on the wire, replace the wire.
Page 45: Battery
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 con- tact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water.
Page 46: Bolt And Nuts
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 bat- tery.
Page 47: Fuel Mixture Check (Ofeedback)
There are two methods available for performing the O feed- back operation : (a) Using a personal computer and the Suzuki Diagnostic Sys- tem software. (Suzuki recommends using this method as it is possible to monitor the feedback condition.) (b) Using the diagnostic harness without a personal computer.
Page 48 PERIODIC MAINTENANCE 2-22 2. Remove grommet and stbd.lower side cover. (See page 7-1) 3. Remove plug from oil pump case and install the O sen- and protector sleeve 18213-74F00 : O sensor 18498-99E40 : Protector sleeve The O sensor used for the feedback test procedure must be in proper working order and installed se- curely.
Page 49 2-23 PERIODIC MAINTENANCE 5. Install stbd.side lower cover. NOTE: Route the diagnostic harness through clearance between re- mote 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.
Page 50 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 op- eration at this ZONE was successfully finished. Go to next step (ZONE 2). •...
Page 51 2-25 PERIODIC MAINTENANCE 16. When finished with the O 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”. Black NOTE: Repeat the O feedback operation with a new O sensor if : •...
Page 52: Oil Pressure
PERIODIC MAINTENANCE 2-26 OIL PRESSURE Oil pressure ( at normal operating temp. ): 295 - 373 kPa (3.0 - 3.8 kg/cm , 42 - 54 psi.) at 4000 r / min. NOTE: The figure shown above is a guideline only, not an absolute service limit.
Page 53 2-27 PERIODIC MAINTENANCE (5) Remove bolt and No.1 ignition coil. (6) Connect special tool (H . T cord with plug cap adapter) be- tween No.1 ignition coil and spark plug. 09930-88720 : H . T cord with plug cap adapter (7) Attach engine tachometer to the special tool.
Page 54: Cylinder Compression
PERIODIC MAINTENANCE 2-28 CYLINDER COMPRESSION Cylinder compression : Standard : 1300 – 1600 kPa (13 - 16 kg / cm 185 – 228 psi.) Max. difference between any two cylinders : 100kPa (1.0 kg / cm , 14 psi.) NOTE: Figures shown are guidelines only, not absolute service limits.
Page 55: Engine Control System
ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM STRUCTURE ____________________ SYSTEM STRUCTURE 1 ................3-1 SYSTEM STRUCTURE 2 ................3-2 WIRING DIAGRAM FOR ENGINE CONTROL ..........3-3 COMPONENTS FOR SYSTEM CONTROL ______________________ ENGINE CONTROL MODULE (ECM) ............3-4 ECM CONNECTORS / TERMINALS LAYOUT ..........3-5 ECM INTERNAL STRUCTURE ...............
Page 56: Engine Control System Structure
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 INPUT CONTROL OUTPUT...
Page 57: System Structure 2
ENGINE CONTROL SYSTEM SYSTEM STRUCTURE 2...
Page 58: Wiring Diagram For Engine Control
ENGINE CONTROL SYSTEM WIRING DIAGRAM FOR ENGINE CONTROL No.1 No.2 No.3 Cyl. Cyl. Cyl. Spark plug Alternator Ignition Battery coil charge coil W W W Rectifier & Fuel injector regulator No.1 Cyl. IAC valve To PTT sw. No.2 Cyl. ENGINE main CONTROL No.3 Cyl.
Page 59: Components For System Control
ENGINE CONTROL SYSTEM 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 •...
Page 60: Ecm Connectors / Terminals Layout
ENGINE CONTROL SYSTEM ECM CONNECTORS / TERMINALS LAYOUT ECM CIRCUITS TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR No.2 Ignition (–) B/ W Ground for sensors Ground for power source Power source for MAP sensor No.3 Ignition (–) Lg/W Cylinder temperature sensor No.1 Fuel injector (–) Oil pressure switch No.1 Ignition (–)
Page 61: Ecm Internal Structure
ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE...
Page 62: Sensor And Switch
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.
Page 63 ENGINE CONTROL SYSTEM 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.
Page 64 ENGINE CONTROL SYSTEM 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.).
Page 65 ENGINE CONTROL SYSTEM 3-10 SENSOR (Optional item) The O sensor is installed in the exhaust manifold only when Zirconia element the O feedback operation is performed. Housing This sensor is a zirconia element (platinum plated) the output voltage of which changes depending on the oxygen concen- tration.
Page 66: Ignition System
3-11 ENGINE CONTROL SYSTEM IGNITION SYSTEM The ignition system used by the DF40/DF50 is a fully transistorized, electronic microcomputer timing ad- vanced type. On this system, power is totally supplied from the battery with the ECM controlling all ignition timing func- tions.
Page 67 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...
Page 68: Electronic Fuel Injection System
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.).
Page 69 ENGINE CONTROL SYSTEM 3-14 FUEL INJECTION TIMING CHART BTDC 65° on #1 exhaust stroke 120° 120° 120° 120° 60° CKP Sensor Signal 1 CKP Sensor Signal 2 CKP Sensor Signal 3 30° CMP Sensor Signal BTDC 545° on #1 Injection time duration exhaust stroke #1 Injection Signal #3 Injection Signal...
Page 70: Fuel Delivery System Components
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.
Page 71 ENGINE CONTROL SYSTEM 3-16 FUEL VAPOR SEPARATOR The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separa- tor 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.
Page 72 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 sepa- rator chamber by approx.
Page 73: Fuel Pump Control System
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.
Page 74: Air Intake Components
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.
Page 75: Idle Air Control System Outline
ENGINE CONTROL SYSTEM 3-20 BY-PASS AIR SCREW / PASSAGE Since the throttle valve is almost fully closed when idling/ troll- ing, 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 adjust- ing the total amount of air necessary for idling / trolling.
Page 76 3-21 ENGINE CONTROL SYSTEM Duty cycle signal for IAC valve (example : 20% duty) Battery charge “ON” time × 100 = duty (%) coil 1 cycle time main Rectifier & relay 20 ms regulator 30A fuse Sensor / switch signal input Time Ignition switch...
Page 77: Caution System
ENGINE CONTROL SYSTEM 3-22 CAUTION SYSTEM MONITOR-TACHOMETER 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 OVER-REV CAUTION CAUTION CAUTION LIMITER...
Page 78: Low Oil Pressure Caution System
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 / cm , 14 psi.). ACTION : Engine speed Automatically reduced to approx.
Page 79: Overheat Caution
ENGINE CONTROL SYSTEM 3-24 OVERHEAT CAUTION CONDITION 1 (Maximum temperature) Immediate activation of system when : (a) Cylinder temperature reaches 121°C (b) Exhaust manifold temperature reaches 121°C CONDITION 2 (Temp. rise Vs Time) Immediate activation of system when : (a) 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.
Page 80: Electrical
3-25 ENGINE CONTROL SYSTEM LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION : System 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.
Page 81: Self-Diagnostic System
ENGINE CONTROL SYSTEM 3-26 SELF-DIAGNOSTIC SYSTEM MONITOR-TACHOMETER The self-diagnostic system alerts the operator when an ab- normality 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.
Page 82 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”.
Page 83: Condition For Self-Diagnostic System Operation
ENGINE CONTROL SYSTEM 3-28 CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION FAILED ITEM CONDITION MAP sensor 1 • No signal (With engine running) • Receiving an out of range “37 – 860 mmHg (0.50 – 4.84V)” signal ( With engine running ) CKP sensor •...
Page 84: Fail-Safe System
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 pre- programmed value for the failed sensors. This allows the engine to continue running under the fail-safe condition.
Page 85: Operating Hour Indication System
ENGINE CONTROL SYSTEM 3-30 OPERATING HOUR INDICATION SYS- MONITOR-TACHOMETER 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.
Page 86: Start-In-Gear Protection System
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.
Page 87: O 2 Feedback System
ENGINE CONTROL SYSTEM 3-32 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 O sensor is temporally installed to the exhaust manifold.
Page 88: Inspection
3-33 ENGINE CONTROL SYSTEM INSPECTION PRECAUTION ON SYSTEM INSPECTION To prevent an unexpected engine start, perform the following before proceeding with any CRANK- ING tests. • When performing tests not related to fuel injector operation : • Disconnect all fuel injector wire connectors. •...
Page 89 ENGINE CONTROL SYSTEM 3-34 CIRCUIT VOLTAGE TABLE WIRE COLOR TER- STANDARD CIRCUIT CONDITION / REMARKS MINAL VOLTAGE ENGINE TEST CORD No.2 Ignition (–) Approx. 12V Ignition switch ON Ground for power source — — No.3 Ignition (–) Approx. 12V Ignition switch ON No.1 Fuel injector (–) Approx.
Page 90: Inspection For Resistance
3-35 ENGINE CONTROL SYSTEM INSPECTION FOR RESISTANCE 09930-99320 : Digital tester Tester range : W W W W W (Resistance) 4 5 6 9 10 11 12 5 6 7 8 1 2 3 (1) Turn ignition switch OFF. 1 2 3 4 (2) Disconnect battery cables from battery.
Page 91: Other Inspection
ENGINE CONTROL SYSTEM 3-36 NOTE1: Disconnect remote control wire harness, and connect tester probe to terminal (Gray wire). OTHER INSPECTION FUEL INJECTOR OPERATING SOUND (CRANKING) (1) Touch a sound scope or long blade screw driver to fuel in- jector body as shown. (2) Crank engine and check for injector operating sound.
Page 92 3-37 ENGINE CONTROL SYSTEM (3) Connect the tester probe (Red) to each terminal. (Voltage) Wire color Injector Terminal Engine Test cord No.1 No.2 (Time) Peak voltage reading (NEG) No.3 0V level for peak voltmeter (4) Crank engine and measure voltage. Fuel injector operating signal : 6 –...
Page 93 ENGINE CONTROL SYSTEM 3-38 CMP SENSOR SIGNAL 09930-89910 : 4-pin test cord Peak voltmeter Stevens CD-77 Tester range : POS 50 (1) Connect the test cord as shown, then turn ignition switch (2) Connect the tester probe (+) (Red) to terminal. Wire color Terminal Engine...
Page 94 3-39 ENGINE CONTROL SYSTEM MAP SENSOR OUTPUT VOLTAGE CHANGE 09917-47910 : 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.
Page 95 ENGINE CONTROL SYSTEM 3-40 OIL PRESSURE SWITCH 09940-44120 : Air pressure gauge 09821-00004 : Air pump Assy 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 conti- nuity.
Page 96: Troubleshooting
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.
Page 97 ENGINE CONTROL SYSTEM 3-42 CHART3 : SELF-DIAGNOSTIC CODE “3-1” START < Ignition switch “OFF” > Check IAC valve resistance. IAC valve failure Is result OK? (See page 3-35.) < Ignition switch “ON” > ECM failure Check “B4” terminal voltage. Is result OK? (See page 3-33.) Possible cause : •...
Page 98 3-43 ENGINE CONTROL SYSTEM CHART6 : SELF-DIAGNOSTIC CODE “1-4” START < Ignition switch “OFF” > Check cylinder temp. sensor resistance. Cylinder temp. sensor failure Is result OK? (See page 3-35.) Possible cause : • ECM failure • Wire continuity/connection failure CHART 7 : SELF-DIAGNOSTIC CODE “2-3”...
Page 99 ENGINE CONTROL SYSTEM 3-44 CHART9 : SELF-DIAGNOSTIC CODE “1-1” START < Individual check > Check rectifier & regulator resistance. Rectifier & regulator failure [NOTE1] Is result OK? (See page 4-3.) < Engine running > Check “B5” terminal voltage at idle speed.
Page 100 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. •...
Page 101 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” > < Individual check > (Always 0 V) Check “C8”...
Page 102: Removal / Installation
3-47 ENGINE CONTROL SYSTEM REMOVAL / INSTALLATION FLYWHEEL / CKP SENSOR / CMP SENSOR 200 N . m (20.0 kg-m, 145 lb.-ft.) Flywheel bolt Washer Flywheel CKP sensor Screw CMP sensor Bolt Crankshaft NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent.
Page 103 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 fly- wheel remover tools.
Page 104 3-49 ENGINE CONTROL SYSTEM INSTALLATION Installation is reverse order of removal with special attention to the following steps. CKP sensors Apply Thread Lock 1342 to the sensor mounting screws. 99000-32050 : Thread Lock 1342 Flywheel • Clean flywheel and crankshaft mating surfaces with cleaning solvent.
Page 105: Oil Pressure Switch
ENGINE 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. •...
Page 106 ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ______________________________ 4-1 OUTLINE ......................INSPECTION ....................REMOVAL / INSTALLATION ................ELECTRIC STARTER SYSTEM _______________________________ 4-6 OUTLINE ......................TROUBLESHOOTING ..................INSPECTION ....................4-11 STARTING MOTOR ..................MONITOR-TACHOMETER ___________________________________ 4-17 4-17 INSPECTION ....................
Page 107: Battery Charging System
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 cur- rent which is used to charge the battery.
Page 109 2. Measure resistance between leads in the combinations shown. NOTE: The values given below are for a SUZUKI digital tester. As thyristors, diodes, etc. are used inside this rectifier & regula- tor, the resistance values will differ when an ohmmeter other than SUZUKI digital tester is used.
Page 110: Removal / Installation
ELECTRICAL 4-4 REMOVAL / INSTALLATION System construction 200 N . m Bolt (1) (20.0 kg-m, 145 Ib.-ft.) Washer (1) Key (1) Flywheel (1) Battery charge coil (1) Screw (3) Rectifier & regulator (1) Bolt (2) Fuse case (1) 30A fuse (1) REMOVAL Prior to removing electrical parts : •...
Page 111 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 •...
Page 112: Electric Starter System
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. Starter motor To ECM main relay To Rectifier & regulator 30A Fuse To ECM Battery...
Page 113: Troubleshooting
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 Starter motor relay Sub cable Starter motor 30A Fuse...
Page 114: Inspection
ELECTRICAL 4-8 INSPECTION IGNITION SWITCH 09930-99320 : Digital tester Tester range : (Continuity) (OFF) 1. Disconnect the ignition switch from remo-con box wiring (ON) harness. 2. Check continuity between wiring leads at the key positions (START) shown in the chart. Switch Lead Wires Position Black Green White Gray Brown Orange...
Page 115 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 REVERSE FORWARD 1. Disconnect neutral switch lead wire from ignition switch and remo-con box wiring lead. 2.
Page 116 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 : W W W W W (Resistance) Tester probe connection Black Yellow / Green...
Page 117: Starting Motor
4-11 ELECTRICAL STARTING MOTOR REMOVAL Prior to removing starter motor : • Disconnect battery cables from battery. 1. Remove four bolts and flywheel cover. 2. Remove bolt and silencer case 3. Disconnect lead wire connector from IAT (Intake air tem- perature) sensor.
Page 118 ELECTRICAL 4-12 Stopper ring Pinion stopper (1) Spring (1) Pinion (1) Bolt (2) Front cover (1) Washer Washer Stator (1) Armature (1) Washer Rear cover (1) Nut (1) Washer (1) Washer (1) Screw Brush holder Brush Brush spring DISASSEMBLY NOTE: For correct assembly, scribe an alignment mark on the front cover, stator and rear cover.
Page 119 4-13 ELECTRICAL Push down the pinion stopper , remove stopper ring Remove pinion stopper , spring , and pinion Wear safety grasses when disassembling and assembling stopper ring. NOTE: Using a screw-driver, pry off the stopper ring. Remove two bolts Remove following parts : •...
Page 120 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 Measure commutator outside diameter. 09900-20101 : Vernier calipers Commutator outside diameter: Standard : 33mm (1.30 in.)
Page 121 4-15 ELECTRICAL Check for continuity between the commutator and the arma- Armature core Commutator ture core / shaft. Shaft Replace armature if continuity is indicated. Check for continuity between the adjacent commutator seg- ments. Replace armature if no continuity is indicated. 09930-99320 : Digital tester Tester range : (Continuity)
Page 122 When installing armature, exercise care to avoid break- ing 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 reassem- bling stopper ring.
Page 123: Monitor-Tachometer
4-17 ELECTRICAL MONITOR-TACHOMETER “CHECK ENGINE” TEMP “ ” INSPECTION OIL “ ” REV “LIMIT” 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. 09930- 89240).
Page 124 FUEL SYSTEM CONTENTS PRECAUTION ON FUEL SYSTEM SERVICE ____________________ 5-1 GENERAL PRECAUTION ................FUEL PRESSURE RELIEF PROCEDURE ............. FUEL LINE _______________________________________________ 5-3 REMOVAL / INSTALLATION ................FUEL LEAKAGE CHECK PROCEDURE ............FUEL HOSE CONNECTION ................FUEL PRESSURE INSPECTION ..............FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP______ 5-7 REMOVAL / INSTALLATION ................
Page 125: Precaution On Fuel System Service
5-1 FUEL SYSTEM PRECAUTION ON FUEL SYSTEM SERVICE GENERAL PRECAUTION Gasoline is extremely flammable and toxic. Always ob- serve the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing / inspection. •...
Page 126: Fuel Pressure Relief Procedure
FUEL 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.
Page 127: Fuel Line
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.
Page 128: Fuel Hose Connection
FUEL 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 “A”...
Page 129: Fuel Pressure Inspection
5-5 FUEL SYSTEM FUEL PRESSURE INSPECTION 1. Relieve fuel pressure in fuel feed line. (See page 5-2) 2. Connect special tools (pressure gauge, pressure hose & pressure joint) between fuel feed hose and 3-way joint pipe as shown in figure. Clamp hose securely to ensure no leaks occur during check- ing.
Page 130 FUEL SYSTEM 6. After checking fuel pressure, remove fuel pressure gauge. 7. Reconnect fuel line. 8. With engine not running and ignition switch “ON”, check fuel system for leaks.
Page 131: Fuel Vapor Separator / High Pressure Fuel Pump
5-7 FUEL SYSTEM FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP REMOVAL / INSTALLATION Removal The components after the high pressure fuel pump re- main pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. •...
Page 132: Disassembly
FUEL SYSTEM DISASSEMBLY Remove five screws Remove separator cover with high pressure fuel pump from separator case NOTE: Separator cover and case are a set. Make sure paint marks on both items are matched when as- sembling. Remove float pin and float Remove needle valve , screw, plate and valve seat...
Page 133: Inspection
5-9 FUEL SYSTEM Remove screw and pump bracket Remove high pressure fuel pump from separator cover and then disconnect pump lead wire connector. INSPECTION NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component. Needle valve / Valve seat Check needle valve and valve seat.
Page 134 FUEL SYSTEM 5-10 Filter Check pump suction filter. If clogged or damaged, clean or replace filter. Fuel pressure regulator Check fuel pressure regulator operation. 09821-00004 : Hand air pump 09940-44120 : Air pressure gauge 09940-44130 : Attachment 09912-58490 : Hose 1.
Page 135: Assembly
Install fuel pressure regulator and tighten screw securely. NOTE: Apply fuel to O-ring before installing regulator. 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: •...
Page 136: Fuel Injector
FUEL SYSTEM 5-12 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.
Page 137: Installation
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.
Page 138: Low Pressure Fuel Pump
FUEL SYSTEM 5-14 LOW PRESSURE FUEL PUMP REMOVAL / INSTALLATION REMOVAL 1. Disconnect inlet hose and outlet hose from low pres- sure fuel pump. 2. Remove two bolts 3. Remove fuel pump and O-ring INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Page 139: Disassembly / Reassembly
5-15 FUEL SYSTEM DISASSEMBLY / REASSEMBLY DISASSEMBLY NOTE: For correct assembly, scribe an alignment mark on each part of fuel pump. Remove six screws and remove in sequence the outer plate , diaphragm and valve body Turn piston until pin comes out through cutaway of pump body Remove following parts :...
Page 140: Inspection
FUEL SYSTEM 5-16 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 dam- age is found, replace fuel pump. Pump body Inspect each fuel pump body and outer plate. If cracks, nicks, distortion or damage is found, replace fuel pump.
Page 141: Fuel Tank
5-17 FUEL SYSTEM FUEL TANK DISASSEMBLY / REASSEMBLY When disassembly or reassembling fuel tank, refer to the construction diagram below. Plastic tank Steel tank –(a) –(b) Fuel hose assy (1) Connector plug (1) Tank cap (1) Screw (2)] Connector Outlet (1) Gasket (1) Float (1)] –(a),...
Page 142: Inspection
FUEL SYSTEM 5-18 INSPECTION Fuel connector Inspect fuel connector. If leakage,deterioration or other dam- age is found, replace fuel connector. 1. Connector 2. Connector plug 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.
Page 143 POWER UNIT CONTENTS INTAKE MANIFOLD ASSEMBLY _____________________________ 6-1 REMOVAL ......................INSTALLATION ....................POWER UNIT _____________________________________________ 6-3 REMOVAL ......................INSTALLATION ....................OIL PUMP / CASE _________________________________________ 6-10 6-10 REMOVAL ......................6-10 DISASSEMBLY ....................6-11 INSPECTION ....................6-11 MEASURING PUMP COMPONENTS ............6-12 ASSEMBLY ......................
Page 144: Intake Manifold Assembly
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.
Page 145: Installation
POWER UNIT 6-2 10. Remove two bolts and high pressure fuel filter 11. Disconnect lead wire connectors from all fuel injectors. 12. Remove four (4) bolts and Throttle body Remove IAC valve hose from Throttle body. 13. Remove bolts and nuts, and then remove intake manifold assembly INSTALLATION Installation is reverse order of removal with special attention to...
Page 146: Power Unit
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 Disconnect ignition coil connectors. Remove the bolt securing the ignition coil Remove all ignition coils and spark plugs.
Page 147 POWER UNIT 6-4 Remove battery charge coil . (See page 4-4) Disconnect CKP sensor connector and remove sensors Disconnect cylinder temperature sensor connector and remove sensor Remove two bolts and rectifier & regulator. Remove bolt and low pressure fuel filter bracket. Disconnect water hose from thermostat cover and engine holder.
Page 148 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 and clutch control lever Remove bolt and neutral switch with bracket. Remove two bolts securing front panel bracket Remove screw...
Page 149 POWER UNIT 6-6 Remove eight bolts and nut. Lift up and remove power unit from engine holder.
Page 150: Installation
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 : 23 N .
Page 151 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 Assemble new O-rings and cylinder head cover gasket to cylin- der head cover.
Page 152 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 opera- tion of the repaired unit. • All parts removed have been returned to their original posi- tions .
Page 153: Oil Pump / Case
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 hous- ing to oil pump case, then remove the under oil seal hous- ing.
Page 154: Inspection
6-11 POWER UNIT INSPECTION Oil seal Check oil seal lip for wear or other damage. Replace as necessary. Oil pump components Check outer and inner rotors, rotor plate and oil pump case for excessive wear or damage. Replace as necessary. 1.
Page 155: Assembly
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. 1.
Page 156 6-13 POWER UNIT Apply sealant to areas as shown in figure. 99000-31140 : Suzuki Bond 1207B Sealant Sealant 4. Apply a continuous bead of sealant to oil pump case mating surface as shown in figure. 99000-31140 : Suzuki Bond 1207B 5.
Page 157 POWER UNIT 6-14 6. Install dowel pin and gasket to oil pump case. 7. Apply grease to oil seal lip. 99000-25160 : Water Resistant Grease 8. Install under oil seal housing and tighten bolts.
Page 158: Timing Chain / Tensioner
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) Crankshaft / timing sprocket Timing chain Timing chain guide No.1 Timing chain tensioner Timing chain tensioner link Timing chain tensioner adjuster...
Page 159 POWER UNIT 6-16 5. Remove the bolt and timing chain tensioner 6. Remove the bolts and timing chain guide No.2 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.
Page 160: Inspection
6-17 POWER UNIT 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. Tensioner adjuster Inspect tensioner adjuster for smooth operation. Replace if faulty.
Page 161: Installation
POWER UNIT 6-18 INSTALLATION Installation is reverse of removal with special attention to fol- lowing steps. (1) Align crankshaft timing mark with timing mark crankcase as shown in figure by turning crankshaft. (2) Install dowel pin in intake camshaft. Then turn the camshaft to position the dowel pin at the top, as shown in figure.
Page 162 6-19 POWER UNIT (5) Install timing chain guide No.2 (6) Insert spacer into chain tensioner. Install chain tensioner as shown in figure. Apply oil to chain tensioner. (7) Install timing chain guide No.1 (8) With latch of tensioner adjuster returned and plunger pushed back into body, insert stopper into latch and body.
Page 163 POWER UNIT 6-20 (10) Install timing chain tensioner link (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.
Page 164: Cylinder Head Assembly
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) 1. Remove the bolts securing the camshaft housing to cylin- der head, then remove each camshaft housing.
Page 165 POWER UNIT 6-22 2. Position cylinder head on cylinder. 3. Apply engine oil to cylinder head bolts and tighten them gradually as follows. (a) Tighten all bolts to 30 N . m (3.0 kg-m, 21.5 lb.-ft.) ac- cording to numerical order in figure. (b) Loosen all bolts to 0 N .
Page 166 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 I : Intake side E : Exhaust side indicating position and direction of installation. Install housings as indicated by these marks.
Page 167: Disassembly
POWER UNIT 6-24 DISASSEMBLY 1. Remove tappets with shims. 2. Using valve lifter and attachment, remove valve cotters while compressing valve spring. 09916-14510 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers 3. Remove valve spring retainer , valve spring and valve 4.
Page 168: Inspection / Servicing
6-25 POWER UNIT INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component. CYLINDER HEAD Remove all carbon from combustion chambers. NOTE: • Do not use any sharp edged tool to scrape carbon off cylin- der head or its components.
Page 169 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 cyl- inder head.
Page 170 6-27 POWER UNIT Camshaft identification DF40 and DF50 camshafts differ as indicated below. Model Identification Groove No groove DF40 DF50 Groove Groove Camshaft runout Position camshaft between two “V” blocks and measure runout using a dial gauge. 09900-20606 : Dial gauge 09900-21304 : “V”...
Page 171 yy yy yy yy 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).
Page 172 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.
Page 173 POWER UNIT 6-30 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.
Page 174 6-31 POWER UNIT Valve stem end deflection If unable to measure valve guide inside diameter, check “Valve stem end deflection”. 09900-20606 : 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.
Page 175 POWER UNIT 6-32 Valve stem runout Measure valve stem runout. 09900-20606 : Dial gauge 09900-20701 : Magnetic stand 09900-21304 : “V” block set Valve stem runout Service limit : 0.05 mm (0.0020 in.) If measurement exceeds service limit, replace valve. Valve head radial runout Measure valve head radial runout.
Page 176 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. 09916-10910 : Valve lapper (5) Rotate valve while gently tapping valve contact area against seat.
Page 177 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° ° ° ° ° 45° Exhaust side : 15°...
Page 178 6-35 POWER UNIT NOTE: Clean and assemble cylinder head and valve components. Fill intake and exhaust ports with solvent to check for leaks be- tween valve seat and valve. If any leaks occur , inspect valve seat and face for burrs or other things that could prevent valve from sealing.
Page 179 POWER UNIT 6-36 (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.
Page 180 6-37 POWER UNIT VALVE SPRING Valve spring free length Check spring strength by measuring free length. 09900-20101 : Vernier calipers Valve spring free length Standard : IN & EX 33.13 mm (1.3043 in.) Service limit : IN & EX 31.80 mm (1.2520 in.) If lower than service limit, replace valve spring.
Page 181: Reassembly
POWER UNIT 6-38 REASSEMBLY Reassemble in reverse order of disassembly paying special attention to the following steps. VALVE Install valve spring seat to cylinder head. After applying engine oil to stem seal and spindle of special tool ( Installer attachment ), fit stem seal to spindle. Then, pushing special tool by hand, install stem seal to valve guide.
Page 182 6-39 POWER UNIT Hold valve spring compressed with special tool and install valve cotters Make sure valve cotters are properly seated in groove 09916-14510 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers...
Page 183: Cylinder / Crankshaft / Piston
POWER UNIT 6-40 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 the five (5) bolts securing the upper oil seal housing to cylinder, then remove the oil seal housing.
Page 184 6-41 POWER UNIT NOTE: For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint. Remove all conrod cap nuts and conrod caps NOTE: To prevent damage to crank pin and cylinder walls, install a Guide hose piece of hose over threads of rod bolts.
Page 185 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. Piston pin circlip Remove piston pin from conrod. NOTE: Reassemble each piston, piston pin and conrod in their original combination and position.
Page 186: Inspection / Servicing
6-43 POWER UNIT INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, 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.
Page 187 POWER UNIT 6-44 • 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 : •...
Page 188 6-45 POWER UNIT (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.
Page 189 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 Piston ring of carbon. Fit piston ring into piston groove, and measure clearance be- tween ring and ring groove using thickness gauge.
Page 190 6-47 POWER UNIT PISTON RING Piston ring end gap Measure piston ring end gap with piston ring in the lowest posi- Cylinder tion of cylinder bore. 09900-20803: Thickness gauge Piston ring end gap Piston ring Standard: 1 st 0.10 – 0.25 mm (0.0039 – 0.0098 in.) 2 nd 0.25 –...
Page 191 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.
Page 192 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.
Page 193 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.
Page 194 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.
Page 195 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.) 1. Thrust bearing Out - of - round and taper (uneven wear) of journals An unevenly worn crankshaft journal shows up as a differ- ence in diameter at a cross section or along its length (or both).
Page 196 6-53 POWER UNIT 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. CRANKSHAFT JOURNAL OIL CLEARANCE Check clearance using Plastigauge according to the following procedure.
Page 197 POWER UNIT 6-54 (5) Assemble crankcase to cylinder. Tightening order (6) Apply engine oil to crankcase bolts. Tighten crankcase bolts in three(3) steps following the or- der indicated below. Crankcase bolt: 5 N . m (0.5 kg-m, 3.6 lb.-ft.) 1st step 8 mm 11 N .
Page 198 6-55 POWER UNIT SELECTION OF MAIN BEARING Whenever a bearing requires replacement, select a new bear- No.2 Journal code ing according to following procedure. No.1 Journal code (1) First check journal diameter. As shown in figure, upper (flywheel side) crank web of No.1 Flywheel cylinder has four (4) stamped code numerals.
Page 199 POWER UNIT 6-56 (3) There are five (5) main bearings available, each of dif- fering 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 Color mark...
Page 200: Reassembly
6-57 POWER UNIT REASSEMBLY Assembly is reverse order of disassembly paying special atten- tion 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 Up mark “O”...
Page 201 POWER UNIT 6-58 PISTON RING TO PISTON Oil ring • Apply engine oil to piston rings. • Install spacer first, then side rails to piston. When installing spacer, do not allow ends to overlap in Incorrect groove. Correct 1st ring and 2nd ring •...
Page 202 6-59 POWER UNIT PISTON TO CYLINDER Install conrod bearing to conrod and conrod cap. • Assemble each conrod bearing to its original posi- tion. • Do not apply oil between conrod and bearing or be- tween bearing cap and bearing. Apply engine oil to piston and cylinder walls.
Page 203 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.
Page 204 Clean mating surface of cylinder and crankcase. Apply Bond to marked line 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. 99000-31030 : Suzuki Bond No.1104...
Page 205 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 crank- shaft rotates smoothly when turned by hand. Crankcase bolt 5 N .
Page 206 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)
Page 207: Thermostat
POWER UNIT 6-64 THERMOSTAT REMOVAL • Disconnect water hose from thermostat cover. • Remove the four (4) bolts securing the thermostat cover, then remove the cover and thermostat INSPECTION • If salt deposits, corrosion, wear or other damage is found, clean or replace.
Page 208: Operation
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 build- up or component damage.
Page 209: Engine Lubrication System
POWER UNIT 6-66 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.
Page 210 POWER TRIM AND TILT CONTENTS SYSTEM WIRING DIAGRAM _________________________________ 8-1 SERVICE PROCEDURE ____________________________________ 8-2 OIL LEVEL ....................... AIR BLEEDING ....................POWER TRIM AND TILT UNIT ________________________________ 8-3 REMOVAL ......................DISASSEMBLY ....................CLEANING AND INSPECTING ..............REASSEMBLY ....................8-10 PTT MOTOR..................... 8-14 INSTALLATION ....................
Page 211: System Wiring Diagram
8-1 POWER TRIM AND TILT SYSTEM WIRING DIAGRAM PTT switch PTT relay (UP) W tube PTT motor To ignition switch Remote control box PTT relay (DOWN) Starting motor relay PTT switch Battery...
Page 212: Service Procedure
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 3. Remove the oil filler plug 4. If oil can be seen at filler plug level, the unit is full. 5.
Page 213: Power Trim And Tilt Unit
8-3 POWER TRIM AND TILT POWER TRIM AND TILT UNIT REMOVAL Tilt engine fully up and lower the manual tilt lock levers During the following procedures, firmly secure the engine and support its weight. (see right) Remove the tilt rod snap ring and push tilt cylinder upper shaft pin out.
Page 214: Disassembly
POWER TRIM AND TILT 8-4 Remove the tilt pin Loosen the PTT cylinder lower shaft nut and remove the lower shaft bolt 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...
Page 215 8-5 POWER TRIM AND TILT Pull the tilt rod / piston assembly out of the cylinder body. Remove the free piston from the cylinder body Remove the PTT motor. Note the position of drive joint and O-ring , before remov- ing them.
Page 216: Cleaning And Inspecting
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 com- posed 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.
Page 217 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.
Page 218: Reassembly
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 and main check valve...
Page 219 8-9 POWER TRIM AND TILT Installing tilt rod / piston Free piston Pour 100 ml of PTT fluid into cylinder. Top OFF Insert the free piston into cylinder and push it down to the bot- tom of the cylinder. Cylinder Pour PTT fluid into the cylinder until it is topped off.
Page 220: Ptt Motor
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 and O-ring and remove them.
Page 221 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.
Page 222 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 re- placed .
Page 223 8-13 POWER TRIM AND TILT PTT Motor Installation Installation is reverse of removal with special attention to fol- lowing steps. • Ensure that the drive joint is aligned and firmly inserted into the gear pump assembly. • Fit O-ring to pump & reservoir. •...
Page 224: Installation
POWER TRIM AND TILT 8-14 INSTALLATION Installation is reverse of removal with special attention to fol- lowing steps. Lower tilt rod full down position. Apply Water Resistant Grease to the tilt cylinder lower shaft and lower shaft bushes 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.
Page 225 8-15 POWER TRIM AND TILT Apply Water Resistant Grease to the PTT rod upper shaft then insert the shaft through the swivel bracket and tilt rod. 99000-25160 : Water Resistant Grease Secure the upper shaft with the snap ring Route the PTT motor cable in through the lower cover and con- nect the terminals to the PTT relays.
Page 226: Ptt Motor Relay
POWER TRIM AND TILT 8-16 PTT MOTOR RELAY Two methods can be used to test PTT relays. Method 1. Lbl(P) Measure resistance between wiring leads of the relay. 09930-99320 : Digital tester Tester range : W W W W W (Resistance) Tester probe connection Red (+) Black (–)
Page 227: Ptt Switch
8-17 POWER TRIM AND TILT PTT SWITCH Test continuity between the wires at each of the three switch (W/R) positions. 09930-99320 : Digital tester Tester range : (Continuity) Tester probe connection Tester indicates Red (+) Black (–) “DN” side Gray Pink Continuity depressed...
Page 228: Operation
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”.
Page 229: Principles Of Operation
8-19 POWER TRIM AND TILT PRINCIPLES OF OPERATION TRIM/TILT “UP” CIRCUIT The electric motor is operating in a clockwise direction. Check valve 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.
Page 230 POWER TRIM AND TILT 8-20 TRIM/TILT “DOWN” CIRCUIT The electric motor is operating in a counterclockwise direction. Check valve 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”...
Page 231 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.
Page 232 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.
Page 233 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.
Page 234 LOWER UNIT CONTENTS REMOVAL & DISASSEMBLY ________________________________ 9-1 PINION BEARING _________________________________________ 9-5 INSPECTION _____________________________________________ 9-7 PROPELLER....................GEARCASE ..................... GEAR ....................... PROPELLER SHAFT COMPONENTS ............PROPELLER SHAFT BEARING HOUSING ..........SHIFT ROD AND SHIFT CAM ................ WATER PUMP AND RELATED ITEMS ............9-10 DRIVESHAFT BEARING HOUSING ..............
Page 235: Removal & Disassembly
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 , then unscrew the turnbuckle Remove six(6) bolts and separate gearcase from driveshaft housing.
Page 236 LOWER UNIT 9-2 Loosen the four(4) nuts , then remove the water pump case , impeller , and pump under plate Keep the impeller key for reuse and discard the plate gas- ket. Remove the two (2) bolts securing the propeller shaft bear- ing housing to the gearcase.
Page 237 9-3 LOWER UNIT To separate the bearing housing from the gearcase, use two (2) 8mm bolts 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 Remove the forward gear (with thrust washer , back-up...
Page 238 LOWER UNIT 9-4 Remove the spring collar and two driveshaft thrust washers from the gear case. Slide the shift rod out of the shift rod guide. Separate the shift cam from the shift rod by driving out the spring pin Remove the lower shift rod guide by driving out the spring Remove the snap ring...
Page 239: Pinion Bearing
9-5 LOWER UNIT (c) Use special tool to push the dog pin out of the clutch dog shifter. 09922-89810 : Shift pin remover (d) Remove the clutch dog shifter , push pin , and return spring from propeller shaft. PINION BEARING Removal &...
Page 240 LOWER UNIT 9-6 2. Place the attachment inside the pinion bearing. 3. Insert the removal shaft into attachment. 4. Thread sliding hammer into top of removal shaft. 5. Put wood block under pinion bearing. 6. Drive the pinion bearing out by striking top of shaft with slid- ing hammer.
Page 241: Inspection
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 •...
Page 242: Gear
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. •...
Page 243: Shift Rod And Shift Cam
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. 3. Using an oil seal installer, drive the two oil seals (one at a time ) into the propeller shaft bearing housing.
Page 244: Driveshaft Bearing Housing
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.
Page 245: Driveshaft
9-11 LOWER UNIT DRIVESHAFT Inspect driveshaft / splines. Replace if worn, twisted or dam- aged. Inspect driveshaft bearing, replace if pitted, noisy or rough.
Page 246: Assembly & Installation
LOWER UNIT 9-12 ASSEMBLY & INSTALLATION Assembly & Installation are reverse of disassembly with spe- cial attention to following steps. Dust boot Shift rod guide O-ring Oil seal O-ring Circlip Shift rod Magnet set Shift rod lower guide Shift cam Ball Spring Notch plate...
Page 247 9-13 LOWER UNIT 55 N . m (5.5 kg-m, 40.0 lb.-ft.) 17 N . m (1.7 kg-m, 12.3 lb.-ft.) 50 N . m (5.0 kg-m, 36.2 lb.-ft.) 13 N . m (1.3 kg-m, 9.5 lb.-ft.) Dog pin Dog spring Return spring Propeller shaft Thrust washer Reverse gear...
Page 248 LOWER UNIT 9-14 • Make sure that all parts used in assembly are clean and lubricated. • After assembly, check parts for tightness and smooth- ness of operation. • Before final assembly, be absolutely certain that all gear contact, shim adjustments and tolerances are correct.
Page 249 Place the forward gear bearing and back-up shim in posi- tion, then install forward gear 99000-22540 : Suzuki Outboard Motor Gear Oil DRIVESHAFT THRUST WASHERS Install the two driveshaft thrust washers The lower washer( with the tab) is located as shown.
Page 250 99000-25160 : Water Resistant Grease Install the gearcase seal ring 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.
Page 251 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...
Page 252 , reverse gear back-up shim and propeller shaft housing 99000-25160 : Water Resistant Grease 99000-22540 : Suzuki Outboard Motor Gear Oil Using special tools, install the propeller shaft and housing as- sembly in the gear case. 09922-59410 : Propeller shaft housing installer...
Page 253 9-19 LOWER UNIT CHECKING PROPELLER SHAFT THRUST PLAY See the “GEARS - SHIMMING AND ADJUSTMENT / CHECK- ING PROPELLER SHAFT THRUST PLAY” section on page 9- LEAKAGE CHECK To check for oil seal or o-ring leakage, use oil leakage tester. Before leakage check, temporarily fasten the driveshaft bear- ing housing to gearcase using two bolts and nuts (placed through the two diagonally opposite gearcase mounting holes).
Page 254 LOWER UNIT 9-20 WATER PUMP ( Impeller & Case ) Place the under panel gasket and under panel into posi- tion. Insert the key in the driveshaft and slide the impeller onto driveshaft, ensuring that key and keyway are aligned. Install the pump case while rotating driveshaft clockwise to flex the impeller vanes in the correct direction.
Page 255 LOWER UNIT INSTALLATION Insert dowel pins 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 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.
Page 256: Trim Tab
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. Chamfered edge Adjustment step : 1. Shift the clutch lever from Neutral through Forward and Re- verse to check that proper engagement of both gears is at an equal angle from Neutral.
Page 257: Lower Unit Gears-Shimming And Adjustment
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 Design Available Numerical...
Page 258 LOWER UNIT 9-24 Adjusting gear backlash 1. Screw gear adjusting gauge into the oil drain hole. 09951-09510 : Gear adjusting gauge When adjusting gauge, align the gauge rod end to con- tact the gear tooth at the convex side (heel end). Make sure the rod does not contact the adjacent tooth.
Page 259 9-25 LOWER UNIT 5. Carefully pull out propeller shaft and housing to check tooth Concave side contact pattern. Tooth width Convex side Heel TOOTH Tooth top CONTACT PATTERN Tooth bottom Optimum tooth contact Optimum tooth contact The optimum tooth contact is shown at right. approx.
Page 260 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. 09951-09510 : Gear adjusting gauge 2. Slowly push driveshaft downward. Read the maximum play. Designate this amount of play as (A).
Page 261 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 ad- justment is required. Propeller shaft thrust play : 0.2 – 0.4 mm (0.008 –...
Page 262 WIRE / HOSE ROUTING CONTENTS WIRING DIAGRAM _________________________________________ 10-1 WIRE ROUTING ___________________________________________ 10-2 FUEL / WATER HOSE ROUTING______________________________ 10-7...
Page 263: Wiring Diagram
10-1 WIRE / HOSE ROUTING WIRING DIAGRAM DF40T / DF50T...
Page 264 Clamp Fix Ex. mani. temp. Clamp sensor lead wire. Fix battery charge coil lead wire. Ex-mani. temperature sensor 30A Fuse Clamp Communication Fix rectifier & connector / cap regulator lead wire PTT motor relay (UP) PTT motor cable Rectifier & regulator PTT relay plate ECM main relay...
Page 265 10-3 WIRE / HOSE ROUTING...
Page 266 WIRE / HOSE ROUTING 10-4...
Page 267 10-5 WIRE / HOSE ROUTING Starter motor Tighten bolt with PTT relay ground wire, battery cable ground wire and harness ground wire. CTP switch Starter motor sub cable IAC valve Battery cable IAT sensor grommet IAT sensor Wiring harness Battery cable Battery cable Route battery cable on fuel hose...
Page 268 PTT switch Trim sender cable Clamp Bind the trim sender cable and PTT motor cable. PTT motor cable PTT attachment Fix PTT cable and trim sender lead to clamp bracket. Clamp Trim sender...
Page 269: Fuel / Water Hose Routing
10-7 WIRE / HOSE ROUTING 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. •...
Page 270 WIRE / HOSE ROUTING 10-8...
Page 271 10-9 WIRE / HOSE ROUTING Fuel hose / Protector (H fuel filter to 3-way joint) MAP sensor High pressure fuel filter Fuel hose MAP sensor hose (H fuel filter to vapor separator) Clamp Throttle body IAC hose 3-way joint Gas filter Vapor separator IAC valve silencer Fuel hose / Protector...
Page 325 OUTBOARD MOTOR For 2006 and 2007 models SUPPLEMENTARY SERVICE MANUAL 9 9 5 0 1 - 8 7 J 5 0 - 0 1 E...
Page 326 DF40/50 “K6” (’06) MODEL DF40/50 “K6” (2006) MODEL FOREWORD This supplementary service manual describes the outline, technical data and servicing proce- dures for the “K6” (2006) models outboard motor. Please read and throughly familiarize yourself with this information before using it for your ser- vice activities.
Page 327: Specifications (Df40T/Df40Qh/Df50T/Df50Th)
DF40/50 “K6” (’06) MODEL SPECIFICATIONS (DF40T/DF40QH/DF50T/DF50TH) Data Item Unit DF40T DF40QH DF50T DF50TH PRE-FIX 04001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 756 (29.8) 852 (33.5) 756 (29.8) 852 (33.5) Overall width (side to side) mm (in) 382 (15.0) Overall height mm (in)
Page 328 DF50T DF50TH FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equiva- lent octane content may be used.
Page 329: Specifications (Df50Wt/Df50Wqh)
DF40/50 “K6” (’06) MODEL SPECIFICATIONS (DF50WT/DF50WQH) Data Item Unit DF50WT DF50WQH PRE-FIX 05001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 756 (29.8) 852 (33.5) Overall width (side to side) mm (in) 382 (15.0) Overall height mm (in) 1 263 (49.7) —...
Page 330 DF50WT DF50WQH FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equiva- lent octane content may be used.
Page 331: Service Data
DF40/50 “K6” (’06) MODEL SERVICE DATA Data Item Unit DF40 DF50 POWERHEAD Recommended Except E01 5 200 – 5 800 r/min 5 900 – 6 500 operating range 5 600 – 6 200 Idle speed r/min 850 ± 50 (in-gear: approx. 850) **Cylinder compression 1 300 –...
Page 332 DF40/50 “K6” (’06) MODEL Data Item Unit DF40 DF50 CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height *37.530 – 37.690 38.230 – 38.390 mm (in) (1.4776 – 1.4839) (1.5051 –...
Page 333 DF40/50 “K6” (’06) MODEL Data Item Unit DF40 DF50 VALVE/VALVE GUIDE Valve diameter mm (in) 24.6 (0.97) mm (in) 21.5 (0.85) Tappet clearance mm (in) 0.18 – 0.24 (0.007 – 0.009) (Cold engine condition) mm (in) 0.18 – 0.24 (0.007 – 0.009) Valve seat angle —...
Page 334 DF40/50 “K6” (’06) MODEL Data Item Unit DF40 DF50 CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.060 (0.0024) Piston to cylinder clearance mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 71.000 – 71.020 (2.7953 – 2.7961) Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface...
Page 335 DF40/50 “K6” (’06) MODEL Data Item Unit DF40 DF50 CRANKSHAFT/CONROD Conrod small end inside mm (in) 18.003 – 18.011 (0.7088 – 0.7091) diameter Conrod big end oil clearance STD mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Limit mm (in) 0.065 (0.0026) Conrod big end inside mm (in)
Page 336 DF40/50 “K6” (’06) MODEL Data Item Unit DF40 DF50 ELECTRICAL Ignition timing Except E01 ATDC 1° – BTDC 27° ATDC 1° – BTDC 24° Degrees ATDC 1° – BTDC 19° ATDC 1° – BTDC 23° Over revolution limiter Except E01 6 500 r/min 6 700...
Page 337 DF40/50 “K6” (’06) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 4.8 (0.19) Commutator outside mm (in) 22.0 (0.87) diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 338: Periodic Maintenance Schedule
DF40/50 “K6” (’06) MODEL 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.
Page 339: Ecm
DF40/50 “K6” (’06) MODEL The ECM has been changed in program. FUEL FILTER A new style fuel filter will be used that provides a drain feature. This new filter requires several new components shown below and a new mounting bracket to retain the fil- ter onto the outboard.
Page 340: Intake Manifold
DF40/50 “K6” (’06) MODEL IAC HOSE ROUTING IAC hose clamp Clamp bolt Hose clamp IAC hose IAC hose clamp INTAKE MANIFOLD The intake manifold has been changed in shape and the plug and gasket have been eliminated. Plug Gasket...
Page 341: Piston
DF40/50 “K6” (’06) MODEL PISTON The alumite treatment has newly been added to the 1st ring groove on the piston. The location of the 1st ring groove has also been changed. WATER PUMP CASE UNDER GASKET The water pump case under gasket has been changed in shape. Thickness of gasket has been changed from 0.5 mm to 0.6 mm.
Page 342: Wiring Diagram
DF40/50 “K6” (’06) MODEL WIRING DIAGRAM DF40T/DF50T/DF50WT (REMOTE CONTROL MODEL)
Page 343 DF40/50 “K6” (’06) MODEL DF50TH (TILLER HANDLE MODEL)
Page 344 DF40/50 “K6” (’06) MODEL DF40QH/DF50QH/DF50WQH (TILLER HANDLE MODEL)
Page 345: Fuel Hose Routing
DF40/50 “K6” (’06) MODEL FUEL HOSE ROUTING Clamp Breather hose Water return hose Fuel hose/Protector (Fuel filter to L·fuel pump) IAC hose Fuel filter Hose clamp Water hose (3-way joint to Clamp Pilot water hole) Water hose (Engine holder to 3-way joint) Water hose (Engine holder to Vapor separator) Fuel hose (Vapor separator to H·fuel filter...
Page 346 DF40/50 “K6” (’06) MODEL High pressure fuel filter Fuel hose/Protector (H filter to 3-way joint) Low pressure fuel pump Clamp Fuel filter 3-way joint Fuel hose/Protector (Fuel filter to low Fuel hose/Protector fuel pump) (3-way to vapor separator) 3-way Water hose (3-way to pilot water hole)
Page 347 DF40/50 “K6” (’06) MODEL Fuel hose/Protector (H·fuel filter to 3-way joint) MAP sensor High pressure fuel filter Fuel hose (H·fuel filter to MAP sensor hose vapor separator) Throttle body IAC hose 3-way joint Gas filter Vapor separator Fuel hose/Protector IAC valve (3-way joint to vapor separator) silencer IAC valve...
Page 348 DF40/50 “K7” (’07) MODEL DF40/50 “K7” (2007) MODEL FOREWORD This supplementary service manual describes the outline, technical data and servicing proce- dures for the “K7” (2007) models outboard motor. Please read and throughly familiarize yourself with this information before using it for your ser- vice activities.
Page 349: Specifications (Df40T/Df40Qh/Df50T/Df50Th)
DF40/50 “K7” (’07) MODEL SPECIFICATIONS (DF40T/DF40QH/DF50T/DF50TH) Data Item Unit DF40T DF40QH DF50T DF50TH PRE-FIX 04001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 756 (29.8) 852 (33.5) 756 (29.8) 852 (33.5) Overall width (side to side) mm (in) 382 (15.0) Overall height mm (in)
Page 350 DF50T DF50TH FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equiva- lent octane content may be used.
Page 351: Specifications (Df50Wt/Df50Wqh)
DF40/50 “K7” (’07) MODEL SPECIFICATIONS (DF50WT/DF50WQH) Data Item Unit DF50WT DF50WQH PRE-FIX 05001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 756 (29.8) 852 (33.5) Overall width (side to side) mm (in) 382 (15.0) Overall height mm (in) 1 263 (49.7) —...
Page 352 DF50WT DF50WQH FUEL & OIL Fuel Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 ((R+M)/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equiva- lent octane content may be used.
Page 353: Service Data
DF40/50 “K7” (’07) MODEL SERVICE DATA Data Item Unit DF40 DF50 POWERHEAD Recommended Except E01 5 200 – 5 800 r/min 5 900 – 6 500 operating range 5 600 – 6 200 Idle speed r/min 850 ± 50 (in-gear: approx. 850) **Cylinder compression 1 300 –...
Page 354 DF40/50 “K7” (’07) MODEL Data Item Unit DF40 DF50 CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height *37.530 – 37.690 38.230 – 38.390 mm (in) (1.4776 – 1.4839) (1.5051 –...
Page 355 DF40/50 “K7” (’07) MODEL Data Item Unit DF40 DF50 VALVE/VALVE GUIDE Valve diameter mm (in) 24.6 (0.97) mm (in) 21.5 (0.85) Tappet clearance mm (in) 0.18 – 0.24 (0.007 – 0.009) (Cold engine condition) mm (in) 0.18 – 0.24 (0.007 – 0.009) Valve seat angle —...
Page 356 DF40/50 “K7” (’07) MODEL Data Item Unit DF40 DF50 CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in) 0.060 (0.0024) Piston to cylinder clearance mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 71.000 – 71.020 (2.7953 – 2.7961) Cylinder measuring position mm (in) 50 (2.0) from cylinder top surface...
Page 357 DF40/50 “K7” (’07) MODEL Data Item Unit DF40 DF50 CRANKSHAFT/CONROD Conrod small end inside mm (in) 18.003 – 18.011 (0.7088 – 0.7091) diameter Conrod big end oil clearance STD mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Limit mm (in) 0.065 (0.0026) Conrod big end inside mm (in)
Page 358 DF40/50 “K7” (’07) MODEL Data Item Unit DF40 DF50 ELECTRICAL Ignition timing Except E01 ATDC 1° – BTDC 27° ATDC 1° – BTDC 24° Degrees ATDC 1° – BTDC 19° ATDC 1° – BTDC 23° Over revolution limiter Except E01 6 500 r/min 6 700...
Page 359 DF40/50 “K7” (’07) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 4.8 (0.19) Commutator outside mm (in) 22.0 (0.87) diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 360: Tightening Torque
DF40/50 “K7” (’07) MODEL TIGHTENING TORQUE * Tightening torque has been changed Tightening torque – Important fasteners from the 2007 year model. THREAD TIGHTENING TORQUE ITEM DIAMETER N·m kg-m Ib-ft Cylinder head cover bolt 6 mm Cylinder head bolt 10 mm 43.5 Crankcase bolt 8 mm...
Page 361: Periodic Maintenance Schedule
DF40/50 “K7” (’07) MODEL 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.
Page 362: Ecm
DF40/50 “K7” (’07) MODEL The warning memory condition program on ECM has been changed. SILENCER The silencer, silencer seal, flame arrester, bolt and washer have been changed in shape. The number of washer has been changed from 2 to 1. The clamp has been added.
Page 363: Tiller Handle (Df40Qh, Df50Qh And Df50Wqh)
• Apply the thread lock to the tiller handle pivot bolt. ! 99000-32050: THREAD LOCK “1342” • Apply the water resistant grease to the bush. " 99000-25160: SUZUKI WATER RESISTANT GREASE 2. The tiller handle pivot bolt is tightened first to the specified torque.
Page 364 DF40/50 “K7” (’07) MODEL Installation on steering bracket # Tiller handle mounting stud bolt: 25 N·m (2.5 kg-m, 18.0 lb-ft) # Tiller handle mounting lock nut: 50 N·m (5.0 kg-m, 36 lb-ft) Lock nut Stud bolt Washer Tiller handle bracket Clamp View of A Tiller handle...
Page 365: Clutch Shaft Arm And Clutch Shaft Side Arm
DF40/50 “K7” (’07) MODEL CLUTCH SHAFT ARM AND CLUTCH SHAFT SIDE ARM The clutch shaft arm and clutch shaft side arm have been changed in shape. The screw has been changed to bolt. Screw Bolt Screw Bolt 4 mm 6 mm Clutch shaft arm Clutch shaft side arm DETENT SPRING AND SHIFT CAM...
Page 366: Engine Side Cover
DF40/50 “K7” (’07) MODEL ENGINE SIDE COVER The side covers and securing screws have been changed in shape. 25 mm 14 mm 30 mm 35 mm marked portion 7.2 mm 7.0 mm 5.7 mm 6.2 mm 15 mm 21 mm Starboard side cover Port side cover...
Page 367 repared by Service Department March, 2007 Manual No.99501-87J50-01E rinted in Japan...
Page 368 Printed in Japan K6, K7...
Page 369 OUTBOARD MOTOR 99501-87J00-01E...
Page 370 FORWARD This supplementary service manual describes the outline, technical data and servicing procedures for the DF40QH/DF50QH outboard motor. Please read and thoroughly familiarize yourself with this information before using it for your service activities. NOTE: Use this supplement with the following service manual: DF40/50 Service Manual ( P/no, 99500-87J00-01E) CONTENTS GENERAL INFORMATION ___________________________________________...
Page 371 Apply THREAD LOCK SUPER otherwise specified. “1333B”. Apply SUZUKI OUTBOARD Measure in DC voltage range. MOTOR GEAR OIL. Apply SUZUKI SUPER GREASE “A”. Measure in resistance range. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”.
Page 372: General Information
DF40QH / DF50QH GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the sym- bol 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.
Page 373 DF40QH / DF50QH • 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.
Page 374: Specifications
DF40QH / DF50QH SPECIFICATIONS Data Item Unit DF40QH DF50QH PRE-FIX 04001F 05001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in.) 852 (33.5) Overall width (side to side) mm (in.) 382 (15.0) Overall height mm (in.) 1263 (49.7) mm (in.) 1390 (54.7) Weight kg (Ib.)
Page 375: Lower Unit
Engine oil amounts 2.2 (2.3/1.9) : Oil change only L (US/Imp. qt) 2.4 (2.5/2.1) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/Imp. oz) 610 (20.6/21.5) BRACKET Trim angle...
Page 376: Service Data
DF40QH / DF50QH SERVICE DATA Data Item Unit DF40QH DF50QH POWERHEAD r/min 5200 – 5800 Recommended operating range 5900 – 6500 Idle speed r/min 850 ± 50 (in-gear: approx.850±50) **Cylinder compression kPa (kg/cm . psi) 1300 – 1600 (13 – 16, 185 – 228) **Cylinder compression max.
Page 377 DF40QH / DF50QH Data Item Unit DF40QH DF50QH ENGINE OIL PUMP Limit mm (in.) 0.31 (0.0122 in.) Radial clearance Limit mm (in.) 0.15 (0.0059 in.) Side clearance CYLINDER HEAD / CAMSHAFT Limit mm (in.) 0.05 (0.002) Cylinder head distortion Manifold seating Limit mm (in.) 0.10 (0.004)
Page 378 DF40QH / DF50QH Data Item Unit DF40QH DF50QH VALVE / VALVE GUIDE mm (in.) 24.6 (0.9685) Valve diameter mm (in.) 21.5 (0.8465) Tappet clearance 0.18 – 0.24 (0.007 – 0.009) mm (in.) (Cold engine 0.18 – 0.24 (0.007 – 0.009) mm (in.) condition) Valve seat...
Page 379 DF40QH / DF50QH Data Item Unit DF40QH DF50QH CYLINDER / PISTON / PISTON RING Limit mm (in.) 0.06 (0.0024) Cylinder distortion mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in.) 0.100 (0.0039) mm (in.) 71.000 –...
Page 380 DF40QH / DF50QH Data Item Unit DF40QH DF50QH CRANKSHAFT / CONROD Conrod small end mm (in.) 18.003 – 18.011 (0.7088 – 0.7091) inside diameter mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance Limit mm (in.) 0.065 (0.0026) Conrod big end mm (in.)
Page 381 DF40QH / DF50QH Data Item Unit DF40QH DF50QH ELECTRICAL Degrees at r/min Ignition timing BTDC 0° – BTDC 32° BTDC 0° – BTDC 25° r/min 6500 7000 Over revolution limiter 168 – 252 at 20°C CKP sensor resistance —— CMP sensor resistance at 20°C Primary 1.9 –...
Page 382: Tightening Torque
DF40QH / DF50QH TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib.-ft. Cylinder head cover bolt 6 mm Cylinder head bolt 43.4 10 mm Crankcase bolt 8 mm 18.1 10 mm 38.3 Conrod cap nut 8 mm 25.3...
Page 383 DF40QH / DF50QH Tightening torque – general bolt NOTE: These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N . m kg-m Ib.-ft. 5 mm 2 –...
Page 384: Special Tools
DF40QH / DF50QH SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) 09821-00004 09900-00410 Hexagon socket Hexagon bit Air pump Assy Hexagon wrench set (included in 09900-00410) (included in 09900-00410) (A) 09900-06107 09900-20101 (150 mm) (B) 09900-06108 09900-20102 (200 mm) 09900-20202 09900-20203 Snap ring pliers...
Page 385 DF40QH / DF50QH 09915-64510 Compression gauge 09915-47340 09915-63210 09915-77310 09915-78211 Oil filter wrench Adaptor Oil pressure gauge Oil pressure gauge adapter 09916-10910 09916-14510 09916-14910 09916-24450 Valve lapper Valve lifter Valve lifter attachment Solid pilot (N-100-5.52) 09916-24440 09916-20630 09916-20620 Handle adaptor 09916-24980 Valve seat cutter Valve seat cutter...
Page 386 DF40QH / DF50QH 09922-89810 09930-30161 09930-30102 09930-39411 Shift lock pin remover Propeller shaft remover Sliding hammer Flywheel rotor remover 09930-39420 09930-48720 09930-76420 09930-89240 Rotor remover bolt Flywheel holder Timing light 4-pin connector test cord 09930-89260 09930-89910 09930-89920 09930-89930 Injector test cord A 4-pin connector test cord 6-pin connector test cord 8-pin connector test cord...
Page 387: Materials Required
99000-25010 99000-25160 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1104” SUZUKI BOND “1207B” THREAD LOCK “1342” 4-Stroke Motor Oil * 99104-33140 99000-31030 99000-31140 99000-32050 API : SE, SF, SG, SH, SJ (100 g)
Page 388: Wiring Diagram
DF40QH / DF50QH WIRING DIAGRAM DF40QH/ DF50QH...
Page 389: Engine Control System
DF40QH / DF50QH ENGINE CONTROL SYSTEM The engine control systems such as ignition and fuel injec- tion are basically the same as DF40/50T model specification except for the following: Caution / Diagnostic System Buzzer ON/OFF pattern Caution and Diagnostic system operator alert signals are audio A.
Page 390: Engine Speed Control During Shifting
DF40QH / DF50QH Engine speed control during shifting On QH-specification models, a special safety feature to con- trol engine speed during shifting has been added. This fea- ture fixes the upper limit of engine speed during shifting to a preset value of 1500 r/min. [ Operation ] If the CTP switch is “OFF”...
Page 391: Mid Unit
DF40QH / DF50QH MID UNIT TILLER HANDLE Functions The tiller handle is equipped with the following centralized component parts necessary for proper operation and han- dling. 1Ignition switch 2Emergency stop switch 3Shift lever 4Throttle control grip 5Throttle friction adjust knob REMOVAL 1.
Page 392: Disassembly
DF40QH / DF50QH 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.
Page 393 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.
Page 394 DF40QH / DF50QH Remove the two bolts M securing the clutch link N to tiller handle housing, then remove clutch link and spacer O.
Page 395: Assembly
DF40QH / DF50QH ASSEMBLY Assembly is reverse order of disassembly. When reassembling tiller handle, refer to the construction diagram below . 1.Tiller handle housing 12.Screw 23.Screw 2.Handle grip 13.Washer 24.Throttle cable 3.Lower cover 14.Handle rod stopper 25. E-ring 4.Screw 15.Spring 26.Bolt 5.Cable grommet 16.Bush...
Page 396: Installation
DF40QH / DF50QH 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. •...
Page 397 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.
Page 398 DF40QH / DF50QH • 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.
Page 399 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 di- rection shown by the arrow H to remove all play in the cable.
Page 400 DF40QH / DF50QH 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. •...
Page 401: Tilt Aid System
DF40QH / DF50QH TILT AID SYSTEM The DF40QH/50QH models are equipped with a tilt aid cylin- der 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 ex- pands as the cylinder rod extends, thereby assisting the manual tilting process.
Page 402: Inspection
DF40QH / DF50QH 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 re- quired. Nut should only be loosened as far as the end of the shaft threads to facilitate removal of the tilt aid gas cylinder.
Page 403: Installation
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. INSTALLATION Installation is reverse order of removal with special attention to following steps. 43 N . m (4.3 kgf .
Page 404 Apply grease to each bush, cylinder lower shaft and cylinder upper shaft. Install bushes 1, 2 and cylinder lower shaft 3. l 99000-25160 : Suzuki Water Resistant Grease Place the tilt aid gas cylinder in position between the clamp brackets.
Page 405 Prepared by Marine & Power Products Division 1 st Ed. January, 1999 Manual No.99501-87J00-01E Printed in Japan...

This manual is also suitable for:

Df 50

Suzuki DF 40 Service Manual

General Information 1

Periodic Maintenance 2

Periodic Maintenance Schedule

Maintenance and Tune-Up Procedures

Oil Pressure

Cylinder Compression

Engine Control System

Electrical

Battery Charging System

Electric Starter System

Monitor-Tachometer

Fuel System

Precaution on Fuel System Service

Fuel Line

Fuel Vapor Separator / High Pressure Fuel Pump

Fuel Injector

Low Pressure Fuel Pump

Fuel Tank

Inspection

Power Unit

Intake Manifold Assembly

Power Unit

Oil Pump / Case

Timing Chain / Tensioner

Cylinder Head Assembly

Cylinder / Crankshaft / Piston

Thermostat

Operation

Power Trim and Tilt

System Wiring Diagram

Service Procedure

Power Trim and Tilt Unit

Ptt Motor Relay

Ptt Switch

Operation

Lower Unit

Removal & Disassembly

Pinion Bearing

Inspection

Assembly & Installation

Trim Tab

Lower Unit Gears-Shimming and Adjustment

Df40150 "K5" (2005) Model .

Df40/50 "K6" (2006) Model

Df40/50 "K7" (2007) Model

Forward

General Information

Specifications

Service Data

Tightening Torque

Special Tools

Materials Required

Wiring Diagram

Engine Control System

MID Unit

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki DF 40