Suzuki DF300 Service Manual

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Page 2 FOREWORD GROUP INDEX This manual contains an introductory description of the SUZUKI DF300 Outboard motor and proce- dures 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 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 : Manifold absolute pressure : Oil control valve : Positive Crankcase Ventilation PORT : Port : Power Trim & Tilt SPC system : SUZUKI Precision Control system : Shift Position Sensor STBD : Starboard : Throttle Position Sensor : Vacuum switching valve...
Page 6: Table Of Contents
ENGINE BREAK-IN ..................1- 6 WARM-UP RECOMMENDATION ............1- 6 THROTTLE RECOMMENDATION ............1- 6 PROPELLERS ....................1- 7 POWERHEAD DIRECTION OF ROTATION ..........1- 8 SUZUKI PRECISION CONTROL SYSTEM ...........1- 8 CYLINDER NUMBER ..................1- 8 SPECIFICATIONS ..................1- 9 SERVICE DATA .....................1-12 TIGHTENING TORQUE .................1-19 SPECIAL TOOLS ..................1-21...
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 300 3 0 0 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 DF300 model is shown below. Recommended full DF300 5 700 – 6 300 r/min...
Page 13: Powerhead Direction Of Rotation
(right-hand) propeller shaft output. SUZUKI PRECISION CONTROL SYSTEM New for Suzuki is the Precision Control System, which electroni- cally controls the throttle and shift systems. This system uses wires in places of the mechanical cables to control the throttle and shift function.
Page 14: Specifications
GENERAL INFORMATION * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF300T DF300Z PRE-FIX 30001F 30001Z DIMENSIONS & WEIGHT Overall length mm (in) 953 (37.5) (front to back) Overall width mm (in) 564 (22.2) (side to side) Overall height mm (in) 1 889 (74.4)
Page 15 Engine oil amounts 8.0 (8.5/7.0) : Oil change only L (US/lmp. qt) 8.2 (8.7/7.2) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts 1 100 (37.2/38.7) (US/lmp. oz) BRACKET Trim angle degree 0 –...
Page 16 GENERAL INFORMATION 1-11 Data Item Unit DF300T DF300Z LOWER UNIT Propeller Counter rotation models Blade × Dia. (in.) × Pitch (in.) × × × × 18 and 1/2 × × × × 21 and 1/2 × × × × 24 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 DF300T/Z POWERHEAD Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 650 ± 50 (in-gear: Approx. 650) **Cylinder compression 1 100 –...
Page 18 GENERAL INFORMATION 1-13 Data Item Unit DF300T/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 mm (in) 45.330 – 45.490 (1.7846 – 1.7909) Limit mm (in) 45.230 (1.7807) mm (in) 44.420 –...
Page 19 1-14 GENERAL INFORMATION Data Item Unit DF300T/Z VALVE/VALVE GUIDE Valve diameter mm (in) 37.9 (1.49) mm (in) 31.4 (1.24) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in) 0.33 – 0.37 (0.013 – 0.015) Valve seat angle —...
Page 20 GENERAL INFORMATION 1-15 Data Item Unit DF300T/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) 98.000 – 98.020 (3.8583 – 3.8591) Cylinder measuring position mm (in) 50 (1.969) from cylinder top surface...
Page 21 1-16 GENERAL INFORMATION Data Item Unit DF300T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in) 22.010 – 22.018 (0.8665 – 0.8668) 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 DF300T/Z ELECTRICAL Ignition timing Degrees ATDC 5° – BTDC 24° at r/min Over revolution limiter r/min 6 400 Ω CKP sensor resistance at 20°C 168 – 252 Ω CMP sensor resistance at 20°C — Ω...
Page 23 1-18 GENERAL INFORMATION PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) Commutator outside diame- mm (in) 22.0 (0.87) Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in SPC system or in the signal from sensors, switches, etc., the code repre- senting the failure is displayed in the digital display screen on the tachometer ·...
Page 24: Tightening Torque
GENERAL INFORMATION 1-19 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 16.5 Cylinder head bolt 11 mm 62.0 8 mm 18.1 Crankcase bolt 10 mm 37.5 Crankshaft drive gear bolt 10 mm...
Page 25 1-20 GENERAL INFORMATION 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 10 mm 36.1 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 26: Special Tools
GENERAL INFORMATION 1-21 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 27 1-22 GENERAL INFORMATION 09912-58413: Fuel pressure gauge set (1) 09912-58442: Fuel pressure gauge 09900-26006 09900-28403 (2) 09912-58432: Fuel pressure hose 09913-50121 Engine tachometer Hydrometer (3) 09912-58490: 3-way joint & hose Oil seal remover 09951-09310 09915-67010 Gear adjust spring 09921-29410 09915-47341 09915-64512 Compression gauge Driveshaft holder...
Page 28 GENERAL INFORMATION 1-23 09916-34550 09916-37320 09916-34542 Valve guide reamer Valve guide reamer Valve seat cutter (15°) Valve guide reamer 09916-44310 (Neway 212) 5.5 mm) handle 10.5 mm) Valve guide remover 09916-77310 09917-47011 09916-69310 09916-57330 Piston ring com- 09916-84511 Vacuum pump Tappet holder Valve guide installer pressor...
Page 29 09900-25002 09944-09820 Remover & installer tool H·T cord adapter Pocket tester Tilt cylinder cap tool SDS Set 09933-19811 • Suzuki Diagnostic Sys- tem Software Ver. 5.00 • Diagnostic harness 09917-49610 • USB cable 09944-09810 Vacuum pump 09952-99310 • USB adapter...
Page 30: 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 31 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 FUEL LINE .....................2-18...
Page 32: 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 33: 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 34 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 35 A short beep will be heard if cancellation is suc- THROTTLE cessfully finished. ONLY (4) Turn main switch key to “OFF” position, then set emer- SUZUKI gency stop switch plate 1 in original position. NOTE: See “OIL CHANGE REMINDER SYSTEM” section on page 3-55.
Page 36: Gear Oil
Gear oil amount: 1 100 ml (37.2/38.7 US/Imp. oz) Recommended oil: SUZUKI OUTBOARD MOTOR GEAR OIL or SAE #90 HYPOID GEAR OIL 5. Install oil level plug before removing oil filler tube from drain hole.
Page 37: 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 Swivel bracket Shift link Swivel bracket Propeller shaft Swivel bracket...
Page 38: 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 39: Tappet Clearance
PERIODIC MAINTENANCE CONDITION OF ELECTRODE Inspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Confirm the thread size and reach when replacing the plug.
Page 40 2-10 PERIODIC MAINTENANCE CHECKING AND ADJUSTING TAPPET CLEARANCE 1. Remove following parts: • Engine side lower cover (See page 7-2.) • Ring gear cover and air intake silencer case (See page 6-2.) • Ignition coils • Spark plugs 2. Remove PORT and STBD cylinder head covers. (See page 6-3.) 3.
Page 41 PERIODIC MAINTENANCE 2-11 2. Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced. 3. Install special tool with camshaft housing bolts as shown in figure. ! 09916-69310: Tappet holder Camshaft housing bolt Plug hole 4.
Page 42 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 43 PERIODIC MAINTENANCE 2-13 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. Always replace with new one. 1. OCV gasket "...
Page 44 2-14 PERIODIC MAINTENANCE...
Page 45 PERIODIC MAINTENANCE 2-15...
Page 46: Idle Speed
NOTE: To check the engine speed, a battery powered personal com- puter and the Suzuki Diagnostic System must be used. 1. Start engine and allow to be warmed up. 2. Check engine speed. Idle speed (in neutral gear): 600 – 700 r/min NOTE: •...
Page 47: Ignition Timing
PERIODIC MAINTENANCE 2-17 IGNITION TIMING Inspect every 200 hours (12 months). NOTE: Before checking the ignition timing, make sure idle speed is within the specification. 1. Remove the bolts and STBD air duct guard 1. 2. Start the engine and allow to warm up. 3.
Page 48: Fuel Line
2-18 PERIODIC MAINTENANCE 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 fuel line.
Page 49: Low Pressure Fuel Filter
10. Restart the engine and check that there are no leaks around the fuel filter. 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 50: Pcv System
2-20 PERIODIC MAINTENANCE PCV SYSTEM • Inspect initially after 20 hours (1 month) and every 50 hours (3 months). • Replace PCV/breather hose every 2 years. NOTE: Be sure to check for any obstruction in the PCV valve or its hose 1.
Page 51: Low Pressure Fuel Pump Filter
PERIODIC MAINTENANCE 2-21 LOW PRESSURE FUEL PUMP FILTER Replace every 1 000 hours. SUZUKI recommends that replacing the low pressure fuel pump filter every 1 000 operating hours. 1. Low pressure fuel pump filter WATER PUMP/WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months).
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 PORT cylinder...
Page 53: Bonding Wires
PERIODIC MAINTENANCE 2-23 BONDING WIRES Inspect every 50 hours (3 months). • If breakage or other damage is found on bonding wire, replace the wire. • If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire.
Page 54: Battery
2-24 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 55: Bolts And Nuts
PERIODIC MAINTENANCE 2-25 BATTERY SOLUTION LEVEL CHECK Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only. Once the battery has been initially serviced, NEVER add diluted sulfuric acid or battery damage will occur. Follow the battery manufacture’s instructions for spe- cific maintenance procedures.
Page 56: Oil Pressure
2-26 PERIODIC MAINTENANCE 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 PERIODIC MAINTENANCE 2-27 4. Start engine and allow to warm up as follows: Summer : 5 min. at 2 000 r/min. Winter : 10 min. at 2 000 r/min. 5. After warming up, shift into forward gear and increase engine speed to 3 000 r/min., then compare pressure indi- cated on gauge to specifications.
Page 58: Cylinder Compression
2-28 PERIODIC MAINTENANCE CYLINDER COMPRESSION Cylinder compression: Standard: 1 100 – 1 500 kPa (11 – 15 kg/cm , 156 – 213 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 10. Move and hold remote control lever on throttle full open posi- SELECT tion. THROTTLE 11. While cranking engine with starter motor by pushing “START ONLY & STOP” button, note maximum compression pressure SUZUKI reading on gauge for each cylinder. 12. Reinstall parts removed earlier (spark plugs, ignition coils etc.).
Page 60 ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM CONTENTS NGINE CONTROL SYSTEM STRUCTURE ..............3- 2 SYSTEM STRUCTURE 1 ................... 3- 2 COMPONENTS FOR SYSTEM CONTROL ..............3- 4 ENGINE CONTROL MODULE (ECM) ............... 3- 4 BOAT CONTROL MODULE (BCM) ..............3- 5 ECM CONNECTOR/TERMINALS LAYOUT ............
Page 61: Engine Control System Structure
ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF300 model will employ an integrated control system which performs the control functions for elec- tronic gear shift system, electronic throttle system, fuel injection, ignition, etc. through the BCM (Boat Control Module) and ECM (Engine Control Module).
Page 62 ENGINE CONTROL SYSTEM INPUT CONTROL OUTPUT (sensor/switch etc.) (BCM) (actuator etc.) Main switch BCM power source Throttle motor relay Lever position sensor 1 (Main, Sub) CAN Communication system Lever position sensor 2 (Main, Sub) Shift motor relay START & STOP switch 1 Caution buzzer START &...
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 and BCM (Boat Control Module). Major controls are as follows: NAME OF CONTROL DESCRIPTION Fuel injection control •...
Page 64: Boat Control Module (Bcm)
ENGINE CONTROL SYSTEM BOAT CONTROL MODULE (BCM) BCM sends a signal value (control signal) to ECM on the basis of input signals from switches and sensors. Based on the received signal value from BCM, ECM controls the engine and the actuators. BCM controls the caution buzzer with the current engine condition detected through ECM.
Page 65 ENGINE CONTROL SYSTEM NOTE 1: • In the case of triple engines, normally the CENTER engine interlinks with the PORT engine. The CENTER engine is controlled with the PORT remote con- trol lever. NOTE 2: • Pressing START & STOP switch once closes (ON) the starter circuit for three seconds but when the engine has been started, the circuit opens (OFF).
Page 66: Ecm Connector/Terminals Layout
ENGINE CONTROL SYSTEM ECM CONNECTOR/TERMINALS LAYOUT FRONT VIEW TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR — — Power source for sensor — — ECM power source Y/Bl CMP sensor #1 Lg/R No.4 Ignition coil (–) CKP sensor No.5 Ignition coil (–) Ex-manifold temp.
Page 67: Bcm Connector/Terminals Layout
ENGINE CONTROL SYSTEM BCM CONNECTOR/TERMINALS LAYOUT (FRONT VIEW) TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR — — — — Power source for LPS main 2 Power source for LPS main 1 Start & Stop switch 2 Lever position sensor sub 1 Lg/B Center control switch Bl/W...
Page 68: Ecm And Bcm Internal Structure [Whole Structure]
ENGINE CONTROL SYSTEM ECM AND BCM INTERNAL STRUCTURE [ WHOLE STRUCTURE...
Page 69 3-10 ENGINE CONTROL SYSTEM BCM INTERNAL STRUCTURE [ PART STRUCTURE-1 To next page 3-11 BATTERY PWR BATTERY BCM PWR INGNITION SW BUZZER RESET SW LPS MAIN1 PWR LPS MAIN1 SIG LPS MAIN1 GND LPS SUB1 PWR LPS SUB1 SIG REMOCON 1 LPS SUB1 GND STRAT &...
Page 70 ENGINE CONTROL SYSTEM 3-11 ECM INTERNAL STRUCTURE [ PART STRUCTURE-2 To previous page 3-10 INJECTOR #1 ECM POWER INJECTOR #2 ECM PWR VB MONI ECM POWER INJECTOR #3 MAIN RELAY INJECTOR #4 NEUTRAL SW INJECTOR #5 STARTER INJECTOR #6 CKP SENSOR RELAY SENSOR1 IGN COIL #1...
Page 71: Location Of Sensor And Switch
3-12 ENGINE CONTROL SYSTEM LOCATION OF SENSOR AND SWITCH EX. temp. sensor (PORT) Purge valve IAT sensor MAP sensor Cylindser temp. sensor . Throttle actuator Charge coil . TPS EX. temp. sensor (STBD) CKP sensor Ground bolt Shift actuator relay Speed sensor Fuse box Battery cable...
Page 72 ENGINE CONTROL SYSTEM 3-13 Fuse box Rectifier & Regulator select 30A 30A 15A MAIN MAIN STARTER SPARE RELAY RELAY " IGN COIL,INJECTOR,ECM,F/P,VVT,CMP STARTER MTR THROTTLE VALVE SHIFT ACTUATOR ISOLATOR Fuse box PTT fuse Oil pressure switch Shift actuator Shift position sensor Neutral switch CMP sensor STBD CMP sensor PORT...
Page 73: Sensor And Switch
3-14 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 74 ENGINE CONTROL SYSTEM 3-15 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. #2 Cyl. #3 Cyl. #4 Cyl. #5 Cyl. #6 Cyl. 34-signals/360˚...
Page 75 3-16 ENGINE CONTROL SYSTEM CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder (top Cylinder temp. sensor 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 76 ENGINE CONTROL SYSTEM 3-17 IAT (Intake Air Temperature) SENSOR The IAT sensor is installed on the bottom of the ring gear cover and air intake silencer case and used to detect the intake air temperature. This sensor is the same type as the cylinder temperature sen- sor, and inputs a signal to the ECM as a voltage value.
Page 77 3-18 ENGINE CONTROL SYSTEM SPS (Shift Position Sensor) The SPS is installed on the shift actuator holder and detects the shift position with the clutch lever operation interlocked. This sensor is a variable resistor that changes resistance (ohms) in accordance with the shift position. The varying resistance value is converted to voltage and input to the ECM.
Page 78 ENGINE CONTROL SYSTEM 3-19 SUB BATTERY CABLE (ECM & BCM power source line) The source voltage is supplied to BCM and ECM each through the two system lines. 1. From the battery, the source is inputted to BCM No.51 termi- nal through the sub-battery cable.
Page 79 3-20 ENGINE CONTROL SYSTEM LEVER POSITION SENSOR (LPS) The lever position sensor is installed in the remote control box and detects the remote control lever position. LPS is of noncontact type using a hall IC (element) supplying voltage signal of two systems, main- and sub-systems, to BCM. This voltage signal as a signal value is sent from BCM to ECM.
Page 80: Switch Panel
ENGINE CONTROL SYSTEM 3-21 SWITCH PANEL BCM performs the engine control according to the signal from various switches as explained below: For dual engine For single For triple engine engine START & STOP SWITCH BCM performs control of engine starting and stopping by a sig- nal from START &...
Page 81 3-22 ENGINE CONTROL SYSTEM SELECT SWITCH SELECT switch • This switch selects the 1st or 2nd station in the case of a 2-station system. By operating the remote control lever and switch in the selected station, BCM control is performed. •...
Page 82 ENGINE CONTROL SYSTEM 3-23 SYNCHRONIZATION SWITCH SYNC switch • In the case of multi engines, BCM monitors the actual speed of each engine and controls the target throttle opening of other than PORT engines to synchronize with PORT engine speed. •...
Page 83 3-24 ENGINE CONTROL SYSTEM PTT SWITCH PTT switch The “Power Trim and Tilt” is operated by pressing the switch. To tilt up, press the UP switch. To tilt down, press the DN switch. NOTE: The tilt up and tilt down switches can not be activated when the main switch is off.
Page 84: Ignition System
ENGINE CONTROL SYSTEM 3-25 IGNITION SYSTEM The ignition system used by the DF300 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 85: Ignition Control System
3-26 ENGINE CONTROL SYSTEM IGNITION CONTROL SYSTEM OUTLINE Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM. Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils.
Page 86 ENGINE CONTROL SYSTEM 3-27 IGNITION TIMING CHART The following chart is an example for ignition at BTDC 10°. 34-signals/360˚ sensor signal 4-signals/720˚ sensor #1 signal Spark timing Ig. coil #1 Ig. coil #6 Ig. coil #5 Ig. coil #4 Ig. coil #3 Ig.
Page 87: Electronic Fuel Injection System
ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF300 is a speed-density, multi-point, sequential, electronic fuel injec- tion 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 88 ENGINE CONTROL SYSTEM 3-29 FUEL INJECTION TIMING CHART 34-signals/360˚ sensor signal 4-signals/720˚ sensor #1 signal ATDC 280˚ on Ex. stroke Injection time duration 240˚ 280˚ Injection signal Injection signal Injection signal Injection signal Injection signal Injection signal In.: Intake, Cm.: Compression, Ep.: Explosion, Ex.: Exhaust CONTROL MODE...
Page 89: Fuel Delivery System Components
3-30 ENGINE CONTROL SYSTEM 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 90 ENGINE CONTROL SYSTEM 3-31 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 91 3-32 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 fuel vapor separator chamber to keep the pressure bal- anced.
Page 92: High Pressure Fuel Pump Control System
ENGINE CONTROL SYSTEM 3-33 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 93: Low Pressure Fuel Pump Control System
3-34 ENGINE CONTROL SYSTEM LOW PRESSURE FUEL PUMP CONTROL SYSTEM Fuel flowing through the pump is the pump coolant. The fuel pump should never be run dry for long peri- ods or it will become damaged. The low pressure fuel pump is an electrically operated type that supplies fuel from the fuel tank to the vapor separator.
Page 94: Air Intake Components
ENGINE CONTROL SYSTEM 3-35 AIR INTAKE COMPONENTS The main components of air intake system are silencer case, electronic throttle body assembly, intake col- lector assembly and intake manifold. Air, after entering through the silencer case, passes through the throttle body and flows into the intake col- lector assembly where it is then distributed to the cylinder intake manifold.
Page 95: Electronic Throttle System
3-36 ENGINE CONTROL SYSTEM ELECTRONIC THROTTLE SYSTEM OUTLINE Description of Electronic Throttle System The electronic throttle system consists of electronic throttle body assembly, lever position sensor assembly, ECM, BCM and throttle actuator control relay. Among them, assembly components are as follows. •...
Page 96 ENGINE CONTROL SYSTEM 3-37 Operation • ECM detects the remote control lever position by the voltage signal supplied from the lever position sen- sor that is built in the remote control box. The lever position sensor signal is inputted to ECM through BCM.
Page 97 3-38 ENGINE CONTROL SYSTEM CONTROL MODE On the basis of lever position sensor voltage signal, throttle position sensor signal and the engine condition, a calculation is operated for driving throttle motor, then the throttle opening is controlled. According to the engine condition, the following controls are performed. •...
Page 98: Vvt (Variable Valve Timing) System
ENGINE CONTROL SYSTEM 3-39 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 99 3-40 ENGINE CONTROL SYSTEM OCV (Oil Control Valve) Two OCV are used, one installed on each (PORT/STBD) 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- Drain...
Page 100: Electronic Shift System
ENGINE CONTROL SYSTEM 3-41 ELECTRONIC SHIFT SYSTEM OUTLINE Description of electronic shift system The electronic shift system consists of lever position sensor assembly, ECM, BCM, shift control actuator relay and shift actuator. OPERATION • ECM detects the remote control lever position by the voltage signal sent from the lever position sensor which is built in the remote control box.
Page 101: Tachometer Monitor
3-42 ENGINE CONTROL SYSTEM TACHOMETER MONITOR DIGITAL DISPLAY SCREEN The digital display screen can indicate the following engine infor- mation. 1. Engine RPM 2. Engine Temperature 3. Engine operation hours 4. Atmospheric pressure 5. Fuel rate : Lit. or Gallons per hour 6.
Page 102: Caution System
• CHECK CONTROL UNIT COMMUNICATION CAUTION • CHECK SECOND STATION CAUTION • CHECK THROTTLE SYSTEM CAUTION BCM (Red) Lamp • CHECK SHIFT CONTROL CAUTION START & STOP SELECT THROTTLE ONLY SUZUKI TACHOMETER CAUTION CAUTION OVER-REV DISPLAY BCM (Red) Lamp TYPE BUZZER LIMITER INDICATION Over-revolution...
Page 103: Over-Revolution 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 DF300: 6 400 r/min ACTION: • When the system detects an engine speed higher than 6 400 r/min, the tachometer display screen will indicate “Rev Limit”...
Page 104: Overheat Caution
ENGINE CONTROL SYSTEM 3-45 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 °F) CONDITION 2 (Temp. rise vs Time) Immediate activation of system when: •...
Page 105: Low Battery Voltage Caution System
3-46 ENGINE CONTROL SYSTEM 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 main switch turned “ON”...
Page 106: Check Second Station Caution
ENGINE CONTROL SYSTEM 3-47 CHECK SECOND STATION CAUTION CONDITION: This system operates when a failure has occurred in the 2nd station control system. ACTION: When the system operates, the tachometer display screen will indicate “Check 2nd Station” and at the same time the caution buzzer sounds and two caution lamps turn on.
Page 107: Check Shift Control Caution
3-48 ENGINE CONTROL SYSTEM CHECK SHIFT CONTROL CAUTION CONDITION: This system operates when a failure has occurred in the electronic shift control system. ACTION: When the system operates, the tachometer display screen will indicate “Check Shift Control” and at the same time the caution buzzer sounds and two caution lamps turn on.
Page 108: Self-Diagnostic System
ENGINE CONTROL SYSTEM 3-49 SELF-DIAGNOSTIC SYSTEM The self-diagnostic system alerts the operator when an abnor- mality occurs in a signal from sensor, switch, etc. When the sys- tem is activated, the “Diagnostic code” appears on the display screen of tachometer- monitor, caution buzzer sound and cau- tion lamps lights.
Page 109 3-50 ENGINE CONTROL SYSTEM NOTE: • If more than one failed items exist, the self-diagnostic system shows the failures in the order of their occur- rence, one at a time, when “ENTER” key is pressed. • If the failed item remains, the self-diagnostic indication appears again after turning the main switch “ON ”. •...
Page 110: Condition For Self-Diagnostic System Operation
ENGINE CONTROL SYSTEM 3-51 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 (1.46 – 33.86 inHg) (0.50 – 4.84 V)” signal (With engine running) Cylinder temp.
Page 111 3-52 ENGINE CONTROL SYSTEM FAILED ITEM CONDITION Speed sensor • Receiving an out of range “0.2 – 4.8 V” signal. Trim sensor • Receiving an out of range “0.2 – 4.8 V” signal. ETV ECM • ECM electronic throttle control circuit failure ETV motor •...
Page 112: Fail-Safe System
ENGINE CONTROL SYSTEM 3-53 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 113 3-54 ENGINE CONTROL SYSTEM FAILED ITEM PRE-PROGRAMMED VALUE ETV ECM • The throttle opening is fixed to default with the throttle motor relay turned off. ECM controls the engine speed at the maximum of 2 000 r/min by operating the remote control lever. (The engine rpm is controlled both by altering the ignition timing and skipping ignition for intermittent misfiring.) ETV motor...
Page 114: Oil Change Reminder System
• Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, SUZUKI strongly recommends that the engine oil be replaced before canceling the system activation. • Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the...
Page 115: Start-In-Gear Protection System
3-56 ENGINE CONTROL SYSTEM START-IN-GEAR PROTECTION SYSTEM To avoid an accidental movement of the boat at the time of engine starting, the system prohibits the starter motor operation when the shift is “IN.” At the time of starting, BCM detects the status of each input signal. When the conditions below are met, pressing “START &...
Page 116: Inspection
NOTE: • To troubleshoot ECM, BCM and the engine control system consisting of sensors and actuators, use the Suzuki Diagnostic System. • When ECM or BCM has been replaced, it is necessary to perform the initialization and re-calibration of SPC system.
Page 117: 26-Pin & 34-Pin Test Cord
3-58 ENGINE CONTROL SYSTEM 26-PIN & 34-PIN TEST CORD This test cord is used when checking the circuit for voltage, etc. and connected between ECM or BCM and the wiring harness. To measure, connect the tester probe to the relevant terminal of the test cord. # 09930-89340: 26-pin (A) &...
Page 118: Inspection For Ecm Circuit Voltage
ENGINE CONTROL SYSTEM 3-59 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 (A) & 34-pin test cord 09930-89850: 26-pin (B) test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.)
Page 119 3-60 ENGINE CONTROL SYSTEM ECM CIRCUIT VOLTAGE TABLE FRONT VIEW WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE — — — — — — — — Y/Bl CMP sensor #1 Approx. 0.3 V or 5 V Main switch ON CKP sensor —...
Page 120 ENGINE CONTROL SYSTEM 3-61 WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE Lg/B IAT sensor 0.04 – 4.46 V Main switch ON — — — — — — — — Br/Y Throttle position sensor (main) 0.5 – 4.5 V Main switch ON R/Bl Power source for TPS Approx.
Page 121 3-62 ENGINE CONTROL SYSTEM WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE • Stop switch plate IN. • Shift into NEUTRAL Approx. 0 V • For 6 sec. after main switch ON. • While engine running High pressure fuel pump (–) •...
Page 122: Inspection For Bcm Circuit Voltage
ENGINE CONTROL SYSTEM 3-63 INSPECTION FOR BCM CIRCUIT VOLTAGE BCM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an BCM which has been disconnected from the BCM wir- ing harness assembly. # 09930-89340: 26-pin (A) & 34-pin test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) 1.
Page 123 3-64 ENGINE CONTROL SYSTEM BCM CIRCUIT VOLTAGE TABLE (FRONT VIEW) WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE — — — — Power source for LPS main 2 Approx. 5 V Main switch ON Main switch ON, Not depressed Start & Approx.
Page 124 ENGINE CONTROL SYSTEM 3-65 WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE CAN 1 (H) Approx. 2.5 or 3.6 V Main switch ON CAN 1 (L) Approx. 2.5 or 1.4 V Main switch ON — — — — — — —...
Page 125: Inspection For Resistance
3-66 ENGINE CONTROL SYSTEM INSPECTION FOR RESISTANCE # 09930-99320: Digital tester & Tester range: Ω (Resistance, See chart for range.) NOTE: Make sure main switch is always OFF when measuring resis- tance. 1. Turn main switch OFF. 2. Disconnect battery cables from battery. 3.
Page 126: Component Inspections
ENGINE CONTROL SYSTEM 3-67 RESISTANCE TABLE TERMINAL FOR TESTER STANDARD RESISTANCE ITEM PROBE CONNECTION (at 20 °C) 168 – 252 Ω CKP sensor 4 (R/B) to 6 (B/W) Fuel injector No. 1 55 (O/B) to Terminal [NOTE 1] Fuel injector No. 2 56 (B/Br) to Terminal [NOTE 1] Fuel injector No.
Page 127 3-68 ENGINE CONTROL SYSTEM [Low pressure side] 1. Install the emergency stop switch lock plate in position. 2. Shift into Neutral. 3. Turn main switch ON and check for fuel pump operating sound. Fuel pump operating sound: Sounds for approx. 6 seconds only 1.
Page 128 ENGINE CONTROL SYSTEM 3-69 FUEL INJECTOR OPERATING SIGNAL 34 pin test cord 27 28 29 30 31 32 33 34 35 36 37 38 39 1 2 3 4 5 6 7 8 9 10 11 12 13 (White connector) (White connector) 56 57 58 59 60 61 62 63 64 65...
Page 129 3-70 ENGINE CONTROL SYSTEM IGNITION COIL OPERATING SIGNAL 26 pin (A) test cord 34 pin test cord 1 2 3 4 5 6 7 8 9 10 11 12 13 27 28 29 30 31 32 33 34 35 36 37 38 39 (White connector) (White connector) 56 57...
Page 130 ENGINE CONTROL SYSTEM 3-71 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 131 3-72 ENGINE CONTROL SYSTEM CMP SENSOR SIGNAL # 09930-89340: 26-pin (A) & 34-pin test cord 09930-89850: 26-pin (B) test cord 27 28 29 30 31 32 33 34 35 36 37 38 39 1 2 3 4 5 6 7 8 9 10 11 12 13 09930-99320: Digital tester (White connector) (White connector)
Page 132 ENGINE CONTROL SYSTEM 3-73 MAP SENSOR OUTPUT VOLTAGE CHANGE # 09917-47011: Vacuum pump gauge 09930-89340: 26-pin (A) & 34-pin test cord 09930-89850: 26-pin (B) test cord 09917-49610: Vacuum pump adaptor 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) MAP sensor 1.
Page 133 3-74 ENGINE CONTROL SYSTEM SHIFT POSITION SENSOR POWER SOURCE AND OUTPUT VOLTAGE # 09930-89340: 26-pin (A) & 34 pin test cord 09930-89850: 26-pin (B) test cord 27 28 29 30 31 32 33 34 35 36 37 38 39 1 2 3 4 5 6 7 8 9 10 11 12 13 09930-99320: Digital tester (White connector) (White connector)
Page 134 ENGINE CONTROL SYSTEM 3-75 8. Connect tester probe (“+”, Red) to No.20 terminal. 26 pin (B) test cord Connect tester probe (“-”, Black) to No.32 terminal (or to body ground). 9. Check for sensor output voltage while operating clutch lever. (Black connector) Sensor output voltage 26 pin (A) test cord...
Page 135 3-76 ENGINE CONTROL SYSTEM SHIFT POSITION SENSOR OUTPUT VOLTAGE OF GEAR ENGAGEMENT START To maintain accurate operation of the electronic shift system, the output voltage from the shift position sen- sor should be adjusted to the specification for each shift position. When the lower unit and its components or the shift link system components have been replaced, make sure to check the output voltage of shift position sen-...
Page 136 ENGINE CONTROL SYSTEM 3-77 5. Connect the 26 pin (A)/(B) and 36 pin test cord between ECM and wire harness as shown in figure. 27 28 29 30 31 32 33 34 35 36 37 38 39 1 2 3 4 5 6 7 8 9 10 11 12 13 (White connector) (White connector) 56 57...
Page 137 3-78 ENGINE CONTROL SYSTEM Adjustment Shift actuator If sensor output voltage is out of specification, the following adjustment procedure must be performed. 12. Remove the five bolts securing shift actuator, then remove shift actuator. (See page 7-4.) 13. Loosen the screw 1 securing shift position sensor. Shift position sensor Loosen the screw 2 securing clutch lever holder.
Page 138 ENGINE CONTROL SYSTEM 3-79 ESA MOTOR/MOTOR RELAY CIRCUIT Check ESA motor/motor relay circuit voltage as following steps. ESA MOTOR CIRCUIT Relay From main relay G/Bl +12 V From main relay Gr/R Gr/R +12 V (Power) Gr/R ESA motor Motor driver ESA motor # 09930-89340: 26-pin (A) &...
Page 139 3-80 ENGINE CONTROL SYSTEM 5. Turn main switch ON and measure terminal voltage. Circuit Terminal Output voltage Shift motor relay Approx. 0.5 V Motor power source 69 or 77 Approx. 12 V Shift motor + Approx. 0 or 12 V Shift motor - Approx.
Page 140 ENGINE CONTROL SYSTEM 3-81 ELECTRONIC THROTTLE BODY Throttle valve visual check 1. Remove the ring gear cover and air intake silencer case. (See page 6-2.) 2. Check that there is not any foreign matter caught between throttle valve and throttle body housing. If there is, take it out after removing throttle body referring to “Electronic Throttle Body Assembly Removal and Installa- tion: in section 3-97”...
Page 141 STOP SELECT THROTTLE ONLY SUZUKI 5. Move remote control lever gradually and check that throttle valve moves smoothly until it opens fully. 6. Return remote control lever in step 5 and check that throttle valve moves back to completely closed position.
Page 142 ENGINE CONTROL SYSTEM 3-83 Throttle Position Sensor performance Check 1. Remove the ring gear cover and air intake silencer case. 2. Turn main switch off. 3. Disconnect connector at electronic throttle body assembly. 4. Check throttle position sensor (main and sub) output voltage as following steps.
Page 143 3-84 ENGINE CONTROL SYSTEM Lever position sensor inspection Check lever position sensor (main and sub) output voltage as following steps. # 09930-99320: Digital tester 09930-89240: 4-pin test cord 1. Turn main switch OFF. 2. Connect 4-pin test cord between lever position sensor and wire harness as shown figure.
Page 144 ENGINE CONTROL SYSTEM 3-85 ETV MOTOR / MOTOR RELAY CIRCUIT Check ETV motor/motor relay circuit voltage as following steps. ETV MOTOR CIRCUIT Relay From main relay +12 V From main relay +12 V (Power) ETV motor Motor driver ETV motor W/Bl # 09930-89340: 26-pin (A) &...
Page 145 3-86 ENGINE CONTROL SYSTEM 5. Turn main switch ON and measure terminal voltage. Circuit Terminal Output voltage Throttle motor relay Approx. 0.5 V Motor power source 58 or 59 Approx. 12 V Throttle motor + Approx. 0 or 12 V Throttle motor - Approx.
Page 146 ENGINE CONTROL SYSTEM 3-87 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 1 from oil pressure switch 2. 2. Check the continuity between the switch terminal and engine body ground.
Page 147 3-88 ENGINE CONTROL SYSTEM OCV (Oil control valve) 1. Remove OCV. (See page 3-96.) 2. Check for operating sound (ticking sound) when battery volt- age applied to and removed from the terminals of oil control valve. 3. Check resistance between the two OCV terminals. OCV resistance: 6.0 –...
Page 148: Switch Panel
ENGINE CONTROL SYSTEM 3-89 SWITCH PANEL SINGLE SWITCH PANEL 10 9 # 09930-99320: Digital tester ( Tester range: )*(Continuity) 1. SWITCH OPERATION (a) Check continuity/infinity between each terminal of the switch by operating them. TERMINAL FOR TESTER PROBE CONNECTION SWITCH OPERA- Tester NAME...
Page 149 3-90 ENGINE CONTROL SYSTEM TRIPLE SWITCH PANEL/DUAL SWITCH PANEL 2 3 4 5 6 7 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 # 09930-99320: Digital tester ( Tester range: )* (Continuity) 1.
Page 150 ENGINE CONTROL SYSTEM 3-91 2. LAMP OPERATION (a) Check if each lamp lights when connecting battery to the ter- minal. Use 4.5 V power source (3 new 1.5 V batteries in series) for test. TERMINAL FOR BATTERY Lamp 2 3 4 CONNECTION condition 5 6 7...
Page 151: Removal/Installation
3-92 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 6. CMP sensor 7. Bolt NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent. REMOVAL Prior to removing flywheel: •...
Page 152 ENGINE CONTROL SYSTEM 3-93 4. Remove eight (8) flywheel bolts 4. 5. Remove flywheel 3 and dowel pin 5. INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Install dowel pin 5. • Install flywheel 3 onto crankshaft making sure to align dowel pin hole.
Page 153: Ckp Sensor
3-94 ENGINE CONTROL SYSTEM CKP SENSOR REMOVAL Prior to removing CKP sensor: • Disconnect battery cables from battery. 1. Remove ring gear cover and air intake silencer case. (See page 6-2.) 2. Disconnect CKP sensor lead wire connector in electric parts holder.
Page 154: Cmp Sensor
ENGINE CONTROL SYSTEM 3-95 CMP SENSOR REMOVAL 1. Remove the ring gear cover. (See page 6-2.) 2. Disconnect CMP sensor lead wire connector at sensor. 3. Remove bolt and CMP sensor. 1. CMP sensor 2. CMP sensor INSTALLATION Installation is reverse order of removal. •...
Page 155: Ocv (Oil Control Valve)
3-96 ENGINE CONTROL SYSTEM OCV (Oil control valve) REMOVAL 1. Remove air duct guard. (See page 6-2.) 2. Disconnect OCV lead wire connector at OCV. 3. Remove the four (4) bolts securing OCV, then remove OCV and discard OCV gasket. 1.
Page 156: Electronic Throttle Body Assembly
ENGINE CONTROL SYSTEM 3-97 ELECTRONIC THROTTLE BODY ASSEMBLY • Do not disassemble electronic throttle body assem- bly. • Be careful not to accumulate foreign materials (such as dust and/or metallic particles) on the throttle body housing and/or throttle valve. Otherwise, damage may occur to the throttle body assembly.
Page 157 3-98 ENGINE CONTROL SYSTEM INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Clean mating surfaces and install new throttle body dumper gasket 1. • Install throttle body dumper 2, then tighten dumper mounting bolts securely.
Page 158: Clutch Link Rod
ENGINE CONTROL SYSTEM 3-99 CLUTCH LINK ROD When replacing a link rod and/or connector, see the illustration below to adjust the link rod length to specification. NOTE: • Be sure an equal length of link rod is threaded into each con- nector.
Page 159: Troubleshooting
3-100 ENGINE CONTROL SYSTEM TROUBLESHOOTING " Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION” section on page 3-57. 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 (4-14).
Page 160 ENGINE CONTROL SYSTEM 3-101 CHART 4: SELF-DIAGNOSTIC CODE “1-5” Ex. mani. sensor STBD START <Main switch “OFF”> Check Ex. manifold temp. sensor STBD • Ex. manifold temp. sensor STBD failure resistance. • Wire continuity/connection failure Is result OK? (See page 3-66.) Possible cause: •...
Page 161 3-102 ENGINE CONTROL SYSTEM CHART 7: SELF-DIAGNOSTIC CODE “3-7” Trim sensor START <Main switch “ON”> • ECM failure Check ECM “44” terminal voltage. • Wire continuity/connection failure Is result OK? (See page 3-59.) <Main switch “ON”> Check ECM “17” terminal voltage. Trim sensor failure Is result OK? (See page 3-59.) Possible cause:...
Page 162 ENGINE CONTROL SYSTEM 3-103 CHART 10: SELF-DIAGNOSTIC CODE “1-1” Over charging START <Individual check> Check rectifier & regulator resistance. Rectifier & regulator failure [NOTE 1] Is result OK? (See page 4-9.) <Engine running> Check ECM “52” terminal voltage at idle speed.
Page 163 3-104 ENGINE CONTROL SYSTEM CHART 12: SELF-DIAGNOSTIC CODE “4-2” CKP sensor START <Main switch “OFF”> CKP sensor failure Check CKP sensor resistance. Is result OK? (See page 3-66.) Possible cause: • ECM failure • Wire continuity/connection failure CHART 13: SELF-DIAGNOSTIC CODE “2-4” CMP sensor START <Main switch “ON”>...
Page 164 ENGINE CONTROL SYSTEM 3-105 CHART 16: SELF-DIAGNOSTIC CODE “2-2” Air intake system START <Main switch “ON”> Check throttle position sensor output Throttle position sensor failure voltage change. Is result OK? (See page 3-83.) <Main switch “OFF”> • Check MAP sensor, throttle body for air leakage.
Page 165 3-106 ENGINE CONTROL SYSTEM CHART 19: SELF-DIAGNOSTIC CODE “5-1” VVT advance (STBD) START <Main switch “ON”> Check ECM “45” “52” terminal voltage ECM power source (battery, battery switch, (ECM power source voltage). sub-battery cable, etc.) failure Is result OK? (See page 3-59.) <Main switch “OFF”>...
Page 166 ENGINE CONTROL SYSTEM 3-107 CHART 21: SELF-DIAGNOSTIC CODE “6-1” OCV (STBD) START <Main switch “OFF”> Check OCV operation. OCV failure Is result OK? (See page 3-88.) <Main switch “OFF”> Check OCV resistance. OCV failure Is result OK? (See page 3-88.) Possible cause: •...
Page 167 3-108 ENGINE CONTROL SYSTEM CHART 24: SELF-DIAGNOSTIC CODE “7-2” ETV motor START <Main switch “OFF”> Check throttle motor resistance. Throttle motor failure (See page 3-82.) Is result OK? <Individual check> ETV motor relay failure Check ETV motor relay. (See page 3-86.) Is result OK? <Main switch “ON”>...
Page 168 ENGINE CONTROL SYSTEM 3-109 CHART 27: SELF-DIAGNOSTIC CODE “7-5” DBW system START <Main switch “ON”> Check BCM “51” terminal voltage. • Wire continuity/connection failure (See page 3-63.) • BCM failure Is result OK? <Main switch “ON”> Select the 1st station. •...
Page 169 3-110 ENGINE CONTROL SYSTEM CHART 29: SELF-DIAGNOSTIC CODE “8-2” ESA motor START <Main switch “OFF”> Check shift motor resistance. Shift motor failure (See page 3-80.) Is result OK? <Individual check> ESA motor relay failure Check ESA motor relay. (See page 3-80.) Is result OK? <Main switch “ON”>...
Page 170 ENGINE CONTROL SYSTEM 3-111 CHART 31: 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 <Main switch “ON”>...
Page 171 3-112 ENGINE CONTROL SYSTEM CHART 32 : UNSTABLE IDLING/TROLLING (OR ENGINE TENDS TO STALL) Before starting this troubleshooting, make sure that: • There is no self-diagnostic code indication. START <Main switch “OFF”> Check throttle valve operation. Electronic throttle body assembly failure (See page 3-81.) Is result OK? <Main switch “OFF”>...
Page 172 ENGINE ELECTRICAL 4-1 ENGINE ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ..............4- 2 OUTLINE ....................4- 2 INSPECTION ..................4- 4 REMOVAL/INSTALLATION ..............4-10 ELECTRIC STARTER SYSTEM ..............4-12 OUTLINE ....................4-12 TROUBLESHOOTING ................4-14 INSPECTION ..................4-15 STARTER MOTOR .................4-18 ELECTRIC PARTS HOLDER ................4-30 REMOVAL ....................4-30 INSTALLATION ..................4-32...
Page 173: Battery Charging System
ENGINE ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the BATTERY CHARGE COIL, RECTIFIER & REGULATORS and BATTERY. The three phase AC current generated from the battery charge coil is converted by the rectifier & regulators into regulated DC current which is used to charge the battery.
Page 174 ENGINE ELECTRICAL ISOLATOR FUNCTION The battery charging system is equipped with an isolator function. When a sub battery is used in addition to the main battery for engine operation, this function allows both the batteries to be charged at the same time. To modify the charging circuit and distribute the power to the individual batteries, relocate the 40 amp fuse in [STD] position to [OPT x] position in the fuse box.
Page 175: Inspection
ENGINE ELECTRICAL INSPECTION BATTERY CHARGE COIL Measure battery charge coil resistance. ! 09930-99320: Digital tester " Tester range: Ω (Resistance) 1. Disconnect battery charge coil leads from rectifier & regula- tors. 2. Measure resistance between leads in the combinations shown. Battery charge coil resistance: Terminal for tester probe Resistance...
Page 176 ENGINE ELECTRICAL FUSE BOX/FUSE Fuse Fuse ! 09930-99320: Digital tester # Tester range: $ (Continuity) Fuse 1. Remove the fuse from fuse box. 2. Inspect continuity between both terminals of fuse. If no continuity is indicated, replace fuse. Main fuse: 60 A Isolator select fuse: 40 A Ign.
Page 177 ENGINE ELECTRICAL 60 amp. main fuse line 1. Disconnect battery cables from battery. 2. Disconnect output lead wire connector from rectifier & regu- lator. 3. Inspect continuity between the white charge lead wire termi- nal 2 and “B” terminal of starter motor magnetic switch. 4.
Page 178 ENGINE ELECTRICAL 30 amp. starter motor relay fuse line 1. Disconnect battery cables from battery. 2. Disconnect starter motor relay from fuse box. 3. Disconnect output lead wire connector from rectifier & regu- lator. 4. Inspect continuity between the lead wire terminal a of starter motor relay and the white charge lead wire terminal 5.
Page 179 ENGINE ELECTRICAL 5. Inspect continuity between the lead wire terminal c of main fuse and the Yellow lead wire terminal 3 of engine main harness (motor relay harness). 6. If no continuity is indicated, replace fuse and/or main har- ness. Throttle motor relay 15 amp.
Page 180 2. Measure resistance between leads in the combinations shown. NOTE: Rectifier & Regulator: The values given below are for a SUZUKI pocket tester. No.1 No.2 As thyristors, diodes, etc. are used inside this rectifier & regula- tor, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.
Page 181: Removal/Installation
4-10 ENGINE ELECTRICAL REMOVAL/INSTALLATION 118 N . m System construction (11.8 kg-m, 85.5 lb-ft) Bolt Flywheel " Dowel pin Screw Battery charge coil Rectifier & regulator & Bolt Seal ring Clamp Bolt Main harness Main fuse 60 A Fuse Main relay Starter relay REMOVAL Prior to removing electrical parts:...
Page 182 Installation is reverse order of removal with special attention to the following steps. Battery charge coil Apply Suzuki Bond to the coil securing screws. % 99000-31140: SUZUKI BOND “1207B” Wire routing Secure coil lead wire with lead wire clamps, then check that coil lead wire is routed properly and away from hot or rotating parts.
Page 183: Electric Starter System
4-12 ENGINE ELECTRICAL ELECTRIC STARTER SYSTEM OUTLINE The starting circuit consists of the battery, starting motor, main switch, “START & STOP” switch, neutral switch, BCM, ECM and related electrical wiring. These components are connected electrically as shown in figure below. STARTING SYSTEM CIRCUIT In the circuit shown in figure below, the magnetic switch coils are magnetized when the main switch is closed (turn to “ON”) and depress the “START &...
Page 184 ENGINE ELECTRICAL 4-13 STARTER MOTOR OPERATION CONDITION The starter motor relay will only engage when the main switch is turned to “ON” position and depress the “START & STOP” button if the all of the following conditions are satisfied. • Lock plate is attached to emergency stop switch. •...
Page 185: Troubleshooting
4-14 ENGINE ELECTRICAL TROUBLESHOOTING NOTE: Before troubleshooting the electric starter system, make sure of the following: • Battery is fully charged. • All cables/wires are securely connected. • Shift is in “NEUTRAL” position. • Emergency stop switch lock plate is set in place. &...
Page 186: Inspection
ENGINE ELECTRICAL 4-15 INSPECTION MAIN SWITCH ! 09930-99320: Digital tester PUSH # Tester range: $ (Continuity) 1. Disconnect the main switch from switch panel wiring har- ness. 2. Check continuity between wiring leads at the key positions PUSH shown in the chart. Switch Lead Wires Position Black...
Page 187 4-16 ENGINE ELECTRICAL NEUTRAL SWITCH Check for continuity/infinity of the neutral switch. ! 09930-99320: Digital tester # Tester range: $ (Continuity) 1. Shift to “NEUTRAL” position. 2. Remove the clip 1, washer 2 and clutch link rod 3 from clutch lever 4. &...
Page 188 ENGINE ELECTRICAL 4-17 EMERGENCY STOP SWITCH ! 09930-99320: Digital tester # Tester range: $ (Continuity) 1. Disconnect the emergency stop switch lead wire. 2. Check continuity/infinity between the wiring leads under the condition shown below. Tester probe connection Tester indicates Red (+) Black (–) Lock plate...
Page 189: Starter Motor
4-18 ENGINE ELECTRICAL STARTER MOTOR REMOVAL Prior to removing starter motor: • Disconnect battery cables from battery. 1. Remove bolts and ring gear cover and air intake silencer case 1. (See page 6-2.) 2. Remove the two (2) bolts 3, negative - battery cable 4 and starter motor band 2.
Page 190 ENGINE ELECTRICAL 4-19 INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Install starter motor and tighten starter motor mounting bolts securely. ' Starter motor mounting bolt: 23 N·m (2.3 kg-m, 16.5 lb-ft) DISASSEMBLY When overhauling starting motor, it is recommended that com- ponent parts be cleaned thoroughly.
Page 191 4-20 ENGINE ELECTRICAL 4. Remove screws 5, long through bolts 6 and rear cover 7. 5. Remove thrust washer 8 with screwdriver. 6. Pull the brush spring 9 up to separate the brush from the surface of the commutator, then remove the brush holder 0. 7.
Page 192 ENGINE ELECTRICAL 4-21 10. Remove the center bracket F (with shift lever H, pinion I and pinion shaft J) from front housing G. 11. Remove the shift lever H. 12. Push the pinion stopper K down, then remove stopper ring Remove the pinion stopper and pinion I.
Page 193 4-22 ENGINE ELECTRICAL INSPECTION AND SERVICING Armature and Commutator • Inspect the commutator surface. If surface is gummy or dirty, clean with #500 grit emery paper • Measure commutator outside diameter. ! 09900-20101: Vernier calipers Commutator outside diameter: Standard: 29.0 mm (1.14 in) Service limit: 28.0 mm (1.10 in) If measurement exceeds service limit, replace armature.
Page 194 ENGINE ELECTRICAL 4-23 • Check for continuity between adjacent commutator segments. Replace armature if no continuity is indicated. ! 09930-99320: Digital tester # Tester range: $ (Continuity) BRUSHES Check the length of each brush. ! 09900-20101: Vernier calipers Brush length: Standard: 16.0 mm (0.63 in) Service limit: 12.0 mm (0.47 in)
Page 195 4-24 ENGINE ELECTRICAL SHIFT LEVER Inspect shift lever for wear. Replace if necessary. PINION AND OVER-RUNNING CLUTCH • Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace if necessary.
Page 196 ENGINE ELECTRICAL 4-25 FRONT HOUSING • Inspect front housing for wear, damage or other abnormal conditions. Replace if necessary. • Inspect bush for wear or other damage. Replace if necessary. ARMATURE SHAFT BUSH Inspect bush for wear or other damage. Replace if necessary.
Page 197 4-26 ENGINE ELECTRICAL Hold-in coil Open circuit Test ! 09930-99320: Digital tester # Tester range: $ (Continuity) Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, the coil is open and should be replaced. Contact points Test ! 09930-99320: Digital tester # Tester range: $ (Continuity)
Page 198 ENGINE ELECTRICAL 4-27 ASSEMBLY Assembly is reverse order of disassembly with special attention to the following steps. & When installing armature, use care to avoid breaking brushes. When installing pinion shift lever, refer to figure in construction diagram for installation direction. Construction diagram 7 N .
Page 199 4-28 ENGINE ELECTRICAL PERFORMANCE TEST & Each test must be performed within 3 – 5 seconds to avoid coil damage from overheating. When performing the following test, be sure to con- nect the battery and the starting motor with a lead wire of the same size as original equipment used there.
Page 200 ENGINE ELECTRICAL 4-29 NO-LOAD PERFORMANCE TEST & Before performing following test, secure the starter motor to the test bench. 1. Connect battery and ammeter to starter motor as shown. 2. Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current. No load current: Within 90 A at 11 V...
Page 201: Electric Parts Holder
4-30 ENGINE ELECTRICAL ELECTRIC PARTS HOLDER REMOVAL Before removing electric parts holder: • Disconnect battery cables from battery. 1. Remove engine side cover. (See page 7-2.) 2. Remove bolts and front panel 1. 3. Disconnect high pressure fuel pump lead wire connector 2 at fuel pump.
Page 202 ENGINE ELECTRICAL 4-31 6. Pull and remove fuse box 7 from electric parts holder. Remove the bolt and negative - battery cable 8. Remove the bolt 9 securing electric parts holder. 7. Remove the three (3) bolts securing electric parts holder. Remove the bolt securing GND lead wire 0.
Page 203: Installation
4-32 ENGINE ELECTRICAL 10. Remove PTT relay E from electric parts holder. 11. Remove cable clamp from electric parts holder by releasing clamp’s lock. 1. Cable clamp 12. To remove the electric parts holder, pull each lead wire out of electric parts holder. INSTALLATION Installation is reverse order of removal.
Page 204 FUEL SYSTEM FUEL SYSTEM CONTENTS PRECAUTIONS WHEN SERVICING FUEL SYSTEM ........5- 2 GENERAL PRECAUTION ..............5- 2 FUEL PRESSURE RELIEF PROCEDURE ........... 5- 3 FUEL LINE ...................... 5- 4 REMOVAL/INSTALLATION ..............5- 4 FUEL LEAKAGE CHECK PROCEDURE ..........5- 4 FUEL HOSE CONNECTION ..............
Page 205: Precautions When Servicing Fuel System
FUEL SYSTEM PRECAUTIONS WHEN SERVICING FUEL SYSTEM GENERAL PRECAUTION Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing/inspection. •...
Page 206: Fuel Pressure Relief Procedure
FUEL SYSTEM FUEL PRESSURE RELIEF PROCEDURE After making sure that engine is cold, relieve fuel pressure as follows. 1. Turn OFF main switch. 2. Disconnect high pressure fuel pump lead wire connector at high pressure fuel pump. High pressure fuel pump 3.
Page 207: Fuel Line
FUEL SYSTEM FUEL LINE REMOVAL/INSTALLATION Pay special attention to the following steps when removing or installing fuel hoses. Fuel components and fuel hoses after the high pres- sure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components.
Page 208: Fuel Hose Connection
FUEL SYSTEM FUEL HOSE CONNECTION Clamp (Clip) “A” Hose Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly by referring to the figure. Joint pipe 3 – 7 mm •...
Page 209 FUEL SYSTEM " A small amount of fuel may be released when the fuel feed hose is disconnected. Place container under the fuel feed hose or 3-way joint pipe with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in an approved container.
Page 210: Low Pressure Fuel Pump/Fuel Vapor Separator Set
FUEL SYSTEM LOW PRESSURE FUEL PUMP/FUEL VAPOR SEPARATOR SET REMOVAL Fuel components and fuel hoses after the high pres- sure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. 1.
Page 211 FUEL SYSTEM 8. Disconnect water inlet hose 7 from fuel cooler. 9. Disconnect high pressure fuel feed hose 8 from 3-way joint pipe. 3 way joint 10. Remove the two (2) bolts securing fuel vapor separator 9 to crankcase. 11. Remove the two (2) bolts securing high pressure fuel filter 0 to crankcase.
Page 212: Fuel System Diagram
FUEL SYSTEM 13. Remove the low pressure fuel pump/fuel vapor separator set B, then disconnect cooling water outlet hose C from fuel cooler. FUEL SYSTEM DIAGRAM FUEL VAPOR SEPARATOR SET SECTION OF HIGH PRESSURE FUEL LINE SECTION OF LOW PRESSURE FUEL LINE Needle valve Float Fuel tank...
Page 213: Inspection
5-10 FUEL SYSTEM INSPECTION FUEL FILTER • Remove the fuel filter. • Inspect filter for clog or other damage. Fuel filter Replace or clean if necessary. • Reinstall fuel filter, then secure the hose with hose clamp (clip). RELIEF VALVE Check the relief valve operation.
Page 214: Fuel Vapor Separator/High Pressure Fuel Pump
FUEL SYSTEM 5-11 FUEL VAPOR SEPARATOR/HIGH PRESSURE FUEL PUMP REMOVAL AND DISASSEMBLY Fuel components and fuel hoses after the high pres- sure fuel pump remain pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. 1.
Page 215 5-12 FUEL SYSTEM 5. Disconnect fuel return hose 6 from fuel vapor separator. 6. Remove seven (7) screws 1. Remove separator cover 2 with high pressure fuel pump from separator case 3. 7. Remove float pin 4 and float 5. 8.
Page 216: Inspection
FUEL SYSTEM 5-13 10. Remove suction filter 0. 11. Remove high pressure fuel pump A and grommet B from separator cover and then disconnect pump lead wire con- nector. INSPECTION NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component.
Page 217 5-14 FUEL SYSTEM Filter Inspect pump suction filter for clog or other damage. Replace or clean if necessary. Separator cover and case Inspect separator cover and case. Replace if cracked, damaged or other abnormal condition. NOTE: Separator cover and case are a set. If any repair is required on cover and case, replace them as a fuel vapor separator assembly.
Page 218: Assembly
FUEL SYSTEM 5-15 ASSEMBLY Assembly is reverse order of disassembly with special attention to the following steps. High pressure fuel pump Connect pump lead wire connector, then install grommet 1 and fuel pump 2. NOTE: Apply fuel to grommet before installing. Float/Float pin Install float and float pin.
Page 219 5-16 FUEL SYSTEM Separator cover/Separator case 1. Install seal ring 1, then apply SUZUKI BOND evenly to only the outside mating surface of separator case as shown in fig- ure. $ 99000-31140: SUZUKI BOND “1207B” NOTE: • Clean mating surfaces before applying bond.
Page 220: Evaporation Purge System
FUEL SYSTEM 5-17 EVAPORATION PURGE SYSTEM SYSTEM INSPECTION 1. Warm up engine to normal operating temperature. Purge valve 2. Disconnect purge hose A from fuel vapor separator 1. Do not suck air through valve. Fuel vapor inside valve is harmful. 3.
Page 221 5-18 FUEL SYSTEM 4. With connector disconnected, blow into hose A. Air should not come out of hose B. 5. Remove two (2) bolts 3, purge valve 2 and purge valve bracket. 6. Connect 12-V battery to purge valve terminals. With voltage applied, blow into hose A.
Page 222: Fuel Injector
FUEL SYSTEM 5-19 FUEL INJECTOR INSPECTION 1. Remove the bolts and STBD/PORT air duct guard 1·2. 2. Using sound scope or equivalent, check operating sound of Injector body fuel injector when engine is running or cranking. Injector operating sound cycle should vary according to Click engine speed.
Page 223: Removal
5-20 FUEL SYSTEM REMOVAL 1. Relieve fuel pressure according to procedure described on page 5-3. 2. Remove the ring gear cover and air intake silencer case. (See page 6-2.) 3. Loosen clamp and place a large cloth over end of fuel feed hose.
Page 224: Installation
FUEL SYSTEM 5-21 INSTALLATION Installation is reverse order of removal with special attention to the following steps. " Do not reuse O-ring and cushion once removed. Always use new parts. 1. Replace injector O-ring 1 with new one using care not to damage it.
Page 225 5-22 FUEL SYSTEM 6. Reconnect fuel feed hose securely. 7. Connect lead wire connector to injectors securely. 8. Check to ensure that all removed parts are back in original position. 9. Make sure the emergency stop switch lock plate is in place. Shift into “NEUTRAL”...
Page 226: Low Pressure Fuel Pump
FUEL SYSTEM 5-23 LOW PRESSURE FUEL PUMP The low pressure fuel pump is a non-serviceable component. If it is defective, it must be replaced as a complete unit. The following procedure will determine whether or not the pump is defective. INSPECTION NOTE: 1.
Page 227: Low Pressure Fuel Filter/Fuel Hose
5-24 FUEL SYSTEM LOW PRESSURE FUEL FILTER/FUEL HOSE When disassembling or reassembling fuel line, refer to the con- struction diagram below. 1. Low pressure fuel filter 2. Fuel connector 3. Fuel primer bulb 4. Fuel hose 5. Clip INSPECTION FUEL CONNECTOR Inspect fuel connector for leakage, deterioration or other dam- age.
Page 228 POWER UNIT POWER UNIT CONTENTS RING GEAR COVER AND AIR INTAKE SILENCER CASE ......6- 2 REMOVAL ....................6- 2 INSTALLATION ..................6- 2 CYLINDER HEAD COVER ................6- 3 REMOVAL ....................6- 3 INSTALLATION ..................6- 5 INTAKE COLLECTOR ASSEMBLY ...............6- 7 REMOVAL ....................6- 7 INSTALLATION ..................6- 9 POWER UNIT ....................6-11 REMOVAL ....................6-11...
Page 229: Ring Gear Cover And Air Intake Silencer Case
POWER UNIT RING GEAR COVER AND AIR INTAKE SILENCER CASE REMOVAL Prior to removing Ring gear cover: • Disconnect battery cables from battery. 1. Remove the two bolts and STBD air duct guard 1. 2. Remove the two bolts and PORT air duct guard 2. 3.
Page 230: Cylinder Head Cover
POWER UNIT CYLINDER HEAD COVER REMOVAL Before removing cylinder head cover: • Disconnect battery cables from battery. • Remove both side covers. (See page 7-2.) 1. Remove the ring gear cover and air intake silencer case. (See page 6-2.) 2. Disconnect ignition coil connectors 1. Remove the bolts securing the ignition coils.
Page 231 POWER UNIT • Remove the eleven (11) bolts securing cylinder head cover A to the cylinder head, then remove the cylinder head cover. 4. On the STBD side bank: • Disconnect IN. CMP sensor lead wire connector 1 at sen- sor.
Page 232: Installation
• Remove oil, old sealant, and dust from sealing surfaces. • After cleaning, apply sealant to cylinder heads sealing surface area as shown in figure. ! 99000-31140: SUZUKI BOND “1207B” • Install new cylinder head cover gasket 1 to head cover. NOTE: Examine cylinder head cover gasket for damage.
Page 233 POWER UNIT • Install gasket 3 and OCV 4 and then tighten bolts securely. NOTE: Position the OCV gasket tab as shown right. Do not reuse the OCV gasket, always replace with new one. " OCV bolt: 12 N·m (1.2 kg-m, 8.6 lb-ft) FINAL ASSEMBLY CHECK •...
Page 234: Intake Collector Assembly
POWER UNIT INTAKE COLLECTOR ASSEMBLY REMOVAL Before removing intake collector assembly: • Disconnect battery cables from battery. • Remove both side covers. (See page 7-2.) 1. Remove the ring gear cover and air intake silencer case 1. (See page 6-2.) 2.
Page 235 POWER UNIT 7. Remove four (4) spacers 7. Remove dowel pin 8 and O-ring 9 from each side of spacer. 8. Remove the four (4) bolts securing funnels 0, then remove two funnels. 9. Remove two nuts and intake collector body A.
Page 236: Installation
POWER UNIT INSTALLATION Installation is reverse order of removal with special attention to the following steps. Do not reuse gasket. Always use a new gasket. • Install gasket 1 and dowel pins 2. • Install intake collector body 3, then temporarily tighten two nuts.
Page 237 6-10 POWER UNIT • Install four (4) spacers 7 and gasket 8. • Install intake collector cover 9. Tighten intake collector mounting bolts and nuts to specified torque. " Intake collector bolt and nut: 23 N·m (2.3 kg-m, 16.5 lb-ft) NOTE: Tighten collector mounting bolts and nuts first (following the order shown in figure), then tighten collector cover bolts.
Page 238: Power Unit
POWER UNIT 6-11 POWER UNIT REMOVAL Before removing power unit: • Relieve fuel pressure. (See page 5-3.) • Drain engine oil. • Disconnect battery cables from battery. Remove the low pressure fuel pump/fuel vapor separator 1 as a set. (See page 5-7.) Remove the bolt and speed sensor 2.
Page 239 6-12 POWER UNIT Remove bolts securing fuel delivery pipe 7, then remove fuel delivery pipes and all fuel injectors 8. (See page 5-20.) Remove nut and positive battery cable 9. Remove starter motor 0. (See page 4-18.) Remove flywheel A. (See page 3-92.) $ 09916-99311: Flywheel holder Remove battery charge coil B.
Page 240 POWER UNIT 6-13 Disconnect water inlet hose D and outlet hose E from intake manifold. Remove three (3) bolts and PORT thermostat housing F. Remove three (3) bolts and STBD thermostat housing G. Disconnect PORT and STBD water return hose H·I from engine holder.
Page 241 6-14 POWER UNIT Disconnect water inlet hose 2 from the front crankcase water jacket cover 3. Remove the bolt 4 securing the ground lead wire of PTT relay. Remove bolt and PTT switch lead wire clamp 5. Remove bolts and two (2) Rectifier & regulators 6. (See page 4-11.) Loosen screw 7 and disconnect lead wire from oil pressure switch.
Page 242 POWER UNIT 6-15 • Disconnect cylinder temperature sensor lead wire connector • Disconnect OCV lead wire connector 7 at OCV. • Remove the bolt 8 securing lead wire clamp plate. On the STBD side bank • Disconnect EX. manifold temperature sensor lead wire con- nector 1.
Page 243 6-16 POWER UNIT Remove oil pan cover 1. (See page 7-2.) Remove pins 2 and side cover seal 3. Remove five (5) bolts and upper engine holder cover 4. [From engine upper side] • On the STBD bank, remove three (3) bolts 1. •...
Page 244: Installation
Installation is reverse order of removal with special attention to the following step. Do not reuse gaskets, O-rings and seals. Always replace with new parts. POWER UNIT • Install dowel pins 1, gasket 2. Apply Water Resistant Grease to driveshaft splines. % 99000-31140: SUZUKI WATER RESISTANT GREASE...
Page 245 NOTE: Before installing power unit, apply sealant to the six hatched areas shown in the illustration at right. ! 99000-31140: SUZUKI BOND “1207B” • Lower the power unit onto engine holder. NOTE: Rotate crankshaft to aid alignment of driveshaft and counter...
Page 246 POWER UNIT 6-19 • Apply Suzuki Silicone Seal to power unit mounting bolts and tighten bolts to specified torque. & 99000-31120: SUZUKI SILICONE SEAL " Power unit mounting bolt: 8 mm 23 N·m (2.3 kg-m, 16.5 lb-ft) 10 mm 50 N·m (5.0 kg-m, 36.0 lb-ft)
Page 247 23 N·m (2.3 kg-m, 16.5 lb-ft) NOTE: Before installing upper engine holder cover, apply sealant to the two hatched areas shown in the illustration at right. ! 99000-31140: SUZUKI BOND “1207B” NOTE: Before installing two long bolts, check that the seal washer is attached.
Page 248 POWER UNIT 6-21 FLYWHEEL • Install battery charge coil. (See page 4-11.) • Install flywheel and tighten flywheel bolts to specified torque. (See page 3-93.) $ 09916-99311: Flywheel holder " Flywheel bolt: 118 N·m (11.8 kg-m, 85.5 lb-ft) • Install CKP sensor. (See page 3-94.) FUEL INJECTORS •...
Page 249: Oil Pump
6-22 POWER UNIT OIL PUMP REMOVAL 1. Remove the power unit. (See page 6-11 to 6-17.) [On the PORT side bank] 2. Remove the four (4) bolts securing OCV 1, then remove OCV and gasket 2. 3. Remove the eleven (11) bolts securing cylinder head cover 3 to cylinder head, then remove the cylinder head cover.
Page 250: Disassembly
POWER UNIT 6-23 6. Remove the oil pump driven gear 7. NOTE: • Sprocket bolt is LH thread. • Hold camshaft by placing a wrench on the hexagon area of the camshaft. 7. Remove the bolt securing oil pump drive sprocket 8 to cam- shaft, then remove the oil pump drive sprocket and chain 9.
Page 251: Inspection
6-24 POWER UNIT INSPECTION OIL PUMP ASSEMBLY Check outer and inner rotors, rotor plate and oil pump case for excessive wear or damage. Replace as necessary. NOTE: If any repair is required on outer rotor, inner rotor and oil pump case/plate, replace them as an oil pump assembly.
Page 252: Assembly
POWER UNIT 6-25 ASSEMBLY 1. Wash, clean and then dry all disassembled parts. 2. Apply thin coat of engine oil to inner and outer rotors, inside surfaces of oil pump case and plate. 3. Assemble pin 1 and inner rotor 2 to oil pump shaft. 4.
Page 253: Installation
6-26 POWER UNIT INSTALLATION Installation is reverse order of removal with special attention to following steps. • Install oil pump drive chain 1 and pump drive sprocket 2. • Tighten sprocket bolt, pre-coated with thread lock, to specified torque. ' 99000-32050: THREAD LOCK 1342 "...
Page 254: Timing Chain
POWER UNIT 6-27 TIMING CHAIN REMOVAL Prior to this service work: • Remove the power unit. (See page 6-11 to 6-17.) Crankshaft/Drive gear Driven gear/Timing sprocket " Driven gear holder Chain tensioner adjuster No. 1 Timing chain tensioner Timing chain guide No. 2 &...
Page 255 6-28 POWER UNIT 4. Turn the crankshaft in its normal running direction (R_LH direction) until the match mark (•) on the crankshaft drive gear points to 12 o’clock (toward cylinder head). When timing chain has been removed, never turn crankshaft or camshaft. Match mark (•) on crankshaft drive gear Engine normal running direction 5.
Page 256 POWER UNIT 6-29 9. Remove the driven gear 0 and 1st timing chain A. 10. [On the PORT side bank] • Remove two (2) plugs 1. • Remove the bolts 2 securing lower camshaft housing 3, then remove the lower camshaft housing and dowel pins. •...
Page 257 6-30 POWER UNIT • Remove the IN. camshaft timing sprocket 6, EX. cam- shaft timing sprocket 7, 2nd timing chain 8 and PORT chain tensioner 4. • Remove dowel pins from IN./EX. camshaft. 11. [On the STBD side bank] • Remove two (2) plugs 1. •...
Page 258: Inspection
POWER UNIT 6-31 INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. 1ST TIMING CHAIN • Inspect 1st timing chain. Replace if worn excessively or damaged. 2ND TIMING CHAIN • Inspect 2nd timing chain. Replace if worn excessively or damaged.
Page 259 6-32 POWER UNIT CAMSHAFT TIMING SPROCKET VVT actuator • Check teeth of sprocket for wear or damage. Bolt If excessive wear or other damage is found, replace it. Do not attempt to remove bolts or disassemble the VVT actuator. DRIVEN GEAR HOLDER •...
Page 260: Installation
Match mark c: •• Match mark d: (4) Remove oil, old sealant, and dust from sealing surface. (5) Apply sealant to lower camshaft housing sealing surface area as shown in figure. Install camshaft housing pins 5. ! 99000-31140: SUZUKI BOND “1207B”...
Page 261 6-34 POWER UNIT (6) Install lower camshaft housing 6. Tighten lower camshaft housing bolts 7, pre-coated with engine oil, to specified torque. " Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.6 lb-ft) (7) Install gasket and plugs 8 in lower camshaft housing. (8) Fit the dowel pin 9 on the EX.
Page 262 (5) Apply sealant to lower camshaft housing sealing surface area as shown in figure. Install camshaft housing pins D. ! 99000-31140: SUZUKI BOND “1207B” (6) Install lower camshaft housing E. Tighten lower camshaft housing bolts F, pre-coated with engine oil, to specified torque.
Page 263 6-36 POWER UNIT (7) Install gasket and plugs G in lower camshaft housing. (8) Fit the dowel pin H on the EX. camshaft. Check that the dowel pin is correctly aligned with the match mark k on the lower camshaft housing as shown in the illustration.
Page 264 POWER UNIT 6-37 5. Check that the match marks (•) p/q on both the PORT & STBD side IN. camshaft timing sprockets are correctly aligned with the match marks h·o on the camshaft housing as shown in the illustration. 6. As shown in the illustration, fit the 1st timing chain K with Blue link Blue link one blue link aligned with the match mark (•) p on the PORT...
Page 265 6-38 POWER UNIT 9. Insert the spacer M into chain tensioner N. Install chain tensioner to driven gear holder O, then tighten bolt P securely. Apply engine oil to chain tensioner. 10. Install driven gear holder O, then tighten four (4) bolts securely.
Page 266 POWER UNIT 6-39 14. Turn the crankshaft two (2) complete rotations in direction PORT shown in figure. As shown in the illustration, check that all match marks are in alignment as written below when the match mark (•) a on the drive gear is pointing to 12 o’clock.
Page 267: Cylinder Head Assembly
6-40 POWER UNIT CYLINDER HEAD ASSEMBLY (Cylinder head/valve/camshaft) REMOVAL Prior to removing cylinder head: • Remove the power unit. (See page 6-11 to 6-17.) • Remove the timing chain. (See page 6-27 to 6-30.) 1. Remove the bolts 1 and timing chain guide base 2. 2.
Page 268 POWER UNIT 6-41 4. On the PORT side bank, loosen and remove twelve (12) cyl- inder head bolts in the order indicated in figure. Remove cylinder head assembly and head gasket. 5. On the STBD side bank, loosen first, then remove thirteen (13) cylinder head bolts according to sequence in figure.
Page 269: Assembly
Before installing cylinder head gasket, apply sealant to both sur- faces of the hatched areas shown in illustration. ! 99000-31140: SUZUKI BOND “1207B” 2. Position cylinder head on cylinder. 3. Apply engine oil to cylinder head bolts and tighten them gradually as follows.
Page 270 POWER UNIT 6-43 (b) Loosen all bolts to 0 N·m (0 kg-m, 0 lb-ft) according to reverse sequence in figure. (c) Again tighten all bolts to 50 percent (%) of specified torque according to sequence in figure. " Cylinder head bolt: 3rd step 11 mm 43 N·m (4.3 kg-m, 31.1 lb-ft) 8 mm...
Page 271 6-44 POWER UNIT NOTE: When installing the camshaft, aligns dowel pin on the camshafts with the match mark on lower camshaft housing. 1. Dowel pin on camshaft 2. Match mark on lower camshaft housing 1. Dowel pin on camshaft 2. Match mark on lower camshaft housing 6.
Page 272 POWER UNIT 6-45 8. Apply sealant to lower camshaft housing sealing surface area as shown in figure. ! 99000-31140: SUZUKI BOND “1207B” 9. Install the lower camshaft housing. 1. Lower camshaft housing PORT 2. Lower camshaft housing STBD 10. Check position of camshaft housing.
Page 273 NOTE: Before installing timing chain guide base, apply sealant to hatched areas shown in illustration. ! 99000-31140: SUZUKI BOND “1207B” 14. Install timing chain. (See page 6-33.) 15. Install oil pump assembly. (See page 6-26.) 16. Check tappet clearance and adjust as necessary.
Page 274: Disassembly
POWER UNIT 6-47 DISASSEMBLY 1. Remove tappets with shims. NOTE: For ease of assembly, lay out tappets and record shim thickness for each individual cylinder/valve position. 2. Using valve lifter and attachment, remove valve cotters 1 while compressing valve spring. $ 09916-14510: Valve lifter 09916-14521: Attachment 09916-84511: Tweezers...
Page 275: Inspection/Servicing
6-48 POWER UNIT INSPECTION/SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component. CYLINDER HEAD Remove all carbon from combustion chambers. NOTE: • Do not use any sharp edged tool to scrape carbon off cylinder head or its components.
Page 276 Using micrometer, measure cam height H. $ 09900-20202: Micrometer Cam height Standard: DF300 IN. 45.330 – 45.490 mm (1.7846 – 1.7909 in) EX. 44.420 – 44.580 mm (1.7488 – 1.7551 in) Service limit DF300 IN. 45.230 mm (1.7807 in) EX. 44.320 mm (1.7449 in) If measurement exceeds service limit, replace camshaft.
Page 277 6-50 POWER UNIT Camshaft runout Support camshaft on a surface plate using a set of V-blocks. Measure runout using a dial gauge. $ 09900-20606: Dial gauge : “V” block set 09900-20701: Magnetic stand Camshaft runout Service limit: 0.10 mm (0.004 in) If measurement exceeds service limit, replace camshaft.
Page 278 POWER UNIT 6-51 5. Remove camshaft housing. 6. Using scale on Plastigauge envelope, measure Plastigauge at its widest point. Camshaft journal oil clearance Standard: 0.043 – 0.085 mm (0.0017 – 0.0033 in) Service limit: 0.120 mm (0.0047 in) 1. Plastigauge 2.
Page 279 6-52 POWER UNIT Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance. $ 09900-20202: Micrometer If measurement exceeds service limit, replace tappet or cylinder head. Cylinder head bore to tappet clearance Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in) Service limit: 0.150 mm (0.0059 in) Tappet outer diameter Standard: 33.959 –...
Page 280 POWER UNIT 6-53 Valve guide to valve stem clearance Valve guide to valve stem clearance Standard: IN. 0.020 – 0.047 mm (0.0008 – 0.0019 in) EX. 0.045 – 0.072 mm (0.0018 – 0.0028 in) Service limit: IN. 0.070 mm (0.0028 in) EX.
Page 281 6-54 POWER UNIT Valve stem runout Measure valve stem runout. $ 09900-20606: Dial gauge 09900-20701: Magnetic stand 09900-21304: “V” block set Valve stem runout Service limit: 0.05 mm (0.002 in) If measurement exceeds service limit, replace valve. Valve head radial runout Measure valve head radial runout.
Page 282 POWER UNIT 6-55 $ 09900-20101: Vernier calipers Valve seat contact width A Standard: IN. & EX. 1.1 – 1.3 mm (0.0433 – 0.0512 in) If measurement exceeds specification, repair valve seat. NOTE: For valve seat repair, see “Valve seat servicing” section on page 6-55.
Page 283 6-56 POWER UNIT (6) Lap valve on seat in two steps, first with coarse grit lapping compound applied to face and the second with fine grit compound. (7) Recheck valve seat contact width A. NOTE: Clean and assemble cylinder head and valve components. Fill intake and exhaust ports with solvent to check for leaks between valve seat and valve.
Page 284 POWER UNIT 6-57 (3) Install valve guide to cylinder head. • Heat cylinder head to a temperature of 80 – 100 °C (176 – 212 °F). Apply heat uniformly so that head will not be distorted. • Use special tools to drive new valve guide into hole. Drive in new valve guide until special tool (valve guide installer attachment) contacts cylinder head.
Page 285: Reassembly
6-58 POWER UNIT Valve spring squareness Use a square and surface plate to check each spring for square- ness (clearance between end of valve spring and square). $ 09900-20101: Vernier calipers Valve spring squareness Service limit: IN. & EX. 2.0 mm (0.08 in) If measurement exceeds service limit, replace valve spring.
Page 286 POWER UNIT 6-59 Install valve spring 4, and valve retainer 5. Hold valve spring compressed with special tool and install valve cotters 6. Make sure valve cotters are properly seated in groove A. $ 09916-14510: Valve lifter 09916-14521: Attachment 09916-84511: Tweezers...
Page 287: Cylinder/Crankshaft/Piston
6-60 POWER UNIT CYLINDER/CRANKSHAFT/PISTON DISASSEMBLY Before performing service work in this section: • Remove power unit. (See page 6-11 to 6-17.) • Remove timing chain. (See page 6-27 to 6-30.) • Remove cylinder head. (See page 6-40.) Remove the driven gear 1. Remove the nine (9) bolts 2 securing the oil gallery cover 3, then remove oil gallery cover 3, gasket 4, oil gallery plate 5 and gasket 6.
Page 288 POWER UNIT 6-61 Remove oil filter 3. $ 09915-47341: Oil filter wrench Remove oil pressure switch 4. Remove the bolts 5 and STBD exhaust cover 6. Remove eight (8) bolts 1. Remove sixteen (16) bolts 2. Remove crankcase from cylinder block. NOTE: For proper assembly, mark cylinder number on all pistons, con- rods, and conrod caps, using quick drying paint.
Page 289 6-62 POWER UNIT Remove crankshaft 3. Remove oil seal 4 from crankshaft. Remove the bolt 5, washer 6 and drive gear 7. Remove bolts 8 and piston cooling jets 9 from each cylinder. Mark cylinder number on pistons using quick dry paint. Push piston (with conrod) out through the top of cylinder bore.
Page 290: Inspection/Servicing
POWER UNIT 6-63 Remove piston pin circlips as shown. 1. Piston pin circlip Remove piston pin from conrod. NOTE: Reassemble each piston, piston pin and conrod in their original combination and position. INSPECTION/SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component.
Page 291 6-64 POWER UNIT Water jackets Check water jackets. If clog or obstruction is found, clean water jacket. Driven gear/bearing Inspect driven gear. Replace gear if damaged or worn. Inspect driven gear bearing. Replace bearing if pitted, noisy or rough. Cylinder bore Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear.
Page 292 POWER UNIT 6-65 PISTON TO CYLINDER CLEARANCE (1) Measure the piston diameter at a point 11 mm (0.433 in) above the piston skirt at a right angle to the piston pin bore. $ 09900-20204: Micrometer 11 mm Piston skirt diameter Standard: 97.905 –...
Page 293 6-66 POWER UNIT Oil ring Oversize I.D. mark 0.50 mm One (1) Red paint I.D. mark Oil ring spacer PISTON Inspect piston for faults, cracks or other damage. Damaged or faulty piston(s) should be replaced. Piston ring to groove clearance Before checking, piston grooves must be clean, dry and free of Piston ring carbon.
Page 294 POWER UNIT 6-67 PISTON RING Piston ring end gap Measure piston ring end gap with piston ring in the lowest posi- Cylinder tion of cylinder bore. $ 09900-20803: Thickness gauge Piston ring end gap Standard: Piston ring 1st 0.20 – 0.33 mm (0.0079 – 0.0130 in) 2nd 0.33 –...
Page 295 6-68 POWER UNIT Piston pin hole diameter Standard: 22.006 – 22.014 mm (0.8664 – 0.8667 in) Service limit: 22.030 mm (0.8673 in) Conrod small end bore Standard: 22.010 – 22.018 (0.8665 – 0.8669 in) Pin clearance in piston pin hole Standard: 0.006 –...
Page 296 POWER UNIT 6-69 CONROD BEARING Inspect bearing shell for proper contact pattern and signs of fusion, pitting, burning or flaking. Bearing shells found in defective condition must be replaced. Conrod big end oil clearance Check conrod big end oil clearance as follows; (1) Clean surface of conrod, conrod cap, conrod bearing, and crank pin.
Page 297 6-70 POWER UNIT (6) Remove conrod and conrod cap from crank pin. Plastigauge (7) Using scale on Plastigauge envelope, measure Plastigauge Scale width at its widest point. Conrod big end oil clearance Standard: 0.045 – 0.063 mm (0.0018 – 0.0025 in) Service limit: 0.080 mm (0.0031 in) If measurement exceeds service limit, replace conrod bear- ing.
Page 298 POWER UNIT 6-71 Out-of-round and taper (uneven wear) of journals An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both). This difference, if any, is determined by taking micrometer read- ings.
Page 299 6-72 POWER UNIT (3) Install crankshaft to cylinder. (4) Place a piece of Plastigauge across full width of bearing (parallel to crankshaft) on journal. Do not place Plastigauge over oil hole. $ 09900-22301: Plastigauge NOTE: Do not rotate crankshaft while Plastigauge is installed. Plastigauge (5) Assemble crankcase to cylinder.
Page 300 POWER UNIT 6-73 SELECTION OF MAIN BEARING Whenever a bearing requires replacement, select a new bearing according to following procedure. (1) First, check journal diameter. No. 1 Journal As shown in figure, upper (flywheel side) crank web of No.1 code cylinder has four (4) stamped code numerals.
Page 301 6-74 POWER UNIT (4) Select crankshaft main bearing referring the below table. Numeral stamped on crank web (journal outside diameter) Code stamped on Black No color Yellow cylinder block No color Yellow Blue (Bearing holder Yellow Blue Pink inside diameter) NOTE: Measure crankshaft journal oil clearance again after installing new bearing selected.
Page 302: Reassembly
POWER UNIT 6-75 OIL SEAL Inspect condition. If cracked, cut or damaged, replace. REASSEMBLY Assembly is reverse order of disassembly paying special atten- tion to the following steps. If original components are not replaced, each piston, piston pin and conrod is to be assembled and installed in its original order and position.
Page 303 6-76 POWER UNIT PISTON RING TO PISTON Oil ring • Apply engine oil to piston rings. • Install spacer 1 first, then side rails 2 to piston. When installing spacer, do not allow spacer ends to Incorrect overlap in groove. Correct 1st and 2nd piston ring •...
Page 304 POWER UNIT 6-77 PISTON TO CYLINDER Install conrod bearing to conrod and conrod cap. • Assemble each conrod bearing to its original posi- tion. • Do not apply oil between conrod and bearing or between bearing cap and bearing. Apply engine oil to piston and cylinder walls. Insert piston and conrod assembly into cylinder bore from cylin- der head side using special tool.
Page 305 Install crankshaft main bearings in cylinder and crankcase. Apply Molybdenum Oil Solution to bearings. ) MOLYBDENUM OIL SOLUTION Mix equal amounts of engine oil and SUZUKI MOLY PASTE (P/no. 99000-25140) in a ratio of 1 : 1. • Assemble each bearing to its original position.
Page 306 POWER UNIT 6-79 Crankshaft Apply engine oil to upper oil seal lip. Install upper oil seal to crankshaft. Do not reuse seal removed. Be sure to use new seal. NOTE: Install upper oil seal with its spring/lipped side facing inward. 1.
Page 307 Apply Bond to marked line. Clean mating surface of cylinder and crankcase. Apply SUZUKI BOND to mating surface of crankcase as shown. Apply bond to mating surface only. Do not allow bond to contact surface of bearing. ! 99000-31140: SUZUKI BOND “1207B”...
Page 308 POWER UNIT 6-81 " Crankcase bolt (10 mm thread diameter): 1st step 11 N·m (1.1 kg-m, 8.0 lb-ft) 2nd step 42 N·m (4.2 kg-m, 30.0 lb-ft) Final step 52 N·m (5.2 kg-m, 37.6 lb-ft) " Crankcase bolt (8 mm thread diameter): 1st step 6 N·m (0.6 kg-m, 4.3 lb-ft) 2nd step 20 N·m (2.0 kg-m, 14.5 lb-ft)
Page 309: Thermostat
6-82 POWER UNIT THERMOSTAT REMOVAL • Remove the ring gear cover and air intake silencer case. (See page 6-2.) • Remove the two (2) bolts 2 securing the thermostat cover 1, then remove the cover 1 and thermostat 3. INSPECTION •...
Page 310: Installation
POWER UNIT 6-83 INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Assemble thermostat 3 and thermostat cover 1 to thermo- stat housing 2 and secure with bolts 4. " Thermostat cover bolt: 10 N·m (1.0 kg-m, 7.2 lb-ft) •...
Page 311: Operation
6-84 POWER UNIT OPERATION ENGINE LUBRICATION SYSTEM The engine lubrication system uses a camshaft-driven oil pump that pressure feeds engine oil to the engine’ moving parts. The chart below shows the lubrication system oil flow. Engine oil is drawn up by the oil pump through the oil strainer. After passing through the oil filter, engine oil flows to the main gallery and lower gallery from which various passages distribute oil for lubrication and other engine functions requiring engine oil pressure to operate.
Page 312 POWER UNIT 6-85 ENGINE OIL LUBRICATION CHART NO. 1 CAMSHAFT NO. 1 CAMSHAFT NO. 1 CAMSHAFT NO. 1 CAMSHAFT JOURNAL (EX) JOURNAL (IN) JOURNAL (IN) JOURNAL (EX) NO. 1 NO. 1 NO. 1 NO. 1 CAM FACE CAM FACE CAM FACE CAM FACE NO.
Page 313: Water Cooling System
6-86 POWER UNIT WATER COOLING SYSTEM The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostats. This system cools both the power unit and exhaust and is shown in schematic form below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or component damage.
Page 314: Pcv System
POWER UNIT 6-87 PCV SYSTEM (PCV: POSITIVE CRANKCASE VENTILATION) Due to the necessary piston to cylinder clearance, unburned combustion gasses (blow-by) will naturally pass through and enter the crankcase. The PCV system is provided to recirculate these gasses back to the combustion chamber to be reburned.
Page 315 MID UNIT 7-1 MID UNIT CONTENTS ENGINE SIDE COVER ..................7- 2 REMOVAL ....................7- 2 INSTALLATION ..................7- 2 DRIVESHAFT HOUSING AND OIL PAN ............7- 3 REMOVAL ....................7- 3 INSPECTION ..................7- 9 ASSEMBLY ....................7-12 SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET ..7-19 REMOVAL ....................7-19 INSPECTION ..................7-22 REASSEMBLY ..................7-23...
Page 316: Engine Side Cover
MID UNIT ENGINE SIDE COVER REMOVAL Remove the side cover rubber 1. Remove six (6) screws 2 and STBD side cover 3. Remove four (4) screws 4 and PORT side cover 5. Disconnect PTT switch lead connector. Remove eight (8) screws 6 and STBD/PORT oil pan covers 7 ·...
Page 317: Driveshaft Housing And Oil Pan
MID UNIT DRIVESHAFT HOUSING AND OIL PAN REMOVAL Remove power unit. (See page 6-11 to 6-17.) Remove lower unit. (See page 9-2.) Disconnect following lead wire connectors. • PTT motor cable wire • Neutral switch lead wire • Shift position sensor lead wire •...
Page 318 MID UNIT Disconnect cooling water hose 3 from oil pan. Remove clutch link rod 4. Remove the five (5) bolts securing shift actuator 5, then remove shift actuator. Remove E-ring 6 from clutch lever shaft 7. Remove two (2) bolts 8 and shift actuator holder 9.
Page 319 MID UNIT Remove screw and bonding wire 0 from driveshaft housing. Remove STBD/PORT lower mount nuts A and lower mount bolts B. Account for washers C, dampers D and washer E. Remove eight (8) bolts F and the mount·oil seal cover G. Account for two (2) dowel pins.
Page 320 MID UNIT Remove STBD/PORT upper mount nuts I and washers. Remove driveshaft housing with oil pan. Remove three (3) bolts 1 and upper mount cover 2. Remove upper mounts 3, thrust stoppers 4, mount plate 5 and mount bolts 6. Remove four (4) exhaust tube bolts 7.
Page 321 MID UNIT Remove twelve (12) bolts 8 and engine holder 9. Remove three (3) bolts 1 and oil strainer 2. Remove the exhaust tube 3. Remove the exhaust tube seal 4 from exhaust tube.
Page 322 MID UNIT Remove eight (8) bolts 1 and oil pan 2. Remove water tube 1. Remove bolts 2, lower mount cover 3 and lower mounts 4.
Page 323: Inspection
MID UNIT INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. ENGINE HOLDER • Inspect engine holder. Replace if cracked, damaged, or other abnormal conditions are noted. •...
Page 324 6. Apply Water Resistant Grease to outer circumference of oil seal 4. Drive oil seal into engine holder. Apply Water Resistant Grease to the seal lip. # 99000-25160: SUZUKI WATER RESISTANT GREASE NOTE: Install oil seal as shown in figure. 7. Install circlip 3.
Page 325 MID UNIT 7-11 OIL STRAINER • Inspect oil strainer. Replace if cracked, damaged or other abnormal conditions are noted. If clog or obstruction, clean oil strainer. • Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal conditions are noted. OIL PAN/DRIVESHAFT HOUSING Check oil pan, driveshaft housing.
Page 326: Assembly
7-12 MID UNIT ASSEMBLY Assembly is reverse order of removal with special attention to the following steps. 100 N·m (10 kg-m, 72.5 lb-ft) 1. Mount oil seal cover 2. Bolt 3. Bolt 4. Gasket 5. Oil seal 6. Upper mount cover 7.
Page 327 MID UNIT 7-13 35. Exhaust tube gasket 36. Exhaust tube 37. Pin 38. Exhaust tube seal 39. Gasket 40. Oil level gauge 41. Oil level gauge guide 42. Bolt 44. Exhaust pipe 45. Exhaust release pipe 46. Bolt 47. Oil pan 48.
Page 328 • Install two dowel pins 5 to driveshaft housing 6. Apply sealant to mating surfaces of driveshaft housing and oil pan. & 99000-31120: SUZUKI SILICONE SEAL • Install oil pan 7 to driveshaft housing 6, then tighten eight (8) bolts 8 securely.
Page 329 MID UNIT 7-15 EXHAUST TUBE Place exhaust tube seal 2 to exhaust tube, then install exhaust tube 1. ENGINE HOLDER TO OIL PAN • Apply engine oil to O-rings 1, then install O-rings to oil strainer 2. • Install oil strainer to engine holder, then tighten bolts securely. •...
Page 330 7-16 MID UNIT • Install engine holder 8 to oil pan 9, then securely tighten it with engine holder bolts 0. • Install exhaust tube bolts A, then tighten four (4) exhaust tube bolts securely. UPPER MOUNT AND MOUNT COVER •...
Page 331 MOUNT·OIL SEAL COVER • Install thrust mount 1. • Apply Water Resistant Grease to oil seal. # 99000-25160: SUZUKI WATER RESISTANT GREASE • Install dowel pins 2, gasket 3 and mount·oil seal cover 4, then tighten eight (8) cover bolts securely.
Page 332 7-18 MID UNIT BONDING WIRE Reattach bonding wire to driveshaft housing and tighten screw securely. SHIFT ACTUATOR • Install shift actuator holder 1 to engine holder, then tighten two (2) bolts 2 securely. • Install clutch lever shaft 3 and E-ring 4. •...
Page 333: Swivel Bracket, Steering Bracket And Clamp Bracket
MID UNIT 7-19 SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL Remove driveshaft housing/oil pan. (See page 7-3.) Remove screw and bonding wire from lower mount bracket. Remove circlip 1. Remove lower mount bracket 2, shims 3 and washer 4 from the steering shaft.
Page 334 7-20 MID UNIT Remove two (2) bolts A, tilt limit switch B and switch cover. Remove tilt limit switch cam C. NOTE: Unfasten three (3) stoppers a from the tilt limit switch cam to remove it from cam holder. Remove upper cam holder D and lower cam holder E from clamp bracket shaft.
Page 335 MID UNIT 7-21 Remove bolts L securing PTT unit to the STBD and PORT clamp brackets. Using flat screw-driver, drive locking edge of lock washer 1 to clamp bracket side. Remove the two STBD motor mounting bolts 2. Remove the clamp bracket shaft nut 3 and washer. Remove screw and bonding wire 4 from swivel bracket.
Page 336: Inspection
7-22 MID UNIT INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. BUSHINGS Check all bushings. If excessive wear or other damage is found, replace bushing. If bushing fit is loose when installing, replace bushing. OIL SEAL Check swivel bracket seal.
Page 337: Reassembly
MID UNIT 7-23 REASSEMBLY Reassembly is reverse order of removal with special attention to the following steps. 43 N·m (4.3 kg-m, 31.0 lb-ft) 1. Clamp bracket STBD 2. Clamp bracket PORT 3. Clamp bracket shaft 4. Nut 5. Washer 6. Anode 7.
Page 338 Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings. # 99000-25160: SUZUKI WATER RESISTANT GREASE • Insert PORT and STBD bushings 2 into the swivel bracket • Assemble port clamp bracket 3, washer 4, clamp bracket shaft 5 and swivel bracket 1.
Page 339 MID UNIT 7-25 • Tighten eight (8) PTT unit retaining bolts A, pre-coated with thread lock, to specified torque. $ 99000-32050: THREAD LOCK “1342” % PTT retaining bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft) TILT LIMIT DEVICE • Install the lower cam holder 1 engaging its locating pin a with the clamp bracket shaft hole b, then install the upper cam holder 2.
Page 340 7-26 MID UNIT STEERING BRACKET • Apply Water Resistant Grease to steering bracket shaft. # 99000-25160: SUZUKI WATER RESISTANT GREASE NOTE: Apply grease to bushings, oil seal lip and pilot shaft portion of steering bracket. • Install upper bushing 1 and washer 2 to swivel bracket.
Page 341 MID UNIT 7-27 BONDING WIRE Reattach bonding wire, tightening screw securely. LUBRICATION After completing reassembly of the mid unit, apply grease through each grease nipple. # 99000-25160: SUZUKI WATER RESISTANT GREASE...
Page 342: Water Pressure Valve
7-28 MID UNIT WATER PRESSURE VALVE REMOVAL • Remove oil pan cover. (See page 7-2.) • Remove two bolts 1, pressure valve cover 2 and water pres- sure valve 3. INSPECTION • If salt deposits, corrosion, wear or other damage is found, clean or replace.
Page 343 POWER TRIM AND TILT 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 ..................8- 6 CLEANING AND INSPECTING .............8- 9 REASSEMBLY ..................8-11 PTT MOTOR ...................8-15 REMOVAL..................8-15...
Page 344: System Wiring Diagram
POWER TRIM AND TILT SYSTEM WIRING DIAGRAM PTT switch (Remote control box) Main fuse 60A Fuse 10A Tilt limit switch Switch panel PTT switch (Side cover) 30A Fuse BATT Main switch Battery PTT switch relay (included in wiring harness) PTT motor PTT motor relay NOTE: The input voltage supplied from PTT switch to ECM No.16 (Lbl) and No.22 (P)
Page 345: Service Procedure
4. If oil can be seen at filler plug level, the unit is full. 5. If oil level is low, refill with the recommended oil. Recommended oil: Suzuki Power Trim and Tilt Fluid Dexron automatic transmission fluid or equivalent To ensure consistent pump operation, do not mix dif- ferent types of oil.
Page 346: Power Trim And Tilt Unit
POWER TRIM AND TILT POWER TRIM AND TILT UNIT REMOVAL Remove both side covers. (See page 7-2.) Remove two (2) bolts and front panel. 1. Front panel Raise the engine to the full tilt position and lower the manual tilt lock levers 1.
Page 347 POWER TRIM AND TILT Cut the cable ties binding PTT motor cable and trim sender lead wire. Remove the bolt and clamp. Remove the PTT motor cable from engine lower cover. 1. Clamp Remove the tilt pin 4. Remove two (2) bolts and anode 5. Remove the screw securing bonding wire 6.
Page 348: Disassembly
POWER TRIM AND TILT DISASSEMBLY NOTE: Before disassembly, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air. Place the lower of the PTT unit in a vise. Tighten the vise only enough to secure the PTT unit, DO NOT OVER TIGHTEN.
Page 349 POWER TRIM AND TILT Using special tool, unscrew the PTT cylinder head 7. $ 09944-09820: PTT cylinder cap tool Pull the tilt rod/piston assembly 8 out of the cylinder body. Remove the free piston 9 from the cylinder body. Disassembly of tilt rod/piston assembly Unscrew the piston retaining nut from the bottom of the tilt rod and remove the washer.
Page 350 POWER TRIM AND TILT Pull the trim rod/piston assembly A out of the trim cylinder. NOTE: For PORT side trim cylinder: Trim rod Be careful not to lose the trim chamber valve B on disassembly. Trim cylinder head Disassembly of tilt cylinder assembly Remove screw 1.
Page 351: Cleaning And Inspecting
POWER TRIM AND TILT Remove three (3) O-rings from lower eyelet of PTT manifold. O-ring Remove the manual release valve snap ring 1, then unscrew the manual release valve 2. CLEANING AND INSPECTING Thoroughly wash all metal components with cleaning solvent and dry them with compressed air.
Page 352 8-10 POWER TRIM AND TILT Inspect the cylinder bore for evidence of a rough or grooved sur- face. Light honing may rectify slight surface roughness or scarring, but a deeply scarred surface will require replacement of the tilt cylinder. Inspect manual release valve for damage. Inspect manual release valve O-ring.
Page 353: Reassembly
POWER TRIM AND TILT 8-11 REASSEMBLY Assembly is reverse order of disassembly with special attention to following steps. • Do not reuse O-rings after removal, always use new O-rings. • Lubricate all components and O-rings with PTT fluid before assembly. •...
Page 354 8-12 POWER TRIM AND TILT • Align threaded hole a on the PTT manifold with groove of lower rod, then tighten stopper screw 6 securely. TILT ROD When tightening the piston retaining nut on the tilt rod piston, apply Thread Lock 1342 to the threads. Tighten the nut to specified torque.
Page 355 POWER TRIM AND TILT 8-13 TRIM ROD Trim chamber valve NOTE: Trim rod For PORT side trim cylinder: Before installing trim rod/piston, make sure the trim chamber valve is positioned correctly. Trim cylinder head Pour PTT fluid into the trim cylinder until it is topped off. Insert the trim rod/piston assembly into cylinder and thread the trim cylinder head by hand until fully seated.
Page 356 8-14 POWER TRIM AND TILT AIR BLEEDING (Air bleeding on unit as alone) Before installing the PTT unit on the outboard motor, use the fol- lowing procedure to bleed air from the system. 1. Support the PTT unit in an upright position in a vise. Oil level (when full-tilted position) 2.
Page 357: Ptt Motor
POWER TRIM AND TILT 8-15 PTT MOTOR REMOVAL NOTE: Before removing PTT motor, wash the PTT body with a stiff bris- tle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air. Place the lower of the PTT unit in a vise.
Page 358: Inspection
8-16 POWER TRIM AND TILT Slide the field case upward and away from the brush holder. NOTE: When separating field case from brush holder, push the PTT motor cables into brush holder as the field case is removed. Disconnect PTT motor cables from brush holder. Remove armature from field case.
Page 359: Assembly
POWER TRIM AND TILT 8-17 Ensure that the mica (insulator) between commutator segments is undercut to specified depth. SEGMENT Commutator undercut: Standard 1.6 – 1.9 mm (0.06 – 0.07 in) Service limit 1.0 mm (0.04 in) If undercut is less than service limit, cut to specified depth. MICA NOTE: Commutator undercut...
Page 360 8-18 POWER TRIM AND TILT • Apply silicone seal to PTT motor cable holder and grommets and install cable holder screw. PTT MOTOR INSTALLATION Installation is reverse of removal with special attention to follow- ing steps. • Ensure that the drive joint 1 is aligned and firmly inserted into the gear pump assembly.
Page 361: Installation
POWER TRIM AND TILT 8-19 INSTALLATION Installation is reverse order of removal with special attention to the following steps. Lower tilt rod to full down position. Place the PTT unit in position between the clamp brackets. Tighten the clamp bracket shaft nut 1 to specified torque. "...
Page 362 Align the tilt rod with the hole in the swivel bracket as the tilt rod extends. ( 99000-25160: SUZUKI WATER RESISTANT GREASE Apply Water Resistant Grease to the PTT rod upper shaft 6, then insert the shaft through the swivel bracket and tilt rod.
Page 363: Ptt Motor Relay
POWER TRIM AND TILT 8-21 PTT MOTOR RELAY INSPECTION 1. Disconnect battery cable from battery. 2. Remove the electric parts holder and PTT relay. (See page 4-30.) 3. Disconnect all cables/lead wires from PTT relay. 4. Check resistance between each two (2) lead wires. $ 09930-99320: Digital tester ) Tester range: Ω...
Page 364: Ptt Switch
8-22 POWER TRIM AND TILT PTT SWITCH Test continuity between the switch lead wires at each of the three switch positions. $ 09930-99320: Digital tester & Tester range: ' (Continuity) Tester probe connection Tester Red + Black - indicates DN side terminal 2 terminal 1 Continuity...
Page 365: Operation
POWER TRIM AND TILT 8-23 OPERATION COMPONENT PARTS PTT motor Oil reservoir Gear pump Down shuttle valve Down check valve " Up shuttle valve Up check valve Up relief valve Down relief valve Thermal relief valve Manual release valve Tilt rod Check valve Trim chamber valve Trim rod...
Page 366 8-24 POWER TRIM AND TILT TRIM & TILT UP (1) When the PTT switch is operated in the “UP” position, the motor and gear pump will rotate in a clockwise direction. (2) Pressurized oil will open “Up” check valve A and the oil will flow through “Up” shuttle valve B to the “Down”...
Page 367 POWER TRIM AND TILT 8-25 TILT DOWN & TRIM IN (1) When the PTT switch is operated in the “DOWN” position, the motor and gear pump will rotate in a coun- terclockwise direction. (2) The oil pressure will open the “Down” check valve D and oil will be forced through the “Down” shuttle valve E.
Page 368 8-26 POWER TRIM AND TILT TILT SYSTEM PRESSURE RELIEF (1) If engine speed exceeds approx. 1500 RPM when operating in shallow water drive mode, oil pressure will increase underneath the tilt piston. The relief valve C (incorporated in the manual release valve K) will then open.
Page 369 POWER TRIM AND TILT 8-27 SHOCK ABSORBER CIRCUIT This incorporated safety feature is for protection of the gearcase and prevention of internal PTT pressure build-up in the event of an impact. (1) The pressure from a sudden impact will make impact relief valve L open, allowing oil from the upper area of the tilt cylinder to flow into the area between the tilt rod piston and the free piston.
Page 370 8-28 POWER TRIM AND TILT MANUAL RELEASE CIRCUIT (DOWN MODE) (1) By opening the manual release valve K, the engine can be lowered manually to a running position. Oil underneath the tilt piston will be directed through this valve into the area above the tilt rod piston. (2) The volume of oil flowing from under the tilt rod piston will be larger than the area above the tilt rod piston can accommodate.
Page 371 POWER TRIM AND TILT 8-29 MANUAL RELEASE CIRCUIT (UP MODE) (1) With the manual release valve K open, the engine can also be raised manually to the fully tilted position. (2) Oil from the upper chamber of the tilt cylinder will flow through valve K into the lower chamber of the cyl- inder.
Page 372 LOWER UNIT LOWER UNIT [Standard rotation (Right-hand) model] CONTENTS REMOVAL & DISASSEMBLY .................9- 2 INSPECTION ....................9- 9 PROPELLER ..................9- 9 GEARCASE ....................9- 9 GEARS/BEARING ..................9- 9 PROPELLER SHAFT COMPONENTS ..........9-10 PROPELLER SHAFT BEARING HOUSING ..........9-10 SHIFT ROD GUIDE HOUSING COMPONENTS ........9-11 WATER PUMP AND RELATED ITEMS ..........9-12 DRIVESHAFT OIL SEAL HOUSING ............9-12 DRIVESHAFT ..................9-13...
Page 373: Removal & Disassembly
LOWER UNIT REMOVAL & DISASSEMBLY Always disconnect the battery cable, before removing lower unit. " Remove the main relay or shift actuator fuse from fuse box to avoid damaging shift actuator while clutch link rod has been removed. Shift to “NEUTRAL” position. Remove the clip, washer and clutch link rod 1 from clutch lever Remove bolt and trim tab 3.
Page 374 LOWER UNIT Remove water tube spacer 7. Remove clutch rod 8 from clutch shaft (if necessary). Place a drain pan under oil drain plug. Remove oil drain plug 9 first then oil level plug 0 and allow gear oil to drain. Inspect oil for water, contaminates or metal.
Page 375 LOWER UNIT Loosen four (4) bolts 1, then remove water pump case 2. Remove impeller 3 and impeller key 4. Remove two bolts and shift rod guide housing stopper 5. Remove pump under plate 6 and dowel pins 7. Keep impeller key 4 for reuse and discard the plate gasket. Remove two (2) bolts 1 and shift rod guide housing assembly Remove two (2) bolts 1 securing the propeller shaft bearing housing to the gearcase.
Page 376 LOWER UNIT Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. Remove pinion nut 3 and washer 4. # 09921-29410: Driveshaft holder Use special tool to unscrew driveshaft oil seal housing 1, then remove oil seal housing from drive shaft.
Page 377 LOWER UNIT Remove the driveshaft collar 5. Remove the pinion gear 1. Remove the forward gear 2 and forward gear bearing 3. Remove the bearing 3 and back-up shim 4 from forward gear. Disassembly of propeller shaft components Slide propeller shaft away from reverse gear 1 and bearing housing assembly 2.
Page 378 LOWER UNIT Remove the propeller shaft thrust washer 5, propeller shaft thrust bearing 6, bearing washer 7 and shim 8 from propeller shaft bearing housing. To disassemble propeller shaft components, refer to following: (a) Remove horizontal slider 9. (b) Remove spring 0 from clutch dog shifter. (c) Use special tool to push the dog pin A out of the clutch dog shifter.
Page 379 LOWER UNIT Disassembly of shift rod components (a) Slide shift rod 1 out of shift rod guide housing 2. (b) Remove pin 3 and shifter yoke 4. Disassembly of water pump case Remove inner sleeve 1 and rubber seal ring 2. NOTE: To facilitate the removal of inner sleeve from the pump case, warm up the entire case using a heater like hair dryer.
Page 380: Inspection
LOWER UNIT INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety glasses when using compressed air. PROPELLER •...
Page 381: Propeller Shaft Components
9-10 LOWER UNIT PROPELLER SHAFT COMPONENTS • Inspect horizontal slider and connector pin. Replace if worn, damaged or other abnormal conditions are noted. • Inspect detent balls. Replace if wear, damage or other abnor- mal conditions are noted. • Inspect clutch dog shifter. Replace if chipped, worn, damaged or other abnormal conditions are noted.
Page 382: Shift Rod Guide Housing Components
The lipped portion of the seal must face towards the propel- ler. Apply Water Resistant Grease to the seal lips. $ 99000-25160: SUZUKI WATER RESISTANT GREASE 5. Install the oil seal protector and retaining ring. SHIFT ROD GUIDE HOUSING COMPONENTS •...
Page 383: Water Pump And Related Items
2. Apply Water Resistant Grease to inner circumference of driveshaft oil seal housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE 3. Grease the inner lips of oil seal. With the lips facing away from driveshaft bearing, place seal in position and drive it into the oil seal housing.
Page 384: Driveshaft
LOWER UNIT 9-13 DRIVESHAFT • Inspect driveshaft/splines. Replace if worn, twisted, damaged or other abnormal conditions are noted. • Inspect driveshaft bearing, replace if pitted, noisy, rough or other abnormal conditions are noted.
Page 385: Assembly & Installation
9-14 LOWER UNIT ASSEMBLY & INSTALLATION Assembly & installation are in reverse order of disassembly with special attention to the following steps. 17 N . m (1.7 kg-m, 12.3 lb-ft) 1. Shift rod 2. Cover 3. Dust seal 4. Bolt 5.
Page 386 LOWER UNIT 9-15 44. Driveshaft 55 N . m 45. Oil seal housing 46. O-ring (5.5 kg-m, 47. Oil seal 40 lb-ft) 48. Nut 91 92 49. Spacer 50. Driveshaft bearing 51. Shim 52. Driveshaft collar 53. Pinion gear 54. Washer 55.
Page 387 3-76. FORWARD GEAR Assemble the forward gear 1, back-up shim 2 and forward gear bearing 3, then install forward gear assembly. % 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL DRIVESHAFT COLLAR Install driveshaft collar 1. NOTE: The tongue a of collar must be located into groove on the gear- case.
Page 388 • Apply Water Resistant Grease to O-ring 1, then install O-ring into groove on the driveshaft oil seal housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE • Install driveshaft bearing spacer 2. • Install driveshaft oil seal housing on gearcase, then tighten oil seal housing to specified torque.
Page 389 9-18 LOWER UNIT PINION NUT • Apply THREAD LOCK 1342 to the threads of pinion nut 2 before threading it onto driveshaft. ' 99000-32050: THREAD LOCK “1342” NOTE: It is recommended the original pinion nut be used for the pur- poses of shimming during repair.
Page 390 • Assemble the propeller shaft in the following sequence: $ 99000-25160: SUZUKI WATER RESISTANT GREASE % 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL (a) Apply Water Resistant grease to O-ring 1, then install O-ring into groove on the propeller shaft bearing housing.
Page 391 9-20 LOWER UNIT (c) Install reverse gear back-up shim 7 and reverse gear 8 to propeller shaft bearing housing. (d) Slide propeller shaft 9 into reverse gear and propeller shaft bearing housing. (e) Assemble horizontal slider 0 to connector pin. NOTE: Before installing propeller shaft/bearing housing assembly, move shifter dog to bring horizontal slider to the neutral position.
Page 392 The lipped portion of oil seal must face towards the driveshaft housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE • Attach shifter yoke 4 to shift rod 3, then insert pin 5. • Install pin 6 to shift rod, then slide shift rod guide housing onto shift rod.
Page 393 9-22 LOWER UNIT • Install shift rod guide housing assembly by aligning shifter yoke with groove in horizontal slider, then tighten two (2) housing bolts securely. • Turn shift rod from Neutral position to Forward and Reverse position to check proper gear engagement. •...
Page 394 Before installing pump inner sleeve, apply water resistant grease lightly between inner sleeve and pump case mating sur- faces. $ 99000-25160: SUZUKI WATER RESISTANT GREASE NOTE: Before installing water pump case assembly, apply Water Resis- tant Grease lightly on pump case inner sleeve and under panel for initial lubrication.
Page 395 • Insert two (2) dowel pins 3. • Apply Water Resistant Grease to driveshaft and shift rod splines. • Apply a light coating of SUZUKI SILICONE SEAL to mating surfaces of gearcase and driveshaft housing.
Page 396 Neutral • Apply SUZUKI SILICONE SEAL to seven (7) gearcase bolts 7 and tighten them to specified torque. & Gearcase bolt: 10 mm 55 N·m (5.5 kg-m, 40.0 lb-ft) 12 mm 83 N·m (8.3 kg-m, 60.0 lb-ft)
Page 397: Trim Tab
9-26 LOWER UNIT TRIM TAB The trim tab counteracts or minimizes propeller torque “pull” felt through the steering system. If the steering is pulled to starboard or port side, adjust trim tab with following procedure: Adjusting 1. Loosen the bolt of trim tab. 2.
Page 398: Lower Unit Gears- Shimming And Adjustment
LOWER UNIT 9-27 LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT If lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be checked and/or adjusted to ensure smooth, reliable operation of gears.
Page 399 9-28 LOWER UNIT FORWARD GEAR/PINION GEAR Follow the procedure below to adjust forward gear/pinion gear. Step to prior to adjustment 1. Install standard pinion gear back-up shim thickness modified according to ± design specification mark on gear. ± design spec. mark 2.
Page 400 LOWER UNIT 9-29 (c) Install propeller shaft (with special tool) into gearcase. (d) Install the special tool and then attach it to the propeller shaft as shown. # 09951-99310: Gear holder (e) Turn the bolt 1 clockwise to push forward gear inward. (f) Align dial gauge pointer at 90 °...
Page 401 9-30 LOWER UNIT 5. Carefully pull out propeller shaft and housing to check tooth Concave side contact pattern. Tooth width Convex side Heel TOOTH Tooth top CONTACT PATTERN Tooth bottom Optimum tooth contact Optimum tooth contact The optimum tooth contact is shown at right. approx.
Page 402 LOWER UNIT 9-31 CHECKING GEAR BACKLASH After obtaining optimum tooth contact, gear backlash should be measured. (For measure the gear backlash, see “Adjusting gear backlash” section on page 9-28.) # 09900-20602: Dial gauge 09900-20701: Magnetic stand 09952-09310: Backlash indicator tool Designate this amount of gear backlash as (A).
Page 403 9-32 LOWER UNIT NOTE: • Before installing special tool, move shifter dog to forward posi- tion. • Use longer spring (free length: 42.3 mm, 1.67 in) in the gear adjust spring set to adjust the reverse gear backlash. # 09951-09310: Gear adjust spring set 4.
Page 404 LOWER UNIT 9-33 CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure the propeller shaft thrust play. If not within the following specification, a shim adjustment is required. Propeller shaft thrust play: Approx. 0.1 – 0.2 mm (0.004 – 0.008 in.) NOTE: Use only the propeller shaft reverse thrust washer to adjust thrust play.
Page 405 LOWER UNIT 10-1 LOWER UNIT [Counter rotation (Left-hand) model] CONTENTS REMOVAL & DISASSEMBLY ...............10- 2 INSPECTION ....................10-10 PROPELLER ..................10-10 GEARCASE ..................10-10 GEARS/BEARING ................10-11 FORWARD GEAR BEARING/THRUST BEARING ......10-11 PROPELLER SHAFT COMPONENTS ..........10-11 PROPELLER SHAFT BEARING HOUSING ........10-12 SHIFT ROD GUIDE HOUSING COMPONENTS ........10-13 WATER PUMP AND RELATED ITEMS ..........10-13 DRIVESHAFT OIL SEAL HOUSING ............10-14 DRIVESHAFT ..................10-14...
Page 406: Removal & Disassembly
10-2 LOWER UNIT REMOVAL & DISASSEMBLY Always disconnect the battery cable, before removing lower unit. " Remove the main relay or shift actuator fuse from fuse box to avoid damaging shift actuator while clutch link rod has been removed. Shift to “NEUTRAL” position. Remove the clip, washer and clutch link rod 1 from clutch lever Remove bolt and trim tab 3.
Page 407 LOWER UNIT 10-3 Remove water tube spacer 7. Remove clutch rod 8 from clutch shaft (if necessary). Place a drain pan under oil drain plug. Remove oil drain plug 9 first then oil level plug 0 and allow gear oil to drain. Inspect oil for water, contaminates or metal.
Page 408 10-4 LOWER UNIT Loosen four (4) bolts 1, then remove water pump case 2. Remove impeller 3 and impeller key 4. Remove two bolts and shift rod guide housing stopper 5. Remove pump under plate 6 and dowel pins 7. Keep impeller key 4 for reuse and discard the plate gasket.
Page 409 LOWER UNIT 10-5 Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. Remove pinion nut 3 and washer 4. # 09921-29410: Driveshaft holder Use special tool to unscrew driveshaft oil seal housing 1, then remove oil seal housing from drive shaft.
Page 410 10-6 LOWER UNIT Remove the driveshaft collar 5. Remove the pinion gear 1. Remove the reverse gear 2 and back-up shim 3. Disassembly of forward gear and propeller shaft compo- nents To disassemble forward gear and propeller shaft components, refer to following: (a) Remove horizontal slider 1.
Page 411 LOWER UNIT 10-7 (d) Remove clutch dog shifter 4 and connector pin assembly 5 from propeller shaft. Note the position of two (2) small detent balls 6. NOTE: Be careful not to lose the two small detent balls on disassembly. (e) Loosen and remove the connector pin 7, then take out detent ball 8 and detent spring 9 from connector body 0.
Page 412 10-8 LOWER UNIT (h) Slide propeller shaft assembly E away from propeller shaft bearing housing. (i) Remove the propeller shaft thrust bearing F, bearing washer G and thrust shim H from propeller shaft bearing housing. (j) Remove the forward gear bearing I, concave washer J, thrust spacer K and thrust bearing L from propeller shaft Disassembly of shift rod components (a) Slide shift rod 1 out of shift rod guide housing 2.
Page 413 LOWER UNIT 10-9 Disassembly of water pump case Remove inner sleeve 1 and rubber seal ring 2. NOTE: To facilitate the removal of inner sleeve from the pump case, warm up the entire case using a heater like hair dryer.
Page 414: Inspection
10-10 LOWER UNIT INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety glasses when using compressed air. PROPELLER •...
Page 415: Gears/Bearing
LOWER UNIT 10-11 GEARS/BEARING • Inspect forward, reverse and pinion gear teeth and engaging dogs. Replace gears if damaged, worn or other abnormal conditions are noted. • Inspect propeller shaft forward bearing. Replace bearing if pitted, noisy, rough or other abnormal con- ditions are noted.
Page 416: Propeller Shaft Bearing Housing
The lipped portion of the seal must face towards the propel- ler. Apply Water Resistant Grease to the seal lips. $ 99000-25160: SUZUKI WATER RESISTANT GREASE 5. Install the oil seal protector and retaining ring.
Page 417: Shift Rod Guide Housing Components
LOWER UNIT 10-13 SHIFT ROD GUIDE HOUSING COMPONENTS • Inspect shift rod guide housing. Replace if cracked, damaged or other abnormal conditions are noted. • Inspect shifter yoke. Replace if wear, damaged or other abnormal conditions are noted. • Inspect shift rod/splines. Replace if worn, twisted, damaged or other abnormal conditions are noted.
Page 418: Driveshaft Oil Seal Housing
2. Apply Water Resistant Grease to inner circumference of driveshaft oil seal housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE 3. Grease the inner lips of oil seal. With the lips facing away from driveshaft bearing, place seal in position and drive it into the oil seal housing.
Page 419: Assembly & Installation
LOWER UNIT 10-15 ASSEMBLY & INSTALLATION Assembly & installation are in reverse order of disassembly with special attention to the following steps. 17 N . m (1.7 kg-m, 12.3 lb-ft) 1. Shift rod 2. Cover 3. Dust seal 4. Bolt 5.
Page 420 10-16 LOWER UNIT 55 N . m 44. Driveshaft 45. Oil seal housing (5.5 kg-m, 46. O-ring 40 lb-ft) 47. Oil seal 96 97 48. Nut 49. Spacer 50. Driveshaft bearing 51. Shim 52. Driveshaft collar 53. Pinion gear 54. Washer 55.
Page 421 For shift posi- tion sensor adjustment, see page 3-76. REVERSE GEAR Place the back-up shim 2 into position, then install reverse gear % 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL DRIVESHAFT COLLAR Install driveshaft collar 1. NOTE: The tongue a of collar must be located into groove on the gear- case.
Page 422 • Apply Water Resistant Grease to O-ring 1, then install O-ring into groove on the driveshaft oil seal housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE • Install driveshaft bearing spacer 2. • Install driveshaft oil seal housing on gearcase, then tighten oil seal housing to specified torque.
Page 423 • Assemble the propeller shaft in the following sequence: $ 99000-25160: SUZUKI WATER RESISTANT GREASE % 99000-22540: SUZUKI OUTBOARD MOTOR GEAR OIL (a) Apply Water Resistant grease to O-ring 1, then install the O-ring into groove on the propeller shaft bearing housing.
Page 424 10-20 LOWER UNIT (c) Install the thrust bearing 6, thrust spacer 7, concave washer 8 and forward gear bearing 9 to propeller shaft 0. (d) Slide propeller shaft assembly into propeller shaft bearing housing. (e) Install the forward gear bearing washer A and bearing stop- per B, then tighten bearing stopper to the specified torque.
Page 425 LOWER UNIT 10-21 (f) Install the forward gear C and back-up shim D. (g) Slide the clutch dog shifter E onto the propeller shaft. NOTE: The side of the clutch dog shifter negatively taper machined at both sides of the dog must face towards forward gear. (Opposite side of the dog has been machined only one side.) Forward gear side 1.
Page 426 10-22 LOWER UNIT (k) Align the holes in the shifter dog and connector pin and then slide the dog pin L through both dog and connector pin. (l) Install the dog pin retaining spring M, ensuring that it fits snugly into the groove on the dog shifter. (m) Assemble horizontal slider N to connector pin.
Page 427 The lipped portion of oil seal must face towards the driveshaft housing. $ 99000-25160: SUZUKI WATER RESISTANT GREASE • Attach shifter yoke 4 to shift rod 3, then insert pin 5. • Install pin 6 to shift rod, then slide shift rod guide housing onto shift rod.
Page 428 LOWER UNIT • Apply Water Resistant Grease to the shift rod guide housing O-ring. $ 99000-25160: SUZUKI WATER RESISTANT GREASE NOTE: Before installing shift rod guide housing assembly, bring shifter yoke to neutral position by turning shift rod right or left.
Page 429 LOWER UNIT 10-25 LEAKAGE CHECK Check for leakage of oil seal and O-ring when applying specified pressure inside of the gearcase. # 09950-69512: Oil leakage tester 09952-99310: Air pump Procedure 1. Install the test tool into the oil level hole. 2.
Page 430 Before installing pump inner sleeve, apply Water Resistant Grease lightly between inner sleeve and pump case mating sur- faces. $ 99000-25160: SUZUKI WATER RESISTANT GREASE NOTE: Before installing water pump case assembly, apply Water Resis- tant Grease lightly on pump case inner sleeve and under panel for initial lubrication.
Page 431 • Insert two (2) dowel pins 3. • Apply Water Resistant Grease to driveshaft and shift rod splines. • Apply a light coating of SUZUKI SILICONE SEAL to mating surfaces of gearcase and driveshaft housing.
Page 432 Neutral • Apply SUZUKI SILICONE SEAL to seven (7) gearcase bolts 7 and tighten them to specified torque. & Gearcase bolt: 10 mm 55 N·m (5.5 kg-m, 40.0 lb-ft) 12 mm 83 N·m (8.3 kg-m, 60.0 lb-ft)
Page 433: Trim Tab
LOWER UNIT 10-29 TRIM TAB The trim tab counteracts or minimizes propeller torque “pull” felt through the steering system. If the steering is pulled to starboard or port side, adjust trim tab with following procedure: Adjusting 1. Loosen the bolt of trim tab. 2.
Page 434: Lower Unit Gears- Shimming And Adjustment
10-30 LOWER UNIT LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT (Counter rotation model) If lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and back- lash will have to be checked and/or adjusted to ensure smooth, reliable operation of gears. Shim/Washer &...
Page 435 LOWER UNIT 10-31 REVERSE GEAR/PINION GEAR Follow the procedure below to adjust reverse gear/pinion gear. STEP TO PRIOR TO ADJUSTMENT 1. Install standard pinion gear back-up shim thickness modified according to ± design specification mark on gear. ± design specification mark 2.
Page 436 10-32 LOWER UNIT (c) Install propeller shaft (with special tool) into gearcase. (d) Install the special tool and then attach it to the propeller shaft as shown. # 09951-99310: Gear holder (e) Turn the bolt 1 clockwise to push reverse gear inward. (f) Align dial gauge pointer at 90°...
Page 437 LOWER UNIT 10-33 FORWARD GEAR SHIM After adjusting reverse gear backlash, follow the procedure below to adjust forward gear. Adjusting gear backlash 1. Correctly assemble driveshaft oil seal housing, driveshaft, reverse gear, pinion gear and related components. (See page 10-17 to 10-19.) 2.
Page 438 10-34 LOWER UNIT 6. Align dial gauge pointer at 90 ° to the mark on the backlash indicator tool and read backlash on dial gauge by lightly moving driveshaft clockwise and counterclockwise by hand. Gear backlash: Approx. 0.8 – 1.1 mm (0.030 – 0.043 in) •...
Page 439 LOWER UNIT 10-35 4. Carefully pull out propeller shaft and housing to check tooth Concave side contact pattern. Tooth width Convex side Heel TOOTH Tooth top CONTACT PATTERN Tooth bottom Optimum tooth contact Optimum tooth contact The optimum tooth contact is shown at right. approx.
Page 440 10-36 LOWER UNIT CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure the propeller shaft thrust play. If not within the following specification, a shim adjustment is required. Propeller shaft thrust play: 0.1 – 0.2 mm (0.004 – 0.008 in) NOTE: Use only the propeller shaft thrust shim to adjust thrust play.
Page 441 WIRE/HOSE ROUTING 11-1 WIRE/HOSE ROUTING CONTENTS WIRING DIAGRAM ..................11- 2 DF300 ....................11- 2 • For single engine ................11- 2 • For single engine and dual station ..........11- 4 • For multiple engine ................11- 5 • For multiple engine and dual station ..........11- 6 WIRING ......................11- 8...
Page 442: Wiring Diagram
11-2 WIRE/HOSE ROUTING WIRING DIAGRAM DF300 For single engine...
Page 443 WIRE HOSE ROUTING 11-3...
Page 444: For Single Engine And Dual Station
11-4 WIRE/HOSE ROUTING For single engine and dual station...
Page 445: For Multiple Engine
WIRE HOSE ROUTING 11-5 For multiple engine FOR DUAL ENGINE Lbl/W Lbl/W Lbl/W Bl/B TO REMOTE CONTROL TO STBD ENGINE Bl/R TO PORT ENGINE Bl/R FOR TRIPLE ENGINE Lbl/W Lbl/W Lbl/W Bl/B Bl/B TO REMOTE CONTROL TO STBD ENGINE Bl/R Bl/B TO CENTER ENGINE...
Page 446: For Multiple Engine And Dual Station
11-6 WIRE/HOSE ROUTING For multiple engine and dual station PASSIVE HUB UNIT PASSIVE HUB UNIT ACTIVE HUB UNIT (2ND STATION) (2ND STATION) WATER PRESSURE SPEEDOMETER TACHOMETER VOLT METER FUEL GAUGE TRIM GAUGE GAUGE 15PSI PORT To next page 11-7 B W W B W W B W W B W W...
Page 447 WIRE HOSE ROUTING 11-7 PASSIVE HUB UNIT PASSIVE HUB UNIT (2ND STATION) (2ND STATION) WATER PRESSURE TACHOMETER SPEEDOMETER TRIM GAUGE FUEL GAUGE VOLT METER GAUGE 15PSI Y Bl PORT Y Bl R/W TACHOMETER WATER PRESSURE TRIM GAUGE VOLT METER GAUGE 15PSI CENTER To previous page 11-6...
Page 448: Wiring
11-8 WIRE/HOSE ROUTING WIRING SINGLE ENGINE, SINGLE STATION...
Page 449: Single Engine, Dual Stations
WIRE HOSE ROUTING 11-9 SINGLE ENGINE, DUAL STATIONS...
Page 450: Twin Engines, Single Station
11-10 WIRE/HOSE ROUTING TWIN ENGINES, SINGLE STATION...
Page 451: Twin Engines, Dual Stations
WIRE HOSE ROUTING 11-11 TWIN ENGINES, DUAL STATIONS...
Page 452: Triple Engines, Single Station
11-12 WIRE/HOSE ROUTING TRIPLE ENGINES, SINGLE STATION...
Page 453: Triple Engines, Dual Stations
WIRE HOSE ROUTING 11-13 TRIPLE ENGINES, DUAL STATIONS...
Page 454: Wire Routing
11-14 WIRE/HOSE ROUTING WIRE ROUTING...
Page 455 WIRE HOSE ROUTING 11-15...
Page 456 11-16 WIRE/HOSE ROUTING Starter magnet switch Motor terminal Battery cable Harness lead wire (R) Tighten bolt with battery cable and two Rect and regulator GND lead wire. Rectifier & regulator Battery cable Rect & regulator GND lead wire Clamp Battery cable Battery cable PTT switch fuse Oil pressure...
Page 457 WIRE HOSE ROUTING 11-17 CMP sensor CMP sensor CMP sensor Ignition coil No.1 Ignition coil No.2 Clamp Fuel injector No.1 Fuel injector No.2 Ignition coil No.3 Ignition coil No.4 Fuel injector No.3 Fuel injector No.4 Ignition coil No.5 Clamp Ignition coil No.6 Fuel injector No.5 Fuel injector No.6 NOTICE ON IGNITION COIL ASSEMBLING...
Page 458 11-18 WIRE/HOSE ROUTING...
Page 459 WIRE HOSE ROUTING 11-19 Clamp Tilt limit switch Trim sensor lead wire Tilt limit switch lead wire PTT motor cable Side cover seal Trim sensor lead wire Clamp Tilt limit switch lead wire PTT motor cable Trim sensor Clamp Clamp Clamp Trim sensor lead wire PTT motor cable...
Page 460: Fuel/Water Hose Routing
11-20 WIRE/HOSE ROUTING FUEL/WATER HOSE ROUTING • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. • Check that hoses do not contact rods and levers during either engine operation or standstill. •...
Page 461 WIRE HOSE ROUTING 11-21...
Page 462 11-22 WIRE/HOSE ROUTING...
Page 463 WIRE HOSE ROUTING 11-23...
Page 464: Water Hose Routing
11-24 WIRE/HOSE ROUTING WATER HOSE ROUTING...
Page 465 WIRE HOSE ROUTING 11-25 Water return hose STBD and clip Water return hose PORT and clip Timing chain guide base Clip Water return hose PORT Water return hose STBD Clip Water hose & Water hose Water hose Water hose 3-way joint Water hose Clamp Water hose...
Page 466 11-26 WIRE/HOSE ROUTING...
Page 467 DF300 “K8” (’08) MODEL 12-1 DF300 “K8” (2008) MODEL FOREWORD This supplementary service manual describes the outline, technical data and servicing proce- dures for the “K8” (2008) model outboard motors. Please read and thoroughly familiarize yourself with this information before using it for your ser- vice activities.
Page 468 12-2 DF300 “K8” (’08) MODEL * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF300T DF300Z PRE-FIX 30001F 30001Z DIMENSIONS & WEIGHT Overall length mm (in) 953 (37.5) (front to back) Overall width mm (in) 564 (22.2)
Page 469 Engine oil amounts 8.0 (8.5/7.0) : Oil change only L (US/lmp. qt) 8.2 (8.7/7.2) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts 1 100 (37.2/38.7) (US/lmp. oz) BRACKET Trim angle degree 0 –...
Page 470 4 DF300 “K8” (’08) MODEL Data Item Unit DF300T DF300Z LOWER UNIT Propeller Counter rotation models Blade × Dia. (in.) × Pitch (in.) × × × × 18 and 1/2 × × × × 21 and 1/2 × × ×...
Page 471: Service Data
DF300 “K8” (’08) MODEL * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF300T/Z POWERHEAD Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 650 ± 50 (in-gear: Approx. 650) **Cylinder compression 1 100 –...
Page 472 6 DF300 “K8” (’08) MODEL Data Item Unit DF300T/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 mm (in) 45.330 – 45.490 (1.7846 – 1.7909) Limit mm (in) 45.230 (1.7807)
Page 473 DF300 “K8” (’08) MODEL Data Item Unit DF300T/Z VALVE/VALVE GUIDE Valve diameter mm (in) 37.9 (1.49) mm (in) 31.4 (1.24) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in) 0.33 – 0.37 (0.013 – 0.015) Valve seat angle —...
Page 474 8 DF300 “K8” (’08) MODEL Data Item Unit DF300T/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) 98.000 – 98.020 (3.8583 – 3.8591)
Page 475 DF300 “K8” (’08) MODEL Data Item Unit DF300T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in) 22.010 – 22.018 (0.8665 – 0.8668) diameter Conrod big end oil clearance STD mm (in) 0.045 – 0.063 (0.0018 – 0.0025) Limit mm (in) 0.080 (0.0031)
Page 476 10 DF300 “K8” (’08) MODEL Data Item Unit DF300T/Z ELECTRICAL Ignition timing Degrees ATDC 5° – BTDC 24° at r/min Over revolution limiter r/min 6 400 Ω CKP sensor resistance at 20°C 168 – 252 Ω CMP sensor resistance at 20°C —...
Page 477 DF300 “K8” (’08) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) Commutator outside diame- mm (in) 22.0 (0.87) Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in SPC system or in the signal from sensors, switches, etc., the code repre- senting the failure is displayed in the digital display screen on the tachometer ·...
Page 478: Engine Control
12 DF300 “K8” (’08) MODEL ENGINE CONTROL The program (internal circuit) of ECM has been changed. This change is to add the shift learning function in the electronic shift system. Early (’07 model) Interchange- Late (’08 model) Part Number ability...
Page 479 DF300 “K8” (’08) MODEL Outline The shift learning function is performed in such a process that it memorizes the gear engagement start volt- age of the shift position sensor and on the basis of the memorized value, it determines the travel of clutch dog shifter for forward/reverse gear engagement.
Page 480: Mid Unit
14 DF300 “K8” (’08) MODEL MID UNIT SHIFT ACTUATOR HOLDER (CLUTCH LEVER HOLDER) The shift actuator holder (Clutch lever holder) shape has been changed as shown in the illustration. ’07 model ’08 model Oval Circle Cut the this portion Early (’07 model) Interchange- Late (’08 model)
Page 481: Power Unit
DF300 “K8” (’08) MODEL POWER UNIT CRANKCASE Some bond application locations are added on the crankcase. Apply bond to marked line. Bond Application Location Added Bond Application Locations COLLECTOR COVER The union, screw set and air bypass hose were eliminated from the collector cover.
Page 482: Fuel Hose (Fuel Tank To Low Pressure Fuel Filter)
16 DF300 “K8” (’08) MODEL FUEL HOSE (Fuel tank to low pressure fuel filter) A protector was added to the fuel hose (fuel tank to low pressure fuel filter). Two clamps were added, the water hose and water flash hose were fixed by the clamps.
Page 483: Lower Unit
DF300 “K8” (’08) MODEL LOWER UNIT PROPELLER SHAFT/FORWARD THRUST WASHER (Applicable to right hand rotation model) The length of propeller shaft spline section where the shifter dog is installed has been changed as shown in the illustration. Unit: mm With this change, the forward thrust washer has been added between the propeller shaft and forward gear as shown in the ’07 model...
Page 485 DF300 “K9” (’09) MODEL DF300 “K9” (2009) MODEL FOREWORD This supplementary service manual describes the outline, technical data and servicing proce- dures for the “K9” (2009) model outboard motors. Please read and thoroughly familiarize yourself with this information before using it for your ser- vice activities.
Page 486 2 DF300 “K9” (’09) MODEL * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF300T DF300Z PRE-FIX 30001F 30001Z DIMENSIONS & WEIGHT Overall length mm (in) 953 (37.5) (front to back) Overall width mm (in) 564 (22.2)
Page 487 DF300T DF300Z FUEL & OIL Fuel Suzuki highly recommends the use of 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 488 4 DF300 “K9” (’09) MODEL Data Item Unit DF300T DF300Z REDUCTION SYSTEM 1st reduction gear ratio 32 : 40 (1.250) (Crankshaft drive gear: Driven gear) 2nd reduction gear ratio (Lower unit gear) 12 : 20 (1.667) Total reduction gear ratio...
Page 489: Service Data
DF300 “K9” (’09) MODEL * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF300T/Z POWERHEAD Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 650 ± 50 (in-gear: Approx. 650) **Cylinder compression 1 100 –...
Page 490 6 DF300 “K9” (’09) MODEL Data Item Unit DF300T/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 mm (in) 45.330 – 45.490 (1.7846 – 1.7909) Limit mm (in) 45.230 (1.7807)
Page 491 DF300 “K9” (’09) MODEL Data Item Unit DF300T/Z VALVE/VALVE GUIDE Valve diameter mm (in) 37.9 (1.49) mm (in) 31.4 (1.24) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in) 0.33 – 0.37 (0.013 – 0.015) Valve seat angle —...
Page 492 8 DF300 “K9” (’09) MODEL Data Item Unit DF300T/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) 98.000 – 98.020 (3.8583 – 3.8591)
Page 493 DF300 “K9” (’09) MODEL Data Item Unit DF300T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in) 22.010 – 22.018 (0.8665 – 0.8668) diameter Conrod big end oil clearance STD mm (in) 0.045 – 0.063 (0.0018 – 0.0025) Limit mm (in) 0.080 (0.0031)
Page 494 10 DF300 “K9” (’09) MODEL Data Item Unit DF300T/Z ELECTRICAL Ignition timing Degrees ATDC 5 – BTDC 24 Over revolution limiter r/min 6 400 Ω CKP sensor resistance at 20°C 168 – 252 Ω CMP sensor resistance at 20°C —...
Page 495 DF300 “K9” (’09) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) Commutator outside diame- mm (in) 22.0 (0.87) Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in SPC system or in the signal from sensors, switches, etc., the code repre- senting the failure is displayed in the digital display screen on the tachometer-monitor.
Page 496: Engine Control
12 DF300 “K9” (’09) MODEL ENGINE CONTROL As an ECM parameter for the actuator control, PTT relay has been added. The ON/OFF signal for PTT UP or DOWN is inputted to ECM PTT relay drive circuit from ECM terminal No.16 or No.22. And the output signal from terminal No.82 or No.83 controls ON/OFF for PTT relay’s UP or DOWN circuit.
Page 497 DF300 “K9” (’09) MODEL PTT SYSTEM WIRING DIAGRAM PTT switch (Remote control box) Main fuse 60A Fuse 10A Tilt limit switch Switch panel PTT switch (Side cover) 30A Fuse BATT Main switch Battery PTT motor PTT motor relay NOTE: • When an engine position (port, center, or starboard) is registered to BCM during initial setting of SPC system, the input voltages from PTT switch to ECM terminals No.16 (Lbl) and No.22 (P) are required.
Page 498 14 DF300 “K9” (’09) MODEL ECM CONNECTOR/TERMINALS LAYOUT FRONT VIEW TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR — — Power source for sensor — — ECM power source Y/Bl CMP sensor #1 Lg/R No.4 Ignition coil (–) CKP sensor No.5 Ignition coil (–)
Page 499: Power Unit
For the reason of parts control, camshaft part number has been changed. In accordance with this change, identification mark has also been changed from “8” to “9”. DF200, DF225, DF250 and DF300 camshafts differ as shown below. Model Intake Exhaust...
Page 500: Wiring Diagram
16 DF300 “K9” (’09) MODEL WIRING DIAGRAM DF300...
Page 501 DF300 “K9” (’09) MODEL...
Page 502 repared by Service Department February, 2007 Manual No.99500-98J00-01E rinted in Japan...
Page 503 K7, K8, K9...
Page 504 NOTE: • Use this supplement with the following service manual: DF300 Service Manual (P/no, 99500-98J0 • -01E) DF300 Supplementary Service Manual for 2009 model (P/no, 99501-98J10-01E) • This Supplementary Service Manual describes the modification for 2009 model. CONTENTS SPECIFICATIONS ................2 SERVICE DATA ..................
Page 505 DF300_K10.book Page 2 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF300T DF300Z PRE-FIX 30002F 30002Z DIMENSIONS & WEIGHT Overall length mm (in) 953 (37.5)
Page 506 DF300T DF300Z FUEL & OIL Fuel Suzuki highly recommends the use of 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 507 DF300_K10.book Page 4 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T DF300Z REDUCTION SYSTEM 1st reduction gear ratio 32 : 40 (1.250) (Crankshaft drive gear: Driven gear) 2nd reduction gear ratio (Lower unit gear) 12 : 20 (1.667)
Page 508: Service Data
DF300_K10.book Page 5 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF300T/Z POWERHEAD Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 650 ±...
Page 509 DF300_K10.book Page 6 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T/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 mm (in) 45.330 –...
Page 510 DF300_K10.book Page 7 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T/Z VALVE/VALVE GUIDE Valve diameter mm (in) 37.9 (1.49) mm (in) 31.4 (1.24) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in) 0.33 –...
Page 511 DF300_K10.book Page 8 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T/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)
Page 512 DF300_K10.book Page 9 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in) 22.010 – 22.018 (0.8665 – 0.8668) diameter Conrod big end oil clearance STD mm (in) 0.045 – 0.063 (0.0018 – 0.0025)
Page 513 DF300_K10.book Page 10 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL Data Item Unit DF300T/Z ELECTRICAL Ignition timing Degrees ATDC 5 – BTDC 24 Over revolution limiter r/min 6 400 Ω CKP sensor resistance at 20°C 168 – 252 Ω...
Page 514 DF300_K10.book Page 11 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL 11 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) Commutator outside diame- mm (in) 22.0 (0.87) Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in SPC system or in the signal from sensors, switches, etc., the code repre-...
Page 515: General Information
DF300_K10.book Page 12 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL GENERAL INFORMATION IDENTIFICATION NUMBER LOCATION MODEL, PRE-FIX, SERIAL NUMBER The model pre-fix has been changed as follows: This change is effected in relation to manufacturing control and does not affect the basic performance of the outboard motor.
Page 516: Power Unit
DF300_K10.book Page 13 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL 13 POWER UNIT PISTON Top mark Bottom side view The groove on the piston for removing/installing the piston pin circlip at the bottom side has been eliminated.
Page 517: Power Trim And Tilt
DF300_K10.book Page 14 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL POWER TRIM AND TILT MOORING At the time of mooring, retract the trim rod fully into the trim cylin- der. This will help prevent the trim rod from deteriorating (pitting cor- rosion).
Page 518: Lower Unit
DF300_K10.book Page 15 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL 15 LOWER UNIT CONNECTOR PIN The connector pin has been modified from an assembly type to Early an integrated type. Due to this modification, the number of detent balls 1 used has been changed from one to two.
Page 519: Wire Routing
DF300_K10.book Page 16 Monday, October 26, 2009 12:58 PM DF300 “K10” (’10) MODEL WIRE ROUTING...
Page 520 OUTBOARD MOTOR SUPPLEMENTARY SERVICE MANUAL Applicable model and effective serial number: 30002F-110001 and later 30002Z-110001 and later Use this manual with: • 99500-98J0 -01E 9 9 5 0 1 - 9 8 J 3 0 - 0 1 E...
Page 521 Please read and thoroughly familiarize yourself with this information before using it for your ser- vice activities. NOTE: • Use this supplement with the following service manual: DF300 Service Manual (P/no, 99500-98J0 • -01E) CONTENTS SPECIFICATIONS ................2 SERVICE DATA ..................5 SPECIAL TOOLS ..................
Page 522: Specifications
2 DF300 (30002F-110001 –, 30002Z-110001 –) * SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF300T DF300Z PRE-FIX 30002F 30002Z DIMENSIONS & WEIGHT Overall length mm (in) 953 (37.5) (front to back) Overall width mm (in) 564 (22.2)
Page 523 DF300T DF300Z FUEL & OIL Fuel Suzuki highly recommends the use of 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 524 4 DF300 (30002F-110001 –, 30002Z-110001 –) Data Item Unit DF300T DF300Z REDUCTION SYSTEM 1st reduction gear ratio 32 : 40 (1.250) (Crankshaft drive gear: Driven gear) 2nd reduction gear ratio (Lower unit gear) 12 : 20 (1.667) Total reduction gear ratio...
Page 525: Service Data
DF300 (30002F-110001 –, 30002Z-110001 –) 5 * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF300T/Z POWERHEAD Recommended operating range r/min 5 700 – 6 300 Idle speed r/min 650 ± 50 (in-gear: Approx. 650) **Cylinder compression 1 100 –...
Page 526 6 DF300 (30002F-110001 –, 30002Z-110001 –) Data Item Unit DF300T/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 mm (in) 45.330 – 45.490 (1.7846 – 1.7909)
Page 527 DF300 (30002F-110001 –, 30002Z-110001 –) 7 Data Item Unit DF300T/Z VALVE/VALVE GUIDE Valve diameter mm (in) 37.9 (1.49) mm (in) 31.4 (1.24) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in) 0.33 – 0.37 (0.013 – 0.015) Valve seat angle —...
Page 528 8 DF300 (30002F-110001 –, 30002Z-110001 –) Data Item Unit DF300T/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) 98.000 –...
Page 529 DF300 (30002F-110001 –, 30002Z-110001 –) 9 Data Item Unit DF300T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in) 22.010 – 22.018 (0.8665 – 0.8668) diameter Conrod big end oil clearance STD mm (in) 0.045 – 0.063 (0.0018 – 0.0025) Limit mm (in) 0.080 (0.0031)
Page 530 10 DF300 (30002F-110001 –, 30002Z-110001 –) Data Item Unit DF300T/Z ELECTRICAL Ignition timing Degree BTDC 0 – BTDC 25 Over revolution limiter r/min 6 400 Ω CKP sensor resistance at 20°C 168 – 252 Ω CMP sensor resistance at 20°C —...
Page 531 DF300 (30002F-110001 –, 30002Z-110001 –) 11 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) Commutator outside diame- mm (in) 22.0 (0.87) Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in SPC system or in the signal from sensors, switches, etc., the code repre- senting the failure is displayed in the screen on the SMIS 4"...
Page 532: Special Tools
The special tool has been provided for removal and installation of the O sensor. 09933-39810 sensor socket MATERIALS REQUIRED The liquid gasket applied on mating surface of the crankcase and the cylinder has been changed from Suzuki Bond 1207B to 1217G. SYMBOL DEFINITION Apply SUZUKI BOND “1217G” 99000-31260...
Page 533: Periodic Maintenance
DF300 (30002F-110001 –, 30002Z-110001 –) 13 PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES LOW PRESSURE FUEL FILTER Inspect every 50 hours (3 months) Replace every 400 hours or 2 years If leakage, cracks or other damage is found, replace the fuel fil- ter.
Page 534 14 DF300 (30002F-110001 –, 30002Z-110001 –) Drain the fuel and water in the fuel filter cup 4 into a suit- able container. Pull out the filter element 5. Inspect the filter element 5, O-ring 6 and seal ring 7 for damage.
Page 535: Engine Control System
DF300 (30002F-110001 –, 30002Z-110001 –) 15 ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE In addition to the existing sensor in the engine control system, the O sensor and the water in fuel sensor have been installed. INPUT CONTROL OUTPUT (sensor/switch) (ECM) (actuator etc.)
Page 536 16 DF300 (30002F-110001 –, 30002Z-110001 –) INPUT CONTROL OUTPUT (sensor/switch etc.) (BCM) (actuator etc.) Main switch BCM power source Throttle motor relay Lever position sensor 1 (Main, Sub) CAN Communication system Lever position sensor 2 (Main, Sub) Shift motor relay START &...
Page 537: Components For System Control
DF300 (30002F-110001 –, 30002Z-110001 –) 17 COMPONENTS FOR SYSTEM CONTROL ENGINE CONTROL MODULE (ECM) Due to addition of the “Water in fuel alert system” in the engine control system, the major controls of ECM are as follows: NAME OF CONTROL...
Page 538 18 DF300 (30002F-110001 –, 30002Z-110001 –) ECM CONNECTOR/TERMINALS LAYOUT FRONT VIEW TERMI- WIRE TERMI- WIRE CIRCUIT CIRCUIT COLOR COLOR R/BI Water in fuel sensor Power source for sensor — — ECM power source Y/Bl CMP sensor #1 Lg/R No.4 Ignition coil (–) CKP sensor No.5 Ignition coil (–)
Page 539 DF300 (30002F-110001 –, 30002Z-110001 –) 19 ECM INTERNAL STRUCTURE INJECTOR #1 ECM POWER INJECTOR #2 ECM PWR VB MONI ECM POWER INJECTOR #3 MAIN RELAY INJECTOR #4 NEUTRAL SW INJECTOR #5 STARTER INJECTOR #6 CKP SENSOR RELAY SENSOR1 IGN COIL #1...
Page 540 20 DF300 (30002F-110001 –, 30002Z-110001 –) LOCATION OF SENSOR AND SWITCH EX. temp. sensor (PORT) sensor Purge valve IAT sensor MAP sensor Cylindser temp. sensor . Throttle actuator Charge coil . TPS EX. temp. sensor (STBD) CKP sensor Ground bolt...
Page 541 DF300 (30002F-110001 –, 30002Z-110001 –) 21 SENSOR AND SWITCH CKP (Crankshaft Position) SENSOR/Flywheel The flywheel magneto has been changed and the number of the reluctor bars has been changed from 34 to There are 30 reluctor bars. They are located 10 degrees apart, except at three positions where they are 30 degrees apart.
Page 542 22 DF300 (30002F-110001 –, 30002Z-110001 –) SENSOR The O sensor is installed on the top of the cylinder. To bring the actual air/fuel mixture ratio closer to the theoretical ratio, the O sensor detects the oxygen concentration in the exhaust gas and feeds it back to the ECM, compensating sensor (increasing/decreasing) the fuel injection duration.
Page 543: Ignition System
DF300 (30002F-110001 –, 30002Z-110001 –) 23 IGNITION SYSTEM SPECIFICATION Ignition system Full-transistorized ignition Advance Electronic microcomputer control Ignition timing BTDC 0° – BTDC 25° Firing order 1 – 6 – 5 – 4 – 3 – 2 IGNITION TIMING CHART The following chart is an example for ignition at BTDC 10°.
Page 544: Electronic Fuel Injection System
24 DF300 (30002F-110001 –, 30002Z-110001 –) ELECTRONIC FUEL INJECTION SYSTEM Fuel injection timing and injection duration are compensated by the oxygen concentration value in the exhaust gas detected with the O sensor in addition to the current sensors. Fuel injection end timing is set at 0° – 60° BTDC on the exhaust stroke by engine speed.
Page 545 DF300 (30002F-110001 –, 30002Z-110001 –) 25 FUEL INJECTION TIMING CHART 30 Signals / Crankshaft 1 rotation CKP sensor signal 10˚ 30˚ 40˚ 120˚ 40˚ 160˚ 80˚ 40˚ 80˚ 80˚ CMP sensor signal #1 CMP sensor #1 - 9 signals / 720˚ (crankshaft 2 rotation) #1 Cyl.
Page 546: Inch/2 Inch Gauge
26 DF300 (30002F-110001 –, 30002Z-110001 –) 4 INCH/2 INCH GAUGE The 4 inch gauge and 2 inch gauge can indicate the following 4 inch gauge engine informatiom. 1. Engine RPM 2. Battery voltage 3. Engine operation hours 4. Trim angle 5.
Page 547: Caution System
DF300 (30002F-110001 –, 30002Z-110001 –) 27 CAUTION SYSTEM The following caution systems alert the operator when an abnor- mality occurs on the engine. When a problem is detected, the caution name appears on the display screen of 4 inch/2 inch gauge, caution buzzer sounds continuously.
Page 548 28 DF300 (30002F-110001 –, 30002Z-110001 –) OVER-REVOLUTION CAUTION SYSTEM CONDITION: 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...
Page 549 DF300 (30002F-110001 –, 30002Z-110001 –) 29 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: •...
Page 550 30 DF300 (30002F-110001 –, 30002Z-110001 –) OVERHEAT CAUTION CONDITION 1 (Maximum temperature) Immediate activation of system when: • Cylinder temperature reaches 110 °C (230 °F) • Exhaust manifold temperature reaches 104 °C (219 °F) CONDITION 2 (Temp. rise vs Time) Immediate activation of system when: •...
Page 551 DF300 (30002F-110001 –, 30002Z-110001 –) 31 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 main switch turned “ON”...
Page 552 32 DF300 (30002F-110001 –, 30002Z-110001 –) CHECK SECOND STATION CAUTION CONDITION: This system operates when a failure has occurred in the 2nd station control system. ACTION: When the system operates, the 4 inch gauge screen will indicate “Check 2nd Station” and at the same time the caution buzzer sounds.
Page 553 DF300 (30002F-110001 –, 30002Z-110001 –) 33 CHECK SHIFT CONTROL CAUTION CONDITION: This system operates when a failure has occurred in the electronic shift control system. ACTION: When the system operates, the 4 inch gauge screen will indicate “Check Shift Control” and at the same time the caution buzzer sounds.
Page 554: Water In Fuel Alart System
34 DF300 (30002F-110001 –, 30002Z-110001 –) WATER IN FUEL ALART SYSTEM CONDITION: This system operates when the water has separated from the fuel exceeds a specific volume. ACTION: Water If the system activates, the “Water in Fuel” will indicate on the...
Page 555: Oil Change Reminder System
• Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, SUZUKI strongly recommends that the engine oil be replaced before canceling the system activation. • Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the...
Page 556: Self-Diagnostic System
36 DF300 (30002F-110001 –, 30002Z-110001 –) SELF-DIAGNOSTIC SYSTEM The self-diagnostic system alerts the operator when an abnor- mality occurs in a signal from sensor, switch, etc. When the sys- tem is activated, the “Diagnostic code” appears on the 4 inch gauge screen and caution buzzer sound.
Page 557 DF300 (30002F-110001 –, 30002Z-110001 –) 37 CODE FOR SELF-DIAGNOSTIC SYSTEM OPERATION FAIL-SAFE SYSTEM FAILED ITEM CODE ACTIVE MAP sensor 1 3 – 4 Cylinder temp. sensor 1 – 4 IAT sensor 2 – 3 Exhaust manifold temp. sensor (STBD) 1 – 5 Exhaust manifold temp.
Page 558 38 DF300 (30002F-110001 –, 30002Z-110001 –) NOTE: • If more than one failed items exist, the self-diagnostic system shows the failures in the order of their occur- rence, one at a time, when “ENTER” key is pressed. • If the failed item remains, the self-diagnostic indication appears again after turning the main switch “ON ”.
Page 559 DF300 (30002F-110001 –, 30002Z-110001 –) 39 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 (1.46 – 33.86 inHg) (0.50 – 4.84 V)” signal (With engine running) Cylinder temp.
Page 560 40 DF300 (30002F-110001 –, 30002Z-110001 –) FAILED ITEM CONDITION Speed sensor • Receiving an out of range “0.2 – 4.8 V” signal. Trim sensor • Receiving an out of range “0.2 – 4.8 V” signal. ETV ECM • ECM electronic throttle control circuit failure ETV motor •...
Page 561: Fail-Safe System
DF300 (30002F-110001 –, 30002Z-110001 –) 41 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.
Page 562 42 DF300 (30002F-110001 –, 30002Z-110001 –) FAILED ITEM PRE-PROGRAMMED VALUE ETV ECM • The throttle opening is fixed to default with the throttle motor relay turned off. ECM controls the engine speed at the maximum of 2 000 r/min by operating the remote control lever.
Page 563: Inspection
DF300 (30002F-110001 –, 30002Z-110001 –) 43 INSPECTION INSPECTION FOR ECM CIRCUIT VOLTAGE ECM CIRCUIT VOLTAGE TABLE FRONT VIEW WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE Approx. 12 V Main switch ON. Water in fuel sensor OFF. R/Bl Water in fuel sensor Approx.
Page 564 44 DF300 (30002F-110001 –, 30002Z-110001 –) WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE Approx. 0.5 V Main switch ON. While engine Cranking. Starter relay control Approx. 12 V Main switch ON. Normal MAP sensor 0.5 – 4.5 V Main switch ON...
Page 565 DF300 (30002F-110001 –, 30002Z-110001 –) 45 WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE • Stop switch plate IN. • Shift into NEUTRAL Approx. 0 V • For 6 sec. after main switch ON. • While engine running High pressure fuel pump (–) •...
Page 566 46 DF300 (30002F-110001 –, 30002Z-110001 –) INSPECTION FOR RESISTANCE 61 60 59 58 57 56 55 54 53 33 32 31 30 29 28 27 7 6 5 4 3 2 1 69 68 67 66 65 64 63 62...
Page 567 DF300 (30002F-110001 –, 30002Z-110001 –) 47 RESISTANCE TABLE TERMINAL FOR TESTER STANDARD RESISTANCE ITEM PROBE CONNECTION (at 20 °C) 168 – 252 Ω CKP sensor 4 (R/B) to 6 (B/W) Fuel injector No. 1 55 (O/B) to Terminal [NOTE 1] Fuel injector No.
Page 568 48 DF300 (30002F-110001 –, 30002Z-110001 –) COMPONENT INSPECTIONS SENSOR HEATER RELAY  09930-99320: Digital tester PTT relay sensor  Tester range:  (Continuity) heater relay 1. Remove the electric parts holder. 2. Disconnect O sensor heater relay from wire harness.
Page 569: O 2 Sensor
DF300 (30002F-110001 –, 30002Z-110001 –) 49 SENSOR REMOVAL  The hot engine can burn you. The O sensor removal should be performed when the exhaust system is cool. sensor 1. Remove the ring gear cover. 2. Disconnect O sensor lead wire connector.
Page 570: Troubleshooting
50 DF300 (30002F-110001 –, 30002Z-110001 –) TROUBLESHOOTING SELF-DIAGNOSTIC CODE “5-3” Oil Pressure switch START With the main switch “OFF”, remove the oil pressure switch wire. Possible cause: With the main switch “ON”, check the • ECM failure voltage between the oil pressure switch •...
Page 571: Fuel System
DF300 (30002F-110001 –, 30002Z-110001 –) 51 FUEL SYSTEM LOW PRESSURE FUEL FILTER REMOVAL AND INSTALLATION Refer to “LOW PRESSURE FUEL FILTER/Inspection and cleaning”. INSPECTION FOR WATER IN FUEL SENSOR Stopper  09930-99320: Digital tester  Tester range:  (Continuity) Check continuity between two leads while moving the float up and down.
Page 572: Power Unit
CRANKCASE TO CYLINDER Apply Bond to marked line. Clean mating surface of cylinder and crankcase. Apply SUZUKI BOND to mating surface of crankcase as shown.  Apply bond to mating surface only. Do not allow bond to contact surface of bearing.
Page 573 DF300 (30002F-110001 –, 30002Z-110001 –) 53  Crankcase bolt (10 mm thread diameter): 1st step 11 N·m (1.1 kg-m, 8.0 lb-ft) 2nd step 21 N·m (2.1 kg-m, 15.0 lb-ft) Final step 52 N·m (5.2 kg-m, 37.5 lb-ft)  Crankcase bolt (8 mm thread diameter): 1st step 5 N·m (0.5 kg-m, 3.5 lb-ft)
Page 574: Power Trim And Tilt
54 DF300 (30002F-110001 –, 30002Z-110001 –) POWER TRIM AND TILT The trim and tilt sensor controls the down limit for trim. SETTING OF TRIM DOWN POSITION LIMIT Once the ECM has been replaced or the trim sensor removed and reinstalled, the resetting of the trim down position limit should be performed.
Page 575 DF300 (30002F-110001 –, 30002Z-110001 –) 55 6. Press the “DOWN” side of PTT switch for three seconds and the buzzer will sound twice briefly indicating the setting has been canceled. 7. Return the throttle to the fully closed position. DOWN SETTING THE TRIM DOWN POSITION LIMIT 8.
Page 576: Wire/Hose Routing
56 DF300 (30002F-110001 –, 30002Z-110001 –) WIRE/HOSE ROUTING WIRING DIAGRAM DF300 For single engine...
Page 577 DF300 (30002F-110001 –, 30002Z-110001 –) 57...
Page 578 58 DF300 (30002F-110001 –, 30002Z-110001 –) For single engine and dual station...
Page 579 DF300 (30002F-110001 –, 30002Z-110001 –) 59 For multiple engine FOR DUAL ENGINE Lbl/W Lbl/W Lbl/W Bl/B TO REMOTE CONTROL TO STBD ENGINE Bl/R TO PORT ENGINE Bl/R FOR TRIPLE ENGINE Lbl/W Lbl/W Lbl/W Bl/B Bl/B TO REMOTE CONTROL TO STBD...
Page 580 60 DF300 (30002F-110001 –, 30002Z-110001 –) For multiple engine and dual station To next page 61 RESISTOR 2” GAUGE 2” GAUGE 2” GAUGE PORT CNTR STBD 4” GAUGE 4” GAUGE 4” GAUGE PORT CNTR STBD ENGINE ENGINE ENGINE ANNTENA INTERFACE...
Page 581 DF300 (30002F-110001 –, 30002Z-110001 –) 61 To previous page 60 RESISTOR 2” GAUGE 2” GAUGE 2” GAUGE PORT CNTR STBD 4” GAUGE 4” GAUGE 4” GAUGE PORT CNTR STBD PANEL SWITCH PTT SWITCH EMERGENCY STOP SWITCH LOCK PLATE IN WARNING...
Page 582: Wiring
62 DF300 (30002F-110001 –, 30002Z-110001 –) WIRING SINGLE ENGINE, SINGLE STATION...
Page 583 DF300 (30002F-110001 –, 30002Z-110001 –) 63 SINGLE ENGINE, DUAL STATIONS...
Page 584 64 DF300 (30002F-110001 –, 30002Z-110001 –) TWIN ENGINES, SINGLE STATION...
Page 585 DF300 (30002F-110001 –, 30002Z-110001 –) 65 TWIN ENGINES, DUAL STATIONS...
Page 586 66 DF300 (30002F-110001 –, 30002Z-110001 –) TRIPLE ENGINES, SINGLE STATION...
Page 587 DF300 (30002F-110001 –, 30002Z-110001 –) 67 TRIPLE ENGINES, DUAL STATIONS...
Page 588: Wire Routing
68 DF300 (30002F-110001 –, 30002Z-110001 –) WIRE ROUTING...
Page 589 DF300 (30002F-110001 –, 30002Z-110001 –) 69...
Page 590 70 DF300 (30002F-110001 –, 30002Z-110001 –)
Page 591 DF300 (30002F-110001 –, 30002Z-110001 –) 71 Clamp Tilt limit switch Trim sensor lead wire Tilt limit switch lead wire PTT motor cable Side cover seal Trim sensor lead wire Clamp Tilt limit switch lead wire PTT motor cable Trim sensor...
Page 592 Prepared by Outboard Motor Engineering Department September, 2010 Manual No.99501-98J30-01E Printed in Japan...
Page 593 Printed in Japan...

Suzuki DF300 Service Manual

General Information 1

Periodic Maintenance

Engine Control System

Engine Control System Structure

Components for System Control

Ignition System

Electronic Fuel Injection System

VVT (Variable Valve Timing) SYSTEM

Electronic Shift System

Tachometer Monitor

Caution System

Self-Diagnostic System

Fail-Safe System

Oil Change Reminder System

Start-In-Gear Protection System

Inspection

Removal/Installation

Clutch Link Rod

Troubleshooting

Engine Electrical

Fuel System

Power Unit

MID Unit

Power Trim and Tilt

Lower Unit [Standard Rotation (Right-Hand) Model]

Lower Unit [Counter Rotation (Left-Hand) Model]

Wire/Hose Routing

Wiring Diagram

Df300

Wiring

Wire Routing

Fuel/Water Hose Routing

Fuel Hose Routing

Water Hose Routing

Section 12

Section 13

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki DF300