Suzuki DF150 Service Manual
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Suzuki DF150 Service Manual

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PRE-PRODUCTION
ISSUE
1

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Summary of Contents for Suzuki DF150

  • Page 1 PRE-PRODUCTION ISSUE...

  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description of the SUZUKI DF150/175 Outboard motors and pro- cedures for inspection, service and overhaul of their GENERAL INFORMATION main components. General knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION section...

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference. 3.
  • Page 4 Apply THREAD LOCK SUPER “1333B”. MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI OUTBOARD MOTOR Measure in DC voltage range. GEAR OIL. Apply SUZUKI SUPER GREASE “A”. Measure in resistance range. Apply SUZUKI MOLY PASTE. Measure in continuity test range. 99000-25140 Apply SUZUKI WATER RESISTANT Use peak voltmeter “Stevens CD-77”.
  • Page 5 ABBREVIATIONS Abbreviations used in this service manual are as follows: BTDC : Before Top Dead Center : Crankshaft position : Camshaft position : Close Throttle position : Direct Current DOHC : Double Over Head Camshaft : Engine Control Module EX (Ex.) : Exhaust : Idle Air Control : Intake Air Temperature IN (In.)

  • Page 6: Table Of Contents

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE .................1- 2 GENERAL PRECAUTIONS ................1- 2 IDENTIFICATION NUMBER LOCATION ............1- 4 FUEL AND OIL ....................1- 5 GASOLINE RECOMMENDATION ............1- 5 ENGINE OIL ...................1- 5 ENGINE BREAK-IN ..................1- 6 WARM-UP RECOMMENDATION ............1- 6 THROTTLE RECOMMENDATION ............1- 6 PROPELLERS ....................1- 7 POWERHEAD DIRECTION OF ROTATION ..........1- 8 CYLINDER NUMBER ..................1- 8...

  • Page 7: 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 8 GENERAL INFORMATION " • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiv- alent. • 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 9: Identification Number Location

    GENERAL INFORMATION IDENTIFICATION NUMBER LOCATION MODEL, PRE-FIX, SERIAL NUMBER The MODEL, PRE-FIX and SERIAL NUMBER of motor are stamped on a plate attached to the clamp bracket. Example MODEL DF 175 1 7 5 0 1 F PRE-FIX SERIAL NUMBER ENGINE SERIAL NUMBER A second engine serial number plate is pressed into a boss on the cylinder block.

  • Page 10: Fuel And Oil

    GENERAL INFORMATION FUEL AND OIL GASOLINE RECOMMENDATION Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R/2+M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.

  • Page 11: Engine Break-In

    GENERAL INFORMATION ENGINE BREAK-IN The first 10 hours are critically important to ensure correct run- ning of either a brand new motor or a motor that has been recon- ditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long-term durability.

  • Page 12: 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 DF150/175 models are shown below. DF150 5 000 – 6 000 r/min Recommended full...

  • Page 13: Powerhead Direction Of Rotation

    GENERAL INFORMATION POWERHEAD DIRECTION OF ROTATION This outboard motor is designed with a L.H. (left hand) rotation powerhead utilizing an offset crankshaft. This design has the advantage of reducing the size of the motor and keeping the overall motor’s weight closer to the boat tran- som and therefore closer to the boat C/G (center of gravity).

  • Page 14: Specifications

    GENERAL INFORMATION * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF150T DF150Z DF175T DF175Z PRE-FIX 15001F 15001Z 17501F 17501Z DIMENSIONS & WEIGHT Overall length mm (in.) 839 (33.0) (front to back) Overall width mm (in.) 519 (20.4) (side to side) Overall height...
  • Page 15 Engine oil amounts 8.0 (8.5/7.0) : Oil change only L (US/lmp. qt) 8.5 (9.0/7.5) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity 1 100 (37.2/38.7) (US/lmp. oz) BRACKET Trim angle degree 0 –...
  • Page 16 GENERAL INFORMATION 1-11 Data Item Unit DF150T DF150Z DF175T DF175Z Counter rotation models Propeller Blade × Dia. (in.) × Pitch (in.) × 15 and 1/2 × × 15 and 1/4 × × × × 14 and 3/4 × × 14 and 1/2 × ×...

  • Page 17: Service Data

    1-12 GENERAL INFORMATION * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF150T/Z DF175T/Z POWERHEAD Recommended operating range r/min 5 000 – 6 000 5 500 – 6 100 Idle speed r/min 650 ± 50 (in-gear: Approx. 650) **Cylinder compression 1 100 –...
  • Page 18 GENERAL INFORMATION 1-13 Data Item Unit DF150T/Z DF175T/Z CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in.) 0.03 (0.001) Manifold seating faces dis- Limit mm (in.) 0.10 (0.004) tortion Cam height 42.520 – 42.680 44.420 – 44.580 mm (in.) (1.6740 – 1.6803) (1.7488 –...
  • Page 19 1-14 GENERAL INFORMATION Data Item Unit DF150T/Z DF175T/Z VALVE/VALVE GUIDE Valve diameter mm (in.) 35.9 (1.4) mm (in.) 31.4 (1.2) Tappet clearance mm (in.) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in.) 0.30 – 0.34 (0.012 – 0.013) Valve seat angle —...
  • Page 20 GENERAL INFORMATION 1-15 Data Item Unit DF150T/Z DF175T/Z CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in.) 0.03 (0.001) Piston to cylinder clearance mm (in.) 0.085 – 0.105 (0.0033 – 0.0041) Limit mm (in.) 0.15 (0.0059) Cylinder bore mm (in.) 97.000 – 97.020 (3.8189 – 3.8197) Cylinder measuring position mm (in.) 50 (1.969) from cylinder top surface...
  • Page 21 1-16 GENERAL INFORMATION Data Item Unit DF150T/Z DF175T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in.) 21.968 – 21.979 (0.8649 – 0.8653) diameter Conrod big end oil clearance STD mm (in.) 0.045 – 0.063 (0.0018 – 0.0025) Limit mm (in.) 0.080 (0.0031) Conrod big end inside diam- mm (in.) 57.000 –...
  • Page 22 GENERAL INFORMATION 1-17 Data Item Unit DF150T/Z DF175T/Z ELECTRICAL Ignition timing Degrees BTDC 5 – 26 ± 3 at r/min Over revolution limiter r/min 6 200 6 300 Ω CKP sensor resistance at 20 °C 168 – 252 Ω CMP sensor resistance at 20 °C —...
  • Page 23 1-18 GENERAL INFORMATION STARTER MOTOR Max. continuous time of use Sec. Motor output Brush length mm (in.) 16.0 (0.63) Limit mm (in.) 12.0 (0.47) Commutator undercut mm (in.) 0.5 – 0.8 (0.02 – 0.03) Limit mm (in.) 0.2 (0.01) Commutator outside diame- mm (in.) 29.0 (1.14) Limit...
  • Page 24 GENERAL INFORMATION 1-19 PRIORITY FAIL-SAFE SYS- FAILED ITEM CODE LAMP FLASHING PATTERN TEM ACTIVATING Fuel injector 4 – 3 Throttle position sensor 2 – 1 Shift position sensor 1 – 2 CMP sensor (VVT) 2 – 6 VVT advance 5 – 2 Neutral switch 3 –...

  • Page 25: Tightening Torque

    1-20 GENERAL INFORMATION TIGHTENING TORQUE Tightening torque – Important fasteners THREAD TIGHTENING TORQUE ITEM DIAMETER N·m kg-m lb-ft Cylinder head cover bolt 6 mm 8 mm 16.6 Cylinder head bolt 12 mm 62.0 Outside 10 mm 26.8 Crankcase bolt Inside 11 mm 41.9 Crankshaft drive gear bolt...
  • Page 26 GENERAL INFORMATION 1-21 TIGHTENING TORQUE THREAD ITEM DIAMETER N·m kg-m lb-ft 10 mm 40.0 Gearcase bolt 12 mm 60.0 Propeller shaft bearing housing bolt 8 mm 16.6 Pinion gear nut 16 mm 14.5 105.0 Propeller nut 18 mm 40.0 Tightening torque – General bolt NOTE: These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners”...

  • Page 27: Special Tools

    1-22 GENERAL INFORMATION SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) Hexagon socket 09900-00415 (8 mm) (A) 09900-06107 09900-20101 (150 mm) 09900-00410 (included in Hexagon bit (included (B) 09900-06108 09900-20102 (200 mm) Hexagon wrench set 09900-00410) in 09900-00410) Snap ring pliers Vernier calipers 09900-20203 (50 –...
  • Page 28 GENERAL INFORMATION 1-23 09912-58413: Fuel pressure gauge set 09910-39610 (1) 09912-58442: Fuel pressure gauge 09900-26006 09900-28403 Piston pin remover (2) 09912-58432: Fuel pressure hose Engine tachometer Hydrometer and installer (3) 09912-58490: 3-way joint & hose 09951-09310 09913-50121 Gear adjust spring 09921-29410 09915-47341 09915-64512...
  • Page 29 1-24 GENERAL INFORMATION 09916-34550 09916-37320 09916-34542 Valve guide reamer Valve guide reamer Valve seat cutter (45°) Valve seat cutter (15°) Valve guide reamer (Neway 128) (Neway 212) 5.5 mm) handle 10.5 mm) 09916-77310 09916-44310 09916-69310 09916-57330 Piston ring com- 09916-84511 Valve guide remover Tappet holder Valve guide installer...
  • Page 30 GENERAL INFORMATION 1-25 09930-89220 09930-89240 09930-89340 09930-76420 3-pin connector test 4-pin connector test 09930-89260 26-pin & 34-pin test Timing light cord cord Injector test cord A cord 09932-79910 Diagnostic harness 09950-69512 09930-99320 09932-89910 09940-44121 09940-44130 Gearcase oil leakage Digital tester SDS adapter Air pressure gauge Attachment...

  • Page 31: Materials Required

    99954-53008-820* Peak reading volt- 99954-53883* Digital voltmeter meter Gear oil filler NOTE: * Marked part No. is in U.S. market only. MATERIALS REQUIRED SUZUKI OUTBOARD SUZUKI SUPER WATER RESISTANT SUZUKI SILICONE SUZUKI BOND MOTOR GEAR OIL GREASE “A” GREASE SEAL “1104”...

  • Page 32: Periodic Maintenance

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 MAINTENANCE AND TUNE-UP PROCEDURES ..........2- 3 ENGINE OIL/ENGINE OIL FILTER ............2- 3 GEAR OIL ....................2- 6 LUBRICATION ..................2- 7 SPARK PLUG ..................2- 8 TAPPET CLEARANCE ................2- 9 IDLE SPEED ...................2-16 IGNITION TIMING ..................2-17 BREATHER AND FUEL LINE ..............2-18...

  • Page 33: 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 34: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes servicing procedures for each periodic maintenance requirement. ENGINE OIL/ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use. 1. Place outboard motor upright on a level surface. 2. Remove motor cover. 3.
  • Page 35 PERIODIC MAINTENANCE ENGINE OIL CHANGE/ENGINE OIL FILTER REPLACEMENT ENGINE OIL Change initially after 20 hours (1 month) and every 100 hours (6 months). ENGINE OIL FILTER Replace initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: •...
  • Page 36 PERIODIC MAINTENANCE (3) Screw new filter on by hand until filter O-ring contacts the mounting surface. (4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench. " Engine oil filter: 14 N·m (1.4 kg-m, 10.0 lb-ft), 3/4 turn (5) Install STBD side cover.

  • Page 37: Gear Oil

    Gear oil amount: 1 100 ml (37.2/38.7 US/Imp. oz) Recommended oils: SUZUKI OUTBOARD MOTOR GEAR OIL or SAE #90 HYPOID GEAR OIL 5. Install air vent plug before removing oil filler tube from drain hole.

  • Page 38: Lubrication

    PERIODIC MAINTENANCE LUBRICATION Inspect every 50 hours (3 months). Apply SUZUKI Water Resistant Grease to the following points. $ 99000-25160: SUZUKI WATER RESISTANT GREASE Throttle cable/link Shift link Throttle body/cable Swivel bracket Propeller shaft Swivel bracket Swivel bracket...

  • Page 39: Spark Plug

    PERIODIC MAINTENANCE SPARK PLUG • Inspect every 100 hours (6 months). • Replace every 200 hours (12 months). Standard spark plug: NGK BKR6E Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition and fuel injection system malfunctions.

  • Page 40: Tappet Clearance

    PERIODIC MAINTENANCE INSTALLATION Installation is reverse order of removal. " Spark plug: 28 N·m (2.8 kg-m, 20.0 lb-ft) TAPPET CLEARANCE Inspect every 200 hours (12 months). The tappet clearance specification is different for 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 41 2-10 PERIODIC MAINTENANCE 4. Rotate crankshaft counterclockwise to bring cam nose verti- cal to shim surface. 90˚ 90˚ 5. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance (cold engine condition): IN.: 0.23 – 0.27 mm (0.009 – 0.011 in) EX.: 0.30 –...
  • Page 42 PERIODIC MAINTENANCE 2-11 4. Rotate top of cam 90 degree counterclockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time.) • Do not put your finger between camshaft and tappet while the tappet is being held with the tappet holder. •...
  • Page 43 2-12 PERIODIC MAINTENANCE 6. Install shim. Identification number should face down (towards tappet). 7. Rotate crankshaft to be open (lift up) valve. 8. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. " Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft) Special tool Tappet Camshaft...
  • Page 44 PERIODIC MAINTENANCE 2-13 • Tighten cylinder head cover bolts to specification. " Cylinder head cover bolts: 11 N·m (1.1 kg-m, 8.0 lb-ft) OCV (Oil control valve) • Install gasket and OCV, and then tighten bolts securely. NOTE: Position the OCV gasket tab as shown the right. Do not reuse OCV gasket.
  • Page 45 2-14 PERIODIC MAINTENANCE...
  • Page 46 PERIODIC MAINTENANCE 2-15...

  • Page 47: Idle Speed

    2-16 PERIODIC MAINTENANCE IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: • Before checking idle speed, engine must be warmed up. • Check and/or adjust idle speed after engine speed has stabi- lized.

  • Page 48: Ignition Timing

    PERIODIC MAINTENANCE 2-17 9. During this fixed mode of IAC valve duty, adjust engine speed to 650 ± 50 r/min. by turning by-pass air screw. Turning air screw counterclockwise: Engine speed will increase. Turning air screw clockwise: Engine speed will decrease. 10.

  • Page 49: Breather And Fuel Line

    2-18 PERIODIC MAINTENANCE BREATHER AND FUEL LINE • Inspect initially after 20 hours (1 month) and every 50 hours (3 months). • Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line.

  • Page 50: Low Pressure Fuel Filter

    9. Restart the engine and check that there are no leaks around the fuel filter. 10. Install the cover. HIGH PRESSURE FUEL FILTER Replace every 1 000 hours. SUZUKI recommends that replacing the high pressure fuel filter every 1 000 operating hours. 1. High pressure fuel filter...

  • Page 51: Water Pump/Water Pump Impeller

    Replace if wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLER Replace every 200 hours (12 months). SUZUKI recommends that replacing the water pump impeller every 200 hours (12 months). Inspect water pump impeller. Replace if vanes are cut, torn or worn.

  • Page 52: Anodes

    10 mm bolt to function as a screw jack. 1. Screw jack 2. Anode cover Anode Never paint the anode. NOTE: The anode securing bolt should be covered with SUZUKI SILI- CONE SEAL. & 99000-31120: SUZUKI SILICONE SEAL...

  • Page 53: Battery

    2-22 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 54: Balancer Chain

    ! 09900-28403: Hydrometer BALANCER CHAIN Replace every 1 600 hours. SUZUKI recommends replacing the balancer chain, chain ten- sioner and chain guide every 1 600 hours. For balancer chain replacement procedure, see the “POWER UNIT/TIMING CHAIN/BALANCER CHAIN” section on page...

  • Page 55: Bolts And Nuts

    To perform fuel mixture check (O2 feedback) operation, a bat- tery powered personal computer and the Suzuki Diagnostic Sys- tem software/hardware must be used. For fuel mixture check (O2 feedback) operation, refer to “Suzuki Diagnostic System Operation Manual”. NOTE: See “O2 FEEDBACK SYSTEM” section on page 3-46 before...

  • Page 56: Oil Pressure

    PERIODIC MAINTENANCE 2-25 OIL PRESSURE Oil pressure (at normal operating temp.): 400 – 600 kPa (4.0 – 6.0 kg/cm , 57 – 85 psi) at 3000 r/min. NOTE: The figure shown above is a guideline only, not an absolute ser- vice limit.
  • Page 57 2-26 PERIODIC MAINTENANCE 5. Install oil pressure gauge adaptor into oil pressure switch hole in place of oil pressure switch. ! 09915-77311: Oil pressure gauge 09915-78211: Oil pressure gauge adapter 6. Install the ring gear cover and air intake silencer case. 7.

  • Page 58: Cylinder Compression

    PERIODIC MAINTENANCE 2-27 CYLINDER COMPRESSION Cylinder compression: Standard: 1 100 – 1 700 kPa (11 – 17 kg/cm , 156 – 242 psi) Max. difference between cylinders: 100 kPa (1.0 kg/cm , 14 psi) NOTE: 1. Compression gauge 2. Compression gauge hose Figures shown are guidelines only, not absolute service limits.

  • Page 59: Engine Vacuum Check

    PERIODIC MAINTENANCE ENGINE VACUUM CHECK Engine vacuum is required for proper operation of the Multi-Stage Induction system used on the DF150 & DF175. Engine vacuum is also an indicator of general engine condition. 1. Warm up engine to normal operating temperature.

  • Page 60: Engine Control System

    ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM STRUCTURE ............. 3- 2 SYSTEM STRUCTURE 1 ................3- 2 SYSTEM STRUCTURE 2 ................3- 3 COMPONENTS FOR SYSTEM CONTROL ............3- 4 ENGINE CONTROL MODULE (ECM) ............3- 4 ECM CONNECTOR/TERMINALS LAYOUT ..........

  • Page 61: Engine Control System Structure

    ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF150/DF175 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...

  • Page 62: System Structure 2

    ENGINE CONTROL SYSTEM SYSTEM STRUCTURE 2 [DF150/175]...

  • Page 63: 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 •...

  • Page 64: Ecm Connector/Terminals Layout

    No. 3 Ignition coil — — — — P/Bl Shift position sensor — — MAP sensor No. 1 Ignition coil Model distinction (DF150 only) Bl/W Buzzer Power source for sensor — — Bl/R Emergency stop switch Lg/R No. 4 Ignition coil Br/Y...

  • Page 65: Ecm Internal Structure

    ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE...

  • Page 66: Location Of Sensor And Switch

    ENGINE CONTROL SYSTEM LOCATION OF SENSOR AND SWITCH Cylinder temp. sensor MAP sensor IAC valve IAT sensor Oil pressure switch Fuel injector High pressure fuel pump Shift position sensor Neutral switch...
  • Page 67 ENGINE CONTROL SYSTEM CMP sensor #2 (DF175) CMP sensor #1 (DF150/175) Ignition coil Cylinder CKP sensor temp. sensor Fuse box Fuse box select 30A 10A 30A MAIN MAIN STARTER SPARE RELAY RELAY STARTER MTR PTT SW IAC, CMP, VSV, VVT...

  • Page 68: Sensor And Switch

    ENGINE CONTROL SYSTEM SENSOR AND SWITCH CKP (Crankshaft Position) SENSOR There is one (1) CKP sensor installed below the flywheel rotor. When the reluctor bars on the flywheel pass the sensor, a signal (voltage pulse) is generated and sent to the ECM. This is the fundamental signal used to judge engine speed and crankshaft angle.
  • Page 69 3-10 ENGINE CONTROL SYSTEM ECM cylinder identification: Cylinders are identified by a calculation combined from two signals; one from the CKP sensor and one from the CMP sensor. #1 Cyl. #3 Cyl. #4 Cyl. #2 Cyl. 34-signals/crankshaft 1 rotation sensor signal 10˚...
  • Page 70 ENGINE CONTROL SYSTEM 3-11 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 temperature) and inputs a signal to the ECM as a voltage value.
  • Page 71 3-12 ENGINE CONTROL SYSTEM TPS (Throttle Position Sensor) The TPS is installed on the throttle body and detects the degree of throttle opening. The throttle shaft is interlocked with the TPS shaft. This sensor is a variable resistor changing resistance (Ohms) in accordance with the throttle opening.
  • Page 72 ENGINE CONTROL SYSTEM 3-13 ECM MAIN RELAY The ECM main relay is installed in the fuse box. When ener- gized by turning the ignition switch ON, a circuit is formed which supplies battery voltage to the ECM, fuel injector, ignition coil, IAC valve, CMP sensor, high pressure fuel pump, OCV (Oil con- trol valve) and VSV (Vacuum switching valve).
  • Page 73 3-14 ENGINE CONTROL SYSTEM SUB BATTERY CABLE (ECM POWER SOURCE LINE) The ECM is battery dependent and must be provided with its own dedicated 12V power supply. The electri- cal circuits which provide this supply are: 1. The sub battery cable to the white lead wire in the remote control extension harness to the ignition switch.
  • Page 74 ENGINE CONTROL SYSTEM 3-15 O2 SENSOR (Optional item) The O2 sensor is installed in the exhaust manifold only when the Zirconia element O2 feedback operation is performed. This sensor is a zirconia element (platinum plated) which Housing changes output voltage depending on the oxygen concentration difference between its internal and external surfaces.

  • Page 75: Ignition System

    3-16 ENGINE CONTROL SYSTEM IGNITION SYSTEM The ignition system used by the DF150/DF175 is a fully transistorized, electronic microcomputer timing advanced 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 76: Ignition Control System

    Ignition switch: Informs ECM of “START” signal. Spark plug SPECIFICATION Ignition system Full-transistorized ignition Advance Electronic microcomputer control BTDC 5° – BTDC 26° (DF150) Ignition timing BTDC 5° – BTDC 26° (DF175) Firing order 1 – 3 – 4 – 2...
  • Page 77 3-18 ENGINE CONTROL SYSTEM IGNITION TIMING CHART The following chart is an example for ignition at BTDC 10°. #1 Cyl. #3 Cyl. #4 Cyl. #2 Cyl. sensor signal sensor #1 signal sensor #2 signal (VVT) 180˚ Spark timing Ig. coil #1 Ig.

  • Page 78: Electronic Fuel Injection System

    ENGINE CONTROL SYSTEM 3-19 ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF150/DF175 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 79 3-20 ENGINE CONTROL SYSTEM FUEL INJECTION TIMING CHART #1 Cyl. #3 Cyl. #4 Cyl. #2 Cyl. sensor signal sensor #1 signal sensor #2 signal (VVT) #1. injection signal #2. injection signal #3. injection signal #4. injection signal Injection Start Timing: Injection time duration ATDC 275˚...

  • Page 80: Fuel Delivery System Components

    ENGINE CONTROL SYSTEM 3-21 FUEL DELIVERY SYSTEM COMPONENTS The fuel delivery system is composed of the low pressure fuel 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 81 3-22 ENGINE CONTROL SYSTEM 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 82 ENGINE CONTROL SYSTEM 3-23 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 fuel vapor separator chamber to keep the pressure bal- anced.

  • Page 83: High Pressure Fuel Pump Control System

    3-24 ENGINE CONTROL SYSTEM HIGH PRESSURE 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 (1 000 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 84: Air Intake Components

    ENGINE CONTROL SYSTEM 3-25 AIR INTAKE COMPONENTS Air, after entering through the silencer case, passes through the throttle body and flows into the surge tank where it is then distributed to the 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 85: Idle Air Control System

    3-26 ENGINE CONTROL SYSTEM BY-PASS AIR SCREW/PASSAGE Since the throttle valve is almost fully closed when idling/trolling, the main flow of air necessary to maintain idling/trolling speed passes through the by-pass air passage. The by-pass air 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 86 ENGINE CONTROL SYSTEM 3-27 IAC VALVE • The IAC valve uses a stepper type motor. • The IAC valve is installed on the intake manifold. • The IAC valve controls the volume of bypass air to stabilize the idling/trolling speed. •...
  • Page 87 3-28 ENGINE CONTROL SYSTEM CONTROL MODE BEFORE START: The IAC valve is initialized at 70% opening position when engine is not running (Ignition switch OFF). WHEN CRANKING: The IAC valve is controlled to operate at approx. 40 – 100% duty. Duty change depends on cylinder temperature.

  • Page 88: Multi-Stage Induction

    ENGINE CONTROL SYSTEM 3-29 MULTI-STAGE INDUCTION OUTLINE The multi-stage induction system is designed to improve the intake efficiency by changing the intake tract volume in accor- dance with the engine speed. This system improves low and mid range torque and increases power output at the higher rpm ranges.

  • Page 89: System Operation

    In this operating mode, intake air speed is boosted and, com- bined with the inertia effect to the long intake tract, increases low and mid speed range engine torque. *: Preset value; DF150: approx. 4 700 r/min DF175: approx. 4 800 r/min Air flow...
  • Page 90 ENGINE CONTROL SYSTEM 3-31 • HIGH SPEED RANGE HIGH SPEED Shut off valve opened When the engine speed is above the preset value (*), the ECM generates a signal to turn the VSV OFF, and vacuum is no longer applied to the depression chamber. Without vacuum the shut off valve return spring returns and holds the valve in its normal open position.

  • Page 91: Vvt (Variable Valve Timing) System

    3-32 ENGINE CONTROL SYSTEM VVT (Variable Valve Timing) SYSTEM • The VVT system is designed to continuously vary intake valve timing to best fit the engines current oper- ating condition. • The intake cam timing sprocket assembly (VVT actuator) is located at the front end of the intake cam- shaft.
  • Page 92 ENGINE CONTROL SYSTEM 3-33 OCV (Oil Control Valve) The OCV is used to regulate oil flow and is installed on the lower camshaft housing. RETARD OPERATION Retard operation When the duty ratio of the ECM is small, the OCV spool valve is Advance chamber Engine oil pressure pushed away from the coil by spring force and engine oil pres-...

  • Page 93: Caution System

    The ECM controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed. Over revolution limiter DF150: 6 200 r/min DF175: 6 300 r/min ACTION: Engine speed Automatically reduced to approx.

  • Page 94: Low Oil Pressure Caution System

    ENGINE CONTROL SYSTEM 3-35 LOW OIL PRESSURE CAUTION SYSTEM CONDITION: Immediate activation of system when the oil pressure switch is turned “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 95: Overheat Caution

    3-36 ENGINE CONTROL SYSTEM OVERHEAT CAUTION CONDITION 1 (Maximum temperature) Immediate activation of system when: • Cylinder temperature reaches 120 °C (248 °F) • Exhaust manifold temperature reaches 114 °C (237.2 °F) CONDITION 2 (Temp. rise vs Time) Immediate activation of system when: •...

  • Page 96: Low Battery Voltage Caution System

    ENGINE CONTROL SYSTEM 3-37 LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION 1: System activated when battery voltage decreases to less than 9 volts for 30 seconds. CONDITION 2: System activated if battery voltage is less than 2 V for more than 2 seconds with the ignition switch turned “ON”...

  • Page 97: Self-Diagnostic System

    3-38 ENGINE CONTROL SYSTEM SELF-DIAGNOSTIC SYSTEM The self-diagnostic system alerts the operator when an abnor- MONITOR-TACHOMETER mality 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 98 ENGINE CONTROL SYSTEM 3-39 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 99: Condition For Self-Diagnostic System Operation

    Model discrimination • There is discrepancy between the ECM memory storage and the model discrimination terminal. • [No.13 terminal open. (DF150)] • [No.13 terminal short circuit. (DF175)] Oil control valve • OCV not operating.
  • Page 100 ENGINE CONTROL SYSTEM 3-41 NOTE 1: MAP sensor These conditions will be caused by IAC valve failure or incorrect O-ring by-pass air screw adjustment. If IAC valve is always closed or by-pass air is too low, the ECM controls the IAC valve duty to increase to maintain the idling/trolling speed specified.

  • Page 101: Fail-Safe System

    3-42 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 102: Operating Hour Indication System

    ENGINE CONTROL SYSTEM 3-43 OPERATING HOUR INDICATION SYSTEM When the ignition switch is initially turned “ON” (from “OFF”), the MONITOR-TACHOMETER ECM tests the caution system by turning on all four lamps in the monitor-tachometer and sounding the caution buzzer for an ini- tial two seconds.

  • Page 103: Oil Change Reminder System

    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 104: Start-In-Gear Protection System

    ENGINE CONTROL SYSTEM 3-45 START-IN-GEAR PROTECTION SYSTEM ■ Control by Neutral switch A switch to detect neutral gear position is located on the throttle lever holder and operated by the clutch con- trol lever. 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 105: O2 Feedback System

    The ECM uses the input data from the O2 sensor to correct the compensation coefficient of the fuel injection duration map within the ECM itself. O2 sensor: Feedback Informs ECM of concentration of oxygen in exhaust gas. ! 18213-74F00: O2 sensor NOTE: For fuel mixture check (O2 feedback) operation procedure, refer to “Suzuki Diagnostic System Operation Manual”.

  • Page 106: Inspection

    ENGINE CONTROL SYSTEM 3-47 INSPECTION PRECAUTION ON SYSTEM INSPECTION " To prevent any unexpected engine start, perform the following before proceeding with any CRANKING tests. • When performing tests not related to fuel injector operation: •Disconnect all fuel injector wire connectors. •...

  • Page 107: Inspection For Ecm Circuit Voltage

    3-48 ENGINE CONTROL SYSTEM INSPECTION FOR ECM CIRCUIT VOLTAGE ECM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an ECM which has been disconnected from the engine wiring harness. ! 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) 1.
  • Page 108 Ignition switch ON, Shift in Reverse MAP sensor 0.20 – 4.53 V Ignition switch ON Model distinction Approx. 5 V Ignition switch ON (DF150 only) Power source for sensor Approx. 5 V Ignition switch ON Bl/R Emergency stop switch Approx. 11 V...
  • Page 109 3-50 ENGINE CONTROL SYSTEM WIRE STANDARD   TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE — — — — — — — — No. 3 Fuel injector Approx. 12 V Ignition switch ON — — — — — — — — Br/R Approx. 12 V Ignition switch ON —...

  • Page 110: Inspection For Resistance

    ENGINE CONTROL SYSTEM 3-51 INSPECTION FOR RESISTANCE ! 09930-99320: Digital tester & Tester range: Ω (Resistance, See chart for range.) NOTE: Make sure ignition switch is always OFF when measuring resis- tance. 1. Turn ignition switch OFF. 2. Disconnect battery cables from battery. 3.
  • Page 111 3-52 ENGINE CONTROL SYSTEM NOTE 3: Disconnect 10 amp. (IAC, CMP) fuse from fuse box and connect tester probe to fuse terminal “C” of fuse box side. RESISTANCE TABLE TERMINAL FOR TESTER STANDARD RESISTANCE ITEM PROBE CONNECTION (at 20 °C) 168 –...

  • Page 112: Component Inspections

    ENGINE CONTROL SYSTEM 3-53 COMPONENT INSPECTIONS HIGH PRESSURE FUEL PUMP 6 SEC OPERATING SOUND 1. Install the emergency stop switch lock plate in position. 2. Shift into Neutral. 3. Turn ignition switch ON and check for fuel pump operating sound. Fuel pump operating sound: Sounds for approx.
  • Page 113 3-54 ENGINE CONTROL SYSTEM FUEL INJECTOR OPERATING SIGNAL 34 pin test cord 26 pin test cord (White connector) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 114 ENGINE CONTROL SYSTEM 3-55 IGNITION COIL OPERATING SIGNAL 34 pin test cord 26 pin test cord (White connector) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 115 3-56 ENGINE CONTROL SYSTEM IGNITION COIL ASSEMBLY ! 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) NOTE: The ignition coil power transistor and high-tension lead are an +BAT integral part of the coil’ internal circuit. Using resistance mea- surements to check for a defect on either the primary or second- ary coil is not possible.
  • Page 116 ENGINE CONTROL SYSTEM 3-57 CMP SENSOR SIGNAL ! 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester (White connector) $ Tester range: % DCV (See chart for range.) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 (Black connector) (Black connector)
  • Page 117 3-58 ENGINE CONTROL SYSTEM MAP SENSOR OUTPUT VOLTAGE CHANGE ! 09917-47011: Vacuum pump gauge 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) 1. Remove flywheel. (See page 3-66.) 2. Remove the three bolts and fuel hose guard. 3.
  • Page 118 ENGINE CONTROL SYSTEM 3-59 8. If out of specification, check wire harnesses for open and short. If wire harnesses are in good condition, replace MAP sensor and recheck. TPS (Throttle position sensor) ! 09930-99320: Digital tester 09930-89340: 26-pin & 34-pin test cord $ Tester range: %(DCV (See chart for range.) 1.
  • Page 119 3-60 ENGINE CONTROL SYSTEM SHIFT POSITION SENSOR ! 09930-99320: Digital tester 09930-89220: 3-pin test cord $ Tester range: %(DCV (See chart for range.) 1. Turn ignition switch OFF. 2. Connect 3-pin test cord between shift position sensor and wire harness as shown in figure. 3.
  • Page 120 ENGINE CONTROL SYSTEM 3-61 OIL PRESSURE SWITCH NOTE: Before checking the oil pressure switch, make sure the engine oil pressure is within specification. 1. Remove the blue lead wire from oil pressure switch. 2. Check the continuity between the switch terminal and engine body ground.
  • Page 121 3-62 ENGINE CONTROL SYSTEM IAC VALVE 1. Disconnect connector from IAC valve. 2. Check each coil of IAC valve for resistance. Terminals Resistance Between “1” and “2” “3” and “2” 25 – 34 Ω “4” and “5” “6” and “5” If out of specification, replace IAC valve.

  • Page 122: Multi-Stage Induction

    ENGINE CONTROL SYSTEM 3-63 MULTI-STAGE INDUCTION SYSTEM INSPECTION • Ensure the depression chamber rod pulls the shut off valves to the complete close position after engine start. 1. Depression chamber 2. Intake manifold • Ensure the shut off valve return spring returns the shut off valves to the full open position when the engine is turned off.
  • Page 123 3-64 ENGINE CONTROL SYSTEM VACUUM PASSAGE INSPECTION 1. Disconnect vacuum hose 1 from vacuum switching valve 2. Start engine and run it at idle speed. Place a finger over vacuum hose end 1 and engine vacuum is present. 3. If vacuum is not present, clean vacuum passage with com- pressed air, start engine and check again for vacuum.
  • Page 124 ENGINE CONTROL SYSTEM 3-65 VSV (Vacuum switching valve) 1. With ignition switch OFF, disconnect connector from VSV. 2. Check resistance between VSV terminals. Resistance of VSV: 37 – 44 Ω 3. Disconnect two hoses from VSV. Filter 4. With 12 V applied between the VSV terminals, check that port (E) connects to port (F) but not to the filter section.

  • Page 125: Removal/Installation

    3-66 ENGINE CONTROL SYSTEM REMOVAL/INSTALLATION FLYWHEEL 1. Flywheel bolt 118 N·m (11.8 kg-m, 85.5 lb-ft) 2. Flywheel 3. Dowel pin 4. CKP sensor 5. Bolt NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent. REMOVAL Prior to removing flywheel: •...
  • Page 126 ENGINE CONTROL SYSTEM 3-67 3. Remove eight (8) flywheel bolts 2. 4. Remove flywheel 1 and dowel pin 3. INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Install dowel pin 3. • Install flywheel 1 onto crankshaft making sure to align dowel pin hole.

  • Page 127: Ckp Sensor

    3-68 ENGINE CONTROL SYSTEM CKP SENSOR CKP SENSOR REMOVAL REMOVAL Prior to removing CKP sensor: Prior to removing CKP sensor: • Disconnect battery cables from battery. • Disconnect battery cables from battery. 1. Remove flywheel. (See page 3-66.) 1. Remove flywheel. (See page 3-66.) 2.

  • Page 128: Cmp Sensor

    ENGINE CONTROL SYSTEM 3-69 CMP SENSOR REMOVAL 1. Disconnect CMP sensor lead wire connector at sensor. 2. Remove bolt, CMP sensor and sensor cover. 1. CMP sensor/sensor cover INSTALLATION Installation is reverse order of removal. • Install CMP sensor and sensor cover, then tighten sensor mounting screw securely.

  • Page 129: Oil Pressure Switch

    3-70 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH REMOVAL 1. Remove the ring gear cover and air intake silencer case 1. (See page 6-2.) 2. Remove the three bolts and fuel hose guard 2. 3. Loosen screw 3 and disconnect blue lead wire 4 from switch.

  • Page 130: Ocv (Oil Control Valve)

    ENGINE CONTROL SYSTEM 3-71 OCV (Oil control valve) REMOVAL 1. To remove the cover 1, pull the upper part outward, then lift 2. Disconnect OCV lead wire connector at OCV. 3. Remove the four (4) bolts securing OCV, then remove OCV and discard OCV gasket.

  • Page 131: Troubleshooting

    3-72 ENGINE CONTROL SYSTEM TROUBLESHOOTING " Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION” section on page 3-47. 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 (4-13).
  • Page 132 ENGINE CONTROL SYSTEM 3-73 CHART 3: SELF-DIAGNOSTIC CODE “1-4” Cylinder temp. sensor START <Ignition switch “OFF”> Cylinder temp. sensor failure Check cylinder temp. sensor resistance. Is result OK? (See page 3-51.) Possible cause: • ECM failure • Wire continuity/connection failure CHART 4: SELF-DIAGNOSTIC CODE “2-3”...
  • Page 133 3-74 ENGINE CONTROL SYSTEM CHART 7: SELF-DIAGNOSTIC CODE “2-2” Air intake system START <Ignition switch “ON”> Check throttle position sensor output Throttle position sensor failure voltage change. Is result OK? (See page 3-59.) <Ignition switch “OFF”> • Check MAP sensor, IAC valve for air leakage.
  • Page 134 ENGINE CONTROL SYSTEM 3-75 CHART 10: SELF-DIAGNOSTIC CODE “4-3” Fuel injector START <Ignition switch “ON”> • ECM failure Check “28” “36” “53” “54” terminal voltage. • Wire continuity/connection failure Is result OK? (See page 3-48.) <Ignition switch “ON”> • ECM failure Check fuel injector operating signal.
  • Page 135 3-76 ENGINE CONTROL SYSTEM CHART 13: SELF-DIAGNOSTIC CODE “2-6” CMP sensor (VVT) START <Ignition switch “ON”> • CMP sensor failure Check CMP sensor (VVT) signal. • Wire continuity/connection failure Is result OK? (See page 3-57.) Possible cause: • ECM failure •...
  • Page 136 Check CMP sensor #1, #2 signal. • Wire continuity/connection failure Is result OK? (See page 3-57.) Possible cause: • No. 13 terminal wiring harness/connector open circuit. (DF150) • No. 13 terminal connector short circuit (DF175) CHART 17: SELF-DIAGNOSTIC CODE “6-2” OCV START <Ignition switch “OFF”>...
  • Page 137 3-78 ENGINE CONTROL SYSTEM CHART 19: ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING) Before starting the troubleshooting, make sure that: • There is no self-diagnostic code indication. • Emergency stop switch plate is set in place. START <Ignition switch “ON”>...
  • Page 138 ENGINE CONTROL SYSTEM 3-79 CHART 20: 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”> • Shift position sensor failure Check shift position sensor output voltage [NOTE 1] change.

This manual is also suitable for:

Df175 four stroke

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