Suzuki DF40A Manual
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Suzuki DF40A Manual

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DF40A/50A/60A (110001 and later)
This SUPPLEMENTARY SERVICE MANUAL is a supplement to SUZUKI DF60A SERVICE MANUAL.
It has been prepared exclusively for the following models.
Applicable model and effective serial No.:
DF40AT/QH (04003F-110001 and Later)
DF40AST (04004F-110001 and Later)
DF50AT/TH (05003F-110001 and Later)
DF60AT/TH/QH (06002F-110001 and Later)
This supplementary service manual describes only service information which differ from that of the main man-
ual. Therefore, whenever servicing the above applicable model, consult this supplementary service manual first.
And for any section, item or description not found in this manual, refer to the main manual below.
Main Manual:
Manual Name
DF60A SERVICE MANUAL
Other information considered as generally known is not included.
Read the GENERAL INFORMATION section to familiarize yourself with the outboard motor and its maintenance.
Use this section as well as other sections to use as a guide for proper inspection and service.
This manual will help you to know the outboard motor better so that you can assure your customers of fast and
reliable service.
* This manual has been prepared using the latest information available at the time of publication.
Differences may exist between the content of this manual and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of operation and work procedures and
may not represent the actual outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills
to service SUZUKI Outboard motors.
Persons without such knowledge and skills should not attempt to service Suzuki Outboard engines
by relying on this manual only and should contact an authorized SUZUKI Outboard motor dealer.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2010
FOREWORD
DF40A/50A/60A (110001 and later)
Manual No.
99500-88L00-01E
5

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Summary of Contents for Suzuki DF40A

  • Page 1 SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Outboard motor dealer. © COPYRIGHT SUZUKI MOTOR CORPORATION 2010...
  • Page 2 CAUTION principles. WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result...
  • Page 3 TABLE OF CONTENTS NOTE For the screen toned sections with asterisk (*) in the “TABLE OF CONTENTS” below, refer to the same sections of the service manual mentioned in the “FOREWORD” of this manual. Precautions............... 00-* Precautions ............. 00-* General Information ........... 0-i General Information ..........
  • Page 5 Specifications (DF40A/50A) ........ 0A-1 Low Pressure Fuel Filter Inspection....0B-* Specifications (DF40AS/DF60A)......0A-3 Water Pump and Water Pump Impeller Service Data (DF40A/50A/60A) ......0A-5 Inspection............0B-* Tightening Torque Specifications (DF40A/ Propeller / Propeller Nut and Cotter Pin 50A/60A) ............0A-10 Inspection............
  • Page 6 0A-1 General Information: General Information General Information Specifications Specifications (DF40A/50A) CENBJ6110107004 NOTE These specifications are subject to change without notice. Model Pre-fix Data Item Unit DF40AT DF40AQH DF50AT DF50ATH PRE-FIX 04003F 05003F Dimensions and Weight Data Item Unit DF40AT DF40AQH...
  • Page 7 2.7 (2.9 / 2.4): Oil change only Engine oil amounts L (US/lmp. qt) 2.9 (3.0 / 2.6): Oil filter change SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API Gear oil classification GL-5. Gearcase oil capacity ml (US/lmp. oz) 610 (20.6/21.5)
  • Page 8 0A-3 General Information: Specifications (DF40AS/DF60A) CENBJ6110107005 NOTE These specifications are subject to change without notice. Model Pre-fix Data Item Unit DF40AST DF60AT DF60ATH DF60AQH PRE-FIX 04004F 06002F Dimensions and Weight Data Item Unit DF40AST DF60AT DF60ATH DF60AQH Overall length (front to back) mm (in.) 699 (27.5) 819 (32.2)
  • Page 9 2.7 (2.9 / 2.4): Oil change only Engine oil amounts L (US/lmp. qt) 2.9 (3.0 / 2.6): Oil filter change SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API Gear oil classification GL-5. Gearcase oil capacity ml (US/lmp. oz) 610 (20.6/21.5)
  • Page 10 0A-5 General Information: Service Data (DF40A/50A/60A) CENBJ6110107006 NOTE • These service data are subject to change without notice. • The following data is applied to all version of each model of DF40A/50A/60A. Powerhead Data Item Unit DF40A DF50A DF60A DF40A: 5 000 – 6 000...
  • Page 11 General Information: 0A-6 Valve / Valve Guide Data Item Unit DF40A DF50A DF60A mm (in.) 26.6 (1.05) Valve diameter mm (in.) 21.5 (0.85) Tappet clearance std. mm (in.) 0.18 – 0.22 (0.007 – 0.009) (Cold engine condition) std. mm (in.) 0.28 –...
  • Page 12 0A-7 General Information: Data Item Unit DF40A DF50A DF60A std. mm (in.) 1.02 – 1.04 (0.040 – 0.041) Piston ring groove width std. mm (in.) 1.21 – 1.23 (0.048 – 0.048) std. mm (in.) 2.01 – 2.03 (0.079 – 0.080) std.
  • Page 13 Unit DF40A DF50A DF60A Degrees at r/ Ignition timing BTDC 2 – 22 BTDC 2 – 25 DF40A: 6 200 Over revolution limiter r/min DF40AS/DF50A/DF60A: 6 400 CKP sensor resistance Ω at 20 °C 168 – 252 CMP sensor resistance Ω...
  • Page 14 0A-9 General Information: Self-Diagnostic Code 0: OFF, 1: ON Fail-safe system Failed item Code Lamp flashing pattern activating MAP sensor 1 3 – 4 MCODE00D34-0-01 Cylinder temp. sensor 1 – 4 MCODE00D14-0-01 IAT sensor 2 – 3 MCODE00D23-0-01 CKP sensor 4 –...
  • Page 15 General Information: 0A-10 Tightening Torque Specifications (DF40A/50A/60A) CENBJ6110107007 Important Fasteners Thread Tightening Torque Item Diameter Nm kgf-m lbf-ft Cylinder head cover bolt 6 mm 8 mm 16.5 Cylinder head bolt 10 mm 42.7 Outside 8 mm 18.0 Crankcase bolt Inside 10 mm 33.3...
  • Page 16 0B-1 Maintenance and Tune-Up: Maintenance and Tune-Up General Information Scheduled Maintenance Periodic Maintenance Schedule Chart (DF40A/50A/60A) CENBJ6110205003 Effective serial No. 04003F-110001 and Later 04004F-110001 and Later 05003F-110001 and Later 06002F-110001 and Later NOTE I = Inspect and clean, adjust, lubricate or replace, if necessary...
  • Page 17 Table of Contents 1- i Section 1 Power Head CONTENTS NOTE For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........1-* Inspection of the ECM and Its Circuit....
  • Page 18 Fuel System Diagnosis ........1G-* Crankshaft Inspection ......... 1D-* Fuel Injection System Troubleshooting ....1G-* Crankshaft Main Bearing Inspection ....1D-* Fuel Pressure Inspection (DF40A/50A) ..... 1G-1 Crankshaft Oil Seal Inspection......1D-* Service Instructions ..........1G-2 Crankshaft Upper Oil Seal Replacement .... 1D-* Fuel Pressure Relief Procedure ......
  • Page 19 Table of Contents 1-iii Ignition System.........1H-* Starter System Troubleshooting......1I-* Service Instructions ..........1I-* General Description ..........1H-* Starter Motor Removal and Installation....1I-* Ignition System Description ........ 1H-* Starter Motor Test ..........1I-* Ignition Control Description ......... 1H-* Starter Motor Components........1I-* Component Location ........... 1H-* Starter Motor Disassembly and Assembly ....1I-* Ignition System Components Location ....
  • Page 20 1G-1 Fuel System: Fuel System Power Head Diagnostic Information and Procedures Fuel Pressure Inspection (DF40A/50A) CENBJ6111704004 WARNING Before starting the following procedure, be sure to observe “Precautions on Fuel System Service”: in related manual in order to reduce the risk or fire and personal injury.
  • Page 21 • Cover the joint with rag and loosen joint nut slowly to gradually release any residual fuel pressure. Service Instructions Fuel Injector Removal and Installation (DF40A/ 50A) CENBJ6111706016 Removal 1) Relieve the fuel pressure in the fuel feed line according to “Fuel Pressure Relief Procedure”.
  • Page 22 1G-3 Fuel System: 3) Unfasten cable tie (2). 6) Remove each injector (6) from the delivery pipe. IBJ611170007-01 IBJ611170010-01 4) Disconnect the three fuel injector connectors (3). Installation Installation is in the reverse order of removal with special attention to the following steps. NOTICE Do not re-use O-ring and cushion once removed.
  • Page 23 Fuel System: 1G-4 3) Place delivery pipe bolts (4) and collars (5) in 6) Reconnect the fuel feed hose and fuel line securely. position. 7) Connect the lead wire connector to the injectors securely. IBJ611170012-01 4) Apply a thin coat of fuel to injector O-rings, then IBJ611170015-01 install the injectors into the delivery pipe and intake 8) Make sure the emergency stop switch lock plate is in...
  • Page 24 1G-5 Fuel System:...

  • Page 25: Table Of Contents

    PTT Motor Relay Inspection........ 2B-* Components (DF40A/50A/DF60AQH) ....2A-9 PTT Switch Inspection ........2B-* Clamp / Swivel / Steering Brackets Setting of Trim Down Position Limit (DF40A/ Disassembly (DF40A/50A/DF60AQH) .... 2A-10 50A/60A) ............2B-1 Setting Tilt Up Limit Position (DF40A/50A) ..2B-1...
  • Page 26 2-ii Table of Contents Power Trim and Tilt Unit Removal and Installation (DF40A/50A) ........2B-1...

  • Page 27: Housing And Bracket

    Housing and Bracket: 2A-1 Housing and Bracket Mid Unit Service Instructions Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components (DF40A/50A/DF60AQH) CENBJ6112106014 IBJ611210021-02 1. Gasket 10. Bolt 19. “R” upper thrust mount 28. Bolt 2. Mount case cover 11.
  • Page 28 25. Bolt : 60 Nm (6.0 kgf-m, 43.4 lbf-ft) 6. Bolt 16. Lower mount bolt 26. Bush (Transom: X) : Apply SUZUKI thread lock 1342. 7. Bolt 17. Lower mount bracket 27. Dowel pin (Transom: X) : Apply SUZUKI silicon seal.

  • Page 29: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly

    Engine Holder / Oil Pan / Driveshaft Housing / 6) Unscrew and remove STBD / PORT lower mount nuts (6) and washers (7). Mounts Disassembly (DF40A/50A/DF60AQH) CENBJ6112106015 1) Remove the power unit. Refer to “Power Unit Removal and Installation”: in Section 1D in related manual.
  • Page 30 2A-4 Housing and Bracket: 9) Remove the driveshaft housing with oil pan. 12) Remove the upper mounts (15), upper thrust mount (16), “R” upper thrust mount (17), upper mount bolts (18) and washers (19). Remove the “F” upper thrust mounts (20). IBJ611210023-01 10) Remove the lower mount assembly.

  • Page 31: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Assembly

    IAJ611210051-01 • Install two dowel pins (3) to driveshaft housing (4). Apply sealant to mating surfaces of driveshaft housing and oil pan. : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) IBJ611210006-01 17) Remove the eight bolts securing the driveshaft housing (27) to oil pan, then remove the oil pan (28).
  • Page 32 2A-6 Housing and Bracket: 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. IAJ611210057-02 Upper Mount and Mount Cover •...
  • Page 33 Upper mount cover bolt (a): 50 N·m (5.0 kgf-m, Upper mount nut (a): 60 N·m (6.0 kgf-m, 43.4 lbf- 36.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) Thread Lock 1342 (50 g))
  • Page 34 Tightening torque Lower mount nut (b): 60 N·m (6.0 kgf-m, 43.4 lbf- Tightening torque Lower mount cover bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) IAJ611210068-01 IAJ611210065-01 Water Pressure Valve •...

  • Page 35: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection

    Housing and Bracket: 2A-9 Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection (DF40A/50A/ DF60AQH) CENBJ6112106017 Refer to “Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection”: in related manual. Clamp / Swivel / Steering Brackets Components (DF40A/50A/DF60AQH)

  • Page 36: Clamp / Swivel / Steering Brackets

    8. Plate (QH model) 13. Bolt (QH model) 4. Spacer (QH model) 9. Washer (QH model) : Apply SUZUKI thread lock 1342. 5. Bolt (QH model) 10. Washer (QH model) Clamp / Swivel / Steering Brackets Disassembly 3) Remove circlip (1).
  • Page 37 Housing and Bracket: 2A-11 4) Remove lower mount bracket (2), shims (3), and 8) Remove the two bolts (12) securing PTT lower shaft washer (4) from the steering shaft. to STBD and PORT clamp brackets. IAJ611210080-02 IBJ611210011-05 5) Lift steering bracket (5) upward to remove from 9) Using flat blade screw driver, drive locking edge of swivel bracket.

  • Page 38: Clamp / Swivel / Steering Brackets Assembly (Df40A/50A/Df60Aqh)

    Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings. IBJ611210041-01 : Grease 99000–25161 (SUZUKI Water Resistant • Install STBD clamp bracket (6), lock washer (7) and Grease (250 g)) clamp bracket shaft nut (8).
  • Page 39 • Tighten two PTT lower shaft bolts, pre-coated with thread lock, to specified torque. Tightening torque PTT lower shaft bolt (b): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI “A” Thread Lock 1342 (50 g)) IAJ611210099-01 1. Upper bushing 6.

  • Page 40: Clamp / Swivel / Steering Brackets Related Components Inspection (Df40A/50A/Df60Aqh)

    • Install circlip (5) to retain bracket. Lubrication After completing reassembly of the mid unit, apply grease through each grease nipple. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) IAJ611210101-01 Bonding Wire Reattach bonding wire to swivel bracket and tighten screw securely.

  • Page 41: Gas Cylinder Removal And Installation (Df40Aqh/60Aqh)

    Housing and Bracket: 2A-15 Oil Seal Gas Cylinder Removal and Installation Check swivel bracket seal. If excessive wear or other (DF40AQH/60AQH) damage is found, replace seal. CENBJ6112106022 WARNING This unit contains high pressure gas and it must not be disassembled, punctured, incinerated or exposed to heat.
  • Page 42 Install the lower shaft bushing (1) and cylinder lower shaft (2) to gas cylinder. Install the spacer (3) and (4) to cylinder lower shaft. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) IBJ611210049-01 5) Remove two STBD motor mounting bolts (5).

  • Page 43: Gas Cylinder Related Items Inspection (Df40Aqh/60Aqh)

    • Tighten cylinder lower shaft bolts (8), pre-coated with thread lock, to specified torque. Bushings Check all bushings. : Thread lock cement 99000–32050 (SUZUKI If excessive wear or other damage is found, replace Thread Lock 1342 (50 g)) bushing. Tightening torque If bushing fit is loose when installing, replace bushing.

  • Page 44: Steering Friction Adjuster Disassembly And Assembly (Df40Aqh/50Ath/60Aqh)

    2A-18 Housing and Bracket: Upper Shaft / Lower Shaft Steering Friction Adjuster Disassembly and Inspect lower shaft and upper shaft for bends, twists or Assembly (DF40AQH/50ATH/60AQH) other damage. Replace if necessary. CENBJ6112106024 Disassembly 1) Remove the bolts (1) and steering adjuster plate (2). IBJ611210060-01 IBJ611210061-01 2) Remove the nut (3), washer (4).
  • Page 45 Housing and Bracket: 2A-19 Assembly NOTE Assemble the steering friction adjuster set in the After temporarily tighten the two bolts (11), following sequence: confirm that the edge of washer (6) is located 1) Install the washer (1), steering adjuster (2) and between the punch marks “a”...

  • Page 46: Power Trim And Tilt

    Refer to “Setting of Trim Down Position Limit”: in related manual. Setting Tilt Up Limit Position (DF40A/50A) CENBJ6112206017 DF40A/50A can not be adjusted tilt up Limit position. NOTE The DF40A/50A are equipped with trim down limit setting system as same as the DF60A,...
  • Page 47 Power Trim and Tilt: 2B-2 5) Disconnect the PTT motor cable wire connector from 7) Remove two STBD motor mounting bolts (5). the PTT relay. Cut the cable tie binding PTT motor Using flat screw driver, drive locking edge of lock cable and trim sensor lead.
  • Page 48 Resistant Grease (250 g)) IBJ611220009-01 • Tighten cylinder lower shaft bolts (5), pre-coated with thread lock, to specified torque. IBJ611220007-02 : Thread lock cement 99000–32050 (SUZUKI • Place PTT unit in position between the clamp Thread Lock 1342 (50 g)) brackets. Tightening torque Cylinder lower shaft bolt (b): 50 N·m (5.0 kgf-m,...
  • Page 49 Align the tilt rod with the hole in the swivel bracket as Refer to “Wiring Harness Routing Diagram”: in the tilt rod extends. Section 4A in related manual. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) IAJ611220037-01 • Final assembly check...
  • Page 50 2B-5 Power Trim and Tilt:...
  • Page 51 For the items with asterisk (*) in the “CONTENTS” below, refer to the same section of the service manual mentioned in the “FOREWORD” of this manual. Precautions ..........4-* Wiring Harness Routing Diagram......4A-* Wiring Harness Routing Diagram (DF40A/ Precautions.............. 4-* DF50A)..............4A-4 Precautions for Wire / Hose Routing...... 4-* Component Location ..........

  • Page 52: Wire Routing

    4A-1 Wire Routing: Wire Routing Wire / Hose Routing Schematic and Routing Diagram Wiring Diagram (DF40AT/DF50AT/DF60AT) CENBJ6114102003 Refer to “Wire Color Symbols”: in Section 0A in related manual. IBJ611410001-02...

  • Page 53: Wiring Diagram (Df50Ath/Df60Ath)

    Wire Routing: 4A-2 Wiring Diagram (DF50ATH/DF60ATH) CENBJ6114102004 SUZUKI IBJ611410002-02...

  • Page 54: Wiring Diagram (Df40Aqh/Df60Aqh)

    4A-3 Wire Routing: Wiring Diagram (DF40AQH/DF60AQH) CENBJ6114102005 SUZUKI IBJ611410003-01...

  • Page 55: Wiring Harness Routing Diagram

    Wire Routing: 4A-4 Wiring Harness Routing Diagram (DF40A/DF50A) CENBJ6114102006 IBJ611410004-01 1. No.1 Ign. Coil 4. Main wiring harness 7. No.3 Fuel injector 2. No.2 Ign. Coil 5. No.1 Fuel injector 8. Fuel delivery pipe 3. No.3 Ign. Coil 6. No.2 Fuel injector 9.

  • Page 56: Fuel / Water Hose Routing

    4B-1 Fuel / Water Hose Routing: Fuel / Water Hose Routing Wire / Hose Routing Schematic and Routing Diagram Fuel Hose Routing (DF40A/DF50A) CENBJ6114202003 IBJ611420001-02 1. Fuel hose (Fuel vapor separator to fuel 3. Clip 5. Fuel delivery pipe delivery pipe) 2.

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