Suzuki DF 25 Service Manual
  1. Manuals
  2. Brands
  3. Suzuki Manuals
  4. Outboard Motor
  5. DF 25
  6. Service manual

Suzuki DF 25 Service Manual

Four stroke
Hide thumbs Also See for DF 25:
Table of Contents

Advertisement

Quick Links

See also: Owner's Manual
9 9 5 0 0 - 8 9 J 0 2 - 0 1 E
1

Advertisement

Table of Contents
loading

Related Manuals for Suzuki DF 25

Summary of Contents for Suzuki DF 25

  • Page 1 9 9 5 0 0 - 8 9 J 0 2 - 0 1 E...

  • Page 2: Table Of Contents

    FOREWORD GROUP INDEX This manual contains an introductory description on SUZUKI Outboard motor DF25/30 and procedures for the inspection, service and overhaul of its main GENERAL INFORMATION components. General knowledge information is not included. PERIODIC MAINTENANCE Please read the GENERAL INFORMATION sec- tion to familiarize yourself with basic information concerning this motor.

  • Page 3: How To Use This Manual

    HOW TO USE THIS MANUAL TO LOCATE WHAT YOU ARE LOOKING FOR: 1. The text of this manual is divided into sections. 2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference.
  • Page 4 “1333B”. Apply SUZUKI OUTBOARD Measure in DC voltage range. MOTOR GEAR OIL. Measure in resistance range. Apply SUZUKI SUPER GREASE “A”. Apply SUZUKI WATER Measure in continuity test range. RESISTANT GREASE. Use peak voltmeter Apply SUZUKI BOND “1104”.

  • Page 5: General Information

    GENERAL INFORMATION GENERAL INFORMATION CONTENTS WARNING/CAUTION/NOTE __________________________________ 1- 2 GENERAL PRECAUTIONS __________________________________ 1- 2 IDENTIFICATION NUMBER LOCATION ________________________ 1- 4 FUEL AND OIL ____________________________________________ 1- 4 1- 4 GASOLINE RECOMMENDATION ..............1- 4 ENGINE OIL ....................ENGINE BREAK-IN ________________________________________ 1- 5 PROPELLERS ____________________________________________ 1- 6 SPECIFICATIONS _________________________________________ 1- 7 SERVICE DATA____________________________________________ 1-11...

  • Page 6: Warning/Caution/Note

    GENERAL INFORMATION WARNING/CAUTION/NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the mes- sages highlighted by these signal words. Indicates a potential hazard that could result in death or injury.
  • Page 7 GENERAL INFORMATION • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equiva- lent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

  • Page 8: Identification Number Location

    FUEL AND OIL 1. Serial number plate GASOLINE RECOMMENDATION Suzuki highly recommends that you use alcohol - free un- leaded gasoline with a minimum pump octane rating of 87 (R+M / 2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane con- tent may be used.

  • Page 9: Engine Break-In

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

  • Page 10: Propellers

    GENERAL INFORMATION PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF25 / 30 models are shown below. DF25 5000 – 5600 r/min Recommended full throttle speed range DF30 5500 –...

  • Page 11: Specifications

    60 (2.36) Total displacement (cu in) 597 (36.4) Compression ratio Spark plug DCPR6E Ignition system SUZUKI PEI Fuel supply system Carburetor (Number of carb. : 3) Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump...
  • Page 12 Viscosity rating 10W-40 3.0 (3.2/2.6) : Oil change only Engine oil amounts L (US/Imp. qt) 3.2 (3.4/2.8) : Oil filter change SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gear oil ml (US/Imp. oz) 230 (7.8/8.1) Gearcase oil amounts...
  • Page 13 60 (2.36) Total displacement (cu in) 597 (36.4) Compression ratio Spark plug DCPR6E Ignition system SUZUKI PEI Fuel supply system Carburetor (Number of carb. : 3) Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump...
  • Page 14 Engine oil amounts 3.0 (3.2/2.6) : Oil change only L (US/Imp. qt) 3.2 (3.4/2.8) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts ml (US/Imp. oz) 230 (7.8/8.1) BRACKET Trim angle (PTT system) 8°...

  • Page 15: Service Data

    GENERAL INFORMATION 1-11 SERVICE DATA These service data are subject to change without notice. Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T POWERHEAD Recommended operating 5000 – 5600 r/min 5500 – 6100 range Idle speed r/min 900 ± 50 (in-gear: approx. 850) **Cylinder compression kPa (kg/cm , psi)
  • Page 16 1-12 GENERAL INFORMATION Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T CYLINDER HEAD / CAMSHAFT Limit mm (in) 0.05 (0.002) Cylinder head distortion Manifold seating faces Limit mm (in) — distortion Cam height mm (in) 35.185 – 35.345 (1.3852 – 1.3915) 36.076 – 36.236 (1.4203 – 1.4266) Limit mm (in) 35.085 (1.3813)
  • Page 17 GENERAL INFORMATION 1-13 Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T VALVE / VALVE GUIDE mm (in) 23.1 (0.91) Valve diameter mm (in) 29.6 (1.17) Valve clearance mm (in) 0.13 – 0.17 (0.005 – 0.007) (Cold engine mm (in) 0.13 – 0.17 (0.005 – 0.007) condition) °...
  • Page 18 1-14 GENERAL INFORMATION Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T CYLINDER / PISTON / PISTON RING Limit mm (in) 0.030 (0.0012) Cylinder distortion mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) mm (in) 65.000 –...
  • Page 19 GENERAL INFORMATION 1-15 Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T CRANKSHAFT / CONROD Conrod small end mm (in) 16.003 – 16.011 (0.6300 – 0.6304) inside diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance Limit mm (in) 0.065 (0.0026) Conrod big end...
  • Page 20 1-16 GENERAL INFORMATION Data Item Unit DF25Q/25QE DF25QR/25T DF30Q/30QE DF30QR/30T ELECTRICAL Degrees at r/min BTDC 5° – 31° BTDC 5° – 29° Ignition timing r/min 6300 Over revolution limiter 6500 Ω 148 – 222 [R – B, W/B – R/W] CKP sensor resistance at 20°C Ω...
  • Page 21 GENERAL INFORMATION 1-17 PTT MOTOR (Applicable model) mm (in) 9.8 (0.39) Brush length Limit mm (in) 4.8 (0.19) mm (in) 19.5 (0.77) Commutator outside diameter Limit 18.5 (0.73) mm (in) PEAK VOLTAGE Requirements for peak voltage measurement • Remove all spark plugs to eliminate the variables at cranking speed. •...

  • Page 22: Tightening Torque

    1-18 GENERAL INFORMATION TIGHTENING TORQUE Tightening Torque – Important Fasteners TIGHTENING TORQUE THREAD ITEM DIAMETER N . m kg-m Ib-ft Cylinder head cover bolt 6 mm Cylinder head bolt (Outside) 8 mm 18.0 (Inside) 45.0 10 mm 18.0 (Outside) 8 mm Crankcase bolt (Inside) 10 mm...
  • Page 23 GENERAL INFORMATION 1-19 TIGHTENING TORQUE THREAD ITEM N . m DIAMETER kg-m Ib-ft Water pump case nut 6 mm Gearcase bolt 8 mm 16.5 Propeller shaft bearing housing bolt 6 mm 8 mm Pinion nut 13.0 Propeller nut 14 mm 13.0 Tightening torque –...

  • Page 24: Special Tools

    1-20 GENERAL INFORMATION SPECIAL TOOLS 09900-00413 (5 mm) 09900-00411 09900-00414 (6 mm) 09900-00410 Hexagon socket Hexagon bit Hexagon wrench set (included in 09900-00410) (included in 09900-00410) (A) 09900-06107 09900-20101 (150 mm) 09900-20102 (200 mm) (B) 09900-06108 09900-20202 09900-20203 Snap ring pliers Vernier calipers Micrometer (25 –...
  • Page 25 GENERAL INFORMATION 1-21 09915-64512 Compression gauge 09915-78211 09915-63210 09915-77310 09916-10911 Adaptor Oil pressure gauge Oil pressure gauge adapter Valve lapper 09916-24440 Handle adaptor 09916-24450 09916-14510 09916-14910 (N-503-1) Solid pilot (N-100-5.52) Valve lifter Valve lifter attachment 09916-20620 09916-20610 09916-34550 Valve seat cutter Valve seat cutter Valve guide reamer 09916-54910...
  • Page 26 1-22 GENERAL INFORMATION 09930-39411 09930-76420 09930-48720 09930-39420 Flywheel rotor remover Timing light Flywheel holder Rotor remover bolt 09930-89240 09930-89210 09930-89251 09900-25002 4-pin connector test cord 2-pin connector test cord 6-pin connector test cord Pocket tester Pinion bearing installer and remover (A) 09951-59910 Pinion bearing installer shaft...

  • Page 27: Materials Required

    99000-25010 × (400 ml 24 pcs.) (250 g) (50 g) (500 g) THREAD LOCK “1342” 4-Stroke Motor Oil SUZUKI BOND “1207B” * 99104-33140 99000-32050 API : SE, SF, SG, SH, SJ 99000-31140 (50 g) SAE : 10W-40 (100 g) NOTE:...

  • Page 28: Periodic Maintenance

    PERIODIC MAINTENANCE 2-1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE _______________________ 2- 2 2- 2 PERIODIC MAINTENANCE CHART .............. MAINTENANCE AND TUNE-UP PROCEDURES _________________ 2- 3 2- 3 ENGINE OIL / ENGINE OIL FILTER ............... 2- 6 GEAR OIL ......................2- 7 LUBRICATION ....................

  • Page 29: Periodic Maintenance Schedule

    2-2 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 30: Maintenance And Tune-Up Procedures

    PERIODIC MAINTENANCE 2-3 MAINTENANCE AND TUNE-UP PROCEDURES This section describes the servicing procedures for each of the periodic maintenance requirements. ENGINE OIL / ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use. (1) Place the outboard motor upright on a level surface. (2) Remove the motor cover.

  • Page 31: Engine Oil Change/Filter Replacement

    2-4 PERIODIC MAINTENANCE ENGINE OIL CHANGE / ENGINE OIL FILTER REPLACEMENT ENGINE OIL Change initially after 20 hours (1 month) and every 100 hours (6 months) thereafter. ENGINE OIL FILTER Replace initially after 20 hours (1 month) and every 200 hours (12 months) thereafter. NOTE: •...
  • Page 32 PERIODIC MAINTENANCE 2-5 (3) Screw new filter on by hand until the filter O-ring con- tacts the Mounting surface. (4) Tighten the filter 3/4 turn from the point of contact with the mounting surface using an oil filter wrench. Engine oil filter : 14 N . m (1.4 kg-m, 10.0 lb.-ft.), 3/4 turn.

  • Page 33: Gear Oil

    Gear oil amount : 230 ml ( 7.8 / 8.1 US / Imp. oz) Recommended oil : Suzuki Outboard Motor Gear Oil or SAE # 90 Hypoid gear oil (5) Install the oil level plug before removing the oil filler tube from the drain hole.

  • Page 34: Lubrication

    PERIODIC MAINTENANCE 2-7 LUBRICATION Inspect every 50 hours (3 months). Apply Suzuki Water Resistant Grease to the following points. 99000-25160 : Water Resistant Grease Throttle/shift linkage Throttle/shift linkage (QR/T models) (Q/QE models)

  • Page 35: Spark Plug

    2-8 PERIODIC MAINTENANCE SPARK PLUG • Inspect every 100 hours (6 months). • Replace every 200 hours (12 months). Standard spark plug : NGK DCPR6E Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition system malfunctions.

  • Page 36: Valve Clearance

    PERIODIC MAINTENANCE 2-9 VALVE CLEARANCE Inspect initially after 20 hours (1 month) and every 200 hours (12 months) thereafter CHECKING AND ADJUSTING VALVE CLEARANCE Checking (1) Remove following parts : • Engine side lower cover (see page 8-2) • Recoil starter (Manual start model) •...
  • Page 37 2-10 PERIODIC MAINTENANCE Adjustment (6) Loosen valve adjusting lock nut 1. (7) Turn valve adjusting screw 2 to bring valve clearance to within the specification. 09900-20803 : Thickness gauge (8) Tighten valve adjusting lock nut 1 to specified torque while holding valve adjusting screw 2.

  • Page 38: Idle Speed

    PERIODIC MAINTENANCE 2-11 IDLE SPEED Inspect initially after 20 hours ( 1 month ) and every 200 hours (12 months ) thereafter. Checking NOTE : • Before checking the idle speed, the engine should be al- lowed to warm up. •...
  • Page 39 2-12 PERIODIC MAINTENANCE NOTE : There are two types of carburetor as follows : (A) . Carburetor with covered pilot screw The pilot screw turns open are preset at factory and the screw is covered by plate. Do not try to remove the cover over the pilot screw. (B) .

  • Page 40: Carburetor

    PERIODIC MAINTENANCE 2-13 CARBURETOR Inspect initially after 20 hours ( 1 month ) and every 100 hours (6 months ) thereafter. EXTERNAL CHECK If crack or other damage on carburetor body / lever / rod / con- nector / fuel inlet or silencer, replace. SYNCHRONIZING THROTTLE VALVES 09913-13121 : Carburetor synchronizer NOTE:...
  • Page 41 2-14 PERIODIC MAINTENANCE Turn balancer air screw A to left/right to bring the steel ball to the center line of the tube. 6. Connect each hose of No.1 tube and No.2 tube in synchro- nizer to the adapter 2 in turn. Turn each balancer air screw B .

  • Page 42: Dashpot Adjustment

    PERIODIC MAINTENANCE 2-15 11. Adjust the throttle valve screw(s) 4 until the carburetors are synchronized (steel balls at the same height in each of the tubes) and the engine idles smoothly. NOTE: If the engine speed has been raised or lowered due to the ad- justment, it is necessary to reset the engine at the specified idle speed by turning idle adjusting screw of No.3 carburetor.
  • Page 43 2-16 PERIODIC MAINTENANCE 3. Stop the engine. 4. Remove the flywheel cover or recoil starter. 5. Operate the throttle control grip (or throttle lever) to bring the throttle to full open position. 6. Return the throttle gradually while watching the tip of the dashpot unit rod.

  • Page 44: Ignition Timing

    PERIODIC MAINTENANCE 2-17 IGNITION TIMING Inspect every 200 hours (12 months) NOTE: • Before checking ignition timing, the engine should be al- lowed to warm up. • Before checking the ignition timing, make sure idle speed is adjusted within the specification. (1) Start the engine.

  • Page 45: Water Pump / Water Pump Impeller

    2-18 PERIODIC MAINTENANCE WATER PUMP / WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours (12 months). Inspect case and under panel. Replace If wear, cracks, distortion or corrosion is found. WATER PUMP IMPELLER Replace every 200 hours (12 months). Inspect water pump impeller.

  • Page 46: Anodes And Bonding Wires

    If 2/3 of the zinc anode has corroded away, replace the an- ode. Anode Never paint the anode. NOTE: The anode securing bolt should be covered with Suzuki Sili- cone Seal. 99000-31120 : Suzuki Silicone Seal BONDING WIRES • If breakage or other damage is found on the wire, replace the wire.

  • Page 47: Battery

    2-20 PERIODIC MAINTENANCE 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 48: Bolts And Nuts

    PERIODIC MAINTENANCE 2-21 BATTERY SOLUTION LEVEL CHECK Battery solution level should be between the UPPER level and LOWER level. If the level is low, add distilled water only. Once the battery has been initially serviced, NEVER add diluted sulfuric acid, or you will damage the bat- tery.

  • Page 49: Oil Pressure

    2-22 PERIODIC MAINTENANCE OIL PRESSURE Oil pressure ( at normal operating temp. ): 400 – 500 kPa (4.0 – 5.0 kg / cm , 57 – 71 psi.) at 3000 r/min. NOTE: The figure shown above is a guideline only, not an absolute service limit.
  • Page 50 PERIODIC MAINTENANCE 2-23 (5) Connect the tachometer lead wires as follows: 34200-92E02 : Engine tachometer • Yellow lead wire to the Yellow/Black lead wire of CDI unit. • Gray lead wire to DC 12V power source positive terminal. CDI unit •...

  • Page 51: Cylinder Compression

    2-24 PERIODIC MAINTENANCE CYLINDER COMPRESSION Cylinder compression : Standard : 1000 – 1400 kPa (10 – 14 kg / cm 142 – 199 psi.) Max. difference between any other cylinders : 100kPa (1.0 kg / cm , 14 psi.) NOTE: Figures shown are guidelines only, not absolute service limits.

  • Page 52: Engine Control System

    ENGINE CONTROL 3-1 ENGINE CONTROL SYSTEM CONTENTS IGNITION SYSTEM ________________________________________ 3- 2 3- 2 SYSTEM COMPONENTS ................3- 2 FUNCTION AND FAILURE SYMPTOMS ............3- 4 PRINCIPLES OF OPERATION ............... 3- 5 IGNITION TIMING CONTROL ................. TESTING IGNITION SYSTEM ________________________________ 3- 6 3- 6 IGNITION TROUBLESHOOTING ..............

  • Page 53: Ignition System

    3-2 ENGINE CONTROL IGNITION SYSTEM SYSTEM COMPONENTS Ignition system consists of power source coil, CKP sensor, CDI unit, ignition coil and engine stop switch. FUNCTION AND FAILURE SYMPTOMS IGNITION COIL Function There is an independent coil for each cylinder. Voltage from the CDI unit is greatly increased to produce the power needed for a spark at the plug.
  • Page 54 ENGINE CONTROL 3-3 CDI UNIT Function This is the single most important component in the ignition sys- tem. Its function is to store and discharge current to each ignition coil and operate the caution system. Failure symptoms • No spark. •...

  • Page 55: Principles Of Operation

    CDI microcomputer from the CKP (Crankshaft position) sensor signals. SPECIFICATION Ignition type Advance Electronic microcomputer control Ignition timing DF 25 : BTDC 5° – 31° DF 30 : BTDC 5° – 29° Firing order 1 – 3 – 2 1. CKP sensor No.1 2. CKP sensor No.2 3.

  • Page 56: Ignition Timing Control

    ENGINE CONTROL 3-5 IGNITION TIMING CONTROL Outline The ignition timing varies based upon engine speed. The CKP sensors monitor current engine speed and send signals to the CDI unit. Based on this signal, the CDI unit determines the optimum ignition timing and supplies voltage to the primary winding of the ignition coil.

  • Page 57: Testing Ignition System

    3-6 ENGINE CONTROL TESTING IGNITION SYSTEM IGNITION TROUBLESHOOTING Perform the following ignition system tests when engine is hard to start to determine if the cause is in the ignition or another system. The cause will not be in ignition system. START Sparks Not good...

  • Page 58: Checking Coil Resistance

    ENGINE CONTROL 3-7 CHECKING COIL RESISTANCE Always disconnect the battery cable from battery be- fore commencing electrical resistance check. IGNITION COIL 09930-99320 : Digital tester Tester range : (Resistance) Primary side 1. Disconnect primary coil lead wires from CDI unit. 2.
  • Page 59 3-8 ENGINE CONTROL Spark plug cap 1. Remove spark plug cap from high tension cord. 2. Connect tester probes to both contact ends of cap. 3. Measure resistance. Spark plug cap resistance : 4 – 6 k If measurement exceeds specification, replace spark plug cap. POWER SOURCE COIL 09930-99320 : Digital tester Tester range :...

  • Page 60: Checking Coil / Cdi Unit Output

    ENGINE CONTROL 3-9 CKP SENSOR 09930-99320 : Digital tester Tester range : (Resistance) 1. Disconnect CKP sensor lead wire connector from CDI unit. 2. Connect tester probe to sensor lead wires as shown. Tester probe connection CKP sensor Red (+) Black (–) No.1 Black...
  • Page 61 3-10 ENGINE CONTROL CKP SENSOR 09930-89240 : 4 pin connector test cord Peak voltmeter Stevens CD-77 Tester range : SEN 50 1. Disconnect CKP sensor lead wire connector from CDI unit. 2. Connect the test cord as shown. 3. Connect tester probe to sensor lead wires as shown. Tester probe connection CKP sensor Red (+)

  • Page 62: Engine Stop & Emergency Stop Switch

    ENGINE CONTROL 3-11 ENGINE STOP & EMERGENCY STOP SWITCH 09930-99320 : Digital tester Tester range : (Continuity) 1. Disconnect the emergency stop switch lead wire. 2. Check continuity / infinity between the wiring leads under the condition shown below. Bl/R Tester probe connection Tester indicates Red (+)

  • Page 63: Caution Systems

    3-12 ENGINE CONTROL CAUTION SYSTEMS The following three caution systems alert the operator when an abnormality occurs on the engine. • OVER-REVOLUTION CAUTION • LOW OIL PRESSURE CAUTION • OVER HEAT CAUTION CAUTION OVER-REV CAUTION CAUTION BUZZER LIMITER TYPE LAMP (R / T model only) (3000 r/min) CAUTION lamp...

  • Page 64: Low Oil Pressure Caution System

    ENGINE CONTROL 3-13 LOW OIL PRESSURE CAUTION SYSTEM The low oil pressure caution control activates when internal engine oil lubricating pressure is 49kPa (0.5 kg/ ) or lower, during engine operation. When the oil pressure is higher than the preset value of 49kPa (0.5 kg/cm ), the oil pressure switch is OFF (no continuity).

  • Page 65: Testing Oil Pressure Caution System

    3-14 ENGINE CONTROL TESTING OIL PRESSURE CAUTION SYSTEM To check the oil pressure caution circuit, follow the procedure below. NOTE: Before checking the oil pressure caution circuit, make sure the engine oil pressure is within specification. OIL PRESSURE SWITCH 1. Remove the blue/yellow lead wire from the oil pressure switch. 2.

  • Page 66: Cylinder Temperature Sensor

    ENGINE CONTROL 3-15 CYLINDER TEMPERATURE SENSOR FUNCTION The cylinder temperature sensor is installed on cylinder and used to detect the cylinder temperature. This is a thermistor type sensor (resistance of which changes depending on the temperature) and inputs a signal to the CDI unit as a voltage value.

  • Page 67: Removal / Installation

    3-16 ENGINE CONTROL REMOVAL / INSTALLATION FLYWHEEL / BATTERY CHARGE & POWER SOURCE COIL / CKP SENSOR 190 N . m (19.0 kg-m, 137.5 lb-ft) 1 Flywheel bolt 2 Washer 3 Key 4 Flywheel 5 CKP sensor 6 Screw 7 Battery charge & Power source coil 8 Bolt Crankshaft...
  • Page 68 ENGINE CONTROL 3-17 REMOVAL Prior to removing Flywheel : • Disconnect battery cables from battery. • Remove all spark plug caps from the spark plug. 1. Remove flywheel cover. (Electric start model) Remove recoil starter. (Manual start model) 2. Loosen flywheel bolt 2 – 3 turns. 09930-48720 : Flywheel holder NOTE: Do not remove flywheel bolt at this time.
  • Page 69 3-18 ENGINE CONTROL 6. Remove three bolts 7, battery charge and power source coils 8, then disconnect coil lead wire connectors. INSTALLATION Installation is reverse order of removal with special attention to the following steps. Battery charge & power source coil •...

  • Page 70: Oil Pressure Switch

    ENGINE CONTROL 3-19 OIL PRESSURE SWITCH REMOVAL Loosen screw and disconnect blue/yellow lead wire from switch. Remove oil pressure switch from crankcase. 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.
  • Page 71 ELECTRICAL 4-1 ELECTRICAL CONTENTS BATTERY CHARGING SYSTEM ______________________________ 4- 2 4- 2 OUTLINE ......................4- 3 INSPECTION ....................4- 5 REMOVAL / INSTALLATION ................ELECTRIC STARTER SYSTEM _______________________________ 4- 7 4- 7 OUTLINE ......................4- 8 TROUBLESHOOTING ..................4-10 INSPECTION ....................4-13 STARTER MOTOR ...................

  • Page 72: Battery Charging System

    4-2 ELECTRICAL BATTERY CHARGING SYSTEM OUTLINE The battery charging system circuit is illustrated below. It is composed of the BATTERY CHARGE COIL, RECTIFIER & REGULATOR and BATTERY. The AC current generated from battery charge coil is converted by the rectifier & regulator into regulated DC current which is used to charge the battery.

  • Page 73: Inspection

    ELECTRICAL 4-3 INSPECTION BATTERY CHARGE COIL Two methods can be used to inspect coil condition. Checking coil output Peak voltmeter stevens CD-77 Tester range : POS 50 1. Disconnect battery charge coil leads from rectifier & regula- tor. 2. Connect the peak voltage tester between coil leads. 3.
  • Page 74 2. Measure resistance between leads in the combinations shown. NOTE: The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier & regula- tor, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.

  • Page 75: Removal / Installation

    ELECTRICAL 4-5 REMOVAL / INSTALLATION System construction 1 Bolt (1) 2 Washer (1) 190 N . m 3 Key (1) 4 Flywheel (1) (19.0 kg-m, 137.5 Ib.-ft.) 5 Battery charge coil (1) 6 Screw (3) 7 Rectifier & regulator (1) 8 Bolt (2) 9 Fuse case (1) REMOVAL...
  • Page 76 4-6 ELECTRICAL Rectifier & regulator • Remove two bolts securing the Rectifier & regulator. • Disconnect lead wire connectors. Fuse case • Disconnect fuse case lead wires from engine wiring harness and starter motor relay terminal. INSTALLATION Installation is reverse order of removal with special attention to the following step.

  • Page 77: Electric Starter System

    ELECTRICAL 4-7 ELECTRIC STARTER SYSTEM OUTLINE The circuit of the electric starter system is illustrated below. This circuit is mainly composed of Battery, Starter motor, Relay, Neutral switch and Ignition switch (or starter switch). Tiller handle model Starter motor Starter switch 25A Fuse Neutral...

  • Page 78: Troubleshooting

    4-8 ELECTRICAL TROUBLESHOOTING NOTE: Before troubleshooting the electric starter system, make sure of the following : • Battery is fully charged. • All cables / wires are securely connected. • Shift is in “NEUTRAL” position. Tiller handle model Circuit check schematic Starter motor relay Starter motor Starter motor...
  • Page 79 ELECTRICAL 4-9 Remote control models Circuit check schematic Starter motor relay Sub cable Fuse Starter motor Battery Neutral switch Ignition switch Measure voltage at Starter motor will not run. terminal 1. It must Battery cable be above 12V. failure Is result OK? Check for relay “click”...

  • Page 80: Inspection

    4-10 ELECTRICAL INSPECTION IGNITION SWITCH (Remote control model) 09930-99320 : Digital tester Tester range : (Continuity) 1 (OFF) 1. Disconnect the ignition switch from remo-con box wiring har- 2 (ON) ness. 3 (START) 2. Check continuity between wiring leads at the key positions shown in the chart.
  • Page 81 ELECTRICAL 4-11 NEUTRAL SWITCH Check for continuity / infinity of the neutral switch. 09930-99320 : Digital tester Tester range : (Continuity) 1. Disconnect neutral switch lead wires. 2. Check continuity / infinity between Yellow / Green and Brown FORWARD lead wires while operating shift lever or remo-con handle. NEUTRAL Shift position Tester indicates...
  • Page 82 4-12 ELECTRICAL STARTER MOTOR RELAY Two methods can be used to test starter motor relay. 09930-99320 : Digital tester Method 1 1. Disconnect all cables / lead wires from starter motor relay. 2. Measure resistance between relay wiring leads. Tester range : (Resistance) Tester probe connection Red + + + + +...

  • Page 83: Starter Motor

    ELECTRICAL 4-13 STARTER MOTOR REMOVAL Prior to removing starter motor : • Disconnect battery cables from battery. 1. Remove three bolts and flywheel cover. 2. Remove bolt 1 and negative - battery cable 2. 3. Remove starter motor sub cable 3. 4.
  • Page 84 4-14 ELECTRICAL DISASSEMBLY Motor construction 1 1 1 1 1 Stopper ring 2 2 2 2 2 Pinion stopper (1) 3 3 3 3 3 Spring (1) 4 4 4 4 4 Pinion (1) 5 5 5 5 5 Front cover (1) 6 6 6 6 6 Washer (1) 7 7 7 7 7 Shim (1) 8 8 8 8 8 Washer...
  • Page 85 ELECTRICAL 4-15 Push down the pinion stopper 2, remove stopper ring 1. Remove pinion stopper 2, spring 3, and pinion 4. Wear safety grasses when disassembling and assembling stopper ring. NOTE: Using a screw-driver, pry off the stopper ring. Remove two bolts B. Remove following parts : •...
  • Page 86 4-16 ELECTRICAL INSPECTION & SERVICING Pinion Inspect pinion. Replace pinion if damaged or worn. Armature and Commutator Inspect the commutator surface. If surface is gummy or dirty, clean with 400 grade emery paper Measure commutator outside diameter. 09900-20101 : Vernier calipers Commutator outside diameter: Standard : 30 mm (1.18 in.)
  • Page 87 ELECTRICAL 4-17 Check for continuity between the commutator and the armature Armature core Commutator core / shaft. Shaft Replace armature if continuity is indicated. Check for continuity between the adjacent commutator segments. Replace armature if no continuity is indicated. 09930-99320 : Digital tester Tester range : (Continuity) BRUSHES...
  • Page 88 When installing armature, exercise care to avoid break- ing brushes. Apply grease to armature shaft and shaft holes. 99000-25010 : Suzuki Super Grease “A” 3 – 4.5N . m (0.3 – 0.45kg . m) Align the notch in the cover (Front & Rear) with the tab on the stator when assembling.

  • Page 89: Fuel System

    FUEL SYSTEM 5-1 FUEL SYSTEM CONTENTS PRECAUTION ON FUEL SYSTEM SERVICE ____________________ 5- 2 5- 2 GENERAL PRECAUTION ................FUEL LINE _______________________________________________ 5- 2 5- 2 REMOVAL / INSTALLATION ................5- 3 FUEL LEAKAGE CHECK PROCEDURE ............5- 3 FUEL HOSE CONNECTION ................CARBURETORS __________________________________________ 5- 4 5- 4 REMOVAL ......................

  • Page 90: Precaution On Fuel System Service

    5-2 FUEL SYSTEM PRECAUTION ON FUEL SYSTEM SERVICE GENERAL PRECAUTION Gasoline is extremely flammable and toxic. Always ob- serve the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing / inspection. •...

  • Page 91: Fuel Leakage Check Procedure

    FUEL SYSTEM 5-3 FUEL LEAKAGE CHECK PROCEDURE After performing any fuel system service, always be sure there is not fuel leakage by checking as follows. 1. Squeeze fuel primer bulb until you feel resistance. 2. Once pressurized, check all connections and components for any signs of leakage.

  • Page 92: Recoil Starter

    5-4 FUEL SYSTEM CARBURETORS Before servicing the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in the pre- vious section. REMOVAL 1. Remove recoil starter. (Manual start model) Remove flywheel cover. (Electric start model) Remove the STBD side lower cover. 2.
  • Page 93 FUEL SYSTEM 5-5 7. Remove the four (4) bolts 6 and two (2) nuts securing inlet case 7 to intake manifold. 8. Remove three (3) carburetors 8 with inlet case, then re- move the fuel inlet hose from the bottom 3-way joint. 9.

  • Page 94: Installation

    5-6 FUEL SYSTEM INSTALLATION Installation is the reverse order of removal with special atten- tion to the following steps. Do not re-use gaskets, as sealing abilities will be in- sufficient. Air leakage will induce a lean air / fuel mix which will result in severe engine damage.

  • Page 95: Disassembly

    FUEL SYSTEM 5-7 DISASSEMBLY When disassembling carburetor, refer to the construction dia- gram. Remove : • Drain screw 1 • Screw 2 • Float chamber 3 • Tube 4 • Cap 5 • Cap 6 • Holder 7 • Plunger 8 •...

  • Page 96: Cleaning & Inspection

    5-8 FUEL SYSTEM CLEANING & INSPECTION Clean thoroughly with cleaning solvent and compressed air before inspection. Wear safety glasses when using compressed air to expel solvent, carburetor cleaner etc. Do not place any rubber, plastic and non-metallic parts in cleaning solvent, as severe damage or deteriora- tion will result.

  • Page 97: Reassembly

    FUEL SYSTEM 5-9 NEEDLE VALVE ASSEMBLY Inspect the needle valve assembly. If broken tips or wear are found on the needle valve assembly, replace it. FLOAT Inspect the float. If cracks or other damage are found on the float, replace it. REASSEMBLY Reassembly is reverse order of disassembly with special at- tention to the following steps.
  • Page 98 5-10 FUEL SYSTEM FLOAT Install the float and the float pin. NOTE : After installing float, inspect for smooth movement of float. CHECKING FLOAT HEIGHT Measure the float height. NOTE : Make sure that float weight is not applied to needle valve. 09900-20101 : Vernier calipers Float height H H H H H : 14.6 ±...

  • Page 99: Throttle Control

    FUEL SYSTEM 5-11 THROTTLE CONTROL THROTTLE LINK When replacing a link rod and/or connector, see the illustration below to adjust the link rod length to specifi- cation. NOTE: • Be sure an equal length of link rod is threaded into each connector. •...
  • Page 100 5-12 FUEL SYSTEM Remote control models 1. Throttle cam rod 2. Throttle rod 3. Clutch link rod...

  • Page 101: Throttle Control Cable

    FUEL SYSTEM 5-13 THROTTLE CONTROL CABLE Installation and Adjustment 1. Rotate throttle control grip to bring the throttle to full close. 2. Align the match mark a on throttle cam 1 with the center of throttle lever roller 2 and hold this position. 3.

  • Page 102: Fuel Pump

    5-14 FUEL SYSTEM FUEL PUMP REMOVAL / INSTALLATION Before servicing the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in the pre- vious section. REMOVAL 1. Disconnect inlet hose 1 and outlet hose 2 from fuel pump. 2. Remove two bolts 3. 3.

  • Page 103: Disassembly / Reassembly

    FUEL SYSTEM 5-15 DISASSEMBLY / REASSEMBLY DISASSEMBLY NOTE: For correct assembly, scribe an alignment mark on each part of fuel pump. Remove six screws 1 and remove in sequence the outer plate 2, diaphragm 3 and valve body 4. Turn piston 6 until pin 5 comes out through cutaway of pump body 0.

  • Page 104: Inspection

    5-16 FUEL SYSTEM INSPECTION Diaphragm Inspect all diaphragms. If distortion, tears, or other damage is found, replace diaphragms. Check-valves Inspect the fuel pump check valves. If tears, distortion or dam- age is found, replace fuel pump. Pump body Inspect each fuel pump body and outer plate. If cracks, nicks, distortion or damage is found, replace fuel pump.

  • Page 105: Fuel Tank

    FUEL SYSTEM 5-17 FUEL TANK DISASSEMBLY / REASSEMBLY When disassembling or reassembling fuel tank, refer to the construction diagram below. Plastic tank Steel tank –(a) –(b) 1 Fuel hose assy (1) 7 Connector plug (1) 1 Tank cap (1) [B Screw (2)] 8 Outlet (1) 2 Gasket (1) Connector...

  • Page 106: Inspection

    5-18 FUEL SYSTEM INSPECTION Fuel connector Inspect fuel connector. If leakage,deterioration or other dam- age is found, replace fuel connector. 1. Connector 2. Connector plug Fuel primer bulb Inspect fuel primer bulb. If cracks, leakage, or deterioration is found, replace primer bulb. If check valve function is defective, replace primer bulb.

  • Page 107: Operation

    FUEL SYSTEM 5-19 OPERATION CARBURETOR Float system FUEL Float Fuel inlet joint Float valve seat Float valve Float pin Pilot screw Idle system Idle port Pilot jet Pilot air jet Throttle valve Bypass port FUEL FUEL AIR (MIXTURE) Main Metering system Main air jet Venturi Throttle valve...

  • Page 108: Accelerator Pump System

    5-20 FUEL SYSTEM ACCELERATOR PUMP SYSTEM The DF25/30 models are equipped with an accelerator pump system. This system is composed of an accelerator pump on each carburetor with brass tubes connecting the pump to the fuel output nozzles on each carburetor. A normal engine characteristic during hard acceleration is hesitation caused by an imbalance in the fuel/air ratio.

  • Page 109: Recoil Starter

    RECOIL STARTER 6-1 RECOIL STARTER CONTENTS REMOVAL ________________________________________________ 6-2 DISASSEMBLY ____________________________________________ 6-3 INSPECTION _____________________________________________ 6-5 REASSEMBLY ____________________________________________ 6-6 INSTALLATION ____________________________________________ 6-8 NEUTRAL START INTERLOCK (NSI) __________________________ 6-9 INSTALLATION/ADJUSTMENT ..............

  • Page 110: Removal

    6-2 RECOIL STARTER REMOVAL 1. Loosen the lock nuts 1 and remove NSI cable 2 from the cable bracket 3. 2. Remove NSI cable from the clutch notch plate 4. 3. Loosen and remove the three (3) bolts securing the recoil starter.

  • Page 111: Disassembly

    RECOIL STARTER 6-3 DISASSEMBLY Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this component. 1. Turn the reel 1 clockwise to release the coiled tension in the recoil spring. 2.
  • Page 112 6-4 RECOIL STARTER 5. Remove the recoil spring 9. NOTE: Do not remove recoil spring unless replacement is necessary. It should be visually inspected in its assembled position. 6. Remove NSI cable 0 from the recoil case A. Take off the reel stopper spring B and the reel stopper C.

  • Page 113: Inspection

    RECOIL STARTER 6-5 INSPECTION NOTE : If any parts is worn excessively, cracked, defective or dam- aged in any way, it must be replaced. • Inspect the ratchet (pawl) and all springs. If there is any defect such as excessive wear or damage, replace it.

  • Page 114: Reassembly

    G Bolt Reassembly is the reverse order of disassembly with special attention to the following reassembling steps. 99000-25160 : Suzuki Water Resistant Grease 99000-32050 : Thread Lock 1342 • Install the reel stopper C, reel stopper spring B and then...
  • Page 115 RECOIL STARTER 6-7 • Secure the outer end of the recoil spring 9 on the boss in the recoil case A and wind spring inward towards the center of the case in a counterclockwise direction. Because of the coiled tension in the recoil spring, wear safety glasses and hand protection when winding or unwinding this components.

  • Page 116: Installation

    6-8 RECOIL STARTER • Install the friction plate 3 (with friction spring 4) and se- cure it with the bolt 2. Apply Thread Lock 1342 to the thread of the bolt. NOTE : • Twist friction plate slightly to align holes A in plate with square lugs B on center boss.

  • Page 117: Neutral Start Interlock (Nsi)

    “FORWARD” and “RE- VERSE” position. 6. Tighten the adjustment nut. 7. Apply Suzuki Water Resistant Grease to inner cable, cable end, and cam. 99000-25160 : Suzuki Water Resistant Grease If the NSI cable is removed or left without correct ad- justment, there is a high risk of losing one’s balance...
  • Page 118 POWER UNIT CONTENTS POWER UNIT _____________________________________________ 7- 2 7- 2 REMOVAL ......................7- 7 IINSTALLATION ....................TIMING CHAIN / TENSIONER ________________________________ 7-11 REMOVAL ......................7-11 INSPECTION ....................7-13 INSTALLATION ....................7-14 CYLINDER HEAD ASSEMBLY _______________________________ 7-17 REMOVAL ......................7-17 ASSEMBLY ...................... 7-17 DISASSEMBLY ....................

  • Page 119: Power Unit

    7-2 POWER UNIT POWER UNIT REMOVAL Before removing power unit : • Drain engin oil. • Disconnect battery cable from battery. • Remove both side lower covers. (see page.8-2) [ Manual start model ] • Remove recoil starter. (see page 6-2) [ Electric start model ] •...
  • Page 120 POWER UNIT 7-3 [ Remote control model ] • Remove bolt 1 , throttle drum 2, throttle cam link rod3 and remote control throttle link rod 4 . • Remove bolt 5 , clutch control lever 6 , throttle control lever 7 and clutch lever link rod 8 .
  • Page 121 7-4 POWER UNIT Remove starter motor. (see page 4-13) Remove bolt 1 , neutral switch / switch bracket 2 . Disconnect the switch lead wire connector. Loosen screw 3 and disconnect oil pressure switch lead wire. Remove the two bolts 4 securing front panel 5 . Remove flywheel.
  • Page 122 POWER UNIT 7-5 Remove three (3) ignition coils 1 and disconnect primary lead wire. Remove two bolts and rectifier & regulator 2 . Disconnect water hose from thermostat cover and engine holder. Remove screw, starter motor relay and relay bracket. Remove bolts and PTT motor relay bracket.
  • Page 123 7-6 POWER UNIT Remove screw 1, clutch arm shaft 2, clutch notch plate 3 and clutch arm 4. Remove pins 5 and front panel bracket 6. Remove pins 7 and side cover seal 8. Remove thierteen (13) bolts. Lift up remove power unit from engine holder.

  • Page 124: Iinstallation

    Lower the power unit onto engine holder. NOTE : Rotate crankshaft to aid alignment of driveshaft and crankshaft splines. Apply Suzuki Silicone Seal to power unit mounting bolts and tighten bolts to specified torque. 99000-31120 : Suzuki Silicone Seal Power unit mounting bolt : 8 mm 23 N .
  • Page 125 7-8 POWER UNIT OIL PUMP SHAFT ENGAGEMENT Camshaft Groove Install lock washer 2 and gasket 3 to oil pump stopper1, and then screw (2-3 turns) the oil pump stopper 1 onto oil pan. Oil pump shaft Do not screw oil pump shaft stopper fully before en- gagingoil pump shaft with groove in camshaft.
  • Page 126 CYLINDER HEAD COVER NOTE: Before installing cylinder head cover, check valve clearance. (See page 2-9) Apply Suzuki bond to area as shown in figure. 99000-31140 : Suzuki Bond No.1207B Assemble cylinder head cover gasket to cylinder head cover. NOTE: Be sure to check head cover gasket for wear or any damage before installation and replace any found defective.
  • Page 127 7-10 POWER UNIT FINAL ASSEMBLY CHECK Perform the following checks to ensure proper and safe opera- tion of the repaired unit. • All parts removed have been returned to their original posi- tions. • Lower unit gear engagement is properly adjusted. (See page 10-21) •...

  • Page 128: Timing Chain / Tensioner

    POWER UNIT 7-11 TIMING CHAIN / TENSIONER REMOVAL Prior to this service work : • remove the power unit. (see page 7-2 to 7-6) 1 Crankshaft / timing sprocket 2 Timing chain 3 Timing chain guide 4 Timing chain tensioner 5 Timing chain tensioner adjuster 6 Camshaft and timing sprocket 1.
  • Page 129 7-12 POWER UNIT 3. Turn the crankshaft in its normal running direction (R direc- tion) until No.1 cylinder reaches top dead center. NOTE: To bring No.1 cylinder top dead center, align mark S on the crankshaft with mark a on the crank case. NOTE: After timing chain has been removed, do not turn crankshaft or camshaft.

  • Page 130: Inspection

    POWER UNIT 7-13 INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. Timing chain Inspect timing chain. Replace if worn or damaged. Tensioner adjuster Inspect tensioner adjuster for smooth operation. Replace if faulty.

  • Page 131: Installation

    7-14 POWER UNIT INSTALLATION Installation is reverse of removal with special attention to fol- lowing steps. (1) Align crankshaft timing mark S with timing mark a on crank- case as shown in figure by turning crankshaft. (2) Install dowel pin 1 into camshaft. Then turn the camshaft to locate the dowel pin position at the top as shown in figure.
  • Page 132 POWER UNIT 7-15 (6) Insert spacer into chain tensioner. Install chain tensioner 2 as shown in figure. Apply oil to chain tensioner. (7) With latch of tensioner adjuster returned and plunger pushed back into body, insert stopper into latch and body. After inserting stopper, check to make sure that plunger will not come out.
  • Page 133 NOTE: Before installing power unit, apply sealant to hatched part (6 parts) shown in the illustration right. 99000-31140 : Suzuki Bond 1207B (11) Adjust valve clearance (see page 2-9) To bring each piston to Top Dead Center (TDC) on com- pression stroke, align each match mark on camshaft sprocket with match mark on cylinder head block.

  • Page 134: Cylinder Head Assembly

    POWER UNIT 7-17 CYLINDER HEAD ASSEMBLY (Cylinder head / valve / camshaft) REMOVAL Prior to removing cylinder head: • Remove the power unit. (see page 7-2 to 7-6) • Remove the timing chain. (see page 7-11 to 7-12) 1. Loosen twelve (12) cylinder head bolts in the order indicated in figure and remove them.
  • Page 135 7-18 POWER UNIT 2. Position cylinder head on cylinder. 3. Apply engine oil to cylinder head bolts and tighten them gradu- ally as follows. (a) Tighten all bolts to 50 percent (%) of specified torque according to numerical order in figure. Cylinder head bolt : 1 st step 10 mm 30 N .

  • Page 136: Disassembly

    POWER UNIT 7-19 DISASSEMBLY 1. Remove four (4) bolts 1 and upper cylinder head cover 2 . 2. Remove the eight (8) bolts 1 securing rocker arm shaft brack- ets, then remove rocker arm shaft brackets 2 . Remove intake rocker arm shaft 3 and exhaust rocker arm shaft 4 .
  • Page 137 7-20 POWER UNIT 5. Using valve lifter and attachment, remove valve cotters 1 while compressing valve spring. 09916-14510 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers 6. Remove valve spring retainer 2 , valve spring 3 and valve 7. Remove valve stem seal 5 and valve spring seat 6 . NOTE: Reassemble each valve and valve spring in their original posi-tions.

  • Page 138: Inspection / Servicing

    POWER UNIT 7-21 INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com-ponent, replace component. CYLINDER HEAD Remove all carbon from combustion chambers. NOTE: • Do not use any sharp edged tool to scrape carbon off cylin-der head or its components.
  • Page 139 7-22 POWER UNIT Water jackets Check water jackets. If clogged or obstructed, clean water jack- ets. CAMSHAFT Cam face Inspect cam face for scratches and wear. Cam wear Using micrometer, measure cam height H. 09900-20202 : Micrometer Cam height Standard: DF25 AD 35.185 –...
  • Page 140 POWER UNIT 7-23 Camshaft runout Using a set of V-blocks, support the camshaft on a surface plate. Measure runout using a dial gauge. 09900-20602 : Dial gauge 09900-21304 : "V" block set 09900-20701 : Magnetic stand Camshaft runout Service limit : 0.10 mm (0.004 in.) If measurement exceeds service limit, replace camshaft.
  • Page 141 7-24 POWER UNIT Camshaft journal outside diameter Journal No. Diámetro exterior de los muñones STD : 43.425 – 43.450 mm (1.7096 – 1.7106 in.) Límite : 43.375 mm ( 1.7077 in.) STD : 43.625 – 43.650 mm (1.7175 – 1.7185 pulg.) Límite : 43.575 mm (1.7156 in.) STD : 43.825 –...
  • Page 142 POWER UNIT 7-25 ROCKER ARM / SHAFT Rocker arm and adjusting screw • If the tip of adjusting screw shows excessive wear, replace the screw. • The arm must be replaced if its cam-riding face is badly worn. Rocker arm shaft runout Using a set of V-blocks, support the rocker arm shaft on a sur- face plate.
  • Page 143 7-26 POWER UNIT VALVE / VALVE GUIDE Valve guide to valve stem clearance Using a micrometer and bore gauge, take diameter readings on valve stems and guides to check guide to stem clearance. Be sure to take readings at more than one place along the length of each stem and guide.
  • Page 144 POWER UNIT 7-27 Valve stem end deflection If unable to measure valve guide inside diameter, check “Valve stem end deflection”. 09900-20602 : Dial gauge 09900-20701 : Magnetic stand Measure valve stem end deflection as follows: (1) Install valve into valve guide. (2) Position valve head at approx.
  • Page 145 7-28 POWER UNIT Valve stem runout Measure valve stem runout. 09900-20602 : Dial gauge 09900-20701 : Magnetic stand 09900-21304 : “V”blockset Valve stem runout Service limit : 0.05 mm (0.002 in.) If measurement exceeds service limit, replace valve. Valve head radial runout Measure valve head radial runout.
  • Page 146 POWER UNIT 7-29 Valve seat contact width Measure valve seat contact width as follows: (1) Remove all carbon from valve and seat. (2) Coat valve seat evenly with Prussian blue (orequivalent) (3) Install valve into valve guide. (4) Put valve lapper on valve. 09916-10911 : Valve lapper (5) Rotate valve while gently tapping valve contact area against seat.
  • Page 147 7-30 POWER UNIT VALVE SEAT SERVICING If valve seat contact width is out of specification, reface valve IN, EX seat as follows: • Valve seat angle Valve seat : 15° ° ° ° ° , 45° ° ° ° ° Intake side : 15°...
  • Page 148 POWER UNIT 7-31 NOTE: Clean and assemble cylinder head and valve, components. Fill intake and exhaust ports with solvent to check for leaks be- tween valve seat and valve. If any leaks occur, inspect valve seat and face for burrs or other things that could prevent valve from sealing.
  • Page 149 7-32 POWER UNIT (3) Install valve guide to cylinder head. • Heat cylinder head to a temperature of 80 – 100°C (176 – 212°F). Apply heat uniformly so that head will not be distorted. • Use special tools to drive new valve guide into hole. Drive in new valve guide until special tool (valve guide in- staller attachment) contacts cylinder head.
  • Page 150 POWER UNIT 7-33 VALVE SPRING Valve spring free length Check spring strength by measuring free length. 09900-20101 : Vernier calipers Valve spring free length Standard : IN & EX 47.38 mm (1.865 in.) Service limit : IN & EX 45.48 mm (1.791 in.) If lower than service limit, replace valve spring.

  • Page 151: Reassembly

    7-34 POWER UNIT REASSEMBLY Reassemble in reverse order of disassembly pay special atten- tion to the following steps. VALVE Install valve spring seat 1 to cylinder head. After applying engine oil to stem seal 2 and spindle of special tool ( installer attachment ), fit stem seal to spindle. Then, pshing special tool by hand ,install stem seal to valve guide.
  • Page 152 POWER UNIT 7-35 Hold valve spring compressed with special tool and install valve cotters 6. Make sure valve cotters are properly seated in groove A. 09916-14510 : Valve lifter 09916-14910 : Attachment 09916-84511 : Tweezers CAMSHAFT Apply engine oil to the surface of each camshaft lobe and jour- nal.
  • Page 153 7-36 POWER UNIT Install gasket and upper cylinder head cover 3, then tighten bolts securely. ROCKER ARM / SHAFT Install dowel pins a. Apply engine oil to rocker arms and rocker arm shaft. Install rocker arms 1, rocker arm springs 2, intake rocker arm shaht 3 and exhaust rocker arm shaft 4.

  • Page 154: Cylinder / Crankshaft / Piston

    POWER UNIT 7-37 CYLINDER / CRANKSHAFT / PISTON DISASSEMBLY Before performing service work in this section: • Remove power unit (see page 7-2 to 7-6) • Remove timing chain (see page 7-11 to 7-12) • Remove cylinder head (see page 7-17) Remove oil filter 09915-47340 : Oil filter wrench Remove oil pressure switch.
  • Page 155 7-38 POWER UNIT NOTE: For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint. Remove all conrod cap nuts 1 and conrod caps 2. NOTE: To prevent damage to crank pin and cylinder walls, install a piece Guide hose of hose over threads of rod bolts.
  • Page 156 POWER UNIT 7-39 Remove two compression rings (top and 2nd) and oil ring form piston. Mark cylinder number on conrod using quick drying paint. Remove piston pin circlips as shown. 1. Piston pin circlip Remove piston pin from conrod. NOTE: Reassemble each piston, piston pin conrod in their original com- bination and position.

  • Page 157: Inspection / Servicing

    7-40 POWER UNIT INSPECTION / SERVICING NOTE: If cracks, excessive wear or other damage is found on any com- ponent, replace componet. CYLINDER • Cylinder distortion Using a straightedge and thickness gauge, measure cylinder distortion (gasketed surface) at a total of six (6) location as shown.
  • Page 158 POWER UNIT 7-41 • Cylinder bore wear (difference) Using cylinder gauge, measure cylinder bore in both axial (Vertical line, following crankshaft) and transverse (horizon- tal line across crankshaft) direction at two posirions as shown in figure. 09900-20508 : Cylinder gauge set Check for following : •...
  • Page 159 7-42 POWER UNIT (3) Calculate the piston / cylinder clearance (Clearance equals difference between piston diameter and cylinder bore measurements.) Piston to cylinder clearance Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.) Service limit : 0.100 mm (0.0039 in.) If clearance exceeds service limit, replace piston and / or cylinder or rebore cylinder.
  • Page 160 POWER UNIT 7-43 PISTON • Inspect piston for faults, cracks or other damage. Damaged or faulty piston(s) should be replaced. • Piston ring to groove clearance Before checking, piston grooves must be clean, dry and free Piston ring of carbon. Fit piston ring into piston groove, and measure clearance be- tween ring and ring groove using thickness gauge.
  • Page 161 7-44 POWER UNIT PISTON RING Piston ring end gap Measure piston ring end gap with piston ring in the lowest posi- Cylinder tion of cylinder bore. 09900-20803: Thickness gauge Piston ring end gap Piston ring Standard: 1st. 0.12 – 0.27 mm (0.005 – 0.011 in.) 2nd.
  • Page 162 POWER UNIT 7-45 PISTON PIN Check piston pin, conrod small end bore and piston pin hole for wear or damage. If badly worn or damaged ,replace component. Piston pin clearance • Check the piston pin clearance in the conrod small end . Replace the conrod if its small end is badly worn or damaged or if clearance exceeds service limit.
  • Page 163 7-46 POWER UNIT CONROD BIG END SIDE CLEARANCE Measure conrod big end side clearance with conrod installed on crank pin as shown. 09900-20803 : Thickness gauge Conrod big end side clearance Standard : 0.100 – 0.250 mm (0.0039 – 0.0098 in.) Service limit : 0.350 mm (0.0138 in.) If measurement exceecs service limit, replace conrod and / or crankshaft.
  • Page 164 POWER UNIT 7-47 CONROD BEARING Inspect bearing shell for proper contact pattern and signs of fusion, pitting, burning or flanking. Bearing shells forund in defective condition must be replaced. Conrod big end oil clearance Check coonrod big end oil clearance as follows: (1) Clean surface of conrod, conrod cap, conrod bearing, and crank pin.
  • Page 165 7-48 POWER UNIT (6) Remove conrod and conrod cap from crank pin. (7) Using scale on Plastigauge envelop, measure Plastigauge with at its widest point Conrod big end oil clrearance Standard : 0.020 – 0.040 mm (0.0008 – 0.0016 in.) Service limit : 0.065 mm (0.0026 in.) If measurement exceeds service limit, replace conrod bearing.
  • Page 166 POWER UNIT 7-49 If measurement exceeds service limit, replace crankshaft thrust bearing. Crankshaft thrust bearing thickness Standard : 2.470 – 2.520 mm (0.0972 – 0.0992 in.) 1. Thrust bearing Out - of - round and taper (uneven wear ) of jurnals An unevenly worn crankshaft journal shows up as a differ- ence in diameter at a cross section or along its length (or both).
  • Page 167 7-50 POWER UNIT CRANKSHAFT MAIN BEARING Upper half Lower half Check bearings for pitting, scratches, wear or damage. If any improper condition is found, replace both upper and lower halves. Always replace both bearing halves, never only one half of a bearing set.
  • Page 168 POWER UNIT 7-51 (5) Assemble crankcase to cylinder. Tightening order (6) Apply eingine oil crankcase bolts. Tighten crankcase bolts in three (3) steps following the or- der indicated below. Crankcase: 5 N . m (0.5 kg-m, 3.5 lb.-ft.) 1st step 8 mm 11 N .
  • Page 169 7-52 POWER UNIT SELECTIN OF MAIN BEARING Whenever a bearing requires replacement, select a new bear- No. 2 Jornal code ing according to following procedure. No. 1 Jornal code (1) First check journal diameter. As show in figure, upper (flywheel side) crank web of No.1 Flywheel cylinder has four (4) stamped numerals.
  • Page 170 POWER UNIT 7-53 (3) There are five (5) main bearing available, each of differ- ing thickness. To distinguish them, a color mark is painted at the position indicated in figure. Each color represents the following thickness measured at the center of the bearing. Color mark Bearing thickness Color mark...

  • Page 171: Reassembly

    7-54 POWER UNIT REASSEMBLY Assembly is reverse order of disassembly paying special atten- tion to the following steps. If original components are not replaced, each piston, piston pin and conrod is to be assembled and installed in its original order and position. PISTON TO CONROD Apply engine oli to piston 2, piston pin bore and conrod 3.
  • Page 172 POWER UNIT 7-55 PISTON RING TO PISTON Oil ring • Apply engine oil to piston rings. • Install spacer 1 first, then side rails 2 to piston. When installing spacer, do not allow ends to overlap in Incorrect groove. Correct 1st ring and 2nd ring •...
  • Page 173 7-56 POWER UNIT PISTON TO CYLINDER Install conrod bearing to conrod and conrod cap. • Assemble each conrod bearing to its original posi- tion. • Dont apply oil between conrod and bearing or be- tween bearing cap and bearing. Apply engin oil to piston and cylinder walls. Insert piston and conrod assembly into cylinder bore from cylin- der head side using special tool.
  • Page 174 POWER UNIT 7-57 CRANKSHAFT TO CYLINDER Install crankshaft main bearing in cylinder and crankcase. Apply engine oil to bearings. • Assemble each bearing to its original position. • Do not apply oil between crank bearing holder and crank main bearing. NOTE: Align bearing tab a with notch in cylinder and crankcase.
  • Page 175 Apply Bond to marked line Clean mating surface of cylinder and crankcase. Apply SUZUKI BOND to mating surface of crankcase as shown. Apply bond to mating surface only. Do not allow bond to contact surface of bearing. 99000-31140 : Suzuki Bond 1207B...
  • Page 176 POWER UNIT 7-59 Install crankcase to cylinder. Apply engine oil to crankcase bolts. Tighten crankcase bolts in three (3) steps following the order indicated below. NOTE: After tightening crankcase bolts, check to be sure that crankshatf rotates smoothy when turned by hand. Crankcase bolt 5 N .

  • Page 177: Thermostat

    7-60 POWER UNIT THERMOSTAT REMOVAL • Disconnect water hose 1 from thermostat cover. • Remove the four (4) bolts 2 securing the thermostat cover, then remove the cover 3 and thermostat 4 . INSPECTION • If salt deposits, corrosion, wear or other damage is found, clean or replace.

  • Page 178: Operation

    POWER UNIT 7-61 OPERATION WATER COOLING SYSTEM The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostat. This system cools both the power unit and exhaust and is shown in schematic from below. If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion buidup or component damage.

  • Page 179: Engine Lubrication System

    7-62 POWER UNIT ENGINE LUBRICATION SYSTEM Acamshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication. Oil form the oil pan is drawn theough the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.

  • Page 180: Mid Unit

    MID UNIT 8-1 MID UNIT CONTENTS ENGINE SIDE COVER ______________________________________ 8- 2 8- 2 REMOVAL ......................8- 2 INSTALLATION ....................TILLER HANDLE / HANDLE BRACKET ________________________ 8- 3 8- 3 REMOVAL ......................8- 4 INSTALLATION ....................8- 4 TILLER HANDLE DISASSEMBLY / ASSEMBLY ........... GAS ASSISTED TILT CYLINDER _____________________________ 8- 5 8- 5 REMOVAL ......................

  • Page 181: Engine Side Cover

    8-2 MID UNIT ENGINE SIDE COVER REMOVAL Remove four (4) screws 1 and PORT side cover 2. Remove two (2) screws 3 and STBD side cover 4. INSTALLATION Installation is reverse order of removal. 1. Side cover STBD 2. Side cover PORT 3.

  • Page 182: Tiller Handle / Handle Bracket

    MID UNIT 8-3 TILLER HANDLE / HANDLE BRACKET REMOVAL Remove the STBD side lower cover. Loosen lock nut 1. Remove throttle cables from throttle drum 2. Remove bolt 3 and plate 4. Remove two bolts and handle cover. Remove tiller handle and throttle cable assembly. Disconnect emergency stop switch lead wire.

  • Page 183: Installation

    8-4 MID UNIT INSTALLATION Installation is reverse order of removal with special attention to the following: • Tiller handle cover Install tiller handle and handle cover. Tighten handle cover bolts, pre-coated with thread lock, to the specified torque. 99000-32050 : Thread lock “1342” Tiller handle bolt : 23 N .

  • Page 184: Gas Assisted Tilt Cylinder

    MID UNIT 8-5 GAS ASSISTED TILT CYLINDER This gas assist tilt cylinder contains high pressure gas and it must not be disassembled, punctured, inciner- ated or exposed to heat. REMOVAL Tilt engine fully up and lower the manual tilt lock levers 1. During the following procedure , firmly secure the en- gine and support its weight.

  • Page 185: Inspection

    8-6 MID UNIT Remove the tilt cylinder lower shaft bolts 8. Slide the STBD clamp bracket 9 fully outward to the right hand side. Remove the gas cylinder 0 from between the clamp brackets. INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced.

  • Page 186: Installation

    MID UNIT 8-7 INSTALLATION Installation is reverse order of removal with special attention to following steps. 1. Release lever 2. Lower coller (STBD) 3. Lower coller (PORT) 4. Gas cylinder 5. Tilt cylinder lower shaft 6. Tilt cylinder upper shaft 7.
  • Page 187 Install bushes 1, cylinder lower shaft 2, STBD lower collar 3, PORT lower collar 4 to gas cylinder. 99000-25160 : Suzuki Water Resistant Grease Place the gas cylinder in position between the clamp brackets. Tighten clamp bracket shaft nut to specified torque.

  • Page 188: Driveshaft Housing And Oil Pan

    MID UNIT 8-9 DRIVESHAFT HOUSING AND OIL PAN REMOVAL Remove power unit. (See pages 7-2 to 7-6) Remove lower unit. (See pages 10-2) Remove screw and bonding wire from driveshaft housing. Unscrew the lower mount cover bolts 1 and remove PORT/ STBD lower mount covers 2.
  • Page 189 8-10 MID UNIT Remove bolts 5 and upper mount cover 6. Remove upper mount assembly 7. Remove lower mount assembly 8. Remove four bolts 9 and engine holder 0. Remove bolts A and oil strainer B. Note the position of O-ring and remove it. Remove three bolts C and oil pump assembly D.
  • Page 190 MID UNIT 8-11 Remove oil relief valve E. Remove six bolts F and oil pan G. Remove water tube H. Remove bolts I, water pressure valve cover J, pressure valve Remove bolts L and exhaust tube M. (Transom L type only)

  • Page 191: Inspection

    8-12 MID UNIT INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. Mid unit component Check oil pan, driveshaft housing, engine holder and mount covers. If cracks, defects or other damage is found, replace it. Mount Check upper and lower mount.
  • Page 192 MID UNIT 8-13 Water tube Check water tube. If a clog or obstruction is found, clean water tube. If cracks, corrosion or other damage is found, replace water tube. Check water tube grommet. If excessive wear or other damage is found, replace grommet. Water pressure valve If salt deposits, corrosion, wear, or other damage is found, clean or replace.

  • Page 193: Assembly

    8-14 MID UNIT ASSEMBLY Assembly is reverse order of removal with special attention to the following steps. 35 N . m (3.5 kg-m, 25.5 lb-ft) 27 N . m (2.7 kg-m, 19.5 lb-ft) 50 N . m (5.0 kg-m, 36.0 lb-ft) 23 N .
  • Page 194 MID UNIT 8-15 13 N . m (1.3 kg-m, 9.5 lb-ft) [ Gasket \ Oil pan ] Cover ^ O-ring a Water indicator tube b Exhaust pipe c O-ring d Water plug e Gasket f Plug g Hose h Clip i Bolt 40 N .
  • Page 195 Install two dowel pins 9 to driveshaft housing 0. Apply sealant to mating surfaces of driveshaft housing and oil pan. 99000-31120 : Suzuki Silicone Seal Install oil pan A to driveshaft housing 0, then tighten six (6) bolts B securely.
  • Page 196 MID UNIT 8-17 ENGINE HOLDER TO OIL PAN Install gasket 1 and oil relief valve 2 to engine holder 3, then tighten valve securely. Oil relief valve : 27 N . m ( 2.7 kg-m, 19.5 lb.-ft.) Apply engine oil to O-ring 4, then install O-ring 4 to oil strainer Install oil strainer 5 to engine holder 3, then tighten bolts 6 securely.
  • Page 197 8-18 MID UNIT UPPER AND LOWER MOUNT Upper mount and mount cover Install upper mount (with upper mount bolt and thrust mount). Install upper mount cover. Tighten mount cover bolt , pre-coated with thread lock , to speci- fied torque . NOTE: Install the upper mount to the engine holder with the UP mark (arrow) pointing upside.
  • Page 198 MID UNIT 8-19 Install upper mount nuts. Tighten nuts, pre-coated with thread lock, to specified torque. 99000-32050 : Thread Lock “1342” Upper mount nut : 35 N . m (3.5 kg-m, 25.5 lb.-ft.) Tighten lower mount cover bolts securely. Install lower mount front nuts. Tighten nuts, pre-coated with thread lock, to specified torque.

  • Page 199: Swivel Bracket, Steering Bracket And Clamp Bracket

    8-20 MID UNIT SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL Remove driveshaft housing / oil pan. (See page 8-9) Remove screw and bonding wire from swivel bracket. Remove circlip 1. Remove lower mount bracket 2 from the steering shaft. Account for key 3, shim 4 and washer 5.
  • Page 200 MID UNIT 8-21 Remove circlip B and push out tilt cylinder upper rod C. Remove nut 1 from clamp bracket shaft. Remove tilt cylinder lower shaft bolts 2. Slide STBD clamp bracket 3 off clamp bracket shaft. Remove the PTT unit assembly. (T model) Remove the gas assisted tilt cylinder.

  • Page 201: Inspection

    8-22 MID UNIT INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. BUSHINGS Check all bushings. If excessive wear or other damage is found, replace bushing. If bushing fit is loose when installing, replace bushing. OIL SEAL Check swivel bracket seal.

  • Page 202: Reassembly

    MID UNIT 8-23 REASSEMBLY Reassembly is reverse order of removal with special attention to the following steps. 43 N . m (4.3 kg-m, 31.0 Ib-ft) 1 Clamp bracket STBD 2 Clamp bracket PORT X Bolt 3 Clamp bracket shaft Y Cover 4 Washer Z Washer 5 Nut...
  • Page 203 1. Install clamp bracket shaft nut 6. Leave nut loose for easier installation of PTT unit (or gas assist tilt cylinder). 99000-25160 : Suzuki Water Resistant Grease NOTE: Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings.
  • Page 204 MID UNIT 8-25 STEERING BRACKET Apply Water Resistant Grease to steering bracket shaft. 99000-25160 : Suzuki Water Resistant Grease NOTE: Apply grease to bushings, oil seal lip and pilot shaft portion of steering bracket. Install upper bushing 1, steering adjuster 2, upper plate 3 and washer 4 to swivel bracket.
  • Page 205 Reattach bonding wire to clamp bracket and swivel bracket, then tighten screw securely. Reattach bonding wire to swivel bracket and lower mount bracket, then tighten screw securely. LUBRICATION After completing reassembly of the mid unit, apply grease through each grease nipple. 99000-25160 : Suzuki Water Resistant Grease...

  • Page 206: Power Trim And Tilt

    POWER TRIM AND TILT POWER TRIM AND TILT CONTENTS SYSTEM WIRING DIAGRAM _________________________________ 9- 2 SERVICE PROCEDURE ____________________________________ 9- 3 9- 3 OIL LEVEL ....................... 9- 3 AIR BLEEDING ....................POWER TRIM AND TILT UNIT ________________________________ 9- 4 9- 4 REMOVAL ......................

  • Page 207: System Wiring Diagram

    POWER TRIM AND TILT SYSTEM WIRING DIAGRAM PTT switch PTT relay (UP) W tube PTT motor To ignition switch Remote control box PTT relay (DOWN) Starting motor relay Battery...

  • Page 208: Service Procedure

    POWER TRIM AND TILT SERVICE PROCEDURE OIL LEVEL To check the oil level : 1. Raised the engine to a full-tilt position. 2. Lower the manual tilt lock lever 1. 3. Remove the oil filler plug 2 and oil level plug 3. 4.

  • Page 209: Power Trim And Tilt Unit

    POWER TRIM AND TILT POWER TRIM AND TILT UNIT REMOVAL Raise the engine to the full tilt position and lower the manual tilt lock levers 1. During the following procedures, the engine must be firmly secured and its weight fully supported. (see right) Remove the tilt rod snap ring 2 and push tilt cylinder upper shaft pin 3 out.

  • Page 210: Ptt Motor

    POWER TRIM AND TILT Remove the PTT cylinder lower shaft bolts 6. Slide the STBD clamp bracket 8 fully outward to the right hand side. Remove the PTT unit 9 from between the clamp brackets. PTT MOTOR REMOVAL NOTE: Before removing PTT motor, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air .

  • Page 211: Motor Disassembly

    POWER TRIM AND TILT Remove two screws, then detach the reservoir. Detach the PTT motor from pump & reservoir. Note the position of drive joint 1 and O-ring 2 and remove them. NOTE: Do not lay PTT components out on a rag , as dirt or lint may be transferred to these items which may cause possible system operating problems.

  • Page 212: Inspection

    POWER TRIM AND TILT INSPECTION Armature and Commutator Check for continuity between the commutator and the armature core / shaft. Replace armature if continuity is indicated. 09930-99320 : Digital tester Tester range : (Continuity) Check continuity between the adjacent commutator segments. Replace armature if no continuity is indicated.

  • Page 213: Motor Assembly

    POWER TRIM AND TILT Brushes Check the length of each brush. 09900-20101 : Vernier calipers Brush length : Standard 9.8 mm (0.39 in.) Service limit 4.8 mm (0.19 in.) If brushes are worn down to the service limit, they must be re- placed .

  • Page 214: Reassembly

    POWER TRIM AND TILT REASSEMBLY Reassembly is reverse of removal with special attention to fol- lowing steps. • Ensure that the drive joint 1 is aligned and firmly inserted into the gear pump assembly. • Fit O-ring 2 to PTT motor. •...

  • Page 215: Installation

    9-10 POWER TRIM AND TILT INSTALLATION Installation is reverse order of removal with special attention to the following steps. Lower tilt rod full down position. Apply Water Resistant Grease to the tilt cylinder lower shaft and lower shaft bushes. Install bushes 1, cylinder lower shaft 2 and lower collars 3 to PTT unit.
  • Page 216 POWER TRIM AND TILT 9-11 Apply Water Resistant Grease to the PTT rod upper shaft 6, then insert the shaft through the swivel bracket and tilt rod. 99000-25160 : Water Resistant Grease Secure the upper shaft with the snap ring 7. Route the PTT motor cable in through the lower cover and con- nect the terminals to the PTT relays.

  • Page 217: Ptt Motor Relay

    9-12 POWER TRIM AND TILT PTT MOTOR RELAY Two methods can be used to test PTT relays. Method 1. Lbl(P) Measure resistance between wiring leads of the relay. 09930-99320 : Digital tester Tester range : (Resistance) Tester probe connection Red (+) Black (–) Light Blue Black...

  • Page 218: Ptt Switch

    POWER TRIM AND TILT 9-13 PTT SWITCH Test continuity between the wires at each of the three switch positions. 09930-99320 : Digital tester Tester range : (Continuity) Tester probe connection Tester indicates Red (+) Black (–) “DN” side Pink Gray Continuity depressed “UP”...

  • Page 219: Operation

    9-14 POWER TRIM AND TILT OPERATION The power trim and tilt system is operated by a “rocker” type switch (protected by a rubber thumb pad) on top of the remote control box handle. When the switch is depressed, power is delivered to the electric motor via the relevant relay. The relay with the Blue wire connected to the PTT pump is for trim/ tilt “up”, while the relay with the Green wire is for trim/tilt “down”.

  • Page 220: Principles Of Operation

    POWER TRIM AND TILT 9-15 PRINCIPLES OF OPERATION TRIM/TILT “UP” CIRCUIT The electric motor is operating in a clockwise direction. Check valve A will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the left, opening the “down” pressure main check valve and returning oil from the upper cylinder chamber (plus oil from the reservoir) to the pump.
  • Page 221 9-16 POWER TRIM AND TILT TRIM/TILT “DOWN” CIRCUIT The electric motor is operating in a counterclockwise direction. Check valve B will open, allowing oil to flow from the reservoir to the pump. Oil flow from the pump enters the spool valve, moving it to the right, thereby opening the “up”...

  • Page 222: Lower Unit

    POWER TRIM AND TILT 9-17 SHOCK ABSORBER CIRCUIT ( ) Shock valve Should the lower unit strike an underwater object whilst in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber. The shock valve will then open, allowing oil to flow into the area between the tilt ram piston and the free piston, thereby dampening (absorbing) the impact.
  • Page 223 9-18 POWER TRIM AND TILT MANUAL RELEASE CIRCUIT (MANUAL VALVE) Operation:Turn manual valve maximum three (3) full turns counterclockwise. When the manual valve is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again.
  • Page 224 POWER TRIM AND TILT 9-19 THERMAL VALVE The PTT system incorporates a thermal valve for protection of the internal components, should excessive downward force be exerted on the lower unit with the motor in a tilted position, or (in the case of an impact in reverse gear), the outboard clamp/swivel brackets and the boat transom.

  • Page 225: Lower Unit

    LOWER UNIT 10-1 LOWER UNIT CONTENTS REMOVAL & DISASSEMBLY _______________________________ 10- 2 PINION BEARING ________________________________________ 10- 6 INSPECTION ____________________________________________ 10- 8 10- 8 PROPELLER ....................10- 8 GEARCASE ....................10- 9 GEAR ......................10- 9 PROPELLER SHAFT COMPONENTS ............10- 9 PROPELLER SHAFT BEARING HOUSING ..........

  • Page 226: Removal & Disassembly

    10-2 LOWER UNIT REMOVAL & DISASSEMBLY Before removing lower unit: • Disconnect spark plug caps from all spark plugs. • Disconnect the battery cable. Loosen the clutch rod lock nut 1. To separate the clutch rod from the shift rod, unscrew the turn- buckle 2.
  • Page 227 LOWER UNIT 10-3 To prevent injury from propeller blades, wear gloves and place a block of wood between the anti - cavitation plate and the propeller blade tips to lock the propeller in place. Remove the two (2) bolts 1 securing the propeller shaft bear- ing housing to the gearcase.
  • Page 228 10-4 LOWER UNIT Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. 09921-29510 : Driveshaft holder Remove the two (2) bolts 9 securing the driveshaft bearing housing to the gearcase. To separate the bearing housing from the gearcase, use two (2) 6mm bolts A as screw jacks, by alternately turning each one equally.
  • Page 229 LOWER UNIT 10-5 Take the pinion shim 6 out from the gearcase. Remove the screws 1 securing the shift rod guide stopper. Pull out the shift rod assembly 2. Disassembling drive shaft Remove the circlip 1 and pre-load spring collar 2, washer 3, tab lock washer 4 and pre-load spring 5.

  • Page 230: Pinion Bearing

    10-6 LOWER UNIT To disassemble propeller shaft components, refer to the fol- lowing: (a) Pull the push rod 6 out of the propeller shaft. (b) Remove the spring 7 from the clutch dog shifter. (c) Use special tool to push the dog pin 8 out of the clutch dog shifter.
  • Page 231 LOWER UNIT 10-7 2. Place the attachment 4 inside the pinion bearing. 3. Insert the removal shaft 1 into attachment. 4. Thread sliding hammer 5 into top of removal shaft. 5. Put wood block under pinion bearing. 6. Drive the pinion bearing out by striking top of shaft with slid- ing hammer.

  • Page 232: Inspection

    10-8 LOWER UNIT INSPECTION NOTE: If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced. NOTE: Thoroughly wash all metal components with cleaning solvent and dry with compressed air. Wear safety grasses when using compressed air. PROPELLER •...

  • Page 233: Gear

    LOWER UNIT 10-9 GEAR • Inspect forward, reverse and pinion gear teeth and engaging dogs. Replace gears if damaged or worn. • Inspect forward gear bearing. Replace bearing if pitted, noisy or rough. PROPELLER SHAFT COMPONENTS • Inspect push rod / push pin, replace if worn, broken, or tip is flattened.

  • Page 234: Shift Rod And Shift Cam

    10-10 LOWER UNIT Replacing propeller shaft oil seal 1. Extract the seals with oil seal remover. 09913-50121 : Oil seal remover Do not reuse oil seal once removed. Always use new oil seals. 2. Apply Water Resistant Grease to the inner circumference of the housing.

  • Page 235: Driveshaft Bearing Housing

    LOWER UNIT 10-11 DRIVESHAFT BEARING HOUSING • Inspect housing. Replace if cracked or damaged. • Check condition of oil seals. Replace if nicked, cut or worn. • Inspect O-ring. Replace if worn, nicked or cut. Replacing driveshaft oil seal 1. With the oil seal remover, draw the two oil seals out of the driveshaft bearing housing.

  • Page 236: Assembly & Installation

    10-12 LOWER UNIT ASSEMBLY & INSTALLATION Assembly & Installation are reverse of disassembly with spe- cial attention to following steps. System construction T Dog pin U Dog spring V Return spring 1 Gearcase W Propeller shaft 2 Bearing X Thrust washer 3 Bearing Y Reverse gear 4 Drain plug...
  • Page 237 LOWER UNIT 10-13 i Shift rod j Pin k Boot 8 N . m l Stopper (0.8 kg . m, 5.8 lb-ft) m Screw n Shift rod guide o O-ring p O-ring q Magnet r Holder s Shift cam t Grommet u Water pump case v Key w Water pump impeller...
  • Page 238 FORWARD GEAR Place the forward gear bearing 3 and back-up shim 2 in posi- tion, then install forward gear 1. 99000-22540 : Suzuki Outboard Motor Gear Oil SHIFT ROD ASSEMBLY • Apply Water Resistant Grease to the shift rod guide O-ring 4 .
  • Page 239 (pinion gear side) of the spring collar. Firmly push down pre-load spring collar, then snap on circlip. Installation Apply Suzuki Water Resistant Grease to the O-ring of the hous- ing. Install complete driveshaft and driveshaft bearing housing as- sembly to the gearcase.
  • Page 240 10-16 LOWER UNIT PINION NUT Apply Thread Lock 1342 to the threads of the pinion nut before threading it onto the driveshaft. Tighten nut to the specified torque. Pinion nut : 18 N . m (1.8 kg-m, 13.0 lb.-ft.) 99000-32050 : Thread Lock 1342 09921-29510 : Drive shaft holder CHECKING DRIVESHAFT THRUST PLAY Before installing reverse gear, driveshaft thrust play should be...
  • Page 241 5, reverse thrust washer 1, reverse gear 2, reverse gear back-up shim 3 and propeller shaft housing 99000-25160 : Water Resistant Grease 99000-22540 : Suzuki Outboard Motor Gear Oil NOTE: Before installing propeller shaft / bearing housing assembly, bring shift cam to the forward position by moving shift rod up or down.
  • Page 242 10-18 LOWER UNIT CHECKING PROPELLER SHAFT THRUST PLAY See the “GEARS - SHIMMING AND ADJUSTMENT / CHECK- ING PROPELLER SHAFT THRUST PLAY” section on page 10- LEAKAGE CHECK Check for leakage of oil seal and O-ring when applying speci- fied pressure inside of the gearcase. 09950-69511 : Oil leakage tester : Air Pump Procedure...
  • Page 243 LOWER UNIT 10-19 WATER PUMP ( Impeller & Case ) Place the under panel gasket 1 and under panel 2 in position. Insert the key 3 in the driveshaft and slide the impeller 4 onto driveshaft, ensuring that key and keyway are aligned. Install the pump case 5 while rotating driveshaft clockwise to flex the impeller vanes in the correct direction.
  • Page 244 Insert dowel pins 1. Coat the driveshaft splines with Water Resistant Grease. Apply a light coat of Suzuki Silicone Seal to mating surfaces of gearcase and driveshaft housing. Slide the lower unit 2 into place, making sure that the top of the driveshaft engages properly with the crankshaft and that water tube locates in the water pump case outlet.
  • Page 245 LOWER UNIT 10-21 CLUTCH ADJUSTMENT Connect clutch rod to shift rod as shown. Make sure that chamfered edge of the turnbuckle faces downward to seat against the lower nut when tightened. Chamfered edge Adjustment step : 1. Shift the clutch lever from Neutral through Forward and Re- verse to check that proper engagement of both gears is at an equal angle from Neutral.

  • Page 246: Trim Tab

    10-22 LOWER UNIT TRIM TAB The trim tab counteracts or minimizes propeller torque “pull” felt through the steering system. If the steering is pulled to starboard or port side, adjust trim tab with following procedure: Adjusting 1. Loosen the bolt of trim tab. Bolt 2.

  • Page 247: Lower Unit Gears-Shimming And Adjustment

    LOWER UNIT 10-23 LOWER UNIT GEARS- SHIMMING AND ADJUSTMENT If lower unit has been rebuilt or has had components replaced, shimming for correct gear contact and backlash will have to be adjusted to ensure smooth, reliable operation of gears. Shim / Washer & Mounting position Design Available Numerical...
  • Page 248 10-24 LOWER UNIT Adjusting gear backlash To check the backlash, hold the driveshaft by hand, then gently rock forward gear back and forth by hand. Gear backlash : 0.10 – 0.20 mm (0.004 – 0.008 in.) • If backlash is larger than the specified, thickness of for- ward gear back-up shim must be increased.
  • Page 249 LOWER UNIT 10-25 5. Carefully pull out propeller shaft and housing to check tooth Concave side contact pattern. Tooth width Convex side Heel TOOTH Tooth top CONTACT PATTERN Tooth bottom Optimum tooth contact Optimum tooth contact The optimum tooth contact is shown at right. approx.
  • Page 250 10-26 LOWER UNIT CHECKING DRIVESHAFT THRUST PLAY After obtaining optimum tooth contact, driveshaft thrust play should be measured. 1. Affix gear adjusting gauge to driveshaft. 09951-09511 : Gear adjusting gauge 2. Slowly push driveshaft downward. Read the maximum play. Designate this amount of play as (A).
  • Page 251 LOWER UNIT 10-27 CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions, measure the propeller shaft thrust play. if not within the following specification, a shim ad- justment is required. Propeller shaft thrust play : 0.20 – 0.40 mm (0.008 –...

  • Page 252: Wire / Hose Routing

    WIRE / HOSE ROUTING CONTENTS WIRING DIAGRAM _________________________________________ 11- 2 WIRE ROUTING ___________________________________________ 11- 6 FUEL / WATER HOSE ROUTING ______________________________ 11-14...
  • Page 253 Wire color CKP SENSOR No.2 B : Black B/G : Black / Green CKP SENSOR No.1 Bl : Blue B/Y : Black / Yellow Br : Brown Bl/B: Blue / Black CDI UNIT G : Green Bl/R: Blue / Red MAGNETO Lg : Light green Bl/Y : Blue / Yellow...
  • Page 254 CKP SENSOR No.2 CKP SENSOR No.1 POWER SOURCE COIL CDI UNIT BATTERY CHARGE COIL MAGNETO STARTER MOTOR ENGINE START SWITCH Button pushed START FUSE 25A CYLINDER TEMP. SENSOR IGNITION RECTIFIER COIL # 1 & REGULATOR NEUTRAL SWITCH STARTER MOTOR RELAY Bl/Y IGNITION EMERGENCY STOP &...
  • Page 255 CKP SENSOR No.2 METER ILLUMINATION CKP SENSOR No.1 SWITCH POWER SOURCE COIL MAGNETO CDI UNIT BATTERY CHARGE COIL STARTER ---------- Optional parts MOTOR FUSE 25 A METER CYLINDER TEMP. SENSOR NEUTRAL SWITCH RECTIFIER & REGULATOR OIL PRESSURE SWITCH STARTER 0.5kgf/cm or less MOTOR Bl/Y...
  • Page 256 METER ILLUMINATION CKP SENSOR No.2 SWITCH CKP SENSOR No.1 POWER SOURCE COIL MAGNETO CDI UNIT BATTERY CHARGE COIL STARTER ---------- Optional parts MOTOR METER FUSE 25 A PTT RELAY UP CYLINDER TEMP. SENSOR RECTIFIER & REGULATOR OIL PRESSURE SWITCH PTT MOTOR STARTER 0.5kgf/cm or less...
  • Page 257 CKP sensor No. 1 Battery charge & powre source coil Choke solenoid (R/T models) Breather hose Clamp CKP sensor No. 2 Starter motor (QE / QR / T models)
  • Page 258 Cylinder temp. sensor Clamp Breather hose Electric parts holder When installing sensor, apply water resistant grease to sensor o-ring Ignition coil #1 Clamp Bind the ignition coil primary wire and H.T. cord Ignition coil #2 Clamp Clamp Clamp Bind the ignition coil primary wire and H.T.
  • Page 259 Cylinder temp. sensor Electric parts holder Clamp Breather hose When installing sensor, apply water resistant Fuse / Fuse case grease to sensor o-ring Ignition coil #1 Clamp Bind the rectifier lead wire, ignition coil primary wire and H.T. cord Ignition coil #2 Clamp Clamp Bind the rectifier lead wire,...
  • Page 260 Fuse / Fuse case Electric parts holder marked parts are Cylinder temp. sensor in "T" model only. Clamp Clamp Breather hose When installing sensor, *PTT motor relay "UP" apply water resistant grease to sensor o-ring *PTT motor relay "DOWN" Ignition coil #1 Clamp Bind the rectifier lead wire, ignition coil primary wire and...
  • Page 261 11-10 WIRE / HOSE ROUTING DF25Q / DF30Q Flywheel bolt Oil pressure switch Clamp DF25QE / DF30QE Flywheel bolt Spacer Oil pressure switch Starter motor Battery cable Damper Neutral switch Starter motor band Starter motor relay Starter motor sub cable Clamp Battery cable...
  • Page 262 WIRE / HOSE ROUTING 11-11 DF25QR / DF30QR, DF25T / DF30T Flywheel bolt Spacer Starter motor Oil pressure switch PTT relay ground cable Battery cable Damper Neutral switch Starter motor band Starter motor relay Starter motor sub cable Clamp Battery cable DF25Q / DF30Q 1.
  • Page 263 11-12 WIRE / HOSE ROUTING DF25QE / DF30QE 1. Power source coil connector 2. CKP sensor connector 3. Battery charge coil connector Band 4. Stop switch connector 5. Cylinder temp. sensor connector 6. Caution lamp connector CDI unit Engine main wiring harness Electric parts holder DF25QR / DF30QR, DF25T / DF30T 1.
  • Page 264 WIRE / HOSE ROUTING 11-13 DF25Q / DF30Q, DF25QE / DF30QE (Starter switch) Emergency & engine stop switch Emergency & engine stop switch (Starter switch) DF25T / DF30T Battery cable Clip Remote control harness PTT motor cable wire...
  • Page 265 11-14 WIRE / HOSE ROUTING FUEL / WATER HOSE ROUTING • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. • Check that hoses do not contact rods and levers during either engine operation or standstill. •...
  • Page 266 WIRE / HOSE ROUTING 11-15 DF25Q / DF30Q, DF25QE / DF30QE Clip Fuel connector plug Fuel pump Clip Clamp Clamp Clip Clamp Fuel hose (Connector to Fuel filter) Clamp Fuel filter Fuel hose (Fuel pump to carburetor)
  • Page 267 11-16 WIRE / HOSE ROUTING Clip Clip Clip Clip Fuel hose (Fuel pump Carburetor) Clip 3way joint Breather hose / Protector Clamp...
  • Page 268 Hose cushion Breather hose / Protector Clamp Clip Clip Water return hose Clamp Clip Clip Clip Water hose...
  • Page 269 DF25/30 “K3” (2003) MODEL 12-1 DF25/30 “K3” (2003) MODEL CONTENTS SPECIFICATIONS _______________________________________ 12- 2 SERVICE DATA__________________________________________ 12- 6 ENGINE CONTROL AND ELECTRICAL ______________________ 12-13 WIRE ROUTING _________________________________________ 12-15...

  • Page 270: Specifications

    60 (2.36) Total displacement (cu in) 597 (36.4) Compression ratio Spark plug DCPR6E Ignition system SUZUKI PEI Fuel supply system Carburetor (Number of carb. : 3) Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump...
  • Page 271 Viscosity rating 10W-40 3.0 (3.2/2.6) : Oil change only Engine oil amounts L (US/Imp. qt) 3.2 (3.4/2.8) : Oil filter change SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gear oil Gearcase oil amounts ml (US/Imp. oz) 230 (7.8/8.1)
  • Page 272 60 (2.36) Total displacement (cu in) 597 (36.4) Compression ratio Spark plug DCPR6E Ignition system SUZUKI PEI Fuel supply system Carburetor (Number of carb. : 3) Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump...
  • Page 273 Engine oil amounts 3.0 (3.2/2.6) : Oil change only L (US/Imp. qt) 3.2 (3.4/2.8) : Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts ml (US/Imp. oz) 230 (7.8/8.1) BRACKET Trim angle 8°...

  • Page 274: Service Data

    12-6 DF25/30 “K3” (2003) MODEL SERVICE DATA These service data are subject to change without notice. Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T POWERHEAD Recommended operating r/min 5000 – 5600 5500 – 6100 range Idle speed r/min 900 ± 50 (in-gear: approx. 850) **Cylinder compression kPa (kg/cm , psi)
  • Page 275 DF25/30 “K3” (2003) MODEL 12-7 Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T CYLINDER HEAD / CAMSHAFT Limit mm (in) 0.05 (0.002) Cylinder head distortion Manifold seating faces Limit mm (in) — distortion Cam height mm (in) 35.185 – 35.345 (1.3852 – 1.3915) 36.076 – 36.236 (1.4203 – 1.4266) Limit mm (in) 35.085 (1.3813)
  • Page 276 12-8 DF25/30 “K3” (2003) MODEL Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T VALVE / VALVE GUIDE mm (in) 23.1 (0.91) Valve diameter mm (in) 29.6 (1.17) Valve clearance mm (in) 0.13 – 0.17 (0.005 – 0.007) (Cold engine mm (in) 0.13 –...
  • Page 277 DF25/30 “K3” (2003) MODEL 12-9 Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T CYLINDER / PISTON / PISTON RING Limit mm (in) 0.030 (0.0012) Cylinder distortion mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in) 0.100 (0.0039) mm (in) 65.000 –...
  • Page 278 12-10 DF25/30 “K3” (2003) MODEL Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T CRANKSHAFT / CONROD Conrod small end mm (in) 16.003 – 16.011 (0.6300 – 0.6304) inside diameter mm (in) 0.020 – 0.040 (0.0008 – 0.0016) Conrod big end oil clearance Limit mm (in)
  • Page 279 DF25/30 “K3” (2003) MODEL 12-11 Data Item Unit DF25Q/25QE DF25T DF30Q/30QE DF30T ELECTRICAL Degrees at r/min BTDC 5° – 31° BTDC 5° – 29° Ignition timing r/min 6300 Over revolution limiter 6500 Ω 148 – 222 [R – B, W/B – R/W] CKP sensor resistance at 20°C Ω...
  • Page 280 12-12 DF25/30 “K3” (2003) MODEL PTT MOTOR (Applicable model) mm (in) 9.8 (0.39) Brush length Limit mm (in) 4.8 (0.19) 19.5 (0.77) mm (in) Commutator outside diameter Limit 18.5 (0.73) mm (in) PEAK VOLTAGE Requirements for peak voltage measurement • Remove all spark plugs to eliminate the variables at cranking speed. •...

  • Page 281: Engine Control And Electrical

    DF25/30 “K3” (2003) MODEL 12-13 ENGINE CONTROL AND ELECTRICAL I.D.mark IGNITION COIL The ignition coil has been changed in secondary coil resistance. Early : None 09930-99320 : Digital tester Tester range : (Resistance) Late : S12 Secondary side 1. Remove spark plug cap from high tension cord. 2.
  • Page 282 12-14 DF25/30 “K3” (2003) MODEL EMERGENCY STOP SWITCH AND STARTER SWITCH Emergency stop switch (Q and QE models) Emergency stop switch (with engine stop button) and starter switch have been changed in length of lead wire. In relation to this modification, clamps have been added and wire routing has been changed.

  • Page 283: Wire Routing

    DF25/30 “K3” (2003) MODEL 12-15 WIRE ROUTING DF25Q/DF30Q, DF25QE/DF30QE Starter switch Emergency stop & engine stop switch (QE model only) Clamp: Fix wire(s) with clamp. Emergency stop & engine stop switch Starter switch (QE model only) Slack off wire(s) around 30 mm. Clamp VIEW X...
  • Page 284 Prepared by Marine & Power Products Division 3rd Ed. October, 2002 1st Ed. October, 1999 Manual No. 99500-89J02-01E Printed in Japan...
  • Page 285 Printed in Japan Y K3...

This manual is also suitable for:

Df 30

Table of Contents