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Suzuki GF60A Service Manual

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Summary of Contents for Suzuki GF60A

  • Page 1 9 9 5 0 0 - 8 8 L 0 0 - 0 1 E...
  • Page 2 CAUTION stated, you must also use good judgment and observe basic mechanical safety principles. WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual.
  • Page 3 FOREWORD This manual contains an introductory description of the SUZUKI DF60 Outboard motor and procedures for inspec- tion, service and overhaul of their main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor.

  • Page 4: Table Of Contents

    TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Tune-Up........0B-1 Power Head..............1-i Precautions .............. 1-1 Engine Control ............1A-1 Engine Electrical Devices........1C-1 Power Unit Mechanical ..........1D-1 Power Unit Lubrication ........... 1E-1 Power Unit Cooling System ........
  • Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions............00-1 General Precautions ........... 00-1...

  • Page 6: Precautions

    00-1 Precautions: Precautions Precautions Precautions General Precautions ZAJ6110000001 WARNING • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor. • To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or doing other work, which could cause debris.
  • Page 7 00-2 CAUTION • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. • 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 00-3 Precautions:...

  • Page 9: General Information

    Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Scheduled Maintenance ........0B-1 Periodic Maintenance Schedule Chart....0B-1 General Description ..........0A-1 Lubrication Point ..........0B-2 Symbols .............. 0A-1 Service Instructions ..........0B-3 Abbreviations ............0A-2 Engine Oil Level Check........0B-3 Wire Color Symbols ..........

  • Page 10: General Information

    Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI Outboard Motor Gear Oil. Apply SUZUKI Super Grease A. Apply SUZUKI Moly Paste.

  • Page 11: Abbreviations

    General Information: 0A-2 Abbreviations ZAJ6110101002 IAC: Idle Air Control Abbreviations used in this service manual are as follows: IAT: Intake Air Temperature IG: Ignition ATDC: After Top Dead Center Ign.: Ignition AC: Alternating Current IN (In.): Intake BTDC: Before Top Dead Center LPS: Lever Position Sensor CKP Sensor: Crankshaft Position sensor MAP: Manifold Absolute Pressure...

  • Page 12: Warning, Caution And Information Label Locations

    3. Label S.I.G.P. Genuine Parts Description Example ZAJ6110101005 If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent. They are precision-made to ensure high quality and DF 60A correct fit. 0 6 0 0 2 F...

  • Page 13: Fuel And Oil Recommendations

    Always select good quality engine setting immediately after planning. oil. Suzuki recommends the use of a SAE 10 W – 40 NMMA Next 1 hour certified oil. Operate the engine in-gear at less than 3/4 (three - If NMMA certified FC-W oil is not available, select a good quarter) throttle (4 000 r/min).

  • Page 14: 0A-5 General Information

    ZAJ6110101009 ZAJ6110101010 An outboard motor is designed to develop its rated Suzuki recommends a 12 volt cranking type lead acid power within a specified engine speed range. The battery for the DF60A. maximum rated power delivered by the DF60 model is Minimum battery requirement for starting the engine is shown below.

  • Page 15: Specifications

    General Information: 0A-6 Specifications Specifications ZAJ6110107001 NOTE These specifications are subject to change without notice. Model Pre-fix Data Item Unit DF60AT DF60ATH PRE-FIX 06002F Dimensions and Weight Data Item Unit DF60AT DF60ATH Overall length (front to back) mm (in.) 699 (27.5) 819 (32.2) Overall width (side to side) mm (in.)
  • Page 16 2.7 (2.9 / 2.4): Oil change only Engine oil amounts L (US/lmp. qt) 2.9 (3.0 / 2.6): Oil filter change SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API Gear oil classification GL-5. Gearcase oil capacity ml (US/lmp. oz) 610 (20.6/21.5)

  • Page 17: Service Data

    General Information: 0A-8 Service Data ZAJ6110107002 NOTE These service data are subject to change without notice. Powerhead Data Item Unit DF60AT DF60ATH Recommended operating range r/min 5 300 – 6 300 Idle speed r/min 800 ± 50 (in-gear: Approx. 800) **Cylinder compression pressure 1 200 –...
  • Page 18 0A-9 General Information: Valve / Valve Guide Data Item Unit DF60AT DF60ATH mm (in.) 26.6 (1.05) Valve diameter mm (in.) 21.5 (0.85) Tappet clearance std. mm (in.) 0.18 – 0.22 (0.007 – 0.009) (Cold engine condition) std. mm (in.) 0.28 – 0.32 (0.011 – 0.013) —...
  • Page 19 General Information: 0A-10 Cylinder / Piston / Piston Ring Data Item Unit DF60AT DF60ATH Cylinder distortion Limit mm (in.) 0.06 (0.002) std. mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in.) 0.100 (0.0039) Cylinder bore std.
  • Page 20 0A-11 General Information: Crankshaft / Conrod Data Item Unit DF60AT DF60ATH Conrod small end inside diameter std. mm (in.) 18.003 – 18.013 (0.7088 – 0.7092) std. mm (in.) 0.031 – 0.049 (0.0012 – 0.0019) Conrod big end oil clearance Limit mm (in.) 0.080 (0.0031) Conrod big end inside diameter...
  • Page 21 General Information: 0A-12 Starter Motor Data Item Unit DF60AT DF60ATH Max. continuous time of use Sec. Motor output std. mm (in.) 16.0 (0.63) Brush length Limit mm (in.) 12.0 (0.47) std. mm (in.) 0.5 – 0.8 (0.02 – 0.03) Commutator undercut Limit mm (in.) 0.2 (0.01)

  • Page 22: Tightening Torque Specifications

    0A-13 General Information: Tightening Torque Specifications ZAJ6110107003 Important Fasteners Thread Tightening Torque Item Diameter N·m kgf-m lbf-ft Cylinder head cover bolt 6 mm 8 mm 16.5 Cylinder head bolt 10 mm 42.7 Outside 8 mm 18.0 Crankcase bolt Inside 10 mm 33.3 15 N·m (1.5 kgf-m, 10.8 lbf-ft), then plus turn in 65 Conrod cap bolt...

  • Page 23: Special Tools And Equipment

    Special Tools and Equipment Recommended Service Material ZAJ6110108001 99000–22540 99000–25161 99000–31120 99000–31140 99000–32020 SUZUKI Outboard SUZUKI Water SUZUKI Silicone Seal SUZUKI Bond 1207B SUZUKI Thread Lock Motor Gear Oil Resistant Grease (250 (50 g) (100 g) Super 1333B (50 g) 99000–32050 99000–25140...

  • Page 24: Special Tool

    0A-15 General Information: Special Tool ZAJ6110108002 01500–08403 09900–20101 09900–20202 09900–20203 09900–20205 Bolt Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (0 – 25 09900–20605 09900–20606 09900–20701 09900–20803 09900–21304 Dial calipers (10 – 34 Dial gauge Magnetic stand Thickness gauge Steel “V”...
  • Page 25 General Information: 0A-16 09916–37320 09916–44310 09916–58210 09916–68810 09916–77310 Valve guide reamer (ø Valve guide remover Valve guide installer Tappet holder Piston ring 10.5 mm) handle compressor 09916–84511 09917–87010 09917–98221 09919–16010 09921–29511 Tweezers Valve guide installer Valve guide stem seal Deep socket wrench Driveshaft holder attachment installer attachment...
  • Page 26 0A-17 General Information: 09945–69010 09945–79310 09950–69512 09951–09530 09951–19431 PTT rod holder PTT cable extension Gearcase oil leakage Gear adjusting gauge Attachment tester 09951–39914 09951–59910 09952–99310 99954–53873* 99954–53008-820* Plate Shaft (removal and Hand air pump Stevens peak reading Digital voltmeter installation) voltmeter CD-77 99954–53883* Gear oil filler...

  • Page 27: Maintenance And Tune

    Maintenance and Tune-Up: 0B-1 Maintenance and Tune-Up General Information Precautions Precautions for Maintenance ZAJ6110200001 The “Periodic Maintenance Schedule Chart” 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.

  • Page 28: Lubrication Point

    Lubrication Point ZAJ6110205002 Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor. Apply Suzuki Water Resistant Grease to the following point. Lubricate Every 50 hours (3 months) : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) IAJ611020001-03 1.

  • Page 29: Service Instructions

    Maintenance and Tune-Up: 0B-3 Service Instructions Engine Oil Level Check ZAJ6110206001 Inspect oil level Before every use 1) Place outboard motor upright on a level surface. 2) Remove motor cover. 3) Remove oil level dipstick (1) and wipe it clean. IAJ611020008-02 Engine Oil Change and Engine Oil Filter Replacement...
  • Page 30 0B-4 Maintenance and Tune-Up: 5) Install new gasket and oil drain plug. 7) To reset oil change reminder system’s operation time Tighten engine oil drain plug to specified torque. to zero (cancellation). NOTE CAUTION Refer to “Oil Change Reminder System To avoid water entry into oil pan or oil Description”...
  • Page 31 Maintenance and Tune-Up: 0B-5 Engine Oil Filter Replacement 6) Tighten the filter 3/4 turn from the point of contact with mounting surface using an oil filter wrench. 1) Drain engine oil in the same manner of engine oil change procedure. Tightening torque 2) Remove STBD and PORT side covers.

  • Page 32: Gear Oil Change

    1) Remove the two bolts and fuel hose guard (1). Recommended Gear Oil • Suzuki Outboard Motor Gear Oil or API classification GL5, Viscosity rating SAE # 90 Hypoid gear oil.

  • Page 33: Spark Plug Inspection And Cleaning

    Maintenance and Tune-Up: 0B-7 3) Remove the ignition coil and spark plug. Carbon Deposits Inspect for carbon deposits on spark plug base. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. IAJ611020019-01 I9J011020005-01 Installation...

  • Page 34: Tappet Clearance Inspection And Adjustment

    0B-8 Maintenance and Tune-Up: Tappet Clearance Inspection and Adjustment 3) Rotate crankshaft clockwise to bring cam nose ZAJ6110206006 vertical to shim surface. Inspect tappet clearance 4) Measure tappet clearances by inserting thickness Every 200 hours (12 months) gauge between cam and shim surface. Inspection NOTE The tappet clearance specification is different for intake...
  • Page 35 Maintenance and Tune-Up: 0B-9 Adjustment 4) Rotate top of cam 90 degree clockwise and remove Tappet clearances are adjusted by replacing tappet shim from cut- away at tappet. shim. (Two tappets can be adjusted at the same time) 1) With cam nose vertical to valve, turn tappet cut-away towards center of cylinder head as shown in figure.
  • Page 36 0B-10 Maintenance and Tune-Up: 9) Recheck tappet clearance. “C” NOTE After completing tappet clearance adjustment and securing camshaft housing “ a ” bolts, inspect tappet clearance again. I9J011020013-01 “C”: I.D No. “a”: 2.50 mm Shim size chart Thickness Thickness I.D. No. I.D.
  • Page 37 Maintenance and Tune-Up: 0B-11 Tappet shim selection chart (IN. side) IAJ611020024-02...
  • Page 38 0B-12 Maintenance and Tune-Up: Tappet shim selection chart (EX. side) IAJ611020048-02...

  • Page 39: Idle Speed And Idle Air Control (Iac) Duty Inspection

    Maintenance and Tune-Up: 0B-13 Idle Speed and Idle Air Control (IAC) Duty 5) Shift into forward, Check in-gear idle speed. If not, check idle air control system. Inspection ZAJ6110206007 NOTE Inspect idle speed and IAC Duty Initially after 20 hours (1 month) and every 200 hours •...

  • Page 40: Breather Line And Fuel Line Inspection

    0B-14 Maintenance and Tune-Up: Breather Line and Fuel Line Inspection ZAJ6110206009 Inspect breather line and fuel line Initially after 20 hours (1 month) and every 50 hours (3 months) Replace breather line and fuel line Every 2 years If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line. Fuel line check point IAJ611020028-01...

  • Page 41: Low Pressure Fuel Filter Inspection

    Maintenance and Tune-Up: 0B-15 Low Pressure Fuel Filter Inspection 3) Remove the two bolts securing filter bracket (3), then ZAJ6110206010 remove the filter bracket and low pressure fuel filter (4). Inspect low pressure fuel filter Every 50 hours (3 months) Replace low pressure fuel filter Every 400 hours or 2 years If leakage, cracks or other damage is found, replace the...

  • Page 42: Water Pump And Water Pump Impeller Inspection

    3) Inspect water pump impeller. IAJ611020029-01 Replace if vanes are cut, torn or worn. SUZUKI recommends that replacing the water pump impeller every 200 hours (12 months). 4) Assemble the water pump related items. Refer to “Water Pump Removal and Installation” in Section 3A (Page 3A-6).

  • Page 43: Anodes Inspection

    10 mm bolt (2) to function as a screw jack. IAJ611020038-01 IAJ611020036-02 NOTE The anode (3) securing bolt should be covered with suzuki silicone seal. : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) IAJ611020039-01 I9J011020023-01...

  • Page 44: Bonding Wires Inspection

    0B-18 Maintenance and Tune-Up: Bonding Wires Inspection Battery Inspection ZAJ6110206015 ZAJ6110206016 Inspect bonding wires Inspect battery Every 50 hours (3 months) Every 50 hours (3 months) 1) If breakage or other damage is found on bonding WARNING wire (1), replace the wire. •...
  • Page 45 Maintenance and Tune-Up: 0B-19 Connecting Battery Battery Solution Level Check CAUTION CAUTION Once the battery has been initially serviced, • If the battery leads are loose, incorrectly NEVER add diluted sulfuric acid or battery connected or reversed, the electrical damage will occur. system could be damaged.

  • Page 46: Bolts And Nuts Inspection

    0B-20 Maintenance and Tune-Up: Bolts and Nuts Inspection ZAJ6110206017 Inspect bolts and nuts Initially after 20 hours (1 month) and every 100 hours (6 months) Check that all bolts and nuts listed below are tightened to their specified torque. Refer to “Tightening Torque Specifications” in Section 0A (Page 0A-13).

  • Page 47: Cylinder Compression Pressure Check

    Maintenance and Tune-Up: 0B-21 High oil pressure 6) Disconnect remote control throttle cable from throttle lever. • Using an engine oil of too high viscosity 7) Move and hold throttle lever (1) in full-open position. • Clogged oil passage • Clogged oil pressure regulator •...
  • Page 48 0B-22 Maintenance and Tune-Up:...

  • Page 49: Power Head

    Table of Contents 1- i Section 1 Power Head CONTENTS Precautions ..........1-1 Inspection of the ECM and Its Circuit....1A-32 ECM Main Relay Inspection......1A-35 Precautions............. 1-1 Precautions for Powerhead........1-1 Engine Electrical Devices ....... 1C-1 Engine Control......... 1A-1 Precautions............1C-1 Precaution for Engine Electrical Device ....1C-1 Precautions............1A-1 General Description ..........1C-1 Precautions on Engine Diagnosis .......
  • Page 50 1-ii Table of Contents Upper Oil Seal Housing Removal and Displacement Type Water Pump Description ..1F-1 Installation ............1D-8 Water Pressure Valve Description ...... 1F-1 Intake Manifold and Throttle Body Schematic and Routing Diagram ......1F-2 Components............1D-9 Cooling Water Circulation Chart......1F-2 Throttle Body Removal and Installation ....1D-10 Diagnostic Information and Procedures ....
  • Page 51 Table of Contents 1-iii Ignition Control Description .........1H-2 Service Instructions ..........1I-6 Starter Motor Removal and Installation....1I-6 Component Location ...........1H-4 Starter Motor Test ..........1I-7 Ignition System Components Location ....1H-4 Starter Motor Components........1I-9 Diagnostic Information and Procedures....1H-4 Starter Motor Disassembly and Assembly ..1I-10 Ignition System Symptom Diagnosis....1H-4 Starter Motor Components Inspection and Ignition System Troubleshooting......1H-5...

  • Page 52: Precautions

    1-1 Precautions: Precautions Power Head Precautions Precautions for Powerhead ZAJ6111000001 Refer to “General Precautions” in Section 00 (Page 00-1).

  • Page 53: Engine Control

    NOTE • To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use the Suzuki Diagnostic System. • The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected. • Each electrical circuit is affected by battery voltage, always use a full-charged battery.
  • Page 54 1A-2 Engine Control: General Description Engine Control System Description ZAJ6111101001 The DF60A model employ an integrated system which performs the control functions for fuel injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine Control Module). System Structure INPUT CONTROL OUTPUT...
  • Page 55 Engine Control: 1A-3 Engine Control System Flow Diagram IAJ611110002-01 1. Flywheel 10. IAC valve 19. PTT relay 28. Low pressure fuel filter 2. CKP sensor 11. PTT switch 20. PTT motor 29. Low pressure fuel pump 3. Cylinder temp. sensor 12.
  • Page 56 1A-4 Engine Control: Engine Control Module (ECM) ZAJ6111101002 The ECM sends signals to control the actuators based on the information inputs from each sensor / switch. Major controls are as follows: Name of Control Description Fuel injection control • Controls fuel injection amount and timing. Ignition control •...
  • Page 57 Engine Control: 1A-5 ECM Input / Output Circuit Diagram IAJ611110003-01...
  • Page 58 1A-6 Engine Control: ECM Connector / Terminals Layout 48 47 46 45 44 43 42 41 40 39 38 37 12 11 10 9 8 7 6 5 4 3 2 1 60 59 58 57 56 55 54 53 52 51 50 49 24 23 22 21 20 19 18 17 16 15 14 13 72 71 70 69 68 67 66 65 64 63 62 61 36 35 34 33 32 31 30 29 28 27 26 25...
  • Page 59 Engine Control: 1A-7 Caution System Description ZAJ6111101003 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 Monitor-Tachometer “A” “D”...
  • Page 60 1A-8 Engine Control: Low Oil Pressure Caution System Condition: Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop below 100 kPa (1.0 kg/cm , 14 psi.) while the engine is running. Action: Engine speed •...
  • Page 61 Engine Control: 1A-9 Action: Engine speed • Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel injection and ignition signals. • The engine automatically stops 3 minutes after the caution system is activated. Caution lamp • “TEMP” lamp lights continuously. •...
  • Page 62 1A-10 Engine Control: Self-Diagnostic System Description ZAJ6111101004 The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or 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 63 Engine Control: 1A-11 NOTE • If two or more items fail at once, the self-diagnostic indication appears according to the 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 64 1A-12 Engine Control: Fail-Safe System Description ZAJ6111101005 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 65 Engine Control: 1A-13 Chart of Total Operating Hours Indication Monitor-Tachometer Total Operating Hours Needle “A” Indication REV-LIMIT Lamp “B” Flashing* 0 h – (49 h) 50 h 500 r/min. 60 h 600 r/min. ↓ ↓ 540 h 5 400 r/min. 550 h 500 r/min.
  • Page 66 Oil lamp replaced. Once the system has been activated, SUZUKI strongly recommends that the engine oil be replaced before canceling the system. • If the engine oil has been replaced with the...
  • Page 67 Engine Control: 1A-15 Component Location Engine Control System Components / Engine Electrical Device Location ZAJ6111103001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4). Diagnostic Information and Procedures ECM Power and Ground Circuit Check ZAJ6111104001 Wiring Diagram B/Bl BATT IAJ611110004-01 1.
  • Page 68 1A-16 Engine Control: Troubleshooting Step Action Is operation of the main relay heard when the ignition switch Go to step 4. Go to step 2. is turned “ON”? Are the main fuses (30 amp.), and (for Ignition and ECM) in Go to step 3.

  • Page 69: Troubleshooting

    Engine Control: 1A-17 Self-Diagnostic Code “3 – 4” MAP Sensor ZAJ6111104003 Wiring Diagram Lg/B Br/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Lg/B Br/Y IAJ611110005-02...
  • Page 70 1A-18 Engine Control: Step Action 1) Check the MAP sensor output voltage change. Substitute a known- • Faulty MAP sensor. Refer to “MAP Sensor Output Voltage Inspection” in good ECM and recheck. • “R” wire shorted to Section 1C (Page 1C-12). “W”...
  • Page 71 Engine Control: 1A-19 Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor ZAJ6111104004 Wiring Diagram Lg/W I9J011110021-03 1. Cylinder temp. sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the Cylinder Go to step 2. • “Lg/W” wire shorted Temp.
  • Page 72 1A-20 Engine Control: Self-Diagnostic Code “2 – 3” IAT Sensor ZAJ6111104005 Wiring Diagram Lg/B Br/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Lg/B Br/Y IAJ611110006-01...
  • Page 73 Engine Control: 1A-21 Self-Diagnostic Code “4 – 2” CKP Sensor ZAJ6111104006 Wiring Diagram IAJ611110007-01 1. CKP sensor Troubleshooting Step Action 1) Check the CKP sensor air gap. Go to step 2. Incorrectly adjusted air Refer to “CKP Sensor Removal and Installation” in gap.
  • Page 74 1A-22 Engine Control: Self-Diagnostic Code “2 – 4” CMP Sensor ZAJ6111104007 Wiring Diagram B/Bl Y/Bl I9J011110055-01 1. CMP sensor 2. + 12 V (From Ign. switch) Troubleshooting Step Action Is the CMP sensor installed properly and the wire harness Go to step 2. Correct.
  • Page 75 Engine Control: 1A-23 Self-Diagnostic Code “2 – 2” Air Intake System ZAJ6111104008 Wiring Diagram Lg/B Br/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Lg/B Br/Y...
  • Page 76 1A-24 Engine Control: Self-Diagnostic Code “3 – 2” MAP Sensor 2 ZAJ6111104009 Wiring Diagram Lg/B Br/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Lg/B Br/Y...
  • Page 77 Engine Control: 1A-25 Self-Diagnostic Code “4 – 3” Fuel Injector ZAJ6111104011 Wiring Diagram 12 V (From main relay) B/Br IAJ611110010-01 1. Fuel injector Troubleshooting Step Action 1) Using a sound scope, check that each injector has an Fuel injector and its Go to step 2.
  • Page 78 1A-26 Engine Control: Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor) ZAJ6111104012 Wiring Diagram Lg/B Br/Y 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Lg/B Br/Y...
  • Page 79 Engine Control: 1A-27 Step Action 1) Check the TPS output voltage change. Substitute a known- • Faulty TPS. Refer to “TPS Inspection” in Section 1C (Page 1C-13). good ECM and recheck. • “R” wire shorted to “Br/Y” wire, “B/W” Is it in good condition? wire open, poor “B/ W”...
  • Page 80 1A-28 Engine Control: Self-Diagnostic Code “1 – 1” Rectifier/Regulator (Over Charging) ZAJ6111104015 NOTE • This self-diagnostic code indication may be canceled when turning the ignition switch “ON” (engine not running), because ECM detects battery voltage. • It is difficult to thoroughly check the rectifier/regulator. Before replacing it with new one, check that the ground point has good electrical contact.
  • Page 81 Engine Control: 1A-29 Self-Diagnostic Code “3 – 7” Trim Sensor ZAJ6111104017 Wiring Diagram I9J011110065-01 1. Trim sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect trim sensor Go to step 2. • “R” wire open, “R” connector. wire shorted to ground circuit or poor 2) With the ignition switch “ON”, check the voltage at the wire connection.
  • Page 82 1A-30 Engine Control: Troubleshooting Without Self-Diagnostic Code ZAJ6111104018 Before troubleshooting, make sure that there is not a self-diagnostic code indication. Condition Possible cause Correction / Reference Item Unstable idling / trolling Clogged MAP sensor vacuum passage. Check the vacuum passage. (or engine tends to stall) Malfunctioning TPS.
  • Page 83 Engine Control: 1A-31 IAC System Troubleshooting ZAJ6111104019 Wiring Diagram 12V (From Main relay) I9J011110036-02 1. IAC valve Troubleshooting Step Action 1) Warm up the engine to normal operating temperature IAC system is in good Go to step 2. and keep it idling. condition.
  • Page 84 1A-32 Engine Control: Service Instructions How to Use the 36 Pin Test Cord Set ZAJ6111106001 This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring harness. To take a measurement, connect the tester probe to the relevant terminal of the test cord. Special tool (A): 09930–88730 (36-pin test cord set) (White connector)
  • Page 85 Engine Control: 1A-33 (White connector) 40 41 42 43 44 45 46 47 48 49 58 59 60 61 62 63 64 65 66 67 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31 14 15 16 17 18...
  • Page 86 1A-34 Engine Control: Wire Terminal Circuit Standard Voltage Condition / Remarks color Approx. 5 V Ignition switch ON, Stop switch plate IN. Bl/R Emergency stop switch Approx. 0 V Ignition switch ON, Stop switch plate OUT. — — — — —...
  • Page 87 Engine Control: 1A-35 Wire Terminal Circuit Standard Voltage Condition / Remarks color Approx. 2.5 V Ignition switch ON. Starter switch Approx. 12 V Ignition switch START position. Bl/B OIL lamp — — — — — — — — — — G/W CHECK ENGINE lamp —...

  • Page 88: Engine Electrical Devices

    1C-1 Engine Electrical Devices: Engine Electrical Devices Power Head Precautions Precaution for Engine Electrical Device ZAJ6111300001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Engine Diagnosis” in Section 1A (Page 1A-1). General Description Sensor and Switch Description CMP Sensor ZAJ6111301001 •...
  • Page 89 Engine Electrical Devices: 1C-2 • The CMP sensor is a GMR (Giant Magnet Resistive) • Failure symptom: semiconductor type sensor. Without the CMP sensor signal input, the ECM does The GMR semiconductor has the property of varying not output the ignition and fuel injection signals. the electrical resistance depending on the intensity of •...
  • Page 90 1C-3 Engine Electrical Devices: Cylinder Temperature Sensor IAT Sensor The cylinder temperature sensor is installed on the Three sensors (MAP sensor / TPS / IAT sensor) are cylinder (top side) and is used to detect the cylinder combined into one unit that is installed on top of the temperature.
  • Page 91 Engine Electrical Devices: 1C-4 Throttle Position Sensor (TPS) • When the shift lever is in forward or reverse at the Three sensors (MAP sensor / TPS / IAT sensor) are time of engine start, the ECM will not supply power to combined into one unit that is installed on top of the the starter motor relay, thus preventing starter motor throttle body.
  • Page 92 1C-5 Engine Electrical Devices: Cranking Switch Signal • Failure symptom: The ECM detects if the engine is being started by the In the event of sensor failure: position of ignition switch. When the ignition key is – The ECM performs the control on the assumption turned to ST position, a voltage (12 V) signal is input to that the sensor output is 3.9 V.
  • Page 93 Engine Electrical Devices: 1C-6 ECM Power Source Line Main Harness Capacitor ZAJ6111301002 This capacitor stabilizes the voltage in the engine control The ECM is battery dependent and must be provided system circuit. with its own dedicated 12 V power supply. The electrical •...

  • Page 94: Location Of Sensor And Switch

    1C-7 Engine Electrical Devices: Component Location Location of Sensor and Switch ZAJ6111303001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4). Service Instructions Resistance Check ZAJ6111306001 Special tool : 09930–99320 (Digital tester) Tester knob indication Resistance (Ω) NOTE Make sure ignition switch is always OFF when measuring resistance.
  • Page 95 Engine Electrical Devices: 1C-8 Cylinder Temp. Sensor Removal and • Connect connector to sensor securely. Installation • Check to ensure that all removed parts are back in ZAJ6111306002 original position. Removal • Check wire routing. 1) Unfasten cable tie (1). Refer to “Wiring Harness Routing Diagram”...
  • Page 96 1C-9 Engine Electrical Devices: MAP Sensor / TPS / IAT sensor Removal and CKP Sensor Removal and Installation ZAJ6111306006 Installation Removal ZAJ6111306019 Refer to “Throttle Body Removal and Installation” in 1) Remove the ring gear cover. Section 1D (Page 1D-10). Refer to “Ring Gear Cover Removal and Installation”...
  • Page 97 Engine Electrical Devices: 1C-10 Installation IAT Sensor Inspection ZAJ6111306009 Installation is reverse order of removal with special NOTE attention to the following steps. The IAT sensor is a thermistor type sensor, • Install CKP sensor with air gap of 0.75 mm between which is very sensitive to temperature sensor and reluctor bar on flywheel, then tighten change.
  • Page 98 1C-11 Engine Electrical Devices: CMP Sensor Removal and Installation 4) Connect the 36-pin test cord set between ECM and ZAJ6111306010 wire harness as shown in figure. Removal Special tool 1) Remove the two bolts and fuel hose guard (1). (A): 09930–88730 (36-pin test cord set) 40 41 42 43 44 45 46 47 48 49 58 59...
  • Page 99 Engine Electrical Devices: 1C-12 7) Turn Ignition switch ON. 3) Install STBD lower side cover. Refer to “Lower Side Cover Removal and 8) Measure the voltage when the tip of a steel Installation” in Section 2A (Page 2A-3). screwdriver is brought near and then pulled away from the sensor tip.
  • Page 100 1C-13 Engine Electrical Devices: 3) Remove screws (2) and IAC valve. I9J011130018-01 7) If the valve does not turn, check the wiring harness for continuity (between ECM and IAC valve and IAJ611130025-02 connector contact condition. Installation 8) Reinstall IAC valve. Installation is reverse order of removal.
  • Page 101 Engine Electrical Devices: 1C-14 3) Connect tester probe (“+”, Red) to No. 6 terminal. Trim Sensor Inspection ZAJ6111306018 4) Connect tester probe (“–”, Black) to No. 25 terminal 1) Turn ignition switch OFF. (or to body ground). 2) Connect 3-pin test cord between trim sensor and 36-pin test cord (White connector) wire harness as shown in figure.
  • Page 102 1C-15 Engine Electrical Devices: 5) Connect tester probe as shown in the illustration. Emergency Stop Switch Inspection ZAJ6111306021 Check for sensor output voltage. 1) Disconnect the emergency stop switch lead wire. Operate the PTT switch, and check if voltage changes linearly within specification, according to 2) Check the continuity / infinity between the wiring trim/tilt position.

  • Page 103: Power Unit Mechanical

    Power Unit Mechanical: 1D-1 Power Unit Mechanical Power Head General Description Power Unit Construction Description Cylinder Number ZAJ6111401001 Cylinder number is as mentioned in figure. The power unit is direct water cooled, in line 3 cylinder, 4 stroke gasoline unit with its DOHC (Double overhead camshaft) valve mechanism for “V”...
  • Page 104 1D-2 Power Unit Mechanical: Service Instructions Tappet Clearance Inspection Cylinder Head Cover Removal and Installation ZAJ6111406001 ZAJ6111406003 Refer to “Tappet Clearance Inspection and Adjustment” Removal in Section 0B (Page 0B-8). Before removing cylinder head cover, disconnect battery cables from battery. Ring Gear Cover Removal and Installation 1) Remove both lower side covers.
  • Page 105 • Remove oil, old sealant, and dust from sealing surfaces. • After cleaning, apply sealant to cylinder head sealing surface area as shown in figure. : Sealant 99000–31140 (SUZUKI Bond 1207B (100 g)) IAJ611140037-01 7) Remove the bolt and joint connector bracket (10).
  • Page 106 1D-4 Power Unit Mechanical: • Install cylinder head cover (2) to cylinder head, then 2) Remove the breather hose (1) from silencer case tighten cylinder head cover bolts to specified torque. (2). Tightening torque Cylinder head cover bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) IAJ611140045-01 Installation...
  • Page 107 Power Unit Mechanical: 1D-5 4) Disconnect lead wire connectors from ECM (2). 7) Disconnect IAC valve lead wire connector (5) at IAC Remove ECM from electric parts holder. valve. Identify the lead wire connectors for the cylinder temp. sensor (6), high pressure fuel pump (7) and disconnect them from main harness.
  • Page 108 1D-6 Power Unit Mechanical: 10) Disconnect lead wire connector from rectifier/ 13) To remove the electric parts holder, refer to following: regulator (13). a) Remove the nut (18), positive (+) battery cable Disconnect the white charge output lead wire (19) and positive lead wire (20) from magnetic connector (14).
  • Page 109 Power Unit Mechanical: 1D-7 e) Remove the bolt (26) securing PTT motor relay h) Disconnect the PTT relay lead wire connector GND lead wire and harness GND lead wire. (31). Remove the PTT relay (32). IAJ611140060-01 Disconnect CKP sensor lead wire connector IAJ611140062-01 (27), then pull out CKP sensor lead wire of Remove the capacitor (33), joint connectors (34)

  • Page 110: Upper Oil Seal Housing Removal And Installation

    1D-8 Power Unit Mechanical: k) To free the electric parts holder (35), remove the 2) Remove the bolts securing hose clamps (2). cable clamps (36) from electric parts holder by releasing clamp’s lock. IAJ611140068-01 3) Remove the screws and CKP sensor (3). IAJ611140066-01 Installation Installation is reverse order.

  • Page 111: Intake Manifold And Throttle Body Components

    Power Unit Mechanical: 1D-9 Installation • Apply engine oil to lip area of upper oil seal. Installation is reverse order of removal with special Install upper oil seal housing (3) and secure with bolts. attention to the following steps. Tightening torque Upper oil seal housing bolt (6 mm) (a): 11 N·m ( CAUTION 1.1 kgf-m, 8.0 lbf-ft)

  • Page 112: Throttle Body Removal And Installation

    1D-10 Power Unit Mechanical: Throttle Body Removal and Installation 5) Remove the four bolts (5) securing throttle body to ZAJ6111406008 intake manifold, then detach the throttle body. Removal 6) Disconnect the MAP / throttle position / IAT sensor 1) Remove the starter motor and air intake silencer lead wire connector (6) at sensor.

  • Page 113: Throttle Body Inspection

    Power Unit Mechanical: 1D-11 • Perform the following final assembly checks to ensure Intake Manifold Removal and Installation ZAJ6111406007 proper and safe operation. Removal – All parts removed have been returned to their 1) Relieve fuel pressure. original positions. Refer to “Fuel Pressure Relief Procedure” in Section 1G (Page 1G-15).
  • Page 114 1D-12 Power Unit Mechanical: 8) Disconnect the IAC valve lead wire connector (4) at 11) To remove the intake manifold, refer to following. IAC valve. a) Disconnect the high pressure fuel pump lead wire connector (7) at fuel pump. IAJ611140083-02 9) Disconnect fuel outlet hose (5) from low pressure IAJ611140087-01 fuel pump.
  • Page 115 Power Unit Mechanical: 1D-13 d) Remove the intake manifold (with fuel vapor • Install the intake manifold assembly (2), then tighten separator). bolts and nuts securely. e) Remove the fuel vapor separator from intake Tightening torque manifold. Intake manifold bolt / nut (a): 23 N·m (2.3 kgf-m, Refer to “Fuel Vapor Separator Removal and 16.5 lbf-ft) Installation”...

  • Page 116: Power Unit Removal And Installation

    1D-14 Power Unit Mechanical: Power Unit Removal and Installation 6) Remove the starter motor (3). ZAJ6111406010 Refer to “Starter Motor Removal and Installation” in Removal Section 1I (Page 1I-6). 1) Relieve fuel pressure. Refer to “Fuel Pressure Relief Procedure” in Section 1G (Page 1G-15).
  • Page 117 Power Unit Mechanical: 1D-15 9) Remove the bolts and fuel hose guard (6). 13) Remove the five bolts and upper oil seal housing (11). IAJ611140099-01 10) Disconnect ignition coil connectors (7). IAJ611140103-01 Remove the bolts securing the ignition coils (8). 14) Remove the two bolts securing front panel (12).
  • Page 118 1D-16 Power Unit Mechanical: 17) Remove the water return hose (16) from engine 21) Remove the screws and neutral switch (24) (if holder. necessary). 22) Remove the two bolts and clutch lever holder (25) (with clutch shaft (26)). IAJ611140107-01 18) Disconnect the neutral switch lead wire connector (17).
  • Page 119 IAJ611140117-01 NOTE Before installing power unit, apply sealant to the four hatched areas shown in the illustration at below. : Sealant 99000–31140 (SUZUKI Bond 1207B (100 g)) IAJ611140115-01 26) Lift up and remove power unit from engine holder. Installation Installation is reverse order of removal with special attention to the following step.
  • Page 120 Refer to “Thermostat Removal and Installation” in driveshaft and crank shaft splines. Section 1F (Page 1F-3). • Apply suzuki silicone seal to power unit mounting bolts and tighten bolts to specified torque. : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) Tightening torque Power unit mounting bolt (8 mm) (a): 23 N·m (2.3...
  • Page 121 Power Unit Mechanical: 1D-19 • Install dowel pins (1), gasket (2) and upper oil seal • Install battery charge coil (2). housing (3), then tighten bolts (4) to specified torque. Refer to “Battery Charge Coil Removal and Installation” in Section 1K (Page 1K-5). Tightening torque Upper oil seal housing bolt (a): 10 N·m (1.0 kgf- m, 7.2 lbf-ft)
  • Page 122 1D-20 Power Unit Mechanical: Intake manifold Throttle body Install the throttle body. • Install gaskets and intake manifold (1), then tighten Refer to “Throttle Body Removal and Installation” (Page bolts and nuts to specified torque. 1D-10). Refer to “Intake Manifold Removal and Installation” (Page 1D-11).

  • Page 123: Timing Chain, Chain Tensioner And Camshaft Sprockets Components

    Power Unit Mechanical: 1D-21 Timing Chain, Chain Tensioner and Camshaft Sprockets Components ZAJ6111406011 IAJ611140133-02 1. Timing chain 6. Spacer 11. Bolt 16. Bolt 2. Bolt 7. Chain tensioner 12. Exhaust camshaft sprocket 17. Crankshaft 3. Chain guide 8. Bolt 13. Dowel pin : 65 N·m (6.5 kgf-m, 47.0 lbf-ft) 4.

  • Page 124: Timing Chain, Chain Tensioner And Camshaft Sprockets Removal And Installation

    1D-22 Power Unit Mechanical: Timing Chain, Chain Tensioner and Camshaft 3) Remove the bolts (1) and timing chain tensioner link (2). Sprockets Removal and Installation ZAJ6111406012 Removal 1) Remove the oil pump. Refer to “Oil Pump Removal and Installation” in Section 1E (Page 1E-3).
  • Page 125 Power Unit Mechanical: 1D-23 7) Loosen and remove the bolt (9) securing IN. 2) Check that match mark “C” on exhaust camshaft camshaft timing sprocket to camshaft. timing sprocket aligns with match mark “D” on cylinder head as shown in figure. NOTE 3) Fit the dowel pin (1) onto IN.
  • Page 126 1D-24 Power Unit Mechanical: 5) Bring blue plate “F” of timing chain into alignment 8) With latch of tensioner adjuster (8) pushed in and with arrow mark “H” on intake camshaft timing plunger pushed back into body, insert stopper into sprocket (2), then install intake cam timing sprocket latch and body.
  • Page 127 Power Unit Mechanical: 1D-25 10) Install timing chain tensioner link (10). • Engraved line “I” on intake camshaft timing sprocket is aligned with cylinder head cover 11) Apply engine oil to timing chain. mating face “J”. 12) Remove the stopper from tensioner adjuster to release plunger.

  • Page 128: Timing Chain, Chain Tensioner And Camshaft Sprockets Inspection

    1D-26 Power Unit Mechanical: Timing Chain, Chain Tensioner and Camshaft Timing Chain Tensioner/Chain Guide Sprockets Inspection • Check chain tensioner shoe for wear or damage. ZAJ6111406013 If excessive wear or other damage is found, replace it. NOTE • Check chain guide shoe for wear or damage. If any component is worn excessively, If excessive wear or other damage is found, replace it.
  • Page 129 Power Unit Mechanical: 1D-27 3) Remove the bolts securing camshaft housing (1) to Installation cylinder head, then remove each camshaft housing. 1) Apply engine oil around tappets and install them. 2) Install tappet shims. NOTE For ease of assembly, note position of each individual camshaft housing.

  • Page 130: Camshaft, Tappet And Shim Inspection

    1D-28 Power Unit Mechanical: 7) Apply engine oil lightly to housing bolts. 8) Lightly seat all housing bolts. 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. Tightening torque Camshaft housing bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
  • Page 131 Power Unit Mechanical: 1D-29 Cam Wear Camshaft Journal Wear Using micrometer, measure cam height. Check camshaft journals and camshaft housings for If measurement exceeds service limit, replace camshaft. pitting, scratches, wear or damage. If any of the above conditions are found, replace Cam height “a”...
  • Page 132 1D-30 Power Unit Mechanical: 4) Install camshaft housing. Tighten housing bolts in 3 If journal oil clearance exceeds the service limit, steps (1/3 of specification, 2/3 of specification, full measure camshaft journal (outside dia.) and torque specification) in the indicated order. camshaft housing (inner dia.).
  • Page 133 Power Unit Mechanical: 1D-31 Wear of Tappet and Shim Check tappet and shim for pitting, scratches, or damage. If any above conditions are found, replace component. I9J011140031-01 I9J011140076-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance. If clearance exceeds service limit, replace tappet or cylinder head.

  • Page 134: Cylinder Head Assembly Components

    1D-32 Power Unit Mechanical: Cylinder Head Assembly Components ZAJ6111406016 IAJ611140011-02 1. Intake valve 5. Valve stem seal 9. Tappet : 59 N·m (5.9 kgf-m, 42.7 lbf-ft) 2. Exhaust valve 6. Valve spring 10. Tappet shim : 23 N·m (2.3 kgf-m, 16.5 lbf-ft) 3.

  • Page 135: Cylinder Head Removal And Installation

    Installation” (Page 1D-26). shown in illustration. 2) Loosen and remove twelve cylinder head bolts in the order indicated in figure. : Sealant 99000–31140 (SUZUKI Bond Remove cylinder head assembly and head gasket. 1207B (100 g)) NOTE Use special tool (10 mm deep socket wrench) when loosening cylinder head bolts.

  • Page 136: Cylinder Head Disassembly And Assembly

    1D-34 Power Unit Mechanical: 3) Apply engine oil to cylinder head bolts and tighten 4) Install the IN. and EX. camshafts. them gradually as follows. Refer to “Camshaft, Tappet and shim Removal and Installation” (Page 1D-26). a) Tighten all cylinder head bolts to 50 percent (%) of specified torque according to sequence in 5) Install the timing chain.
  • Page 137 Power Unit Mechanical: 1D-35 3) Remove valve stem seal (5) and valve spring seat (6). NOTE Reassemble each valve and valve spring in their original positions. I9J011140033-03 3) Apply engine oil to stem seal, valve guide bore and valve stem. 4) Install valve (3) to valve guide.

  • Page 138: Cylinder Head Components Inspection And Servicing

    1D-36 Power Unit Mechanical: 6) Hold valve spring compressed with special tool and Cylinder Head Components Inspection and install valve cotters (6). Servicing Make sure valve cotters are properly seated in ZAJ6111406019 NOTE groove “A”. If cracks, excessive wear or other damage is NOTE found on any component, replace When compressing the valve spring, be...
  • Page 139 Power Unit Mechanical: 1D-37 • Check water jackets. If clogged or obstructed, clean Manifold seating faces distortion water jackets. Using a straightedge and thickness gauge, check cylinder head to manifold seating faces. If measurement exceeds service limit, resurface or replace cylinder head. Special tool (A): 09900–20803 (Thickness gauge) Manifold seating faces distortion...
  • Page 140 1D-38 Power Unit Mechanical: Valve guide inside diameter Valve stem end Using a small bore gauge, measure valve guide inside Inspect valve stem end face for pitting and wear. diameter. If pitting or wear is found, valve stem end may be resurfaced.
  • Page 141 Power Unit Mechanical: 1D-39 Valve head radial runout Valve seat contact width Measure valve head radial runout. Measure valve seat contact width as follows: To measure runout, rotate valve slowly. 1) Remove all carbon from valve and seat. If measurement exceeds service limit, replace valve. 2) Coat valve seat evenly with Prussian blue (or Special tool equivalent).
  • Page 142 1D-40 Power Unit Mechanical: Valve seat servicing • If width “a” is too high (or wide), reface valve seat If valve seat contact width is out of specification, reface using small angle cutter (Intake side: 30°, Exhaust valve seat as follows: side: 15°).
  • Page 143 Power Unit Mechanical: 1D-41 Valve guide replacement 3) Install valve guide to cylinder head. • Heat cylinder head to a temperature of 80 – 100 CAUTION °C (176 – 212 °F). Be careful not to damage cylinder head when Apply heat uniformly so that head will not be replacing valve guide.
  • Page 144 1D-42 Power Unit Mechanical: Valve spring free length Valve spring squareness Check spring strength by measuring free length. Use a square and surface plate to check each spring for If lower than service limit, replace valve spring. squareness (clearance between end of valve spring and square).

  • Page 145: Pistons, Piston Rings, Connecting Rods, Cylinder And Crankshaft Components

    Power Unit Mechanical: 1D-43 Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components ZAJ6111406020 IAJ611140239-02 1. Cylinder block 7. Conrod bearing 13. Dowel pin : 15 N·m (1.5 kgf-m, 10.8 lbf-ft), then plus turn in 65 degrees. 2. Piston ring set 8.

  • Page 146: Pistons, Piston Rings, Connecting Rods, Cylinder And Crankshaft Disassembly And Assembly

    1D-44 Power Unit Mechanical: Pistons, Piston Rings, Connecting Rods, NOTE Cylinder and Crankshaft Disassembly and For proper assembly, mark cylinder number Assembly on all pistons, conrods, and conrod caps, ZAJ6111406021 using quick drying paint. Disassembly 1) Before performing service work in this section: •...
  • Page 147 Power Unit Mechanical: 1D-45 6) Mark cylinder number on pistons using quick dry 8) Remove piston pin circlips (9) as shown. paint. Push piston (with conrod) out through the top of cylinder bore. NOTE • To prevent damage to piston rings, decarbon top of cylinder bore wall before removing piston.
  • Page 148 1D-46 Power Unit Mechanical: Assembly Piston ring to piston Assembly is reverse order of disassembly paying special 1) Install the oil ring. attention to the following steps. • Apply engine oil to piston rings. • Install spacer (1) first, then side rails (2) to piston. CAUTION If original components are not replaced, each piston, piston pin and conrod is to be...
  • Page 149 Power Unit Mechanical: 1D-47 2) Install the piston rings. 3) Position piston rings so gaps are staggered at approximately 90 degree angles as shown. • Apply engine oil to piston ring. • Install 2nd ring (3) and 1st ring (4) to piston. CAUTION Failure to stagger piston ring gaps may result in crankcase oil dilution.
  • Page 150 1D-48 Power Unit Mechanical: 2) Apply engine oil to piston and cylinder walls. NOTE 3) Insert piston and conrod assembly into cylinder bore Align bearing tab “A” with notch in cylinder from cylinder head side using special tool. and crankcase. NOTE Position the circle mark “A”...
  • Page 151 Power Unit Mechanical: 1D-49 2) Install conrod cap. 3) Apply engine oil to conrod bolts. Tighten conrod cap bolts in three steps as follows. a) Apply molybdenum oil solution to crank pin and conrod bearing. a) Lightly seat all conrod bolts at first, then tighten bolts 10 N·m (1.0 kgf-m, 7.2 lbf-ft) of specified b) Install dowel pins (2) and conrod cap (3) (with torque.
  • Page 152 3) Install crankcase to cylinder. Apply engine oil to crankcase bolts. 1) Clean mating surface of cylinder and crankcase. Tighten crankcase bolts in three steps following the Apply suzuki bond to mating surface of crankcase as order indicated below. shown. NOTE CAUTION Tighten 10 mm (0.394 in.) thread diameter...

  • Page 153: Cylinder, Piston And Piston Ring Inspection And Servicing

    Power Unit Mechanical: 1D-51 NOTE After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand. IAJ611140208-01 IAJ611140207-01 Cylinder head Refer to “Cylinder Head Removal and Installation” (Page 1D-33). Timing chain Refer to “Timing Chain, Chain Tensioner and Camshaft IAJ611140209-02 Sprockets Removal and Installation”...
  • Page 154 1D-52 Power Unit Mechanical: Cylinder Bore Wear (Difference) Piston to Cylinder Clearance Using telescoping gauge (1), measure cylinder bore in 1) Measure the piston diameter at a point 8 mm (0.315 both axial (vertical line, following crankshaft) and in.) above the piston skirt at a right angle to the transverse (horizontal line across crankshaft) directions piston pin bore.
  • Page 155 Power Unit Mechanical: 1D-53 Identification of Oversize Piston / Piston Ring Piston One oversize piston / piston ring components, 0.50 mm Visual inspection is available. Oversize piston / piston ring are marked as Inspect piston for faults, cracks or other damage. shown, below.

  • Page 156: Piston Pin And Conrod Inspection

    1D-54 Power Unit Mechanical: Piston ring end gap Piston pin clearance Standard (1st): 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Check the piston pin clearance in the conrod small end. Standard (2nd): 0.30 – 0.45 mm (0.0118 – 0.0177 in.) Replace the conrod if its small end is badly worn or Service limit (1st): 0.70 mm (0.028 in.) damaged or if clearance exceeds service limit.

  • Page 157: Crank Pin And Conrod Bearing Inspection

    Power Unit Mechanical: 1D-55 Conrod big end side clearance Crank Pin and Conrod Bearing Inspection ZAJ6111406024 Measure conrod big end side clearance with conrod Crank Pin Diameter installed on crank pin as shown. Inspect crank pin for uneven wear or damage. If measurement exceeds service limit, replace conrod Measure crank pin for out-of-round “a”...
  • Page 158 1D-56 Power Unit Mechanical: Conrod Big End Oil Clearance 4) Install conrod cap (with bearing) to conrod with the Check conrod big end oil clearance as follows: embossed mark on cap toward flywheel side. CAUTION Never reuse the conrod cap bolt after it has been threaded into position and torqued.

  • Page 159: Selection Of Conrod Bearing

    Power Unit Mechanical: 1D-57 c) Finally tighten bolts 65 degrees turn from the Selection of Conrod Bearing ZAJ6111406025 point of step b) using an angular torque gauge. NOTE Tightening torque • If bearing is in malfunction, or bearing Conrod cap bolt (Final step): 15 N·m (1.5 kgf- clearance is not in specification, select a m, 10.8 lbf-ft), then plus turn in 65 degrees.
  • Page 160 1D-58 Power Unit Mechanical: 2) Next, check crankshaft pin outside diameter. On 3) There are five kinds of standard bearing differing in crank web No.2, three numbers are stamped as thickness available. To distinguish them, they are shown in the figure. painted in four colors at the position indicated in the Three kinds of number (“1”, “2”...

  • Page 161: Crankshaft Inspection

    Power Unit Mechanical: 1D-59 4) From number stamped on conrod and its cap and Crankshaft Thrust Play numbers stamped on crank web No.2, determine 1) Measure thrust play with crankshaft, journal bearing new standard bearing to be installed into conrod big and crankcase / cylinder block assembled in a end, by referring to the table.

  • Page 162: Crankshaft Main Bearing Inspection

    1D-60 Power Unit Mechanical: Out-of-Round and Taper (Uneven Wear) of Journals Crankshaft Journal Oil Clearance An unevenly worn crankshaft journal shows up as a Check clearance using Plastigauge according to the difference in diameter at a cross section or along its following procedure.
  • Page 163 Power Unit Mechanical: 1D-61 3) Install crankshaft to cylinder. NOTE 4) Place a piece of Plastigauge across full width of Crankcase must be torqued to specification bearing (parallel to crankshaft) on journal. in order to assure proper compression of Do not place Plastigauge over oil hole. plastigauge and accurate reading of clearance.
  • Page 164 1D-62 Power Unit Mechanical: 9) If measurement exceeds service limit, replace 2) Next, check bearing holder inside diameter without crankshaft main bearing. bearing. As shown in figure, the cylinder block STBD side has NOTE four stamped code letters or numerals. For bearing replacement, see the “Selection The letters (A, B and C) or numerals (1, 2 and 3) represent the bearing holder inside diameters shown...

  • Page 165: Crankshaft Oil Seal Inspection

    Power Unit Mechanical: 1D-63 Crankshaft Upper Oil Seal Replacement ZAJ6111406030 1) Remove the upper oil seal housing. Refer to “Upper Oil Seal Housing Removal and Installation” (Page 1D-8). 2) Extract oil seal with oil seal remover. Special tool (A): 09913–50121 (Oil seal remover) “I”...

  • Page 166: Power Unit Lubrication

    1E-1 Power Unit Lubrication: Power Unit Lubrication Power Head General Description Engine Lubrication Description ZAJ6111501001 A crankshaft 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 167: Diagnostic Information And Procedures

    Power Unit Lubrication: 1E-2 Diagnostic Information and Procedures Oil Pressure Check ZAJ6111504001 Refer to “Oil Pressure Check” in Section 0B (Page 0B-20). Oil Change Reminder System ZAJ6111504002 Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14). Low Oil Pressure Caution System ZAJ6111504003 Refer to “Caution System Description”...

  • Page 168: Service Instructions

    1E-3 Power Unit Lubrication: Service Instructions Oil Pump Removal and Installation ZAJ6111506001 Removal 1) Remove the power unit. Refer to “Power Unit Removal and Installation” in Section 1D (Page 1D-14). 2) Remove the seven bolts securing oil pump (1), then remove the oil pump.

  • Page 169: Inspection Oil Pump Component Parts

    Power Unit Lubrication: 1E-4 Assembly Inspection Oil Pump Component Parts ZAJ6111506003 1) Wash, clean and then dry all disassembly parts. NOTE 2) Apply thin coat of engine oil to inner and outer rotors, If any repair is required on outer rotor, inner inside surfaces of oil pump case and plate.

  • Page 170: Oil Pressure Switch Removal And Installation

    1E-5 Power Unit Lubrication: Measuring Side Clearance Installation Using straightedge and feeler gauge, measure side Installation is reverse order of removal with special clearance. attention to the following steps. If measurement is not within specifications, replace oil • Before installing oil pressure switch, wrap screw pump assembly.

  • Page 171: Oil Pressure Switch Inspection

    Power Unit Lubrication: 1E-6 Oil Pressure Switch Inspection Oil Strainer Removal and Installation ZAJ6111506005 ZAJ6111506006 NOTE Removal Refer to “Engine Holder / Oil Pan / Driveshaft Housing / Before checking the oil pressure switch, Mounts Disassembly” in Section 2A (Page 2A-13). make sure the engine oil pressure is within specification.

  • Page 172: Power Unit Cooling System

    1F-1 Power Unit Cooling System: Power Unit Cooling System Power Head General Description Water Cooling System Description ZAJ6111601001 The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead assembly. To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine operation, there is a thermostat in the cylinder block.

  • Page 173: Schematic And Routing Diagram

    Power Unit Cooling System: 1F-2 Schematic and Routing Diagram Cooling Water Circulation Chart ZAJ6111602001 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 form below.

  • Page 174: Diagnostic Information And Procedures

    1F-3 Power Unit Cooling System: Diagnostic Information and Procedures Powerhead Cooling System Diagnosis ZAJ6111604001 Condition Possible cause Correction / Reference Item Overheating powerhead Water inlet screen obstructed. Clean. Water passage obstructed. Clean or replace. Pump plate not sealing. Check and repair. Water pump impeller damage.

  • Page 175: Thermostat Inspection

    Power Unit Cooling System: 1F-4 I9J011160002-01 IAJ611160007-01 1. Thermometer 3. Thermostat • Check to ensure that all removed parts are back in 2. Heater place. 4) Install the thermostat. Refer to “Thermostat Removal and Installation” Thermostat Inspection (Page 1F-3). ZAJ6111606002 Inspect the thermostat in the following procedures: 1) Remove the thermostat.

  • Page 176: Water Pressure Valve Related Item Inspection

    1F-5 Power Unit Cooling System: Installation 2) Inspect the water pressure valve. If salt deposits, corrosion, wear or other damage is 1) Install O-ring (1) to pressure valve cover (2). found, clean or replace. Inspect O-ring. Replace if nicked, cut or torn. I9J011160013-01 2) Install pressure valve (3) and pressure valve cover I9J011160015-01...

  • Page 177: Fuel System

    Fuel System: 1G-1 Fuel System Power Head Precautions Precautions on Fuel System Service ZAJ6111700001 WARNING Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing / inspection. •...

  • Page 178: General Description

    1G-2 Fuel System: General Description Electronic Fuel Injection System Description ZAJ6111701001 The fuel injection system used by the DF60A 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 179 Fuel System: 1G-3 Fuel Injection Timing Chart 30 signals / crankshaft 1 rotation CKP sensor signal CMP sensor signal CMP sensor - 9 signals / 720° (crankshaft 2 rotation) No.1 cylinder E p. No.3 cylinder E p. No.2 cylinder Injection time duration Injection end timing: 60°...

  • Page 180: Fuel Delivery System Components Description

    1G-4 Fuel System: Fuel Delivery System Components Description ZAJ6111701002 The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor separator, high pressure fuel pump, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel injectors and hoses.
  • Page 181 Fuel System: 1G-5 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 182 1G-6 Fuel 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 constant fuel pressure to the injectors while the engine is operating. The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure balanced. Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in the fuel vapor separator chamber by approx.

  • Page 183: High Pressure Fuel Pump Control System Description

    Fuel System: 1G-7 High Pressure Fuel Pump Control System Description ZAJ6111701003 To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON” / “OFF” signal, at a specified rate (1 000 times a second). Based on engine speed and battery voltage, the ECM determines the optimum duty cycle (repeating “ON”...

  • Page 184: Air Intake Components Description

    1G-8 Fuel System: Control Modes Before start: For 3 seconds after the ignition switch is turned “ON”, the fuel pump is controlled to operate at a 100% duty cycle to initially pressurize the high pressure fuel line. When cranking: The fuel pump is controlled to operate at a 50 – 100% duty cycle. The duty cycle changes depending on cylinder temperature.

  • Page 185: Idle Air Control System Description

    Fuel System: 1G-9 Throttle Body • The throttle body assembly consists of the main bore, throttle valve and MAP sensor / TPS (Throttle Position Sensor) / IAT sensor. • Three sensors (MAP sensor / TPS / IAT sensor) are combined into one unit that is installed on top of the throttle body.
  • Page 186 1G-10 Fuel System: +12 V IAC valve IAC1 IAC2 IAC3 W/Bl IAC4 Air flow I9J011170010-02 1. Valve pintle 2. Screw shaft 3. Rotor 4. Coil Idle Air Control System Outline The ECM controls the position of the IAC valve to regulate a portion of the intake air flow to the intake manifold. This system is used for the following purposes: •...

  • Page 187: Diagnostic Information And Procedures

    Fuel System: 1G-11 IAC Valve Control Mode Before started: The IAC valve is initialized at a 70% opening position when engine is not running. (Ignition switch “OFF”). When cranking: The IAC valve is controlled to operate at approx. 30 – 80% open position. The open position changes depending on the cylinder temperature.
  • Page 188 1G-12 Fuel System: 3) Connect special tools (pressure gauge, pressure 4) Ensure the emergency stop switch lock plate is in hose and pressure joint) between fuel feed hose (1) place. and fuel delivery pipe upper union as shown in Shift into “Neutral” position. figure.

  • Page 189: Fuel System Diagnosis

    Fuel System: 1G-13 11) After checking fuel pressure, remove fuel pressure 12) Reconnect fuel line. gauge. 13) With the engine not running and ignition switch “ON”, check the fuel system for leaks. I9J011170019-01 4. Joint nut Fuel System Diagnosis ZAJ6111704002 Condition Possible cause Correction / Reference Item...

  • Page 190: Fuel Injection System Troubleshooting

    1G-14 Fuel System: Fuel Injection System Troubleshooting ZAJ6111704003 Before starting the troubleshooting, make sure that: • There is no self-diagnostic code indication. • Emergency stop switch plate is set in place. Step Action Check fuel injector operating sound. Fuel injector circuit is in Go to step 2.

  • Page 191: Service Instructions

    Fuel System: 1G-15 Service Instructions Fuel Pressure Relief Procedure 6) Upon completion of servicing, connect the ignition ZAJ6111706001 coil primary lead wire. After making sure that engine is cold, relieve fuel 7) Install the 15 amp. fuel pump fuse. pressure as follows: 1) Turn “OFF”...

  • Page 192: Fuel Leakage Check Procedure

    1G-16 Fuel System: Fuel Leakage Check Procedure • For type “C” pipe, hose must fit up against the flanged ZAJ6111706004 part of pipe. After performing any fuel system service, always be sure Type “C” there is no fuel leakage by checking as follows. 1) Squeeze fuel primer bulb until you feel resistance.

  • Page 193: Fuel Vapor Separator Removal And Installation

    Fuel System: 1G-17 4) If no pump operating sound is heard: Fuel Vapor Separator Disassembly and Assembly a) Turn ignition key to the “OFF” position, check for ZAJ6111706008 contact failure in the lead wire connector. Disassembly b) Check that the drive voltage is outputting from 1) Remove five screws (1).
  • Page 194 1G-18 Fuel System: 3) Remove the suction filter (8). 6) Remove the screw (14) and valve seat (15). IAJ611170026-01 IAJ611170030-01 4) Disconnect the pump lead wire connector. 7) Remove the fuel pressure regulator assembly (16) Remove the high pressure fuel pump (9), bush (10), from separator cover.
  • Page 195 Fuel System: 1G-19 Assembly NOTE Assembly is in the reverse order of disassembly with After assembling, check for smooth and free special attention to the following steps. float movement. High pressure fuel pump Connect the pump lead wire connector, then install the filter (1), bush (2), joint (3), bush (4) and fuel pump (5).
  • Page 196 Setting float height Separator cover / Separator case To correct specification, bend only adjustment tab (1). 1) Install the seal ring (1) and then apply Suzuki Bond evenly to only the outside mating surface of the CAUTION separator case as shown in figure.

  • Page 197: Inspection Of Fuel Vapor Separator Component Parts

    Fuel System: 1G-21 Inspection of Fuel Vapor Separator Component Separator Cover and Case Inspect the separator cover and case. Parts Replace if cracked, damaged or other abnormal ZAJ6111706009 NOTE conditions. If cracks, excessive wear or other damage is NOTE found on any component, replace the component.

  • Page 198: Fuel Injector Inspection With Injector In Place

    1G-22 Fuel System: Fuel Injector Inspection with Injector in place Individual Fuel Injector Operating Sound ZAJ6111706010 Inspection 1) Using a sound scope or equivalent, check the ZAJ6111706011 operating sound of the fuel injector when the engine 1) Disconnect the ignition coil lead wire connectors is running or cranking.

  • Page 199: Fuel Injector Operating Signal Inspection

    Fuel System: 1G-23 Fuel Injector Operating Signal Inspection ZAJ6111706012 40 41 42 43 44 45 46 47 48 49 58 59 60 61 62 63 64 65 66 67 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31 14 15 16 17 18...

  • Page 200: Fuel Injector Removal And Installation

    1G-24 Fuel System: Fuel Injector Removal and Installation 4) Remove the two bolts (3) and the fuel delivery pipe ZAJ6111706013 (4) (with the fuel injectors). Removal CAUTION 1) Relieve the fuel pressure in the fuel feed line according to “Fuel Pressure Relief Procedure”. A small amount of fuel may be released when Refer to “Fuel Pressure Relief Procedure”...
  • Page 201 Fuel System: 1G-25 Installation 4) Tighten the delivery pipe bolts (3) and make sure Installation is in the reverse order of removal with special that the injectors rotate smoothly. attention to the following steps. Tightening torque Fuel delivery pipe bolt (a): 11 N·m (1.1 kgf-m, 8.0 CAUTION lbf-ft) Do not re-use O-ring and cushion once...

  • Page 202: Low Pressure Fuel Pump Removal And Installation

    1G-26 Fuel System: Low Pressure Fuel Pump Removal and Tightening torque Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-m, Installation 7.2 lbf-ft) ZAJ6111706014 NOTE The low pressure fuel pump is a non- repairable component. Do not attempt to disassemble the low pressure fuel pump.

  • Page 203: Ignition System

    Ignition System: 1H-1 Ignition System Power Head General Description Ignition System Description ZAJ6111801001 The ignition system used by the DF60A is a fully transistorized, electronic microcomputer timing advanced type. This system is battery powered, with the ECM controlling all of the ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch etc.).

  • Page 204: Ignition Control Description

    1H-2 Ignition System: Ignition Control Description ZAJ6111801002 Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM. Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils. Basic sensors MAP sensor: Ignition timing is determined by a...
  • Page 205 Ignition System: 1H-3 Ignition Timing Chart The following chart is an example for ignition at 20° BTDC. 30 signals / crankshaft 1 rotation CKP sensor signal CMP sensor signal CMP sensor - 9 signals / 720° (crankshaft 2 rotation) No.1 cylinder E p.

  • Page 206: Component Location

    1H-4 Ignition System: Component Location Ignition System Components Location ZAJ6111803001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4). Diagnostic Information and Procedures Ignition System Symptom Diagnosis ZAJ6111804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition system.

  • Page 207: Ignition System Troubleshooting

    Ignition System: 1H-5 Ignition System Troubleshooting ZAJ6111804002 Before starting the troubleshooting, make sure that: • There is not self-diagnostic code indication. • Emergency stop switch plate is set in place. Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system.

  • Page 208: Service Instructions

    1H-6 Ignition System: Service Instructions Spark Plug Removal and Installation Ignition Coil Inspection ZAJ6111806001 ZAJ6111806004 Refer to “Spark Plug Removal and Installation” in NOTE Section 0B (Page 0B-6). The ignition coil power transistor and high tension lead are an integral part of the coils Spark Plug Inspection internal circuit.

  • Page 209: Ignition Coil Operating Signal Inspection

    Ignition System: 1H-7 5) Connect the wiring harness connector to the ignition 4) Connect the tester probe Black (–) to No. 51 terminal coil and measure the ignition operating signal. (or to body ground). Refer to “Ignition Coil Operating Signal Inspection” 5) Crank the engine and measure the voltage.

  • Page 210: Starting System

    1I-1 Starting System: Starting System Power Head General Description Electric Starter System Description ZAJ6111901001 The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay, ECM and related electrical wiring. These components are connected electrically as shown in the figure below. In the circuit shown in the figure below, the magnetic switch coils and starter relay coil are magnetized when the ignition switch is closed (turned to “START”).

  • Page 211: Starter Motor Operation Condition Description

    Starting System: 1I-2 Starter Motor Operation Condition Description ZAJ6111901002 The starter motor relay is controlled by the ECM. • The starter motor relay will only engage when the ignition switch is turned to the “START” position if the all of the following conditions are satisfied.

  • Page 212: Component Location

    1I-3 Starting System: Component Location Starting System Components Location ZAJ6111903001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4). Diagnostic Information and Procedures Starter System Symptom Diagnosis ZAJ6111904002 Condition Possible cause Correction / Reference Item Motor not running. (No Poor or broken battery connection.

  • Page 213: Starter System Troubleshooting

    Starting System: 1I-4 Starter System Troubleshooting ZAJ6111904001 CAUTION If any abnormality is found, immediately disconnect the battery cables from the battery. NOTE Before troubleshooting the electric starter system, make sure of the following: • Battery is fully charged. • All cables / wires are securely connected. •...
  • Page 214 1I-5 Starting System: Starter Motor will not Run Step Action 1) Check main fuse and connection. Go to step 2. Repair or replace. 2) Check circuit fuse (for starter motor relay) and connection. Are main fuse and circuit fuse good condition? 1) Disconnect lead wire connector “A”...

  • Page 215: Service Instructions

    Starting System: 1I-6 Step Action 1) Measure voltage between No.65 terminal of ECM and Go to step 12. Starter switch circuit body ground when turning ignition switch to “START”. open, shorted or poor connection. Is the voltage approx. 8 – 12 V? 12 1) Measure voltage between No.16 terminal of ECM and If check result is Emergency stop switch...

  • Page 216: Starter Motor Test

    1I-7 Starting System: 7) Push starter motor down as shown in figure. Installation Installation is in the reverse order of removal with special attention to the following steps. • Install the starter motor and tighten starter motor mounting bolts securely. Tightening torque Starter motor mounting bolt (a): 23 N·m (2.3 kgf- m, 16.5 lbf-ft)
  • Page 217 Starting System: 1I-8 Pull-In / Hold-In Test Plunger and Pinion Return Test Disconnect the negative lead from the switch / motor NOTE body. Before testing, disconnect the brush lead Check that the plunger and pinion return inward. from terminal “M”. If the plunger and pinion don't return inward, replace the magnetic switch.

  • Page 218: Starter Motor Components

    1I-9 Starting System: Starter Motor Components ZAJ6111906003 24 23 22 28 I9J011190006-02 1. Nut 9. Shift lever 17. Armature 25. Center bracket 2. Bolt 10. Front housing 18. Center cover plate 26. Rubber ring 3. Magnetic switch 11. Screw 19. Internal gear 27.

  • Page 219: Starter Motor Disassembly And Assembly

    Starting System: 1I-10 Starter Motor Disassembly and Assembly 4) Remove screws (5), long through bolts (6) and the ZAJ6111906004 rear cover (7). Disassembly When overhauling the starting motor, it is recommended that the component parts be cleaned thoroughly. However, the yoke assembly, armature coil, over- running clutch assembly, magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent.
  • Page 220 1I-11 Starting System: 8) Remove the center cover plate (13). 12) Push the pinion stopper (21) down, then remove the stopper ring (22). Remove the pinion stopper and 9) Remove the planetary gears (14) and internal gear pinion (19). (15). I9J011190017-01 I9J011190014-01 13) Remove the E-ring (23).

  • Page 221: Starter Motor Components Inspection And Servicing

    Starting System: 1I-12 Assembly • Measure the commutator outside diameter. If the Assembly is in the reverse order of disassembly with measurement exceeds the service limit, replace the special attention to the following steps. armature. Reassemble the starter motor, refer to “Starter Motor Special tool Components”...
  • Page 222 1I-13 Starting System: • Check for continuity between the commutator (4) and Brushes the armature core (5) / shaft (6). Check the length of each brush (1). Replace the armature if continuity is indicated. If brushes are worn down to the service limit, they must be replaced.
  • Page 223 Starting System: 1I-14 Shift Lever Gear Inspect the shift lever for wear. Replace if necessary. Inspect planetary gears and internal gear for wear, damage or other abnormal conditions. Replace if necessary. I9J011190029-01 Pinion and Over-Running Clutch I9J011190032-01 • Inspect the pinion for wear, damage or other abnormal Pinion Shaft / Pinion Shaft Bushing conditions.
  • Page 224 1I-15 Starting System: Armature Shaft Bush Pull-in coil open circuit test Inspect the bushing for wear or other damage. Check for continuity across the magnetic switch “S” Replace if necessary. terminal (1) and “M” terminal (2). If no continuity exists, the coil is open and should be replaced.

  • Page 225: Ignition Switch Inspection

    Starting System: 1I-16 Contact points test Put the plunger on the under side and then push the magnetic switch down. (OFF) (ON) At this time, check for continuity between terminal “B” FREE and terminal “M”. (START) Continuity indicates proper condition. If no continuity exists, replace the magnetic switch and/or plunger.

  • Page 226: Neutral Switch Inspection

    1I-17 Starting System: 2) Check continuity between terminal (2) and (3) each Neutral Switch Inspection ZAJ6111906008 time 12 V power supply is applied to terminal (4) and Check for continuity / infinity of the neutral switch. (5). Connect the positive (+) lead to terminal (5), and Special tool negative (–) lead to terminal (4).

  • Page 227: Emergency Stop Switch Inspection

    Starting System: 1I-18 Neutral switch on engine side 3) If out of specification: 1) Disconnect the neutral switch lead wire connector. • 1st: Check the remo-con cable adjustment, readjust if 2) Check continuity / infinity between the Yellow / Green necessary.

  • Page 228: Charging System

    1K-1 Charging System: Charging System Power Head General Description Charging System Description ZAJ6111B01001 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 the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the battery.

  • Page 229: Battery Requirement Description

    Charging System: 1K-2 Battery Requirement Description ZAJ6111B01002 Refer to “Battery Requirement” in Section 0A (Page 0A-5). Component Location Charging System Components Location ZAJ6111B03001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4). Diagnostic Information and Procedures Charging System Diagnosis ZAJ6111B04001 Condition Possible cause...

  • Page 230: Service Instructions

    3. Flywheel 10. Rectifier/Regulator 17. O-ring : Apply engine oil. 4. Key 11. Bolt 18. Fuse (30 amp.) : Apply SUZUKI Bond 1207B. 5. Battery charge coil 12. Cushion 19. Main relay 6. Screw 13. Washer 20. Starter motor relay 7.

  • Page 231: Flywheel Removal And Installation

    Charging System: 1K-4 Flywheel Removal and Installation 4) Remove the flywheel bolt (1), washer (2), flywheel ZAJ6111B06002 (3) and key (4). Removal CAUTION Prior to removing flywheel, disconnect battery cables from battery. 1) Remove the ring gear cover. Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).

  • Page 232: Battery Charge Coil Removal And Installation

    Removal attention to the following steps. CAUTION Battery charge coil Prior to removing electrical parts, disconnect • Apply suzuki bond No. 1207B to the coil securing battery cables from battery. screws. : Sealant 99000–31140 (SUZUKI Bond 1) Remove flywheel. 1207B (100 g)) Refer to “Flywheel Removal and Installation”...

  • Page 233: Battery Charge Coil Inspection

    Charging System: 1K-6 Battery Charge Coil Inspection Rectifier/Regulator Removal and Installation ZAJ6111B06004 ZAJ6111B06005 Measure battery charge coil resistance in the following Removal procedure. CAUTION 1) Remove the ring gear cover. Refer to “Ring Gear Cover Removal and Installation” Prior to removing electrical parts, disconnect battery cables from battery.

  • Page 234: Rectifier/Regulator Inspection

    If measurement exceeds specification, replace rectifier/regulator. NOTE The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier/regulator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.

  • Page 235: Main Fuse Inspection

    Charging System: 1K-8 Main Fuse Inspection ZAJ6111B06007 Inspect the main fuse in the following procedures. 1) Remove the main fuse from fuse box. 2) Inspect continuity between both terminal of fuse. If no continuity is indicated, replace fuse. Special tool : 09930–99320 (Digital tester) Tester knob indication Continuity (...
  • Page 236 1K-9 Charging System:...
  • Page 237 Table of Contents 2- i Section 2 Mid Unit CONTENTS Precautions ..........2-1 Power Trim and Tilt ......... 2B-1 Precautions............. 2-1 Precautions............2B-1 Precaution for Mid Unit ......... 2-1 Precaution for Power Trim and Tilt......2B-1 General Description ..........2B-1 Housing and Bracket....... 2A-1 Power Trim and Tilt Description ......2B-1 Precautions............2A-1 Principles of Power Trim and Tilt Operation...

  • Page 238: Precautions

    2-1 Precautions: Precautions Mid Unit Precautions Precaution for Mid Unit ZAJ6112000001 Refer to “General Precautions” in Section 00 (Page 00-1).

  • Page 239: Housing And Bracket

    Housing and Bracket: 2A-1 Housing and Bracket Mid Unit Precautions Precaution for Housing and Bracket ZAJ6112100001 CAUTION Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic corrosion or build up of static charges. Replace any damaged wire.

  • Page 240: Service Instructions

    2A-2 Housing and Bracket: Service Instructions Lower Side Cover Components ZAJ6112106001 IAJ611210001-02 1. Side cover rubber 8. Bolt 15. Bolt 22. Hook lever latch 2. Side cover seal 9. Washer 16. Rear hook lever 23. Bolt 3. Lower side cover STBD 10.

  • Page 241: Lower Side Cover Removal And Installation

    Housing and Bracket: 2A-3 Lower Side Cover Removal and Installation 5) Remove two screws (5) and STBD side cover (6). ZAJ6112106002 Removal 1) Pull the hook lever (1) out and remain the lever at this position. IAJ611210009-01 Installation Installation is reverse order of removal with special attention to the following step.
  • Page 242 2A-4 Housing and Bracket: 3) Remove the lock pin (3), washer (4) and cable 7) Remove the two bolts (14) securing tiller handle connector (5) from throttle control lever. bracket (15) to steering bracket extension, then Remove the cable connector from throttle control remove the tiller handle assembly (16).
  • Page 243 : Thread lock cement 99000–32050 NOTE (SUZUKI Thread Lock 1342 (50 g)) Install the spring washers (4) with direction as shown in figure. Tightening torque Tiller handle mounting bolt (c): 50 N·m (5.0 kgf- : Thread lock cement 99000–32050...
  • Page 244 2A-6 Housing and Bracket: 2) Secure the cable (1) and (2) in the cable holder (5) 4) Install the washer (4) and snap pin (5), then tighten by fitting groove on the cable into a slot on the the cable lock nut (6) against the connector to holder.
  • Page 245 Housing and Bracket: 2A-7 3) Thread the connector (4) onto the throttle control 6) Return the throttle control grip to the fully closed cable (5). position. Push in cable connector while adjusting it to align Check that the throttle control lever (1) is in fully with pivot pin “A”...

  • Page 246: Tiller Handle Component

    43. Shift lever : 50 N·m (5.0 kgf-m, 36.0 lbf-ft) 12. Ignition switch assembly 28. E-ring 44. Bush : Apply SUZUKI water resistance grease. 13. Handle wire harness 29. Lock plate 45. Tiller handle bracket : Apply SUZUKI thread lock 1342.

  • Page 247: Tiller Handle Disassembly And Assembly

    Housing and Bracket: 2A-9 Tiller Handle Disassembly and Assembly 4) Remove the screw (8) and handle grip (9). ZAJ6112106016 Disassembly 1) Remove the tiller handle. Refer to “Tiller Handle Removal and Installation (TH model)” (Page 2A-3). 2) Remove the six screws (1) and take off tiller handle lower cover (2).
  • Page 248 2A-10 Housing and Bracket: 7) Remove the E-ring (17), then remove the lock plate 10) Remove the two bolts (25) securing the shift gear (18) from throttle arm assembly (19). assembly (26) to tiller handle housing, then remove Remove the two screws (20) securing the throttle shift gear assembly (26) and bush (27).

  • Page 249: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components

    13. Upper mount cover 21. Bolt : Apply engine oil. 6. Oil seal 14. Bolt 22. Water indicator : Apply SUZUKI water resistant grease. 7. Gasket 15. Upper mount Bolt 23. Bolt : Apply SUZUKI thread lock 1342. 8. Engine holder 16.
  • Page 250 28. Bolt : 60 N·m (6.0 kgf-m, 43.4 lbf-ft) 9. Water jacket cover 19. Lower thrust mount 29. Bush (Transom: X) : Apply SUZUKI thread lock 1342. 10. Gasket 20. Washer 30. Dowel pin (Transom: X) : Apply SUZUKI silicon seal.

  • Page 251: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly

    Housing and Bracket: 2A-13 Engine Holder / Oil Pan / Driveshaft Housing / 6) Unscrew and remove STBD / PORT lower mount nuts (6) and washers (7). Mounts Disassembly ZAJ6112106004 1) Remove the power unit. Refer to “Power Unit Removal and Installation” in Section 1D (Page 1D- 14).
  • Page 252 2A-14 Housing and Bracket: 9) Remove the driveshaft housing with oil pan. 12) Remove the upper mounts (19), upper thrust mount (20), upper mount bolts (21) and washers (22). IAJ611210039-01 10) Remove the lower mount assembly. IAJ611210043-01 Account for lower mount bolt (10), washer (11), side 13) Remove the bolt and water indicator union (23) and lower mount (12), lower mount (13), forward damper water hose (24) (if necessary).

  • Page 253: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Assembly

    IAJ611210051-01 • Install two dowel pins (3) to driveshaft housing (4). Apply sealant to mating surfaces of driveshaft housing and oil pan. : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) IAJ611210048-02 17) Remove the eight bolts securing the driveshaft housing (29) to oil pan, then remove the oil pan (30).
  • Page 254 2A-16 Housing and Bracket: Engine Holder to Oil Pan • Install engine holder (6) to oil pan (7), then securely tighten it with engine holder bolts (8). • Apply engine oil to O-rings (1), then install O-rings to oil strainer (2). •...
  • Page 255 • Tighten upper mount cover bolts (6), pre-coated with thread lock, to specified torque. IAJ611210063-01 Tightening torque Upper mount cover bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) IAJ611210061-02...
  • Page 256 (4), then tighten seven cover bolts securely. Tightening torque Upper mount nut (a): 60 N·m (6.0 kgf-m, 43.4 lbf- : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) IAJ611210066-01 IAJ611210064-01 • Install washer (4) and lower mount nut (3), then tighten two nuts, pre-coated with thread lock, to specified torque.

  • Page 257: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection

    Housing and Bracket: 2A-19 Water Pressure Valve Engine Holder • Install water pressure valve (1) and cover (2). • Inspect the engine holder. Replace if cracked, Refer to “Water Pressure Valve Removal and damaged, or other abnormal conditions are noted. Installation”...
  • Page 258 2A-20 Housing and Bracket: Oil Strainer Mount • Inspect the oil strainer. Replace the strainer if • Check upper, lower and thrust mounts. cracked, damaged or other abnormal conditions are If excessive wear, corrosion or other damage is found, found. replace mount.

  • Page 259: Clamp / Swivel / Steering Brackets Components

    19. Washer 31. Screw : 43 N·m (4.3 kgf-m, 31.0 lbf-ft) 8. Bolt 20. Shim 32. Plate STBD : Apply SUZUKI water resistance grease. 9. Washer 21. Lower mount bracket 33. Plate PORT : Apply SUZUKI thread lock 1342. 10. Bolt 22.

  • Page 260: Clamp / Swivel / Steering Brackets Disassembly

    2A-22 Housing and Bracket: Clamp / Swivel / Steering Brackets Disassembly 5) Lift steering bracket (5) upward to remove from ZAJ6112106011 swivel bracket. 1) Remove engine holder / oil pan and driveshaft Remove washer (6) and upper bushing (7). housing. Refer to “Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly”...
  • Page 261 Housing and Bracket: 2A-23 9) Remove the upper trim sensor cam (13) from clamp 13) Using flat blade screw driver, drive locking edge of bracket shaft. lock washer (19) to clamp bracket side. 14) Remove the two PORT motor mounting bolts (20). Remove the clamp bracket shaft nut (21) and washer.

  • Page 262: Clamp / Swivel / Steering Brackets Assembly

    STBD clamp bracket. bracket (27). Remove washer (28) and bushing (29) Install the shaft bolt (5), then tighten it securely. from each side of swivel bracket. : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) IAJ611210090-01 IAJ611210093-01 Clamp / Swivel / Steering Brackets Assembly •...
  • Page 263 Tightening torque PTT lower shaft bolt (b): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) IAJ611210098-01 Steering Bracket • Apply water resistant grease to steering bracket shaft.
  • Page 264 After completing reassembly of the mid unit, apply • Install washer (3) and shim (4), and then slide the grease through each grease nipple. lower mount bracket (2) upward on the splines until it : Grease 99000–25161 (SUZUKI Water Resistant contacts the shim. Grease (250 g)) IAJ611210100-01 IAJ611210104-01 •...

  • Page 265: Clamp / Swivel / Steering Brackets Related Components Inspection

    Housing and Bracket: 2A-27 Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft Check clamp bracket shaft. Components Inspection If clamp bracket shaft is bent or twisted, replace shaft. ZAJ6112106013 Refer to “Clamp / Swivel / Steering Brackets Disassembly” (Page 2A-22) and “Clamp / Swivel / Steering Brackets Assembly”...

  • Page 266: Power Trim And Tilt

    2B-1 Power Trim and Tilt: Power Trim and Tilt Mid Unit Precautions Precaution for Power Trim and Tilt ZAJ6112200001 WARNING Before removing the PTT unit, the motor should be fully supported to prevent personal injury. CAUTION • To prevent system malfunctions, ensure that all components are kept free from dirt or contamination.
  • Page 267 Power Trim and Tilt: 2B-2 Power Trim and Tilt Hydraulic Diagram IAJ611220001-02 1. PTT motor 8. Trim piston 15. Down main valve 2. Tilt rod 9. Free piston 16. “UP” relief valve 3. Oil reservoir 10. Lower cylinder chamber 17. “DOWN” relief valve 4.

  • Page 268: Principles Of Power Trim And Tilt Operation Description

    2B-3 Power Trim and Tilt: Principles of Power Trim and Tilt Operation Description ZAJ6112201002 By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder. Trim / Tilt Up Circuit When the PTT switch is operated “UP”...
  • Page 269 Power Trim and Tilt: 2B-4 Trim / Tilt Down Circuit When the PTT switch is operated in the “Down” position, the electric motor will rotate in a counterclockwise direction and turn the gear pump (1). “Down main valve” (2) will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve (3), moving it to the left, thereby opening the “Down check valve”...
  • Page 270 2B-5 Power Trim and Tilt: Shock Absorber Circuit Shock valve Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
  • Page 271 Power Trim and Tilt: 2B-6 Manual Release Circuit (Manual Valve) Turn the manual valve a maximum of four full turns counterclockwise. When the manual release valve (1) 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 272 2B-7 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 (1) caused by rising temperature will release the thermal valve (2) and make the oil flow to the reservoir to prevent damage to the PTT unit.

  • Page 273: Schematic And Routing Diagram

    Power Trim and Tilt: 2B-8 Schematic and Routing Diagram Power Trim and Tilt System Diagram ZAJ6112202001 BATT W-tube B GND W BATT Gr IGN Br START IAJ611220007-02 1. PTT switch (Remote control box) 5. Ignition switch 9. ECM fuse 30 amp. 2.

  • Page 274: Diagnostic Information And Procedures

    2B-9 Power Trim and Tilt: Diagnostic Information and Procedures Diagnose PTT System Malfunction ZAJ6112204001 Condition Possible cause Correction / Reference Item Motor will not trim / tilt at Blown fuse for PTT system. Inspection and replace. all (no up, no down). (Main: 30 A, PTT switch: 15 A, ECM: 30 Defective PTT switch.

  • Page 275: Service Instructions

    Power Trim and Tilt: 2B-10 Service Instructions Checking PTT Fluid Level Air Bleeding from PTT Unit ZAJ6112206001 ZAJ6112206002 1) Raise the engine to a full-tilt up position. 1) Check that the manual release valve (1) is tightened to the specified torque. 2) Lower the manual tilt lock lever (1).

  • Page 276: Setting Of Trim Down Position Limit

    2B-11 Power Trim and Tilt: Setting of Trim Down Position Limit 5) Press the “DOWN” side of the PTT switch for three ZAJ6112206003 seconds and the buzzer will sound two times briefly Once the ECM has been replaced or the trim sensor indicating the setting has been canceled.

  • Page 277: Setting Tilt Up Limit Position

    Power Trim and Tilt: 2B-12 Setting Tilt Up Limit Position 5) Press the “UP” side of the PTT switch for three ZAJ6112206004 seconds and the buzzer will sound twice briefly If the outboard motor contacts the motor well of the boat indicating the setting has been canceled.

  • Page 278: Power Trim And Tilt Unit Removal And Installation

    2B-13 Power Trim and Tilt: Power Trim and Tilt Unit Removal and 3) Remove the tilt rod snap ring (2) and push the tilt cylinder upper shaft pin (3) out. Installation To remove the tilt cylinder upper shaft pin, pull up the ZAJ6112206005 Removal manual tilt lever.
  • Page 279 • Apply water resistant grease to the tilt cylinder lower shaft and lower shaft bushing. Install the lower shaft bushing (1) and cylinder lower shaft (2) to PTT unit. Install the spacer (3) to cylinder lower shaft. : Grease 99000–25161 (SUZUKI Water IAJ611220025-01 Resistant Grease (250 g)) IAJ611220026-01 IAJ611220029-01 8) Remove two PORT motor mounting bolts (6).
  • Page 280 • Tighten cylinder lower shaft bolts (5), pre-coated with Secure the upper shaft with the snap ring (9). thread lock, to specified torque. : Grease 99000–25161 (SUZUKI Water : Thread lock cement 99000–32050 (SUZUKI Resistant Grease (250 g)) Thread Lock 1342 (50 g)) Tightening torque Cylinder lower shaft bolt (b): 50 N·m (5.0 kgf-m,...

  • Page 281: Power Trim And Tilt Unit Components

    Power Trim and Tilt: 2B-16 Power Trim and Tilt Unit Components ZAJ6112206006 IAJ611220008-01 1. Joint 9. Screw 17. Drive joint 25. Circlip 2. Tank 10. O-ring 18. Filter 26. Anode 3. Plug 11. Armature 19. Gear pump 27. Bolt 4. O-ring 12.

  • Page 282: Power Trim And Tilt Unit Disassembly

    2B-17 Power Trim and Tilt: Power Trim and Tilt Unit Disassembly 4) Remove the manual release valve snap ring (1), ZAJ6112206007 then unscrew the manual release valve (2). NOTE Before disassembly, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt.
  • Page 283 Power Trim and Tilt: 2B-18 7) Remove the three bolts (7) and pump assembly (8). 9) Using special tool, unscrew the upper eye (12). Special tool (B): 09945–69010 (PTT rod holder) IAJ611220042-01 8) Remove the check valve (9), down-blow valve (10) and O-rings (11).

  • Page 284: Power Trim And Tilt Unit Reassembly

    Reservoir bolt (a): 4.7 N·m (0.47 kgf-m, 3.4 lbf-ft) IAJ611220050-01 IAJ611220048-01 Upper Eye • Apply thread lock super 1333B to threads of upper eye before threading it onto tilt rod. : Thread lock cement 99000–32020 (SUZUKI Thread Lock Super 1333B (50 g)) IAJ611220051-01...
  • Page 285 Power Trim and Tilt: 2B-20 • Install the pump assembly (3), then tighten three PTT Motor screws (4) to specified torque. • Install the PTT motor. Refer to “Power Trim and Tilt Motor Removal and Tightening torque Installation” (Page 2B-22). Pump securing screw (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft) PTT Fluid...

  • Page 286: Power Trim And Tilt Unit Components Cleaning And Inspecting

    2B-21 Power Trim and Tilt: 6) Reverse the two extension cable lead wires (Bl to • Inspect reservoir for cracks, nicks or damage. positive / G to negative). Replace if necessary. Operate the PTT motor until the PTT rod is in the full •...

  • Page 287: Power Trim And Tilt Motor Removal And Installation

    Power Trim and Tilt: 2B-22 • Inspect manual release valve for damage. Replace if 2) Place the lower section of the PTT unit in a vise. necessary. Tighten the vise only enough to secure the PTT unit, DO NOT OVER TIGHTEN. •...

  • Page 288: Power Trim And Tilt Motor Disassembly And Assembly

    2B-23 Power Trim and Tilt: Installation Power Trim and Tilt Motor Disassembly and Installation is reverse of removal with special attention to Assembly following steps. ZAJ6112206011 Disassembly • Ensure that the drive joint (1) is aligned and firmly 1) For correct assembly, scribe an alignment mark on inserted into the gear pump assembly.

  • Page 289: Ptt Motor Related Items Inspection

    Power Trim and Tilt: 2B-24 Assembly • Inspect the commutator surface. Assembly is reverse of disassembly with special If surface is gummy or dirty, clean with 400 grit emery attention to following steps. paper (1). • Install O-ring (1). • Measure commutator outside diameter. If measurement exceeds service limit, replace •...

  • Page 290: Ptt Motor Relay Inspection

    2B-25 Power Trim and Tilt: Brushes PTT Motor Relay Inspection ZAJ6112206013 • Check the length of each brush. 1) Remove the PTT motor relay from the electric parts If brushes are worn down to the service limit, they holder. must be replaced. Refer to “Electric Parts Holder Removal and Special tool Installation”...

  • Page 291: Ptt Switch Inspection

    Power Trim and Tilt: 2B-26 4) Temporarily connect a jumper wire (1) from the “P” PTT Switch Inspection ZAJ6112206014 lead wire to the battery positive (+) terminal, then Test continuity between the switch lead wires at each of check the voltage between the “G” wire and the “B” the three switch positions.
  • Page 292 2B-27 Power Trim and Tilt:...

  • Page 293: Lower Unit

    Table of Contents 3- i Section 3 Lower Unit CONTENTS Precautions ..........3-1 Lower Unit Removal and Installation....3A-5 Water Pump Removal and Installation....3A-6 Precautions............. 3-1 Water Pump and Related Items Inspection..3A-8 General Precautions ..........3-1 Lower Unit Disassembly........3A-8 Precaution for Lower Unit ........3-1 Pinion Bearing Removal and Installation ..3A-11 Right Hand Rotation Unit......

  • Page 294: Precautions

    3-1 Precautions: Precautions Lower Unit Precautions General Precautions ZAJ6113000001 Refer to “General Precautions” in Section 00 (Page 00-1). Precaution for Lower Unit ZAJ6113000002 WARNING • When installing or removing the propeller, shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally. •...

  • Page 295: Right Hand Rotation Unit

    Right Hand Rotation Unit: 3A-1 Right Hand Rotation Unit qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqq qqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqqLower Unit Diagnostic Information and Procedures Diagnose Lower Unit Malfunction ZAJ6113104001 Trouble Check Chart Condition Possible cause Correction / Reference Item Engine stalls when Idling speed set too low. Adjustment.

  • Page 296: Service Instructions

    9. Pin 20. Gasket 31. Sealing : 8 N·m (0.8 kgf-m, 6.0 lbf-ft) 10. Magnet 21. Water filter STBD 32. Under panel : Apply SUZUKI Water Resistant Grease. 11. Guide 22. Water Filter PORT 33. Gasket : Apply SUZUKI Silicon seal.
  • Page 297 30. Oil seal : Apply SUZUKI Water Resistant Grease. 9. Driveshaft bearing 20. Propeller shaft 31. Stopper : Apply SUZUKI Outboard Motor Gear Oil. 10. Forward gear bearing 21. Thrust washer 32. Propeller : Apply SUZUKI Thread Lock 1342. 11. Shim 22.

  • Page 298: Propeller Removal And Installation

    3A-4 Right Hand Rotation Unit: Propeller Removal and Installation Installation ZAJ6113106002 1) Coat the propeller shaft splines liberally with Suzuki WARNING water resistant grease. : Grease 99000–25161 (SUZUKI Water • When installing or removing the propeller, shift into “Neutral” and remove the...

  • Page 299: Propeller / Nut / Cotter Pin Inspection

    Lower Unit Removal and Installation Resistant Grease (250 g)) ZAJ6113106004 Removal 3) Apply a light coating of suzuki silicone seal to mating surfaces of gearcase and driveshaft housing. WARNING : Sealant 99000–31120 (SUZUKI Silicone Always disconnect the battery cable, before Seal (50 g)) removing lower unit.

  • Page 300: Water Pump Removal And Installation

    3A-6 Right Hand Rotation Unit: 6) Connect the clutch rod and the shift rod using the Water Pump Removal and Installation ZAJ6113106005 clutch rod connector in the following procedure: Removal NOTE 1) Remove the lower unit. Refer to “Lower Unit Removal and Installation”...
  • Page 301 IAJ611310015-02 IAJ611310013-01 NOTE Before installing pump inner sleeve, apply SUZUKI Bond 1207B lightly between inner sleeve and pump case mating surfaces. : Sealant 99000–31140 (SUZUKI Bond 1207B (100 g)) 3) Install inner sleeve (5) into the pump case (6), ensuring that projection of inner sleeve and groove of pump case are aligned.

  • Page 302: Water Pump And Related Items Inspection

    3A-8 Right Hand Rotation Unit: Water Pump and Related Items Inspection 4) Place a drain pan under oil drain plug. Remove oil ZAJ6113106006 drain plug (1) first then oil level plug (2) and allow Inspect the following parts. gear oil to drain. •...
  • Page 303 Right Hand Rotation Unit: 3A-9 7) Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. Remove pinion nut (5). Special tool (C): 09921–29511 (Driveshaft holder) IAJ611310026-01 10) Remove the nut (11) from shift rod. Lift out driveshaft (12), driveshaft bearing housing (13).
  • Page 304 3A-10 Right Hand Rotation Unit: 12) Remove the detent ball (16), spring (17) and plate 14) Remove the pin (21) and driveshaft collar (22) from (18). driveshaft (if necessary). IAJ611310031-01 13) Remove driveshaft (12) from driveshaft bearing IAJ611310035-01 15) Remove the snap ring (23) and push shift rod guide housing.

  • Page 305: Pinion Bearing Removal And Installation

    Right Hand Rotation Unit: 3A-11 18) To disassemble propeller shaft components, refer to d) Remove the clutch dog shifter (37), push pin following. (39), and return spring (40) from propeller shaft. a) Slide propeller shaft away from reverse gear (31) and bearing housing assembly (32).
  • Page 306 3A-12 Right Hand Rotation Unit: Removal Installation 1) Disassemble the lower unit. Refer to “Lower Unit CAUTION Disassembly” (Page 3A-8). 2) Remove the water pump stud bolts (1). • Before installing bearing, ensure that inside of gearcase is clean and free of debris.

  • Page 307: Lower Unit Related Items Inspection

    Right Hand Rotation Unit: 3A-13 Lower Unit Related Items Inspection Gears / Bearing ZAJ6113106009 • Inspect forward, reverse and pinion gear teeth and WARNING engaging dogs. Replace gears if damaged worn or other abnormal Wear safety glasses when using compressed conditions are noted.
  • Page 308 3A-14 Right Hand Rotation Unit: • Check clutch return spring by measuring its free Shift Rod and Shift Cam Components length. If free length is not within specifications, • Inspect the “stepped” surface of shift cam. Replace if replace clutch return spring. worn, damaged or other abnormal conditions are noted.

  • Page 309: Propeller Shaft Oil Seal Replacement

    • Inspect driveshaft / splines. Replace if worn, twisted, damaged or other abnormal conditions are noted. : Grease 99000–25161 (SUZUKI Water • Inspect driveshaft bearing, replace if pitted, noisy, Resistant Grease (250 g)) rough or other abnormal conditions are noted.

  • Page 310: Lower Unit Assembly

    3A-16 Right Hand Rotation Unit: 4) Grease the inner lips of oil seal. • Insert the plate (6), spring (7) and detent ball (8) into With the lips facing away from driveshaft bearing, gearcase. place seal in position and drive it into the bearing housing.
  • Page 311 (5). IAJ611310064-01 IAJ611310067-01 • Apply water resistant grease to the driveshaft oil seal Driveshaft (6). • Assemble the driveshaft collar (1) to driveshaft. : Grease 99000–25161 (SUZUKI Water • Install the pin (2). Resistant Grease (250 g)) IAJ611310065-01 IAJ611310069-01...
  • Page 312 A new pinion nut should be used on final assembly. IAJ611310070-01 • Install the gearcase seal ring (9) into the groove on Special tool the driveshaft bearing housing. Apply suzuki silicone (A): 09921–29511 (Driveshaft holder) seal to gearcase and driveshaft bearing housing surfaces. Tightening torque Pinion nut (a): 45 N·m (4.5 kgf-m, 32.5 lbf-ft)
  • Page 313 • Install back-up shim (3) and reverse gear (4) to propeller shaft bearing housing (5). “F” • Slide propeller shaft into reverse gear and propeller shaft bearing housing. IAJ611310075-01 : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) : Gear Oil 99000–22540 (SUZUKI Outboard Motor Gear Oil) IAJ611310078-02...
  • Page 314 3A-20 Right Hand Rotation Unit: • Apply water resistant grease to the bearing housing Rechecking Driveshaft Thrust Play O-ring (6). Recheck the driveshaft thrust play. This should not be less than previously checked. If less, reduce the number / thickness of the reverse gear back-up shims. Refer to “Lower Unit Gears - Shimming and Adjustment”...

  • Page 315: Trim Tab Adjustment

    Right Hand Rotation Unit: 3A-21 2) Install the test tool into the oil level hole. Lower Unit Install the Lower Unit. 3) Connect the air pump to the tester. Refer to “Lower Unit Removal and Installation” (Page 4) Rotate driveshaft and propeller shaft clockwise 3A-5).

  • Page 316: Lower Unit Gears - Shimming And Adjustment

    3A-22 Right Hand Rotation Unit: Lower Unit Gears - Shimming and Adjustment ZAJ6113106014 If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash will have to be checked and/or adjusted to ensure smooth, reliable operation. Shim / Washer and Mounting Position Design specification thickness Item...
  • Page 317 Right Hand Rotation Unit: 3A-23 Forward Gear / Pinion Gear Back-Up Shim Checking driveshaft thrust play Adjustment 1) Affix the gear adjusting gauge to driveshaft. Follow the procedure below to adjust forward gear / Special tool pinion gear. (A): 09951–09530 (Gear adjusting gauge) Prior to adjustment 2) To check driveshaft thrust play, push the forward 1) Install standard pinion gear back-up shim thickness...
  • Page 318 3A-24 Right Hand Rotation Unit: Checking and adjusting tooth contact pattern 5) Carefully remove the propeller shaft and housing to (Pinion and Forward gear) check the tooth contact pattern. Check tooth contact pattern using the following procedure. “A” “a” 1) To assess tooth contact, apply a light coat of “B”...
  • Page 319 Right Hand Rotation Unit: 3A-25 Example [A] Rechecking driveshaft thrust play Incorrect topside toe contact. After obtaining optimum tooth contact, driveshaft thrust Correction measures. play should be measured. • Decrease thickness of forward gear shim. 1) Affix the gear adjusting gauge to the driveshaft. •...
  • Page 320 3A-26 Right Hand Rotation Unit: Reverse Gear Back-Up Shim Adjustment 5) Compare play “B” to play “A”. After adjusting the forward gear tooth contact pattern, Refer to “Rechecking driveshaft thrust play” (Page follow the procedure below to adjust the reverse gear. 3A-25).
  • Page 321 Table of Contents 4- i Section 4 Wire / Hose Routing CONTENTS Precautions ..........4-1 Wiring Harness Routing Diagram......4A-4 Precautions............. 4-1 Fuel / Water Hose Routing ...... 4B-1 Precautions for Wire / Hose Routing..... 4-1 Precautions............4B-1 Component Location ..........4-1 Precautions for Fuel / Water Hose Routing..4B-1 Electrical Component Location ......

  • Page 322: Precautions

    4-1 Precautions: Precautions Wire / Hose Routing Precautions Precautions for Wire / Hose Routing ZAJ6114000001 Refer to “General Precautions” in Section 00 (Page 00-1). Component Location Electrical Component Location ZAJ6114003001 Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-4).

  • Page 323: Wire Routing

    Wire Routing: 4A-1 Wire Routing Wire / Hose Routing Schematic and Routing Diagram Wiring Diagram ZAJ6114102001 Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
  • Page 324 4A-2 Wire Routing: DF60AT IAJ611410001-03...
  • Page 325 Wire Routing: 4A-3 DF60ATH SUZUKI IAJ611410002-01...

  • Page 326: Wiring Harness Routing Diagram

    4A-4 Wire Routing: Wiring Harness Routing Diagram ZAJ6114102002 “A” “B” IAJ611410003-03 1. Electric parts holder 7. PTT relay lead wire (Red) 13. Main harness GND lead wire 2. PTT relay 8. Cable tie 14. CKP sensor connector : Secure the harness with the cable tie. 3.
  • Page 327 Wire Routing: 4A-5 “B” “A” IAJ611410005-01 1. Battery cable 3. Remote control harness “A”. Inside : Position the taping (2) of battery cable into the rigging port grommet as shown illustration. 2. Taping 4. Rigging port grommet “B”. Outside “B” 11 12 13 15 14 “A”...
  • Page 328 4A-6 Wire Routing: IAJ611410007-02 1. Starter motor 5. Nut 9. Battery cable : 9 N·m (0.9 kgf-m, 6.5 lbf-ft) : Cover the nut with cap (6). : Route the battery cable under the fuel hose. 2. Starter motor band 6. Cap 10.
  • Page 329 Wire Routing: 4A-7 9 8 10 IAJ611410009-02 1. CMP sensor 4. No.3 Ign. Coil 7. Main wiring harness 10. Clamp 2. No.1 Ign. Coil 5. Harness bracket 8. Harness bracket 3. No.2 Ign. Coil 6. Joint connector 9. Bolt IAJ611410010-02 1.

  • Page 330: Fuel / Water Hose Routing

    4B-1 Fuel / Water Hose Routing: Fuel / Water Hose Routing Wire / Hose Routing Precautions Precautions for Fuel / Water Hose Routing ZAJ6114200001 CAUTION • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. •...
  • Page 331 Fuel / Water Hose Routing: 4B-2 IAJ611420002-04 1. Clamp: 4. Clamp: 7. Clamp Clamp the hose at the white marking position Clamp the hoses (3) and (5) at the white marking position on the hose. on the hose. 2. Clamp 5.
  • Page 332 4B-3 Fuel / Water Hose Routing: IAJ611420004-03 1. Fuel hose (Low pressure fuel pump to fuel vapor 4. Fuel hose (Fuel filter to fuel pump) 7. Water outlet hose (Fuel vapor separator to separator) engine holder) 2. Low pressure fuel pump 5.

  • Page 333: Water Hose Routing

    Fuel / Water Hose Routing: 4B-4 Water Hose Routing ZAJ6114202002 IAJ611420006-03 1. Water return hose 2. Clip 3. Thermostat cover IAJ611420007-01 1. Water inlet hose (Engine holder to fuel vapor separator) 3. Hose protector 5. Clamp 2. Water outlet hose (Fuel vapor separator to engine holder) 4.
  • Page 334 4B-5 Fuel / Water Hose Routing: IAJ611420008-02 1. Water return hose 4. Water indicator hose 7. Bolt 2. Clip 5. Water indicator union 3. Water outlet hose (Fuel vapor separator to engine holder) 6. Clip...
  • Page 335 Prepared by Marine Design Department December, 2009 Manual No. 99500-88L00-01E Printed in Japan...

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