Suzuki DF200 Service Manual
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Suzuki DF200 Service Manual

Outboard motors four stroke v6
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PRE - PRODUCTION
ISSUE
1

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Questions and answers

Егор
April 11, 2025

Check engine 3-6 что за проблема?

0
1 comments:
Mr. Anderson
May 14, 2025

The check engine 3-6 code for a Suzuki DF200 indicates an "Oxygen Sensor Problem."

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robert peting
January 24, 2025

cooling system schematic

-1
1 comments:
Mr. Anderson
May 14, 2025

The cooling system schematic for the Suzuki DF200 includes the following components:

- Lower unit water pump
- Water supply tube from the lower unit to the power unit
- Oil pan water pressure valve
- Power unit water passages
- Thermostats

This system cools both the power unit and the exhaust. If the engine overheats, inspect the system for blockages, corrosion, or damaged components.

This answer is automatically generated

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Summary of Contents for Suzuki DF200

  • Page 1 PRE - PRODUCTION ISSUE...

  • Page 2: General Information

    FOREWORD GROUP INDEX This manual contains an introductory description of the SUZUKI DF200/225/250 Outboard motors and procedures for inspection, service and overhaul of GENERAL INFORMATION their main components. General knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION section...

  • Page 3: Component Parts And Item Illustrations

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference. 3.
  • Page 4 Apply THREAD LOCK SUPER “1333B”. erwise specified. Apply SUZUKI OUTBOARD MOTOR Measure in DC voltage range. GEAR OIL. Apply SUZUKI SUPER GREASE “A”. Measure in resistance range. Apply SUZUKI WATER RESISTANT Measure in continuity test range. GREASE. Apply SUZUKI BOND “1104”.
  • Page 5 ABBREVIATIONS Abbreviations used in this service manual are as follows: BTDC : Before Top Dead Center : Crankshaft position : Camshaft position : Close Throttle position : Direct Current DOHC : Double Over Head Camshaft : Engine Control Module EX (Ex.) : Exhaust : Idle Air Control : Intake Air Temperature IN (In.)

  • Page 6: Table Of Contents

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

  • Page 7: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 8 GENERAL INFORMATION " • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiv- alent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

  • Page 9: Identification Number Location

    GENERAL INFORMATION IDENTIFICATION NUMBER LOCATION MODEL, PRE-FIX, SERIAL NUMBER The MODEL, PRE-FIX and SERIAL NUMBER of motor are stamped on a plate attached to the clamp bracket. Example MODEL DF 250 2 5 0 0 1 F PRE-FIX SERIAL NUMBER ENGINE SERIAL NUMBER A second engine serial number plate is pressed into a boss on the cylinder block.

  • Page 10: Fuel And Oil

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

  • Page 11: Engine Break-In

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

  • Page 12: Propellers

    GENERAL INFORMATION PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF200/225/250 models are shown below. DF200 5 000 – 6 000 r/min Recommended full DF225 5 000 –...

  • Page 13: Powerhead Direction Of Rotation

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

  • Page 14: Specifications

    GENERAL INFORMATION * SPECIFICATIONS These specifications are subject to change without notice. For DF200Z/225Z/250Z specification, see page 1-11. Data Item Unit DF200T DF225T DF250T PRE-FIX 20001F 22501F 25001F DIMENSIONS & WEIGHT Overall length mm (in.) 897 (35.3) (front to back) Overall width mm (in.) 572 (22.5)
  • Page 15 Engine oil amounts 8.0 (8.5/7.0) : Oil change only L (US/lmp. qt) 8.2 (8.7/7.2) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity 1 100 (37.2/38.7) (US/lmp. oz) BRACKET Trim angle degree 0 –...
  • Page 16 GENERAL INFORMATION 1-11 These specifications are subject to change without notice. For DF200T/225T/250T specification, see page 1-9. Data Item Unit DF200Z DF225Z DF250Z PRE-FIX 20001Z 22501Z 25001Z DIMENSIONS & WEIGHT Overall length mm (in.) 897 (35.3) (front to back) Overall width mm (in.) 572 (22.5) (side to side)
  • Page 17 Engine oil amounts 8.0 (8.5/7.0) : Oil change only L (US/lmp. qt) 8.2 (8.7/7.2) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil capacity 1 100 (37.2/38.7) (US/lmp. oz) BRACKET Trim angle degree 0 –...

  • Page 18: Service Data

    GENERAL INFORMATION 1-13 * SERVICE DATA These service data are subject to change without notice. Data Item Unit DF200T/Z DF225T/Z DF250T/Z POWERHEAD Recommended operating range r/min 5 000 – 6 000 5 000 – 6 000 5 500 – 6 100 Idle speed r/min 650 ±...
  • Page 19 1-14 GENERAL INFORMATION Data Item Unit DF200T/Z DF225T/Z DF250T/Z CYLINDER HEAD/CAMSHAFT Cylinder head distortion Limit mm (in.) 0.03 (0.001) Manifold seating faces dis- Limit mm (in.) 0.10 (0.004) tortion Cam height 43.020 – 43.180 42.420 – 42.580 44.920 – 45.080 mm (in.) (1.6937 –...
  • Page 20 GENERAL INFORMATION 1-15 Data Item Unit DF200T/Z DF225T/Z DF250T/Z VALVE/VALVE GUIDE Valve diameter mm (in.) 35.9 (1.4) mm (in.) 31.4 (1.2) Tappet clearance mm (in.) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) mm (in.) 0.33 – 0.37 (0.013 – 0.015) Valve seat angle —...
  • Page 21 1-16 GENERAL INFORMATION Data Item Unit DF200T/Z DF225T/Z DF250T/Z CYLINDER/PISTON/PISTON RING Cylinder distortion Limit mm (in.) 0.03 (0.001) Piston to cylinder clearance mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Limit mm (in.) 0.100 (0.0039) Cylinder bore mm (in.) 95.000 – 95.020 (3.0472 – 3.7409) Cylinder measuring position mm (in.) 50 (1.969) from cylinder top surface...
  • Page 22 GENERAL INFORMATION 1-17 Data Item Unit DF200T/Z DF225T/Z DF250T/Z CRANKSHAFT/CONROD Conrod small end inside mm (in.) 22.003 – 22.011 (0.8663 – 0.8666) diameter Conrod big end oil clearance STD mm (in.) 0.045 – 0.063 (0.0018 – 0.0025) Limit mm (in.) 0.080 (0.0031) Conrod big end inside diam- mm (in.)
  • Page 23 1-18 GENERAL INFORMATION Data Item Unit DF200T/Z DF225T/Z DF250T/Z ELECTRICAL Ignition timing Degrees BTDC 0 – 26 ± 3 BTDC 0 – 25 ± 3 BTDC 0 – 26 ± 3 at r/min Over revolution limiter r/min 6 200 6 300 Ω...
  • Page 24 GENERAL INFORMATION 1-19 PTT MOTOR Brush length mm (in.) 9.8 (0.39) Limit mm (in.) 5.5 (0.22) Commutator outside diame- mm (in.) 22.0 (0.87) Limit mm (in.) 21.0 (0.83) SELF-DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the moni- tor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
  • Page 25 1-20 GENERAL INFORMATION PRIORITY FAIL-SAFE SYS- FAILED ITEM CODE LAMP FLASHING PATTERN TEM ACTIVATING CMP sensor (VVT·STBD) 2 – 5 CMP sensor (VVT·PORT) 2 – 6 VVT advance (STBD) 5 – 1 VVT advance (PORT) 5 – 2 Neutral switch 3 –...

  • Page 26: Tightening Torque

    GENERAL INFORMATION 1-21 TIGHTENING TORQUE Tightening torque – Important fasteners THREAD TIGHTENING TORQUE ITEM DIAMETER N·m kg-m lb-ft Cylinder head cover bolt 6 mm 8 mm 16.6 Cylinder head bolt 11 mm 62.0 8 mm 19.5 Crankcase bolt 10 mm 37.6 Crankshaft drive gear bolt 10 mm...
  • Page 27 1-22 GENERAL INFORMATION TIGHTENING TORQUE THREAD ITEM DIAMETER N·m kg-m lb-ft 10 mm 40.0 Gearcase bolt 12 mm 60.0 Propeller shaft bearing housing bolt 8 mm 16.6 Pinion gear nut 14 mm 14.5 105.0 Propeller nut 18 mm 40.0 Tightening torque – General bolt NOTE: These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners”...

  • Page 28: Special Tools

    GENERAL INFORMATION 1-23 SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) Hexagon socket 09900-00415 (8 mm) (A) 09900-06107 09900-20101 (150 mm) 09900-00410 (included in Hexagon bit (included (B) 09900-06108 09900-20102 (200 mm) Hexagon wrench set 09900-00410) in 09900-00410) Snap ring pliers Vernier calipers 09900-20203 (50 –...
  • Page 29 1-24 GENERAL INFORMATION 09912-58413: Fuel pressure gauge set (1) 09912-58442: Fuel pressure gauge 09900-26006 09900-28403 (2) 09912-58432: Fuel pressure hose 09913-50121 Engine tachometer Hydrometer (3) 09912-58490: 3-way joint & hose Oil seal remover 09951-09310 09915-67010 Gear adjust spring 09921-29410 09915-47341 09915-64512 Compression gauge Driveshaft holder...
  • Page 30 GENERAL INFORMATION 1-25 09916-34550 09916-37320 09916-34542 Valve guide reamer Valve guide reamer Valve seat cutter (15°) Valve guide reamer 09916-44310 (Neway 217) 5.5 mm) handle 10.5 mm) Valve guide remover 09916-77310 09917-47011 09916-69310 09916-57330 Piston ring com- 09916-84511 Vacuum pump Tappet holder Valve guide installer pressor...
  • Page 31 1-26 GENERAL INFORMATION 09930-89220 09930-89240 09930-89340 3-pin connector test 4-pin connector test 09930-89260 26-pin & 34-pin test 09930-99320 cord cord Injector test cord A cord Digital tester 09932-79910 Diagnostic harness 09950-69512 09951-09511 09932-89910 09940-44121 09940-44130 Gearcase oil leakage Gear adjusting SDS adapter Air pressure gauge Attachment...

  • Page 32: Materials Required

    GENERAL INFORMATION 1-27 MATERIALS REQUIRED SUZUKI OUTBOARD SUZUKI SUPER WATER RESISTANT SUZUKI SILICONE SUZUKI BOND MOTOR GEAR OIL GREASE “A” GREASE SEAL “1104” 99000-25030* 99000-22540 99000-25010 99000-25160 99000-31120 99000-31030 (400 ml × 24 pcs) (500 g) (250 g) (50 g)
  • Page 33 PERIODIC MAINTENANCE PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE ............2- 2 PERIODIC MAINTENANCE CHART .............2- 2 MAINTENANCE AND TUNE-UP PROCEDURES ..........2- 3 ENGINE OIL/ENGINE OIL FILTER ............2- 3 GEAR OIL ....................2- 6 LUBRICATION ..................2- 7 SPARK PLUG ..................2- 8 TAPPET CLEARANCE ................2- 9 IDLE SPEED ...................2-16 IGNITION TIMING ..................2-17 FUEL LINE .....................2-18...

  • Page 34: Periodic Maintenance Schedule

    PERIODIC MAINTENANCE PERIODIC MAINTENANCE SCHEDULE The chart below lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first. NOTE: More frequent servicing should be performed on outboard motors that are used under severe conditions.

  • Page 35: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE MAINTENANCE AND TUNE-UP PROCEDURES This section describes servicing procedures for each periodic maintenance requirement. ENGINE OIL/ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use. 1. Place outboard motor upright on a level surface. 2. Remove motor cover. 3.
  • Page 36 PERIODIC MAINTENANCE ENGINE OIL CHANGE/ENGINE OIL FILTER REPLACEMENT ENGINE OIL Change initially after 20 hours (1 month) and every 100 hours (6 months). ENGINE OIL FILTER Replace initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: •...
  • Page 37 PERIODIC MAINTENANCE (3) Screw new filter on by hand until filter O-ring contacts the mounting surface. (4) Tighten filter 3/4 turn from point of contact with mounting surface using an oil filter wrench. " Engine oil filter: 14 N·m (1.4 kg-m, 10.0 lb-ft), 3/4 turn 6.

  • Page 38: Gear Oil

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

  • Page 39: Lubrication

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

  • Page 40: Spark Plug

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

  • Page 41: Tappet Clearance

    PERIODIC MAINTENANCE INSTALLATION Installation is reverse order of removal. " Spark plug: 28 N·m (2.8 kg-m, 20.0 lb-ft) TAPPET CLEARANCE Inspect initially after 20 hours (1 month) and every 200 hours (12 months). The tappet clearance specification is different for intake and exhaust valves.
  • Page 42 2-10 PERIODIC MAINTENANCE 3. Rotate crankshaft counterclockwise to bring cam nose verti- cal to shim surface. 90˚ 90˚ 4. Measure tappet clearances by inserting thickness gauge between cam and shim surface. Tappet clearance (cold engine condition): IN.: 0.23 – 0.27 mm (0.009 – 0.011 in) EX.: 0.30 –...
  • Page 43 PERIODIC MAINTENANCE 2-11 4. Rotate top of cam 90 degree counterclockwise and remove shim from cut-away at tappet. (Two tappets can be adjusted at the same time.) • Do not put your finger between camshaft and tappet while the tappet is being held with the tappet holder. •...
  • Page 44 2-12 PERIODIC MAINTENANCE 6. Install shim. Identification number should face down (towards tappet). 7. Rotate crankshaft to be open (lift up) valve. 8. Remove tappet holder 1 and tighten camshaft housing bolts to specified torque. " Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft) Special tool Tappet Camshaft...
  • Page 45 PERIODIC MAINTENANCE 2-13 OCV (Oil control valve) • On the DF250 model, install gasket and OCV, and then tighten bolts securely. NOTE: Position the projection of OCV gasket as shown the right. Do not re-use OCV gasket. Always replace with new 1.
  • Page 46 2-14 PERIODIC MAINTENANCE...
  • Page 47 PERIODIC MAINTENANCE 2-15...

  • Page 48: Idle Speed

    2-16 PERIODIC MAINTENANCE IDLE SPEED Inspect initially after 20 hours (1 month) and every 200 hours (12 months). NOTE: • Before checking idle speed, engine must be warmed up. No. 1 Ign. coil • Check and/or adjust idle speed after engine speed has stabi- lized.

  • Page 49: Ignition Timing

    PERIODIC MAINTENANCE 2-17 9. When finished adjusting the idle speed, opening the throttle will automatically cancel the IAC fixed mode. NOTE: The fixed mode of IAC can also be canceled manually by shift- ing to Forward or Reverse or raising the engine speed (causes the fully close throttle signal of TPS to be OFF ).

  • Page 50: Fuel Line

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

  • Page 51: Low Pressure Fuel Filter

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

  • Page 52: Pcv System

    2-20 PERIODIC MAINTENANCE PCV SYSTEM • Inspect initially after 20 hours (1 month) and every 50 hours (3 months). • Replace every 2 years. NOTE: Be sure to check for any obstruction in the PCV valve or its hose before checking engine idle speed/IAC duty. An obstructed PCV valve or hose prevents proper operation of 1.

  • Page 53: Low Pressure Fuel Pump Filter

    PERIODIC MAINTENANCE 2-21 LOW PRESSURE FUEL PUMP FILTER Replace every 1 000 hours. SUZUKI recommends that replacing the low pressure fuel pump filter every 1 000 operating hours. 1. Low pressure fuel pump filter WATER PUMP/WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months).

  • Page 54: Anodes

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

  • Page 55: Battery

    PERIODIC MAINTENANCE 2-23 BATTERY Inspect every 50 hours (3 months). • Never expose battery to open flame or electric spark as batteries generate gas, which is flammable and explosive. • Battery acid is poisonous and corrosive. Avoid con- tact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water.
  • Page 56 2-24 PERIODIC MAINTENANCE BATTERY SOLUTION LEVEL CHECK Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only. Once the battery has been initially serviced, NEVER add diluted sulfuric acid or battery damage will occur. Follow the battery manufacture’s instructions for spe- cific maintenance procedures.

  • Page 57: Bolts And Nuts

    To perform fuel mixture check (O2 feedback) operation, a bat- tery powered personal computer and the Suzuki Diagnostic Sys- tem software/hardware must be used. For fuel mixture check (O2 feedback) operation, refer to “Suzuki Diagnostic System Operation Manual”. NOTE: See “O2 FEEDBACK SYSTEM” section on page 3-47 before...

  • Page 58: Oil Pressure

    2-26 PERIODIC MAINTENANCE OIL PRESSURE Oil pressure (at normal operating temp.): 400 – 600 kPa (4.0 – 6.0 kg/cm , 57 – 85 psi) at 3000 r/min. NOTE: The figure shown above is a guideline only, not an absolute ser- vice limit.
  • Page 59 PERIODIC MAINTENANCE 2-27 4. Start engine and allow to warm up as follows: Summer : 5 min. at 2 000 r/min. Winter : 10 min. at 2 000 r/min. 5. After warming up, shift into forward gear and increase engine speed to 3 000 r/min., then compare pressure indi- cated on gauge to specifications.

  • Page 60: Cylinder Compression

    2-28 PERIODIC MAINTENANCE CYLINDER COMPRESSION Cylinder compression: Standard: 1 100 – 1 700 kPa (11 – 17 kg/cm , 156 – 242 psi) Max. difference between any other cylinders: 100 kPa (1.0 kg/cm , 14 psi) NOTE: Figures shown are guidelines only, not absolute service limits. Low compression pressure can indicate one or more of the fol- lowing: •...

  • Page 61: Engine Vacuum Check

    PERIODIC MAINTENANCE 2-29 ENGINE VACUUM CHECK Engine vacuum is required for proper operation of the Multi-Stage Induction system used on the DF225 & DF250. Engine vacuum is also an indicator of general engine condition. 1. Warm up engine to normal operating temperature. Make sure engine idle speed is within specification.
  • Page 62 ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM STRUCTURE ............. 3- 2 SYSTEM STRUCTURE 1 ................3- 2 SYSTEM STRUCTURE 2 ................3- 3 COMPONENTS FOR SYSTEM CONTROL ............3- 5 ENGINE CONTROL MODULE (ECM) ............3- 5 ECM CONNECTOR/TERMINALS LAYOUT ..........

  • Page 63: Engine Control System Structure

    ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF200/DF225/DF250 models employ an integrated control system which performs the control functions for fuel injection, ignition, idle/trolling speed (idle air), etc. through the ECM (Engine Control Module). SYSTEM STRUCTURE 1 INPUT CONTROL...

  • Page 64: System Structure 2

    ENGINE CONTROL SYSTEM SYSTEM STRUCTURE 2 [DF200]...
  • Page 65 ENGINE CONTROL SYSTEM [DF225/DF250]...

  • Page 66: Components For System Control

    ENGINE CONTROL SYSTEM COMPONENTS FOR SYSTEM CONTROL ENGINE CONTROL MODULE (ECM) The ECM sends signals to control the actuators based on the information inputs from each sensor/switch. Major controls are as follows: NAME OF CONTROL DESCRIPTION Fuel injection control • Controls fuel injection amount and timing. Ignition control •...

  • Page 67: Ecm Connector/Terminals Layout

    — — P/Bl Shift position sensor — — MAP sensor No. 1 Ignition coil (–) Model distinction (DF200 only) Bl/W Buzzer Power source for sensor Low pressure fuel pump (–) Bl/R Emergency stop switch Lg/R No. 4 Ignition coil (–)

  • Page 68: Ecm Internal Structure

    ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE...

  • Page 69: Location Of Sensor And Switch

    ENGINE CONTROL SYSTEM LOCATION OF SENSOR AND SWITCH Fuel injector Ignition coil EX. temp. sensor (STBD) MAP sensor IAC valve Cylinder temp. sensor IAT sensor Purge valve CMP sensor EX. temp. sensor (PORT) CKP sensor Ground cable bolt 60 A fuse Starter motor reray ECM main relay Fuel pump (High pressure)
  • Page 70 ENGINE CONTROL SYSTEM Shift position sensor Neutral switch Oil pressure swtich Parts holder Battery cable CMP sensor (DF250) CMP sensor STBD (DF250) CMP sensor (DF200/225) CMP sensor PORT (DF250) Ignition coil Fuel injector...

  • Page 71: Sensor And Switch

    PORT exhaust camshaft. This sensor detects piston position. • For DF200/225 models: CMP sensor #1 is mounted on the STBD cylinder head cover with trigger vanes pressed onto the end of the Intake cam- shaft.
  • Page 72 ENGINE CONTROL SYSTEM 3-11 ECM cylinder identification: Cylinders are identified by a calculation combined from two signals; one from the CKP sensor and one from the CMP sensor. #1 Cyl. #2 Cyl. #3 Cyl. #4 Cyl. #5 Cyl. #6 Cyl. 34-signals/360˚...
  • Page 73 3-12 ENGINE CONTROL SYSTEM CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder (top side) and used to detect the cylinder temperature. Cylinder This is a thermistor type sensor (resistance of which changes temp. sensor depending on temperature) and inputs a signal to the ECM as a voltage value.
  • Page 74 ENGINE CONTROL SYSTEM 3-13 IAT (Intake Air Temperature) SENSOR The IAT sensor is installed on the bottom of the ring gear cover and air intake silencer case and used to detect the intake air temperature. This sensor is the same type as the cylinder temperature sen- sor, and inputs a signal to the ECM as a voltage value.
  • Page 75 3-14 ENGINE CONTROL SYSTEM SPS (Shift Position Sensor) The SPS is installed on the throttle lever holder and detects the shift position with the clutch lever operation interlocked. Shift position sensor This sensor is a variable resistor that changes resistance (ohms) in accordance with the shift position.
  • Page 76 ENGINE CONTROL SYSTEM 3-15 SUB BATTERY CABLE The ECM power source is through the gray lead wire which sup- plies power directly from the battery. The white lead wire in the remote control extension harness car- ries battery power to the ignition switch. When the ignition switch is turned ON, battery power passes from the white lead wire, through the ignition switch contacts to the gray output lead wire to the ECM.
  • Page 77 3-16 ENGINE CONTROL SYSTEM O2 SENSOR (Optional item) The O2 sensor is installed in the exhaust manifold only when the Zirconia element O2 feedback operation is performed. This sensor is a zirconia element (platinum plated) which Housing changes output voltage depending on the oxygen concentration difference between its internal and external surfaces.

  • Page 78: Ignition System

    ENGINE CONTROL SYSTEM 3-17 IGNITION SYSTEM The ignition system used by the DF200/DF225/DF250 is a fully transistorized, electronic microcomputer tim- ing advanced type. This system is totally battery powered, with the ECM controlling all ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch etc.)

  • Page 79: Ignition Control System

    SPECIFICATION Ignition system Full-transistorized ignition Advance Electronic microcomputer control BTDC 0° – BTDC 26° (DF200) Ignition timing BTDC 0° – BTDC 25° (DF225) BTDC 0° – BTDC 26° (DF250) Firing order 1 – 6 – 5 – 4 – 3 – 2...
  • Page 80 The ignition timing is controlled within the range of BTDC 0° ± 5° to provide stable engine operation at the specified idling/trolling speed. WHEN RUNNING (NORMAL OPERATION): The ignition timing ranges between BTDC 0° – 26° (DF200), BTDC 0° – 25° (DF225) or BTDC 0° – 26° (DF250), depending on current engine operating conditions.

  • Page 81: Electronic Fuel Injection System

    ENGINE CONTROL SYSTEM ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF200/DF225/DF250 is a speed-density, multi-point, sequential, elec- tronic 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 82 ENGINE CONTROL SYSTEM 3-21 FUEL INJECTION TIMING CHART 34-signals/360˚ sensor signal 4-signals/720˚ sensor #1 signal ATDC 280˚ on Ex. stroke Injection time duration 240˚ 280˚ Injection signal Injection signal Injection signal Injection signal Injection signal Injection signal In.: Intake, Cm.: Compression, Ep.: Explosion, Ex.: Exhaust CONTROL MODE...

  • Page 83: Fuel Delivery System Components

    3-22 ENGINE CONTROL SYSTEM FUEL DELIVERY SYSTEM COMPONENTS The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel injector and hoses.
  • Page 84 ENGINE CONTROL SYSTEM 3-23 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 85 3-24 ENGINE CONTROL SYSTEM FUEL PRESSURE REGULATOR The fuel pressure regulator is located in the fuel vapor separator. The regulator’s function in the system is to maintain a constant fuel pressure relative to the injector while the engine is operating. The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure bal- anced.

  • Page 86: High Pressure Fuel Pump Control System

    ENGINE CONTROL SYSTEM 3-25 HIGH PRESSURE FUEL PUMP CONTROL SYSTEM OUTLINE To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated ON/OFF signal, at a specified rate (1 000 times a second). Based on engine speed and battery voltage, the ECM determines the optimum duty (repeating “ON” time rate within a cycle) and sends this signal to the fuel pump.

  • Page 87: Low Pressure Fuel Pump Control System

    3-26 ENGINE CONTROL SYSTEM LOW PRESSURE FUEL PUMP CONTROL SYSTEM Fuel flowing through the pump is the pump coolant. The fuel pump should never be run dry for long peri- ods or it will become damaged. The low pressure fuel pump is an electrically operated type that Low pressure supplies fuel from the fuel tank to the vapor separator.

  • Page 88: Air Intake Components

    ENGINE CONTROL SYSTEM 3-27 AIR INTAKE COMPONENTS Air, after entering through the silencer case, passes through the throttle bodies and flows into the collector assembly (surge tank) where it is then distributed to the cylinder intake manifold. Collector assembly (surge tank) pressure, monitored by the MAP sensor, is an indirect measure of the intake air amount.

  • Page 89: Idle Air Control System

    3-28 ENGINE CONTROL SYSTEM BY-PASS AIR SCREW/PASSAGE Since the throttle valve is almost fully closed when idling/trolling, the main flow of air necessary to maintain idling/trolling speed passes through the by-pass air passage. The by-pass air screw controls the flow of air through the pas- sage and provides a means of partially adjusting the total amount of air necessary for idling/trolling.
  • Page 90 ENGINE CONTROL SYSTEM 3-29 IAC VALVE • The IAC valve uses a stepper type motor. • The IAC valve is installed on the intake collector assembly. • The IAC valve controls the volume of bypass air to stabilize the idling/trolling speed. •...
  • Page 91 3-30 ENGINE CONTROL SYSTEM CONTROL MODE BEFORE START: The IAC valve is initialized at 70% opening position when engine is not running (Ignition switch OFF). WHEN CRANKING: The IAC valve is controlled to operate at approx. 50 – 100% duty. Duty change depends on cylinder temperature.

  • Page 92: Multi-Stage Induction

    ENGINE CONTROL SYSTEM 3-31 MULTI-STAGE INDUCTION OUTLINE The multi-stage induction system is designed to improve the intake efficiency by changing the intake tract volume in accor- dance with the engine speed. This system improves low and mid range torque and increases power output at the higher rpm ranges.

  • Page 93: System Operation

    3-32 ENGINE CONTROL SYSTEM SYSTEM OPERATION LOW & MID SPEED This system is operated by the vacuum created during engine Shut off valve closed operation and controlled by the ECM. To operate the system (open/close the shut off valve to change the intake tract), the collector, check valve, vacuum tank, VSV and depression chamber are connected with hoses as shown in the illustration.

  • Page 94: Vvt (Variable Valve Timing) System

    ENGINE CONTROL SYSTEM 3-33 VVT (Variable Valve Timing) SYSTEM • The VVT system is designed to continuously vary intake valve timing to best fit the engines current oper- ating condition. • The intake cam timing sprocket assembly (VVT actuator) is located at the front end of the intake cam- shaft.
  • Page 95 3-34 ENGINE CONTROL SYSTEM OCV (Oil Control Valve) Two OCV are used, one installed on each (PORT/STBD) lower camshaft housing. RETARD OPERATION Retard operation When the duty ratio of the ECM is small, the OCV spool valve is Advance chamber Engine oil pressure pushed away from the coil by spring force and engine oil pres- Drain...

  • Page 96: Caution System

    The ECM controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed. Over revolution limiter DF200/DF225 : 6 200 r/min DF250 : 6 300 r/min...

  • Page 97: Low Oil Pressure Caution System

    3-36 ENGINE CONTROL SYSTEM LOW OIL PRESSURE CAUTION SYSTEM CONDITION: Immediate activation of system when the oil pressure switch is turned “ON” due to an engine oil pressure drop below 100 kPa (1.0 kg/cm , 14 psi). ACTION: Engine speed Automatically reduced to approx.

  • Page 98: Overheat Caution

    ENGINE CONTROL SYSTEM 3-37 OVERHEAT CAUTION CONDITION 1 (Maximum temperature) Immediate activation of system when: • Cylinder temperature reaches 120 °C (248 °F) • Exhaust manifold temperature reaches 114 °C (237.2 °F) CONDITION 2 (Temp. rise vs Time) Immediate activation of system when: •...

  • Page 99: Low Battery Voltage Caution System

    3-38 ENGINE CONTROL SYSTEM LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION 1: System activated when battery voltage decreases to less than 9 volts for 30 seconds. CONDITION 2: System activated if battery voltage is less than 2 V for more than 2 seconds with the ignition switch turned “ON”...

  • Page 100: Self-Diagnostic System

    ENGINE CONTROL SYSTEM 3-39 SELF-DIAGNOSTIC SYSTEM The self-diagnostic system alerts the operator when an abnor- MONITOR-TACHOMETER mality occurs in a signal from sensor, switch, etc. When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code pattern along with a buzzer sound.
  • Page 101 3-40 ENGINE CONTROL SYSTEM NOTE: • If more than two items fail at once, the self-diagnostic indication appears according to priority order. The indication repeats three times. • If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch “ON”.

  • Page 102: Condition For Self-Diagnostic System Operation

    Model discrimination • There is discrepancy of signal between the ECM memory storage and the model discrimination terminal. • [No.13 terminal open. (DF200)] • [No.13 terminal short circuit. (DF225/250)] Oil control valve • OCV not operating.
  • Page 103 3-42 ENGINE CONTROL SYSTEM NOTE 1: These conditions will be caused by IAC valve failure or incorrect O-ring by-pass air screw adjustment. If IAC valve is always closed or by-pass air is too low, the ECM controls the IAC valve duty to Passage increase to maintain the idling/trolling speed specified.

  • Page 104: Fail-Safe System

    ENGINE CONTROL SYSTEM 3-43 FAIL-SAFE SYSTEM The fail-safe system is closely related to the self-diagnostic system. When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a pre-programmed value for the failed sensors. This allows the engine to continue running under the fail-safe condition. PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM FAILED ITEM PRE-PROGRAMMED VALUE...

  • Page 105: Operating Hour Indication System

    3-44 ENGINE CONTROL SYSTEM OPERATING HOUR INDICATION SYSTEM When the ignition switch is initially turned “ON” (from “OFF”), the MONITOR-TACHOMETER ECM tests the caution system by turning on all four lamps in the monitor-tachometer and sounding the caution buzzer for an ini- tial two seconds.

  • Page 106: Oil Change Reminder System

    NOTE: • Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced. Once the system has operated, however, SUZUKI strongly recommends that the engine oil be replaced before canceling the system activation.

  • Page 107: Start-In-Gear Protection System

    3-46 ENGINE CONTROL SYSTEM START-IN-GEAR PROTECTION SYSTEM ■ Control by Neutral switch A switch to detect neutral gear position is located on the throttle lever holder and operated by the clutch con- trol lever. This ON/OFF type switch is ON in neutral and OFF in forward or reverse. On starting the engine, the ECM detects the shift position using the neutral switch.

  • Page 108: O2 Feedback System

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

  • Page 109: Inspection

    3-48 ENGINE CONTROL SYSTEM INSPECTION PRECAUTION ON SYSTEM INSPECTION To prevent any unexpected engine start, perform the following before proceeding with any CRANKING tests. • When performing tests not related to fuel injector operation: •Disconnect all fuel injector wire connectors. •...

  • Page 110: Inspection For Ecm Circuit Voltage

    ENGINE CONTROL SYSTEM 3-49 INSPECTION FOR ECM CIRCUIT VOLTAGE ECM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an ECM which has been disconnected from the engine wiring harness. " 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) 1.
  • Page 111 Ignition switch ON, Shift in Reverse MAP sensor 0.20 – 4.53 V Ignition switch ON Model distinction Approx. 5 V Ignition switch ON (DF200 only) Power source for sensor Approx. 5 V Ignition switch ON Bl/R Emergency stop switch Approx. 11 V...
  • Page 112 ENGINE CONTROL SYSTEM 3-51 WIRE STANDARD TERMINAL CIRCUIT CONDITION/REMARKS COLOR VOLTAGE — — — — O/Bl No. 5 Fuel injector Approx. 12 V Ignition switch ON No. 3 Fuel injector Approx. 12 V Ignition switch ON No. 6 Fuel injector Approx.

  • Page 113: Inspection For Resistance

    3-52 ENGINE CONTROL SYSTEM INSPECTION FOR RESISTANCE " 09930-99320: Digital tester & Tester range: Ω (Resistance, See chart for range.) NOTE: Make sure ignition switch is always OFF when measuring resis- tance. 1. Turn ignition switch OFF. 2. Disconnect battery cables from battery. 3.

  • Page 114: Component Inspections

    ENGINE CONTROL SYSTEM 3-53 RESISTANCE TABLE TERMINAL FOR TESTER STANDARD RESISTANCE ITEM PROBE CONNECTION (at 20 °C) 168 – 252 Ω CKP sensor 4 (R/B) to 49 (B/W) Fuel injector No. 1 54 (O/B) to Terminal [NOTE 1] Fuel injector No. 2 36 (B/Br) to Terminal [NOTE 1] Fuel injector No.
  • Page 115 3-54 ENGINE CONTROL SYSTEM [Low pressure side] 1. Install the emergency stop switch lock plate in position. 2. Turn ignition switch ON and check for fuel pump operating sound. Fuel pump operating sound: Sounds for approx. 6 seconds only 1. Low pressure fuel pump FUEL INJECTOR OPERATING SOUND (CRANKING) 1.
  • Page 116 ENGINE CONTROL SYSTEM 3-55 FUEL INJECTOR OPERATING SIGNAL 34 pin test cord 26 pin test cord (White connector) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 117 3-56 ENGINE CONTROL SYSTEM IGNITION COIL OPERATING SIGNAL 34 pin test cord 26 pin test cord (White connector) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26...
  • Page 118 ENGINE CONTROL SYSTEM 3-57 IGNITION COIL ASSEMBLY " 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) NOTE: The ignition coil power transistor and high-tension lead are an +BAT integral part of the coil’ internal circuit. Using resistance mea- surements to check for a defect on either the primary or second- ary coil is not possible.
  • Page 119 3-58 ENGINE CONTROL SYSTEM CMP SENSOR SIGNAL " 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester (White connector) 30 31 32 33 34 35 36 37 38 39 47 48 49 50 51 52 53 54 55 56 $ Tester range: % DCV (See chart for range.) (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13...
  • Page 120 ENGINE CONTROL SYSTEM 3-59 MAP SENSOR OUTPUT VOLTAGE CHANGE " 09917-47011: Vacuum pump gauge 09930-89340: 26-pin & 34-pin test cord 09930-99320: Digital tester $ Tester range: % DCV (See chart for range.) 1. Remove ring gear cover and silencer case. (See page 6-2.) MAP sensor 2.
  • Page 121 3-60 ENGINE CONTROL SYSTEM TPS (Throttle position sensor) " 09930-99320: Digital tester 09930-89220: 3-pin test cord $ Tester range: %(DCV (See chart for range.) 1. Turn ignition switch OFF. 2. Remove ring gear cover and silencer case. (See page 6-2.) 3.
  • Page 122 ENGINE CONTROL SYSTEM 3-61 SHIFT POSITION SENSOR " 09930-99320: Digital tester 09930-89220: 3-pin test cord $ Tester range: %(DCV (See chart for range.) 1. Turn ignition switch OFF. 2. Connect 3-pin test cord between shift position sensor and wire harness as shown in figure. 3.
  • Page 123 3-62 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH NOTE: Before checking the oil pressure switch, make sure the engine oil pressure is within specification. 1. Remove the blue lead wire from oil pressure switch. 2. Check the continuity between the switch terminal and engine body ground.

  • Page 124: Multi-Stage Induction

    ENGINE CONTROL SYSTEM 3-63 IAC VALVE 1. Remove IAC valve. (See page 3-69.) 2. When the ignition switch is turned ON and OFF, check that the rotary valve turns to open and returns to closed. 3. If the valve does not turn, check the wiring harness for conti- nuity (between ECM and IAC valve) and connector contact condition.
  • Page 125 3-64 ENGINE CONTROL SYSTEM VACUUM PASSAGE INSPECTION 1. Disconnect vacuum hose 1 from vacuum switching valve 2. Start engine and run it at idle speed. Place a finger over vacuum hose end 1 and engine vacuum is present. 3. If vacuum is not present, clean vacuum passage with com- pressed air, start engine and check again for vacuum.
  • Page 126 ENGINE CONTROL SYSTEM 3-65 VSV (Vacuum switching valve) 1. With ignition switch OFF, disconnect connector from VSV. 2. Check resistance between VSV terminals. Resistance of VSV: 37 – 44 Ω 3. Disconnect two hoses from VSV. 4. With 12 V applied between the VSV terminals, check that port (E) connects to port (F) but not to the filter section.

  • Page 127: Removal/Installation

    3-66 ENGINE CONTROL SYSTEM REMOVAL/INSTALLATION FLYWHEEL 1. Flywheel bolt 118 N·m (11.8 kg-m, 85.3 lb-ft) 2. Flywheel 3. Dowel pin 4. CKP sensor 5. Bolt 6. CMP sensor 7. Bolt NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent. REMOVAL Prior to removing flywheel: •...
  • Page 128 ENGINE CONTROL SYSTEM 3-67 4. Remove eight (8) flywheel bolts 4. 5. Remove flywheel 3 and dowel pin 5. INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Install dowel pin 5. • Install flywheel 3 onto crankshaft making sure to align dowel pin hole.

  • Page 129: Ckp Sensor

    3-68 ENGINE CONTROL SYSTEM CKP SENSOR REMOVAL Prior to removing CKP sensor: • Disconnect battery cables from battery. 1. Remove ring gear cover and air intake silencer case. (See page 6-2.) 2. Disconnect CKP sensor lead wire connector in electric parts holder.

  • Page 130: Cmp Sensor

    ENGINE CONTROL SYSTEM 3-69 CMP SENSOR REMOVAL 1. Remove collector assembly. (See page 6-3, 6-6.) 2. Disconnect CMP sensor lead wire connector at sensor. 3. Remove bolt and CMP sensor. 1. CMP sensor 2. CMP sensor INSTALLATION Installation is reverse order of removal. •...

  • Page 131: Ocv (Oil Control Valve)

    3-70 ENGINE CONTROL SYSTEM INSTALLATION Installation is reverse order of removal with special attention to the following steps. • Before installing oil pressure switch, wrap screw threads with sealing tape then tighten switch to specified torque. NOTE: Cut off any excess sealing tape from switch threads before installation.

  • Page 132: Throttle Control

    ENGINE CONTROL SYSTEM 3-71 THROTTLE CONTROL SYNCHRONIZING THROTTLE BODIES 1. Check that the throttle link operates smoothly. Throttle lever 2. Loosen screw 1. 3. Check that the tip of both the STBD and PORT throttle stop screws 2 contacts the throttle lever stop 3. This condition indicates the throttle valve is completely closed.

  • Page 133: Throttle Control Cable

    3-72 ENGINE CONTROL SYSTEM THROTTLE CONTROL CABLE Installation and Adjustment 1. Lightly push throttle lever to bring the throttle to full close. Throttle lever 2. Align the match mark a (▲) on throttle cam 1 with the cen- ter of throttle lever roller 2 and hold this position. 3.

This manual is also suitable for:

Df225Df250

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