Suzuki DF200, DF225, DF250 Outboard Motor Service Manual
The Suzuki DF200, DF225, DF250 Outboard Motors are high-performance, four-stroke outboards designed for a variety of boating applications. These motors feature a variety of advanced technologies, including a lightweight and compact design, a powerful and fuel-efficient engine, and a smooth and quiet operation. The DF200, DF225, DF250 are also equipped with a number of safety features, including a tilt limit switch, a manual release valve, and a thermal expansion relief valve.
PDF
Download
Document
Advertisement
Advertisement
MID UNIT 7-1 MID UNIT CONTENTS ENGINE SIDE COVER ....................................................................................7- 2 REMOVAL ..............................................................................................7- 2 INSTALLATION ......................................................................................7- 2 DRIVESHAFT HOUSING AND OIL PAN ........................................................7- 3 REMOVAL ..............................................................................................7- 3 INSPECTION ..........................................................................................7- 8 ASSEMBLY ............................................................................................7-10 SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET .........7-17 REMOVAL ..............................................................................................7-17 INSPECTION ..........................................................................................7-20 REASSEMBLY .......................................................................................7-21 WATER PRESSURE VALVE ..........................................................................7-26 REMOVAL ..............................................................................................7-26 INSPECTION ..........................................................................................7-26 INSTALLATION ......................................................................................7-26 6 7 1 7-2 MID UNIT ENGINE SIDE COVER REMOVAL Remove five (5) screws 1 and STBD side cover 2. Remove three (3) screws 3 and PORT side cover 4. Disconnect PTT switch lead connector. Remove eight (8) screws 5 and STBD/PORT oil pan covers 6/7. INSTALLATION Installation is reverse order of removal. 2 MID UNIT 7-3 DRIVESHAFT HOUSING AND OIL PAN REMOVAL Remove power unit. (See page 6-12 to 6-18.) Remove lower unit. (See page 9-2.) Remove the bolts securing harness clamp plates to engine holder, then remove the engine wiring harness 1. Remove E-ring 3 from clutch lever shaft 2. Remove two (2) bolts 5 and throttle lever holder 4. Remove screw and bonding wire 6 from driveshaft housing. 3 7-4 MID UNIT Remove STBD/PORT lower mount nuts 7 and lower mount bolts 8. Account for washers 9, dampers 0 and washer A. Remove eight (8) bolts C and the mount·oil seal cover B. Account for two (2) dowel pins. Remove thrust mount D. Remove STBD/PORT upper mount nuts E and washers. 4 MID UNIT 7-5 Remove driveshaft housing with oil pan. Remove three (3) bolts 1 and upper mount cover 2. Remove upper mounts 3, thrust stoppers 4, mount plate 5 and mount bolts 6. Remove four (4) exhaust tube bolts 7. 5 7-6 MID UNIT Remove twelve (12) bolts 8 and engine holder 9. Remove eight (8) bolts 1 and engine holder cover 2. Remove three (3) bolts 3 and oil strainer 4. Remove the exhaust tube 5. 6 MID UNIT 7-7 Remove the exhaust tube seal 6 from oil pan. Remove eight (8) bolts 1 and oil pan 2. Remove water tube 1. Remove bolts 2, lower mount cover 3 and lower mounts 4. 7 7-8 MID UNIT INSPECTION NOTE: If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced. ENGINE HOLDER • Inspect engine holder. Replace if cracked, damaged, or other abnormal condition. • Check water passage. If clogged or obstructed, clean water passage. • Visually check the clutch shaft bearing. Replace if pitted, noisy, rough or other abnormal condition. MOUNT·OIL SEAL COVER • Inspect mount·oil seal cover. Replace if cracked, damaged or other abnormal condition. • Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal condition. • Check condition of oil seal. Replace oil seal if nicked, cut, worn or other abnormal condition. NOTE: Install oil seal with lip (spring side) facing downward (oil pan side). OIL STRAINER • Inspect oil strainer. Replace if cracked, damaged or other abnormal condition. If clog or obstruction, clean oil strainer. • Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal condition. 8 MID UNIT 7-9 OIL PAN/DRIVESHAFT HOUSING Check oil pan, driveshaft housing. If cracks, defects or other damage is found, replace it. MOUNT • Check upper, lower and thrust mounts. If excessive wear, corrosion or other damage is found, replace mount. • Inspect mount cover. Replace if cracked, damaged or other abnormal condition. EXHAUST TUBE/SEAL • Inspect exhaust tube. Replace if cracked, damaged or other abnormal condition. • Check water passage. If clogged or obstructed, clean water passage. • Check exhaust passage. If clogged or obstructed, clean exhaust passage. • Check exhaust tube seal. If excessive wear or other damage is found, replace seal. 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. 9 7-10 MID UNIT ASSEMBLY Assembly is reverse order of removal with special attention to the following steps. 5 2 3 1 9 4 7 8 6 10 100 N·m (10 kg-m, 72 lb-ft) 15 14 11 12 13 16 1. Mount oil seal cover 2. Bolt 3. Bolt 4. Gasket 5. Oil seal 6. Upper mount cover 7. Bolt 8. Bolt 9. Upper thrust mount 10. Bolt 11. Mount plate 12. Thrust stopper 13. Upper mount 14. Washer 15. Nut 16. Gasket 17. Water indicator union 18. Engine holder 19. Oil seal 20. Water return seal 21. Water plug 22. Gasket 23. Engine holder cover 24. Bolt 25. Gasket 26. Pin 27. Pin 28. Bolt 29. Bolt 30. Bolt 31. Bolt 32. Bolt 33. O-ring 34. Oil strainer 22 20 30 18 21 24 28 26 23 25 19 27 17 28 29 31 28 32 33 34 10 MID UNIT 7-11 35 37 36 38 39 40 46 83 42 84 41 45 55 44 50 43 47 85 49 86 52 48 51 53 13 N·m (1.3 kg-m, 9.5 lb-ft) 54 57 58 56 60 59 62 63 61 100 N·m (10 kg-m, 72 lb-ft) 65 66 64 73 74 67 68 75 71 77 76 70 69 80 78 72 82 71 81 79 35. Exhaust tube gasket 36. Exhaust tube 37. Pin 38. Exhaust tube seal 39. Gasket 40. Oil level gauge 41. Oil level gauge guide 42. Bolt 43. Gasket 44. Exhaust pipe 45. Exhaust release pipe 46. Bolt 47. Oil pan 48. Bolt 49. Bolt 50. Pin 51. Bolt 52. Clamp 53. Gasket 54. Drain plug 55. O-ring 56. Union 57. Anode 58. O-ring 59. Anode cover 60. Bolt 61. Driveshaft housing 62. Bolt 63. Pin 64. Anode 65. Nut 66. Washer 67. Damper 68. Mount cover 69. Bolt 70. Lower mount 71. Washer 72. Lower mount bolt 73. Thrust mount 74. Lower mount bracket 75. Bonding wire 76. Screw 77. Bush 78. Snap ring 79. Extension case (Type_XX) 80. Bolt 81. Bolt 82. Pin 83. Bush 84. Water tube 85. Bush 86. Water tube spacer 11 7-12 MID UNIT LOWER MOUNT/MOUNT COVER • Install lower mount 1 and lower mount cover 2. Tighten mount cover bolts 3, pre-coated with thread lock, to specified torque. NOTE: Install the lower mount cover to driveshaft housing with arrow (→) mark facing forward. ! 99000-32050: THREAD LOCK “1342” " Lower mount cover bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft) OIL PAN TO DRIVESHAFT HOUSING • Install water tube 4. • Install two dowel pins 5 to driveshaft housing 6. Apply sealant to mating surfaces of driveshaft housing and oil pan. # 99000-31120: SUZUKI SILICONE SEAL • Install oil pan 7 to driveshaft housing 6, then tighten eight (8) bolts 8 securely. 12 MID UNIT 7-13 EXHAUST TUBE • Place exhaust tube seal 2 into oil pan, then install exhaust tube 1. ENGINE HOLDER TO OIL PAN • Apply engine oil to O-ring 1, then install O-ring to oil strainer 2. • Install oil strainer to engine holder, then tighten bolts securely. • Install two (2) dowel pins 3 and gasket 4 to oil pan. $ Do not re-use gasket. Always assemble with a new gasket. • Install two (2) dowel pins 5 and gasket 6 to exhaust tube 7. 13 7-14 MID UNIT • Install engine holder 8 to oil pan 9, then securely tighten it with engine holder bolts 0. • Install exhaust tube bolts A, then tighten four (4) exhaust tube bolts securely. UPPER MOUNT AND MOUNT COVER • Assemble these items in the following sequence: Place upper mount plate 3, thrust stopper plates 2 and upper mounts 1 on upper mount bolts 4. • Place upper mount assembly and upper mount cover 5 into position. • Tighten upper mount cover bolts, pre-coated with thread lock, to specified torque. ! 99000-32050: THREAD LOCK “1342” " Upper mount cover bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft) 14 MID UNIT 7-15 DRIVESHAFT HOUSING/OIL PAN • Install driveshaft housing/oil pan to steering bracket. • Install washer 1 and upper mount nut 2, then tighten two (2) nuts, pre-coated with thread lock, to specified torque. ! 99000-32050: THREAD LOCK “1342” " Upper mount nut: 100 N·m (10.0 kg-m, 72.3 lb-ft) LOWER MOUNT BOLT/NUT • Place washer 1, dampers 2 and washer 3 into driveshaft housing. • Install lower mount bolt 5, washer 4 and nut 6, then tighten nut, pre-coated with thread lock, to specified torque. ! 99000-32050: THREAD LOCK “1342” " Lower mount bolt/nut: 100 N·m (10.0 kg-m, 72.3 lb-ft) MOUNT·OIL SEAL COVER • Install thrust mount 1. • Apply Water Resistant Grease to oil seal. % 99000-25160: SUZUKI WATER RESISTANT GREASE • Install dowel pins 2, gasket 3 and mount·oil seal cover 4, then tighten eight (8) cover bolts securely. 15 7-16 MID UNIT BONDING WIRE Reattach bonding wire to driveshaft housing and tighten screw securely. THROTTLE LEVER HOLDER • Install throttle lever holder 1 to engine holder, then tighten two (2) bolts 2 securely. • Install clutch lever shaft 3 and E-ring 4. POWER UNIT Install power unit. (See page 6-18 to 6-22.) Tighten power unit mounting bolts and engine holder bolts to specified torque. " Power unit mounting bolt & Engine holder bolt: 8 mm 23 N·m (2.3 kg-m, 16.5lb-ft) 10 mm 50 N·m (5.0 kg-m, 36.0 lb-ft) 16 MID UNIT 7-17 SWIVEL BRACKET, STEERING BRACKET AND CLAMP BRACKET REMOVAL Remove driveshaft housing/oil pan. (See page 7-3.) Remove screw and bonding wire from lower mount bracket. Remove circlip 1. Remove lower mount bracket 2, shims 3 and washer 4 from the steering shaft. Lift steering bracket 5 upward to remove from swivel bracket. Remove washer 6 and upper bushing 7. Remove swivel bracket seal 8 and lower bushing 9. Remove two (2) bolts 0 and tilt limit switch A. 17 7-18 MID UNIT Remove tilt limit switch cam B. NOTE: Unfasten three (3) stoppers a from the tilt limit switch cam to remove it from cam holder. Remove upper cam holder C and lower cam holder D from clamp bracket shaft. NOTE: Use thin flat screw-driver to release the two hooks to separate the cam holder upper and lower halves. Remove circlip E and push out tilt cylinder upper rod F. Remove bolts G and anode H. Remove nut I and tilt pin J. Remove bolts K securing PTT unit to the STBD and PORT clamp brackets. 18 MID UNIT 7-19 Using flat screw-driver, drive locking edge of lock washer 1 to clamp bracket side. Remove the two STBD motor mounting bolts 2. Remove the clamp bracket shaft nut 3 and washer. Slide STBD clamp bracket 4 off clamp bracket shaft, then remove PTT unit 5. Pull PORT clamp bracket 6 outward to remove clamp bracket and bracket shaft 8 from swivel bracket 7. Remove washer 9 and bushing 0 from each side of swivel bracket. 19 7-20 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. If excessive wear or other damage is found, replace seal. CLAMP BRACKET SHAFT Check clamp bracket shaft. If clamp bracket shaft is bent or twisted, replace shaft. BRACKET Check clamp brackets, steering bracket and swivel bracket. If cracks or other damage is found, replace bracket (s). 20 MID UNIT 7-21 REASSEMBLY Reassembly is reverse order of removal with special attention to the following steps. 10 4 43 N·m (4.3 kg-m, 31.0 lb-ft) 5 1 20 21 11 12 23 24 18 21 22 17 2 25 26 19 29 17 1. Clamp bracket STBD 2. Clamp bracket PORT 3. Clamp bracket shaft 4. Nut 5. Washer 6. Anode 7. Bolt 8. Tilt pin 9. Nut 10. Steering bracket 11. Washer 12. Bush 13. Oil seal 14. Shim 15. Lower mount bracket 16. Circlip 17. Bush 18. Washer 19. Grease nipple 20. Tilt lock lever 21. Bush 22. Spring 23. Bracket 24. Screw 25. Spring 26. Link 27. Tilt lock lever PORT 28. Nut 29. Washer 30. Pin 31. Bonding wire 32. Screw 18 30 27 28 3 32 31 12 13 11 14 8 9 15 31 6 7 32 16 21 7-22 MID UNIT CLAMP BRACKET AND SWIVEL BRACKET NOTE: Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings. % 99000-25160: SUZUKI WATER RESISTANT GREASE • Insert PORT and STBD bushings 2 into the swivel bracket 1. • Assemble port clamp bracket 3, washer 4, clamp bracket shaft 5 and swivel bracket 1. NOTE: For proper operation of the tilt limit device, install the clamp bracket shaft to the port clamp bracket so the red paint mark on the hex section and the cam holder location hole on the clamp bracket shaft are positioned as shown in the illustration. Red paint Location hole • Install PTT unit assembly 6. (For PTT unit assembly installation, see page 8-18 to 8-19.) • Install washer 7, STBD clamp bracket 8, lock washer 9 and clamp bracket shaft nut 0, then tighten clamp bracket shaft nut to specified torque. " Clamp bracket shaft nut: 43 N·m (4.3 kg-m, 31.0 lb-ft) • After tightening clamp bracket shaft nut with specific torque, bend lock washer edge toward nut for locking. 22 MID UNIT 7-23 • Tighten eight (8) PTT unit retaining bolts A, pre-coated with thread lock, to specified torque. ! 99000-32050: THREAD LOCK “1342” " PTT retaining bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft) TILT LIMIT DEVICE • Install the lower cam holder 1 engaging its locating pin a with the clamp bracket shaft hole b, then install the upper cam holder 2. • Install tilt limit switch cam 3. • Install tilt limit switch 4 and switch holder 5, then secure with bolts. 23 7-24 MID UNIT 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 and washer 2 to swivel bracket. • Install lower bushing 3 and swivel bracket seal 4 to swivel bracket. NOTE: Install seal 4 with lip (spring side) facing downward. • Install steering bracket 5 to swivel bracket. Seal lip LOWER MOUNT BRACKET • Install lower thrust mount 0 to lower mount bracket 8. • Install washer 6 and shim 7, and then slide the lower mount bracket 8 upward on the splines until it contacts the shim. • Install circlip 9 to retain bracket. 24 MID UNIT 7-25 BONDING WIRE Reattach bonding wire, tightening screw securely. LUBRICATION After completing reassembly of the mid unit, apply grease through each grease nipple. % 99000-25160: SUZUKI WATER RESISTANT GREASE 25 7-26 MID UNIT WATER PRESSURE VALVE REMOVAL • Remove oil pan cover. (See page 7-2.) • Remove two bolts 1, pressure valve cover 2 and water pressure valve 3. INSPECTION • If salt deposits, corrosion, wear or other damage is found, clean or replace. • Inspect O-ring. Replace if nicked, cut or torn. INSTALLATION • Install O-ring 1 to pressure valve cover. • Install pressure valve 2 and pressure valve cover 3 to oil pan and secure with bolts 4. 26 POWER TRIM AND TILT 8-1 POWER TRIM AND TILT CONTENTS SYSTEM WIRING DIAGRAM ..........................................................................8- 2 SERVICE PROCEDURE .................................................................................8- 3 OIL LEVEL .............................................................................................8- 3 AIR BLEEDING ......................................................................................8- 3 POWER TRIM AND TILT UNIT .......................................................................8- 4 REMOVAL ..............................................................................................8- 4 DISASSEMBLY ......................................................................................8- 5 CLEANING AND INSPECTING .............................................................8- 9 REASSEMBLY .......................................................................................8-10 PTT MOTOR ...........................................................................................8-14 REMOVAL........................................................................................8-14 DISASSEMBLY................................................................................8-14 INSPECTION....................................................................................8-15 ASSEMBLY......................................................................................8-16 INSTALLATION ...............................................................................8-17 INSTALLATION ......................................................................................8-18 PTT MOTOR RELAY .......................................................................................8-20 PTT SWITCH ...................................................................................................8-21 TILT LIMIT SWITCH ........................................................................................8-21 OPERATION ....................................................................................................8-22 COMPONENT PARTS ...........................................................................8-22 PRINCIPLES OF OPERATION ..............................................................8-22 6 6 8 27 8-2 POWER TRIM AND TILT SYSTEM WIRING DIAGRAM Starter motor 60 A Fuse R M PTT switch Battery P Tilt limit switch Lbl P Lbl P R G Bl PTT motor P PTT motor relay Lbl PTT switch Lbl W/R P Lbl W/R B To main relay Lbl W/R P Remote control box To ignition switch 28 POWER TRIM AND TILT 8-3 SERVICE PROCEDURE OIL LEVEL To check the PTT 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. 4. If oil can be seen at filler plug level, the unit is full. 5. If oil level is low, refill with the recommended oil. Recommended oil: Dexron automatic transmission fluid or equivalent ! To ensure consistent pump operation, do not mix different types of oil. 6. Reinstall oil filler plug. AIR BLEEDING 1. Check that the manual release valve is tightened to the specified torque. " Manual release valve: 3.5 N·m (0.36 kg-m, 2.6 lb-ft) ! Do not over-tighten manual release valve. Counterclockwise = Open Clockwise = Close ) Manual release valve 2. Operate the PTT switch, raising and lowering the motor up and down (full tilt position to full trim down position) 4 to 5 times. 3. Check oil level, topping off if necessary. 4. Reinstall oil filler plug. 29 8-4 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. Lower tilt rod to full down position and disconnect the battery cable. Disconnect the PTT motor cable wire connector from the PTT relay. Remove the PTT motor cable from engine lower cover. Remove the tilt pin 4. Remove two (2) bolts and anode 5. 30 POWER TRIM AND TILT 8-5 Remove the eight (8) bolts 6 securing PTT unit to STBD/PORT clamp bracket. Remove two STBD motor mounting bolts 7. Using flat screw driver, drive locking edge of lock washer 8 to clamp bracket side. Loosen the clamp bracket shaft nut 9. NOTE: Complete removal of the clamp bracket shaft nut is not required. Nut should be loosened as far as the end of the shaft threads only to facilitate removal of the PTT unit. Slide the STBD clamp bracket 0 fully outward to the right hand side. Remove the PTT unit A from between the clamp brackets. DISASSEMBLY NOTE: Before disassembly, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air. Place the lower of the PTT unit in a vise. Tighten the vise only enough to secure the PTT unit, DO NOT OVER TIGHTEN. NOTE: To prevent damage to the PTT cylinder use wood blocks, vise jaw protectors, etc., between the vise jaws and PTT components before tightening vise. 31 8-6 POWER TRIM AND TILT Connect the PTT cable extension to PTT motor cable connector. $ 09945-79310: PTT cable extension Connect the PTT cable extension leads (G, Bl) to battery and operate PTT motor until tilt piston rod is at maximum stroke. (full-tilt up position) Remove the PTT motor assembly 1. (See page 8-14.) Note the position of drive joint 3 and O-ring 2, before removing them. Unscrew the filler plug 4 and drain PTT oil into suitable container. Remove the two (2) screws 6 securing reservoir 5, then detach the reservoir from PTT manifold. Note the position of O-ring and remove it. Using special tool, unscrew the PTT cylinder head 7. $ 09944-09420: PTT cylinder cap tool Pull the tilt rod/piston assembly 8 out of the cylinder body. Remove the free piston 9 from the cylinder body. 32 POWER TRIM AND TILT 8-7 Disassembly of tilt rod/piston assembly Unscrew the piston retaining nut from the bottom of the tilt rod and remove the washer. Carefully retain and account for four shock valves, each composed of spring, rod and ball. Remove the piston assembly and PTT cylinder head from the tilt rod by sliding them down and off the rod end. Disassembly of trim rod/piston assembly Using special tool, unscrew the trim cylinder head 0. $ 09944-09420: PTT cylinder cap tool Pull the trim rod/piston assembly A out of the trim cylinder. NOTE: For PORT side trim cylinder: Be careful not to lose the trim chamber valve B on disassembly. Trim rod Trim cylinder head 33 8-8 POWER TRIM AND TILT Disassembly of tilt cylinder assembly Remove screw 1. Push the lower rod 2 out by tapping gently with a soft faced mallet. Detach the tilt cylinder 3 from PTT manifold. Note the position of three (3) O-rings and remove them from cylinder lower eyelet. Remove washer 4 from each side of tilt cylinder lower eyelet. PTT manifold Lower rod O-ring Tilt cylinder Remove three (3) O-rings from lower eyelet of PTT manifold. O-ring Remove the manual release valve snap ring 1, then unscrew the manual release valve 2. 34 POWER TRIM AND TILT 8-9 CLEANING AND INSPECTING Thoroughly wash all metal components with cleaning solvent and dry them with compressed air. Arrange all components on a clean sheet of paper. NOTE: Do not lay PTT components out on a rag, as dirt or lint may be transferred to these items which may cause possible system operating problems. Inspect tilt rod and trim rod, replace if damaged or bent. Inspect the surface of tilt rod and trim rod for scores, grooves or roughness. Slight roughness may be removed with fine emery paper. A badly scored or grooved rod must be replaced. Inspect the PTT cap seal and O-ring. Replace if cuts, nicks or excessive wear is found. NOTE: It is recommended that the O-ring always be replaced once the tilt/trim cylinder has been disassembled. Inspect the shock valves (spring, rod and ball). Replace if there are any signs of rust or pitting. Inspect the cylinder bore for evidence of a rough or grooved surface. Light honing may rectify slight surface roughness or scarring, but a deeply scarred surface will require replacement of the tilt cylinder. Inspect manual release valve for damage. Inspect manual release valve O-ring. Replace if nicked or cut. 35 8-10 POWER TRIM AND TILT Inspect lower rod. If a clog or obstruction is found, clean lower rod. If bending, cracks, corrosion or other damage is found, replace lower rod. Inspect upper shaft for bent, twist or other damage. Replace if necessary. Inspect all bushings for excessive wear or other damage. Replace if necessary. If bushing fit is loose when installing, replace bushing. REASSEMBLY Assembly is reverse order of disassembly with special attention to following steps. ! • Do not reuse O-rings after removal, always use new O-rings. • Lubricate all components and O-rings with PTT fluid before assembly. • Do not reuse PTT fluid, always refill with new fluid. TILT CYLINDER • Install three (3) O-rings 1 into the grooves in the tilt cylinder lower eyelet. POWER TRIM AND TILT • Install three (3) O-rings 2 into the grooves in the PTT manifold lower eyelet. • Place the tilt cylinder 3 and washer 4 in position, then slide the lower rod 5 through both PTT manifold lower eyelets and tilt cylinder lower eyelet. • Align threaded hole a on the PTT manifold with groove of lower rod, then tighten stopper screw 6 securely. TILT ROD When tightening the piston retaining nut on the tilt rod piston, apply Thread lock 1342 to the threads. Tighten the nut to specified torque. % 99000-32050: THREAD LOCK “1342” " Piston retaining nut: 100 N·m (10 kg-m, 72 lb-ft) Installing tilt rod/piston Pour 100 ml (3.4 oz.) of PTT fluid into cylinder. Insert the free piston into cylinder and push it down to the bottom of the cylinder. Pour PTT fluid into the cylinder until it is topped off. Insert the tilt rod/piston into cylinder and thread the tilt cylinder head by hand until fully seated. Free piston Top OFF Cylinder 8-11 8-12 POWER TRIM AND TILT Tighten the cylinder head to specified torque using special tool. " Tilt cylinder head: 160 N·m (16 kg-m, 115.7 lb-ft) $ 09944-09420: PTT cylinder cap tool TRIM ROD NOTE: For PORT side trim cylinder: Before installing trim rod/piston, make sure of trim chamber valve positioned correctly. Trim rod Trim chamber valve Trim cylinder head Pour PTT fluid into the trim cylinder until it is topped off. Insert the trim rod/piston assembly into cylinder and thread the trim cylinder head by hand until fully seated. Tighten the trim cylinder head to specified torque using special tool. " Trim cylinder head: 130 N·m (13 kg-m, 94 lb-ft) $ 09944-09420: PTT cylinder cap tool MANUAL RELEASE VALVE Oil and install the manual release valve 1. Tighten the valve to specified torque. Install snap ring 2. " Manual release valve: 3.5 N·m (0.36 kg-m, 2.6 lb-ft) PTT MOTOR See the PTT motor installation section on page 8-17. RESERVOIR Install O-ring 1 and reservoir 2, then tighten screws to specified torque. Pour recommended PTT fluid into reservoir until specified level. " Reservoir screw: 5 N·m (0.5 kg-m, 3.5 lb-ft) Upper edge POWER TRIM AND TILT AIR BLEEDING (Air bleeding on unit as alone) Before installing the PTT unit on the outboard motor, use the following procedure to bleed air from the system. 1. Support the PTT unit in an upright position in a vise. 2. Fill the reservoir with PTT oil to the specified level, then install oil filler plug. 3. Tighten the manual release valve to the specified torque. 4. Connect the PTT cable extension to the PTT motor cable connector. $ 09945-79310: PTT cable extension 5. Connect the two extension cable lead wires (Bl to pos./G to neg.) to the battery as shown in the illustration. Operate the PTT motor until the PTT rod is in the fully trimmed down position (completely contracted). If the rod does not come down smoothly, push it in by hand while operating the motor. 6. Reverse the two extension cable lead wires (G to pos./Bl to neg.). Operate the PTT motor until the PTT rod is in the full tilt up position (fully extended) If the rod does not come up smoothly, pull it up by hand while operating the motor. 7. Remove the reservoir oil filler plug and fill with PTT fluid to the specified level. 8. Repeat procedures 5 – 7 until the fluid level in the PTT unit stabilizes at the specified position. NOTE: Repeat the air bleeding procedure after the PTT unit has been installed on the outboard motor. (For air bleeding, see page 8-3.) Oil level (when full-tilted position) 8-13 8-14 POWER TRIM AND TILT PTT MOTOR REMOVAL NOTE: Before removing PTT motor, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt and dry the PTT body with compressed air. Place the lower of the PTT unit in a vise. Tighten the vise only enough to secure the PTT unit, DO NOT OVER TIGHTEN. PTT motor NOTE: To prevent damage to the PTT cylinder use wood blocks, vise jaw protectors, etc., between the vise jaws and PTT components before tightening vise. Remove the four (4) screws securing the PTT motor to the PTT manifold. Detach the PTT motor from PTT manifold. Note the position of drive joint 1 and O-ring 2 and remove them. PTT MOTOR DISASSEMBLY For correct assembly, scribe an alignment mark on the field case and brush holder. Slide cable protector tube upward. Remove the screw securing the motor cable holder 1, then slide motor cable holder and grommets 2 out as shown in figure. Remove the two (2) screws 3 securing the field case to the brush holder. Protector tube POWER TRIM AND TILT Slide the field case upward and away from the brush holder. NOTE: When separating field case from brush holder, push the PTT motor cables into brush holder as the field case is removed. Disconnect PTT motor cables from brush holder. Remove armature from field case. Note the position of the O-ring encircling the brush holder. 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 adjacent commutator segments. Replace armature if no continuity is indicated. Inspect the commutator surface. If surface is gummy or dirty, clean with 400 grit emery paper. Measure commutator outside diameter. $ 09900-20101: Vernier calipers Commutator outside diameter: Standard 22 mm (0.87 in) Service limit 21 mm (0.83 in) If measurement exceeds service limit, replace armature. 8-15 8-16 POWER TRIM AND TILT Ensure that the mica (insulator) between commutator segments is undercut to specified depth. SEGMENT Commutator undercut: Standard 1.6 – 1.9 mm (0.06 – 0.07 in) Service limit 1.0 mm (0.04 in) If undercut is less than service limit, cut to specified depth. NOTE: Remove all particles of mica and metal using compressed air. MICA Commutator undercut # Wear safety grasses when using compressed air. Brushes Check the length of each brush. $ 09900-20101: Vernier calipers Brush length: Standard 9.8 mm (0.39 in) Service limit 5.0 mm (0.20 in) If brushes are worn down to the service limit, they must be replaced. O-Ring Inspect the O-ring between the PTT motor and PTT manifold. Replace if cuts, nicks or tears are found. ASSEMBLY Assembly is reverse of disassembly with special attention to following steps. • Install armature to brush holder first. When installing the armature, use care to avoid breaking the brushes. • Match up previously scribed alignment marks. • When assembling field case to brush holder, pull out on the PTT motor cables at the field case is assembled into position. O-ring POWER TRIM AND TILT 8-17 • Apply silicone seal to PTT motor cable holder and grommets and install cable holder screw. PTT MOTOR INSTALLATION Installation is reverse of removal with special attention to following steps. • Ensure that the drive joint 1 is aligned and firmly inserted into the gear pump assembly. • Fit O-ring 2 to PTT motor. • Check the level of PTT fluid contained in the PTT manifold. If level is low, add recommended PTT fluid until level with mating surface of PTT motor. • Ensure that the faces of the PTT motor and pump unit are free of dirt or debris. When attaching the PTT motor to the PTT manifold, ensure that the tip of armature shaft fits firmly into the drive joint 1. Armature shaft • Tighten the four (4) screws to specified torque. " PTT motor screw: 5 N·m (0.5 kg-m, 3.6 lb-ft) • Pour recommended PTT fluid into reservoir until specified level. • Perform the air bleeding procedure. For air bleeding, see page 8-13. PTT motor 8-18 POWER TRIM AND TILT INSTALLATION Installation is reverse order of removal with special attention to the following steps. Lower tilt rod to full down position. Place the PTT unit in position between the clamp brackets. Tighten the clamp bracket shaft nut 1 to specified torque. " Clamp bracket shaft nut: 43 N·m (4.3 kg-m , 31.0 lb-ft) NOTE: After tightening clamp bracket shaft nut with specific torque, bend lock washer edge a toward nut for locking. Tighten eight (8) PTT unit retaining bolts 2, pre-coated with thread lock, to specified torque. % 99000-32050: THREAD LOCK “1342” " PTT unit retaining bolt: 50 N·m (5.0 kg-m, 36.0 lb-ft) Install anode 3, then tighten bolts securely. POWER TRIM AND TILT Apply Water Resistant Grease to tilt rod upper bushes 4, then install bushes in tilt rod. Operate the PTT motor to extend the PTT rod upward. Align the tilt rod with the hole in the swivel bracket as the tilt rod extends. ( 99000-25160: SUZUKI WATER RESISTANT GREASE Apply Water Resistant Grease to the PTT rod upper shaft 5, then insert the shaft through the swivel bracket and tilt rod. ( 99000-25160: SUZUKI WATER RESISTANT GREASE Secure the upper shaft with the snap ring 6. Route the PTT motor cable in through the lower cover and connect the PTT cable connector to the PTT relay. (Cable routing – See the WIRE/HOSE ROUTING section on page x-xx to x-xx.) 8-19 8-20 POWER TRIM AND TILT PTT MOTOR RELAY INSPECTION 1. Disconnect battery cable from battery. 2. Disconnect all cables/lead wires from PTT relay. 3. Check resistance between each two (2) lead wires. $ 09930-99320: Digital tester ) Tester range: Ω (Resistance) Between “P” wire and “B” wire: 25 – 37 Ω Between “Lbl” wire and “B” wire: 25 – 37 Ω 4. Connect “R” wire to positive + terminal, and black wire to negative - terminal of 12 V battery. Lbl P R B ! Bl Each operation test must be performed within 3 – 5 seconds to avoid overheat damage to the relay coil. 5. Temporarily connect a jumper wire from the “P” lead wire to the battery positive + terminal, then check voltage between “G” wire and “B” wire. G 1. Jumper wire $ 09930-99320: Digital tester * Tester range: DCV Between “G” wire and “B” wire: 12 V (Battery voltage) 6. Temporarily connect a jumper wire from the “Lbl” lead wire to the battery positive + terminal, then check voltage between “Bl” wire and “B” wire. Between “Bl” wire and “B” wire: 12 V (Battery voltage) 7. If inspection in step 3 and/or step 5, 6 fails, replace PTT relay. Lbl B P R 1 Bl BATTERY 12 V G POWER TRIM AND TILT 8-21 PTT SWITCH Test continuity between the switch lead wires at each of the three switch positions. (W/R) P Lbl $ 09930-99320: Digital tester & Tester range: ' (Continuity) Tester probe connection Red + Black • Red • Lg (with white tube) DN side depressed • Pink • White/Red • Lg (with white tube) UP side Light Blue depressed • White/Red • Red • Lg (with white tube) Not • Pink depressed Light Blue • White/Red Tester indicates Lg (W. tube) Continuity Lbl Continuity R Infinity TILT LIMIT SWITCH INSPECTION Test continuity between wires. If found defective, replace switch. Tilt limit switch $ 09930-99320: Digital tester & Tester range: ' (Continuity) Push the switch actuator plate. (Full tilt up position) Release the switch actuator plate. (Except for full tilt up position) No continuity Continuity Switch cam 8-22 POWER TRIM AND TILT OPERATION COMPONENT PARTS PTT motor Oil reservoir Gear pump Down shuttle valve Down check valve ! Up shuttle valve " Up check valve # Up relief valve $ Down relief valve % Thermal relief valve Manual release valve Tilt rod Check valve Trim chamber valve Trim rod Impact relief valve Trim cylinder Free piston * When the manual valve is to be opened, turn the manual release valve to the left about three (3) turns. * When the oil level of the system should be checked, inspect the reservoir by placing the motor in the full tilt up position. PRINCIPLES OF OPERATION By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will change its direction, and this causes up and down movements of the piston rod of the tilt cylinder and the trim rod of the trim cylinder. POWER TRIM AND TILT 8-23 TRIM & TILT UP (1) When the PTT switch is operated in the “UP” position, the motor and gear pump will rotate in a clockwise direction. (2) Pressurized oil will open “Up” check valve A and the oil will flow through “Up” shuttle valve B to the “Down” shuttle valve E. Following operation of valve E, “Down” check valve D will open mechanically. (3) Pressurized oil flows through the “Up” check valve A to the bottom of the trim and tilt cylinders, thereby pushing the trim and tilt pistons upward. (4) Residual oil in the upper area of the tilt cylinder H is returned to the geared pump through “Down” check valve D. (5) Any oil in the area above both trim cylinder pistons will be returned to the reservoir and to the geared pump through the check valve F. (6) Oil will then flow from the reservoir to the geared pump to stabilize the balance of the oil volumes. (7) When the engine is fully tilted up, oil pressure will correspondingly increase in the lower chamber of the tilt and trim cylinders. But, to protect the PTT unit from excessively high pump pressure, the “Up” relief valve G begins to open. 8-24 POWER TRIM AND TILT TILT DOWN & TRIM IN (1) When the PTT switch is operated in the “DOWN” position, the motor and gear pump will rotate in a counterclockwise direction. (2) The oil pressure will open the “Down” check valve D and oil will be forced through the “Down” shuttle valve E. When the oil reaches “Up” shuttle valve B, the “Up” check valve A will begin to open mechanically. (3) The pressurized oil flows through “Down” check valve D and then enters the upper area of the tilt cylinder. This thereby forces the tilt rod piston downward. (4) When the swivel bracket contacts the trim rams, the check valve F will begin to open, oil flows into the upper area in the trim cylinder. This pressure forces the trim pistons downward. (5) Oil from the lower area of the trim and tilt cylinders now returns to the pump through “Up” check valve A. (6) Throughout the tilt action operation range, there is a difference in oil volume between the upper and lower chambers of the tilt cylinder, and any surplus oil is therefore directed to the reservoir by means of the “Down” relief valve J. (7) Throughout trim operation range, oil will be discharged from the bottom of all three cylinders and the pump will supply oil to the upper chamber of the tilt and trim cylinders. Excess oil is then vented to the reservoir through the “Down” relief valve J. (8) To prevent damage from excessive oil pressure when all three rods are fully retraced, this pressure is relieved through the “Down” relief valve J. POWER TRIM AND TILT 8-25 TILT SYSTEM PRESSURE RELIEF (1) If engine speed exceeds approx. 1500 RPM when operating in shallow water drive mode, oil pressure will increase underneath the tilt piston. The relief valve C (incorporated in the manual release valve K) will then open. (2) The oil below the tilt piston will then flow to the reservoir through the relief valve C. (3) As the power of the engine continues to exert downward force on the tilt piston, this will open “Down” check valve D, thereby allowing oil from the reservoir to flow into the chamber above the tilt piston. (4) In this way, high internal pressure is relieved and the engine will slowly tilt downward until it reaches the highest position in the Trim range. THERMAL EXPANSION RELIEF (1) High ambient temperature will, through thermal expansion, induce a build-up of oil pressure inside the PTT unit. (2) Expansion of the oil and the resulting high pressure will open the relief valve C, thereby providing unit protection by directing oil back to the reservoir. Expanded oil in the tilt cylinder upper chamber will return to reservoir passing through impact relief valve L+ free piston check valve M+ thermal relief valve C. Tilt relief Thermal relief 8-26 POWER TRIM AND TILT SHOCK ABSORBER CIRCUIT This incorporated safety feature is for protection of the gearcase and prevention of internal PTT pressure build-up in the event of an impact. (1) The pressure from a sudden impact will make impact relief valve L open, allowing oil from the upper area of the tilt cylinder to flow into the area between the tilt rod piston and the free piston. The tilt rod will then extend. (2) When the moment of impact has passed, the PTT DOWN switch must be activated to return the engine to within the normal trim range. When the switch is pressed, the oil between the piston and free piston will be directed to the cylinder upper chamber via the return valve N below the tilt piston. POWER TRIM AND TILT 8-27 MANUAL RELEASE CIRCUIT (DOWN MODE) (1) By opening the manual release valve K, the engine can be lowered manually to a running position. Oil underneath the tilt piston will be directed through this valve into the area above the tilt rod piston. (2) The volume of oil flowing from under the tilt rod piston will be larger than the area above the tilt rod piston can accommodate. Excess oil therefore returns through the manual release valve K to the reservoir. \ 8-28 POWER TRIM AND TILT MANUAL RELEASE CIRCUIT (UP MODE) (1) With the manual release valve K open, the engine can also be raised manually to the fully tilted position. (2) Oil from the upper chamber of the tilt cylinder will flow through valve K into the lower chamber of the cylinder. (3) The upward movement of the piston rod will increase the cylinder area beneath it, thereby allowing oil from the reservoir to flow into this area. ">

Public link updated
The public link to your chat has been updated.
Advertisement
Key features
- Lightweight and compact design
- Powerful and fuel-efficient engine
- Smooth and quiet operation
- Tilt limit switch
- Manual release valve
- Thermal expansion relief valve
Frequently asked questions
To check the PTT oil level, raise the engine to a full-tilt position, lower the manual tilt lock lever, remove the oil filler plug, check if oil can be seen at filler plug level, if oil level is low, refill with the recommended oil (Dexron automatic transmission fluid or equivalent).
Check that the manual release valve is tightened to the specified torque, operate the PTT switch, raising and lowering the motor up and down 4 to 5 times, check oil level, topping off if necessary, re-install oil filler plug.
Disconnect the battery cable, disconnect all cables/lead wires from the PTT relay, check resistance between each two lead wires, connect “R” wire to positive terminal, and black wire to negative terminal of 12 V battery, temporarily connect a jumper wire from the “P” lead wire to the battery positive terminal, then check voltage between “G” wire and “B” wire, temporarily connect a jumper wire from the “Lbl” lead wire to the battery positive terminal, then check voltage between “Bl” wire and “B” wire, if inspection in step 3 and/or step 5, 6 fails, replace PTT relay.