Do you have a question about the DF200 and is the answer not in the manual?
Questions and answers
Егор
April 11, 2025
Check engine 3-6 что за проблема?
1 comments:
Mr. Anderson
May 14, 2025
The check engine 3-6 code for a Suzuki DF200 indicates an "Oxygen Sensor Problem."
This answer is automatically generated
robert peting
January 24, 2025
cooling system schematic
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.
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...
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.
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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”.
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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.)
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.
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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.
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.
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.
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.
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 –...
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).
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)
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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)
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 ±...
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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 –...
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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 —...
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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...
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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.)
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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...
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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.
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...
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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”...
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)
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.
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.
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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: •...
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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.
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.
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.
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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 –...
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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. •...
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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...
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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.
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 ).
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.
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...
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.
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...
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.
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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.
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...
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.
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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.
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: •...
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.
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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 ..........
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...
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 •...
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.
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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˚...
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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.
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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.
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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.
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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.
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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.
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.)
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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.
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.).
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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...
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.
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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.
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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.
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.
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.
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.
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.
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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. •...
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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.
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.
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.
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.
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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...
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...
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.
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: •...
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”...
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.
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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”.
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.
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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.
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...
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.
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.
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.
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”.
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. •...
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.
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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...
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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.
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.
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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.
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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...
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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.
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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.
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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.
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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.
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.
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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.
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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.
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: •...
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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.
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.
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. •...
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.
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.
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.
Need help?
Do you have a question about the DF200 and is the answer not in the manual?
Questions and answers
Check engine 3-6 что за проблема?
The check engine 3-6 code for a Suzuki DF200 indicates an "Oxygen Sensor Problem."
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cooling system schematic
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