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Suzuki DF 60 Service Manual

For ’03 model
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For '03 model –
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Summary of Contents for Suzuki DF 60

  • Page 1 For ’03 model – 9 9 5 0 0 - 9 9 E 1 0 - 0 1 E...

  • Page 2: Table Of Contents

    FOREWORD GROUP INDEX This manual contains an introductory description on SUZUKI Outboard motor DF60/70 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 informa- tion concerning this motor.
  • Page 3 HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference.
  • Page 4 “1333B”. Apply SUZUKI OUTBOARD Measure in DC voltage range. MOTOR GEAR OIL. & Measure in resistance range. Apply SUZUKI SUPER GREASE “A”. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”. “Stevens CD-77”.
  • Page 5 GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING / CAUTION / NOTE________________________________ 1- 2 GENERAL PRECAUTIONS __________________________________ 1- 2 IDENTIFICATION NUMBER LOCATION ________________________ 1- 4 FUEL AND OIL ____________________________________________ 1- 4 1- 4 GASOLINE RECOMMENDATION ..............1- 4 ENGINE OIL ....................ENGINE BREAK-IN ________________________________________ 1- 5 1- 5 WARM-UP RECOMMENDATION ..............

  • Page 6: Warning / Caution / Note

    GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages 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 equiva- lent. • 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

    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 DF60/70 models are shown below. DF60 4700 – 5300 r/min Recommended full throttle speed range DF70 5200 –...

  • Page 11: Specifications

    GENERAL INFORMATION *SPECIFICATIONS * These specifications are subject to change without notice. Data Item Unit DF60T DF70(W)T DF70WTH PRE-FIX 06001F 07001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 795 (31.3) 795 (31.3) 892 (35.1) Overall width (side to side) mm (in) 435 (17.1) Overall height...
  • Page 12 Engine oil amounts 4.5 (4.8/4.0) : Oil change only L (US/Imp. qt) 4.8 (5.1/4.2) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts ml (US/Imp. oz) 1050 (35.5/37.0) BRACKET Trim angle...

  • Page 13: Service Data

    GENERAL INFORMATION *SERVICE DATA *These service data are subject to change without notice. Data Item Unit DF60T DF70(W)T/70WTH POWERHEAD r/min 4700 – 5300 5200 – 5800 Recommended operating range Idle speed r/min 700 ± 50 (in-gear: approx.700) *Cylinder compression kPa (kg/cm .
  • Page 14 1-10 GENERAL INFORMATION Data Item Unit DF60T DF70(W)T/70WTH VALVE / VALVE GUIDE mm (in) Valve diameter 36 (1.4) mm (in) 30 (1.2) Valve clearance mm (in) 0.11 – 0.15 (0.004 – 0.006) (when cold) mm (in) 0.13 – 0.17 (0.005 – 0.007) Valve guide to mm (in) 0.020 –...
  • Page 15 GENERAL INFORMATION 1-11 Data Item Unit DF60T DF70(W)T/70WTH CYLINDER / PISTON / PISTON RING mm (in) Cylinder distortion Limit 0.060 (0.0024) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 74.000 –...
  • Page 16 1-12 GENERAL INFORMATION Data Item Unit DF60T DF70(W)T/70WTH CRANKSHAFT / CONROD Conrod small end mm (in) 16.968 – 16.979 (0.6680 – 0.6685) inside diameter mm (in) 0.020 – 0.050 (0.0008 – 0.0020) Conrod big end oil clearance mm (in) Limit 0.080 (0.0031) Conrod big end mm (in)
  • Page 17 GENERAL INFORMATION 1-13 Data Item Unit DF60T DF70(W)T/70WTH ELECTRICAL Ignition timing BTDC 4° – BTDC 29° BTDC 4° – BTDC 33° r/min Approx. 6500 Over revolution limiter Ω CKP sensor resistance at 20°C Ω CMP sensor resistance 168 – 252 at 20°C Ω...

  • Page 18: Self-Diagnostic System Indication

    1-14 GENERAL INFORMATION SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch etc., the “CHECK ENGINE” lamp on the monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding. FAIL-SAFE SYSTEM PRIORITY FAILED ITEM CODE LAMP FLASHING PATTERN ACTIVATING...

  • Page 19: Tightening Torque

    GENERAL INFORMATION 1-15 TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM N . m DIAMETER kg-m Ib-ft. Cylinder head cover bolt 6 mm Cylinder head bolt 10 mm 53.0 Crankcase bolt 8 mm 18.0 10 mm 36.0 Conrod cap nut 8 mm 25.5...
  • Page 20 1-16 GENERAL INFORMATION 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 21: Special Tools

    GENERAL INFORMATION 1-17 SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) (A) 09900-06107 09900-00410 Hexagon socket Hexagon bit (B) 09900-06108 Hexagon wrench set (included in 09900-00410) (included in 09900-00410) Snap ring pliers 09900-20101 (150 mm) 09900-20205 09900-20102 (200 mm) 09900-20202 09900-20203 Micrometer (0 –...
  • Page 22 1-18 GENERAL INFORMATION 09915-78211 09915-64512 09915-47341 09915-77311 Oil pressure gauge adapter Oil filter wrench Compression gauge Oil pressure gauge 09916-10911 09916-14510 09916-24910 09916-24935 Valve lapper Valve lifter Valve seat cutter (N-212) Valve seat cutter (N-608) 09916-34520 09916-34542 Valve guide reamer 09916-24940 09916-54910 Valve guide reamer handle...
  • Page 23 GENERAL INFORMATION 1-19 09930-30161 09930-30104 09930-39411 09930-39420 Propeller shaft remover Sliding hammer Flywheel rotor remover Rotor remover bolt 09930-48720 09930-76420 09930-89240 09930-89260 Flywheel holder Timing light 4-pin connector test cord Injector test cord A • SDS software ver. 4.00 09930-89950 •...

  • Page 24: Materials Required

    99000-22540 99000-25010 99000-25160 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1207B” THREAD LOCK “1342” 4-Stroke Motor Oil THREAD LOCK SUPER “1333B” * 99104-33140 99000-31140 99000-32050 99000-32020 API : SE, SF, SG, SH, SJ...

  • Page 25: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE _______________________ 2- 2 2- 2 PERIODIC MAINTENANCE CHART .............. MAINTENANCE AND TUNE-UP PROCEDURES _________________ 2- 3 2- 3 ENGINE OIL / ENGINE OIL FILTER ............... 2- 6 GEAR OIL ......................2- 7 LUBRICATION ....................

  • Page 26: Periodic Maintenance Schedule

    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 27: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE 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 the oil level before every use. 1. Place the outboard motor upright on a level surface. 2.
  • Page 28 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 29 PERIODIC MAINTENANCE 7. Install the gasket and the oil drain plug. Tighten the engine oil drain plug. " Engine oil drain plug: 13 N·m (1.3 kg-m, 9.5 lb-ft) Do not re-use the gasket once removed. Always use a new gasket. 8.

  • Page 30: Gear Oil

    Gear oil amount: 1050 ml (35.5/37.0 US/Imp. oz) Recommended oil: Suzuki Outboard Motor Gear Oil or SAE #90 Hypoid gear oil 5. Install the oil level plug before removing the oil filler tube from the drain hole.

  • Page 31: Lubrication

    PERIODIC MAINTENANCE LUBRICATION Inspect every 50 hours (3 months). Apply the Water Resistant Grease to the following points. $ 99000-25160: Suzuki Water Resistant Grease Swivel bracket Throttle linkage Steering bracket Propeller shaft...

  • Page 32: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG • Inspect every 100 hours (6 months). • Replace every 200 hours (12 months). Standard spark plug : NGK BPR6ES Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition system malfunctions.

  • Page 33: Valve Clearance

    PERIODIC MAINTENANCE VALVE CLEARANCE Inspect initially after 20 hours (1 month) and every 200 hours (12 months) thereafter. 1. Remove the following parts: • Side covers (See page 7-2.) • Flywheel cover • Spark plugs • Ignition coils 2. Remove the breather hose 2 from the cylinder head cover 3.
  • Page 34 2-10 PERIODIC MAINTENANCE 6. Insert the thickness gauge between the valve stem end and the valve adjusting screw on the rocker arm. ! 09900-20803: Thickness gauge Valve clearance (when cold): IN. 0.11 – 0.15 mm (0.004 – 0.006 in) EX. 0.13 – 0.17 mm (0.005 – 0.007 in) If the measurement is out of the specification, adjust the valve clearance.

  • Page 35: Timing Belt

    PERIODIC MAINTENANCE 2-11 TIMING BELT • Inspect every 200 hours (12 months). • Replace every 800 hours or 4 years. If wear, crack or other damage is found, replace the timing belt. 1. Replace the following parts. • Flywheel cover •...
  • Page 36 2-12 PERIODIC MAINTENANCE 6. Rotate the crankshaft to align the HOLLOW mark on the tim- ing pulley with the INDEX mark on the cylinder block. ! 09911-49910: Crankshaft holder Rotate the crankshaft in the normal running direction only (clockwise) to prevent water pump impeller dam- age.
  • Page 37 PERIODIC MAINTENANCE 2-13 12. Rotate the crankshaft 2 or 4 rotations to remove looseness. 13. Make sure that the PUNCH mark “1” on the cam pulley aligns with the INDEX mark on the cylinder head block when the PUNCH mark on the timing pulley aligns with the INDEX mark on the cylinder block.

  • Page 38: Idle Speed

    2-14 PERIODIC MAINTENANCE IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: • Before checking the idle speed, the engine should be allowed to warm up. • Check and/or adjust the idle speed after the engine speed has stabilized.

  • Page 39: Ignition Timing

    PERIODIC MAINTENANCE 2-15 Open the throttle valve to turn the CTP switch off. NOTE: The fixed mode of the IAC valve duty can be manually cancelled by turning the CTP switch off. 8. Close the throttle valve and then recheck the engine speed. It should now be stable at 650 –...

  • Page 40: Breather And Fuel Line

    2-16 PERIODIC MAINTENANCE BREATHER HOSE AND FUEL LINE • Inspect initially after 20 hours (1 month) and every 50 hours (3 months) thereafter. • Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace the breather line and/or the fuel line. LOW PRESSURE FUEL FILTER •...

  • Page 41: Water Pump Impeller / Water Pump

    PERIODIC MAINTENANCE 2-17 WATER PUMP IMPELLER / WATER PUMP WATER PUMP IMPELLER Replace every 200 hours (12 months). WATER PUMP Inspect every 200 hours (12 months). If excessive wear, crack distortion or corrosion is found on the pump case or the under panel, replace. Do not re-use the gasket once removed.

  • Page 42: Anodes And Bonding Wires

    ANODES If 2/3 of the anode has corroded away, replace the anode. Never paint the anode. NOTE: Anode The anode securing bolt should be covered with the Suzuki Sili- cone Seal. & 99000-31120: Suzuki Silicone Seal BONDING WIRES If breakage or other damage is found, replace the wire.

  • Page 43: Battery

    PERIODIC MAINTENANCE 2-19 BATTERY Inspect every 50 hours (3 months). • Never expose battery to open flame or electric spark as batteries generate gas which is flammable and ex- plosive. • 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 44: Bolts And Nuts

    2-20 PERIODIC MAINTENANCE BATTERY SOLUTION LEVEL CHECK The battery solution level should be between the UPPER level and the LOWER level. If the level is low, add distilled water only. Once the battery has been initially serviced, NEVER add diluted sulphuric acid, or you will damage the battery. Follow the battery manufacture’s instructions for spe- cific maintenance procedures.

  • Page 45: Fuel Mixture Check (Ofeedback)

    To perform the O feedback on 2003 year models, use the Suzuki Diagnostic System (SDS) updated by the database version 4.10 (program version 4.00). This section contains a set-up procedure on the outboard motor side only.
  • Page 46 2-22 PERIODIC MAINTENANCE The O sensor used for the feedback test procedure must be in proper working order and installed se- curely. If either sensor or installation is improper, the O feed- back operation will be performed incorrectly and could possibly result in engine operating problems.

  • Page 47: Oil Pressure

    PERIODIC MAINTENANCE 2-23 OIL PRESSURE Oil pressure (at normal operating temp.): 420 – 490 kPa (4.2 – 4.9 kg/cm , 60 – 70 psi.) at 3000 r/min. NOTE: The figure shown above is guideline only, not absolute service limit. If the oil pressure is lower or higher than the specification, the following causes may be considered: Low oil pressure High oil pressure...

  • Page 48: Cylinder Compression

    2-24 PERIODIC MAINTENANCE CYLINDER COMPRESSION Cylinder compression: 1300 – 1600 kPa (13 – 16 kg/cm , 185 – 228 psi) Max. difference between any other cylinders: 200 kPa (2.0 kg/cm , 28 psi) or less NOTE: The figures shown above are guidelines only, not absolute service limits.

  • Page 49: Engine Control System

    ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM STRUCTURE ____________________ 3- 2 3- 2 SYSTEM STRUCTURE 1 ................3- 3 SYSTEM STRUCTURE 2 ................3- 4 WIRING DIAGRAM FOR ENGINE CONTROL ..........COMPONENTS FOR SYSTEM CONTROL ______________________ 3- 5 3- 5 ENGINE CONTROL MODULE (ECM) ............

  • Page 50: Engine Control System Structure

    ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF60/DF70 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 (sensor/switch) (ECM)

  • Page 51: System Structure 2

    ENGINE CONTROL SYSTEM SYSTEM STRUCTURE 2...

  • Page 52: Wiring Diagram For Engine Control

    ENGINE CONTROL SYSTEM WIRING DIAGRAM FOR ENGINE CONTROL ENGINE CONTROL MODULE...

  • Page 53: 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 Controls fuel injection amount and timing. Ignition control Controls ignition timing.
  • Page 54 ENGINE CONTROL SYSTEM ECM CONNECTOR/TERMINALS LAYOUT ECM CIRCUITS TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR — — Oil pressure switch Bl/R Emergency stop switch Lg/R CTP switch Buzzer cancel REV-LIMIT lamp Y / B Tachometer G / W CHECK ENGINE lamp Neutral switch, Engine start signal B l / W Buzzer...
  • Page 55 ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE...

  • Page 56: Sensor And Switch

    ENGINE CONTROL SYSTEM SENSOR AND SWITCH CKP (Crankshaft Position) SENSOR The CKP sensor which is a “Hall effect sensor” type is installed below the flywheel rotor. When the reluctor bars on the flywheel passes the sensor, signals are generated and rectified to create “ON”...
  • Page 57 ENGINE CONTROL SYSTEM CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder (be- hind the electric part holder) and used to detect the cylinder tem- perature. 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 58 3-10 ENGINE CONTROL SYSTEM CTP (Closed Throttle Position) SWITCH The CTP switch is installed on the bottom of throttle body and used to detect whether the throttle is fully closed or not. This switch is “ON” at closed throttle and “OFF” at any open throttle position.
  • Page 59 ENGINE CONTROL SYSTEM 3-11 SENSOR (Optional item) The O sensor is installed in the exhaust manifold only when the feedback operation is performed. Zirconia element This sensor is a zirconia element (platinum plated) which changes Housing output voltage depending on the oxygen concentration difference between its internal and external surface.

  • Page 60: Ignition System

    3-12 ENGINE CONTROL SYSTEM IGNITION SYSTEM The ignition system used by the DF60/DF70 is a fully transistorized, electronic microcomputer timing ad- vanced type. This system is totally battery powered, with the ECM controlling all ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch, etc.).
  • Page 61 ENGINE CONTROL SYSTEM 3-13 IGNITION TIMING CHART • The following chart shows the example for the ignition at BTDC 24°. • The ignition timing is varied by the condition of the engine running. • Angles indicated in the following chart show the CRANKSHAFT angle. 34-signals/360˚...

  • Page 62: Electronic Fuel Injection System

    3-14 ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF60/DF70 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 63 ENGINE CONTROL SYSTEM 3-15 FUEL INJECTION TIMING CHART • The fuel injection timing is always fixed at BTDC 484° on exhaust stroke. • The fuel ignition time duration (amount) is varied by the condition of the engine running. • Angles indicated in the following chart show the CRANKSHAFT angle. 34-signals/360˚...

  • Page 64: Fuel Delivery System Components

    3-16 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), delivery pipe, fuel injector and hoses.
  • Page 65 ENGINE CONTROL SYSTEM 3-17 FUEL VAPOR SEPARATOR The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber. As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump. The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator.
  • Page 66 3-18 ENGINE CONTROL SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator is located in the fuel vapor separator. The regulator’s 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.

  • Page 67: Fuel Pump Control System

    ENGINE CONTROL SYSTEM 3-19 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 68: Air Intake Components

    3-20 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 the engine idle passes through the by-pass air passage.

  • Page 69: Idle Air Control System

    ENGINE CONTROL SYSTEM 3-21 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 screw controls the flow of air through the pas- sage and provides a means of partially adjusting the total amount of air necessary for idling / trolling.
  • Page 70 3-22 ENGINE CONTROL SYSTEM Duty cycle signal for IAC valve (example: 25% duty) Battery charge “ON” time × 100 = duty (%) coil 1 cycle time main 25 ms Rectifier & relay regulator 30A fuse fuse Sensor/switch Time signal input 100 ms (1 cycle) Ignition switch...

  • Page 71: Caution System

    ENGINE CONTROL SYSTEM 3-23 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 72: Low Oil Pressure Caution System

    3-24 ENGINE CONTROL SYSTEM LOW OIL PRESSURE CAUTION SYSTEM CONDITION: Immediate activation of the system when the oil pressure switch turns “ON” due to an engine oil pressure drop below 1.0 kg/cm (100 kPa, 14 psi). ACTION: Engine speed Automatically reduced to approx. 3000 r/min by intermittent fuel injection and ignition signals if the system is activated at 3000 r/min or higher.

  • Page 73: Overheat Caution System

    ENGINE CONTROL SYSTEM 3-25 OVERHEAT CAUTION SYSTEM CONDITION 1 (Maximum temperature) Immediate activation of the system when: • Cylinder temperature reaches 111°C. • Exhaust manifold temperature reaches 101°C. CONDITION 2 (Temperature rise vs Time) Immediate activation of the system when: •...

  • Page 74: Low Battery Voltage Caution System

    3-26 ENGINE CONTROL SYSTEM LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION: The system is activated when the 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 75: Self-Diagnostic System

    ENGINE CONTROL SYSTEM 3-27 SELF-DIAGNOSTIC SYSTEM MONITOR-TACHOMETER The self-diagnostic system alerts the operator when an abnor- mality occurs in a signal from the 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 76 3-28 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 77: Condition For Self-Diagnostic System Operation

    ENGINE CONTROL SYSTEM 3-29 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 (0.20 – 4.53 V)” signal (With engine running) CKP sensor •...

  • Page 78: Fail-Safe System

    3-30 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. PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM FAILED ITEM PRE-PROGRAMMED VALUE...

  • Page 79: Operating Hour Indication System

    ENGINE CONTROL SYSTEM 3-31 OPERATING HOUR INDICATION SYSTEM (For remote control model) When the ignition switch is initially turned “ON” (from “OFF”), MONITOR-TACHOMETER 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 80: Oil Change Reminder System

    3-32 ENGINE CONTROL SYSTEM OIL CHANGE REMINDER SYSTEM Action This system informs the operator of the time for replacing EN- Starting operation GINE OIL on the basis of the recommended maintenance sched- (*1) (*4) ule. When the total motor operating hours have reached the Indication Cancellation preprogrammed hours;...
  • Page 81 NOTE: • Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, Suzuki strongly recommends that the engine oil be replaced before canceling the system activation.

  • Page 82: Start-In-Gear Protection System

    3-34 ENGINE CONTROL SYSTEM START-IN-GEAR PROTECTION SYSTEM A switch to detect neutral gear position is located on the cylinder block (starboard 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 83: O 2 Feedback System

    ENGINE CONTROL SYSTEM 3-35 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 must be temporally installed in the exhaust manifold.

  • Page 84: Inspection

    3-36 ENGINE CONTROL SYSTEM INSPECTION PRECAUTION ON SYSTEM INSPECTION To prevent any unexpected engine start, perform the following before proceeding with any CRANK- ING tests. • When performing tests not related to the fuel injector operation: - Disconnect all fuel injector wire connectors. •...

  • Page 85: Inspection For Ecm Circuit Voltage

    ENGINE CONTROL SYSTEM 3-37 INSPECTION FOR ECM CIRCUIT VOLTAGE " ECM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an ECM separated from the engine wiring harness. # 09930-89950: 44-pin test cord 09930-99320: Digital tester $ Tester range: % % V (DC voltage)
  • Page 86 3-38 ENGINE CONTROL SYSTEM CIRCUIT VOLTAGE TABLE TERMINAL STANDARD CIRCUIT CONDITION / REMARKS NUMBER VOLTAGE – – – Emergency stop switch Approx. 5V Ignition switch ON, plate IN Approx. 0V Ignition switch ON, plate OUT Buzzer cancel Approx. 12V Ignition switch ON, key pushed Approx.

  • Page 87: Inspection For Resistance

    ENGINE CONTROL SYSTEM 3-39 INSPECTION FOR RESISTANCE # 09930-99320: Digital tester & Tester range: Ω Ω Ω Ω Ω (Resistance) NOTE: Make sure that the ignition switch is always OFF when measur- ing resistance. 1. Disconnect the battery cables from the battery. 2.

  • Page 88: Component Inspections

    3-40 ENGINE CONTROL SYSTEM NOTE 1: Disconnect the remote control wire harness, and connect the tester probe to the terminal A (Gray wire). NOTE 2: Measure resistance with the shift in the NEUTRAL position. COMPONENT INSPECTIONS FUEL INJECTOR OPERATING SOUND (CRANKING) 1.
  • Page 89 ENGINE CONTROL SYSTEM 3-41 3. Connect the tester probe + (Red) to each terminal. (Voltage) Injector Terminal No. No.1 No.2 No.3 (Time) No.4 A Peak voltage reading (NEG) B 0V level for peak voltmeter 4. Crank the engine and measure voltage. Fuel injector operating signal: 6 –...
  • Page 90 3-42 ENGINE CONTROL SYSTEM IGNITION SECONDARY COIL RESISTANCE # 09930-99320: Digital tester & Tester range: Ω Ω Ω Ω Ω (Resistance) 1. Disconnect the spark plug cap from the spark plug. 2. Measure resistance between both spark plug caps as shown. Ignition secondary coil resistance: NO.
  • Page 91 ENGINE CONTROL SYSTEM 3-43 MAP SENSOR OUTPUT VOLTAGE CHANGE 09917-47011: Vaccum pump gauge 09930-89950: 44-pin test cord 09930-99320: Digital tester Tester range: % % V (DC voltage) 1. Disconnect the MAP sensor hose from the intake manifold (surge tank) side. 2.
  • Page 92 3-44 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH # 09940-44121 : Air pressure gauge 09930-99320 : Digital tester : Air pump ) Tester range: *( *( (Continuity) 1. Remove the oil pressure switch (See the page 3-53). 2. Connect the gauge and an air pump as shown. 3.

  • Page 93: Troubleshooting

    ENGINE CONTROL SYSTEM 3-45 TROUBLESHOOTING Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION” section on the page 3-36. 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 the page 4-6.
  • Page 94 3-46 ENGINE CONTROL SYSTEM CHART3: SELF-DIAGNOSTIC CODE “3-1” START < Ignition switch “OFF” > Check IAC valve resistance. IAC valve failure Is result OK? (See page 3-39.) < Ignition switch “ON” > ECM failure Check “18” terminal voltage. Is result OK? (See page 3-38.) Possible cause: •...
  • Page 95 ENGINE CONTROL SYSTEM 3-47 CHART6: SELF-DIAGNOSTIC CODE “1-4” START < Ignition switch “OFF” > Check cylinder temp. sensor resistance. Cylinder temp. sensor failure Is result OK? (See page 3-39.) Possible cause: • ECM failure • Wire continuity/connection failure CHART 7: SELF-DIAGNOSTIC CODE “2-3” START <...
  • Page 96 3-48 ENGINE CONTROL SYSTEM CHART9: SELF-DIAGNOSTIC CODE “1-1” START < Individual check > Check rectifier & regulator resistance. Rectifier & regulator failure [NOTE1] Is result OK? < Engine running > Check “30” terminal voltage at idle speed. (See page 3-38.) Is result 16 V or over? Possible cause: •...
  • Page 97 ENGINE CONTROL SYSTEM 3-49 CHART12: ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING) Before starting this troubleshooting, make sure that: • There is no self-diagnostic code indication. • Emergency stop switch plate is set in place. START < Ignition switch “ON” > Emergency stop switch ECM main relay failure Check “30”...
  • Page 98 3-50 ENGINE CONTROL SYSTEM CHART13: UNSTABLE IDLING/TROLLING (OR ENGINE TENDS TO STALL) Before starting this troubleshooting, make sure that: • There is no self-diagnostic code indication. START < Ignition switch “ON” > < Individual check > (Always 0 V) Check “5” terminal voltage. Check neutral switch function.

  • Page 99: Removal/Installation

    ENGINE CONTROL SYSTEM 3-51 REMOVAL/INSTALLATION FLYWHEEL/CKP SENSOR/CMP SENSOR 1 Flywheel bolt (1) 2 Washer (1) 3 Key (1) 4 Flywheel magneto (1) 5 CKP sensor (1) 6 Bolt (1) 7 CMP sensor (1) 8 Screw (2) 9 Spacer (1) # 09930-48720: Flywheel holder 09930-39411: Flywheel remover 09930-39420: Flywheel remover bolt...
  • Page 100 3-52 ENGINE CONTROL SYSTEM REMOVAL 1. Remove the flywheel cover. 2. Loosen the flywheel bolt by 2 – 3 turns. # 09930-48720: Flywheel holder NOTE: Do not remove the flywheel bolt from the crankcase before un- fastening flywheel using the bolts. 3.

  • Page 101: Oil Pressure Switch

    ENGINE CONTROL SYSTEM 3-53 OIL PRESSURE SWITCH REMOVAL 1. Remove the ECM from the electric parts holder. 2. Loosen the bolt and disconnect the switch wire (Blue). 3. Remove the oil pressure switch from the cylinder block. INSTALLATION Installation is reverse order of removal with the special attention to the following steps.
  • Page 102 ELECTRICAL ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ______________________________ 4- 2 4- 2 OUTLINE ......................4- 2 INSPECTION ....................4- 4 REMOVAL / INSTALLATION ................ELECTRIC STARTER SYSTEM_______________________________ 4- 6 4- 6 OUTLINE ......................4- 7 TROUBLESHOOTING ..................4- 8 INSPECTION ....................4-10 STARTER MOTOR ...................

  • Page 103: Battery Charging System

    ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the battery charge coil, the rectifier & regulator and the battery. The three phase AC current generated from the battery charge coil is converted by the rectifier & regulator into regulated DC current which is used to charge the battery.

  • Page 104: Inspection

    2. Measure resistance between the terminals for all combina- tions. NOTE: The values given below are for the SUZUKI digital tester. As thyristors, diodes, etc. are used inside this rectifier & regula- tor, the resistance values will differ when an ohmmeter other than the SUZUKI digital tester is used.

  • Page 105: Removal/Installation

    ELECTRICAL REMOVAL/INSTALLATION 190 N . m 1 Bolt (1) (19.0 kg-m, 137.5 Ib-ft) & 2 Washer (1) 3 Key (1) 4 Flywheel (1) 5 Battery charge coil (1) 6 Screw (3) 7 Rectifier & regulator (1) 8 Bolt (2) REMOVAL Before removing electrical parts: •...
  • Page 106 ELECTRICAL INSTALLATION Installation is reverse order of removal with the special attention to the following step. Battery charge coil Apply the thread lock to the coil securing screws. % 99000-32050: Thread Lock 1342...

  • Page 107: Electric Starter System

    ELECTRICAL ELECTRIC STARTER SYSTEM OUTLINE The electric starter system circuit is illustrated below. It is mainly composed of the battery, the starter motor, the relay, the neutral switches and the ignition switch. Starter motor To ECM main relay To Rectifier &...

  • Page 108: Troubleshooting

    ELECTRICAL TROUBLESHOOTING NOTE: Before troubleshooting the electric starter system, make sure the followings: • 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 Battery...

  • Page 109: Inspection

    ELECTRICAL INSPECTION IGNITION SWITCH 09930-99320: Digital tester ' Tester range: (Continuity) 1. Shift into NEUTRAL. 2. Disconnect the remo-con box wire harness connector from the engine side. 3. Inspect continuity between the wires while operating the switch key. : Continuity Ignition switch function: Black Green White Gray Brown Orange...
  • Page 110 ELECTRICAL Neutral switch on cylinder block 09930-99320: Digital tester ' Tester range: (Continuity) Neutral Forward 1. Disconnect the neutral switch wire located in the electric parts holder. 2. Inspect continuity between the Yellow/Green wire and the Brown wire while operating the remo-con handle. Reverse Neutral switch function: Continuity...

  • Page 111: Starter Motor

    4-10 ELECTRICAL STARTER MOTOR REMOVAL Before removing starter motor: • Disconnect battery cables from battery. 1. Remove the screw and the flywheel cover. 2. Remove the breather hose and the evaporation hose. 3. Remove the bolt, the fastening band and the silencer cover. 4.
  • Page 112 ELECTRICAL 4-11 8. Loosen the two silencer bracket bolts. 9. Remove the silencer and the throttle body. 10. Remove the starter motor sub cable. 11. Remove the four bolts, the motor band and the starter motor assy. INSTALLATION Installation is reverse order of removal with the special attention to the following steps.
  • Page 113 4-12 ELECTRICAL 1. Front cover (1) 2. Stopper ring (1) 3. Pinion stopper (1) 4. Spring (1) 5. Pinion (1) 6. Cover (1) 7. Armature (1) 8. Washer (2) 9. Stator (1) 10. Brush (1) 11. Brush spring (2) 12. Brush holder (1) 13.
  • Page 114 ELECTRICAL 4-13 1. Remove the nut 1 on the + terminal. 2. Remove the two screws 1 and the sub rear cover 2. 3. Remove the circlip 1, the washer 2 and 3. NOTE: When installing, set the thicker washer 3 to the circlip side. 4.
  • Page 115 4-14 ELECTRICAL 7. Remove the front cover 1 and the stator 2. 8. Push down the pinion stopper 1, remove the stopper ring 9. Remove the pinion stopper 1, the spring 3, the pinion 4 and the cover 5. Wear safety grasses when disassembling and assem- bling stopper ring.
  • Page 116 ELECTRICAL 4-15 3. Check that the mica (insulator) between the segments is un dercut to the specified depth. SEGMENT Commutator undercut: Standard : 0.5 – 0.8 mm (0.02 – 0.03 in) Service limit: 0.2 mm (0.01 in) If the measurement exceeds the service limit, cut to the specified MICA depth.
  • Page 117 • Apply the grease to the armature shaft and the shaft holes. * 99000-25010: Suzuki Super Grease “A” • Align the front cover, the stator and the rear cover with the alignment lines scribed earlier and assemble the starter mo- tor.

  • Page 118: Electric Parts Holder

    ELECTRICAL 4-17 ELECTRIC PARTS HOLDER REMOVAL Before removing electric parts holder: • Disconnect battery cables from battery. 1. Remove the electric parts holder cover with pushing it up- ward. 2. Remove the breather hose and evaporation hose. 3. Remove the bolt, the fastening band and the silencer cover. 4.

  • Page 119: Monitor-Tachometer

    4-18 ELECTRICAL MONITOR-TACHOMETER 1 “CHECK ENGINE” 2 TEMP “ ” INSPECTION 3 OIL “ ” 4 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 120 FUEL SYSTEM FUEL SYSTEM CONTENTS PRECAUTION ON FUEL SYSTEM SERVICE ____________________ 5- 2 5- 2 GENERAL PRECAUTION ................5- 2 FUEL PRESSURE RELIEF PROCEDURE ............ FUEL LINE _______________________________________________ 5- 3 5- 3 REMOVAL / INSTALLATION ................5- 3 FUEL LEAKAGE CHECK PROCEDURE ............5- 4 FUEL HOSE CONNECTION ................

  • Page 121: Precaution On Fuel System Service

    FUEL SYSTEM PRECAUTION ON FUEL SYSTEM SERVICE GENERAL PRECAUTION Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except using battery power for servicing / inspection. •...

  • Page 122: Fuel Line

    FUEL SYSTEM FUEL LINE REMOVAL/INSTALLATION Remove or install the fuel hoses with the special attention to the following steps. 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 compo- nents.

  • Page 123: Fuel Hose Connection

    FUEL SYSTEM FUEL HOSE CONNECTION Note that the fuel hose connection varies with each type of the pipe. Be sure to connect and clamp each hose correctly by re- ferring to the following figure. • For the type “A” (short barbed end) pipe, hose should com- “A”...
  • Page 124 FUEL SYSTEM A small amount of fuel may be released when the fuel feed hose is disconnected. Place container under the fuel feed hose with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in an approved container. 6.

  • Page 125: Fuel Vapor Separator / High Pressure Fuel Pump

    FUEL SYSTEM FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP REMOVAL / INSTALLATION 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 the components. (See the page 5-2.) REMOVAL 1.

  • Page 126: Disassembly

    FUEL SYSTEM DISASSEMBLY 1. Remove the five screws 1. 2. Remove the separator cover 2 with the high pressure fuel pump from the separator case. 3. Remove the float pin 1 and the float 2. 4. Remove the needle valve 1, the screw 2, the plate 3 and the valve seat 4.

  • Page 127: Inspection

    FUEL SYSTEM 9. Remove the high pressure fuel pump 1 and the grommet 2 from the separator cover and then disconnect the pump lead wire connector. INSPECTION NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component.

  • Page 128: Reassembly

    FUEL SYSTEM Fuel pressure regulator Check the fuel pressure regulator operation. 09940-44121 : Air pressure gauge – 1 09940-44130 : Attachment – 2 09912-58490 : Hose – 3 : Hand air pump – 4 1. Connect the special tools to the inlet side of the regulator as shown in the figure.
  • Page 129 Apply fuel to the O-ring before installing the regulator. 2. Install the plate. Separator cover / Separator case 1. Install the seal ring, then apply the Suzuki Bond evenly to only the outside mating surface of the separator case as shown in the figure.

  • Page 130: Fuel Injector / Delivery Pipe

    FUEL SYSTEM 5-11 FUEL INJECTOR / DELIVERY PIPE 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. (See the page 5-2.) 1.

  • Page 131: Installation

    5-12 FUEL SYSTEM INSTALLATION Installation is reverse order of removal with the special atten- tion to the following steps. Do not re-use the O-ring and the cushion once re- moved. Always use new parts. 1. Replace the injector O-ring 1 with new one using care not to damage it.

  • Page 132: Low Pressure Fuel Pump

    FUEL SYSTEM 5-13 LOW PRESSURE FUEL PUMP REMOVAL / INSTALLATION REMOVAL 1. Remove both side covers. (See the page 7-2.) 2. Disconnect the hose 1 (inlet) and the hose 2 (outlet) from the fuel pump. 3. Remove the two bolts 3. 4.

  • Page 133: Disassembly / Reassembly

    5-14 FUEL SYSTEM DISASSEMBLY / REASSEMBLY DISASSEMBLY NOTE: For correct assembly, scribe an alignment mark on each part of the fuel pump. 1. Remove the six screws 1. 2. Remove the following parts: • Outer plate 2 • Diaphragm 3 •...

  • Page 134: Inspection

    FUEL SYSTEM 5-15 INSPECTION Diaphragm Inspect all diaphragms. If distortion, tear or other damage is found, replace the fuel pump assembly. Check-valves Inspect the check valves in the valve body. If tear, distortion or other damage is found, replace the fuel pump assembly. Pump body Inspect the pump body.

  • Page 135: Fuel Tank

    5-16 FUEL SYSTEM FUEL TANK DISASSEMBLY / REASSEMBLY When disassembling or reassembling the fuel tank, refer to the construction diagram below. Plastic tank Steel tank –(a) –(b) 1 Fuel hose assy ( 1 ) 7 Connector plug ( 1 ) 1 Tank cap (1) [B Screw (2)] 8 Outlet ( 1 )

  • Page 136: Inspection

    FUEL SYSTEM 5-17 INSPECTION Fuel connector Inspect the fuel connector and the connector plug. If leakage, de- terioration or other damage is found, replace the connector and/ or the plug. 1. Connector 2. Connector plug Fuel primer bulb Inspect the fuel primer bulb. If crack, leakage or deterioration is found, replace the bulb.
  • Page 137 POWER UNIT POWER UNIT CONTENTS INTAKE MANIFOLD ASSY _________________________________ 6- 2 REMOVAL ..................6- 2 INSTALLATION ................6- 5 POWER UNIT ___________________________________________ 6- 6 REMOVAL ..................6- 6 INSTALLATION ................6-10 CYLINDER HEAD ASSY __________________________________ 6-14 REMOVAL ..................6-14 INSTALLATION ................6-14 DISASSEMBLY ................

  • Page 138: Intake Manifold Assy

    POWER UNIT INTAKE MANIFOLD ASSY REMOVAL Before removing the intake manifold assy: • Remove the fuel pressure in line. (See the page 5-2.) • Disconnect the battery cables from the battery. • Remove the flywheel cover. • Remove both side covers. (See the page 7-2.) 1.
  • Page 139 POWER UNIT 9. Disconnect the water hose 1 from the oil pan. 10. Disconnect the water hose 2 from the joint. 11. Remove the bolt and the low pressure fuel filter with the bracket. 12. Disconnect the throttle rod 1. 13.
  • Page 140 POWER UNIT 17. Remove the two bolts. 18. Disconnect the wire from the high pressure fuel pump. 19. Pull out the oil level gauge 1. 20. Remove the bolt and the gauge guide 2. 21. Disconnect the evaporation hose from the fuel vapor sepa- rator.

  • Page 141: Installation

    POWER UNIT INSTALLATION Installation is reverse order of removal with the special attention to the following steps. Do not re-use the gaskets once removed. Always use new gaskets. • Install the two dowel pins 1 and the gaskets 2. • Apply the thread lock to the two bolts as shown. "...

  • Page 142: Power Unit

    POWER UNIT POWER UNIT REMOVAL Before removing the power unit: • Drain the engine oil. • Remove the intake manifold assy. (See the page 6-2.) 1. Remove the electric parts holder. (See the page 4-17.) 2. Remove the two bolts and the rectifier & regulator. 3.
  • Page 143 POWER UNIT 7. Remove the flywheel. (See the page 3-52.) $ 09930-48720: Flywheel holder 09930-39411: Flywheel remover 09930-39420: Flywheel remover bolt 8. Remove the battery charge coil. (See the page 4-4.) 9. Remove the CKP sensor and the CMP sensor. (See the page 3-52.) 10.
  • Page 144 POWER UNIT 16. Disconnect the water hose from the thermostat cover. 17. Disconnect the elbow joint from the engine holder. 18. Remove the two bolts and the front panel. 19. Loosen the nut 2 and push the clutch shaft 1 toward the port side.
  • Page 145 POWER UNIT 24. Remove the six bolts and cylinder head cover. 25. Disconnect the breather hose from cylinder head cover. 26. Loosen all valve adjusting lock nuts 1. 27. Loosen all valve adjusting screws 2 fully. To prevent valve damage, loosen the valve adjusting lock nuts and the valve adjusting screws fully before remov- ing the timing belt.

  • Page 146: Installation

    1. Set the two dowel pins and the gasket. 2. Apply the grease to the drive shaft splines. & 99000-25160: Suzuki Water Resistant Grease 3. Install the power unit to the engine holder. NOTE: Rotate the crankshaft to aid alignment of the drive shaft and the...
  • Page 147 POWER UNIT 6-11 4. Apply the seal to the bolts and the nuts. 99000-31120: Suzuki Silicone Seal 5. Tighten the ten bolts and the two nuts. Power unit mounting bolt / nut: 23 N . m (2.3 kg-m, 16.5 lb-ft) 8 mm 10 mm 50 N .
  • Page 148 6-12 POWER UNIT TIMING BELT Install the timing belt, the cam pulley and the belt tensioner. (See the page 2-12.) Cam pulley bolt: 60 N·m (6.0 kg-m, 43.5 lb-ft) FLYWHEEL 1. Install the battery charge coil. (See the page 4-5.) 2.
  • Page 149 POWER UNIT 6-13 INTAKE MANIFOLD / FUEL INJECTOR / DELIVERY PIPE 1. Install the intake manifold assy. (See the page 6-5.) 2. Install the fuel injector and the delivery pipe. (See the page 5-12.) FINAL ASSEMBLY CHECK Perform the following checks in order to ensure proper and safe operation of the repaired unit.

  • Page 150: Cylinder Head Assy

    6-14 POWER UNIT CYLINDER HEAD ASSY REMOVAL Before removing the cylinder head assy: • Remove the power unit. (See page 6-6.) 1. Remove the ten bolts. 2. Remove the cylinder head assy and the gasket. INSTALLATION Installation is reverse order of removal with the special attention to the following steps.

  • Page 151: Disassembly

    POWER UNIT 6-15 DISASSEMBLY 1. Remove the ten screws 1. 2. Remove the intake rocker arm shaft 2 and the exhaust rocker arm shaft 3. 3. Remove all rocker arms 4 and all springs 5. NOTE: The intake rocker arm shaft differs from the exhaust one in shape Intake as shown.
  • Page 152 6-16 POWER UNIT 7. Remove the valve cotters 1 while compressing the valve spring. 8. Remove the valve spring retainer 2, the valve spring 3 and the valve 4. $ 09916-14510: Valve lifter 09916-48210: Attachment 09916-84511: Tweezers NOTE: Reassemble each valve and valve spring to their original posi- tions.

  • Page 153: Inspection / Servicing

    POWER UNIT 6-17 INSPECTION / SERVICING NOTE: If crack, excessive wear or other damage is found on any com- ponent, replace. CYLINDER HEAD 1. Remove all carbon from the combustion chamber. NOTE: • Do not use any sharp edged tool to scrape carbon off the cylinder head or the head components.
  • Page 154 6-18 POWER UNIT Intake manifold seating faces distortion Measure the intake manifold seating faces distortion. $ 09900-20803: Thickness gauge Straight gauge Service limit: 0.10 mm (0.004 in) If the measurement exceeds the service limit, resurface or re- place the cylinder head. Water jackets Inspect the water jackets.
  • Page 155 POWER UNIT 6-19 Camshaft runout Measure the camshaft runout. $ 09900-20602: Dial gauge 09900-20701: Magnetic stand 09900-21304: Steel “V” block set Service limit: 0.10 mm (0.004 in) If the measurement exceeds the service limit, replace the cam- shaft. Camshaft journal oil clearance Standard : 0.050 –...
  • Page 156 6-20 POWER UNIT ROCKER ARM / SHAFT Rocker arm wear Inspect the arm-riding face and the tip of the adjusting screw. If excessive wear is found, replace the rocker arm and/or the adjusting screw. Rocker arm shaft runout $ 09900-20602: Dial gauge 09900-20701: Magnetic stand 09900-21304: Steel “V”...
  • Page 157 POWER UNIT 6-21 VALVE / VALVE GUIDE Valve guide to valve stem clearance Standard : IN 0.020 – 0.050 mm (0.0008 – 0.0020 in) EX 0.045 – 0.075 mm (0.0018 – 0.0030 in) Service limit: IN 0.070 mm (0.0028 in) EX 0.090 mm (0.0035 in) If the measurement exceeds the service limit, replace the valve and/or the valve guide.
  • Page 158 6-22 POWER UNIT Valve stem end length Measure the valve stem end length 1. $ 09900-20102: Vernier calipers Service limit: IN & EX 6.05 mm (0.238 in) If the measurement exceeds the service limit, replace the valve. Valve stem runout Measure the valve stem runout.
  • Page 159 POWER UNIT 6-23 Valve seating contact width Measure the valve seating contact width A as follows: 1. Coat the valve seat evenly with Prussian blue (or equivalent). 2. Install the valve into the valve guide. 3. Put the valve lapper on the valve. $ 09916-10911: Valve lapper 4.
  • Page 160 6-24 POWER UNIT 5. Refinish the valve guide bore. $ 09916-34520: Valve guide reamer (φ φ φ φ φ 7 mm) 09916-34542: Valve guide reamer handle NOTE: Clean and oil the valve guide bore when reamed. VALVE SEAT SERVICING If the valve seating contact width is out of the specification, reface the valve seat as follows: 15˚...
  • Page 161 POWER UNIT 6-25 NOTE: Clean and assemble the cylinder head and the valve compo- nents. Fill the intake and the exhaust ports with solvent to check for leaks between the valve seat and the valve. If any leaks oc- cur, inspect the valve seat and the face for burrs or other things that could prevent the valve from sealing.

  • Page 162: Reassembly

    6-26 POWER UNIT REASSEMBLY Reassembly is reverse order of disassembly with the special at- tention to the following steps. VALVE 1. Install the valve spring seat 1. 2. Apply the engine oil to the valve stem seal 2. 3. Install the valve stem seal onto the valve guide by pushing the tool with finger tip.
  • Page 163 POWER UNIT 6-27 CAMSHAFT 1. Apply the engine oil to the camshaft and all holder journals. 2. Install the camshaft from the camshaft pulley side. 3. Install the camshaft thrust plate by the two bolts. 4. Apply the engine oil to the lip area of the oil seal 1. 5.

  • Page 164: Cylinder / Crankshaft / Piston

    6-28 POWER UNIT CYLINDER / CRANKSHAFT / PISTON DISASSEMBLY Before disassembling: • Remove the power unit. (See the page 6-6.) • Remove the cylinder head assy. (See the page 6-14.) 1. Remove the timing pulley nut 1. $ 09911-49910: Crankshaft holder Remove the washer 2, the guide 3, the timing pulley 4 and the key 5.
  • Page 165 POWER UNIT 6-29 4. Remove the three bolts, the thermostat cover, the gasket, the thermostat and the stopper plates. 5. Remove the two bolts, the water pressure valve cover, the gasket and the water pressure valve from the exhaust mani- fold.
  • Page 166 6-30 POWER UNIT NOTE: To prevent damage to the crank pin and the bolt threads, install a Guide hose guide hose over the threads of the conrod bolts. 10. Remove the crankshaft. 11. Remove the oil seal 1 and the oil seal housing 2 from the crankshaft.
  • Page 167 POWER UNIT 6-31 14. Remove the piston pin from the piston and the conrod us- Piston ing the tool and an arbor press as shown. $ 09910-38211: Piston pin remover & installer Mark “O” NOTE: Hole Reassemble each piston, piston pin and conrod with their origi- nal combination and position.

  • Page 168: Inspection / Servicing

    6-32 POWER UNIT INSPECTION / SERVICING NOTE: If excessive wear, cracks, defective or other damage is found on any component, replace component. CYLINDER / PISTON Cylinder distortion Measure the cylinder distortion (gasketed surface) at a total of 6 locations as shown. $ 09900-20803: Thickness gauge Straight gauge Service limit: 0.060 mm (0.0024 in)
  • Page 169 POWER UNIT 6-33 Cylinder bore wear (difference) Measure the cylinder bore in the thrust and axial directions at the three positions A, B and C as shown. Check for the followings: • Difference of the measurements at the two positions. (Taper) •...
  • Page 170 6-34 POWER UNIT Identification of oversize piston / piston ring I.D. mark Piston Oversize I.D. mark 0.50 mm (0.020 in) 0.50 1st & 2nd ring Oversize I.D. mark 0.50 mm (0.020 in) I.D. mark 1st, 2nd ring Oil ring Oversize I.D.
  • Page 171 POWER UNIT 6-35 Piston ring end gap Measure the piston ring end gap with the piston ring in the low- est position of the cylinder bore. $ 09900-20803: Thickness gauge Standard : 1st 0.15 – 0.30 mm (0.006 – 0.012 in) 2nd 0.20 –...
  • Page 172 6-36 POWER UNIT Piston pin oil clearance Check for the followings: • The piston pin and the piston pin hole are free from excessive wear and damage. • The piston pin can move smoothly in the piston pin hole with oil.
  • Page 173 POWER UNIT 6-37 CONROD / CRANKSHAFT / CRANKCASE Conrod big end side clearance Measure the conrod big end side clearance with the conrod in- stalled on the crank pin as shown. $ 09900-20803: Thickness gauge Standard : 0.10 – 0.25 mm (0.004 – 0.010 in) Service limit: 0.35 mm (0.014 in) If the measurement exceeds the service limit, replace the conrod and/or the crankshaft.
  • Page 174 6-38 POWER UNIT Conrod big end oil clearance Standard : 0.020 – 0.050 mm (0.0008 – 0.0020 in) Service limit: 0.080 mm (0.0031 in) If the measurement exceeds the service limit, replace the conrod bearing. Measure the conrod big end oil clearance as follows: 1.
  • Page 175 POWER UNIT 6-39 Crankshaft center journal runout Measure the crankshaft center journal runout. $ 09900-20602: Dial gauge 09900-20701: Magnetic stand Service limit: 0.06 mm (0.002 in) If the measurement exceeds the service limit, replace the crank- shaft. Crankshaft thrust clearance Measure the crankshaft thrust clearance as shown, after install- ing the crankshaft bearing, the thrust bearing, the crankshaft and the crankcase to the cylinder in the normal manner.
  • Page 176 6-40 POWER UNIT Crankshaft journal outside diameter / difference Measure the crankshaft journal outside diameter in the thrust and axial directions at the two positions as shown. Check for the followings: • Difference of the measurements at the two positions. (Taper) •...
  • Page 177 POWER UNIT 6-41 3. Install the crankshaft to the cylinder. 4. Place a piece of the plastigauge on the journal with parallel to the crankshaft, avoiding the oil hole. $ 09900-22301: Plastiguage 5. Install the crankcase (with the bearing) to the cylinder. 6.
  • Page 178 6-42 POWER UNIT CRANKSHAFT / CRANKCASE COMBINATION Crankshaft journal outside diameter code #2 Journal code The codes are stamped on the upper (flywheel side) web of the crankshaft as shown. Flywheel #1 Journal code side Standard: Code Crankshaft journal outside diameter 51.994 –...
  • Page 179 POWER UNIT 6-43 Crankshaft bearing thickness code The codes are painted on the side of the bearing as shown. Standard: Code Crankshaft bearing thickness Green 1.998 – 2.002 mm (0.0787 – 0.0788 in) Black 2.001 – 2.005 mm (0.0788 – 0.0789 in) Thickness No paint 2.004 –...
  • Page 180 6-44 POWER UNIT OIL SEAL If crack, cut or other damage is found, replace. THERMOSTAT If deposited salt, corrosion, wear or other damage is found, clean or replace. Thermostat operation Check the thermostat opening temperature as follows. 1. Insert a length of thread between the thermostat valve / Thermometer body and suspend the thermostat in a container filled with water.

  • Page 181: Reassembly

    POWER UNIT 6-45 REASSEMBLY Mark “O” Reassembly is reverse order of disassembly with the special at- tention to the following steps. Flywheel side PISTON TO CONROD 1. Apply the engine oil to the piston pin holes and the conrod. Oil hole Make sure that the conrod is installed with the direction as shown.
  • Page 182 6-46 POWER UNIT PISTON RING TO PISTON Oil ring 1. Apply the engine oil to the piston rings. 2. Install the spacer 1 first, then the side rails 2 to the piston. When installing the spacer, do not allow its two ends to overlap in the groove.
  • Page 183 POWER UNIT 6-47 PISTON TO CYLINDER 1. Install the conrod bearing to the conrod and the conrod cap. • Reassemble each conrod bearing to its original posi- tion. • Install the half of the bearing with the oil hole to the conrod side.
  • Page 184 6-48 POWER UNIT 3. Install the crankshaft thrust bearings to the cylinder. NOTE: Install the thrust bearing with its groove facing outward. Groove 4. Apply the engine oil to the lip area of the upper oil seal. 5. Install the upper oil seal and the lower oil seal housing to the crankshaft.
  • Page 185 Apply bond to marked area. 2. Apply the bond to the mating surface of the crankcase as shown. 99000-31140: Suzuki Bond 1207B Apply the bond to the mating surface avoiding the bear- ing with the bond. 3. Install the three dowel pins.
  • Page 186 WATER PRESSURE VALVE 1. Apply the bond to both surfaces of the gasket in its mating area. 99000-31140: Suzuki Bond 1207B 2. Install the water pressure valve, the gasket and the cover by the two bolts. Do not re-use the gasket once removed. Always use a new gasket.

  • Page 187: Operation

    POWER UNIT 6-51 OPERATION WATER COOLING SYSTEM The water cooling system consists of the water pump (in the lower unit), the water tube (between the lower unit and the power unit), the thermostat and the water pressure valve (in the cylinder). This system cools both the power unit and the exhaust and is shown in the schematic form below.

  • Page 188: Engine Lubrication System

    6-52 POWER UNIT ENGINE LUBRICATION SYSTEM The engine oil stored in the oil pan is pumped up by the trochoid type pump. ENGINE OIL LUBRICATION CHART...

  • Page 189: Mid Unit

    MID UNIT 7-1 MID UNIT CONTENTS ENGINE SIDE COVER ____________________________________ 7- 2 REMOVAL ..................7- 2 INSTALLATION ................7- 3 TILLER HANDLE ________________________________________ 7- 4 REMOVAL / DISASSEMBLY ............7- 4 REASSEMBLY / INSTALLATION ........... 7- 7 DRIVESHAFT HOUSING AND OIL PAN ______________________ 7-12 REMOVAL ..................

  • Page 190: Engine Side Cover

    7-2 MID UNIT ENGINE SIDE COVER REMOVAL 1. Remove the snap pin, the washer, the pin and the fastener. 2. Remove the side cover seal. 3. Remove the four bolts and the side cover (starboard). 4. Remove the two bolts. 5.

  • Page 191: Installation

    MID UNIT 7-3 INSTALLATION Installation is reverse order of removal. Fastener Side cover (port) Snap pin Front panel Grommet Washer Bolt Front panel bracket Cushion Bolt Side cover seal Washer Tube Screw Side cover plug Remocon cable holder Side cover (starboard) Side cover seal Stopper Screw...

  • Page 192: Tiller Handle

    7-4 MID UNIT TILLER HANDLE REMOVAL / DISASSEMBLY REMOVAL 1. Remove the rigging port grommet 1 from the front panel. 2. Remove both side covers. (See the page 7-2.) 3. Remove the snap pin 1, the washer 2 and the throttle cable connector 3 from the throttle control arm.
  • Page 193 MID UNIT 7-5 13. Remove the seals 1 and the connector lock nuts 2 from the throttle / shift cables. 14. Slide the rigging port grommet 3 off. DISASSEMBLY 1. Remove the six screws 1 and take off the tiller handle lower cover 2.
  • Page 194 7-6 MID UNIT 7. Loosen the throttle tension adjuster 1. 8. Remove the two screws 2 and the handle rod plate 3. 9. Remove the E-ring 1 and the lock plate 2 from the throttle link 3. 10. Remove the two screws 4 securing the throttle link 3 to the tiller handle housing, then remove the throttle link 3 and the handle rod assembly 5.
  • Page 195 MID UNIT 7-7 REASSEMBLY / INSTALLATION REASSEMBLY Assembly is reverse order of disassembly. When reassembling the tiller handle, refer to the construction diagram below . 1. Tiller handle housing (1) 12. Screw (1) 23. Screw (2) 34. Switch cover (1) 2.
  • Page 196 7-8 MID UNIT INSTALLATION Installation is reverse order of removal with the special attention to the following steps. Tiller handle assembly 1. Install the three nylon bushes 1 into the tiller handle mount- ing hole and set the tiller handle 2 on the handle bracket. 2.
  • Page 197 MID UNIT 7-9 Throttle/Shift cable installation 1. Insert the shift cable and the throttle cable through the rig- ging port grommet 1 as shown. 2. Install the seals 2 and the connector lock nuts 3 on the throttle / shift cables. 3.
  • Page 198 7-10 MID UNIT 5. Install the washer 6 and the snap pin 7, then tighten the cable lock nut 8 against the connector to maintain adjustment. 6. Make sure that both forward and reverse gears can be engaged with the same angle of the shift lever travel from the “NEUTRAL”...
  • Page 199 MID UNIT 7-11 Rigging port grommet Install both side covers and the rigging port grommet 1. Cable routing Bind the shift cable and the throttle cable with the spiral tube 2 as shown.

  • Page 200: Driveshaft Housing And Oil Pan

    7-12 MID UNIT DRIVESHAFT HOUSING AND OIL PAN REMOVAL 1. Remove the power unit. (See the page 6-6 to 6-10.) 2. Remove the lower unit. (See the page 9-2.) 3. Remove the screw and the bonding wires from the driveshaft housing.
  • Page 201 MID UNIT 7-13 9. Remove the driveshaft housing with the oil pan from the steering bracket. 10. Remove the bolts and the upper mount cover 1. 11. Remove the upper mount assy 2. 12. Remove the lower mount assy 1. 13.
  • Page 202 7-14 MID UNIT 15. Remove the three bolts and the oil pump assy. 16. Remove the eight bolts and the oil pan. 17. Remove the water tube and the grommets.

  • Page 203: Inspection

    MID UNIT 7-15 INSPECTION NOTE: If excessive wear, cracks, defective or other damage is found on any component, replace component. MID UNIT COMPONENT Inspect the oil pan, the driveshaft housing, the engine holder and the mount covers. If crack, defective or other damage is found, replace. MOUNT Inspect the upper mount and the lower mount.

  • Page 204: Reassembly

    7-16 MID UNIT REASSEMBLY Reassembly is reverse order of removal with the special attention to the following steps. 23 N·m Water pipe (2.3 kgf-m, 16.5 lb-ft) O-ring 23 N·m Dowel pin 2.3 kgf-m Engine holder 16.5 lb-ft Gasket Dowel pin Bolt Oil pump assy Oil pressure regulator...
  • Page 205 MID UNIT 7-17 13 N·m 1.3 kgf-m 9.5 lb-ft 23 N·m 2.3 kgf-m 16.5 lb-ft 60 N·m 6.0 kgf-m 43.5 lb-ft Gascket Exhaust pipe Stopper Oil pan Water tube cover Lower mount Screw Dowel pin O-ring Washer Insulation washer Washer Water indicator tube Lower mount bolt Bonding wire...
  • Page 206 7-18 MID UNIT DRIVESHAFT HOUSING AND OIL PAN 1. Apply the seal to the outer surface of the lower bushing. 99000-31120: Suzuki Silicone Seal 2. Install the water tube with the bushings, the washer and the pin to the driveshaft housing.
  • Page 207 MID UNIT 7-19 5. Install the two dowel pins and the gasket to the oil pan. 6. Install the engine holder to the oil pan, then gently tighten it temporarily with the six bolts. NOTE: When installing the power unit, tighten the engine holder mount- ing bolts to the specified torque.
  • Page 208 7-20 MID UNIT 3. Install the lower mount cover to the driveshaft housing, then gently tighten it temporarily with the bolts. DRIVESHAFT HOUSING / OIL PAN 1. Install the driveshaft housing / oil pan to the steering bracket. Insert the bolt hexagon head properly into the lower mount bracket hollow.
  • Page 209 MID UNIT 7-21 6. Install the springs and the pins to the lower mount cover. 7. Install the lower mount cap to the lower mount cover, then tighten the screw. BONDING WIRE Install the bonding wires to the driveshaft housing, then tighten the screw.

  • Page 210: Swivel Bracket, Steering Bracket And Clamp Bracket

    7-22 MID UNIT SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL / DISASSEMBLY 1. Remove the driveshaft housing / oil pan. (See the page 7-12 to 7-13.) 2. Remove the circlip 1. 3. Remove the lower mount bracket 1, the shim 2 and the washer 3 from the steering shaft.
  • Page 211 MID UNIT 7-23 8. Remove the tilt cylinder lower shaft bolts 1. 9. Remove the bolts and anode 2. 10. Remove the starboard motor mounting bolts 1. 11. Remove the clamp bracket shaft nut 2. 12. Remove the screw and bonding wire from the swivel bracket. 13.

  • Page 212: Inspection

    7-24 MID UNIT INSPECTION NOTE: If excessive wear, cracks, defective or damage is found on any component, replace component. BUSHINGS Inspect all bushings for excessive wear or other damage. Replace if necessary. If bushing fit is loose when installing, replace the bushing. OIL SEAL Inspect swivel bracket seal for cuts, nicks, excessive wear or other damage.

  • Page 213: Reassembly

    MID UNIT 7-25 REASSEMBLY Reassembly is reverse order of removal with the special attention to the following steps. 43 N . m (4.3 kg-m, 31.0 lb-ft) Clamp bracket STBD Bushing 50 N . m Clamp bracket PORT Oil seal (5.0 kg-m, Clamp bracket shaft Washer 36.0 lb-ft)
  • Page 214 NOTE: Before installing the clamp bracket to the swivel bracket, apply the grease to the clamp bracket shaft and the bushings. 99000-25160: Suzuki Water Resistant Grease 1. Insert the port and starboard bushings 2 into the swivel bracket 1. 2. Assemble the port clamp bracket 1, the washer 2, the clamp bracket shaft 3 and the swivel bracket 4.
  • Page 215 MID UNIT 7-27 STEERING BRACKET 1. Apply the Water Resistant Grease to the steering bracket shaft. 99000-25160: Suzuki Water Resistant Grease NOTE: Apply the grease to the bushings, the oil seal lip and the pilot shaft portion of the steering bracket.
  • Page 216 7-28 MID UNIT BONDING WIRE Reattach the bonding wires, then tighten the screw securely. LUBRICATION After completing reassembly of the mid unit, apply the Watar Resistant Grease through each grease nipple. 99000-25160: Suzuki Water Resistant Grease...

  • Page 217: Power Trim And Tilt

    POWER TRIM AND TILT 8-1 POWER TRIM AND TILT CONTENTS SYSTEM WIRING DIAGRAM _______________________________ 8- 2 SERVICE PROCEDURE ___________________________________ 8- 3 OIL LEVEL ..................8- 3 AIR BLEEDING ................8- 3 POWER TRIM AND TILT UNIT ______________________________ 8- 4 REMOVAL ..................8- 4 DISASSEMBLY ................

  • Page 218: System Wiring Diagram

    8-2 POWER TRIM AND TILT SYSTEM WIRING DIAGRAM PTT switch PTT motor relay (UP) W tube PTT motor To ignition switch Remote control box PTT motor relay (DOWN) Starter motor relay PTT switch Battery...

  • Page 219: Service Procedure

    POWER TRIM AND TILT 8-3 SERVICE PROCEDURE OIL LEVEL To check the PTT oil level: 1. Raise the engine to a full-tilt position. 2. Lower the manual tilt lock lever 1. 3. Remove the oil filler plug 2. 4. If the oil can be seen at the filler plug level, the unit is full. 5.

  • Page 220: Power Trim And Tilt Unit

    8-4 POWER TRIM AND TILT POWER TRIM AND TILT UNIT REMOVAL 1. Raise the engine to the full tilt position and the lower manual tilt lock levers 1. During the following procedures, the engine must be firmly secured and its weight fully supported. (See right) 2.

  • Page 221: Disassembly

    POWER TRIM AND TILT 8-5 7. Remove the starboard motor mounting bolts 1 and the clamp bracket shaft nut 2. 8. Remove the PTT cylinder lower shaft bolts 1. 9. Remove the two bolts and the anode 2. 10. Slide the starboard clamp bracket 1 off the clamp bracket shaft, then remove the PTT unit 2.
  • Page 222 8-6 POWER TRIM AND TILT 3. Remove the PTT motor. (See the page 8-10) Note the position of the drive joint 1 and the O-ring 2, be- fore removing them. 4. Remove the fill plug and drain the PTT oil into a suitable container.

  • Page 223: Inspection

    POWER TRIM AND TILT 8-7 INSPECTION Arrange all components on a clean sheet of paper. NOTE: Do not lay the PTT components out on a rag, as dirt or lint may be transferred to these items which may cause possible sys- tem operating problems.
  • Page 224 8-8 POWER TRIM AND TILT • Inspect the manual release valve for damage. Replace if necessary. • Inspect the O-rings for cuts, nicks or tears. • Inspect the lower shaft and the upper shaft for bent, twist or other damage. Replace if necessary.

  • Page 225: Reassembly

    POWER TRIM AND TILT 8-9 REASSEMBLY Assembly is reverse order of disassembly with the special atten- tion to the following steps. • Do not re-use the O-ring and seal once removed. Al- ways use new parts. • Lubricate all components and O-rings with the PTT fluid before assembly.

  • Page 226: Ptt Motor

    8-10 POWER TRIM AND TILT PTT MOTOR See the PTT MOTOR INSTALLATION section on the page 8- AIR BLEEDING • Pour the recommended PTT fluid in to the reservoir until the specified level. • Perform the air bleeding procedure. See the AIR BLEEDING section on the page 8-3. PTT MOTOR PTT MOTOR REMOVAL NOTE:...

  • Page 227: Ptt Motor Disassembly

    POWER TRIM AND TILT 8-11 PTT MOTOR DISASSEMBLY Protector 1. For correct assembly, scribe an alignment mark on the field tube case and the brush holder. 2. Remove the tape from the PTT motor cables and the cable protector tube, then slide the cable protector tube upward. 3.

  • Page 228: Ptt Motor Inspection

    8-12 POWER TRIM AND TILT PTT MOTOR INSPECTION Armature and Commutator 1. Inspect the commutator surface for gum or dirt. Clean with #500 grit emery paper if necessary. Measure the commutator outside diameter. 09900-20101: Vernier calipers Commutator outside diameter: Standard : 22.0 mm (0.87 in) Service limit: 21.0 mm (0.83 in) If the measurement exceeds the service limit, replace the arma-...

  • Page 229: Ptt Motor Reassembly

    PTT motor cables out of the field case. 4. Apply the Silicone Seal to the PTT motor cable holder and the grommets, then install the cable holder screw. 99000-31120: Suzuki Silicone Seal 5. Fix the cable protector tube to the PTT motor cables with heat-resisting tape.

  • Page 230: Ptt Motor Installation

    8-14 POWER TRIM AND TILT PTT MOTOR INSTALLATION Installation is reverse order of removal with the special atten- tion to the following steps. 1. Ensure that the drive joint 1 is aligned and firmly inserted Ar Armature shaft Armature shaft mature shaft into the gear pump assembly.

  • Page 231: Installation

    3. Install the bushings 1 and the cylinder lower shaft 2 to the PTT unit. 99000-25160: Suzuki Water Resistant Grease Place the PTT unit in position, then install the clamp bracket. Tighten the clamp bracket shaft nut to the specified torque.
  • Page 232 Align the tilt rod with the hole in the swivel bracket as the tilt rod extends. 99000-25160: Suzuki Water Resistant Grease 10. Apply the Water Resistant Grease to the PTT rod upper shaft 1, then insert the shaft through the swivel bracket and the tilt rod.

  • Page 233: Ptt Motor Relay

    POWER TRIM AND TILT 8-17 PTT MOTOR RELAY Two methods can be used to test the PTT motor relays. PTT motor relay PTT motor relay Method 1. Lbl(P) Measure the resistance between the two lead wires of the relay. 09930-99320: Digital tester Tester range: Ω...

  • Page 234: Ptt Switch

    8-18 POWER TRIM AND TILT PTT SWITCH Test the continuity between the switch lead wires at each of the (W/R) three switch positions. 09930-99320: Digital tester & & % Tester range: & & & (Continuity) Tester probe connection Continuity Red + + + + + Black - - - - - “DN”...

  • Page 235: Operation

    POWER TRIM AND TILT 8-19 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 236: Principles Of Operation

    8-20 POWER TRIM AND TILT PRINCIPLES OF OPERATION TRIM/TILT “UP” CIRCUIT When the PTT switch is operated “UP” position, the electric motor and gear pump 4 will operation on clock- wise direction. Pressurized oil will open check valve A, oil will flow from reservoir to spool valve A via pump and spool valve The spool valve A will down, then “DOWN”...
  • Page 237 POWER TRIM AND TILT 8-21 TRIM/TILT “DOWN” CIRCUIT When the PTT switch is operated “DOWN” position, the electric motor and gear pump will operation on counterclockwise direction. Check valve B will open; oil will flow from reservoir to spool valve A. It makes spool valve B move to downward, then “UP”...

  • Page 238: Lower Unit

    8-22 POWER TRIM AND TILT SHOCK ABSORBER CIRCUIT (i) 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 239 POWER TRIM AND TILT 8-23 MANUAL RELEASE CIRCUIT (MANUAL VALVE) Operation: Turn manual valve maximum three (3) 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 240 8-24 POWER TRIM AND TILT THERMAL VALVE As temperature goes up, oil pressure will increase and the oil in PTT unit will expand. High oil pressure in the upper cylinder chamber caused by rising of outside temperature will release thermal valve and make the oil flow to reservoir to prevent from damaging of PTT unit.
  • Page 241 LOWER UNIT LOWER UNIT CONTENTS REMOVAL & DISASSEMBLY _______________________________ 9- 2 PINION BEARING ________________________________________ 9- 7 INSPECTION ____________________________________________ 9- 9 PROPELLER ................... 9- 9 GEARCASE ..................9- 9 GEARS .................... 9-10 PROPELLER SHAFT COMPONENTS ........... 9-10 PROPELLER SHAFT BEARING HOUSING ........9-10 SHIFT ROD GUIDE HOUSING COMPONENTS ......

  • Page 242: Removal & Disassembly

    9-2 LOWER UNIT REMOVAL & DISASSEMBLY Always disconnect the battery cable before removing the lower unit. 1. Shift to the NEUTARAL position. 2. Remove the bolt and the trim tab. 3. Remove the cotter pin 1 and the connector pin 2. 4.
  • Page 243 LOWER UNIT 9-3 6. Remove the cotter pin 1 from the propeller nut and remove the propeller nut 2. 7. Remove the washer 3, the spacer 4, the propeller 5, the stopper 6 and the spacer 7 from the propeller shaft. To prevent injury from propeller blades, wear gloves and place a block of wood between the anti-cavitation plate and the propeller blade tips to lock the propeller...
  • Page 244 9-4 LOWER UNIT 11. Using the special tools, draw out the propeller shaft bearing housing. Remove the propeller shaft and the bearing housing assem- " bly. " 09930-30104: Sliding hammer A 09930-30161: Propeller shaft remover B 12. Hold the pinion nut securely, then fit the special tool to the driveshaft and loosen the pinion nut.
  • Page 245 LOWER UNIT 9-5 16. Remove the three bolts and the shift rod guide housing as- sembly. Account for the detent ball, the spring and the plate. 17. Remove the three bolts 1, then remove the shift cam hous- ing 2. Account for the dowel pins.
  • Page 246 9-6 LOWER UNIT 5. Remove the clutch dog shifter 1. Remove the push pin 2 and the spring 3. Dissasembly of shift rod components 1. Push the pin 1 and 2 out and remove the clutch cam 3. 2. Remove the circlip 1. 3.

  • Page 247: Pinion Bearing

    LOWER UNIT 9-7 PINION BEARING Removal / installation is in the following procedure. Removal & Installation Tools " 09951-59910: Shaft (removal & installation) 1 09551-39914: plate 2 01500-08403: Bolt 3 09951-19421: Attachment 4 09917-98221: Spacer (Attachment) 5 09930-30104: Sliding hammer 6 REMOVAL 1.
  • Page 248 9-8 LOWER UNIT INSTALLATION • Before installing the bearing, ensure that the inside of the gearcase is clean and free of debris. • Ensure that the bearing stamped mark faces upward. 1. Set the shaft 1, the plate 2, the spacer 5, the attachment 4 and the pinion bearing as shown in the figure.

  • Page 249: Inspection

    LOWER UNIT 9-9 INSPECTION NOTE: If excessive ware, cracks, defective or other damage is found on any component, replace component. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety grasses when using compressed air. PROPELLER •...

  • Page 250: Gears

    9-10 LOWER UNIT GEARS • Inspect the forward, reverse and pinion gear teeth and the engaging dogs for excessive wear or other damage. Replace if necessary. • Inspect the forward gear bearing for pitting, rough or other damage. Replace if necessary. PROPELLER SHAFT COMPONENTS •...

  • Page 251: Shift Rod Guide Housing Components

    The lipped portion of the seal should face toward the propel- ler. Apply the Water Resistant Grease to the seal lips. $ 99000-25160: Suzuki Water Resistant Grease 5. Install the washer and the retaining ring. SHIFT ROD GUIDE HOUSING COMPO- NENTS •...

  • Page 252: Driveshaft Oil Seal Housing

    09913-50121: Oil seal remover 2. Apply the Water Resistant Grease to the inner circumfer- ence of the housing. 99000-25160: Suzuki Water Resistant Grease 3. Using an oil seal installer, drive the two oil seals (one at a Direction of time) into the housing.

  • Page 253: Assembly & Installation

    LOWER UNIT 9-13 ASSEMBLY & INSTALLATION Assembly & installation are reverse order of removal & disassembly with the special attention to the following steps. Shift rod guide housing Bolt O-ring Dust seal Washer O-ring O-ring Washer Circlip Spring Shift rod spring collar Shift rod Magneto Magneto holder...
  • Page 254 9-14 LOWER UNIT 55 N . m (5.5 kg-m, 40.0 lb-ft) 20 N . m 100 N . m (2.0 kg-m, 14.5 lb-ft) (10 kg-m, 72.5 lb-ft) 13 N . m (1.3 kg-m, 9.5 lb-ft) Thrust washer Gasket Reverse gear 13 N .
  • Page 255 1. Apply the Water Rasistant Grease to the inside of the dust seal 4, the O-ring 2, 3 and 9. 09900-25160: Suzuki Water Resistant Grease 2. Align the pin holes of the shift rod 5 and the shift cam 6.
  • Page 256 FORWARD GEAR Place the forward gear bearing 3 and the back-up shim 2 in position, then install the forward gear 1. 09900-22540: Suzuki Outboard Motor Gear Oil PINION GEAR Place the pinion gear in the gearcase. DRIVESHAFT 1. Assemble the washer 1, the washer (with the tab) 2, the wave washer 3, the washer 4 and the driveshaft collar 5 to the driveshaft.
  • Page 257 DRIVESHAFT OIL SEAL HOUSING 1. Apply the Water Resistant Grease to the driveshaft oil seal. 99000-25160: Suzuki Water Resistant Grease 2. Apply the Water Resistant Grease to the O-ring, then install the O-ring into the groove on the driveshaft oil seal housing.
  • Page 258 Reverse gear 2 Reverse gear back-up shim 3 Propeller shaft housing 4 99000-25160: Suzuki Water Resistant Grease 99000-22540: Suzuki Outboard Motor Gear Oil 3. Using the special tools, install the propeller shaft and the " housing assembly in the gear case.
  • Page 259 LOWER UNIT 9-19 4. When the housing is fully seated, tighten the two bolts to the specified torque. & Bearing housing bolt: 20 N . m (2.0 kg-m, 14.5 lb-ft) & RECHECKING DRIVESHAFT THRUST PLAY Recheck the driveshaft thrust play. This should not be less than previously checked on the page 9- 17.
  • Page 260 9-20 LOWER UNIT Do not exceed pressure of 110 kPa (1.1 kg/cm , 15.6 psi) or damage to oil seals will result. 4. Once stabilized, the pressure should remain steady for at least 5 min. If the pressure does not fall, sealing performance is correct. WATER PUMP 1.
  • Page 261 $ 99000-25160: Suzuki Water Resistant Grease ( 99000-31120: Suzuki Silicone Seal 5. Apply the Silicone Seal to the seven gearcase bolts and tighten them to the specified torque.
  • Page 262 See the “PERIODIC MAINTENANCE/GEAR OIL” section on the page 2-5. Necessary amount of gear oil: 1050 ml (35.5/37.0 US/Imp.oz) % 99000-22540: Suzuki Outboard Motor Gear Oil TRIM TAB ADJUSTMENT The trim tab counteracts or minimizes propeller torque “pull” felt through the steering system.

  • Page 263: Lower Unit Gears- Shimming And Adjustment

    LOWER UNIT 9-23 LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT If the lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be adjusted to ensure smooth, reliable operation of gears. Shim/Washer &...
  • Page 264 9-24 LOWER UNIT 5. Depress and hold the driveshaft so that the driveshaft bear- ing is firmly seated in the bearing outer race. 6. Hold the driveshaft against the oil seal housing 3 while mea- suring the clearance B between the gauge and the flat edge of the pinion gear 4 with the thickness gauge.
  • Page 265 LOWER UNIT 9-25 2. Install the propeller shaft and the housing assembly (minus the reverse gear and the internal components). 3. Push the propeller shaft inward and hold in position. Push 4. Using the driveshaft holder, rotate the driveshaft 5 – 6 times. "...
  • Page 266 9-26 LOWER UNIT CHECKING DRIVESHAFT THRUST PLAY After obtaining optimum tooth contact, the driveshaft thrust play should be measured. 1. Affix the gear adjusting gauge to the driveshaft. " 09951-09511: Gear adjusting gauge 2. Slowly push the driveshaft downward and read the maxi- mum play.
  • Page 267 LOWER UNIT 9-27 CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure the propeller shaft thrust play. If the measurement is not within the following speci- " fication, a shim adjustment is required. Propeller shaft thrust play: 0.2 – 0.4 mm (0.01 – 0.02 in) NOTE: Maintain the forward gear thrust washer at the standard thick- ness (3.0 mm) and adjust only reverse gear thrust washer with...

  • Page 268: Routing And Diagram

    ROUTING AND DIAGRAM 10-1 ROUTING AND DIAGRAM CONTENTS WIRE ROUTING _________________________________________ 10- 2 FUEL HOSE ROUTING ___________________________________ 10- 8 WATER HOSE ROUTING __________________________________ 10-11 WIRING DIAGRAM _______________________________________ 10-13...

  • Page 269: Wire Routing

    10-2 ROUTING AND DIAGRAM WIRE ROUTING...
  • Page 270 ROUTING AND DIAGRAM 10-3...
  • Page 271 10-4 ROUTING AND DIAGRAM...
  • Page 272 ROUTING AND DIAGRAM 10-5...
  • Page 273 10-6 ROUTING AND DIAGRAM...
  • Page 274 ROUTING AND DIAGRAM 10-7 PTT cable Clamp Grommet Clamp Trim sender PTT motor wire Clamp Trim sender wire PORT CLAMP BRACKET STBD CLAMP BRACKET Clamp PTT cable Front panel...

  • Page 275: Fuel Hose Routing

    10-8 ROUTING AND DIAGRAM FUEL HOSE ROUTING...
  • Page 276 ROUTING AND DIAGRAM 10-9...
  • Page 277 10-10 ROUTING AND DIAGRAM...

  • Page 278: Water Hose Routing

    ROUTING AND DIAGRAM 10-11 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 279 10-12 ROUTING AND DIAGRAM...

  • Page 280: Wiring Diagram

    ROUTING AND DIAGRAM 10-13 WIRING DIAGRAM DF60T/DF70T/DF70WT T T T T...
  • Page 281 10-14 ROUTING AND DIAGRAM DF70WTH...
  • Page 282 Prepared by Marine & Power Products Division 1st Ed. September, 2002 Manual No.99500-99E10-01E Printed in Japan...
  • Page 283 Printed in Japan...

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