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Page 2: General Information
FOREWORD GROUP INDEX This manual contains an introductory description on SUZUKI Outboard motor DF90/115/140 and proce- GENERAL INFORMATION dures for the inspection, service and overhaul of its main components. General knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION sec-...
Page 3: Product View And Components
HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR : 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference.
Page 4: Symbol Description
“1333B”. Apply SUZUKI OUTBOARD Measure in DC voltage range. MOTOR GEAR OIL. Measure in resistance range. Apply SUZUKI SUPER GREASE “A”. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”.
Page 5: Table Of Contents
GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING / CAUTION / NOTE _______________________________ 1- 2 GENERAL PRECAUTIONS _________________________________ 1- 2 IDENTIFICATION NUMBER LOCATION _______________________ 1- 4 FUEL AND OIL ___________________________________________ 1- 4 1- 4 GASOLINE RECOMMENDATION ..............1- 4 ENGINE OIL ....................ENGINE BREAK-IN _______________________________________ 1- 5 PROPELLERS ___________________________________________ 1- 6 POWERHEAD DIRECTION OF ROTATION _____________________ 1- 6...
Page 6: Warning / Caution / Note
GENERAL INFORMATION WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
Page 7 GENERAL INFORMATION • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 8: Identification Number Location
GASOLINE RECOMMENDATION Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R+M / 2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.
Page 9: 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 reconditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long-term du- rability.
Page 10: Propellers
GENERAL INFORMATION PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF90T/115T models are shown below. DF90T 4500 – 5500 r/min. Recommended full throttle speed range DF115T 5000 –...
Page 11: Specifications
GENERAL INFORMATION These specifications are subject to change without notice. *SPECIFICATIONS Data Item Unit DF90T DF115T 09001F PRE-FIX 11501F DIMENSIONS & WEIGHT Overall length (front to back) 779 (30.7) mm (in) Overall width (side to side) mm (in) 481 (18.9) Overall height mm (in) 1556 (61.3)
Page 12: General Specification
5.5 (5.8 / 4.8) : Oil change only L (US/Imp. qt) 5.7 (6.0 / 5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts ml (US/Imp. oz) 1050 (35.5 / 37.0)
Page 13: Service Data
GENERAL INFORMATION These service data are subject to change without notice. *SERVICE DATA Data Item Unit DF90T DF115T POWERHEAD Recommended operating range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear : approx. 625) **Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 14 1-10 GENERAL INFORMATION Data Item Unit DF115T DF90T CYLINDER HEAD / CAMSHAFT Cylinder head distortion mm (in) Limit 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 37.320 – 37.480 (1.4693 – 1.4756) 39.220 – 39.380 (1.5441 – 1.5504) Limit mm (in) 37.220 (1.4654)
Page 15 GENERAL INFORMATION 1-11 Data Item Unit DF115T DF90T VALVE / VALVE GUIDE mm (in) Valve diameter 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) °...
Page 16 1-12 GENERAL INFORMATION Data Item Unit DF90T DF115T CYLINDER / PISTON / PISTON RING mm (in) Cylinder distortion Limit 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 84.000 –...
Page 17 GENERAL INFORMATION 1-13 Data Item Unit DF90T DF115T CRANKSHAFT / CONROD Conrod small end inside 21.003 – 21.011 (0.8269 – 0.8272) mm (in) diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance mm (in) Limit 0.065 (0.0026) Conrod big end inside 47.000 –...
Page 18 1-14 GENERAL INFORMATION Data Item Unit DF90T DF115T ELECTRICAL Degrees Ignition timing BTDC 1° – BTDC 44° BTDC 3° – BTDC 44° r/min Over revolution limiter 6500 Ω 168 – 252 CKP sensor resistance at 20°C Ω CMP sensor resistance at 20°C Ω...
Page 19: Self-Diagnostic System Indication
GENERAL INFORMATION 1-15 PTT MOTOR mm (in) Brush length 9.8 (0.39) mm (in) 5.5 (0.22) Limit mm (in) 22.0 (0.87) Commutator outside diameter Limit 21.0 (0.83) mm (in) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 20: Tightening Torque
1-16 GENERAL INFORMATION TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib.-ft Cylinder head cover bolt 6 mm 8 mm 16.5 Cylinder head bolt 10 mm 50.5 18.0 8 mm Crankcase bolt 10 mm 40.5 Conrod cap nut...
Page 21 GENERAL INFORMATION 1-17 Tightening torque – general bolt NOTE: These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N . m kg-m Ib-ft 2 –...
Page 22: Special Tools
1-18 GENERAL INFORMATION SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) (A) 09900-06107 09900-00410 Hexagon socket Hexagon bit (B) 09900-06108 Hexagon wrench set (included in 09900-00410) (included in 09900-00410) Snap ring pliers 09900-20101 (150 mm) 09900-20203 (50 – 75 mm) 09900-20205 09900-20102 (200 mm) 09900-20202...
Page 23 GENERAL INFORMATION 1-19 09915-67010 09915-47332 Compression 09915-64530 09915-64512 Oil filter wrench gauge hose attachment Compression gauge hose Compression gauge 09916-10911 09916-14910 09915-77311 09915-78211 Valve lapper Valve lifter attachment Oil pressure gauge Oil pressure gauge adapter 09916-22420 Solid pilot 09916-19030 09916-54910 Valve seat cutter (60°) (Neway.
Page 24 1-20 GENERAL INFORMATION (A) 09922-59410 Propeller shaft housing 09917-98221 installer Valve guide stem seal (B) 09922-59420 09922-89810 09930-30104 installer attachment Housing installer handle Shift lock pin remover Sliding hammer 09930-39411 09930-30161 09930-39420 09930-48720 Flywheel rotor remover Propeller shaft remover Rotor remover bolt Flywheel holder 09930-89240 09930-89260...
Page 25: Materials Required
*99000-25030 99000-22540 99000-25011 99000-25161 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1207B” THREAD LOCK “1342” THREAD LOCK SUPER “1333B” * 99104-33140 99000-32050 99000-31140 99000-32020 (50 g) (100 g) (50 g) 4-Stroke Motor Oil...
Page 26 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE _______________________ 2-2 PERIODIC MAINTENANCE CHART ............. MAINTENANCE AND TUNE-UP PROCEDURES ________________ 2-3 ENGINE OIL / ENGINE OIL FILTER .............. GEAR OIL ...................... LUBRICATION ....................SPARK PLUG ....................TAPPET CLEARANCE .................. 2-14 IDLE SPEED ....................2-15 IGNITION TIMING ...................
Page 27: Periodic Maintenance Schedule
PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.
Page 28: Maintenance And Tune-Up Procedures
PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes servicing procedures for each of peri- odic maintenance requirements. 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.
Page 29: Engine Oil Change/Engine Oil Filterreplacement
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 30 PERIODIC MAINTENANCE (3) Screw new filter on by hand until filter O-ring con- tacts the mounting surface. (4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench. Engine oil filter : 14 N . m (1.4 kg-m, 10.0 lb.-ft.), 3/4 turn.
Page 31: Gear Oil
Gear oil amounts : 1050 ml (35.5 / 37.0 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 32: Lubrication
PERIODIC MAINTENANCE LUBRICATION Inspect every 50 hours (3 months). Apply Suzuki Water Resistant Grease to the following points. 99000-25161 : Water Resistant Grease Throttle / shift linkage Swivel bracket Swivel bracket Propeller shaft...
Page 33: 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 34: Tappet Clearance
PERIODIC MAINTENANCE TAPPET CLEARANCE Inspect initially after 20 hours (1 month) and every 200 hours (12 months). The tappet clearance specification is the same for both intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear.
Page 35 2-10 PERIODIC MAINTENANCE 5. Rotate crankshaft counterclockwise to bring cam nose ver- tical to shim surface. 90˚ 90˚ 6. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance (cold engine condition) : IN. : 0.23 – 0.27 mm (0.009 – 0.011 in.) EX.
Page 36 PERIODIC MAINTENANCE 2-11 4. Rotate top of cam 90 degree clockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time) • Do not put your finger between camshaft and tap- pet while the tappet is being held with the tappet 1 Magnet 2 Shim holder.
Page 37 2-12 PERIODIC MAINTENANCE 6. Install shim. Identification number should face towards tap- pet. 7. Rotate crankshaft to be open (lift up) valve. 8. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. 1 Special tool 2 Tappet 3 Camshaft Camshaft housing bolt : 11 N .
Page 38 PERIODIC MAINTENANCE 2-13...
Page 39: Idle Speed
2-14 PERIODIC MAINTENANCE IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: • Before checking idle speed, engine should be allowed to warm • Check and/or adjust idle speed after engine speed has sta- bilized.
Page 40: Ignition Timing
PERIODIC MAINTENANCE 2-15 7. Open warm-up lever to turn CTP switch off. NOTE: The fixed mode of IAC valve duty can be manually cancelled by turning CTP switch off. 8. Close warm-up lever and then recheck engine speed. It should now be stable at 600 – 650 r/min. NOTE: Idling / trolling speed of 600 –...
Page 41: Breather And Fuel Line
2-16 PERIODIC MAINTENANCE BREATHER AND FUEL LINE • Inspect initially after 20 hours (1 month) and every 50 hours (3 months). • Replace every 2 years. If leakage, cracks, swelling or other damage is found, replace breather line and/or fuel line. LOW PRESSURE FUEL FILTER •...
Page 42: High Pressure Fuel Filter
PERIODIC MAINTENANCE 2-17 HIGH PRESSURE FUEL FILTER Replace every 1000 hours. SUZUKI recommends that high pressure fuel filter be replaced every 1000 operating hours. WATER PUMP / WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months). Inspect case and under panel.
Page 43: Anodes And Bonding Wires
Anode Never paint the anode. NOTE: The anode securing bolt should be covered with Suzuki Sili- cone Seal. 99000-31120 : Suzuki Silicone Seal BONDING WIRES • If breakage or other damage is found on bonding wire, re- place wire.
Page 44: Battery
PERIODIC MAINTENANCE 2-19 BATTERY Inspect every 50 hours (3 months) • Never expose battery to open flame or electric spark as batteries generate gas, which is flammable and 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 45: Bolt And Nuts
FUEL MIXTURE CHECK (O FEEDBACK) Perform every 2 years. To perform fuel mixture check (O feedback) operation, use personal computer and Suzuki Diagnostic System software. For fuel mixture check (O feedback) operation, refer to “Suzuki Diagnostic System Operation Manual”. NOTE: See “O...
Page 46: Oil Pressure
PERIODIC MAINTENANCE 2-21 OIL PRESSURE Oil pressure (at normal operating temp.) : 550 – 600 kPa (5.5 – 6.0 kg/cm , 78 – 85 psi.) at 3000 r/min. NOTE: The figure shown above is a guideline only, not an absolute service limit.
Page 47 2-22 PERIODIC MAINTENANCE 4. Install oil pressure gauge in place of pressure switch hole. 09915-77311 : Oil pressure gauge 09915-78211 : Oil pressure gauge adapter 5. Attach engine tachometer to ignition coil high tension cord. 09900-26006 : Engine tachometer 6. Start engine and allow to warm up as follows : Summer : 5 min.
Page 48: Cylinder Compression
PERIODIC MAINTENANCE 2-23 CYLINDER COMPRESSION Cylinder compression : Standard : 1300 – 1700 kPa (13 – 17 kg/cm , 185 – 242 psi.) Max. difference between any other cylinders : 100kPa (1.0 kg/cm , 14 psi.) NOTE: Figures shown are guidelines only, not absolute service limits. Low compression pressure can indicate one or more of follow- ing : •...
Page 49 ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM STRUCTURE ____________________ SYSTEM STRUCTURE 1 ................3-2 SYSTEM STRUCTURE 2 ................3-3 WIRING DIAGRAM FOR ENGINE CONTROL ..........3-4 COMPONENTS FOR SYSTEM CONTROL _____________________ ENGINE CONTROL MODULE (ECM) ............3-5 ECM CONNECTOR / TERMINALS LAYOUT ..........
Page 50: Engine Control System Structure
ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF90/DF115 models employ an integrated control system which performs the control functions for fuel injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine Control Module). SYSTEM STRUCTURE 1 INPUT CONTROL OUTPUT...
Page 51: System Structure 2
ENGINE CONTROL SYSTEM SYSTEM STRUCTURE 2...
Page 52: Wiring Diagram For Engine Control
ENGINE CONTROL SYSTEM WIRING DIAGRAM FOR ENGINE CONTROL Fuel injector No.1 No.2 No.3 No.4 Cyl. Cyl. Cyl. Cyl. Alternator Battery charge coil Rectifier & regulator 60A Fuse Ignition coil No.1 Cyl. IAC valve ENGINE No.4 Cyl. CONTROL No.2 Cyl. Fuse main MODULE No.3 Cyl.
Page 53: Components For System Control
ENGINE CONTROL SYSTEM COMPONENTS FOR SYSTEM CONTROL ENGINE CONTROL MODULE (ECM) The ECM sends signals to control the actuators based on the information inputs from each sensor / switch. Major controls are as follows : NAME OF CONTROL DESCRIPTION Fuel injection control •...
Page 54: Ecm Connector / Terminals Layout
ENGINE CONTROL SYSTEM ECM CONNECTOR / TERMINALS LAYOUT ECM CIRCUITS TERMI- TERMI- WIRE WIRE CIRCUIT CIRCUIT COLOR COLOR — — Oil pressure switch B l / R Emergency stop switch Lg/R CTP switch Buzzer cancel REV-LIMIT lamp Y / B Tachometer G / W CHECK ENGINE lamp...
Page 55: Ecm Internal Structure
ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE...
Page 56: Sensor And Switch
ENGINE CONTROL SYSTEM SENSOR AND SWITCH CKP (Crankshaft Position) SENSOR There is one (1) CKP sensor installed below the flywheel rotor. When the reluctor bars on the flywheel pass the sensor, a sig- nal (voltage pulse) is generated and sent to the ECM. This is the fundamental signal used to judge the engine speed CKP sensor CKP sensor...
Page 57 ENGINE CONTROL SYSTEM CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder (top Cylinder temp. sensor Cylinder temp. sensor side) and used to detect the cylinder temperature. This is a thermistor type sensor (resistance of which changes depending on the temperature) and inputs a signal to the ECM as a voltage value.
Page 58 3-10 ENGINE CONTROL SYSTEM CTP (Closed Throttle Position) SWITCH The CTP switch is installed on the bottom of throttle body and used to detect whether the throttle is fully closed or not. This switch is “ON” at closed throttle and “OFF” at any open throttle position.
Page 59 ENGINE CONTROL SYSTEM 3-11 SENSOR (Optional item) The O sensor is installed in the exhaust manifold only when Zirconia element the O feedback operation is performed. Housing This sensor is a zirconia element (platinum plated) which changes output voltage depending on the oxygen concentra- tion difference between its internal and external surfaces.
Page 60: Ignition System
3-12 ENGINE CONTROL SYSTEM IGNITION SYSTEM The ignition system used by the DF90/DF115 is a fully transistorized, electronic microcomputer timing ad- vanced type. This system is totally battery powered, with the ECM controlling all ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch, etc.).
Page 61 (idle speed) is delayed for a programmed duration to prevent engine stalling or unstable running. SPECIFICATION Ignition system Full-transistorized ignition Advance Electronic microcomputer control Ignition timing DF 90 : BTDC 1° – 44°, DF 115 : BTDC 3° – 44° Firing order 1 – 3 – 4 – 2...
Page 62: Electronic Fuel Injection System
3-14 ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF90/DF115 is a speed-density, multi-point, sequential, electronic fuel injection type. The fuel injection system is composed of the fuel line components, air intake components, and components for system control (ECM, sensors, switches, etc.).
Page 63 ENGINE CONTROL SYSTEM 3-15 FUEL INJECTION TIMING CHART 34-signals/360˚ 10˚ 30˚ CKP sensor signal 120˚ 120˚ 120˚ CMP sensor signal 4-signals/720˚ Injection time duration BTDC 445˚ on exhaust stroke #1 Injection signal #3 Injection signal #4 Injection signal #2 Injection signal In.
Page 64: Fuel Delivery System Components
3-16 ENGINE CONTROL SYSTEM FUEL DELIVERY SYSTEM COMPONENTS The fuel delivery system is composed of the low pressure line components (fuel tank, filter, pump, etc.), fuel vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel injector and hoses.
Page 65 ENGINE CONTROL SYSTEM 3-17 FUEL VAPOR SEPARATOR The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber. As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump. The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator.
Page 66 3-18 ENGINE CONTROL SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator is located in the fuel vapor separator. The regulator’s function in the system is to maintain a constant fuel pressure relative to the injector while the engine is operating. The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure bal- anced.
Page 67: Fuel Pump Control System
ENGINE CONTROL SYSTEM 3-19 FUEL PUMP CONTROL SYSTEM OUTLINE To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated ON / OFF signal, at a specified rate (1000 times a second). Based on engine speed and battery voltage, the ECM determines the optimum duty (repeating “ON” time rate within a cycle) and sends this signal to the fuel pump.
Page 68: Air Intake Components
3-20 ENGINE CONTROL SYSTEM AIR INTAKE COMPONENTS Air, after entering through the silencer, passes through the throttle body and flows into the surge tank where it is then distributed to the cylinder intake manifold. Intake manifold pressure, monitored by the MAP sensor, is an indirect measure of the intake air amount. When the throttle is fully closed, the main supply of intake manifold air necessary to sustain engine idle passes through the by-pass air passage.
Page 69: Idle Air Control System
ENGINE CONTROL SYSTEM 3-21 BY-PASS AIR SCREW / PASSAGE Since the throttle valve is almost fully closed when idling / troll- ing, the main flow of air necessary to maintain idling / trolling speed passes through the by-pass air passage. The by-pass air screw controls the flow of air through the pas- sage and provides a means of partially adjusting the total amount of air necessary for idling / trolling.
Page 70 3-22 ENGINE CONTROL SYSTEM Duty cycle signal for IAC valve Battery (example : 20% duty) charge coil “ON” time × 100 = duty (%) 1 cycle time main Rectifier & relay 0.8 ms regulator 30A fuse 60A fuse Sensor / switch Time signal input Ignition...
Page 71: Caution System
ENGINE CONTROL SYSTEM 3-23 CAUTION SYSTEM MONITOR-TACHOMETER The following four caution systems alert the operator when an abnormality occurs on the engine. • OVER-REVOLUTION CAUTION • LOW OIL PRESSURE CAUTION • OVERHEAT CAUTION • LOW BATTERY VOLTAGE CAUTION OVER-REV CAUTION CAUTION CAUTION LIMITER...
Page 72: Low Oil Pressure Caution System
3-24 ENGINE CONTROL SYSTEM LOW OIL PRESSURE CAUTION SYSTEM CONDITION : Immediate activation of system when the oil pressure switch turns “ON” due to an engine oil pressure drop below 100 kPa (1.0 kg / cm , 14 psi.). ACTION : Engine speed Automatically reduced to approx.
Page 73: Overheat Caution System
ENGINE CONTROL SYSTEM 3-25 OVERHEAT CAUTION SYSTEM CONDITION 1 (Maximum temperature) Immediate activation of system when : • Cylinder temperature reaches 121°C. • Exhaust manifold temperature reaches 114°C. CONDITION 2 (Temp. rise vs Time) Immediate activation of system when : •...
Page 74: Low Battery Voltage Caution System
3-26 ENGINE CONTROL SYSTEM LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION : System is activated when battery voltage decreases to less than 9 volts for 30 seconds. ACTION: Engine speed No engine speed limiter is activated. Caution lamp “CHECK ENGINE” lamp lights continuously. Caution buzzer Sounds in a series of long (1.5 sec.) beeps.
Page 75: Self-Diagnostic System
ENGINE CONTROL SYSTEM 3-27 SELF-DIAGNOSTIC SYSTEM MONITOR-TACHOMETER The self-diagnostic system alerts the operator when an abnor- mality occurs in a signal from sensor, switch, etc. When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code pattern along with a buzzer sound.
Page 76 3-28 ENGINE CONTROL SYSTEM NOTE: • If more than two items fail at once, the self-diagnostic indication appears according to priority order. The indication repeats three times. • If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch “ON”. •...
Page 77: Condition For Self-Diagnostic System Operation
ENGINE CONTROL SYSTEM 3-29 CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION FAILED ITEM CONDITION MAP sensor 1 • No signal (With engine running) • Receiving an out of range “37–860 mmHg (0.20–4.53V)” signal (With engine running) CKP sensor • During one crankshaft rotation, 34 signals are not input to the ECM •...
Page 78: Fail-Safe System
3-30 ENGINE CONTROL SYSTEM FAIL-SAFE SYSTEM The fail-safe system is closely related to the self-diagnostic system. When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a pre- programmed value for the failed sensors. This allows the engine to continue running under the fail-safe condition.
Page 79: Operating Hour Indication System
ENGINE CONTROL SYSTEM 3-31 OPERATING HOUR INDICATION SYSTEM When the ignition switch is initially turned “ON” (from “OFF”), MONITOR-TACHOMETER the ECM tests the caution system by turning on all four lamps in the monitor-tachometer and sounding the caution buzzer for an initial two seconds.
Page 80: Oil Change Reminder System
NOTE: • Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, Suzuki strongly recommends that the engine oil be replaced before canceling the system activation.
Page 81: Start-In-Gear Protection System
ENGINE CONTROL SYSTEM 3-33 START-IN-GEAR PROTECTION SYSTEM A switch to detect neutral gear position is located on the cylinder block (STBD side) and operated by the clutch control lever. This ON / OFF type switch is “ON” in neutral and “OFF” in forward or reverse. On starting the engine, the ECM detects the shift position using the neutral switch.
Page 82: O 2 Feedback System
ECM itself. sensor : Feedback Informs ECM of concentration of oxygen in exhaust gas. 18213-74F00 : O sensor NOTE: For fuel mixture check (O feedback) operation procedure, refer to “Suzuki Diagnostic System Operation Manual”.
Page 83: Inspection
ENGINE CONTROL SYSTEM 3-35 INSPECTION PRECAUTION ON SYSTEM INSPECTION To prevent any unexpected engine start, perform the following before proceeding with any CRANK- ING tests. • When performing tests not related to fuel injector operation : • Disconnect all fuel injector wire connectors. •...
Page 84: Inspection For Ecm Circuit Voltage
3-36 ENGINE CONTROL SYSTEM INSPECTION FOR ECM CIRCUIT VOLTAGE ECM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an ECM separated from the engine wiring harness. 09930-89950 : 44-pin test cord 09930-99320 : Digital tester Tester range : V (DC voltage) 1.
Page 85 ENGINE CONTROL SYSTEM 3-37 CIRCUIT VOLTAGE TABLE STANDARD TER- WIRE CIRCUIT CONDITION / REMARKS MINAL VOLTAGE COLOR — — — — Approx. 5V Ignition switch ON, stop switch plate IN Bl/R Emergency stop switch Approx. 0V Ignition switch ON, stop switch plate OUT Approx.
Page 86: Inspection For Resistance
3-38 ENGINE CONTROL SYSTEM INSPECTION FOR RESISTANCE 09930-99320 : Digital tester Tester range : Ω Ω Ω Ω Ω (Resistance) NOTE: Make sure ignition switch is always OFF when measuring resistance. 1. Disconnect battery cables from battery. 2. Disconnect wire harness connector from ECM. 3.
Page 87: Component Inspections
ENGINE CONTROL SYSTEM 3-39 NOTE1: Disconnect remote control wire harness, and connect tester probe to terminal A (Gray wire). COMPONENT INSPECTIONS FUEL PUMP 3 SEC. OPERATING SOUND Turn ignition switch ON and check for fuel pump operating sound. Fuel pump operating sound : Sounds for approx.
Page 88 3-40 ENGINE CONTROL SYSTEM FUEL INJECTOR OPERATING SIGNAL Starter motor magnetic switch “B” terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 23 24 25 26 27 28 29 30 31 32 33 34 35 14 15 16 17 18 19 20 21 36 37...
Page 89 ENGINE CONTROL SYSTEM 3-41 IGNITION COIL OPERATING SIGNAL Starter motor magnetic switch “B” terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 23 24 25 26 27 28 29 30 31 32 33 34 35 14 15 16 17 18 19 20 21 36 37 38...
Page 90 3-42 ENGINE CONTROL SYSTEM IGNITION SECONDARY COIL RESISTANCE 09930-99320 : Digital tester Tester range : Ω Ω Ω Ω Ω (Resistance) 1. Disconnect spark plug caps from spark plugs. 2. Measure resistance between both spark plug caps as shown in figure. Ignition secondary coil resistance : 18 –...
Page 91 ENGINE CONTROL SYSTEM 3-43 MAP SENSOR OUTPUT VOLTAGE CHANGE 09917-47011 : Vacuum pump gauge 09930-89950 : 44-pin test cord 09930-99320 : Digital tester Tester range : V (DC voltage) 1. Remove bolts and MAP sensor from intake manifold. MAP sensor MAP sensor 2.
Page 92 3-44 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH 09940-44121 : Air pressure gauge 09952-99310 : Air pump Tester range : (Continuity) 1. Remove bolts and air duct 1. 2. Remove oil pressure switch. (See page 3-54) 3. Connect the gauge and pump as shown in figure. Oil pressure switch Oil pressure switch 4.
Page 93: Troubleshooting
ENGINE CONTROL SYSTEM 3-45 TROUBLESHOOTING Before starting troubleshooting, read and follow the “PRECAUTION ON SYSTEM INSPECTION” section on page 3-35. 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 4-9.
Page 94 3-46 ENGINE CONTROL SYSTEM CHART3 : SELF-DIAGNOSTIC CODE “3-1” START < Ignition switch “OFF” > Check IAC valve resistance. IAC valve failure Is result OK? (See page 3-38) < Ignition switch “ON” > ECM failure Check “18” terminal voltage. Is result OK? (See page 3-37) Possible cause : •...
Page 95 ENGINE CONTROL SYSTEM 3-47 CHART6 : SELF-DIAGNOSTIC CODE “1-4” START < Ignition switch “OFF” > Cylinder temp. sensor failure Check cylinder temp. sensor resistance. Is result OK? (See page 3-38) Possible cause : • ECM failure • Wire continuity / connection failure CHART 7 : SELF-DIAGNOSTIC CODE “2-3”...
Page 96 3-48 ENGINE CONTROL SYSTEM CHART9 : SELF-DIAGNOSTIC CODE “1-1” START < Individual check > Check rectifier & regulator resistance. Rectifier & regulator failure [NOTE1] Is result OK? (See page 4-4) < Engine running > Check “30” terminal voltage at idle speed.
Page 97 ENGINE CONTROL SYSTEM 3-49 CHART12 : ENGINE CRANKED, BUT NOT START (OR STOPS SHORTLY AFTER STARTING) Before starting this troubleshooting, make sure that : • There is no self-diagnostic code indication. • Emergency stop switch plate is set in place. START <...
Page 98 3-50 ENGINE CONTROL SYSTEM CHART13 : UNSTABLE IDLING / TROLLING (OR ENGINE TENDS TO STALL) Before starting this troubleshooting, make sure that : • There is no self-diagnostic code indication. START < Ignition switch “ON” > < Individual check > (Always 0 V) Check “5”...
Page 99: Removal / Installation
ENGINE CONTROL SYSTEM 3-51 REMOVAL / INSTALLATION FLYWHEEL Flywheel bolt is a left hand thread. 245 N·m (24.5 kg-m, 177.0 lb.-ft.) 1 Flywheel bolt 2 Washer 3 Key 4 Flywheel Crankshaft 5 CKP sensor 6 Bolt 7 CMP sensor NOTE: 8 Bolt Clean flywheel and crankshaft mating surfaces with cleaning solvent.
Page 100 3-52 ENGINE CONTROL SYSTEM 3. Using special tools, loosen flywheel from crankshaft. 09930-39411 : Flywheel remover 09930-39420 : Flywheel remover bolt 4. Remove flywheel bolt 1, washer 2, flywheel 3 and key INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Page 101 ENGINE CONTROL SYSTEM 3-53 CKP SENSOR REMOVAL Prior to removing CKP sensor : • Disconnect battery cables from battery. 1. Remove flywheel cover. 2. Remove three (3) bolts and air silencer case 1. Disconnect IAT sensor lead wire connector at IAT sensor. 3.
Page 102: Oil Pressure Switch
3-54 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH REMOVAL 1. Remove bolts and air duct 1. 2. Loosen bolt and disconnect blue lead wire from switch. Oil pressure switch Oil pressure switch 3. Remove oil pressure switch from cylinder block. INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Page 103 ELECTRICAL ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM _____________________________ 4-2 OUTLINE ......................INSPECTION ....................REMOVAL / INSTALLATION ................. ELECTRIC STARTER SYSTEM ______________________________ 4-7 OUTLINE ......................TROUBLESHOOTING ................... 4-10 INSPECTION ....................4-12 STARTER MOTOR ..................4-12 REMOVAL / INSTALLATION ............... 4-13 DISASSEMBLY .................... 4-16 INSPECTION &...
Page 104: Battery Charging System
ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the BATTERY CHARGE COIL, RECTIFIER & REGULATOR and BATTERY. The three phase AC current generated from battery charge coil is converted by the rectifier & regulator into regulated DC cur- rent which is used to charge the battery.
Page 105: Inspection
ELECTRICAL INSPECTION BATTERY CHARGE COIL Measure battery charge coil resistance. 09930-99320 : Digital tester Tester range : Ω Ω Ω Ω Ω (Resistance) 1. Disconnect battery charge coil leads from rectifier & regu- lator. 2. Measure resistance between leads in the combinations shown.
Page 106 2. Measure resistance between leads in combinations shown. NOTE: The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier & regu- lator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.
Page 107: Removal / Installation
ELECTRICAL REMOVAL / INSTALLATION 245 N . m System construction (24.5 kg-m, 177.0 lb.-ft.) Flywheel bolt is a left hand thread. 1 1 1 1 1 Bolt (1) 2 2 2 2 2 Washer (1) 3 3 3 3 3 Key (1) 4 4 4 4 4 Flywheel (1) 5 5 5 5 5 Battery charge coil (1) 6 6 6 6 6 Screw (4)
Page 108 4. Remove exhaust cover with rectifier & regulator. INSTALLATION Installation is reverse order of removal with special attention to the following step. Battery charge coil Apply Suzuki Bond to coil securing screws. 99000-31140 : Suzuki Bond 1207B Wire routing Check wire routing. (See page 10-2 to 10-7)
Page 109: Electric Starter System
ELECTRICAL ELECTRIC STARTER SYSTEM OUTLINE The starting circuit consists of the battery, starting motor, ignition switch, neutral switch 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 ignition switch is closed (turn to “START”).
Page 110 ELECTRICAL STARTER ENGAGEMENT MECHANISM A solenoid (electromagnetic force) type starter switch, utilizing a torsion spring and shift lever, engages the pinion gear to the flywheel. When the ignition key is turned to “START”, current flows through the switch winding creating an electromag- net pulling the plunger in.
Page 111: Troubleshooting
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. If any abnormality is found, immediately disconnect battery cables from battery. Engine does not start.
Page 112: Inspection
4-10 ELECTRICAL INSPECTION IGNITION SWITCH 09930-99320 : Digital tester Tester range : (Continuity) 1 (OFF) 1. Disconnect ignition switch from remo-con box wiring har- 2 (ON) ness. 3 (START) 2. Inspect continuity between wiring leads at key positions shown in chart. Switch Lead Wires Position Black Green White...
Page 113 ELECTRICAL 4-11 NEUTRAL SWITCH Inspect continuity of neutral switch. 09930-99320 : Digital tester Tester range : (Continuity) REVERSE FORWARD Neutral switch in remo-con box 1. Disconnect neutral switch lead wires in remo-con box. 2. Inspect continuity between switch Brown lead wires while operating remo-con handle.
Page 114: Starter Motor
4-12 ELECTRICAL STARTER MOTOR REMOVAL Prior to removing starter motor : • Disconnect battery cables from battery. 1. Remove bolt 1 and flywheel cover 2. 2. Remove bolt 3 and negative - battery cable 4. 3. Remove nut 5 and positive + battery cable 6 from magnetic switch of starter motor.
Page 115: Disassembly
ELECTRICAL 4-13 DISASSEMBLY For overhauling of starting motor, it is recommended that com- ponent parts should be cleaned thoroughly. However, yoke assembly, armature coil, over-running clutch assembly, magnetic switch assembly, rubber or plastic parts should not be washed in degreasing tank or with grease dis- solving solvent.
Page 116 4-14 ELECTRICAL 5. Remove thrust washer 9 with screwdriver. 6. Pull brush spring 0 up so that brush is separated from surface of commutator, then remove brush holder A. 7. Remove yoke B and armature C. 8. Remove center cover plate D. 9.
Page 117 ELECTRICAL 4-15 11. Remove shift lever I and pinion J. 12. Remove E-ring L and washer M. 13. Remove pinion shaft K, washer M and rubber ring N from center bracket.
Page 118: Inspection & Servicing
4-16 ELECTRICAL INSPECTION & SERVICING Armature and Commutator 1. Inspect commutator sur face for gum or dirt. Clean with #500 grit emery paper A if necessary. 2. 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 119 ELECTRICAL 4-17 4. Inspect continuity between commutator and armature core Commutator / shaft. Shaft If continuity exists, replace armature. 09930-99320 : Digital tester Tester range : (Continuity) Armature core 5. Inspect continuity between adjacent commutator segments. If no continuity exists, replace armature. BRUSHES Measure length of each brush.
Page 120 4-18 ELECTRICAL BRUSH SPRING Inspect brush spring for wear or other damage. Measure brush spring tension. Replace if necessary. Brush spring tension Standard : 15 – 18 N (1.5 – 1.8kg, 3.3 – 4.0 lb.) SHIFT LEVER Inspect shift lever for wear. Replace if necessary.
Page 121 ELECTRICAL 4-19 PINION SHAFT / PINION SHAFT BUSH Inspect pinion shaft for wear, damage or other abnormal condi- tions. Inspect pinion shaft bush for wear or other damage. Replace if necessary. FRONT HOUSING BEARING Inspect bearing for wear or other damage. Replace if necessary.
Page 122 4-20 ELECTRICAL MAGNETIC SWITCH Push in plunger and release. Plunger should return quickly to its original position. Replace if necessary. 1. Plunger 1. Plunger Plunger Pull-in coil Open circuit Test 09930-99320 : Digital tester Tester range : (Continuity) Inspect continuity between terminal“S” and terminal“M” . If no continuity exists, replace magnetic switch.
Page 123: Assembly
ELECTRICAL 4-21 ASSEMBLY Assembly is reverse order of disassembly with special atten- tion to the following steps. When installing armature, exericise care to avoid breaking brushes. When installing pinion shift lever, refer to figure in construction diagram for its installation direction. Construction diagram 7 N .
Page 124: Performance Test
4-22 ELECTRICAL PERFORMANCE TEST Each test must be performed within 3 – 5 seconds to avoid coil from burning. When performing the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as the cable that was originally used there. PULL-IN / HOLD-IN COIL TEST Connect battery to magnetic switch as shown in figure.
Page 125 ELECTRICAL 4-23 NO-LOAD PERFORMANCE TEST Before performing following test, set starter motor se- curely on 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 cur- rent.
Page 126: Monitor-Tachometer
4-24 ELECTRICAL MONITOR-TACHOMETER 1 1 1 1 1 “CHECK ENGINE” 2 2 2 2 2 TEMP “ ” 3 3 3 3 3 OIL “ INSPECTION ” 4 4 4 4 4 REV “LIMIT” MONITOR LAMP CHECK 1. Connect test cord as shown in figure . 09930-89240 : 4-pin test cord NOTE: This check can be performed without test cord (P/no.
Page 127: Erectric Parts Holder
ELECTRICAL 4-25 ELECTRIC PARTS HOLDER REMOVAL Before removing electric parts holder : • Disconnect battery cables from battery. • Remove PORT side cover. 1. Remove electric parts holder cover. 2. Remove three bolts and silencer case 1. 3. Disconnect lead wire connector from ECM, then remove ECM.
Page 128: Removal / Installation
FUEL SYSTEM FUEL SYSTEM CONTENTS PRECAUTION ON FUEL SYSTEM SERVICE ___________________ 5-2 GENERAL PRECAUTION ................FUEL PRESSURE RELIEF PROCEDURE ............ FUEL LINE ______________________________________________ 5-4 REMOVAL / INSTALLATION ................FUEL LEAKAGE CHECK PROCEDURE............FUEL HOSE CONNECTION ................FUEL PRESSURE INSPECTION ..............FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP _____ 5-7 REMOVAL / INSTALLATION ................
Page 129: Precaution On Fuel System Service
FUEL SYSTEM PRECAUTION ON FUEL SYSTEM SERVICE GENERAL PRECAUTION Gasoline is extremely flammable and toxic. Always ob- serve the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing / inspection. •...
Page 130: Fuel Pressure Relief Procedure
FUEL SYSTEM FUEL PRESSURE RELIEF PROCEDURE After making sure that engine is cold, relieve fuel pressure as follows. 1. Turn OFF ignition switch. 2. Disconnect high pressure fuel pump lead wire connector at high pressure fuel pump. 3. Disconnect ignition coil primary lead wire connector from all ignition coils.
Page 131: Fuel Leakage Check Procedure
FUEL SYSTEM FUEL LINE REMOVAL / INSTALLATION Pay special attention to the following steps when removing or installing fuel hoses. The components after the high pressure fuel pump re- main pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components.
Page 132: Fuel Hose Connection
FUEL SYSTEM FUEL HOSE CONNECTION Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly by referring to following figures. “A” Clamp (Clip) • For type “A” (short barbed end) pipe, hose should completely Hose cover pipe.
Page 133 FUEL SYSTEM A small amount of fuel may be released when the fuel feed hose is disconnected. Place container under the fuel feed hose with a shop cloth so that released fuel is caught in container or absorbed in cloth. Place fuel soaked cloth in an ap- proved container.
Page 134: Fuel Vapor Separator / High Pressure Fuel Pump
FUEL SYSTEM FUEL VAPOR SEPARATOR / HIGH PRESSURE FUEL PUMP REMOVAL / INSTALLATION REMOVAL The components after the high pressure fuel pump re- main pressurized at all times. To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components. 1.
Page 135: Disassembly
FUEL SYSTEM DISASSEMBLY 1. Remove five screws 1. 2. Remove separator cover 2 with high pressure fuel pump from separator case 3. 3. Remove float pin 4 and float 5. 4. Remove needle valve 6, screw 7, plate and valve seat 8. 5.
Page 136: Inspection
FUEL SYSTEM 7. 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. Needle valve / Valve seat Inspect needle valve and valve seat for groove, other damage or dirt.
Page 137: Assembly
5-10 FUEL SYSTEM Fuel pressure regulator Check fuel pressure regulator operation. 09952-99310 : Hand air pump 1 09940-44121 : Air pressure gauge 2 09940-44130 : Attachment 3 09912-58490 : Hose 4 1. Connect special tools to inlet side of regulator as shown in figure.
Page 138 Apply fuel to O-ring Apply fuel to O-ring 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 figure. 99000-31140 : Suzuki Bond 1207B NOTE: •...
Page 139: Fuel Injector
5-12 FUEL SYSTEM FUEL INJECTOR INSPECTION 1. Using sound scope or equivelent, check operating sound of fuel injector when engine is running or cranking. Injector operating sound cycle should vary according to engine speed. If no sound or an unusual sound is heard, check injector circuit (wire or connector) or injector.
Page 140: Installation
FUEL SYSTEM 5-13 INSTALLATION Installation is reverse order of removal with special attention to the following steps. Do not re-use 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 141: Low Pressure Fuel Pump
5-14 FUEL SYSTEM LOW PRESSURE FUEL PUMP REMOVAL / INSTALLATION REMOVAL 1. Disconnect inlet hose 1 and outlet hose 2 from low pres- sure fuel pump. 2. Remove two bolts 3. 3. Remove fuel pump 4. Note position before removing O-ring 5. INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Page 142: Disassembly / Reassembly
FUEL SYSTEM 5-15 DISASSEMBLY / REASSEMBLY DISASSEMBLY NOTE: For correct assembly, scribe an alignment mark on each part of fuel pump. 1. Remove four screws 1 and valve body assembly 2. 2. Turn piston 3 until pin 4 comes out through cutaway of pump body 5.
Page 143: Inspection
5-16 FUEL SYSTEM INSPECTION Diaphragm Inspect diaphragm for distortion, tears, or other damage. Replace fuel pump assembly if necessary. Check-valves Inspect fuel pump check valves for tears, distortion or damage. Replace fuel pump assembly if necessary. Pump body Inspect fuel pump body and valve body assembly for cracks, nicks, distortion or other damage.
Page 144: Fuel Tank
FUEL SYSTEM 5-17 FUEL TANK (OPTIONAL PART) DISASSEMBLY / REASSEMBLY When disassembling or reassembling fuel tank, refer to the construction diagram below. Plastic tank Steel tank –(a) –(b) 1 Fuel hose assy ( 1 ) 7 Connector plug ( 1 ) 1 Tank cap (1) [B Screw (2)] 8 Outlet ( 1 )
Page 145: Inspection
5-18 FUEL SYSTEM INSPECTION Fuel connector Inspect fuel connector for leakage,deterioration or other dam- age. Replace if necessary. 1. Connector 2. Connector plug Fuel primer bulb Inspect fuel primer bulb for cracks, leakage, deterioration or check valve function. Replace if necessary. Fuel hose Inspect fuel hose for cuts, cracks, leakage, tears or deteriora- tion.
Page 146 POWER UNIT 6-1 POWER UNIT CONTENTS INTAKE MANIFOLD ASSEMBLY _____________________________ 6-2 REMOVAL ...................... INSTALLATION ....................POWER UNIT ____________________________________________ 6-5 REMOVAL ...................... INSTALLATION ....................OIL PUMP _______________________________________________ 6-12 6-12 REMOVAL ...................... 6-12 INSPECTION ....................6-13 INSTALLATION ....................TIMING CHAIN / TENSIONER _______________________________ 6-14 6-14 REMOVAL ......................
Page 147: Intake Manifold Assembly
POWER UNIT INTAKE MANIFOLD ASSEMBLY REMOVAL Before removing intake manifold : • Relieve fuel pressure. (See page 5-3) • Disconnect battery cables from battery. • Remove both side covers. (See page 7-2) 1. Remove flywheel cover. 2. Remove two bolts and air duct 1. 3.
Page 148 POWER UNIT 8. Remove bolts and low pressure fuel filter bracket 9. 9. Remove two (2) bolts securing fuel delivery pipe 6, then remove fuel delivery pipe and all fuel injectors 0. 10. Remove two (2) bolts and fuel return pipe A. 11.
Page 149: Installation
POWER UNIT 19. Disconnect water inlet hose K and water outlet hose L from 3-way joint. 20. Remove nine (9) bolts and two (2) nuts and then remove intake manifold assembly M . INSTALLATION Installation is reverse order of removal with special attention to the following steps.
Page 150: Power Unit
POWER UNIT POWER UNIT REMOVAL Before removing power unit : • Drain engine oil. (See page 2-4) • Remove intake manifold assembly. (See page 6-2) • Remove electric parts holder. (See page 4-25) 1. Remove bolts and fuel pump 1 . 2.
Page 151 POWER UNIT 7. Remove battery charge coil 1 . (See page 4-5) 8. Remove CKP sensor 2 .(See page 3-53) Disconnect water return hose 3 from thermostat cover. 10. Remove bolt and water return hose pipe 4 . 11. Disconnect cylinder temp sensor lead wire connector. 12.
Page 152 POWER UNIT 17. Loosen screw A and disconnect lead wire from oil pres- sure switch. 18. Remove two bolts B and front panel C. 19. Disconnect water inlet hose D and water outlet hose E from crankcase. 20. Remove cotter pin F and washer G , then separate clutch lever link H from clutch shaft arm I .
Page 153 POWER UNIT 24. Remove pins O and side cover seal P . 25. Remove sixteen ( 16 ) bolts. 26. Lift up and remove power unit from engine holder.
Page 154: Installation
2. Apply Suzuki Water Resistant Grease to driveshaft splines. 99000-25161 : Suzuki Water Resistant Grease NOTE: Before installing power unit, apply Suzuki Bond to hatched part (2 parts) as shown in figure. 99000-31140 : Suzuki Bond 1207B 3. Lower power unit onto engine holder.
Page 155 NOTE: Before installing cylinder head cover, check tappet clearance. (See page 2-9) 1. Apply Suzuki Bond to area as shown in figure. 99000-31140 : Suzuki Bond No. 1207B 2. Assemble new O-rings and cylinder head cover gasket to cylinder head cover.
Page 156 POWER UNIT 6-11 INTAKE MANIFOLD Install intake manifold assembly. (See page 6-4) FUEL INJECTOR Install fuel injectors. (See page 5-13) FINAL ASSEMBLY CHECK Perform following checks to ensure proper and safe operation of repaired unit : • All parts removed have been returned to their original posi- tions.
Page 157: Oil Pump
6-12 POWER UNIT OIL PUMP REMOVAL 1. Remove power unit. (See page 6-5 to 6-8) NOTE: Hold camshaft by placing a wrench on hexagon area of cam- shaft. 1. Oil pump dr 1. Oil pump drive sprocket Oil pump drive sprocket 2.
Page 158: Installation
POWER UNIT 6-13 INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Assemble washer 1 , pin 2 , driven sprocket 3 and circlip 4 to oil pump shaft. • Apply engine oil to seal ring 5 , then install seal ring to oil pump body.
Page 159: Timing Chain / Tensioner
6-14 POWER UNIT TIMING CHAIN / TENSIONER REMOVAL Prior to this service work : • Remove power unit. (See page 6-5 to 6-8) 1 Crankshaft / Drive gear 2 Driven gear / Timing sprocket 3 Timing chain 4 Timing chain guide 5 Timing chain tensioner 6 Timing chain tensioner adjuster 7 Oil pump drive sprocket...
Page 160 POWER UNIT 6-15 2. Remove bolt 1 and oil pump drive sprocket 2. (See page 6-12) NOTE: Hold camshaft by placing a wrench on the hexagon area of camshaft. 3. Remove bolts 3 and timing chain guide 4. 4. Remove bolt, nut and chain tensioner adjuster 5. 5.
Page 161: Inspection
6-16 POWER UNIT INSPECTION NOTE: If cracks, excessive wear, defective or other damage is found on any component, replaced component. Timing chain Inspect timing chain for wear or other damage. Replace if necessary. Tensioner adjuster Inspect tensioner adjuster for smooth operation. Inspect oil passage for clog.
Page 162: Installation
POWER UNIT 6-17 INSTALLATION Installation is reverse order of removal with special attention to the following steps. 1. Check that match mark (key way) a on crankshaft drive gear points to 12 o’clock (towards cylinder head). (Check that #1 cylinder is at top dead center.) 2.
Page 163 6-18 POWER UNIT 5. As shown in figure, position timing chain on driven gear Blue plate Blue plate sprocket with GOLD plate of chain aligned with match mark ( • ) b on driven gear. 6. As shown in figure, engage timing chain with exhaust sprocket with one BLUE plate of chain aligned with match mark (dot) g of exhaust sprocket.
Page 164 POWER UNIT 6-19 11. Install timing chain tensioner adjuster 0. Tighten bolt and nut, pre-coated with thread lock, to speci- Stopper Stopper fied torque. 99000-32050 : Thread lock “1342” Tensioner adjuster bolt / nut : 11 N . m (1.1 kg-m, 8.0 lb.-ft.) 12.
Page 165: Cylinder Head Assembly
6-20 POWER UNIT CYLINDER HEAD ASSEMBLY (Cylinder head / valve / camshaft) REMOVAL Prior to removing cylinder head : • Remove power unit. (See page 6-5 to 6-8) • Remove timing chain. (See page 6-14 to 6-15) 1. Remove bolts 1 and oil pump 2. 2.
Page 166: Installation
POWER UNIT 6-21 INSTALLATION Installation is in reverse order of removal with special attention to the following steps. Do not re-use gasket once removed. Always use a new gasket. 1. Insert dowel pins and place cylinder head gasket into posi- tion on cylinder.
Page 167 6-22 POWER UNIT NOTE: Before installing camshafts, turn crankshaft until No.1 cylinder reaches top dead center. (See page 6-14) NOTE: When install camshaft, adjust relative position between sprock- ets and chain so that match marks (dot) on timing sprockets are as shown in figure and engraved lines on sprockets align with cylinder head cover mating face.
Page 168 POWER UNIT 6-23 10. Apply engine oil lightly to housing bolts. 11. Lightly seat all housing bolts at first. According to numerical order in figure, tighten bolts to 1/3 of specified torque, then 2/3 of specified torque and finally to full specified torque. Camshaft housing bolt : 11 N .
Page 169: Disassembly
6-24 POWER UNIT DISASSEMBLY 1. Remove tappets with shims. 2. Using valve lifter and attachment, remove valve cotters 1 while compressing valve spring. 09916-19030 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers 3. Remove valve spring retainer 2, valve spring 3 and valve 4.
Page 170: Inspection / Servicing
POWER UNIT 6-25 INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component. CYLINDER HEAD Remove all carbon from combustion chambers. NOTE: • Do not use any sharp edged tool to scrape carbon off cylin- der head or its components.
Page 171 6-26 POWER UNIT Manifold seating faces distortion Using a straightedge and thickness gauge, measure cylinder head distortion to intake manifold seating faces. Manifold seating faces distortion: Service limit : 0.10 mm (0.004 in.) If measurement exceeds service limit, resurface or replace cyl- inder head.
Page 172 POWER UNIT 6-27 Camshaft identification DF90 and DF115 camshafts differ as shown below. Model Identification mark Dent DF90 DF115 No dent Camshaft runout Using a set of V-blocks, support the camshaft on a surface plate. Measure runout using dial gauge. 09900-20602 : Dial gauge 09900-20701 : Magnetic stand Camshaft runout :...
Page 173 6-28 POWER UNIT Camshaft journal oil clearance Measure journal oil clearance using Plastigauge as follows. 1. Clean housing and camshaft journals. 2. Install camshaft to cylinder head. 3. Place Plastigauge across full width of camshaft journal (par- allel to camshaft). 09900-22302 : Plastigauge (0.051 —...
Page 174 POWER UNIT 6-29 Camshaft journal (housing) inside diameter : Standard : Top, 2nd, 3rd, 4th journal 23.000 – 23.021 mm (0.9055 – 0.9063 in.) 5th journal 26.000 – 26.021 mm (1.0236 – 1.0244 in.) Service limit : Top, 2nd, 3rd, 4th journal 23.171 mm (0.9122 in.) 5th journal 26.171 mm (1.0304 in.)
Page 175 6-30 POWER UNIT VALVE / VALVE GUIDE Valve guide to valve stem clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check guide to stem clearance. Be sure to take readings at more than one place along length of each stem and guide.
Page 176 POWER UNIT 6-31 Valve stem end deflection If unable to measure valve guide inside diameter, measure “Valve stem end deflection”. 09900-20602 : Dial gauge 09900-20701 : Magnetic stand Measure valve stem end deflection as follows : 1. Install valve into valve guide. 2.
Page 177 6-32 POWER UNIT Valve stem runout Measure valve stem runout. 09900-20602 : 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 178 POWER UNIT 6-33 Valve seat contact width Measure valve seat contact width as follows : 1. Remove all carbon from valve and seat. 2. Coat valve seat evenly with Prussian blue (or equivalent). 3. Install valve into valve guide. 4. Put valve lapper on valve. 09916-10911 : Valve lapper 5.
Page 179 6-34 POWER UNIT VALVE SEAT SERVICING If valve seat contact width is out of specification, reface valve seat as follows : Valve seat angle : 60˚ : 15° ° ° ° ° , 45° ° ° ° ° , 60° ° ° ° ° Intake side 45˚...
Page 180 POWER UNIT 6-35 NOTE: Clean and assemble cylinder head and valve components. Fill intake and exhaust ports with solvent to check for leaks be- tween valve seat and valve. If any leaks occur , inspect valve seat and face for burrs or other things that could prevent valve from sealing.
Page 181 6-36 POWER UNIT 3. Install valve guide to cylinder head as follows. Heat cylinder head to a temperature of 80 – 100°C (176 – 212°F). Apply heat uniformly so that head will not be dis torted. 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 182 POWER UNIT 6-37 VALVE SPRING Valve spring free length Measure valve spring free length. 09900-20101 : Vernier calipers Valve spring free length : Standard : IN & EX 42.7 mm (1.68 in.) Service limit : IN & EX 41.0 mm (1.61 in.) If measurement exceeds service limit, replace valve spring.
Page 183: Reassembly
6-38 POWER UNIT REASSEMBLY Reassemble is reverse order of disassembly with special at- tention to the following steps. VALVE 1. Install valve spring seat 1 to cylinder head. 2. After applying engine oil to stem seal 2 and spindle of spe cial tool (Installer attachment), fit stem seal to spindle.
Page 184 POWER UNIT 6-39 7. Hold valve spring compressed with special tool and install valve cotters 6. 8. Make sure valve cotters are properly seated in groove A. 09916-19030 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers...
Page 185: Cylinder / Crankshaft / Piston
6-40 POWER UNIT CYLINDER / CRANKSHAFT / PISTON DISASSEMBLY Before performing service work in this section : • Remove power unit (See page 6-5 to 6-8) • Remove timing chain (See page 6-14 to 6-15) • Remove cylinder head (See page 6-20) 1.
Page 186 POWER UNIT 6-41 NOTE: For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint. 6. Remove all conrod cap nuts 1 and conrod caps 2 . NOTE: To prevent damage to crank pin and cylinder walls, install a Guide hose piece of hose over threads of rod bolts.
Page 187 6-42 POWER UNIT 11. Remove two compression rings (top and 2nd) and oil ring from piston. 12. Mark cylinder number on conrod using quick dry paint. 13. Remove piston pin circlips as shown. 1. Piston pin circlip 14. Remove piston pin from conrod. NOTE: Reassemble each piston, piston pin and conrod in their origi- nal combination and position.
Page 188: Inspection / Servicing
POWER UNIT 6-43 INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace component. CYLINDER Cylinder distortion Using a straightedge and thickness gauge, measure cylinder distortion (gasketed surface) at a total of six (6) locations as shown in figure.
Page 189 6-44 POWER UNIT Cylinder bore Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear. If cylinder bore is very rough or deeply scratched, or ridged, rebore cylinder and use oversize piston. Cylinder bore wear (difference) Using cylinder gauge, measure cylinder bore in both axial (ver- tical line, following crankshaft) and transverse (horizontal line across crankshaft) directions at two positions as shown in fig- ure.
Page 190 POWER UNIT 6-45 3. Calculate the piston / cylinder clearance (Clearance equals difference between piston diameter and cylinder bore mea- surements). Piston to cylinder clearance : Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.) Service limit : 0.100 mm (0.0039 in.) If clearance exceeds service limit, replace piston and/or cylin- der or rebore cylinder.
Page 191 6-46 POWER UNIT PISTON Inspect piston for faults, cracks or other damage. Replace if necessary. Piston ring to groove clearance Before checking, piston grooves should be clean, dry and free Piston ring of carbon. Fit piston ring into piston groove, and measure clearance be- tween ring and ring groove using thickness gauge.
Page 192 POWER UNIT 6-47 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 Piston ring end gap : Standard : 1 st 0.20 – 0.35 mm (0.008 – 0.014 in.) 2 nd 0.35 –...
Page 193 6-48 POWER UNIT PISTON PIN Inspect piston pin, conrod small end bore and piston pin hole for wear or other damage. Replace if necessary. Piston pin clearance Measure piston pin clearance in conrod small end. Replace conrod if its small end is badly worn or damaged or if clearance exceeds service limit.
Page 194 POWER UNIT 6-49 CONROD BIG END SIDE CLEARANCE Measure conrod big end side clearance with conrod installed on crank pin as shown in figure. 09900-20803 : Thickness gauge Conrod big end side clearance : Standard : 0.100 – 0.250 mm (0.0039 – 0.0098 in.) Service limit : 0.350 mm (0.0138 in.) If measurement exceeds service limit, replace conrod and/or crankshaft.
Page 195 6-50 POWER UNIT CONROD BEARING Inspect bearings for proper contact pattern and signs of fusion, pitting, burning or flaking. Replace if necessary. Always replace both bearing halves, never replace only one half of a bearing set. Conrod big end oil clearance Check conrod big end oil clearance as follows : 1.
Page 196 POWER UNIT 6-51 6. Remove conrod and conrod cap from crank pin. Plastigauge Plastigauge Scale Scale 7. Using scale on Plastigauge envelope, measure Plastigauge width at its widest point. Conrod big end oil clearance : Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.) Service limit : 0.065 mm (0.0026 in.) If measurement exceeds service limit, replace conrod bearing.
Page 197 6-52 POWER UNIT If measurement exceeds service limit, replace crankshaft thrust bearing. Crankshaft thrust bearing thickness : Standard : 2.425 – 2.475 mm (0.0955 – 0.0974 in.) 1. Thrust bearing Out-of-round and taper (uneven wear) of journals Inspect crankshaft journal for uneven wear or other damage. Measure journal for out-of-round or taper with micrometer.
Page 198 POWER UNIT 6-53 CRANKSHAFT MAIN BEARING Inspect bearings for proper contact pattern and signs of fusion, pitting, burning or flaking. Replace if necessary. Always replace both bearing halves, never replace only one half of a bearing set. CRANKSHAFT JOURNAL OIL CLEARANCE Check crankshaft journal oil clearance as follows: 1.
Page 199 6-54 POWER UNIT 5. Install crankcase to cylinder. Tightening order 6. Apply engine oil lightly to crankcase bolts. Tighten crankcase bolts in three (3) steps according to the order shown below and in figure. Crankcase bolt : 5 N . m (0.5 kg-m, 3.5 lb.-ft.) 1st step 8 mm 11 N .
Page 200 POWER UNIT 6-55 SELECTION OF MAIN BEARING Whenever a bearing requires replacement, select a new bear- ing according to following procedure. 1. First, check journal diameter. As shown in figure, upper (flywheel side) crank web of No.1 cylinder has five (5) stamped code numerals. No.1 Journal code The numerals (1, 2 &...
Page 201 6-56 POWER UNIT 3. There are five (5) main bearings available, each of dif- fering thickness. To distinguish them, a color mark is painted at position indi- cated in figure. Each color represents the following thickness measured at center of bearing. Color mark Bearing thickness Color mark...
Page 202: Reassembly
POWER UNIT 6-57 REASSEMBLY Assembly is reverse order of disassembly with special atten- tion to the following steps. If original components are not replaced, each piston, piston pin and conrod is to be assembled and installed in its original order and position. PISTON TO CONROD 1.
Page 203 6-58 POWER UNIT PISTON RING TO PISTON Oil ring 1. Apply engine oil to piston rings. 2. Install spacer 1 first, then side rails 2 to piston. When installing spacer, do not allow ends to overlap in groove. Incorrect Correct 1st ring and 2nd ring 1.
Page 204 POWER UNIT 6-59 PISTON TO CYLINDER 1. Install conrod bearing to conrod and conrod cap. • Assemble each conrod bearing to its original posi- tion. • Do not apply oil between conrod and bearing or be- tween conrod cap and bearing. 2.
Page 205 6-60 POWER UNIT CRANKSHAFT TO CYLINDER 1. Install crankshaft main bearings in cylinder and crankcase. 2. Apply engine oil to bearings. • Assemble each bearing to its original position. • Assemble main bearing half containing oil groove / hole to cylinder block. Assemble the half without oil groove to crankcase.
Page 206 CRANKCASE TO CYLINDER 1. Clean mating surface of cylinder and crankcase. Apply Bond to marked line. 2. Apply Suzuki Bond to mating surface of crankcase as shown in figure. 99000-31140 : Suzuki Bond 1207B Apply bond to mating surface only.
Page 207 6-62 POWER UNIT 4. Install crankcase to cylinder. 5. Apply engine oil lightly to crankcase bolts. 6. Tighten crankcase bolts in three (3) steps according to the order shown below and in figure. NOTE: After tightening crankcase bolts, check to be sure that crank- shaft rotates smoothly when turned by hand.
Page 208: Thermostat
POWER UNIT 6-63 THERMOSTAT REMOVAL 1. Disconnect water hose 1 from thermostat cover. 2. Remove the three (3) bolts 2 securing the thermostat cover, then remove the cover 3 and thermostat 4 . INSPECTION Inspect thermostat for salt deposits, corrosion, wear or other damage.
Page 209: Operation
6-64 POWER UNIT OPERATION WATER COOLING SYSTEM The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostat. This system cools both the power unit and exhaust and is shown in schematic from below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build- up or component damage.
Page 210: Engine Lubrication System
POWER UNIT 6-65 ENGINE LUBRICATION SYSTEM A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication. Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.
Page 211 MID UNIT MID UNIT CONTENTS ENGINE SIDE COVER _____________________________________ 7-2 REMOVAL ...................... INSTALLATION ....................DRIVESHAFT HOUSING AND OIL PAN _______________________ 7-3 REMOVAL ...................... INSPECTION ....................ASSEMBLY ....................SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET ________________________________________ 7-13 7-13 REMOVAL ...................... 7-15 INSPECTION ....................
Page 212: Engine Side Cover
MID UNIT ENGINE SIDE COVER REMOVAL 1. Remove side cover seal 1. 2. Remove seven screws 2 and STBD side cover 3. 3. Remove two screws 4 and PORT side cover 5. 4. Disconnect PTT switch lead connector. INSTALLATION Installation is reverse order of removal.
Page 213: Driveshaft Housing And Oil Pan
MID UNIT DRIVESHAFT HOUSING AND OIL PAN REMOVAL 1. Remove power unit. (See pages 6-5 to 6-8) 2. Remove lower unit. (See page 9-2) 3. Disconnect water hose 1 and 2. 4. Remove screw and bonding wire from driveshaft housing. 5.
Page 214 MID UNIT 9. Remove two upper mount nuts 9 and washers. 10. Remove driveshaft housing with oil pan. 11. Remove two bolts 0 and clutch shaft holder A. 12. Remove four bolts B and upper mount cover C. 13. Remove upper mount assemblys D. 14.
Page 215: Inspection
MID UNIT 15. Remove three bolts G and oil strainer H. 16. Remove eight bolts I and oil pan J. 17. Remove water tube K. INSPECTION NOTE: If excessive ware, cracks, defective or other damage is found on any component, replace component. Mid unit component Inspect oil pan, driveshaft housing, engine holder and mount covers for cracks, defects or other damage.
Page 216 MID UNIT Mount Inspect upper and lower mount for excessive wear, corrosion or other damage. Replace if necessary. Water tube Inspect water tube for clog, obstruction, crack, corrosion or other damage. Clean or replace if necessary. Inspect water tube grommet for excessive wear or other dam- age.
Page 217: Assembly
MID UNIT ASSEMBLY Assembly is reverse order of removal with special attention to the following steps. 80 N . m (8.0 kg-m, 58.0 lb.-ft.) 85 N . m (8.5 kg-m, 61.5 lb.-ft.) 1 1 1 1 1 Clutch lever K K K K K Ring 2 2 2 2 2 E-ring L L L L L Engine holder 3 3 3 3 3 Bushing...
Page 218 MID UNIT 13 N . m (1.3 kg-m, 9.5 lb.-ft.) i i i i i Gasket y y y y y Pin j j j j j Gasket z z z z z Bolt k k k k k Plug { { { { { Lower mount cover l l l l l Oil pan | | | | | Nut...
Page 219 2. Install two dowel pins 2 to driveshaft housing 3. 3. Apply sealant to mating surfaces of driveshaft housing and oil pan. 99000-31120 : Suzuki Silicone Seal 4. Install oil pan 4 to driveshaft housing, then tighten eight bolts 5 securely.
Page 220 99000-32050 : Thread Lock “1342” Upper mount cover plate bolt : 50 N . m (5.0 kg-m, 36.0 lb.-ft.) 5. Install clutch shaft holder 9 to engine holder, then tighten bolts 0, pre-coated with silicone seal, to securely. 99000-31120 : Suzuki silicone seal...
Page 221 MID UNIT 7-11 DRIVESHAFT HOUSING / OIL PAN 1. Install driveshaft housing / oil pan to steering bracket. NOTE: Be sure upper mount bolt head properly fits into the steering bracket groove when installing driveshaft housing / oil pan as- sembly.
Page 222 7-12 MID UNIT 3. Install lower mount covers to driveshaft housing, then tighten lower mount cover bolts securely. BONDING WIRE Reattach bonding wire to driveshaft housing and tighten screw securely. POWER UNIT 1. Install power unit. (See page 6-9 to 6-11) 2.
Page 223: Swivel Bracket, Steering Bracket And Clamp Bracket
MID UNIT 7-13 SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL 1. Remove driveshaft housing / oil pan. (See page 7-3) 2. Remove screw and bonding wire from lower mount bracket. 3. Remove circlip 1. 4. Remove lower mount bracket 2, shim 3, and washer 4 from the steering shaft.
Page 224 7-14 MID UNIT 9. Remove tilt cylinder lower shaft bolts B. 10. Remove bolts and anode C. 11. Remove STBD motor mounting bolts D. 12. Remove clamp bracket shaft nut E. 13. Slide STBD clamp bracket F off clamp bracket shaft, then remove screw and bonding wire from swivel bracket.
Page 225: Inspection
MID UNIT 7-15 INSPECTION NOTE: If excessive ware, cracks, defective or damage is found on any component, replace component. BUSHINGS Inspect all bushings for excessive wear or other damage. Replace if necessary. If bushing fit is loose when installing, replace bushing. OIL SEAL Inspect swivel bracket seal for cuts, nicks, excessive wear or other damage.
Page 226: Reassembly
7-16 MID UNIT 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 1 1 1 1 Clamp bracket STBD F F F F F Bushing 2 2 2 2 2 Clamp bracket PORT G G G G G Oil seal 3 3 3 3 3 Clamp bracket shaft H H H H H Washer...
Page 227 Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings. 99000-25161 : Suzuki Water Resistant Grease 1. Insert PORT and STBD bushings 2 into swivel bracket 2. Assemble port clamp bracket 3, washer 4, clamp bracket shaft 5 and swivel bracket 1.
Page 228 7-18 MID UNIT STEERING BRACKET 1. Apply Water Resistant Grease to steering bracket shaft. 99000-25161 : Suzuki Water Resistant Grease NOTE: Apply grease to bushings, oil seal lip and pilot shaft portion of steering bracket. 2. Install upper bushing 1, and washer 2 to swivel bracket.
Page 229 MID UNIT 7-19 BONDING WIRE Reattach bonding wire, then tighten screw securely. LUBRICATION After completing reassembly of mid unit, apply grease through each grease nipple. 99000-25161 : Suzuki Water Resistant Grease...
Page 230: Water Pressure Valve
7-20 MID UNIT WATER PRESSURE VALVE REMOVAL 1. Remove PORT side lower cover. (See page 7-2) 2. Remove two bolts 1, pressure valve cover 2 and water pressure valve 3. INSPECTION Inspect water pressure valve and valve cover for salt deposits, corrosion, wear or other damage.
Page 231 POWER TRIM AND TILT POWER TRIM AND TILT CONTENTS SYSTEM WIRING DIAGRAM ________________________________ 8-2 SERVICE PROCEDURE ____________________________________ 8-3 OIL LEVEL ..................... AIR BLEEDING ....................POWER TRIM AND TILT UNIT _______________________________ 8-4 REMOVAL ...................... DISASSEMBLY ....................INSPECTION ....................REASSEMBLY ....................8-10 PTT MOTOR ....................
Page 232: System Wiring Diagram
POWER TRIM AND TILT SYSTEM WIRING DIAGRAM PTT switch PTT motor relay (UP) W tube PTT motor To ignition switch Remote control box PTT motor relay (DOWN) Fuse 60A Starter motor magnetic switch Fuse 30A Main relay PTT switch Battery...
Page 233: Service Procedure
POWER TRIM AND TILT SERVICE PROCEDURE OIL LEVEL To check PTT oil level : 1. Raised engine to a full-tilt position. 2. Lower manual tilt lock lever 1. 3. Remove oil filler plug 2. 4. If oil can be seen at filler plug level, unit is full. 5.
Page 234: Power Trim And Tilt Unit
POWER TRIM AND TILT POWER TRIM AND TILT UNIT REMOVAL Raise engine to the full tilt position and lower manual tilt lock levers 1. During the following procedures, the engine must be firmly secured and its weight fully supported. (See right) 1.
Page 235: Disassembly
POWER TRIM AND TILT 6. Remove PTT cylinder lower shaft bolts 6. 7. Remove two bolts and anode 7. 8. Slide STBD clamp bracket 8 off clamp bracket shaft, then remove PTT unit. DISASSEMBLY NOTE: Before disassembly, wash PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry PTT body with compressed air.
Page 236 POWER TRIM AND TILT 5. Remove manual release valve snap ring 5, then remove manual release valve 6. 6. Remove three bolts securing PTT pump case 7, then detach PTT pump case from PTT body. Note position of O-rings and remove them. O-ring 7.
Page 237: Inspection
POWER TRIM AND TILT INSPECTION Arrange all components on a clean sheet of paper. NOTE: Do not lay PTT components out on a rag, as dirt or lint may be transferred to these items which may cause possible system operating problems. NOTE: If excessive wear, cracks, defective or other damage is found on any component, replace component.
Page 238 POWER TRIM AND TILT • Inspect manual release valve for damage. Replace if necessary. • Inspect O-rings for cuts, nicks or tears. • Inspect lower shaft and upper shaft for bent, twist or other damage. Replace if necessary. • Inspect all bushings for excessive wear or other damage. Replace if necessary.
Page 239: Reassembly
POWER TRIM AND TILT REASSEMBLY Assembly is reverse order of disassembly with special atten- tion to the following steps. • Do not re-use O-ring and seal once removed. Always use new parts. • Lubricate all components and O-rings with PTT fluid before assembly.
Page 240: Ptt Motor
8-10 POWER TRIM AND TILT PTT MOTOR See PTT MOTOR INSTALLATION section on page 8-14. AIR BLEEDING • Pour recommended PTT fluid in to reservoir until specified level. • Perform air bleeding procedure. See AIR BLEEDING section on page 8-3. PTT MOTOR PTT MOTOR REMOVAL NOTE:...
Page 241: Ptt Motor Disassembly
POWER TRIM AND TILT 8-11 PTT MOTOR DISASSEMBLY Protector 1. For correct assembly, scribe an alignment mark on field case tube and brush holder. 2. Remove tape from PTT motor cables and cable protector tube, then slide cable protector tube upward. 3.
Page 242: Ptt Motor Inspection
8-12 POWER TRIM AND TILT PTT MOTOR INSPECTION Armature and Commutator 1. Inspect continuity between commutator and armature core / shaft. If continuity exists, replace armature. 09930-99320 : Digital tester Tester range : (Continuity) 2. Inspect continuity between adjacent commutator segments. If no continuity exists, replace armature.
Page 243: Ptt Motor Assembly
PTT motor cables out of field case. 4. Apply Silicone Seal to PTT motor cable holder and grom- mets, then install cable holder screw. 99000-31120 : Suzuki Silicone Seal 5. Fix cable protector tube to PTT motor cables with heat-re- sisting tape.
Page 244: Ptt Motor Installation
8-14 POWER TRIM AND TILT PTT MOTOR INSTALLATION Installation is reverse order of removal with special attention to the following steps. 1. Ensure that drive joint 1 is aligned and firmly inserted into Armature shaft Armature shaft gear pump assembly. 2.
Page 245: Installation
POWER TRIM AND TILT 8-15 INSTALLATION Installation is reverse order of removal with special attention to the following steps. 1. Lower tilt rod to full down position. 2. Apply Water Resistant Grease to tilt cylinder lower shaft and lower shaft bushes. 3.
Page 246 8-16 POWER TRIM AND TILT 8. Apply Water Resistant Grease to tilt rod upper bushings 6, then install bushings in tilt rod. 9. Operate PTT motor to extend PTT rod upward. Align tilt rod with hole in swivel bracket as tilt rod extends. 99000-25161 : Water Resistant Grease 10.
Page 247: Ptt Motor Relay
POWER TRIM AND TILT 8-17 PTT MOTOR RELAY Two methods can be used to test PTT motor relays. PTT motor relay PTT motor relay Method 1. Lbl(P) Measure resistance between two lead wires of relay. 09930-99320 : Digital tester Tester range : Ω Ω Ω Ω Ω (Resistance) Tester probe connection Red + + + + + Black - - - - -...
Page 248: Ptt Switch
8-18 POWER TRIM AND TILT PTT SWITCH Test continuity between switch lead wires at each of three switch (W/R) positions. 09930-99320 : Digital tester Tester range : (Continuity) Tester probe connection Continuity Red + + + + + Black - - - - - “DN”...
Page 249: Operation
POWER TRIM AND TILT 8-19 OPERATION The power trim and tilt system is operated by a “rocker” type switch (protected by a rubber thumb pad) on top of the remote control box handle. When the switch is depressed, power is delivered to the electric motor via the relevant relay. The relay with the Blue wire connected to the PTT pump is for trim / tilt “UP”, while the relay with the Green wire is for trim / tilt “DOWN”.
Page 250: Principles Of Operation
8-20 POWER TRIM AND TILT PRINCIPLES OF OPERATION TRIM / TILT “UP”CIRCUIT When the PTT switch is operated “UP” position, the electric motor and gear pump 4 will operation on clock- wise direction. Pressurized oil will open check valve A, oil will flow from reservoir to spool valve A via pump and spool valve The spool valve A will down, then “DOWN”...
Page 251 POWER TRIM AND TILT 8-21 TRIM / TILT “DOWN” CIRCUIT When the PTT switch is operated “DOWN” position, the electric motor and gear pump will operation on counterclockwise direction. Check valve B will open ; oil will flow from reservoir to spool valve A. It makes spool valve B move to downward, then “UP”...
Page 252 8-22 POWER TRIM AND TILT SHOCK ABSORBER CIRCUIT ( i ) Shock valve Should the lower unit strike an underwater object whilst in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber. The shock valve will then open, allowing oil to flow into the area between the tilt ram piston and the free piston, thereby dampening (absorbing) the impact.
Page 253 POWER TRIM AND TILT 8-23 MANUAL RELEASE CIRCUIT (MANUAL VALVE) Operation : Turn manual valve maximum three (3) full turns counterclockwise. When the manual valve is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again.
Page 254 8-24 POWER TRIM AND TILT THERMAL VALVE As temperature goes up, oil pressure will increase and the oil in PTT unit will expand. High oil pressure in the upper cylinder chamber caused by rising of outside temperature will release thermal valve and make the oil flow to reservoir to prevent from damaging of PTT unit.
Page 255 LOWER UNIT 9-1 LOWER UNIT CONTENTS REMOVAL & DISASSEMBLY ________________________________ 9-2 PINION BEARING ________________________________________ 9-7 INSPECTION ____________________________________________ 9-9 PROPELLER ....................GEARCASE ....................9-10 GEARS ......................9-10 PROPELLER SHAFT COMPONENTS ............9-10 PROPELLER SHAFT BEARING HOUSING ..........9-11 SHIFT ROD GUIDE HOUSING COMPONENTS ........... 9-11 WATER PUMP AND RELATED ITEMS ............
Page 256: Removal & Disassembly
LOWER UNIT REMOVAL & DISASSEMBLY Always disconnect the battery cable, before remov- ing lower unit. 1. Shift to “NEUTRAL” position. 2. Remove bolt and trim tab 1. 3. Remove seven ( 7 ) bolts 2 and separate gearcase 3 from driveshaft housing.
Page 257 LOWER UNIT 6. Remove cotter pin 7 from propeller nut and remove pro peller nut 8. 7. Remove washer 9, spacer 0, propeller A, stopper B and spacer C from propeller shaft. To prevent injury from propeller blades, wear gloves and place a block of wood between the anti-cavitation plate and the propeller blade tips to lock the propeller in place.
Page 258 LOWER UNIT 11. Remove two bolts 1 securing propeller shaft bearing housing to gearcase. 12. Using special tools, draw out propeller shaft bearing housing. Remove propeller shaft and bearing housing assembly. 09930-30104 : Sliding hammer A 09930-30161 : Propeller shaft remover B 13.
Page 259 LOWER UNIT 16. Remove pinion gear 1. Remove forward gear 2 (with thrust washer 5, back-up shim 4 and bearing 3). 17. Remove three bolts 1 securing shift cam housing, then remove shift cam housing 2. Account for dowel pins. Disassembly of propeller shaft components 1.
Page 260 LOWER UNIT 5. Remove clutch dog shifter 9 and connector pin 0 from propeller shaft. Disassembly of shift rod components 1. Remove circlip 1 and washer 2. 2. Slide shift rod 3 out of shift rod guide housing. 3. Remove detent ball 4 and spring 5. 4.
Page 261: Pinion Bearing
LOWER UNIT PINION BEARING Removal / installation is in following procedure. Removal & Installation Tools 09951-59910 : Shaft (removal & installation) 1 09551-39914 : plate 2 01500-08403 : Bolt 3 09951-19421 : Attachment 4 09917-98221 : Spacer 5 09930-30104 : Sliding hammer 6 REMOVAL 1.
Page 262 LOWER UNIT INSTALLATION • Before installing bearing, ensure that inside of gearcase is clean and free of debris. • Ensure that the bearing stamped mark faces upward. 1. Set shaft 1, plate 2, spacer 5, attachment 4 and pinion bearing as shown in figure. 2.
Page 263: Inspection
LOWER UNIT INSPECTION NOTE: If excessive ware, cracks, defective or other damage is found on any component, replace component. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety grasses when using compressed air. PROPELLER •...
Page 264: Gears
9-10 LOWER UNIT GEARS • Inspect forward, reverse and pinion gear teeth and engag- ing dogs for excessive wear or other damage. Replace if necessary. • Inspect forward gear bearing for pitting, rough or other dam- age. Replace if necessary. PROPELLER SHAFT COMPONENTS •...
Page 265: Shift Rod Guide Housing Components
LOWER UNIT 9-11 Replacing propeller shaft oil seal 1. Remove retaining ring 1 and washer 2. 2. Extract oil seals 3 using oil seal remover. 09913-50121 : Oil seal remover Do not re-use oil seal once removed. Always use a new oil seal. 3.
Page 266: Driveshaft Oil Seal Housing
9-12 LOWER UNIT DRIVESHAFT OIL SEAL HOUSING • Inspect housing for cracks or other damage. Replace if nec- essary. • Inspect oil seals and O-ring for wear, cuts, nicks or tears. Replacing driveshaft oil seal 1. Extract oil seals using oil seal remover. 09913-50121 : Oil seal remover 2.
Page 267: Assembly & Installation
LOWER UNIT 9-13 ASSEMBLY & INSTALLATION Assembly & Installation are reverse order of disassembly with special attention to the following steps. 1 1 1 1 1 Dust seal 2 2 2 2 2 Shift rod guide housing 3 3 3 3 3 Bolt 4 4 4 4 4 Ball 5 5 5 5 5 Spring 6 6 6 6 6...
Page 268 9-14 LOWER UNIT 55 N . m (5.5 kg-m, 40.0 lb.-ft.) 20 N . m 100 N . m (2.0 kg-m, 14.5 lb.-ft.) (10.0 kg-m, 72.5 lb.-ft.) 13 N . m (1.3 kg-m, 9.5 lb.-ft.) } } } } } Propeller shaft ~ ~ ~ ~ ~ Thrust washer ;...
Page 269 Install dowel pins 1 and shift cam housing 2, then tighten three bolts 3 securely. FORWARD GEAR Place forward gear bearing 3 and back-up shim 2 in position, then install forward gear 1. 99000-22540 : Suzuki Outboard Motor Gear Oil PINION GEAR Place pinion gear in gearcase.
Page 270 9-16 LOWER UNIT DRIVESHAFT 1. Assemble washer 1, washer (with tab) 2, wave washer 3, washer 4 and driveshaft collar 5 to driveshaft. 2. After installing driveshaft collar, fit convex part of collar in concave part of driveshaft by turning collar. 3.
Page 271 LOWER UNIT 9-17 PINION NUT Apply Thread Lock 1342 to threads of pinion nut, then tighten nut to specified torque. Pinion nut : 100 N . m (10.0 kg-m, 72.5 lb.-ft.) 99000-32050 : Thread Lock 1342 09921-29410 : Drive shaft holder CHECKING DRIVESHAFT THRUST PLAY Before installing reverse gear, driveshaft thrust play should be checked.
Page 272 Reverse gear 2, Reverse gear back-up shim 3, Propeller shaft housing 4. 99000-25161 : Water Resistant Grease 99000-22540 : Suzuki Outboard Motor Gear Oil 2. Assemble horizontal slider 6 to connector pin. 3. Using special tools, install propeller shaft and housing assembly in gear case.
Page 273 LOWER UNIT 9-19 CHECKING PROPELLER SHAFT THRUST PLAY See page 9-28. SHIFT ROD GUIDE HOUSING 1. Install spring 2 and detent ball 3 into shift rod guide housing. 2. Apply Water Resistant Grease to shift rod oil seal. 99000-25161 : Water Resistant Grease 3.
Page 274 9-20 LOWER UNIT 5. Install shift rod guide housing assembly by aligning shifter yoke with groove in horizontal slider, then tighten three housing bolts securely. 6. Turn shift rod from neutral position to forward and reverse position to check proper gear engagement. Horizontal slider Shifter yoke LEAKAGE CHECK...
Page 275 LOWER UNIT 9-21 WATER PUMP 1. Place dowel pins 1, under panel gasket 2 and under panel 3 into position. 2. Insert key 4 in driveshaft and slide impeller 5 onto driveshaft, ensuring that key and keyway are aligned. 3. Install pump case 6 while rotating driveshaft clockwise to flex impeller vanes in correct direction.
Page 276 3. Insert two dowel pins 3. 4. Apply driveshaft splines and shift rod splines with Water Resistant Grease. 5. Apply Suzuki Silicone Seal lightly to mating surfaces of gearcase and driveshaft housing. 6. Set clutch control lever 4 at neutral position, then slide...
Page 277: Trim Tab
LOWER UNIT 9-23 TRIM TAB Trim tab counteracts or minimizes propeller torque “pull” felt through steering system. If steering is pulled to starboard or port side, adjust trim tab with following procedure : Adjusting 1. Loosen bolt of trim tab. 2.
Page 278: Lower Unit Gears-Shimming And Adjustment
9-24 LOWER UNIT LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT If lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be adjusted to ensure smooth, reliable operation of gears. Shim / Washer & Mounting position Design Available Numerical...
Page 279 LOWER UNIT 9-25 5. Depress and hold driveshaft so that driveshaft bearing is firmly seated in bearing outer race. 6. Hold driveshaft against oil seal housing 3 while measur- ing clearance B between gauge and flat edge of pinion gear 4 with thickness gauge. 7.
Page 280 9-26 LOWER UNIT 2. Install propeller shaft and housing assembly (minus reverse gear and internal components). Push 3. Push propeller shaft inward and hold in position. 4. Using driveshaft holder, rotate driveshaft 5 - 6 times. 09921-29410 : Driveshaft holder 5.
Page 281 LOWER UNIT 9-27 CHECKING DRIVESHAFT THRUST PLAY After obtaining optimum tooth contact, driveshaft thrust play should be measured. 1. Affix gear adjusting gauge to driveshaft. 09951-09530 : Gear adjusting gauge 2. Slowly push driveshaft downward and read maximum play. Designate this amount of play as (A). Driveshaft thrust play : Approx.
Page 282 9-28 LOWER UNIT CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure propeller shaft thrust play. If not within following specification, a shim adjustment is required. Propeller shaft thrust play : 0.2 – 0.4 mm (0.01 – 0.02 in.) NOTE: Maintain forward gear thrust washer at standard thickness (3.0 mm) and adjust only reverse gear thrust washer with shim.
Page 283 WIRE / HOSE ROUTING 10-1 WIRE / HOSE ROUTING CONTENTS WIRING DIAGRAM ________________________________________ 10-2 WIRE ROUTING __________________________________________ 10-3 FUEL / WATER HOSE ROUTING _____________________________ 10-8...
Page 284 10-2 WIRE / HOSE ROUTING WIRING DIAGRAM DF90T / DF115T...
Page 285 WIRE / HOSE ROUTING 10-3 WIRE ROUTING...
Page 286 10-4 WIRE / HOSE ROUTING...
Page 287 WIRE / HOSE ROUTING 10-5...
Page 288 10-6 WIRE / HOSE ROUTING...
Page 289 WIRE / HOSE ROUTING 10-7...
Page 290 10-8 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 291 WIRE / HOSE ROUTING 10-9...
Page 292 10-10 WIRE / HOSE ROUTING...
Page 293 WIRE / HOSE ROUTING 10-11 Breather hose / Protector 3-way joint High pressure fuel filter Fuel delivery pipe union 60˚ Fuel injector Silencer Fuel hose / Protector (Low pressure fuel pump to Fuel vapor separator) Upper union bolt 35 N . m(3.5 kg-m, 25.5 lb-ft) Fuel injector Fuel delivery pipe Fuel injector...
Page 294: Specifications _________________________________________ 1
DF140 “K2” (’02) MODEL 11-1 DF140 “K2” (’02) MODEL CONTENTS GENERAL INFORMATION ______________________________________ 11-2 SPECIFICATIONS _________________________________________ 11-2 SERVICE DATA ___________________________________________ 11-4 TIGHTENING TORQUE _____________________________________ 11-11 SPECIAL TOOLS __________________________________________ 11-13 MATERIALS REQUIRED ___________________________________ 11-16 ENGINE CONTROL SYSTEM ____________________________________ 11-17 POWER UNIT _________________________________________________ 11-18 ENGINE OIL COOLER _____________________________________ 11-18...
Page 295: General Information
11-2 DF140 “K2” (’02) MODEL GENERAL INFORMATION *SPECIFICATIONS These specifications are subject to change without notice. Data Item Unit DF140T DF140Z 14001F PRE-FIX 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 296 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/Imp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/Imp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 297: Service Data
11-4 DF140 “K2” (’02) MODEL Data Item Unit DF140T DF140Z REDUCTION SYSTEM 1st reduction gear ratio 29 : 36 (1.24) (Crankshaft drive gear: Driven gear) 2nd reduction gear ratio 12 : 23 (1.92) (Lower unit gear) Total reduction gear ratio 36 ×...
Page 298 DF140 “K2” (’02) MODEL 11-5 Data Item Unit DF140T DF140Z CYLINDER HEAD / CAMSHAFT Cylinder head distortion mm (in) Limit 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 299 11-6 DF140 “K2” (’02) MODEL Data Item Unit DF140Z DF140T VALVE / VALVE GUIDE mm (in) Valve diameter 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) Valve seat angle °...
Page 300 DF140 “K2” (’02) MODEL 11-7 Data Item Unit DF140Z DF140T CYLINDER / PISTON / PISTON RING mm (in) Cylinder distortion Limit 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 86.000 –...
Page 301 11-8 DF140 “K2” (’02) MODEL Data Item Unit DF140T DF140Z CRANKSHAFT / CONROD Conrod small end 21.003 – 21.011 (0.8269 – 0.8272) mm (in) inside diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance mm (in) Limit 0.065 (0.0026) Conrod big end...
Page 302 DF140 “K2” (’02) MODEL 11-9 Data Item Unit DF140T DF140Z ELECTRICAL Degrees BTDC 5° – BTDC 45° Ignition timing r/min 6500 Over revolution limiter Ω 168 – 252 CKP sensor resistance at 20°C Ω CMP sensor resistance at 20°C Ω Primary 1.9 –...
Page 303 11-10 DF140 “K2” (’02) MODEL PTT MOTOR mm (in) Brush length 9.8 (0.39) mm (in) 5.0 (0.20) Limit mm (in) 22.0 (0.87) Commutator outside diameter Limit 21.0 (0.83) mm (in) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 304: Tightening Torque
DF140 “K2” (’02) MODEL 11-11 TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib-ft Cylinder head cover bolt 6 mm 8 mm 16.5 Cylinder head bolt 10 mm 50.5 18.0 8 mm Crankcase bolt 10 mm 40.5...
Page 305 11-12 DF140 “K2” (’02) MODEL Tightening torque – general bolt NOTE: These values are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N . m kg-m Ib-ft 2 –...
Page 306: Special Tools
DF140 “K2” (’02) MODEL 11-13 SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) (A) 09900-06107 09900-00410 Hexagon socket Hexagon bit (B) 09900-06108 Hexagon wrench set (included in 09900-00410) (included in 09900-00410) Snap ring pliers 09900-20101 (150 mm) 09900-20203 (50 – 75 mm) 09900-20205 09900-20102 (200 mm) 09900-20202...
Page 307 11-14 DF140 “K2” (’02) MODEL 09915-67010 09915-47332 Compression 09915-64530 09915-64512 Oil filter wrench gauge hose attachment Compression gauge hose Compression gauge 09916-10911 09916-19030 09915-77311 09915-78211 Valve lapper Valve lifter Oil pressure gauge Oil pressure gauge adapter 09916-22420 Solid pilot 09916-14910 09916-54910 Valve seat cutter (60°) (Neway N-120-6.0)
Page 308 DF140 “K2” (’02) MODEL 11-15 (A) 09922-59410 Propeller shaft housing 09917-98221 installer Valve guide stem seal (B) 09922-59420 09922-89810 09930-30161 installer attachment Housing installer handle Shift lock pin remover Propeller shaft remover 09930-39411 09930-30104 09930-39420 09930-48720 Flywheel rotor remover Sliding hammer Rotor remover bolt Flywheel holder 09930-89240...
Page 309: Materials Required
*99000-25030 99000-22540 99000-25011 99000-25161 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1207B” THREAD LOCK “1342” THREAD LOCK SUPER “1333B” * 99104-33140 99000-32050 99000-32020 99000-31140 (50 g) (50 g) (100 g) 4-Stroke Motor Oil...
Page 310: Engine Control System
BTDC 10° ± 5° OVER REVOLUTION LIMITER The over-rev detecting speed is as follows: • DF140: 6500 rpm SUZUKI DIAGNOSTIC SYSTEM The database specially provided for DF140 needs to be added to the program ver. 4 currently used. FLYWHEEL MAGNETO...
Page 311: Power Unit
11-18 DF140 “K2” (’02) MODEL POWER UNIT ENGINE OIL COOLER To keep a engine oil temp. properly and to show its optimum engine performance, a engine oil cooler was installed. The water flow to cool the engine oil is shown in the figure. Bottom side PIPING...
Page 312 DF140 “K2” (’02) MODEL 11-19 Removal 1. Remove the STBD side lower cover. 2. Using oil filter wrench to loosen the oil filter 1, then remove engine oil filter and O-ring. 09915-47332: Oil filter wrench 3. Disconnect both inlet 2 and outlet 3 water hoses from engine oil cooler.
Page 313: Camshaft
11-20 DF140 “K2” (’02) MODEL 3. Install oil filter stand 3, then tighten filter stand to specified torque. Oil filter stand: 40 N . m (4.0 kg-m, 29 lb-ft) Connect inlet 4 and outlet 5 water hoses to each fitting of engine oil cooler.
Page 314: Cylinder Block
DF140 “K2” (’02) MODEL 11-21 CYLINDER BLOCK The cylinder bore is different from DF90/115. The diameter for the cylinder of DF140 has become as the fol- lowing. Cylinder bore Standard: 86.000 – 86.020 mm (3.3858 – 3.3866 in.) PISTON & PISTON RING Piston and piston ring diameters are different from DF90/115.
Page 315: Crankshaft
11-22 DF140 “K2” (’02) MODEL CRANKSHAFT The crankshaft for DF140 is different from that for DF90/115. To identify the crankshaft for each different model, check for the shape on the upper part of crankshaft (tapered portion). (See right illustrations.) CONROD ASSEMBLY Conrod bolts and nuts are different between DF140 and DF90/ 115.
Page 316: Mid Unit
DF140 “K2” (’02) MODEL 11-23 MID UNIT Upper mount Main components of DF140 are the same as those of DF90/ 115, but the followings are different. • Upper mount and Lower mount are different between DF90/ 115 and DF140. DF140 mounts are harder than those of DF90/115. DF90/115 DF140 Lower mount...
Page 317 11-24 DF140 “K2” (’02) MODEL CLAMP BRACKET / SWIVEL BRACKET / STEERING BRACKET When disassembling or reassembling the components, refer to the construction diagram below. 43 N . m (4.3 kg-m, 31.0 lb-ft) 1 1 1 1 1 Clamp bracket STBD G G G G G Oil seal 2 2 2 2 2 Clamp bracket PORT H H H H H Washer...
Page 318: Power Trim And Tilt
DF140 “K2” (’02) MODEL 11-25 POWER TRIM AND TILT PTT unit of DF140 is new design and unit is 3 cylinder (two trim ram, one tilt rod) type. SERVICE PROCEDURE OIL LEVEL To check the oil level: 1. Raised the engine to a full-tilt position. 2.
Page 319: Power Trim And Tilt Unit
11-26 DF140 “K2” (’02) MODEL POWER TRIM AND TILT UNIT REMOVAL Raise the engine to the full tilt position and lower the manual tilt lock levers 1. During the following procedures, the engine must be firmly secured and its weight fully supported. (See right) Remove the tilt rod snap ring 2 and push tilt cylinder upper shaft pin 3 out.
Page 320: Disassembly
DF140 “K2” (’02) MODEL 11-27 Remove the PTT cylinder lower shaft bolts 6. Remove the two (2) bolts and anode 7. Slide the STBD clamp bracket 8 off the clamp bracket shaft, then remove the PTT unit. 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.
Page 321 11-28 DF140 “K2” (’02) MODEL Remove the PTT motor assembly. (See page 11-33) Note the position of drive joint 3 and O-ring 4, before remov- motor ing them. Remove the manual release valve snap ring 5, then unscrew the manual release valve 6. Remove the three (3) screws securing the PTT pump case 7, then detach the PTT pump case from PTT cylinder body.
Page 322 DF140 “K2” (’02) MODEL 11-29 Pull the tilt rod/piston assembly 1 out of the cylinder body. Remove the free piston 2 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 323: Cleaning And Inspecting
11-30 DF140 “K2” (’02) MODEL CLEANING AND INSPECTING Thoroughly wash all metal components with cleaning solvent and dry them with compressed air. Arrange all components on a clean sheet of paper. NOTE: Do not lay PTT components out on a rag, as dirt or lint may be transferred to these items which may cause possible system operating problems.
Page 324: Reassembly
DF140 “K2” (’02) MODEL 11-31 REASSEMBLY Assembly is reverse order of disassembly with special atten- tion 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 325 11-32 DF140 “K2” (’02) MODEL TRIM ROD 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. Tighten the trim cylinder head to specified torque using special tool.
Page 326: Ptt Motor
DF140 “K2” (’02) MODEL 11-33 PTT MOTOR Removal NOTE: Before removing PTT motor, 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 mounting eye of the PTT cylinder in a vise. Tighten the vise only enough to secure the PTT unit, do not over tighten.
Page 327 11-34 DF140 “K2” (’02) MODEL Remove the two (2) screws 3 securing the field case to the brush holder. Slide the field case upward and away from the brush holder. NOTE: When separating field case from brush holder, proceed by push- ing PTT motor cables into brush holder side.
Page 328 DF140 “K2” (’02) MODEL 11-35 Inspect the commutator surface. If surface is gummy or dirty, clean with 400 grit emery paper. Measure commutator outside diameter. 09900-20101: Vernier calipers Commutator outside diameter: Standard 22.0 mm (0.87 in.) Service limit 21.0 mm (0.83 in.) If measurement exceeds service limit, replace armature.
Page 329 11-36 DF140 “K2” (’02) MODEL Assembly Assembly is reverse of disassembly with special attention to O-ring following steps. • Install armature to brush holder first. When installing the armature, exercise care not to break the brushes. • Match up previously scribed alignment marks. •...
Page 330: Installation
DF140 “K2” (’02) MODEL 11-37 INSTALLATION Installation is reverse order of removal with special attention to the following steps. Lower tilt rod to full down position. Apply Water Resistant Grease to the tilt cylinder lower shaft and lower shaft bushes. Install bushes 1 and cylinder lower shaft 2 to PTT unit.
Page 331 11-38 DF140 “K2” (’02) MODEL Apply Water Resistant Grease to tilt rod upper bushes 6, then install bushes in tilt rod. Operate the PTT motor to extend the PTT rod upward. Align the tilt rod with the hole in the swivel bracket as the tilt rod extends.
Page 332: Component Parts
DF140 “K2” (’02) MODEL 11-39 COMPONENT PARTS 1 Down shuttle valve 2 Down check valve 3 Up shuttle valve 4 Up check valve 5 Down relief orifice 6 Down relief check valve 7 Pump room orifice 8 Tank room orifice 9 Up relief valve * When the manual valve is to be opened, turn the manual release valve to the left about two turns.
Page 333 11-40 DF140 “K2” (’02) MODEL 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 334 DF140 “K2” (’02) MODEL 11-41 TILT DOWN / TRIM IN (1) When the PTT switch is operated in the “DOWN” position, the motor and gear pump will rotate in a counterclockwise direction. (2) The oil pressure will open the “Down” check valve D and oil will be forced through the “Down” shuttle valve E.
Page 335 11-42 DF140 “K2” (’02) MODEL 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 336 DF140 “K2” (’02) MODEL 11-43 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 I 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 337 11-44 DF140 “K2” (’02) MODEL 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 trim and tilt pistons will be directed through this valve into the area above the tilt rod piston.
Page 338 DF140 “K2” (’02) MODEL 11-45 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 cylinder.
Page 339: Lower Unit (Normal Rotation Model)
11-46 DF140 “K2” (’02) MODEL LOWER UNIT (Normal rotation model) REMOVAL AND INSTALLATION Refer to the procedures in DF90/115 service manual. Always disconnect the battery cable, before removing lower unit. DISASSEMBLY Place a drain pan under the oil drain plug. Remove oil drain plug 1 first then oil level plug 2 and allow gear oil to drain.
Page 340 DF140 “K2” (’02) MODEL 11-47 Remove the impeller 3, impeller key 6, pump under plate 4 and dowel pins 5. Keep the impeller key 6 for reuse and discard the plate gas- ket. Remove three ( 3 ) bolts 1 and shift rod guide housing assem- bly 2.
Page 341 11-48 DF140 “K2” (’02) MODEL Unscrew the four ( 4 ) bolts 1 securing driveshaft oil seal hous- ing 2, then remove oil seal housing and pinion shim 3. Lift out driveshaft assembly 4. Remove the driveshaft collar 5, washer 6, wave washer 7, washer (with tab) 8 and washer 9 from driveshaft.
Page 342 DF140 “K2” (’02) MODEL 11-49 Disassembly of propeller shaft components Slide propeller shaft away from reverse gear 3 and bearing housing assembly 1. Account for the reverse gear back-up shim 2 and reverse gear thrust washer 4. To disassemble propeller shaft components, refer to the follow- ing: (a) Remove horizontal slider 5 and forward gear thrust washer (b) Remove the spring 7 from the clutch dog shifter.
Page 343 11-50 DF140 “K2” (’02) MODEL (c) Remove the detent ball 4 and spring 5. (d) Remove the pin 6 and shifter yoke 7.
Page 344: Assembly
DF140 “K2” (’02) MODEL 11-51 ASSEMBLY Assembly is reverse of disassembly with special attention to following steps. 1 1 1 1 1 Oil seal 2 2 2 2 2 Shift rod guide housing 3 3 3 3 3 Bolt 4 4 4 4 4 Ball 5 5 5 5 5 Spring 6 6 6 6 6 Notch plate 7 7 7 7 7 O-ring...
Page 345 11-52 DF140 “K2” (’02) MODEL 55 N . m (5.5 kg-m, 40.0 lb-ft) 20 N . m (2.0 kg-m, 14.5 lb-ft) 120 N . m (12.0 kg-m, 87.0 lb-ft) 13 N . m (1.3 kg-m, 9.5 lb-ft) } } } } } Propeller shaft ~ ~ ~ ~ ~ Thrust washer ;...
Page 346 • Install dowel pin 1 and forward gear bearing housing 2. FORWARD GEAR Place the forward gear back-up shim 1, thrust washer 2, for- ward gear thrust bearing 3 in position, then install forward gear 99000-22540: Suzuki Outboard Motor Gear Oil PINION GEAR Place pinion gear in gearcase.
Page 347 11-54 DF140 “K2” (’02) MODEL DRIVESHAFT • Assemble the washer 1, washer (with the tab) 2, wave washer 3, washer 4 and driveshaft collar 5 to the driveshaft. • After installing driveshaft collar, fit the convex part of the col- lar in the concave part of the driveshaft by turning collar.
Page 348 DF140 “K2” (’02) MODEL 11-55 PINION NUT Apply Thread Lock 1342 to the threads of the pinion nut before threading it onto the driveshaft. Tighten nut to the specified torque. Pinion nut: 120 N . m (12.0 kg-m, 87.0 lb-ft) 99000-32050: Thread Lock 1342 09921-29410: Driveshaft holder CHECKING DRIVESHAFT THRUST PLAY...
Page 349 2, reverse gear back-up shim 3 and propeller shaft hous- ing 4. 99000-25161: Water Resistant Grease 99000-22540: Suzuki Outboard Motor Gear Oil Assemble horizontal slider 6 to connector pin. Using special tools, install the propeller shaft and housing assembly in the gear case.
Page 350 DF140 “K2” (’02) MODEL 11-57 CHECKING PROPELLER SHAFT THRUST PLAY See the “GEARS - SHIMMING AND ADJUSTMENT/CHECK- ING PROPELLER SHAFT THRUST PLAY” section on page 11-65. SHIFT ROD GUIDE HOUSING • Install the spring 1 and detent ball 2 into shift rod guide housing.
Page 351 11-58 DF140 “K2” (’02) MODEL • Install the shift rod guide housing assembly 7 by aligning the shifter yoke with the groove in the horizontal slider, then tighten three ( 3 ) housing bolts securely. • Shift the shift rod from Neutral through Forward and Reverse to check proper gear engagement.
Page 352 DF140 “K2” (’02) MODEL 11-59 LEAKAGE CHECK Check for leakage of oil seal and O-ring when applying speci- fied pressure inside of the gearcase. 09950-69511 : Oil leakage tester 09952-99310 : Air pump Procedure 1. Install the test tool into the oil level hole. 2.
Page 353 99000-25161: Water Resistant Grease Propeller nut: 55 N . m (5.5 kg-m, 40.0 lb-ft) GEAR OIL Fill the gearcase with specified gear oil for initial testing and recheck the level after 10 minutes. Top up if necessary. 99000-22540: Suzuki Outboard Motor Gear Oil...
Page 354: Lower Unit Gears-Shimming And Adjustment
DF140 “K2” (’02) MODEL 11-61 LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT (Normal 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 adjusted to ensure smooth, reliable operation of gears. Shim/Washer &...
Page 355 11-62 DF140 “K2” (’02) MODEL (6) Hold driveshaft against oil seal housing 3 while measuring clearance B between gauge and flat edge of pinion gear 4 with thickness gauge, measured clearance plus shim 2 is the total shim thickness to be used in gear housing reas- sembly for correct pinion gear position.
Page 356 DF140 “K2” (’02) MODEL 11-63 2. Install propeller shaft and housing assembly (minus reverse gear and internal components). 3. Push propeller shaft inward and hold in position. Push 4. Using driveshaft holder tool, rotate the driveshaft 5 – 6 times. 09921-29410: Driveshaft holder 5.
Page 357 11-64 DF140 “K2” (’02) MODEL CHECKING DRIVESHAFT THRUST PLAY After obtaining optimum tooth contact, driveshaft thrust play should be measured. 1. Affix gear adjusting gauge to driveshaft. 09951-09530: Gear adjusting gauge 2. Slowly push driveshaft downward. Read the maximum play. Designate this amount of play as (A).
Page 358 DF140 “K2” (’02) MODEL 11-65 CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure the propeller shaft thrust play. If not within the following specification, a shim ad- justment is required. Propeller shaft thrust play: 0.2 – 0.4 mm (0.008 –...
Page 359: Counter Rotation Lower Unit (Df140Z)
For counter-rotation model, newly designed stainless steel pro- Blade × Diam. (in.) × Pitch (in.) pellers are available as follows. × × Suzuki highly recommend to use the genuine Suzuki counter- × × rotation propeller for the counter rotation model. ×...
Page 360: Removal And Installation
DF140 “K2” (’02) MODEL 11-67 REMOVAL AND INSTALLATION Refer to the procedures in DF90/115 service manual. Always disconnect the battery cable, before removing lower unit. DISASSEMBLY Place a drain pan under the oil drain plug. Remove oil drain plug 1 first then oil level plug 2 and allow gear oil to drain.
Page 361 11-68 DF140 “K2” (’02) MODEL Remove the impeller 3, impeller key 6, pump under plate 4 and dowel pins 5. Keep the impeller key 6 for reuse and discard the plate gas- ket. Remove three ( 3 ) bolts 1 and shift rod guide housing assem- bly 2.
Page 362 DF140 “K2” (’02) MODEL 11-69 Unscrew the four ( 4 ) bolts 1 securing driveshaft oil seal hous- ing 2, then remove oil seal housing and pinion shim 3. Lift out driveshaft assembly 4. Remove the driveshaft collar 5, washer 6, wave washer 7, washer (with tab) 8 and washer 9 from driveshaft.
Page 363 11-70 DF140 “K2” (’02) MODEL Remove the reverse gear bearing housing 7 and dowel pin 8. Disassembly of propeller shaft components Slide propeller shaft away from forward gear 1 and bearing housing assembly 2. Remove the forward gear 3, forward gear thrust bearing 4, forward gear thrust washer 5, forward gear back-up shim 6.
Page 364 DF140 “K2” (’02) MODEL 11-71 (c) Use special tool to push the dog pin D out of the clutch dog shifter. 09922-89810: Shift pin remover (d) Remove the clutch dog shifter E and connector pin F from propeller shaft. Disassembly of shift rod components (a) Remove the circlip 1 and washer 2.
Page 365: Inspection
11-72 DF140 “K2” (’02) MODEL INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety grasses when using compressed air. PROPELLER •...
Page 366 DF140 “K2” (’02) MODEL 11-73 GEAR • Inspect forward, reverse and pinion gear teeth and engaging dogs. Replace gears if damaged or worn. • Inspect forward gear thrust bearing. Replace bearing if pit- ted, noisy or rough. PROPELLER SHAFT COMPONENTS •...
Page 367 11-74 DF140 “K2” (’02) MODEL Replacing propeller shaft oil seal 1. Remove the retaining ring 1 and washer 2. 2. Extract the seals 3 with oil seal remover. 09913-50121: Oil seal remover Do not reuse oil seal once removed. Always use new oil seal. 3.
Page 368 DF140 “K2” (’02) MODEL 11-75 DRIVESHAFT OIL SEAL HOUSING • Inspect housing. Replace if cracked or damaged. • Check condition of oil seals. Replace if nicked, cut or worn. • Inspect O-ring. Replace if worn, nicked or cut. Replacing driveshaft oil seal 1.
Page 369: Assembly
11-76 DF140 “K2” (’02) MODEL ASSEMBLY Assembly is reverse of disassembly with special attention to following steps. 1 1 1 1 1 Oil seal 2 2 2 2 2 Shift rod guide housing 3 3 3 3 3 Bolt 4 4 4 4 4 Ball 5 5 5 5 5 Spring 6 6 6 6 6 Notch plate 7 7 7 7 7 O-ring...
Page 370 DF140 “K2” (’02) MODEL 11-77 20 N . m (2.0 kg-m, 14.5 lb-ft) 55 N . m (5.5 kg-m, 40.0 lb-ft) 120 N . m (12.0 kg-m, 87.0 lb-ft) 13 N . m (1.3 kg-m, 9.5 lb-ft) / / / / / Thrust washer + + + + + Back-up shim 13 N .
Page 371 • Place R-gear back-up shim 1 and bearing thrust washer 2 in position. • Assemble the R-gear thrust bearing 3, reverse gear retainer 4 and reverse gear 5, then install reverse gear/retainer as- sembly. 99000-22540: Suzuki Outboard Motor Gear Oil PINION GEAR Place pinion gear in gearcase.
Page 372 DF140 “K2” (’02) MODEL 11-79 DRIVESHAFT • Assemble the washer 1, washer (with the tab) 2, wave washer 3, washer 4 and driveshaft collar 5 to the driveshaft. • After installing driveshaft collar, fit the convex part of the col- lar in the concave part of the driveshaft by turning collar.
Page 373 11-80 DF140 “K2” (’02) MODEL PINION NUT Apply Thread Lock 1342 to the threads of the pinion nut before threading it onto the driveshaft. Tighten nut to the specified torque. Pinion nut: 120 N . m (12.0 kg-m, 87.0 lb-ft) 99000-32050: Thread Lock 1342 09921-29410: Driveshaft holder CHECKING DRIVESHAFT THRUST PLAY...
Page 374 • Assemble the propeller shaft in the following sequence: 99000-25161 : 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 the groove on the propeller shaft bearing hous- ing.
Page 375 11-82 DF140 “K2” (’02) MODEL When the housing is fully seated, tighten both retaining bolts to the specified torque. Bearing housing bolt: 20 N . m (2.0 kg-m, 14.5 lb-ft) RECHECKING DRIVESHAFT THRUST PLAY Recheck the driveshaft thrust play. Driveshaft thrust play: Approx.
Page 376 DF140 “K2” (’02) MODEL 11-83 NOTE: Before install the shift unit (Shift rod guide housing assembly), be sure to put the horizontal slider in the neutral position. 1. Horizontal slider 2. R-Gear bearing housing 3. Shift rod center • Apply Water Resistant Grease to the shift rod guide housing O-ring.
Page 377 11-84 DF140 “K2” (’02) MODEL LEAKAGE CHECK Check for leakage of oil seal and O-ring when applying speci- fied pressure inside of the gearcase. 09950-69511 : Oil leakage tester 09952-99310 : Air pump Procedure 1. Install the test tool into the oil level hole. 2.
Page 378 99000-25161: Water Resistant Grease Propeller nut: 55 N . m (5.5 kg-m, 40.0 lb-ft) GEAR OIL Fill the gearcase with specified gear oil for initial testing and recheck the level after 10 minutes. Top up if necessary. 99000-22540: Suzuki Outboard Motor Gear Oil...
Page 379: Lower Unit Gears-Shimming And Adjustment (Counter Rotation Model)
11-86 DF140 “K2” (’02) MODEL 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 backlash will have to be adjusted to ensure smooth, reliable operation of gears. Shim/Washer &...
Page 380 DF140 “K2” (’02) MODEL 11-87 PINION GEAR BACK-UP SHIM ADJUSTMENT (1) Position the shimming gauge A horizontally in a vise and tighten vise securely. 09951-09010: Shimming gauge (2) Assemble the bearing outer race 1, back-up shim 2 and driveshaft oil seal housing 3 to the driveshaft. NOTE: Use a thinner pinion back-up shim 2 than the standard shim so that a clearance B exists.
Page 381 11-88 DF140 “K2” (’02) MODEL REVERSE GEAR BACK-UP SHIM ADJUSTMENT 1. Correctly assemble reverse gear bearing housing, reverse gear thrust bearing, reverse gear retainer, reverse gear, re- verse gear spacer, pinion gear, driveshaft assembly/oil seal housing and related components. 2. Tighten pinion nut to specified torque. Pinion nut: 120 N .
Page 382 DF140 “K2” (’02) MODEL 11-89 FORWARD GEAR BACK-UP SHIM ADJUSTMENT Follow the procedure below to adjust forward gear. Step to prior to adjustment 1. Correctly assemble reverse gear, driveshaft oil seal hous- ing, driveshaft, pinion gear and related components. (See page 11-78 –...
Page 383 11-90 DF140 “K2” (’02) MODEL Checking and adjusting tooth contact pattern (Pinion and Forward gear) Check tooth contact pattern by using the following procedure: (A) To assess tooth contact, apply a light coat of Prussian Blue on the convex surface of forward gear. (B) In accordance with step 1 –...
Page 384 DF140 “K2” (’02) MODEL 11-91 Example ( 2 ) EXAMPLE OF INCORRECT Incorrect bottom side toe contact: Bottom side toe contact Correction measures: • Increase thickness of forward gear shim. (• Slightly decrease pinion gear shim thickness.) HEEL Do not set tooth contact in this position (bottom side toe contact).
Page 385: Wiring Diagram
11-92 DF140 “K2” (’02) MODEL WIRING DIAGRAM DF140T/140Z...
Page 386: Hose Routing
DF140 “K2” (’02) MODEL 11-93 HOSE ROUTING Fuel hose/protector (3 way joint to H·Fuel filter) High pressure fuel filter 3 way joint Clamp Fuel hose/protector (3 way joint to fuel delivery pipe) Evaporation hose (Vapor separator to cylinder head cover) Fuel delivery pipe Water hose (Fuel return pipe to...
Page 387 DF90/115 “K2” (’02) MODEL 12-1 DF90/115 “K2” (’02) MODEL CONTENTS SPECIFICATIONS________________________________________ 12-2 SERVICE DATA __________________________________________ 12-4 TIGHTENING TORQUE ___________________________________ 12-11 MATERIALS REQUIRED __________________________________ 12-12 FUEL/WATER HOSE ROUTING _____________________________ 12-13 OVER-REVOLUTION CAUTION SYSTEM _____________________ 12-16 CRANK PIN AND CONROD BEARING _______________________ 12-16 CONROD ASSY AND BEARING ____________________________ 12-16 CRANKSHAFT AND FLYWHEEL ___________________________ 12-17 CAMSHAFT AND TAPPET SHIM ____________________________ 12-17...
Page 388: Specifications
12-2 DF90/115 “K2” (’02) MODEL These specifications are subject to change without notice. *SPECIFICATIONS Data Item Unit DF90T DF115T 09001F PRE-FIX 11501F DIMENSIONS & WEIGHT Overall length (front to back) 779 (30.7) mm (in) Overall width (side to side) mm (in) 481 (18.9) Overall height mm (in)
Page 389 5.5 (5.8 / 4.8) : Oil change only L (US/Imp. qt) 5.7 (6.0 / 5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/Imp. oz) 1050 (35.5 / 37.0)
Page 390: Service Data
12-4 DF90/115 “K2” (’02) MODEL These service data are subject to change without notice. *SERVICE DATA Data Item Unit DF90T DF115T POWERHEAD Recommended operating range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear : approx. 625) **Cylinder compression kPa (kg/cm , psi)
Page 391 DF90/115 “K2” (’02) MODEL 12-5 Data Item Unit DF115T DF90T CYLINDER HEAD / CAMSHAFT ** New “K2” service data Cylinder head distortion mm (in) Limit 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) **36.920 –...
Page 392 12-6 DF90/115 “K2” (’02) MODEL Data Item Unit DF115T DF90T VALVE / VALVE GUIDE mm (in) Valve diameter 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) °...
Page 393 DF90/115 “K2” (’02) MODEL 12-7 Data Item Unit DF90T DF115T CYLINDER / PISTON / PISTON RING mm (in) Cylinder distortion Limit 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 84.000 –...
Page 394 12-8 DF90/115 “K2” (’02) MODEL Data Item Unit DF90T DF115T CRANKSHAFT / CONROD Conrod small end inside 21.003 – 21.011 (0.8269 – 0.8272) mm (in) diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance mm (in) Limit 0.065 (0.0026) Conrod big end inside...
Page 395 DF90/115 “K2” (’02) MODEL 12-9 Data Item Unit DF90T DF115T ELECTRICAL ** New “K2” service data Degrees Ignition timing BTDC 1° – BTDC 44° BTDC 3° – BTDC 44° r/min Over revolution limiter **6200 Ω 168 – 252 CKP sensor resistance at 20°C Ω...
Page 396 12-10 DF90/115 “K2” (’02) MODEL PTT MOTOR mm (in) Brush length 9.8 (0.39) mm (in) 5.5 (0.22) Limit mm (in) 22.0 (0.87) Commutator outside diameter Limit 21.0 (0.83) mm (in) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 397: Tightening Torque
DF90/115 “K2” (’02) MODEL 12-11 TIGHTENING TORQUE * Tightening torques have been changed from the middle of 2002 year model. Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib.-ft Cylinder head cover bolt 6 mm 8 mm 16.5 Cylinder head bolt...
Page 398: Materials Required
SEAL *99000-25030 99000-22540 99000-25011 99000-25161 99000-31120 × (500 g) (250 g) (50 g) (400 ml 24 pcs.) SUZUKI BOND “1207B” THREAD LOCK “1342” THREAD LOCK SUPER “1333B” * 99104-33140 99000-32050 99000-31140 99000-32020 (50 g) (100 g) (50 g) **THREAD LOCK...
Page 399: Fuel/Water Hose Routing
DF90/115 “K2” (’02) MODEL 12-13 FUEL / WATER HOSE ROUTING Fuel and water hose routing have been changed from the middle of 2002 year model. • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. •...
Page 400 12-14 DF90/115 “K2” (’02) MODEL...
Page 401 DF90/115 “K2” (’02) MODEL 12-15...
Page 402: Over-Revolution Caution System
If you install a 2002 year model ECM to the 2001 engine, the over revolution limiter will activate at about 6200 r/min. CRANK PIN AND CONROD BEARING Before installing conrod cap, apply Suzuki Moly Paste and engine oil to crank pin and connecting rod bearing. 99000-25140: Suzuki Moly Paste CONROD ASSY AND BEARING The conrod assy and bearing have been changed from the middle of 2002 year model DF90/115.
Page 403: Crankshaft And Flywheel
DF90/115 “K2” (’02) MODEL 12-17 CRANKSHAFT AND FLYWHEEL The shape of crankshaft has changed from the middle of 2002 year model DF90/115. As the result of this change, flywheel, flywheel bolt and washer also have been changed. CAMSHAFT AND TAPPET SHIM The shape of base circle (opposite side of cam face) of camshafts have been changed from 2002 year model DF90 and from the middle of 2001 year model DF115.
Page 404: Engine Holder Gasket
The shape of camshafts has been changed from the middle of 2002 year model. And each camshaft has own identification mark. ENGINE HOLDER GASKET When installing the engine holder gasket, apply Suzuki Bond “1207B” as shown in figure. 99000-31140 (Except for U.S. market) Suzuki Bond “1207B” 99104-33140 (Only for U.S. market)
Page 405: Engine Holder Bolt
DF90/115 “K2” (’02) MODEL 12-19 ENGINE HOLDER BOLT The engine holder bolt has been changed from the middle of 2002 year model. A conical spring washer and plane washer have been added. In addition, the tightening torque of engine holder bolt also has been changed. Engine holder bolt 1st step 23 N .
Page 406: Clutch Linkage
12-20 DF90/115 “K2” (’02) MODEL CLUTCH LINKAGE Apply Water Resistant Grease to the following points. 99000-25161: Water Resistant Grease...
Page 407 DF90/115/140 “K3” (‘03) MODEL 13-1 DF90/115/140 “K3” (2003) MODEL CONTENTS SPECIFICATIONS (DF90T/115(W)T) _________________________ 13-2 SPECIFICATIONS (DF140(W)T/140Z) ________________________ 13-4 SERVICE DATA (DF90T/115(W)T) ___________________________ 13-6 SERVICE DATA (DF140(W)T/140Z) __________________________ 13-13 TIGHTENING TORQUE ___________________________________ 13-20 ECM___________________________________________________ 13-21 ECM MAIN RELAY AND STARTER MOTOR RELAY ____________ 13-21 BATTERY CHARGE COIL _________________________________ 13-22 RECTIFIER &...
Page 408 13-2 DF90/115/140 “K3” (‘03) MODEL These specifications are subject *SPECIFICATIONS (DF90T/115T/115WT) to change without notice. Data Item Unit DF90T DF115(W)T 09001F PRE-FIX 11501F DIMENSIONS & WEIGHT Overall length (front to back) 779 (30.7) mm (in) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 409 5.5 (5.8 / 4.8) : Oil change only L (US/Imp. qt) 5.7 (6.0 / 5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) ml (US/Imp. oz) Gearcase oil capacity 1050 (35.5 / 37.0)
Page 410 13-4 DF90/115/140 “K3” (‘03) MODEL These specifications are subject *SPECIFICATIONS (DF140T/140W/140Z) to change without notice. Data Item Unit DF140(W)T DF140Z 14001F PRE-FIX 14001Z DIMENSIONS & WEIGHT Overall length (front to back) 779 (30.7) mm (in) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 411 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/Imp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) ml (US/Imp. oz) Gearcase oil capacity 1050 (35.5/37.0) BRACKET Trim angle...
Page 412 13-6 DF90/115/140 “K3” (‘03) MODEL These service data are subject *SERVICE DATA (DF90T/115T/115WT) to change without notice. Data Item Unit DF90T DF115(W)T POWERHEAD r/min Recommended operating range 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear : approx. 625) **Cylinder compression kPa (kg/cm , psi)
Page 413 DF90/115/140 “K3” (‘03) MODEL 13-7 Data Item Unit DF115(W)T DF90T ** New “K3” service data CYLINDER HEAD / CAMSHAFT Cylinder head distortion mm (in) Limit 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 –...
Page 414 13-8 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF115(W)T DF90T VALVE/VALVE GUIDE mm (in) Valve diameter 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) °...
Page 415 DF90/115/140 “K3” (‘03) MODEL 13-9 Data Item Unit DF90T DF115(W)T CYLINDER/PISTON/PISTON RING mm (in) Cylinder distortion Limit 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 84.000 –...
Page 416 13-10 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF90T DF115(W)T CRANKSHAFT / CONROD Conrod small end inside 21.003 – 21.011 (0.8269 – 0.8272) mm (in) diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance mm (in) Limit 0.065 (0.0026) Conrod big end inside...
Page 417 DF90/115/140 “K3” (‘03) MODEL 13-11 Data Item Unit DF90T DF115(W)T ELECTRICAL Degrees at r/min Ignition timing BTDC 1° – BTDC 44° BTDC 3° – BTDC 44° r/min Over revolution limiter 6200 Ω at 20°C 168 – 252 CKP sensor resistance Ω...
Page 418 13-12 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF90T DF115(W)T PTT MOTOR mm (in) Brush length 9.8 (0.39) mm (in) 5.5 (0.22) Limit mm (in) 22.0 (0.87) Commutator outside diameter Limit 21.0 (0.83) mm (in) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 419 DF90/115/140 “K3” (‘03) MODEL 13-13 These service data are sub- *SERVICE DATA (DF140T/140WT/140Z) ject to change without notice. Data Item Unit DF140(W)T DF140Z POWERHEAD r/min. Recommended operating range 5600 – 6200 Idle speed r/min. 700 ± 50 (in-gear : approx. 700) **Cylinder compression kPa (kg/cm , psi)
Page 420 13-14 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF140(W)T DF140Z CYLINDER HEAD/CAMSHAFT Cylinder head distortion mm (in) Limit 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520) mm (in)
Page 421 DF90/115/140 “K3” (‘03) MODEL 13-15 Data Item Unit DF140Z DF140(W)T VALVE/VALVE GUIDE mm (in) Valve diameter 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) °...
Page 422 13-16 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF140Z DF140(W)T CYLINDER/PISTON/PISTON RING mm (in) Cylinder distortion Limit 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance mm (in) Limit 0.100 (0.0039) mm (in) Cylinder bore 86.000 –...
Page 423 DF90/115/140 “K3” (‘03) MODEL 13-17 Data Item Unit DF140(W)T DF140Z CRANKSHAFT/CONROD Conrod small end inside 21.003 – 21.011 (0.8269 – 0.8272) mm (in) diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance mm (in) Limit 0.065 (0.0026) Conrod big end 47.000 –...
Page 424 13-18 DF90/115/140 “K3” (‘03) MODEL Data Item Unit DF140(W)T DF140Z ELECTRICAL Degrees BTDC 5° – BTDC 45° Ignition timing r/min 6500 Over revolution limiter Ω at 20°C 168 – 252 CKP sensor resistance Ω CMP sensor resistance at 20°C Ω Primary at 20°C 1.9 –...
Page 425 DF90/115/140 “K3” (‘03) MODEL 13-19 Data Item Unit DF140(W)T DF140Z PTT MOTOR mm (in) Brush length 9.8 (0.39) mm (in) 5.0 (0.20) Limit mm (in) 22.0 (0.87) Commutator outside diameter Limit 21.0 (0.83) mm (in) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 426: Tightening Torque
13-20 DF90/115/140 “K3” (‘03) MODEL * Tightening torques have been changed TIGHTENING TORQUE from the 2003 year model. Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib.-ft Cylinder head cover bolt 6 mm 8 mm *2.5 *18.0 Cylinder head bolt...
Page 427: Ecm
• The IAC valve operating duty at idle speed (625 r/min) has been changed from 15 % to 30 %. This duty can be monitored by using the Suzuki Diagnostic System (SDS). DF140 • For U. S. model, the motion under operation of the emergency stop switch has been changed.
Page 428: Battery Charge Coil
2. Measure resistance between leads in combinations shown. NOTE: The values given below are for a SUZUKI pocket tester. 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 429: Exhaust Camshaft (For Df115 Only)
DF90/115/140 “K3” (‘03) MODEL 13-23 EXHAUST CAMSHAFT (FOR DF115 ONLY) The profile of exhaust cam has been changed. As the result of this change, cam height has been changed. Cam height (DF115 exhaust cam) Standard : 38.820 – 38.980 mm Cam height (1.5283 –...
Page 430: Cylinder Head Instllation
13-24 DF90/115/140 “K3” (‘03) MODEL CYLINDER HEAD INSTALLATION Installation is in reverse order of removal with special attention to the following steps. Do not re-use gasket once removed. Always use a new gasket. 1. Insert dowel pins and place cylinder head gasket into posi- tion on cylinder.
Page 431: Crankcase To Cylinder Instllation
DF90/115/140 “K3” (‘03) MODEL 13-25 CRANKCASE TO CYLINDER INSTALLATION 1. Clean mating surface of cylinder and crankcase. 2. Apply Suzuki Bond to mating surface of crankcase as shown in figure. 99000-31140 : Suzuki Bond 1207B Apply bond to mating surface only.
Page 432: Upper Mount
13-26 DF90/115/140 “K3” (‘03) MODEL UPPER MOUNT Upper mount FOR DF90/115 The upper mount has been changed in shape of core metal. In accordance with this change, the thrust stopper washer has been changed in diameter. 32 mm → 24 mm Early Late Thrust...
Page 433: Df115W And Df140W
DF90/115/140 “K3” (‘03) MODEL 13-27 DF115WT AND DF140WT Identification mark This section describes servicing procedures which differ from those of the DF115/140 “K2” models. EXHAUST VALVE The exhaust valve has been changed in surface treatment. The identification mark “P” has been added on the valve head. WATER PUMP CASE The sleeve has been added inside of water pump case.
Page 434: Wiring Diagram
13-28 DF90/115/140 “K3” (‘03) MODEL WIRING DIAGRAM...
Page 435: Wire Routing
DF90/115/140 “K3” (‘03) MODEL 13-29 WIRE ROUTING...
Page 436 13-30 DF90/115/140 “K3” (‘03) MODEL...
Page 437: Water Hose Routing
DF90/115/140 “K3” (‘03) MODEL 13-31 WATER HOSE ROUTING White paint mark Thermostat cover Water return hose Water return hose Water hose (Fuel return pipe to Water return pipe (Engine holder) Water return pipe) Pilot water tube...
Page 438 DF90/115/140 “K4” (’04) MODEL 14-1 DF90/115/140 “K4” (’04) MODEL CONTENTS SPECIFICATIONS (DF90T/115T/115WT) ........14-2 SPECIFICATIONS (DF140T/140WT/140Z) ........14-4 SERVICE DATA (DF90/115) ............14-6 SERVICE DATA (DF140) ..............14-13 TEMPERATURE SENSOR .............. 14-20 CYLINDER BLOCK ................. 14-20 RECTIFIER & REGULATOR ............14-20 POWER TRIM &...
Page 439: Specifications (Df90T/115T/115Wt)
14-2 DF90/115/140 “K4” (’04) MODEL *SPECIFICATIONS (DF90T/115T/115WT) * These specifications are subject to change without notice. Data Item Unit DF90T DF115(W)T PRE-FIX 09001F 11501F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 440 SAE10W-40 Engine oil amounts 5.5 (5.8/4.8): Oil change only L (US/lmp. qt) 5.7 (6.0/5.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 441: Specifications (Df140T/140Wt/140Z)
14-4 DF90/115/140 “K4” (’04) MODEL *SPECIFICATIONS (DF140T/140WT/140Z) * These specifications are subject to change without notice. Data Item Unit DF140(W)T DF140Z PRE-FIX 14001F 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 442 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/lmp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 443: Service Data (Df90/115)
14-6 DF90/115/140 “K4” (’04) MODEL SERVICE DATA (DF90/115) Data Item Unit DF90T DF115(W)T POWERHEAD Recommended operation range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 444 DF90/115/140 “K4” (’04) MODEL 14-7 Data Item Unit DF90T DF115(W)T CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 – 37.080 (1.4535 – 1.4598) 38.820 –...
Page 445 14-8 DF90/115/140 “K4” (’04) MODEL Data Item Unit DF90T DF115(W)T VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 446 DF90/115/140 “K4” (’04) MODEL 14-9 Data Item Unit DF90T DF115(W)T CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 447 14-10 DF90/115/140 “K4” (’04) MODEL Data Item Unit DF90T DF115(W)T CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 448 DF90/115/140 “K4” (’04) MODEL 14-11 Data Item Unit DF90T DF115(W)T ELECTRICAL Ignition timing Degrees BTDC 1° – BTDC 44° BTDC 3° – BTDC 44° Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 449 14-12 DF90/115/140 “K4” (’04) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 450: Service Data (Df140)
DF90/115/140 “K4” (’04) MODEL 14-13 SERVICE DATA (DF140) Data Item Unit DF140(W)T DF140Z POWERHEAD Recommended operation range r/min 5600 – 6200 Idle speed r/min 700 ± 50 (in-gear: approx. 700) * Cylinder compression kPa (kg/cm , psi) 1200 – 1600 (12 – 16, 171 – 228) * Cylinder compression max.
Page 451 14-14 DF90/115/140 “K4” (’04) MODEL Data Item Unit DF140(W)T DF140Z CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 452 DF90/115/140 “K4” (’04) MODEL 14-15 Data Item Unit DF140(W)T DF140Z VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 453 14-16 DF90/115/140 “K4” (’04) MODEL Data Item Unit DF140(W)T DF140Z CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 86.000 –...
Page 454 DF90/115/140 “K4” (’04) MODEL 14-17 Data Item Unit DF140(W)T DF140Z CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 455 14-18 DF90/115/140 “K4” (’04) MODEL Data Item Unit DF140(W)T DF140Z ELECTRICAL Ignition timing Degrees BTDC 5 – BTDC 45 Over revolution limiter r/min 6500 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 456 DF90/115/140 “K4” (’04) MODEL 14-19 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.0 (0.20) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 457: Temperature Sensor
14-20 DF90/115/140 “K4” (’04) MODEL TEMPERATURE SENSOR The cylinder temperature sensor has been changed. 1 Change of sensor shape 2 Change of connector 3 Elimination of O-ring 4 Change of tube color O-ring Tube color: Gray Tube color: Green 12 mm 9 mm CYLINDER BLOCK The cylinder block has been changed because of the change of temperature sensor.
Page 458: Power Trim & Tilt (P.t.t.) Relay
DF90/115/140 “K4” (’04) MODEL 14-21 POWER TRIM & TILT (P.T.T.) RELAY The P.T.T. relays (for UP and for DOWN) have been incorporated and changed in shape. In accordance with this change, the P.T.T. relay plate and the ground cable have been eliminated and the holder has been added.
Page 459: Tilt Limit Switch System
14-22 DF90/115/140 “K4” (’04) MODEL TILT LIMIT SWITCH SYSTEM To adjust the maximum tilt position, the tilt limit switch system has been added on the clamp bracket shaft. Adjusting procedure: To reduce the amount of tilt, move the tab “A” of cam upward. To increase the amount of tilt, move the tab “A”...
Page 460: Port Clamp Bracket
DF90/115/140 “K4” (’04) MODEL 14-23 PORT CLAMP BRACKET The hole in the port clamp bracket has been enlarged. 17 mm × 25 mm 25 mm Early Late DRIVESHAFT The driveshaft has been changed in shape. In accordance with this change, the washers pre-loading to driveshaft have been eliminated. Washers Flange ( 40 mm) Early...
Page 461: Lower Unit Gears-Shimming And Adjustment
14-24 DF90/115/140 “K4” (’04) MODEL LOWER UNIT GEARS-SHIMMING AND ADJUSTMENT In accordance with the eliminate of the washers preloading to driveshaft, the servicing procedure for “Tooth Contact Pattern Check” has been changed. Checking and adjusting tooth contact pattern (Pinion and Forward gear) Check the tooth contact pattern by using the following procedure: 1.
Page 462: Wiring Diagram
DF90/115/140 “K4” (’04) MODEL 14-25 WIRING DIAGRAM DF90/115/140...
Page 463 DF90/115/140 “K5” (’05) MODEL 15-1 DF90/115/140 “K5” (2005) MODEL CONTENTS SPECIFICATIONS (DF90T/115T/115WT) ........15-2 SPECIFICATIONS (DF140T/140WT/140Z/140WZ) ......15-4 SERVICE DATA (DF90T/115T/115WT) ........... 15-6 SERVICE DATA (DF140T/140WT/140Z/140WZ) ......15-13 ENGINE WIRING HARNESS ............15-20 SAFETY RELAY SYSTEM .............. 15-20 ECM ....................15-21 SUB-BATTERY CABLE ..............
Page 464: Specifications (Df90T/115T/115Wt)
15-2 DF90/115/140 “K5” (’05) MODEL *SPECIFICATIONS (DF90T/115T/115WT) * These specifications are subject to change without notice. Data Item Unit DF90T DF115T/115WT PRE-FIX 09001F 11501F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 465 SAE10W-40 Engine oil amounts 5.5 (5.8/4.8): Oil change only L (US/lmp. qt) 5.7 (6.0/5.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 466: Specifications (Df140T/140Wt/140Z/140Wz)
15-4 DF90/115/140 “K5” (’05) MODEL *SPECIFICATIONS (DF140T/140WT/140Z/140WZ) * These specifications are subject to change without notice. Data Item Unit DF140T/140WT DF140Z/140WZ PRE-FIX 14001F 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall heigt...
Page 467 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/lmp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 468: Service Data (Df90T/115T/115Wt)
15-6 DF90/115/140 “K5” (’05) MODEL SERVICE DATA (DF90T/115T/115WT) Data Item Unit DF90T DF115T/115WT POWERHEAD Recommended operation range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 469 DF90/115/140 “K5” (’05) MODEL 15-7 Data Item Unit DF90T DF115T/115WT CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 – 37.080 (1.4535 – 1.4598) 38.820 –...
Page 470 15-8 DF90/115/140 “K5” (’05) MODEL Data Item Unit DF90T DF115T/115WT VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 471 DF90/115/140 “K5” (’05) MODEL 15-9 Data Item Unit DF90T DF115T/115WT CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 472 15-10 DF90/115/140 “K5” (’05) MODEL Data Item Unit DF90T DF115T/115WT CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 473 DF90/115/140 “K5” (’05) MODEL 15-11 Data Item Unit DF90T DF115T/115WT ELECTRICAL Ignition timing Degrees BTDC 1 – BTDC 44 BTDC 3 – BTDC 44 Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 474 15-12 DF90/115/140 “K5” (’05) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 475: Service Data (Df140T/140Wt/140Z/140Wz)
DF90/115/140 “K5” (’05) MODEL 15-13 SERVICE DATA (DF140T/140WT/140Z/140WZ) Data Item Unit DF140T/140WT DF140Z/140WZ POWERHEAD Recommended operation range r/min 5600 – 6200 Idle speed r/min 700 ± 50 (in-gear: approx. 700) * Cylinder compression kPa (kg/cm , psi) 1200 – 1600 (12 – 16, 171 – 228) * Cylinder compression max.
Page 476 15-14 DF90/115/140 “K5” (’05) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 477 DF90/115/140 “K5” (’05) MODEL 15-15 Data Item Unit DF140T/140WT DF140Z/140WZ VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 478 15-16 DF90/115/140 “K5” (’05) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 86.000 –...
Page 479 DF90/115/140 “K5” (’05) MODEL 15-17 Data Item Unit DF140T/140WT DF140Z/140WZ CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 480 15-18 DF90/115/140 “K5” (’05) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ ELECTRICAL Ignition timing Degrees BTDC 5 – BTDC 45 Over revolution limiter r/min 6500 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 481 DF90/115/140 “K5” (’05) MODEL 15-19 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.0 (0.20) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 482: Engine Wiring Harness
15-20 DF90/115/140 “K5” (’05) MODEL ENGINE WIRING HARNESS The connectors of engine wiring harness have been changed from 8-pin to 16-pin type connector. In accordance with this change, the connector holder has been changed and Monitor-Tachometer wire has been eliminated. 16-pin connector 8-pin connector SAFETY RELAY SYSTEM...
Page 483: Ecm
DF90/115/140 “K5” (’05) MODEL 15-21 In accordance with addition of the safety relay system, ECM has been changed. SUB-BATTERY CABLE The sub-battery cable (ECM power source cable) is newly provided for accurate ECM operation. The ECM power source flows through the white lead wire in the remote control extension harness which car- ries battery power to the ignition switch.
Page 484: Remote Control Box And Remote Control Wire
15-22 DF90/115/140 “K5” (’05) MODEL REMOTE CONTROL BOX AND REMOTE CONTROL WIRE The remote control box and remote control wire have been changed. Remote control box Remote control wire Fuse for meter 16-pin connector...
Page 485 DF90/115/140 “K5” (’05) MODEL 15-23 1 Top-mount remote control box 7 Side-mount remote control box 2 PTT switch extension wire 8 Remote control wire 3 Ignition switch 9 Extension wire 4 Emergency stop switch 0 Remote control wire adaptor 5 Ignition & stop switch panel A Remote control wire adaptor 6 Caution buzzer B Sub-battery cable (3.7 m)
Page 486: Tilt Limit Switch Cover
15-24 DF90/115/140 “K5” (’05) MODEL TILT LIMIT SWITCH COVER The cover has been added on the tilt limit switch. In accordance with this change, the tilt limit switch holder bolts have been changed in length and shape as indicated below. 15 mm 18 mm 20 mm...
Page 487: Engin Holder
DF90/115/140 “K5” (’05) MODEL 15-25 ENGIN HOLDER The exhaust plug has been changed in length. The circlip retaining the clutch shaft bearing has been added. Exhaust plug Circlip added 8 mm 15 mm UPPER AND LOWER MOUNT The upper mount washer has been changed in inside diameter from 12.0 mm to 12.5 mm. The lower mount washer has been changed in thickness from 2.5 mm to 3.0 mm.
Page 488: Transom Bolt
15-26 DF90/115/140 “K5” (’05) MODEL TRANSOM BOLT The transom bolt and related parts have been changed as shown below: The transom bolt has been changed in thread pitch from 1.75 mm to 1.25 mm. The lock washer has been eliminated. The plane washer (O.D.
Page 489: Wire/Hose Routing
DF90/115/140 “K5” (’05) MODEL 15-27 WIRE/HOSE ROUTING...
Page 490 15-28 DF90/115/140 “K5” (’05) MODEL MAP sensor When installing sensor, apply engine oil to sensor O-ring. CTP switch IAC valve Battery charge coil CKP sensor IAC valve MAP sensor IAT sensor Battery cable CTP switch Battery cable Electric parts holder cover screw VIEW C Tilt limit lead clamp...
Page 491 DF90/115/140 “K5” (’05) MODEL 15-29...
Page 492: Wiring Diagram
15-30 DF90/115/140 “K5” (’05) MODEL WIRING DIAGRAM...
Page 493 DF90/115/140 “K6” (’06) MODEL 16-1 DF90/115/140 “K6” (2006) MODEL CONTENTS SPECIFICATIONS (DF90T/115T/115WT) ........16-2 SPECIFICATIONS (DF140T/140WT/140Z/140WZ) ......16-4 SERVICE DATA (DF90T/115T/115WT) ........... 16-6 SERVICE DATA (DF140T/140WT/140Z/140WZ) ......16-13 TIGHTENING TORQUE ..............16-20 PERIODIC MAINTENANCE SCHEDULE ........16-21 ECM ....................16-22 NEUTRAL SWITCH .................
Page 494: Specifications (Df90T/115T/115Wt)
16-2 DF90/115/140 “K6” (’06) MODEL *SPECIFICATIONS (DF90T/115T/115WT) * These specifications are subject to change without notice. Data Item Unit DF90T DF115T/115WT PRE-FIX 09001F 11501F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 495 SAE10W-40 Engine oil amounts 5.5 (5.8/4.8): Oil change only L (US/lmp. qt) 5.7 (6.0/5.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 496: Specifications (Df140T/140Wt/140Z/140Wz)
16-4 DF90/115/140 “K6” (’06) MODEL *SPECIFICATIONS (DF140T/140WT/140Z/140WZ) * These specifications are subject to change without notice. Data Item Unit DF140T/140WT DF140Z/140WZ PRE-FIX 14001F 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 497 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/lmp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 498: Service Data (Df90T/115T/115Wt)
16-6 DF90/115/140 “K6” (’06) MODEL SERVICE DATA (DF90T/115T/115WT) Data Item Unit DF90T DF115T/115WT POWERHEAD Recommended operation range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 499 DF90/115/140 “K6” (’06) MODEL 16-7 Data Item Unit DF90T DF115T/115WT CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 – 37.080 (1.4535 – 1.4598) 38.820 –...
Page 500 16-8 DF90/115/140 “K6” (’06) MODEL Data Item Unit DF90T DF115T/115WT VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 501 DF90/115/140 “K6” (’06) MODEL 16-9 Data Item Unit DF90T DF115T/115WT CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 502 16-10 DF90/115/140 “K6” (’06) MODEL Data Item Unit DF90T DF115T/115WT CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 503 DF90/115/140 “K6” (’06) MODEL 16-11 Data Item Unit DF90T DF115T/115WT ELECTRICAL Ignition timing Degrees BTDC 1 – BTDC 44 BTDC 3 – BTDC 44 Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 504 16-12 DF90/115/140 “K6” (’06) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 505: Service Data (Df140T/140Wt/140Z/140Wz)
DF90/115/140 “K6” (’06) MODEL 16-13 SERVICE DATA (DF140T/140WT/140Z/140WZ) Data Item Unit DF140T/140WT DF140Z/140WZ POWERHEAD Recommended operation range r/min 5600 – 6200 Idle speed r/min 700 ± 50 (in-gear: approx. 700) * Cylinder compression kPa (kg/cm , psi) 1200 – 1600 (12 – 16, 171 – 228) * Cylinder compression max.
Page 506 16-14 DF90/115/140 “K6” (’06) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 507 DF90/115/140 “K6” (’06) MODEL 16-15 Data Item Unit DF140T/140WT DF140Z/140WZ VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 508 16-16 DF90/115/140 “K6” (’06) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 86.000 –...
Page 509 DF90/115/140 “K6” (’06) MODEL 16-17 Data Item Unit DF140T/140WT DF140Z/140WZ CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 510 16-18 DF90/115/140 “K6” (’06) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ ELECTRICAL Ignition timing Degrees BTDC 5 – BTDC 45 Over revolution limiter r/min 6500 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 511 DF90/115/140 “K6” (’06) MODEL 16-19 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.0 (0.20) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 512 16-20 DF90/115/140 “K6” (’06) MODEL TIGHTENING TORQUE * Tightening torque has been changed Tightening torque – Important fasteners from the 2006 year model. TIGHTENING TORQUE THREAD ITEM DIAMETER N·m kg-m lb-ft Cylinder head cover bolt 6 mm 8 mm 18.0 Cylinder head bolt 10 mm 50.0...
Page 513: Periodic Maintenance Schedule
DF90/115/140 “K6” (’06) MODEL 16-21 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 514: Ecm
16-22 DF90/115/140 “K6” (’06) MODEL The ECM has been changed in program. NEUTRAL SWITCH The neutral switch feature has been redesigned with a micro type switch. FUEL FILTER A new style fuel filter will be used that provides a drain feature. This new filter requires several new components shown below and a new mounting bracket to retain the fil- ter onto the outboard.
Page 515: Delivery Pipe
DF90/115/140 “K6” (’06) MODEL 16-23 DELIVERY PIPE The delivery pipe has been changed in shape. 90.5 mm 89.0 mm 16.5 mm 14.5 mm R13 mm R20 mm 36 mm 37.5 mm (4 places) OIL STRAINER The O-ring of oil strainer has been changed in number from one O-ring to two.
Page 516: Engine Holder And Cylinder Block
16-24 DF90/115/140 “K6” (’06) MODEL ENGINE HOLDER AND CYLINDER BLOCK The cooling water passage in the engine holder has been changed. In accordance with this change, the engine holder, engine holder gasket and cylinder block have been changed at the part of water passage. The upper mount case cover, mount case cover gasket and bolts have newly been added.
Page 517: Cltuch Link
DF90/115/140 “K6” (’06) MODEL 16-25 CLTUCH LINK The clutch link and related parts have been changed. Apply Water Resistant Grease to the following points.  99000-25161: Water Resistant Grease Bolt Hose clamp Clutch lever Clutch lever link Clutch lever bush Clutch shaft Clutch notch ball Spring...
Page 518 16-26 DF90/115/140 “K6” (’06) MODEL CLAMP BRACKET SHAFT AND BUSHING The clamp bracket shaft has been redesigned with a clearance hole in place of a slot for routing the grease lubrication. Grease groove Yellow paint mark Red paint mark Grease hole Locating hole NOTE: Install the clamp bracket shaft with “Red”...
Page 519: Clamp Bracket (For Df90 And Df115)
DF90/115/140 “K6” (’06) MODEL 16-27 CLAMP BRACKET (For DF90 and DF115) The clamp bracket shaft has been redesigned to use lock nut with a lock washer which is bent during assembly. Lock washer Detention boss Detention hole To prevent the lock washer from rotation, a boss has been Bending edge of added to the clamp bracket.
Page 520: Swivel Bracket
16-28 DF90/115/140 “K6” (’06) MODEL SWIVEL BRACKET The swivel bracket has been redesigned to hold the tilt limit lead from a bolt and clamp design to a plastic tie strap looped through two holes in the swivel bracket. Tie band Tilt limit lead Holes Holes...
Page 521: Steering Bracket
DF90/115/140 “K6” (’06) MODEL 16-29 STEERING BRACKET The upper mount system has been redesigned. The steering bracket required modification in the upper mount boss surface. UPPER MOUNT The upper mount and related parts have been changed. Tightening torque of the upper mount front nut has been changed from 85 N·m to 80 N·m Upper thrust reverse mount Upper mount rear nut Bolt...
Page 522 16-30 DF90/115/140 “K6” (’06) MODEL 2. Remove the upper thrust reverse mount 3. 3. Remove the two nuts 4 and upper mount plate 5. 4. Remove the four bolts 6 and upper mount covers 7. Remove the upper mount assembly. Reassemble the upper mount When reassembling the upper mount parts, follow the removal instruction in reverse.
Page 523: Water Pump
DF90/115/140 “K6” (’06) MODEL 16-31 Install the upper mount cover with rib side to be facing to for- ward. Forward WATER PUMP The water pump and related parts have been changed. Bolt Water pump case (Material: Resin) Pump case No.2 seal Water pump sleeve Pump case No.1 seal Pump case under panel...
Page 524: Water Pump Tube
16-32 DF90/115/140 “K6” (’06) MODEL 2. Apply Suzuki Bond No.1207B onto the outer-surface of water pump sleeve. Install the water pump sleeve into the water pump case by confirming the boss on the sleeve should be meeting with the groove on the pump case.
Page 525: Shift Rod Guide Housing
DF90/115/140 “K6” (’06) MODEL 16-33 SHIFT ROD GUIDE HOUSING The shift rod guide housing and related parts have been changed as follows: * The shift rod guide housing has been changed in shape. * The shift rod guide housing has been changed in materials from aluminum to resin. * Number of securing bolts have been changed from 3 to 2.
Page 526: Shift Rod, Shifter Yoke And Horizontal Slider
16-34 DF90/115/140 “K6” (’06) MODEL SHIFT ROD, SHIFTER YOKE AND HORIZONTAL SLIDER The shift rod, shifter yoke and horizontal slider have been changed in shape. 13 mm 16 mm DRIVE SHAFT The outside diameter of drive shaft has partially been changed from 18 mm to 20 mm. 18 mm 20 mm...
Page 527: Propeller Shaft And Connector Pin
DF90/115/140 “K6” (’06) MODEL 16-35 PROPELLER SHAFT AND CONNECTOR PIN The propeller shaft having an additional detent function. Detent spring Connector pin Detent No.1 ball Detent No.2 ball FORWARD GEAR AND CLUTCH DOG The forward gear and clutch dog shifter have been changed in engage angle from 5° to 2.5°. Forward gear Clutch dog shifter 5˚...
Page 528 16-36 DF90/115/140 “K6” (’06) MODEL The punch letter on the reverse gear side of clutch dog shifter has been changed from “R, E, V,” to “R”.
Page 529: Wiring/Hose Routing
DF90/115/140 “K6” (’06) MODEL 16-37 WIRING/HOSE ROUTING Oil pressure switch High pressure fuel pump lead wire: Fix switch lead wire as shown. Route lead wire behind intake manifold. Clamp: Fix main harness. 45˚ Battery cable Route battery cable under fuel hose. Main harness Clamp: Fix neutral switch...
Page 530 16-38 DF90/115/140 “K6” (’06) MODEL...
Page 531: Wiring Diagram
DF90/115/140 “K6” (’06) MODEL 16-39 WIRING DIAGRAM...
Page 532 DF90/115/140 “K7” (’07) MODEL 17-1 DF90/115/140 “K7” (2007) MODEL CONTENTS SPECIFICATIONS (DF90T/115T/115WT) ........17-2 SPECIFICATIONS (DF140T/140WT/140Z/140WZ) ......17-4 SERVICE DATA (DF90T/115T/115WT) ........... 17-6 SERVICE DATA (DF140T/140WT/140Z/140WZ) ......17-13 PERIODIC MAINTENANCE SCHEDULE ........17-20 ECM ....................17-21 FUEL HOSE, CABLE GROMMET AND FRONT PANEL ....17-21 PINION/GEAR SET ................
Page 533: Specifications (Df90T/115T/115Wt)
17-2 DF90/115/140 “K7” (’07) MODEL *SPECIFICATIONS (DF90T/115T/115WT) * These specifications are subject to change without notice. Data Item Unit DF90T DF115T/115WT PRE-FIX 09001F 11501F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 534 SAE10W-40 Engine oil amounts 5.5 (5.8/4.8): Oil change only L (US/lmp. qt) 5.7 (6.0/5.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 535: Specifications (Df140T/140Wt/140Z/140Wz)
17-4 DF90/115/140 “K7” (’07) MODEL *SPECIFICATIONS (DF140T/140WT/140Z/140WZ) * These specifications are subject to change without notice. Data Item Unit DF140T/140WT DF140Z/140WZ PRE-FIX 14001F 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 536 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/lmp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 537: Service Data (Df90T/115T/115Wt)
17-6 DF90/115/140 “K7” (’07) MODEL SERVICE DATA (DF90T/115T/115WT) Data Item Unit DF90T DF115T/115WT POWERHEAD Recommended operation range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 538 DF90/115/140 “K7” (’07) MODEL 17-7 Data Item Unit DF90T DF115T/115WT CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 – 37.080 (1.4535 – 1.4598) 38.820 –...
Page 539 17-8 DF90/115/140 “K7” (’07) MODEL Data Item Unit DF90T DF115T/115WT VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 540 DF90/115/140 “K7” (’07) MODEL 17-9 Data Item Unit DF90T DF115T/115WT CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 541 17-10 DF90/115/140 “K7” (’07) MODEL Data Item Unit DF90T DF115T/115WT CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 542 DF90/115/140 “K7” (’07) MODEL 17-11 Data Item Unit DF90T DF115T/115WT ELECTRICAL Ignition timing Degrees BTDC 1 – BTDC 44 BTDC 3 – BTDC 44 Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 543 17-12 DF90/115/140 “K7” (’07) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 544: Service Data (Df140T/140Wt/140Z/140Wz)
DF90/115/140 “K7” (’07) MODEL 17-13 SERVICE DATA (DF140T/140WT/140Z/140WZ) Data Item Unit DF140T/140WT DF140Z/140WZ POWERHEAD Recommended operation range r/min 5600 – 6200 Idle speed r/min 700 ± 50 (in-gear: approx. 700) * Cylinder compression kPa (kg/cm , psi) 1200 – 1600 (12 – 16, 171 – 228) * Cylinder compression max.
Page 545 17-14 DF90/115/140 “K7” (’07) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 546 DF90/115/140 “K7” (’07) MODEL 17-15 Data Item Unit DF140T/140WT DF140Z/140WZ VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 547 17-16 DF90/115/140 “K7” (’07) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 86.000 –...
Page 548 DF90/115/140 “K7” (’07) MODEL 17-17 Data Item Unit DF140T/140WT DF140Z/140WZ CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 549 17-18 DF90/115/140 “K7” (’07) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ ELECTRICAL Ignition timing Degrees BTDC 5 – BTDC 45 Over revolution limiter r/min 6500 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 550 DF90/115/140 “K7” (’07) MODEL 17-19 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.0 (0.20) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 551: Periodic Maintenance Schedule
17-20 DF90/115/140 “K7” (’07) MODEL PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.
Page 552: Ecm
DF90/115/140 “K7” (’07) MODEL 17-21 The warning memory condition program on ECM has been changed. FUEL HOSE, CABLE GROMMET AND FRONT PANEL The fuel hose, cable grommet and front panel have been changed. Cable grommet Cable grommet Front panel Front panel Fuel hose Fuel hose...
Page 553 17-22 DF90/115/140 “K7” (’07) MODEL FUEL HOSE The fuel hose has been changed in length. The hose joint has been added. The fuel connector plug and related parts have been eliminated. NOTE: When connecting the fuel hose A and B, disconnect the joint from fuel hose B. Fuel hose A Fuel hose Joint...
Page 554: Pinion/Gear Set
DF90/115/140 “K7” (’07) MODEL 17-23 FRONT PANEL The fuel connector plug and related parts have been eliminated. The hole on front panel for fuel connector plug has been eliminated. Fuel connector plug Early Late PINION/GEAR SET DF140 The tooth numbers of forward and reverse gears for DF140 have been changed from 23 to 25.
Page 555 DF90/115/140 “K8” (’08) MODEL 18-1 DF90/115/140 “K8” (2008) MODEL CONTENTS SPECIFICATIONS (DF90T/115T/115WT) ........18-2 SPECIFICATIONS (DF140T/140WT/140Z/140WZ) ......18-4 SERVICE DATA (DF90T/115T/115WT) ........... 18-6 SERVICE DATA (DF140T/140WT/140Z/140WZ) ......18-13 PERIODIC MAINTENANCE ............. 18-20 IDLE SPEED ................18-20 ENGINE CONTROL SYSTEM ............18-22 ECM ...................
Page 556: Specifications (Df90T/115T/115Wt)
18-2 DF90/115/140 “K8” (’08) MODEL *SPECIFICATIONS (DF90T/115T/115WT) * These specifications are subject to change without notice. Data Item Unit DF90T DF115T/115WT PRE-FIX 09001F 11501F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 557 SAE10W-40 Engine oil amounts 5.5 (5.8/4.8): Oil change only L (US/lmp. qt) 5.7 (6.0/5.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 558: Specifications (Df140T/140Wt/140Z/140Wz)
18-4 DF90/115/140 “K8” (’08) MODEL *SPECIFICATIONS (DF140T/140WT/140Z/140WZ) * These specifications are subject to change without notice. Data Item Unit DF140T/140WT DF140Z/140WZ PRE-FIX 14001F 14001Z DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 559 Engine oil amounts 5.5 (5.8/4.8) : Oil change only L (US/lmp. qt) 5.7 (6.0/5.0) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity ml (US/lmp. oz) 1050 (35.5/37.0) BRACKET Trim angle...
Page 560: Service Data (Df90T/115T/115Wt)
18-6 DF90/115/140 “K8” (’08) MODEL SERVICE DATA (DF90T/115T/115WT) Data Item Unit DF90T DF115T/115WT POWERHEAD Recommended operation range r/min 4500 – 5500 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 561 DF90/115/140 “K8” (’08) MODEL 18-7 Data Item Unit DF90T DF115T/115WT CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 36.920 – 37.080 (1.4535 – 1.4598) 38.820 –...
Page 562 18-8 DF90/115/140 “K8” (’08) MODEL Data Item Unit DF90T DF115T/115WT VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 563 DF90/115/140 “K8” (’08) MODEL 18-9 Data Item Unit DF90T DF115T/115WT CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 564 18-10 DF90/115/140 “K8” (’08) MODEL Data Item Unit DF90T DF115T/115WT CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 565 DF90/115/140 “K8” (’08) MODEL 18-11 Data Item Unit DF90T DF115T/115WT ELECTRICAL Ignition timing Degrees BTDC 1 – BTDC 44 BTDC 3 – BTDC 44 Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 566 18-12 DF90/115/140 “K8” (’08) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 567: Service Data (Df140T/140Wt/140Z/140Wz)
DF90/115/140 “K8” (’08) MODEL 18-13 SERVICE DATA (DF140T/140WT/140Z/140WZ) Data Item Unit DF140T/140WT DF140Z/140WZ POWERHEAD Recommended operation range r/min 5600 – 6200 Idle speed r/min 700 ± 50 (in-gear: approx. 700) * Cylinder compression kPa (kg/cm , psi) 1200 – 1600 (12 – 16, 171 – 228) * Cylinder compression max.
Page 568 18-14 DF90/115/140 “K8” (’08) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 39.520 – 39.680 (1.5560 – 1.5622) Limit mm (in) 39.420 (1.5520)
Page 569 DF90/115/140 “K8” (’08) MODEL 18-15 Data Item Unit DF140T/140WT DF140Z/140WZ VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 –...
Page 570 18-16 DF90/115/140 “K8” (’08) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 86.000 –...
Page 571 DF90/115/140 “K8” (’08) MODEL 18-17 Data Item Unit DF140T/140WT DF140Z/140WZ CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside...
Page 572 18-18 DF90/115/140 “K8” (’08) MODEL Data Item Unit DF140T/140WT DF140Z/140WZ ELECTRICAL Ignition timing Degrees BTDC 5 – BTDC 45 Over revolution limiter r/min 6500 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 573 DF90/115/140 “K8” (’08) MODEL 18-19 PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.0 (0.20) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 574: Periodic Maintenance
18-20 DF90/115/140 “K8” (’08) MODEL PERIODIC MAINTENANCE IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). Change the idle speed adjustment procedure as following: The idle adjustment of 2008 model can be performed by fixing duty of IAC valve as well as DF150 –...
Page 575 DF90/115/140 “K8” (’08) MODEL 18-21 6. During this fixed mode, adjust engine speed to 625 ± 25 r/min (DF140: 700 ± 50 r/min) by turning by-pass air screw. Turning air screw counterclockwise: Engine speed will increase. Turning air screw clockwise: Engine speed will decrease.
Page 576: Engine Control System
18-22 DF90/115/140 “K8” (’08) MODEL ENGINE CONTROL SYSTEM The program (internal circuit) of ECM has been changed. This change is performed by following reasons: 1. Addition of the IAC valve fixing mode. 2. Accommodation of the optional digital gauges (Teleflex gauges).
Page 577: Digital Gauge System
DF90/115/140 “K8” (’08) MODEL 18-23 DIGITAL GAUGE SYSTEM DIGITAL GAUGE The digital gauge and the components required for installing the digital gauge are available as optional com- ponents. The new gauge system components are as follows. Refer Part name Part No. Remarks Speedometer assy.
Page 578: Modification Of Harness Connection
18-24 DF90/115/140 “K8” (’08) MODEL MODIFICATION OF HARNESS CONNECTION For operating the digital gauge, disconnect the gauge connector A from gauge connector B, and connect the gauge connector A to the SDS communication connector as shown in the illustration. Gauge connector Gauge connector Gauge connector Gauge connector...
Page 579 • In the case that the wiring harness gauge connector is connected to the SDS communication connector, SDS (SUZUKI Diagnosis System) cannot be used. • When SDS has to be used, disconnect the SDS communication connector from the gauge connector.
Page 580: Set-Up Of Tachometer
18-26 DF90/115/140 “K8” (’08) MODEL SET-UP OF TACHOMETER NOTE: Each tachometer should be set up according to the applicable engine. If the setting is incorrect, the tachometer does not function as required. Default value of the tachometer is “SETUP Eng Posi- tion 0”.
Page 581: Tachometer-Monitor
DF90/115/140 “K8” (’08) MODEL 18-27 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 582: Tachometer Display Indication
18-28 DF90/115/140 “K8” (’08) MODEL TACHOMETER DISPLAY INDICATION CAUTION SYSTEM When a problem is detected, the caution name appears on the display screen of tachometer-monitor, caution buzzer sounds and caution lamps lights continuously. TACHOMETER CAUTION TYPE DISPLAY INDICATION Over-revolution Rev Limit [ NOTE 1] Over Revolution [NOTE 2 ] Display screen...
Page 583: Engine Holder
DF90/115/140 “K8” (’08) MODEL 18-29 OIL CHANGE REMINDER SYSTEM When the total motor operating hours have reached the prepro- grammed hours, the “Change Oil” appears on the display screen Display screen of tachometer-monitor, caution buzzer sounds if engine is not running (but ignition switch ON) and caution lamps lights contin- uously.
Page 584: Wiring Diagram
18-30 DF90/115/140 “K8” (’08) MODEL WIRING DIAGRAM DF90/115/140...
Page 585: Wire Routing
DF90/115/140 “K8” (’08) MODEL 18-31 WIRE ROUTING...
Page 586 18-32 DF90/115/140 “K8” (’08) MODEL...
Page 587 DF100 “K9” (’09) MODEL 19- 1 DF100 “K9” (2009) MODEL FOREWORD This supplementary service manual describes service data and servicing procedures which dif- fer from those of the DF115 “K9” model. The entire manual should be thoroughly reviewed before any servicing is performed. NOTE: * Refer to the DF90/115/140 service manual (P/no.
Page 588: General Information
19-2 DF100 “K9” (’09) MODEL GENERAL INFORMATION *SPECIFICATIONS * These specifications are subject to change without notice. Data Item Unit DF100T/100WT PRE-FIX 10001F DIMENSIONS & WEIGHT Overall length (front to back) mm (in) 779 (30.7) Overall width (side to side) mm (in) 481 (18.9) Overall height...
Page 589 DF100T/100WT 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 equiva- lent octane content may be used.
Page 590: Service Data
19-4 DF100 “K9” (’09) MODEL *SERVICE DATA * These service data are subject to change without notice. Data Item Unit DF100T/100WT POWERHEAD Recommended operation range r/min 5000 – 6000 Idle speed r/min 625 ± 25 (in-gear: approx. 625) * Cylinder compression kPa (kg/cm , psi) 1300 –...
Page 591 DF100 “K9” (’09) MODEL 19-5 Data Item Unit DF100T/100WT CYLINDER HEAD / CAMSHAFT Cylinder head distortion Limit mm (in) 0.05 (0.002) Manifold seating faces Limit mm (in) 0.10 (0.004) distortion Cam height mm (in) 38.120 – 38.280 (1.5008 – 1.5071) Limit mm (in) 38.020 (1.4969)
Page 592 19-6 DF100 “K9” (’09) MODEL Data Item Unit DF100T/100WT VALVE / VALVE GUIDE Valve diameter mm (in) 33 (1.3) mm (in) 28 (1.1) Tappet clearance mm (in) 0.23 – 0.27 (0.009 – 0.011) (Cold engine EX STD mm (in) 0.23 – 0.27 (0.009 – 0.011) condition) Valve seat angle —...
Page 593 DF100 “K9” (’09) MODEL 19-7 Data Item Unit DF100T/100WT CYLINDER / PISTON / PISTON RING Cylinder distortion Limit mm (in) 0.05 (0.002) mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) Cylinder bore mm (in) 84.000 –...
Page 594 19-8 DF100 “K9” (’09) MODEL Data Item Unit DF100T/100WT CRANKSHAFT / CONROD Conrod small end inside mm (in) 21.003 – 21.011 (0.8269 – 0.8272) diameter mm (in) 0.030 – 0.050 (0.0012 – 0.0020) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end inside mm (in)
Page 595 DF100 “K9” (’09) MODEL 19-9 Data Item Unit DF100T/100WT ELECTRICAL Ignition timing Degrees BTDC 2 – BTDC 26 Over revolution limiter r/min 6200 Ω CKP sensor resistance 168 – 252 at 20 °C Ω CMP sensor resistance at 20 °C —...
Page 596 19-10 DF100 “K9” (’09) MODEL PTT MOTOR Brush length mm (in) 9.8 (0.39) Limit mm (in) 5.5 (0.22) mm (in) 22.0 (0.87) Commutator outside diameter Limit mm (in) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
Page 597 DF100 “K9” (’09) MODEL 19-11 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 18.0 Cylinder head bolt 10 mm 50.0 8 mm 18.0 Crankcase bolt 10 mm 37.5 Conrod cap nut...
Page 598 19-12 DF100 “K9” (’09) MODEL Tightening torque – General bolt NOTE: These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. TIGHTENING TORQUE THREAD TYPE OF BOLT DIAMETER N·m kg-m lb-ft 5 mm 2 –...
Page 599: Special Tools
DF100 “K9” (’09) MODEL 19-13 SPECIAL TOOLS 09900-00411 09900-00413 (5 mm) Hexagon socket 09900-00414 (6 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 600 19-14 DF100 “K9” (’09) MODEL 09913-50121 09914-79010 09919-16010 09921-29410 09915-47341 Oil seal remover Test wheel Deep socket wrench Driveshaft holder Oil filter wrench 09915-64530 09915-67010 09915-78211 09915-64512 Compression gauge Compression gauge 09915-77311 Oil pressure gauge Compression gauge hose hose attachment Oil pressure gauge adapter 09916-20610...
Page 601 DF100 “K9” (’09) MODEL 19- 15 09917-98221 09917-47011 09917-49610 09917-87810 Valve guide stem 09916-84511 Vacuum pump Vacuum pump Valve guide installer seal installer attach- Tweezers gauge adapor attachment ment (A) 09922-59410 Propeller shaft housing installer (B) 09922-59420 09922-89810 09930-30161 09930-39411 Housing installer Shift lock pin 09930-30104...
Page 602 19-16 DF100 “K9” (’09) MODEL X.XX XXXXX 09950-69512 09933-19861 SDS software 09940-44121 09940-44130 09945-79310 Gearcase oil leakage (Ver. 5.00) Air pressure gauge Attachment PTT cable extension tester (A) 09951-59910: Pinion bearing installer & remover shaft (B) 01500-0840A: Bolt 09951-09010 09951-09530 (C) 09951-39914: Pinion bearing plate 09952-99310 Shimming gauge...
Page 603: Materials Required
DF100 “K9” (’09) MODEL 19-17 MATERIALS REQUIRED SUZUKI OUTBOARD SUZUKI SUPER WATER RESISTANT SUZUKI SILICONE SUZUKI BOND MOTOR GEAR OIL GREASE “A” GREASE SEAL “1207B” 99000-25030* 99104-33140* 99000-22540 99000-25011 99000-25161 99000-31120 99000-31140 (400 ml × 24 pcs) (500 g) (250 g)
Page 604: Engine Control
• Ignition timing advance range: BTDC 2° – 26° • Ignition timing (at idling/trolling): BTDC 8° ± 5° SUZUKI DIAGNOSTIC SYSTEM (SDS) The SDS software version 4.00 or 5.00 can communicate with the DF100’s ECM.
Page 605 DF100 “K9” (’09) MODEL 19-19 POWER UNIT INTAKE CAMSHAFT The intake camshaft for DF100 was specially designed. The cam height of the intake comshaft is different from DF115. Cam height Standard: IN 38.120 – 38.280 mm (1.5008 – 1.5071 in) Service limit: IN 38.020 mm (1.4969 in) Intake camshaft...
Page 606: Wire/Hose Routing
19-20 DF100 “K9” (’09) MODEL WIRE/HOSE ROUTING WIRING DIAGRAM...
Page 607: Wire Routing
DF100 “K9” (’09) MODEL 19-21 WIRE ROUTING...
Page 608 19-22 DF100 “K9” (’09) MODEL...
Page 609 DF100 “K9” (’09) MODEL 19-23 Oil pressure switch High pressure fuel pump CMP sensor Cylinder temp. sensor...
Page 610 19-24 DF100 “K9” (’09) MODEL...
Page 611: Fuel/Water Hose Routing
DF100 “K9” (’09) MODEL 19-25 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 612 19-26 DF100 “K9” (’09) MODEL...
Page 613 DF100 “K9” (’09) MODEL 19-27...
Page 614 19-28 DF100 “K9” (’09) MODEL Fuel hose/Protector (Low pressure fuel pump to Fuel vapor separator) Upper union bolt 35 N . m(3.5 kg-m, 25.5 lb-ft) Fuel injector Fuel delivery pipe Fuel injector Fuel injector Fuel hose/Protector (Low pressure fuel pump to Low pressure fuel filter) Low pressure fuel pump Lower plug...
Page 615 Prepared by Service Department 1st Ed. October, 2000 Manual No.99500-90J07-03E...
Page 616 Printed in Japan K1 K2 K3 K4 K5 K6 K7 K8 K9...

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Df 140 Df 140 four strokeDf115Df100Df90t Df115t ... Show all

Suzuki DF 90 Service Manual

General Information 1

Periodic Maintenance 2

Periodic Maintenance Schedule

Maintenance and Tune-Up Procedures

Oil Pressure

Cylinder Compression

Engine Control System

Electrical

Battery Charging System

Electric Starter System

Monitor-Tachometer

Erectric Parts Holder

Fuel System

Precaution on Fuel System Service

Removal / Installation

Fuel Line ______________________________________________ 5-4

Fuel Vapor Separator / High Pressure Fuel Pump

Fuel Injector

Low Pressure Fuel Pump

Fuel Tank

Power Unit

Intake Manifold Assembly

Power Unit

Oil Pump

Timing Chain / Tensioner

Cylinder Head Assembly

Cylinder / Crankshaft / Piston

Thermostat

Operation

Removal / Inspection / Installation

MID Unit

Engine Side Cover

Driveshaft Housing and Oil Pan

Swivel Bracket, Steering Bracket and Clamp Bracket

Clamp Bracket ________________________________________ 7-13

Water Pressure Valve

Power Trim and Tilt

System Wiring Diagram

Service Procedure

Power Trim and Tilt Unit

Ptt Motor Relay

Ptt Switch

Operation

Lower Unit

Removal & Disassembly

Pinion Bearing

Inspection

Assembly & Installation

Trim Tab

Lower Unit Gears-Shimming and Adjustment

Df140 "K2" ('02) Model

Df90/115 "K2" ('02) Model

Df90/115/140 "K3" (2003) Model

Service Data (Df140(W)T/140Z) __________________________ 13-13

Service Data (Df90T/115(W)T) ___________________________ 13-6

Df90/115/140 "K4" ('04) Model

Quick Links

Chapters

Troubleshooting

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Summary of Contents for Suzuki DF 90