Suzuki DF70A, DF80A, DF90A Service Manual
Suzuki DF80A is a reliable and powerful outboard motor that is perfect for a variety of boating applications. With its 80 horsepower, it provides plenty of power for getting your boat on plane quickly and easily. It also features a number of advanced features that make it easy to operate and maintain.
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99500-87L00-01E DF70A/80A/90A Service Manual Cover for PS printing (13mm) 5/0 2008/10/29
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IMPORTANT NOTICE
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 messages highlighted by these signal words.
!
WARNING
Indicates a potential hazard that could result in death or injury.
CAUTION
Indicates a potential hazard that could result in motor damage.
NOTE:
Indicates special information to make maintenance easier or instructions clearer.
Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the
!
WARNING
and
CAUTION
stated, you must also use good judgment and observe basic mechanical safety principles.
!
WARNING
This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only.
Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers.
FOREWORD
This manual contains an introductory description of the SUZUKI DF70/80/90 Outboard motors and procedures for inspection, service and overhaul of their main components.
General knowledge information is not included.
Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.
This manual will help you better understand these outboard motors, assisting you in providing your customers with optimum and quick service.
* This manual has been prepared using the latest information available at the time of publication. Differences may exist between the content of this manual and the actual outboard motor.
* Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the actual outboard motor in exact detail.
* This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service
Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Outboard motor dealer.
NOTE:
This manual is compiled based on 2009 (K9) model.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2008
TABLE OF CONTENTS
Precautions............................................................... 00-i
Precautions ............................................................ 00-1
General Information ................................................... 0-i
General Information ............................................... 0A-1
Maintenance and Tune-Up..................................... 0B-1
Power Head................................................................. 1-i
Precautions .............................................................. 1-1
Engine General Information and Diagnosis ........... 1A-1
Engine Electrical Devices.......................................1C-1
Power Unit Mechanical ..........................................1D-1
Power Unit Lubrication ........................................... 1E-1
Power Unit Cooling System ................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1
Housing and Bracket.............................................. 2A-1
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Right Hand Rotation Unit ....................................... 3A-1
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1
Fuel / Water Hose Routing..................................... 4B-1
1
2
00
0
3
4
5
8
9
10
11
6
7
Section 00
Precautions
CONTENTS
Table of Contents 00- i
00
Precautions ...............................................00-1
Precautions........................................................... 00-1
General Precautions ........................................... 00-1
00-1 Precautions:
Precautions
Precautions
Precautions
General Precautions
!
WARNING
Z9J0110000002
• Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor.
• To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or doing other work, which could cause debris.
• When two or more persons work together, pay attention to the safety of each other.
• When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented outdoors.
• When testing an outboard motor in the water, ensure that the necessary safety equipment is on board.
Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first aid kit, emergency starter rope, etc.
• When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material manufacturer’s instructions.
• Never use gasoline as a cleaning solvent.
• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly after engine operation.
• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and moisture-proof gloves (such as latex gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil.
• After servicing the fuel, lubrication, cooling and/or the exhaust system, check all lines and fittings related to the system for leaks.
• Carefully adhere to the battery handling instructions laid out by the battery supplier.
Precautions: 00-2
CAUTION
• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.
• When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
• Be sure to use special tools where instructed.
• Make sure that all parts used in assembly are clean and also lubricated when specified.
• When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type.
• When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable.
• When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery.
• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter. Always tighten from inside to outside diagonally to the specified tightening torque.
• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips, and certain other parts as specified, always replace them with new. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.
• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.
• Use a torque wrench to tighten fasteners to the torque values when specified.
• Remove grease or oil from screw / bolt threads unless a lubricant is specified.
• After assembly, check parts for tightness and operation.
• To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries.
• To protect the Earth's natural resources, properly dispose of used motor parts.
00-3 Precautions:
Section 0
General Information
CONTENTS
Table of Contents 0- i
0
General Information ................................ 0A-1
General Description .............................................0A-1
Symbols .............................................................. 0A-1
Abbreviations ...................................................... 0A-1
Wire Color Symbols ............................................ 0A-2
Warning, Caution and Information Label
Locations........................................................... 0A-2
Genuine Parts Description .................................. 0A-3
Outboard Motor Identification Number
Location ............................................................ 0A-3
Fuel and Oil Recommendations.......................... 0A-3
Break-In Procedures ........................................... 0A-4
Propeller Selection Guide ................................... 0A-4
Battery Requirement ........................................... 0A-5
Powerhead Direction of Rotation Description ..... 0A-5
Specifications.......................................................0A-6
Specifications...................................................... 0A-6
Service Data ....................................................... 0A-8
Tightening Torque Specifications......................0A-13
Special Tools and Equipment ...........................0A-14
Recommended Service Material....................... 0A-14
Special Tool ......................................................0A-15
Maintenance and Tune-Up...................... 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 0B-1
General Description .............................................0B-1
Recommended Oil and Lubricants...................... 0B-1
Scheduled Maintenance ......................................0B-1
Periodic Maintenance Schedule Chart................0B-1
Lubrication Point .................................................0B-2
Service Instructions.............................................0B-3
Engine Oil Level Check.......................................0B-3
Engine Oil Change and Engine Oil Filter
Replacement .....................................................0B-3
Gear Oil Change .................................................0B-6
Spark Plug Removal and Installation ..................0B-6
Spark Plug Inspection and Cleaning ...................0B-7
Tappet Clearance Inspection and Adjustment ....0B-8
Idle Speed and Idle Air Control (IAC) Duty
Inspection........................................................0B-13
Ignition Timing Inspection .................................0B-13
Breather Line and Fuel Line Inspection ............0B-14
Low Pressure Fuel Filter Inspection..................0B-15
High Pressure Fuel Filter Replacement ............0B-15
Water Pump and Water Pump Impeller
Inspection........................................................0B-16
Propeller / Propeller Nut and Cotter Pin
Inspection........................................................0B-16
Anodes Inspection.............................................0B-17
Bonding Wires Inspection .................................0B-18
Battery Inspection .............................................0B-18
Bolts and Nuts Inspection .................................0B-20
Oil Pressure Check ...........................................0B-20
Cylinder Compression Pressure Check ............0B-21
0A-1 General Information:
General Information
General Information
General Description
Symbols
Z9J0110101001
Listed in the table below are the symbols indicating instructions and other important information necessary for proper servicing.
Please note the definition for each symbol. You will find these symbols used throughout this manual.
Refer back to this table if you are not sure of any symbol (s) meanings.
Symbol Definition
Torque control required.
Data beside it indicates specified torque.
Apply oil.
Use engine oil unless otherwise specified.
Apply molybdenum oil solution.
(Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1)
Apply SUZUKI Outboard Motor Gear Oil.
Apply SUZUKI Super Grease A.
Apply SUZUKI Moly Paste.
99000-25140
Apply SUZUKI Water Resistant Grease.
Apply SUZUKI Bond 1207B.
Apply SUZUKI Silicone Seal.
Apply SUZUKI Thread Lock 1342.
Apply SUZUKI Thread Lock Super 1333B.
Use special tool.
Do not reuse.
Note on reassembly.
Use peak voltmeter Stevens CD-77.
Abbreviations
Z9J0110101002
Abbreviations used in this service manual are as follows:
A:
ATDC:
After Top Dead Center
AC:
Alternating Current
B:
BTDC:
Before Top Dead Center
C:
CKP Sensor:
Crankshaft Position sensor
CMP Sensor:
Camshaft Position sensor
CTP:
Close Throttle Position
D:
DC:
Direct Current
DOHC:
Double Over Head Camshaft
E:
ECM:
Engine Control Module
EX (Ex.):
Exhaust
F:
FP:
Fuel Pump
G:
GND:
Ground
I:
IAC:
Idle Air Control
IAT:
Intake Air Temperature
IG:
Ignition
Ign.:
Ignition
IN (In.):
Intake
L:
LPS:
Lever Position Sensor
M:
MAP:
Manifold Absolute Pressure
P:
PCV:
Positive Crankcase Ventilation
PORT:
Port
PTT:
Power Trim and Tilt
S:
SPS:
Shift Position Sensor
STBD:
Starboard
SIGP:
Start-In-Gear Protection
T:
TPS:
Throttle Position Sensor
General Information: 0A-2
Wire Color Symbols
Z9J0110101010
There are two kinds of colored wire used in this product.
One is single colored wire and the other is dual colored (striped) wire.
The single colored wire uses only one color symbol. example: B (Black).
The dual colored wire uses two color symbols. example: Bl/B.
The first symbol represents the base color of the wire and the second symbol represents the color of the stripe.
Example: Bl/B (Blue with Black stripe).
Wire color Wire color Symbol
B
Bl
Br
Dg
G
Gr
Lbl
Black
Blue
Brown
Dark green
Green
Gray
Light blue
Symbol
Lg
O
P
R
V
W
Y
Light green
Orange
Pink
Red
Violet
White
Yellow
B (Base Color)
Bl (Blue Color)
Black (Stripe Color)
Bl/B
I9J011010001-02
Warning, Caution and Information Label Locations
The figure shows main labels among others that are attached to outboard motor.
When servicing outboard motor, refer to WARNING / CAUTION instructions printed on labels.
If any WARNING / CAUTION label is found stained or damage, clean or replace it as necessary.
Do not reuse a label after it has been removed. Always use new label.
1
3
Z9J0110101011
1. Label, engine cover 2. Label, mag cover 3. Label S.I.G.P.
2
I9J011010004-02
0A-3 General Information:
Genuine Parts Description
Z9J0110101012
If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent.
They are precision-made to ensure high quality and correct fit.
Outboard Motor Identification Number Location
Z9J0110101013
Model, Pre-fix, Serial number
The Model, Pre-fix and Serial number of motor are stamped on a plate attached to the clamp bracket.
1. Identification number plate
Example
1
0 9 0 0 2 F
1
DF 90
I9J011010005-01
2 3
I9J011010002-03
1. Model
2. Pre-fix
3. Serial number
Engine Serial Number Location
A second engine serial number plate is pressed into a boss on the cylinder block.
Fuel and Oil Recommendations
Z9J0110101015
Gasoline
Suzuki highly recommends that you use alcohol-free unleaded 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 content may be used.
Allowable maximum blend of a single additive (not combination)
5% Methanol, 10% Ethanol, 15% MTBE
CAUTION
If leaded gasoline is used, engine damage may result. Use only unleaded gasoline.
Engine oil
Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil.
Suzuki recommends the use of a SAE 10 W – 40 NMMA certified oil.
If NMMA certified FC-W oil is not available, select a good quality 4-cycle motor oil from the following chart according to the average temperatures in your area.
API Classification
SG
SH
SJ
SL
SM
TEMP.
C
F
SAE Viscosity Grade
10W–40
10W–30
–20 –10
–4 14
0
32
10
50
20
68
30 40
86 104
I9J011010003-02
Gear oil
Suzuki recommends the use of SUZUKI Outboard Motor
Gear Oil. If it is not available, use SAE 90 hypoid gear oil which is rated GL-5 under the API classification system.
XXXXXX
1
1. Serial number plate
I9J011010012-02
Break-In Procedures
Z9J0110101016
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.
Break-in period
10 hours
Warm-up recommendation
Allow sufficient idling time (more than 5 minutes) for the engine to warm up after cold engine starting.
Throttle recommendation
NOTE
Avoid maintaining a constant engine speed for an extended period at any time during the engine break-in period by varying the throttle position occasionally.
First 2 hours
For the first 15 minutes, operate the engine in-gear at idling speed. During the remaining 1 hour and 45 minutes, operate the engine in-gear at less than 1/2
(half) throttle (3 000 r/min).
NOTE
The throttle may be briefly opened beyond the recommended setting to plane the boat, but must be reduced to the recommended setting immediately after planning.
Next 1 hour
Operate the engine in-gear at less than 3/4 (three - quarter) throttle (4 000 r/min).
Last 7 hours
Operate the engine in-gear at a desired engine speed.
However, do not operate continuously at full throttle for more than 5 minutes.
General Information: 0A-4
Propeller Selection Guide
Z9J0110101017
An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF70 / 80 / 90 models are shown below.
Recommended full throttle speed range
DF70 5 000 – 6 000 r/min
DF80
DF90
5 000 – 6 000 r/min
5 500 – 6 300 r/min
CAUTION
Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor.
If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified above.
Propeller size chart
Blade x Dia. (in.) x Pitch (in.)
3 x 14 x 13
3 x 13 and 7/8 x 15
3 x 13 and 3/4 x 17
3 x 13 and 3/4 x 19
3 x 13 and 3/4 x 21
3 x 13 and 3/4 x 23
3 x 13 and 1/2 x 15
3 x 14 x 17
3 x 14 x 19
3 x 14 x 21
3 x 14 x 23
0A-5 General Information:
Battery Requirement
Z9J0110101018
Suzuki recommends a 12 volt cranking type lead acid battery for the DF70A / 80A / 90A.
Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below.
NOTE
• The specifications listed below are the minimum battery rating requirements for starting the engine.
• Additional electrical loads from the boat will require larger capacity batteries.
• Dual-purpose (Cranking / Deep Cycle) batteries can be used if they meet the minimum specifications listed below
(MCA, CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or
Gel-Cell batteries is not recommended because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of similar age. When replacement is necessary, they should be replaced as a set.
• It is recommended that the battery be installed in an enclosed case.
• When connecting batteries, hexagon nuts must be used to secure battery leads to battery terminals.
Battery Specification
650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold
Cranking Amps (CCA)/SAE or 160 Reserve Capacity
(RC) Minutes/SAE or 12 V 100 AH
Powerhead Direction of Rotation Description
Z9J0110101019
This outboard motor is designed with a L.H. (left hand) rotation powerhead utilizing an offset crankshaft. This design has the advantage of reducing the size of the motor and keeping the overall motor’s weight closer to the boat transom and therefore closer to the boat C/G
(Center of Gravity).
Rotation of the driveshaft is accomplished through a crankshaft drive gear and a driveshaft driven gear.
These gears are located beneath the powerhead in the same oil bath location as the camshaft chain.
As the rotational direction of the driven gear will be opposite of the drive gear, a left hand rotation powerhead design was adopted to retain a conventional, standard rotation (right hand) propeller shaft output.
General Information: 0A-6
Specifications
Specifications
NOTE
These specifications are subject to change without notice.
Model Pre-fix
Item Unit
PRE-FIX
DF70AT
07002F
Z9J0110107001
Data
DF80AT
08001F
DF90AT
09002F
Dimensions and Weight
Item
Overall length (front to back)
Overall width (side to side)
Overall height
Weight (without engine oil)
Transom height
Unit
L
X
L
X mm (in.) mm (in.) mm (in.) mm (in.) kg (lbs) kg (lbs)
L mm (in. type)
X mm (in. type)
Performance
Item
Maximum output
Recommended operating range
Idle speed
Powerhead
Item
Engine type
Number of cylinders
Bore
Stroke
Total displacement
Compression ratio
Spark plug
Ignition system
Fuel supply system
Exhaust system
Cooling system
Lubrication system
Starting system
Throttle control
Fuel and Oil
Item
Fuel
Unit
kW (PS) r/min r/min mm (in.) mm (in.) cm 3
Unit
(cu. in)
: 1
NGK
Unit
DF70AT
DF70AT
51.5 (70)
5 000 – 6 000
DF70AT
Data
DF80AT
724 (28.5)
459 (18.1)
1 480 (58.2)
1 607 (63.3)
155 (341)
158 (348)
510 (20)
637 (25)
Data
DF80AT
58.8 (80)
5 000 – 6 000
600
±
50 (in-gear: Approx. 600)
Data
DF80AT
4-stroke DOHC
4
75 (2.95)
85 (3.35)
1 502 (91.6)
9.5
DF90AT
DF90AT
66.2 (90)
5 500 – 6 300
DF90AT
DCPR6E
Full-transistorized ignition
Multi-point sequential electronic fuel injection
Through prop exhaust
Water cooled
Wet sump by trochoid pump
Electric
Remote control
DF70AT
Data
DF80AT DF90AT
Suzuki highly recommends the use of alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R/2+M/2 method) or 91
(Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.
0A-7 General Information:
Engine oil
Engine oil amounts
Gear oil
Gearcase oil capacity
Bracket
Item
Trim angle
Number of trim position
Maximum tilt angle
Propeller
Item Unit
L (US/lmp. qt) ml (US/lmp. oz)
Unit
degree degree
Lower unit
Item Unit
Reversing system
Transmission
Reduction system
Gear ratio
Drive line impact protection
Propeller shaft rotation (when shift into forward)
DF70AT
Data
DF80AT DF90AT
• API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM
• Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
4.0 (4.2 / 3.5): Oil change only
4.3 (4.5 / 3.8): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API classification GL-5.
850 (28.7/30.0)
DF70AT
DF70AT
Data
DF80AT
0 – 20 (–6 to 14)
PTT system
75 (–6 to 69)
Data
DF80AT
Gear
Forward-Neutral-Reverse
Bevel gear
12 : 25 (2.08)
Spline drive rubber hub
Clockwise
Blade x Dia. (in.) x Pitch (in.)
3 x 14 x 13
3 x 13 and 7/8 x 15
3 x 13 and 3/4 x 17
3 x 13 and 3/4 x 19
3 x 13 and 3/4 x 21
3 x 13 and 3/4 x 23
3 x 13 and 1/2 x 15
3 x 14 x 17
3 x 14 x 19
3 x 14 x 21
3 x 14 x 23
DF90AT
DF90AT
Reduction system
Item Unit
1st reduction gear ratio
(Crankshaft drive gear: Driven gear)
2nd reduction gear ratio (Lower unit gear)
Total reduction gear ratio
DF70AT
Data
DF80AT
29 : 36 (1.24)
12 : 25 (2.08)
2.59 (36/29 x 25/12)
DF90AT
General Information: 0A-8
Service Data
NOTE
These service data are subject to change without notice.
Powerhead
Item
Recommended operating range
Idle speed
**Cylinder compression pressure
**Cylinder compression pressure max. difference between cylinders
**Engine oil pressure
Engine oil
Engine oil amounts
Thermostat operating temperature
Unit
r/min r/min kPa
(kgf/cm 2 , psi.) kPa
(kgf/cm 2 , psi.) kPa
(kgf/cm 2 , psi.)
L (US/lpm. qt)
°
C (
°
F)
DF70AT
Data
DF80AT DF90AT
5 000 – 6 000 5 000 – 6 000 5 500 – 6 300
600
±
50 (in-gear: Approx. 600)
1 200 – 1 800 (12 – 18, 171 – 256)
100 (1.0, 14)
Z9J0110107002
400 – 600 (4.0 – 6.0, 57 – 85) at 3 000 r/min
(at normal operating temp.)
• API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM
• Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
4.0 (4.2 / 3.5): Oil change only
4.3 (4.5 / 3.8): Oil filter change
58 – 62 (136 – 144)
**Figures shown are guidelines only, not absolute service limits.
Cylinder Head / Camshaft
Item
Cylinder head distortion
Manifold seating faces distortion
Cam height
Camshaft journal oil clearance
Camshaft journal (housing) inside diameter
Camshaft journal outside diameter
Camshaft runout
Cylinder head bore to tappet clearance
Tappet outer diameter
Cylinder head tappet bore
IN
EX
5th
Top,
2nd,
3rd,
4th
5th
Top,
2nd,
3rd,
4th,
5th
Top,
2nd,
3rd,
4th
Limit std.
Limit std.
Limit std.
Limit std.
Limit
Limit std.
Limit std.
std.
Limit
Limit std.
Limit std.
Limit std.
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
Unit
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
DF70AT
Data
DF80AT
0.03 (0.001)
0.10 (0.004)
DF90AT
38.620 – 38.780
(1.5205 – 1.5268)
39.620 – 39.780
(1.5598 – 1.5661)
41.120 – 41.280
(1.6189 – 1.6252)
38.520 (1.5165) 39.520 (1.5559) 41.020 (1.6150)
40.920 – 41.080
(1.6110 – 1.6173)
40.820 (1.6071)
0.045 – 0.087 (0.0018 – 0.0034)
0.120 (0.0047)
23.000 – 23.021 (0.9055 – 0.9063)
—
26.000 – 26.021 (1.0236 – 1.0244)
—
22.934 – 22.955 (0.9029 – 0.9037)
—
25.936 – 25.957 (1.0211 – 1.0291)
—
0.10 (0.004)
0.025 – 0.062 (1.0010 – 1.0024)
0.150 (0.0059)
27.959 – 27.975 (1.1007 – 1.1014)
28.000 – 28.021 (1.1024 – 1.1032)
0A-9 General Information:
Valve / Valve Guide
Item
Valve diameter
Tappet clearance
(Cold engine condition)
Valve seat angle
Valve guide to valve stem clearance
Valve guide inside diameter
Valve guide protrusion
Valve stem outside diameter
Valve stem deflection
Valve stem runout
Valve head radial runout
Valve head thickness
Valve seat contact width
Valve spring free length
Valve spring preload
Valve spring squareness
Unit
IN
EX
IN std.
EX std.
IN
EX
IN
EX std.
Limit std.
Limit
IN,
EX
IN,
EX
IN,
EX
IN,
EX std.
std.
IN std.
EX std.
IN Limit
EX Limit
Limit
Limit mm (in.) mm (in.) mm (in.) mm (in.)
—
— mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
IN
EX std.
Limit std.
Limit
IN std.
EX std.
std.
Limit mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) std.
N (kg, lbs)
Limit N (kg, lbs)
Limit mm (in.)
DF70AT
Data
DF80AT
27.5 (1.08)
22.9 (0.90)
0.23 – 0.27 (0.009 – 0.011)
0.30 – 0.34 (0.012 – 0.013)
30
°
, 45
°
, 60
°
15
°
, 45
°
DF90AT
0.020 – 0.047 (0.0008 – 0.0019)
0.070 (0.0028)
0.045 – 0.072 (0.0018 – 0.0028)
0.090 (0.0035)
5.500 – 5.512 (0.2165 – 0.2170)
10.8 – 11.6 (0.43 – 0.46)
5.465 – 5.480 (0.2152 – 0.2157)
5.440 – 5.455 (0.2142 – 0.2148)
0.14 (0.006)
0.18 (0.007)
0.05 (0.002)
0.08 (0.003)
0.75 (0.03)
0.5 (0.02)
0.95 (0.04)
0.7 (0.03)
1.1 – 1.3 (0.04 – 0.05)
1.1 – 1.3 (0.04 – 0.05)
33.1 (1.30)
31.8 (1.25)
95 – 111 (9.6 – 11.2, 21.1 – 24.6) at 28.5 mm (1.12 in)
87 (8.8, 19.4) at 28.5 mm (1.12 in)
2.0 (0.08)
Cylinder / Piston / Piston Ring
Item
Cylinder distortion
Piston to cylinder clearance
Limit std.
Limit std.
Cylinder bore
Cylinder measuring position
Piston skirt diameter
Piston measuring position
Cylinder bore wear std.
Piston ring end gap
Piston ring free end gap
Piston ring to groove clearance
Piston ring groove width
Piston ring thickness
Pin clearance in piston pin hole
Piston pin outside diameter
Piston pin hole diameter
Conrod small end bore
Limit std.
1st
Limit std.
2nd
Limit std.
1st
Limit std.
2nd
Limit std.
1st
Limit std.
2nd
Limit
1st std.
2nd std.
Oil std.
1st std.
2nd std.
std.
Limit
Pin clearance in conrod small end std.
Limit std.
Limit std.
Limit std.
Unit
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
General Information: 0A-10
DF70AT
Data
DF80AT DF90AT
0.03 (0.001)
0.020 – 0.040 (0.0008 – 0.0016)
0.100 (0.0039)
75.000 – 75.020 (2.9598 – 2.9535)
50 (1.969) from cylinder top surface
74.970 – 74.990 (2.9516 – 2.9524)
13 (0.512) from piston skirt end
0.10 (0.039)
0.15 – 0.30 (0.0059 – 0.0118)
0.70 (0.028)
0.30 – 0.45 (0.0118 – 0.0177)
1.00 (0.039)
Approx 9.9 (0.3898)
7.9 (0.3110)
Approx 9.7 (0.3819)
7.8 (0.3070)
0.030 – 0.070 (0.0012 – 0.0028)
0.12 (0.005)
0.020 – 0.060 (0.0008 – 0.0024)
0.10 (0.004)
1.02 – 1.04 (0.040 – 0.041)
1.21 – 1.23 (0.048 – 0.048)
2.01 – 2.03 (0.079 – 0.080)
0.97 – 0.99 (0.038 – 0.039)
1.17 – 1.19 (0.046 – 0.047)
0.006 – 0.019 (0.0002 – 0.0007)
0.005 (0.0019)
17.995 – 18.000 (0.7085 – 0.7087)
17.980 (0.7079)
18.006 – 18.014 (0.7089 – 0.7092)
18.030 (0.7098)
0.003 – 0.016 (0.0001 – 0.0006)
0.050 (0.0020)
18.003 – 18.011 (0.7088 – 0.7091)
0A-11 General Information:
Crankshaft / Conrod
Item
Conrod small end inside diameter
Conrod big end oil clearance
Conrod big end inside diameter
Crank pin outside diameter
Crank pin outside diameter difference (out-of-round and taper)
Conrod bearing thickness
Conrod big end side clearance
Conrod big end width
Crank pin width
Crankshaft center journal runout
Crankshaft journal oil clearance std.
std.
Limit std.
std.
Limit
Crankcase bearing holder inside diameter std.
Crankshaft journal outside diameter std.
Crankshaft journal outside diameter difference (out-of-round and taper)
Limit
Crankshaft bearing thickness std.
std.
Crankshaft thrust play
Limit
Crankshaft thrust bearing thickness std.
std.
std.
Limit std.
std.
Limit std.
Limit
Electrical
Item Unit
Ignition timing
Degrees at r/ min
Over revolution limiter
CKP sensor resistance
CMP sensor resistance
Ignition coil resistance
Battery charge coil resistance
Battery charge coil output (12 V)
Primary r/min
Ω
at 20
°
C
Ω
at 20
°
C
Ω
at 20
°
C
Secondary k
Ω
at 20
°
C
Ω
at 20
°
C
Watt
Standard spark plug
Type
Gap
NGK mm (in.)
Unit
mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.)
Fuse amp. rating A
Recommended battery capacity (12 V)
Fuel injector resistance
IAC valve resistance
IAT sensor / Cylinder temp. sensor / Ex. mani. temp. sensor (Thermistor characteristic)
ECM main relay coil resistance
Starter motor relay coil resistance
PTT motor relay coil resistance
Ah (kC)
Ω
at 20
°
C
Ω
at 20
°
C k
Ω
at 25
°
C
Ω
at 20
°
C
Ω
at 20
°
C
Ω
at 20
°
C
DF70AT
Data
DF80AT DF90AT
18.003 – 18.011 (0.7088 – 0.7091)
0.032 – 0.050 (0.0013 – 0.0020)
0.080 (0.0031)
45.000 – 45.018 (1.7717 – 1.7724)
41.982 – 42.000 (1.6528 – 1.6535)
0.010 (0.0004)
1.487 – 1.502 (0.0585 – 0.0591)
0.100 – 0.250 (0.0039 – 0.0098)
0.350 (0.0138)
21.950 – 22.000 (0.8642 – 0.8661)
22.100 – 22.200 (0.8071 – 0.8740)
0.04 (0.002)
0.016 – 0.032 (0.0006 – 0.0014)
0.056 (0.0022)
56.000 – 56.018 (2.2047 – 2.2054)
51.994 – 52.012 (2.0470 – 2.0477)
0.010 (0.0004)
1.992 – 2.008 (0.0784 – 0.0791)
0.11 – 0.31 (0.004 – 0.012)
0.35 (0.014)
2.47 – 2.52 (0.0972 – 0.0992)
DF70AT
BTDC 0 – 26
Data
DF80AT DF90AT
BTDC 0 – 27
6 200
168 – 252
—
—
—
0.10 – 0.30
324
DCPR6E
0.8 – 0.9 (0.031 – 0.035)
6 400
Main fuse: 40
Starter motor: 30
Ignition coil, Injector, ECM, Fuel pump: 30
PTT switch: 10
IAC: 10
100 (360) or larger
10 – 14
25 – 34
1.8 – 2.3
145 – 190
145 – 190
25 – 37
Starter Motor
Item
Max. continuous time of use
Motor output
Brush length
Commutator undercut
Commutator outside diameter
PTT Motor
Item
Brush length
Commutator outside diameter
Self-Diagnostic Code
0: OFF, 1: ON
Failed item
MAP sensor 1
Cylinder temp. sensor
IAT sensor
CKP sensor
CMP sensor
Air intake system
MAP sensor 2
Exhaust manifold temp. sensor
Fuel injector
Throttle position sensor
Shift position sensor
Neutral switch std.
Limit std.
Limit std.
Limit
Unit
Sec.
kW mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) std.
Limit std.
Limit
Unit
mm (in.) mm (in.) mm (in.) mm (in.)
4 – 2
2 – 4
2 – 2
3 – 2
Code
3 – 4
1 – 4
2 – 3
1 – 5
4 – 3
2 – 1
1 – 2
3 – 3
General Information: 0A-12
DF70AT
Data
DF80AT
30
1.4
16.0 (0.63)
12.0 (0.47)
0.5 – 0.8 (0.02 – 0.03)
0.2 (0.01)
29.0 (1.14)
28.0 (1.10)
DF90AT
DF70AT
Data
DF80AT
9.8 (0.39)
5.5 (0.22)
22.0 (0.87)
21.0 (0.83)
DF90AT
Lamp flashing pattern
1
0
MCODE00D34-0-01
1
0
MCODE00D14-0-01
1
0
MCODE00D23-0-01
1
0
MCODE00D42-0-01
1
0
MCODE00D24-0-01
1
0
MCODE00D22-0-01
1
0
MCODE00D32-0-01
1
0
MCODE00D15-0-01
1
0
MCODE00D43-0-01
1
0
MCODE00D21-0-01
1
0
MCODE00D12-0-01
1
0
MCODE00D33-0-01
Fail-safe system activating
YES
YES
YES
NO
NO
YES
NO
YES
NO
YES
YES
NO
0A-13 General Information:
Failed item
Trim sensor
Oil pressure switch
Rectifier/Regulator (Over-charging)
Tightening Torque Specifications
Important Fasteners
Item
Cylinder head cover bolt
Cylinder head bolt
Crankcase bolt
Conrod cap bolt
Camshaft housing bolt
Oil pump bolt
IN. camshaft timing sprocket
EX. camshaft timing sprocket
Chain tensioner adjuster bolt
Timing chain guide bolt
Intake manifold bolt / nut
Oil pressure switch
Fuel delivery pipe bolt
Fuel delivery pipe plug / union bolt
Low pressure fuel pump bolt
Thermostat cover bolt
Flywheel bolt
Starter motor mounting bolt
Engine oil filter
Engine oil drain plug
Power unit mounting bolt
Outside
Inside
Upper
Lower
Driveshaft housing bolt
Upper mount nut
Upper mount cover bolt
Lower mount bolt
Clamp bracket shaft nut
Water pump case bolt
Driveshaft oil seal housing
Gearcase bolt
Propeller shaft bearing housing bolt
Pinion gear nut
Propeller nut
8 mm
14 mm
14 mm
6 mm
6 mm
16 mm
8 mm
—
12 mm
8 mm
10 mm
10 mm
12 mm
10 mm
12 mm
7/8-14 UNF
Thread
Diameter
6 mm
8 mm
10 mm
8 mm
10 mm
9 mm
6 mm
6 mm
—
6 mm
6 mm
8 mm
8 mm
—
8 mm
8 mm
10 mm
8 mm
14 mm
18 mm
Code
3 – 7
5 – 3
1 – 1
50
60
43
17
23
50
50
80
23
55
23
120
55
196
23
14
13
35
35
10
10
23
23
13
23
15
78
11
11
N
⋅
m
11
23
70
25
52
47
11
Lamp flashing pattern
1
0
MCODE00D37-0-01
1
0
MCODE00D53-0-01
1
0
MCODE00D11-0-01
Fail-safe system activating
NO
NO
NO
Tightening Torque kgf-m
1.1
2.3
7.0
2.5
5.2
4.7
1.1
1.5
7.8
1.1
1.1
2.3
2.3
1.3
2.3
3.5
3.5
1.0
1.0
19.7
2.3
1.4
1.3
2.3
5.0
5.0
8.0
5.0
6.0
4.3
1.7
2.3
5.5
2.3
12.0
5.5
Z9J0110107003
16.5
36.0
36.0
57.8
36.0
43.4
31.0
12.3
25.5
25.5
7.0
7.0
142.0
16.6
10.0
9.5
16.5
40.0
16.6
86.8
40.0
11.0
56.0
8.0
8.0
16.6
16.5
9.5
16.5
lbf-ft
8.0
16.6
51.0
18.0
37.5
40.0
8.0
General Information: 0A-14
General Bolt
NOTE
These value are only applicable when torque for a general bolt is not listed in the “Important
Fasteners” table.
Type of Bolt
I9J011010014-01
(Conventional or “4” marked bolt)
Thread
Diameter
5 mm
6 mm
8 mm
10 mm
N
⋅
m
2 – 4
4 – 7
10 – 16
22 – 35
Tightening Torque kgf-m
0.2 – 0.4
0.4 – 0.7
1.0 – 1.6
2.2 – 3.5
lbf-ft
1.5 – 3.0
3.5 – 5.0
7.0 – 11.5
16.0 – 25.5
(Stainless steel bolt)
I9J011010015-01
5 mm
6 mm
8 mm
10 mm
2 – 4
6 – 10
15 – 20
34 – 41
0.2 – 0.4
0.6 – 1.0
1.5 – 2.0
3.4 – 4.1
1.5 – 3.0
4.5 – 7.0
11.0 – 14.5
24.5 – 29.5
(“7” marked bolt)
I9J011010016-01
5 mm
6 mm
8 mm
10 mm
3 – 6
8 – 12
18 – 28
40 – 60
0.3 – 0.6
0.8 – 1.2
1.8 – 2.8
4.0 – 6.0
2.0 – 4.5
6.0 – 8.5
13.0 – 20.0
29.0 – 43.5
Recommended Service Material
Special Tools and Equipment
Z9J0110108001
99000–22540
SUZUKI Outboard
Motor Gear Oil
99000–25161
SUZUKI Water
Resistant Grease (250 g)
99000–31120
SUZUKI Silicone Seal
(50 g)
99000–31140
SUZUKI Bond 1207B
(100 g)
99000–32020
SUZUKI Thread Lock
1333B (50 g)
99000–32050
SUZUKI Thread Lock
1342 (50 g)
99000–25140
SUZUKI Moly Paste
(50g)
0A-15 General Information:
Special Tool
Z9J0110108002
01500–08403
Bolt
09900–20101
Vernier calipers (150 mm)
09900–20202
Micrometer (25 – 50 mm)
09900–20203
Micrometer (50 – 75 mm)
09900–20205
Micrometer (0 – 25 mm)
09900–20605
Dial calipers (10 – 34 mm)
09900–20606
Dial gauge
09900–20701
Magnetic stand
09900–20803
Thickness gauge
09900–21304
Steel “V” block set
09900–22301
Plastigauge (0.025 –
0.076 mm)
09900–28403
Hydrometer
09911–49910
Crankshaft holder
09912–58432
Fuel pressure hose
09912–58442
Fuel pressure gauge
09912–58490
3-way joint & hose
09913–50121
Oil seal remover
09915–47341
Oil filter wrench
09915–64512
Compression gauge
09915–69910
Compression gauge attachment
09915–77311
Oil pressure gauge
09915–78211
Oil pressure gauge adapter
09916–10911
Valve lapper
09916–14521
Valve lifter attachment
09916–19030
Valve lifter
General Information: 0A-16
09916–34542
Valve guide reamer handle
09916–34550
Valve guide reamer (
φ
5.5 mm)
09916–37320
Valve guide reamer (
φ
10.5 mm)
09916–44310
Valve guide remover
09916–58210
Valve guide installer handle
09916–68710
Tappet holder
09916–77310
Piston ring compressor
09916–84511
Tweezers
09917–47011
Vacuum pump gauge
09917–49610
Vacuum pump adapter
09917–87010
Valve guide installer attachment
09917–98221
Valve guide stem seal installer attachment
09919–16010
Deep socket wrench
(10 mm)
09921–28710
Driveshaft holder
09922–89810
Shift lock pin remover
09923–73210
Bearing remover
09930–25002
Pocket tester
09930–30104
Sliding hammer
09930–30161
Propeller shaft remover
09930–39411
Flywheel remover
09930–39420
Flywheel remover bolts
09930–48720
Flywheel holder
09930–76420
Timing light
09930–88730
36-pin test cord set
09930–89220
3-pin connector test cord
0A-17 General Information:
09930–89260
Injector test cord (A)
09930–99320
Digital tester
09940–44121
Air pressure gauge
09940–44130
Attachment
09941–64511
Bearing remover
09945–69010
PTT rod holder
09945–79310
PTT cable extension
09950–69512
Gearcase oil leakage tester
09951–09530
Gear adjusting gauge
09951–18730
Attachment
09951–38710
Plate
09951–59910
Shaft (removal and installation)
09952–99310
Hand air pump
99954–53873*
Stevens peak reading voltmeter CD-77
99954–53008–820*
Digital voltmeter
99954–53883*
Gear oil filler
NOTE
* Marked part No. is in U.S. market only.
Maintenance and Tune-Up: 0B-1
General Information
Maintenance and Tune-Up
Precautions
Precautions for Maintenance
Z9J0110200001
The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy.
Maintenance intervals should be judged by number of hours or months, whichever comes first.
NOTE
More frequent servicing should be performed on outboard motors that are used under severe conditions.
General Description
Recommended Oil and Lubricants
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-3).
Z9J0110201001
Scheduled Maintenance
Periodic Maintenance Schedule Chart
Item to serviced
Spark plug
Breather hose and fuel line
Engine oil
Gear oil
Lubrication
Anodes and bonding wires
Battery
Engine oil filter
Low pressure fuel filter
High pressure fuel filter
Ignition timing
Idle speed
Tappet clearance
Water pump
Water pump impeller
Propeller nut and pin
Bolt and Nuts
Z9J0110205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace
Initial 20 hrs. or 1 month
—
I
R
R
—
—
—
R
—
Interval
Every 50 hrs. Every 100 hrs. or 3 months
—
or 6 months
I
I I
Replace every 2 years.
—
—
R
R
I
—
I
I
I
—
I
I
I I
Replace every 400 hours or 2 years.
Replace every 1000 hours.
— —
Every 200 hrs. or 12 months
R
I
R
R
I
I
I
R
I
—
I
T
—
I
—
—
—
—
—
—
—
—
—
—
—
—
I
T
R
I
T
I
I
I
I
0B-2 Maintenance and Tune-Up:
Lubrication Point
Z9J0110205002
Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor.
Apply Suzuki Water Resistant Grease to the following point.
Lubricate
Every 50 hours (3 months)
: Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g))
1
1
1
5
2 2
2
4
3
1. Throttle and shift linkage
2. Grease nipple, swivel bracket
3. Grease nipple, swivel bracket
4. Propeller shaft
5. Grease nipple, shift lever
I9J011020034-04
Maintenance and Tune-Up: 0B-3
Service Instructions
Engine Oil Level Check
Z9J0110206039
Inspect oil level
Before every use
1) Place outboard motor upright on a level surface.
2) Remove motor cover.
3) Remove oil level dipstick (1) and wipe it clean.
1
I9J011020002-02
4) Reinsert dipstick fully into dipstick tube, then remove it to check oil level.
5) Oil level should be between full level Max. mark
(hole) and low level Min. mark (hole).
If level is low, add recommended oil to full level Max. mark.
Recommended Engine Oil
• 4 stroke motor oil
• NMMA FC-W classification:
SG, SH, SJ, SL, SM.
or API classification:
SG, SH, SJ, SL, SM.
• Viscosity rating:
NMMA FC-W 10W-40 or SAE 10W-40
I9J011020036-01
Engine Oil Change and Engine Oil Filter
Replacement
Z9J0110206008
Change engine oil
Initially after 20 hours (1 month) and every 100 hours
(6 months)
Replace Engine oil filter
Initially after 20 hours (1 month) and every 200 hours
(12 months)
NOTE
• Engine oil should be changed while engine is warm.
• When replacing engine oil filter, change engine oil at the same time.
Engine Oil Change
1) Place outboard motor upright on a level surface.
2) Remove oil filler cap (1).
1
I9J011020037-01
“A”: Max. mark (hole)
“A”
“B”
“B”: Min. mark (hole)
I9J011020035-01
0B-4 Maintenance and Tune-Up:
3) Place a container under engine oil drain plug.
4) Remove engine oil drain plug (2) and gasket (3) to drain engine oil.
6) Pour the recommended engine oil into oil filler opening, then install oil filler cap.
Recommended Engine Oil
• 4 stroke motor oil
• NMMA FC-W classification:
SG, SH, SJ, SL, SM. or API classification:
SG, SH, SJ, SL, SM.
• Viscosity rating:
NMMA FC-W 10W-40 or SAE 10W-40
Engine oil amounts
Oil change only: 4.0 L (4.2/3.5 US/Imp.qt)
Oil filter change: 4.3 L (4.5/3.8 US/Imp.qt)
2 3
I9J011020038-01
5) Install new gasket and oil drain plug.
Tighten engine oil drain plug to specified torque.
CAUTION
To avoid water entry into oil pan or oil leakage into the environment do not reuse gasket once removed. Always use a new gasket.
Tightening torque
Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft)
(a)
I9J011020042-01
I9J011020039-01
7) To reset oil change reminder system’s operation time to zero (cancellation).
NOTE
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-14).
a) Turn ignition key to “ON” position.
b) Pull out emergency stop switch plate (4).
c) Pull up emergency stop switch knob (5) three times in ten seconds. A short beep will be heard if cancellation is successfully finished.
d) Turn ignition key to “OFF” position, then set emergency stop switch plate (4) in original position.
4
5
I9J011020003-01
8) Start engine and allow it to run for several minutes at idle speed.
Check oil drain plug for oil leakage.
Turn off engine and wait for approx. two minutes, then recheck engine oil level.
Engine Oil Filter Replacement
1) Drain engine oil in the same manner of engine oil change procedure.
2) Remove STBD and PORT side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
3) Place a shop cloth under the oil filter before removal to absorb any oil released.
4) Using an oil filter wrench to loosen the oil filter, then remove the filter and O-ring.
Special tool
(A): 09915–47341 (Oil filter wrench)
Maintenance and Tune-Up: 0B-5
6) Tighten the filter 3/4 turn from the point of contact with mounting surface using an oil filter wrench.
Tightening torque
Engine oil filter (a): 14 N·m (1.4 kgf-m, 10.0 lbf-ft)
(a)
(A)
I9J011020043-01
NOTE
Before fitting a new oil filter, be sure to oil the
O-ring.
I9J011020004-01
5) Screw the new filter on by hand until filter O-ring contacts the mounting surface.
7) Install PORT and STBD side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
I9J011020044-01
8) Pour the recommended engine oil into the oil filler opening, then install oil filler cap. Check the oil level in the same manner of engine oil change procedure.
Recommended Engine Oil
• 4 stroke motor oil
• NMMA FC-W classification:
SG, SH, SJ, SL, SM. or API classification: SG,
SH, SJ, SL, SM.
• Viscosity rating:
NMMA FC-W 10W-40 or SAE 10W-40
Engine oil amounts
Oil change only: 4.0 L (4.2/3.5 US/Imp.qt)
Oil filter change: 4.3 L (4.5/3.8 US/Imp.qt)
9) Reset oil change reminder system’s operation time
to zero (cancellation). Refer to “Engine Oil Change”
10) Start engine and allow it to run for several minutes at idle speed.
Check oil filter for oil leakage.
Turn off engine and wait for approx. two minutes, then recheck engine oil level.
0B-6 Maintenance and Tune-Up:
Gear Oil Change
Z9J0110206040
Change gear oil
Initially after 20 hours (1 month) and every 100 hours
(6 months)
1) Place outboard motor upright on a level surface.
2) Place a container under the lower unit.
3) Remove lower gear oil drain plug (1) first, then remove gear oil level plug (2) and drain gear oil.
2
1
I9J011020040-01
4) Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole.
Recommended Gear Oil
• Suzuki Outboard Motor Gear Oil or API classification GL5, Viscosity rating SAE # 90
Hypoid gear oil.
Gear oil amount
850 ml (28.7/30.0 US/Imp. oz)
Spark Plug Removal and Installation
Z9J0110206004
Inspect spark plug
Every 100 hours (6 months)
Replace spark plug
Every 200 hours (12 months)
Standard spark plug
NGK DCPR6E
CAUTION
Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition and fuel injection system malfunctions.
Removal
!
WARNING
The hot engine can burn you. Wait until the engine is cool enough to touch.
1) Disconnect wiring harness connector from ignition coil (1), then remove the bolt (2) securing the ignition coil.
2
1
5) Install oil level plug before removing oil filler tube from drain hole.
6) Install oil drain plug.
I9J011020041-01
CAUTION
Do not reuse gaskets once removed.
Always use a new gasket.
NOTE
To avoid a possible low gear oil level, recheck gear oil level 10 minutes after doing procedure in step 6. If oil level is low, add additional gear oil until level is correct.
2) Remove the ignition coil and spark plug.
I9J011020045-01
I9J011020046-01
Maintenance and Tune-Up: 0B-7
Installation
Installation is reverse order of removal.
Pay attention to the following:
• Tighten the spark plug to specified torque.
Tightening torque
Spark plug (a): 18 N·m (1.8 kgf-m, 13 lbf-ft)
(A)
(a)
I9J011020006-01
Spark Plug Gap
Measure spark plug gap with a thickness gauge. Adjust to within specified range if gap is out of specification.
Special tool
: 09900–20803 (Thickness gauge)
Spark plug gap “a” (Standard)
0.8 – 0.9 mm (0.031 – 0.035 in.)
I9J011020047-01
Spark Plug Inspection and Cleaning
Z9J0110206005
CAUTION
Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition and fuel injection system malfunctions.
Inspect spark plug
Every 100 hours (6 months)
Replace spark plug
Every 200 hours (12 months)
Standard spark plug
NGK DCPR6E
Carbon Deposits
Inspect for carbon deposits on spark plug base.
If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool.
“ a ”
I9J011020007-01
Condition of Electrodes
Inspect electrode for a worn or burnt condition.
If it is extremely worn or burnt, replace spark plug.
Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc.
CAUTION
Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage.
I9J011020005-01
0B-8 Maintenance and Tune-Up:
Tappet Clearance Inspection and Adjustment
Z9J0110206041
Inspect tappet clearance
Every 200 hours (12 months)
Inspection
The tappet clearance specification is different for intake and exhaust valves.
Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear.
When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. Using the proper tools provides for easy removal and installation of the shim disc.
Tappet clearance adjustment should be checked and adjusted:
• During scheduled periodic inspection.
• When valve mechanism is serviced.
• When camshafts are disturbed by removing them for inspection.
1) Remove following parts:
• Engine lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
• Ring gear cover.
Refer to “Ring Gear Cover Removal and
Installation” in Section 1D (Page 1D-2).
• Ignition coils and spark plugs.
Refer to “Spark Plug Removal and Installation”
(Page 0B-6) and “Spark Plug Inspection and
2) Remove the cylinder head cover (1).
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-2).
3) Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface.
4) Measure tappet clearances by inserting thickness gauge between cam and shim surface.
CAUTION
This is a left hand (LH) rotation powerhead.
Rotate crankshaft counterclockwise to prevent water pump impeller damage.
NOTE
• Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface.
• All tappet clearances can be measured during two crankshaft rotations.
Special tool
(A): 09900–20803 (Thickness gauge)
Tappet clearance (cold engine condition)
IN.: 0.23 – 0.27 mm (0.009 – 0.011 in.)
EX.: 0.30 – 0.34 mm (0.012 – 0.013 in.)
“ a ”
(A)
I9J011020008-01
“a”: 90
°
5) If out of specification, adjust tappet clearance by changing shim.
1
I9J011020048-01
Adjustment
Tappet clearances are adjusted by replacing tappet shim.
1) With cam nose vertical to valve, turn tappet cut-away towards center of cylinder head as shown in figure.
Maintenance and Tune-Up: 0B-9
4) Rotate top of cam 90 degree counterclockwise and remove shim from cut- away at tappet.
(Two tappets can be adjusted at the same time)
3
1
“B”
1
“A”
I9J011020009-01
1. Shim
“A”: Cut section of the tappet
“B”: Spark plug hole
2) Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced.
3) Install special tool with camshaft housing bolts as shown in figure.
Special tool
(A): 09916–68710 (Tappet holder)
2
“B”
I9J011020011-01
1. Shim
3. Magnet
CAUTION
• Do not put your finger between camshaft and tappet while the tappet is being held with the tappet holder.
• Use a magnet to remove and install shim.
• When installing shim, identification mark on the shim should face down (towards tappet).
5) After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula.
Special tool
(B): 09900–20205 (Micrometer (0 – 25 mm))
(A)
I9J011020010-01
2. Camshaft housing bolt
“B”: Spark plug hole
(B)
I9J011020012-01
Tappet clearance specifications
IN. side: A = B + (C – 0.25 mm)
EX. side: A = B + (C – 0.32 mm)
A: Correct thickness of shim for proper tappet clearance (mm)
B: Thickness of original shim (mm)
C: Original tappet clearance (mm)
0B-10 Maintenance and Tune-Up:
“C”
250
“ a ”
NOTE
After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again.
I9J011020013-01
“C”: I.D No.
“a”: 2.50 mm
Shim size chart
I.D. No.
Thickness
(mm)
208
210
2.080
2.100
212
214
216
218
2.120
2.140
2.160
2.180
220
222
224
226
228
230
232
234
2.200
2.220
2.240
2.260
2.280
2.300
2.320
2.340
236
238
240
242
244
246
248
2.360
2.380
2.400
2.420
2.440
2.460
2.480
I.D. No.
266
268
270
272
274
276
278
280
282
284
286
288
290
250
252
254
256
258
260
262
264
Thickness
(mm)
2.500
2.520
2.540
2.560
2.580
2.600
2.620
2.640
2.660
2.680
2.700
2.720
2.740
2.760
2.780
2.800
2.820
2.840
2.860
2.880
2.900
6) Install shim with the identification number facing down (towards tappet).
7) Rotate crankshaft to open (lift up) valve.
8) Remove tappet holder (A) and tighten camshaft housing bolts (a) to specified torque.
Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
4
(A)
10) After checking and adjusting all valves, reinstall parts removed earlier.
Installation is reverse order of removal.
a) Cylinder Head Cover Installation.
I9J011020015-02
• Install the cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Installation” in Section 1D (Page 1D-2).
NOTE
Examine cylinder head cover gasket for damage. Always replace gasket if sealing performance is suspect.
Tightening torque
Cylinder head cover bolts (b): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
(b)
(a)
I9J011020049-01 b) Final assembly check
• All parts removed have been returned to their original positions.
• Check hose and wire routing.
Refer to “Wiring Harness Routing Diagram” in
• Check oil leakage.
5
4. Tappet
5. Camshaft
9) Recheck tappet clearance.
I9J011020014-01
Maintenance and Tune-Up: 0B-11
Tappet shim selection chart (IN. side)
I9J011020016-06
0B-12 Maintenance and Tune-Up:
Tappet shim selection chart (EX. side)
I9J011020017-05
Idle Speed and Idle Air Control (IAC) Duty
Inspection
Z9J0110206030
Inspect idle speed and IAC Duty
Initially after 20 hours (1 month) and every 200 hours
(12 months)
NOTE
Before checking idle speed / IAC duty, make sure of the following.
• Engine must be warmed up.
• Check idle speed after engine speed has stabilized.
• Check throttle link mechanism and throttle valve for smooth operation.
• Lead wire and hoses of electronic fuel injection and engine control systems are connected securely.
• Ignition timing is within specification.
• Tappet clearance is checked according to maintenance schedule.
• No abnormal air drawn in from air intake system. After all items are confirmed, check idle speed and IAC duty.
Maintenance and Tune-Up: 0B-13
5) Shift into forward, Check in-gear idle speed.
If not, check idle air control system.
NOTE
• Trolling speed (in-gear idle speed) is same as idle speed.
• Idling / trolling speed of 550 – 650 r/min. is controlled by IAC system.
Idle speed in gear (IAC duty)
550 – 650 r/min (Duty: Approx. 0 – 30%)
Ignition Timing Inspection
Z9J0110206042
Inspect ignition timing
Every 200 hours (12 months)
NOTE
Before checking the ignition timing, make sure idle speed is adjusted within specification.
1) Start the engine and allow to warm up.
2) Attach the timing light cord to the No.1 ignition coil
(1) primary wire.
Special tool
(A): 09930–76420 (Timing light)
1
(A)
1
2
I9J011020050-01
1. IAC valve 2. Throttle body
Check idle speed and IAC duty as follows. To perform idle speed and IAC duty inspection, use personal computer and SDS tool.
1) Connect SDS tool to engine.
Refer to SDS operation manual for the step 1 procedure.
2) Start engine and allow to warm up.
3) Check engine speed and IAC duty by using “Service data / Engine data” mode on SDS.
4) If IAC duty and / or idle speed is out of specification, inspect idle speed control system referring to “Idle air control system check”.
Idle speed in neutral gear (IAC duty)
550 – 650 r/min (Duty: Approx. 0 – 30%)
I9J011020051-02
3) Check the ignition timing while operating the engine in neutral gear at 1 000 r/min.
Ignition timing
Approx. BTDC 2
° ±
5
°
at 1 000 r/min
(A)
I9J011020018-02
0B-14 Maintenance and Tune-Up:
Breather Line and Fuel Line Inspection
Inspect breather line and fuel line
Initially after 20 hours (1 month) and every 50 hours (3 months)
Replace breather line and fuel line
Every 2 years
If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line.
Z9J0110206043
Fuel line check point
I9J011020019-04
Low Pressure Fuel Filter Inspection
Z9J0110206044
Inspect low pressure fuel filter
Every 50 hours (3 months)
Replace low pressure fuel filter
Every 400 hours or 2 years
If leakage, cracks or other damage is found, replace the fuel filter.
Maintenance and Tune-Up: 0B-15
3) Remove the fuel filter (3) from filter bracket (4).
4) Remove the cap (5), then drain and clean fuel filter.
5) Install the cap, then secure it with clamp (6).
1
I9J011020052-01
1. Low pressure fuel filter
!
WARNING
• Stop the motor before cleaning the fuel filter.
• Do not smoke and keep open flames and sparks away while working near any part of the fuel system.
1) Turn the engine off.
2) Disconnect the inlet hose (1) and outlet hose (2) from fuel filter.
4
5
3
6
I9J011020054-01
6) Install fuel filter to filter bracket properly.
7) Connect the fuel inlet and outlet hose to fuel filter, then secure the fuel hoses to the fuel filter with the hose clamp.
8) Restart the engine and check that there are no leaks around the fuel filter.
High Pressure Fuel Filter Replacement
Z9J0110206045
Replace high pressure fuel filter
Every 1 000 hours
SUZUKI recommends that replacing the high pressure fuel filter every 1 000 operating hours.
1
2
1
I9J011020055-01
1. High pressure fuel filter
I9J011020053-01
0B-16 Maintenance and Tune-Up:
Water Pump and Water Pump Impeller
Inspection
Z9J0110206046
Inspect water pump
Every 200 hours (12 months)
Replace water pump impeller
Every 200 hours (12 months)
Propeller / Propeller Nut and Cotter Pin
Inspection
Z9J0110206047
Inspect propeller / propeller nut and cotter pin
Initially after 20 hours (1 month) and every 100 hours
(6 months).
1) Inspect propeller for bent, chipped or broken blades.
Replace propeller if damage noticeably affects operation.
2) Remove the propeller.
Refer to “Propeller Removal and Installation” in
3) Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted.
4) Inspect propeller bush for slippage.
Replace if necessary.
I9J011020020-02
1) Remove the lower unit and water pump case.
Refer to “Water Pump Removal and Installation” in
2) Inspect water pump case, inner sleeve and under panel. Replace if wear, cracks, distortion or corrosion is found.
3) Inspect water pump impeller.
Replace if vanes are cut, torn or worn.
SUZUKI recommends that replacing the water pump impeller every 200 hours (12 months).
4) Assemble the water pump related items.
Refer to “Water Pump Removal and Installation” in
5) Install the lower unit assembly.
Refer to “Lower Unit Removal and Installation” in
I9J011020021-01
I9J011020056-01
5) Install the propeller and related parts.
Refer to “Propeller Removal and Installation” in
6) Make sure that propeller nut is torqued to specification and cotter pin is installed securely.
Tightening torque
Propeller nut: 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
Maintenance and Tune-Up: 0B-17
Anodes Inspection
Z9J0110206048
Inspect anodes
Every 50 hours (3 months)
If 2/3 of zinc anode has corroded away, replace anode.
The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness.
CAUTION
Never paint the anode.
NOTE
The anode cover (1) may be separated from the power unit body by inserting and turning a 10 mm bolt (2) to function as a screw jack.
2
1
1
1
1
I9J011020057-01
I9J011020058-01
I9J011020022-04
NOTE
The anode (3) securing bolt should be covered with suzuki silicone seal.
: Sealant 99000–31120 (SUZUKI Silicone Seal
(50 g))
3
3
I9J011020025-02
NOTE
To access the anode in the gearcase, remove the water inlet filter.
I9J011020023-01
3
I9J011020026-02
0B-18 Maintenance and Tune-Up:
Bonding Wires Inspection
Z9J0110206049
Inspect bonding wires
Every 50 hours (3 months)
1) If breakage or other damage is found on bonding wire (1), replace the wire.
2) If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire.
1
1
1
I9J011020027-02
I9J011020028-01
Battery Inspection
Z9J0110206050
Inspect battery
Every 50 hours (3 months)
!
WARNING
• 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 contact with eyes, skin, clothing, and painted surfaces.
If battery acid comes in contact with any of these, flush immediately with large amounts of water.
If acid contacts the eyes or skin, get immediate medical attention.
• Batteries should always be kept out of reach of children.
• When checking or servicing the battery, disconnect the negative (black) cable. Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the motor at the same time.
• Wear approved eye protection.
Recommended battery
12 V 100 AH (360 kC) or larger
Refer to “Battery Requirement” in Section 0A (Page 0A-
Connecting Battery
CAUTION
• If the battery leads are loose, incorrectly connected or reversed, the electrical system could be damaged.
• Wing nuts must not be used and hexagon nuts must be used to secure sub battery cable to the battery terminals to avoid loss of electrical power.
How to connect
1) Connect positive (+) terminal first.
2) Connect negative (–) terminal second.
3) Upon completion of connection, lightly apply grease to battery terminals.
1
2
3
Maintenance and Tune-Up: 0B-19
Battery Solution Level Check
CAUTION
Once the battery has been initially serviced,
NEVER add diluted sulfuric acid or battery damage will occur.
Follow the battery manufacture's instructions for specific maintenance procedures.
Battery solution level should be between UPPER level and LOWER level.
If level is low, add distilled water only.
I9J011020031-01
Battery Solution Specific Gravity Check
Measure the specific gravity of battery solution using a hydrometer.
Battery solution specific gravity (temperature)
1.28 (20
°
C)
Special tool
: 09900–28403 (Hydrometer)
1. Red lead
2. Sub battery cable
3. Black lead
How to disconnect
1) Disconnect negative (–) terminal first.
2) Disconnect positive (+) terminal second.
I9J011020029-03
1
2
3
I9J011020032-01
I9J011020030-02
1. Red lead
2. Sub battery cable
3. Black lead
0B-20 Maintenance and Tune-Up:
Bolts and Nuts Inspection
Z9J0110206025
Inspect bolts and nuts
Initially after 20 hours (1 month) and every 100 hours
(6 months)
Check that all bolts and nuts listed below are tightened to their specified torque.
Refer to “Tightening Torque Specifications” in Section 0A
• Cylinder head cover bolts
• Intake manifold bolts and nuts
• Exhaust manifold cover bolts
• Flywheel bolt
• ECM ground bolt
• Power unit mounting bolts
• Clamp bracket shaft nut
• Gearcase bolts
• Propeller nut
Oil Pressure Check
Z9J0110206027
Check the engine oil pressure periodically.
1) Check the engine oil level.
2) Loosen screw and disconnect blue lead wire (1) from oil pressure switch (2).
Remove the oil pressure switch.
1
2
I9J011020059-01
3) Install oil pressure gauge adaptor into oil pressure switch hole in place of oil pressure switch.
Special tool
(A): 09915–77311 (Oil pressure gauge)
(B): 09915–78211 (Oil pressure gauge adapter)
4) Start engine and warm up.
Engine warm up (engine speed)
Summer: 5 min. (2 000 r/min.)
Winter: 10 min. (2 000 r/min.)
(A)
(B)
I9J011020060-02
I9J011020033-01
5) After warming up, shift into forward gear and increase engine speed to 3 000 r/min, then compare pressure indicated on gauge to specifications.
NOTE
The figure shown below is a guideline only, not an absolute service limit.
Oil pressure
400 – 600 kPa (4.0 – 6.0 kg/cm 2 , 57 – 85 psi.)
6) If oil pressure is lower or higher than specification, the following causes may be considered.
Low oil pressure
• Clogged oil filter
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
• Damaged O-ring
• Combination of above items
High oil pressure
• Using an engine oil of too high viscosity
• Clogged oil passage
• Clogged oil pressure regulator
• Combination of above items
7) After testing, reinstall oil pressure switch.
Refer to “Oil Pressure Switch Removal and
Installation” in Section 1E (Page 1E-5).
Cylinder Compression Pressure Check
Z9J0110206026
The compression pressure reading of cylinder is good indicator of its internal condition.
The decision to overhaul the power unit is often based on the results of a compression test.
Periodic maintenance records kept at your dealership should include compression readings for each maintenance service.
1) Start engine and allow to warm up, then shut engine off.
2) Disconnect all fuel injector connectors at fuel injector.
3) Disconnect all ignition coil connectors.
4) Remove the bolts securing the ignition coil, then remove all ignition coils and spark plugs.
5) Install compression gauge attachment into spark plug hole, then connect compression gauge attachment to compression gauge.
Special tool
(A): 09915–64512 (Compression gauge)
(B): 09915–69910 (Compression gauge attachment)
(A)
Maintenance and Tune-Up: 0B-21
6) Disconnect remote control throttle cable from throttle lever.
7) Move and hold throttle lever (1) in full-open position.
I9J011020063-02
8) While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder.
NOTE
Figures shown are guidelines only, not absolute service limits.
Cylinder compression pressure
Standard: 1 200 – 1 800 kPa (12 – 18 kgf/cm 2 , 171
– 256 psi.)
Cylinder compression pressure max. difference between cylinders
100 kPa (1.0 kgf/cm 2 , 14 psi.)
Low compression pressure can indicate one or more of following:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head gasket
9) Reinstall parts removed earlier (spark plugs, ignition coils, etc.).
(B)
1
I9J011020061-01
I9J011020062-01
0B-22 Maintenance and Tune-Up:
Table of Contents 1- i
Section 1
Power Head
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Powerhead................................... 1-1
Engine General Information and
Diagnosis ................................................. 1A-1
Precautions...........................................................1A-1
Precautions on Engine Diagnosis ....................... 1A-1
General Description .............................................1A-2
Engine Control System Description .................... 1A-2
Engine Control Module (ECM) ............................ 1A-4
Caution System Description................................ 1A-7
Self-Diagnostic System Description ..................1A-10
Fail-Safe System Description............................1A-12
Operating Hour Indication System
Description ......................................................1A-13
Oil Change Reminder System Description........ 1A-14
Component Location .........................................1A-15
Engine Control System Components / Engine
Electrical Device Location...............................1A-15
Diagnostic Information and Procedure............1A-20
ECM Power and Ground Circuit Check.............1A-20
Troubleshooting with Self-Diagnostic Code ......1A-21
Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-22
Self-Diagnostic Code “1 – 4” Cylinder Temp.
Sensor.............................................................1A-23
Self-Diagnostic Code “2 – 3” IAT Sensor.......... 1A-24
Self-Diagnostic Code “4 – 2” CKP Sensor ........ 1A-25
Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-26
Self-Diagnostic Code “2 – 2” Air Intake
System ............................................................1A-27
Self-Diagnostic Code “3 – 2” MAP Sensor 2.....1A-28
Self-Diagnostic Code “1 – 5” Ex. Manifold
Temp. Sensor ................................................. 1A-30
Self-Diagnostic Code “4 – 3” Fuel Injector ........ 1A-31
Self-Diagnostic Code “2 – 1” TPS (Throttle
Position Sensor).............................................. 1A-32
Self-Diagnostic Code “1 – 2” Shift Position
Sensor.............................................................1A-33
Self-Diagnostic Code “3 – 3” Neutral Switch.....1A-34
Self-Diagnostic Code “1 – 1” Rectifier/
Regulator (Over Charging).............................. 1A-35
Self-Diagnostic Code “5 – 3” Oil Pressure
Switch .............................................................1A-35
Self-Diagnostic Code “3 – 7” Trim Sensor ........1A-36
Troubleshooting Without Self-Diagnostic
Code................................................................1A-37
IAC System Troubleshooting ............................1A-38
Service Instructions...........................................1A-39
How to Use the 36 Pin Test Cord Set ...............1A-39
Inspection of the ECM and Its Circuit................1A-39
ECM Main Relay Inspection..............................1A-42
Engine Electrical Devices ....................... 1C-1
Precautions...........................................................1C-1
Precaution for Engine Electrical Device ..............1C-1
General Description .............................................1C-1
Sensor and Switch Description ...........................1C-1
ECM Power Source Line.....................................1C-6
Component Location ...........................................1C-7
Location of Sensor and Switch............................1C-7
Service Instructions.............................................1C-7
Resistance Check ...............................................1C-7
Cylinder Temp. Sensor Removal and
Installation .........................................................1C-8
Cylinder Temp. Sensor Inspection ......................1C-8
Ex. Manifold Temp. Sensor Removal and
Installation .........................................................1C-9
Ex. Manifold Temp. Sensor Inspection ...............1C-9
CKP Sensor Removal and Installation ..............1C-10
CKP Sensor Inspection .....................................1C-10
IAT Sensor Removal and Installation................1C-10
IAT Sensor Inspection.......................................1C-11
CMP Sensor Removal and Installation .............1C-11
CMP Sensor Inspection ....................................1C-11
MAP Sensor Removal and Installation..............1C-12
MAP Sensor Output Voltage Inspection............1C-13
IAC Valve Removal and Installation..................1C-14
IAC Valve Inspection.........................................1C-14
TPS Inspection..................................................1C-15
Shift Position Sensor Inspection .......................1C-16
Trim Sensor Inspection .....................................1C-17
Power Unit Mechanical ........................... 1D-1
General Description .............................................1D-1
Power Unit Construction Description ..................1D-1
Diagnostic Information and Procedures............1D-1
Cylinder Compression Check..............................1D-1
Oil Pressure Check .............................................1D-1
1
1-ii Table of Contents
Service Instructions.............................................1D-2
Tappet Clearance Inspection ..............................1D-2
Ring Gear Cover Removal and Installation.........1D-2
Cylinder Head Cover Removal and
Installation.........................................................1D-2
Air Intake Silencer Case Removal and
Installation.........................................................1D-5
Electric Parts Holder Removal and Installation ....1D-5
Intake Manifold and Throttle Body
Components......................................................1D-7
Intake Manifold Removal and Installation ...........1D-7
Throttle Body Removal and Installation ............1D-10
Throttle Body Inspection ...................................1D-11
Power Unit Removal and Installation ................1D-11
Timing Chain, Chain Tensioner and Camshaft
Sprockets Components...................................1D-19
Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation................1D-20
Timing Chain, Chain Tensioner and Camshaft
Sprockets Inspection.......................................1D-24
Camshaft, Tappet and shim Removal and
Installation.......................................................1D-25
Camshaft, Tappet and Shim Inspection ............1D-27
Cylinder Head Assembly Components .............1D-31
Cylinder Head Removal and Installation ...........1D-32
Cylinder Head Disassembly and Assembly ......1D-33
Cylinder Head Components Inspection and
Servicing .........................................................1D-35
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Components ............1D-42
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and
Assembly ........................................................1D-43
Piston Pin and Conrod Inspection.....................1D-53
Crank Pin and Conrod Bearing Inspection........1D-54
Selection of Conrod Bearing .............................1D-56
Crankshaft Inspection .......................................1D-57
Crankshaft Main Bearing Inspection .................1D-58
Crankshaft Drive Gear Inspection .....................1D-61
Crankshaft Oil Seal Inspection..........................1D-61
Power Unit Lubrication ............................1E-1
General Description .............................................1E-1
Engine Lubrication Description ...........................1E-1
Schematic and Routing Diagram........................1E-1
Engine Oil Lubrication Chart ...............................1E-1
Diagnostic Information and Procedures............1E-2
Oil Pressure Check .............................................1E-2
Oil Change Reminder System.............................1E-2
Low Oil Pressure Caution System ......................1E-2
Powerhead Lubrication System Diagnosis..........1E-2
Service Instructions.............................................1E-3
Oil Pump Removal and Installation .....................1E-3
Oil Pump Disassembly and Assembly ................1E-3
Inspection Oil Pump Component Parts ...............1E-4
Oil Pressure Switch Removal and Installation ....1E-5
Oil Pressure Switch Inspection ...........................1E-6
Oil Strainer Removal and Installation..................1E-6
Oil Strainer Related Parts Inspection ..................1E-6
Power Unit Cooling System.....................1F-1
General Description ............................................. 1F-1
Water Cooling System Description ..................... 1F-1
Displacement Type Water Pump Description ..... 1F-1
Water Pressure Valve Description ...................... 1F-1
Schematic and Routing Diagram ........................ 1F-2
Cooling Water Circulation Chart.......................... 1F-2
Diagnostic Information and Procedures ............ 1F-3
Powerhead Cooling System Diagnosis ............... 1F-3
Service Instructions ............................................. 1F-3
Thermostat Removal and Installation.................. 1F-3
Thermostat Inspection......................................... 1F-4
Water Pressure Valve Removal and
Installation ......................................................... 1F-4
Water Pressure Valve Related Item
Inspection.......................................................... 1F-5
Water Pump Removal and Installation................ 1F-5
Water Pump Related Item Inspection ................. 1F-5
Water Tube Removal and Installation ................. 1F-5
Water Tube Related Item Inspection................... 1F-5
Fuel System ............................................. 1G-1
Precautions.......................................................... 1G-1
Precautions on Fuel System Service ................. 1G-1
General Description ............................................ 1G-2
Electronic Fuel Injection System Description ..... 1G-2
Fuel Delivery System Components
Description ....................................................... 1G-4
High Pressure Fuel Pump Control System
Description ....................................................... 1G-7
Air Intake Components Description.................... 1G-8
Idle Air Control System Description ................... 1G-9
Diagnostic Information and Procedures ......... 1G-11
Fuel Pressure Inspection ................................. 1G-11
Fuel System Diagnosis .................................... 1G-13
Fuel Injection System Troubleshooting ............ 1G-14
Service Instructions .......................................... 1G-15
Fuel Pressure Relief Procedure ....................... 1G-15
Fuel Line Removal and Installation .................. 1G-15
Fuel Line Inspection ......................................... 1G-15
Fuel Leakage Check Procedure....................... 1G-16
Inspection of Fuel Hose Connections .............. 1G-16
High Pressure Fuel Pump Operating Sound
Inspection....................................................... 1G-16
Fuel Vapor Separator Removal and
Installation ...................................................... 1G-17
Fuel Vapor Separator Disassembly and
Assembly........................................................ 1G-17
Inspection of Fuel Vapor Separator
Component Parts ........................................... 1G-20
Fuel Injector Inspection with Injector in place .. 1G-21
Individual Fuel Injector Operating Sound
Inspection....................................................... 1G-22
Fuel Injector Operating Signal Inspection ........ 1G-22
Fuel Injector Removal and Installation ............. 1G-23
Low Pressure Fuel Pump Removal and
Installation.......................................................1G-25
Low Pressure Fuel Pump Inspection ................1G-26
Ignition System........................................ 1H-1
General Description .............................................1H-1
Ignition System Description ................................1H-1
Ignition Control Description .................................1H-2
Component Location ...........................................1H-4
Ignition System Components Location ...............1H-4
Diagnostic Information and Procedures............1H-4
Ignition System Symptom Diagnosis...................1H-4
Ignition System Troubleshooting.........................1H-5
Service Instructions.............................................1H-6
Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
Ignition Coil Removal and Installation.................1H-6
Ignition Coil Inspection........................................1H-6
Ignition Coil Operating Signal Inspection ............1H-7
CKP Sensor Inspection.......................................1H-7
CMP Sensor Inspection ......................................1H-7
Ignition Switch Inspection ...................................1H-7
ECM Main Relay Inspection................................1H-7
Starting System .........................................1I-1
General Description .............................................. 1I-1
Electric Starter System Description...................... 1I-1
Starter Motor Operation Condition
Description ......................................................... 1I-2
Start-In-Gear Protection System Description ....... 1I-2
Table of Contents 1-iii
Component Location ............................................ 1I-3
Starting System Components Location................ 1I-3
Diagnostic Information and Procedures............. 1I-3
Starter System Troubleshooting........................... 1I-3
Service Instructions.............................................. 1I-4
Starter Motor Removal and Installation................ 1I-4
Starter Motor Test ................................................ 1I-5
Starter Motor Components................................... 1I-6
Starter Motor Disassembly and Assembly ........... 1I-7
Starter Motor Components Inspection and
Servicing ............................................................ 1I-9
Ignition Switch Inspection................................... 1I-13
Starter Motor Relay Inspection........................... 1I-13
Neutral Switch Inspection................................... 1I-14
Emergency Stop Switch Inspection.................... 1I-15
Charging System ..................................... 1K-1
General Description .............................................1K-1
Charging System Description..............................1K-1
Battery Requirement Description ........................1K-2
Component Location ...........................................1K-3
Charging System Components Location.............1K-3
Diagnostic Information and Procedures............1K-3
Charging System Diagnosis................................1K-3
Service Instructions.............................................1K-4
Charging System Construction ...........................1K-4
Flywheel Removal and Installation......................1K-5
Battery Charge Coil Removal and Installation ....1K-6
Battery Charge Coil Inspection ...........................1K-7
Rectifier/Regulator Removal and Installation ......1K-7
Rectifier/Regulator Inspection .............................1K-8
Main Fuse Inspection ..........................................1K-8
1-1 Precautions:
Power Head
Precautions
Precautions
Precautions for Powerhead
Refer to “General Precautions” in Section 00 (Page 00-1).
Z9J0111000001
Engine General Information and Diagnosis: 1A-1
Power Head
Engine General Information and Diagnosis
Precautions
Precautions on Engine Diagnosis
Z9J0111100001
!
WARNING
To prevent any unexpected engine starting, perform the following before proceeding with any
CRANKING tests.
• When performing tests not related to fuel injector operation:
– Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation:
– Disconnect the high pressure fuel pump wire connector located on the fuel vapor separator.
CAUTION
• Always turn the ignition switch “OFF” and disconnect the battery cables when wires are being disconnected or connected.
• Hold and pull the connectors when disconnecting. Do not pull the wires.
NOTE
• To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use the Suzuki Diagnostic System.
• The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected.
• Each electrical circuit is affected by battery voltage, always use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires / cables are securely connected.
1A-2 Engine General Information and Diagnosis:
General Description
Engine Control System Description
Z9J0111101001
The DF70 / 80 / 90 models employ an integrated system which performs the control functions for fuel injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine Control Module).
System Structure
INPUT
(sensor/switch)
CKP sensor
CMP sensor
CONTROL
(ECM)
Fuel injection system
Ignition system
Idle air control system
Fuel pump system
OUTPUT
(actuator etc.)
Fuel injector
Ignition coil
IAC valve
High pressure fuel pump MAP sensor
IAT sensor
Cylinder temp. sensor
Exhaust manifold temp. sensor
Throttle position sensor
Neutral switch
Shift position sensor
Oil pressure switch
Emergency stop switch
Ignition switch
PTT switch
Trim/Tilt sensor
Water pressure sensor (Optional)
Speedo sensor (Optional)
Caution system
Self diagnostic system
Fail safe system
Operating hour indication system
Oil changing reminder system
Start-in-gear protection system
Starter motor relay control system
Power trim and tilt relay control system
Caution Buzzer
Monitor-tachometer
Starer motor relay,
(Starter motor)
PTT motor relay
Trim gauge
Water pressure gauge
Speedometer
I9J011110001-02
Engine General Information and Diagnosis: 1A-3
Engine Control System Flow Diagram
28
23
19
20
18
15
16
14
13
17
12
1. Flywheel
2. CKP sensor
3. Ex. manifold temp. sensor
4. Cylinder temp. sensor
5. Spark plug
6. Ignition coil
7. CMP sensor
8. MAP sensor
9. Throttle position sensor
10. IAT sensor
11. IAC valve
12. PTT switch
13. ECM main relay
14. Ignition switch
15. Fuse (30 amp.)
16. Fuse (15 amp.)
17. Starter relay
18. Neutral switch
19. Trim/Tilt sensor
20. Shift position sensor
29
21
25
22
30
32
35
33
34
26
37
27
36
24
11
31
6
7
8
2
1
4 5
3
10 9
21. PTT relay
22. PTT motor
23. Battery
24. Fuel injector
25. Air intake silencer
26. Throttle body
27. Intake manifold
28. Fuel tank
29. Fuel primer bulb
30. Low pressure fuel filter
I9J011110002-04
31. Low pressure fuel pump
32. Fuel vapor separator
33. Float
34. High pressure fuel pump
35. High pressure fuel filter
36. Fuel cooler
37. Fuel pressure regulator
1A-4 Engine General Information and Diagnosis:
Engine Control Module (ECM)
Z9J0111101002
The ECM sends signals to control the actuators based on the information inputs from each sensor / switch. Major controls are as follows:
Name of Control
Fuel injection control
Ignition control
Idle air control
Fuel pump control
Caution system control
Description
• Controls fuel injection amount and timing.
• Controls ignition timing.
• Controls idling / trolling speed by adjusting the intake air volume through the IAC valve.
• Controls the high pressure fuel pump drive.
• Informs the operator of abnormal engine conditions.
Self-diagnostic system control
Fail-safe system control
• Controls engine speed, if activated.
• Informs the operator of sensor / switch malfunction.
• Allows engine operation with a back-up system during sensor / switch malfunction.
Total operating hour indication system control.
• Informs the operator of the total operating time.
Oil changing reminder system control • Informs the operator that it is time to replace the engine oil,
Start-in-gear protection system control based on the maintenance schedule.
• Prevents engine starting when the shift lever is positioned in
Starter motor relay control system
Power trim and tilt relay control system forward or reverse.
• Prevents starter motor operation when the engine is already operating.
• Controls On / Off for the PTT relay’s up and down circuits.
NOTE
Information related to the Caution System, Self-Diagnostic System, and Total Operating Hours System is retained in the ECM memory.
1
I9J011110042-01
1. ECM
ECM Input / Output Circuit Diagram
Engine General Information and Diagnosis: 1A-5
PTT SW
I9J011110011-04
1A-6 Engine General Information and Diagnosis:
ECM Connector / Terminals Layout
48 47 46 45 44 43 42 41 40 39 38 37
60 59 58 57 56 55 54 53 52 51 50 49
72 71 70 69 68 67 66 65 64 63 62 61
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
20
21
22
23
16
17
18
19
24
25
26
12
13
14
15
8
9
10
11
Terminal
1
2
3
6
7
4
5
31
32
33
34
27
28
29
30
35
36
“A”
“A”: Gray connector
Bl/R
—
—
—
Lg/W
P/Bl
P
Lbl
B
B/W
—
Wire Color
—
G
P/W
—
Bl/B
Br/Y
W/Y
Lg/B
Bl/W
R/W
Bl
Gr
—
—
B/G
Lg/W
—
—
—
V/W
W
R
—
R/B
B/Bl
Circuit
—
Starter relay control
PTT relay DN
—
Water pressure sensor
Throttle position sensor
Trim / Tilt sensor
IAT sensor
Speedo sensor
Power source for sensor
Oil pressure switch
Power source for ECM
—
—
Ignition key switch
Emergency stop switch
—
—
—
Cylinder temp. sensor
Shift position sensor
PTT switch “DN”
PTT switch “UP”
Ground for ECM
Ground for Sensor
—
PTT relay UP
—
—
—
Ex. Manifold temp. sensor
MAP sensor
Power source #1 for sensor
—
Ground for ECM main relay
Ignition switch
“B”
I9J011110003-02
“B”: Black connector
56
57
58
59
52
53
54
55
60
61
62
48
49
50
51
44
45
46
47
Terminal
37
38
39
40
41
42
43
67
68
69
70
63
64
65
66
71
72
—
Lg/R
Bl
P/W
Y/B
G/Y
R/G
Lg
W/B
—
O/Y
Wire Color
—
Y
—
Y/Bl
Gr/Y
O
W/Y
Bl/W
O/B
—
R/W
W/Bl
Y/G
R/B
B
B
O/W
Br
Bl/B
—
—
G/W
R/Y
B/Br
B/R
Circuit
—
PC communication line (B)
—
CMP sensor
No.3 Ignition coil
No.1 Ignition coil
Trim gauge
Buzzer
No.1 Fuel injector
—
No.3 Fuel injector
IAC valve #4
Neutral switch
CKP sensor
Ground for power
—
No.4 Ignition coil
No.2 Ignition coil
Rev – Limit lamp
Tachometer
TEMP lamp
IAC valve #3
No.4 Fuel injector
IAC valve #1
—
PC communication line (A)
Ground for power
Buzzer cancel
Start switch
Oil lamp
—
—
CHECK ENGINE lamp
IAC valve #2
No.2 Fuel injector
High pressure fuel pump (–)
Engine General Information and Diagnosis: 1A-7
Caution System Description
The following four caution systems alert the operator when an abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
• OVERHEAT CAUTION
• LOW BATTERY VOLTAGE CAUTION
Monitor-Tachometer
Z9J0111101003
“D”
“A”
“A”: “REV LIMIT” lamp
“B”: “OIL” lamp
“C” “B”
I9J011110004-02
“C”: “TEMP” lamp
“D”: “CHECK ENGINE” lamp
Caution Type
Over-revolution
Low oil pressure
Overheat
Low battery voltage
Caution Lamp
Yes “A”
Yes “B” (“A”)
Yes “C” (“A”)
Yes “D”
Lamp check / Buzzer Check
When the ignition key is turned to the “ON” position:
• Four Caution lamps turns on for two seconds.
• Caution buzzer sounds for two seconds.
Caution Buzzer
No
Yes
Yes
Yes
Engine RPM Limited
Yes
Yes
Yes
No
Over-Revolution Caution System
Condition:
The ECM controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed.
Over revolution limiter
DF70 / 80: 6 200 r/min.
DF90: 6 400 r/min.
Action:
Engine speed
Caution lamp
Caution buzzer
• Automatically reduced to approx. 3 000 r/min. by an intermittent fuel injection signal.
• If the operator decreases the engine speed below the over revolution system maximum preset value, within 10 seconds, the over-revolution caution control will be canceled.
“REV-LIMIT” lamp lights continuously.
No buzzer sounds.
Reset:
Close the throttle to reduce the engine speed below approx. 3 000 r/min. for one second.
1A-8 Engine General Information and Diagnosis:
Low Oil Pressure Caution System
Condition:
Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop below 100 kPa (1.0 kg/cm 2 , 14 psi.) while the engine is running.
Action:
Engine speed
Caution lamp
Caution buzzer
• Automatically reduced to approx. 1 000 r/min. maximum by an intermittent fuel injection signal.
• The engine automatically stops 3 minutes after the caution system is activated.
• “OIL” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter activation (1 000 r/min, or higher).
• Sounds in a series of long (1.5 sec.) beeps.
NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
However, the caution system will repeatedly activate until the cause is eliminated.
Reset:
Stop the engine and check the engine oil level. Refill the engine oil to the correct level if it is below the low oil level mark.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity.
• Malfunctioning oil pressure switch.
• Clogged oil strainer or oil filter.
• Worn oil pump relief valve.
• Oil leakage from the oil passage.
• Excessive wear / damage of oil pump.
NOTE
The low oil pressure caution system will reset when the oil pressure is restored to over 100 kPa (1.0 kg/cm 2 , 14 psi.) at approx. 1 000 r/min. or less engine speed operation.
The engine must be stopped and checked immediately once the system is activated.
Overheat Caution System
Condition 1 (Maximum temperature)
Immediate activation of the system when:
• Cylinder temperature reaches 120
°
C (248
°
F)
• Exhaust manifold temperature reaches 114
°
C (237.2
°
F)
Condition 2 (Gradient temperature – Temp. rise vs. Time)
Immediate activation of the system when:
• The average temperature difference between three consecutive 10 second measurement periods of the cylinder temperature sensor, at engine speeds of 500 r/min or higher, exceeds the limits as shown below.
Temperature Range
88 – 99
°
C (190 – 210
°
F)
99
°
C – (210
°
F –)
Temperature Difference
Approx. 8
°
C (14.4
°
F)
Approx. 1.5
°
C (2.7
°
F)
• The average temperature difference between three consecutive 10 second measurement periods of the exhaust manifold temperature sensor, at engine speeds of 500 r/min. or higher, exceeds the limits as shown below.
Temperature Range
80 – 95
°
C (176 – 203
°
F)
95
°
C – (203
°
F –)
Temperature Difference
Approx. 14
°
C (25.2
°
F)
Approx. 1.7
°
C (3.1
°
F)
Engine General Information and Diagnosis: 1A-9
Action:
Engine speed
Caution lamp
Caution buzzer
• Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel injection and ignition signals.
• The engine automatically stops 3 minutes after the caution system is activated.
• “TEMP” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter activation (3 000 r/min. or higher).
• Sounds in a series of long (1.5 sec.) beeps.
NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
The caution system will repeatedly activate until the cause is eliminated.
Reset:
Close the throttle completely and then shift into neutral.
System reset will occur when the cylinder temperature drops below the limits shown below. However, the system may be activated again unless the cause for overheat (such as insufficient water) is removed.
Reset Temperature Caution Cause
Condition 1
(Maximum temperature)
Condition 2
(Gradient temp. – Temp. rise vs. Time)
Approx. 78
Approx. 76
°
°
C (172
C (169
°
°
F)
F)
Low Battery Voltage Caution System
Condition 1:
The system is activated when the battery voltage decreases to less than 9 volts for 30 seconds.
Condition 2:
The system is activated if the battery voltage is less than 2 Volts for more than 2 seconds when the ignition switch is turned “ON” and the engine is not running.
Action:
Engine speed
Caution lamp
Caution buzzer
• No engine speed limiter is activated.
• “CHECK ENGINE” lamp lights continuously.
• Sounds in a series of long (1.5 sec.) beeps.
Reset:
Condition 1:
The caution system is automatically reset when battery voltage increases to more than 9 volts.
Refrain from using electrical equipment requiring high amperage, such as hydraulic trim tabs, hydraulic jack plate, etc., after this caution is activated.
Condition 2:
For the caution system to engage under this condition, possibilities such as a deteriorated battery, poor battery cable connection, battery switch in the “OFF” position, etc., must be inspected.
To cancel the caution system activation for these conditions, check all power source related items and eliminate the problem.
1A-10 Engine General Information and Diagnosis:
Self-Diagnostic System Description
Z9J0111101004
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or switch, etc.
When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code pattern, along with a buzzer sound.
When the engine is running, the buzzer sounds a series of short (0.2 sec.) beeps. When the engine is not running, the buzzer sounds according to each code pattern, but not simultaneously with the flashing lamp. The buzzer sound can be temporally canceled by pushing the ignition key in.
Monitor-Tachometer
“A”
I9J011110005-01
“A”: “CHECK ENGINE” lamp
Priority / Code / Pattern for Self-Diagnostic System Operation
0: OFF, 1: ON
Priority Failed Item Code Lamp Flashing Pattern
1
1 MAP sensor 1 3 – 4
0
MCODE00D34-0-01
1
2 Cylinder temp. sensor 1 – 4
0
MCODE00D14-0-01
1
3 IAT sensor 2 – 3
0
MCODE00D23-0-01
1
4 CKP sensor 4 – 2
0
MCODE00D42-0-01
1
5 CMP sensor 2 – 4
0
MCODE00D24-0-01
1
6 Air intake system 2 – 2
0
MCODE00D22-0-01
1
7 MAP sensor 2 3 – 2
0
MCODE00D32-0-01
1
8 Exhaust manifold temp. sensor 1 – 5
0
MCODE00D15-0-01
1
9 Fuel injector 4 – 3
0
MCODE00D43-0-01
1
10 Throttle position sensor 2 – 1
0
MCODE00D21-0-01
1
11 Shift position sensor 1 – 2
0
MCODE00D12-0-01
1
12 Neutral switch 3 – 3
0
MCODE00D33-0-01
Fail-Safe System Active
Yes
Yes
Yes
No
No
Yes
No
Yes
No
Yes
Yes
No
Engine General Information and Diagnosis: 1A-11
Priority
13
14
15
Failed Item
Rectifier/Regulator
(Over-charging)
Oil pressure switch
Trim sensor
Code
1 – 1
5 – 3
3 – 7
Lamp Flashing Pattern Fail-Safe System Active
1
No
0
MCODE00D11-0-01
1
No
0
MCODE00D53-0-01
1
No
0
MCODE00D37-0-01
NOTE
• If two or more items fail at once, the self-diagnostic indication appears according to the priority order. The indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch “ON”.
• After correcting the failed item, the self-diagnostic indication appears until the ECM receives the proper signal with the engine running.
• Cancellation of the self-diagnostic indication is automatically performed when the failure is corrected and a normal signal is received by the ECM for a period of 20 – 30 seconds.
• The Rectifier/Regulator self-diagnostic indication may not be displayed when the ignition switch is turned “ON” because the ECM cannot detect rectifier/regulator charging output if the engine is not running.
Under this condition, the buzzer will not sound a 1 – 1 code.
However, if the rectifier/regulator has failed, the self diagnostic indication will appear again after starting the engine.
Condition for Self-Diagnostic System Operation
Failed Item
MAP sensor 1
Cylinder temp. sensor
IAT sensor
CKP sensor
CMP sensor
Air intake system
MAP sensor 2
Exhaust manifold temp. sensor
Fuel injector
Throttle position sensor
Condition
• No signal (With engine running).
• Receiving an out of range “38 – 855 mmHg (1.49 – 33.66 inHg) (0.2 – 4.5
V)” signal (With the engine running.).
• No signal.
• Receiving an out of range “– 46 to + 170
°
C (– 114.8 – +338
°
F) (0.10 – 4.6
V)” signal.
• No signal.
• Receiving an out of range “– 46 to + 169
°
C (– 114.8 – +336.2
°
F) (0.10 –
4.6 V)” signal.
• During one crankshaft rotation, 32 signals are not received by the ECM.
• During cranking, CMP sensor signal is received by the ECM, but not CKP sensor signal.
• During three crankshaft rotations, the normal CMP sensor signal pattern is not received by the ECM.
• The engine operates at an abnormally high speed when the ECM is receiving a completely closed signal from the throttle position sensor.
(Criteria: 2 100 r/min minimum)
• From TPS sensor, the full close signal is inputted, but from the MAP sensor, the signal voltage exceeds 2.4 V.
• No signal.
• Receiving an out of range “– 46 to + 170
°
C (– 114.8 – +338
°
F) (0.10 – 4.6
V)” signal.
• No operation signal from the ECM.
• No signal.
Shift position sensor
• Receiving an out of range “0.2 – 4.8 V” signal.
• No signal.
• Receiving an out of range “0.2 – 4.8 V” signal.
1A-12 Engine General Information and Diagnosis:
Neutral switch
Failed Item
Rectifier/Regulator
(Over-charging)
Oil pressure switch
Trim sensor
Condition
• While the shift sensor outputs a forward or reverse signal, the ECM receives a neutral signal from the neutral switch.
• Receiving 16 volts or higher signal.
• While the engine is stopped and the ignition switch is on, the ECM receives an “off” signal from the oil pressure switch.
• Receiving an out of range “0.2 – 4.8 V” signal.
Fail-Safe System Description
Z9J0111101005
The fail-safe system is closely related to the self-diagnostic system.
When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a preprogrammed value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.
Pre-Programmed Value for Fail-Safe System
Failed Item
MAP sensor 1
Pre-Programmed Value
• 150 – 758 mmHg / (5.9 – 30 inHg.)
(The value will change according to the current engine speed.)
Air intake system
Cylinder temp. sensor
• The control is executed with the maximum engine speed of 2 000 r/min.
60
°
C (140
°
F)
IAT sensor 45
°
C (113
°
F)
Exhaust manifold temp. sensor 60
°
C (140
°
F)
Throttle position sensor
Shift position sensor
Trim sensor
• The control is executed with the throttle opening at 5 degrees.
• The shift position (Fwd / Neu / Rev) is detected with the neutral switch signal.
• The control is continued with fixed sensor output as 3.5 V.
NOTE
There is no back-up system for the ECM itself. The engine will stop if it has failed.
Engine General Information and Diagnosis: 1A-13
Operating Hour Indication System Description
Z9J0111101006
When the ignition switch is initially turned “ON” (from “OFF”), the ECM tests the caution system by turning on all four lamps in the monitor-tachometer and sounding the caution buzzer for an initial two seconds.
For the next three seconds, the ECM indicates the total operating hours, using a combination of the tachometer needle and “REV-LIMIT” lamp flash.
NOTE
The total operating hours displayed are those of the actual engine operation, not the ignition switch
“ON” time.
Monitor-Tachometer
“B”
“A”
“A”: Needle
Chart of Total Operating Hours Indication
Total Operating Hours
0 h – (49 h)
50 h
60 h
↓
540 h
550 h
560 h
↓
1 040 h
1 050 h
↓
1 540 h
1 550 h
↓
2 030 h
2 040 h or over
*: One lamp flash corresponds to 500 hours.
I9J011110006-01
“B”: “REV-LIMIT” lamp
Monitor-Tachometer
Needle “A” Indication REV-LIMIT Lamp “B” Flashing*
No
500 r/min.
600 r/min.
↓
No
5 400 r/min.
500 r/min.
600 r/min.
↓
1 time
5 400 r/min.
500 r/min.
↓
5 400 r/min.
500 r/min.
↓
5 300 r/min.
5 400 r/min.
2 times
3 times
3 times
1A-14 Engine General Information and Diagnosis:
Oil Change Reminder System Description
Z9J0111101007
This system informs the operator that it is time to change the ENGINE OIL based on the recommended maintenance schedule.
When the total motor operating hours has reached the pre-programmed hours, the “OIL” lamp will flash, and the buzzer will begin a series of double beeps if the engine is not running (but ignition switch is “ON”).
The above mentioned indication will repeat until the activated system is manually canceled.
NOTE
This system will activate up to 2 100 hour’s operation.
Indication of System Activation
Buzzer
Cancellation Procedure
1) Turn the ignition key to the “ON” position.
2) Remove the emergency stop switch plate (1).
3) Pull out the emergency stop switch knob (2) three times in ten seconds.
A short beep will be heard if the cancellation is successful.
4) Turn the ignition key to the “OFF” position.
5) Set the emergency stop switch plate (1) into the original position.
1
2
Oil lamp
I9J011110008-01
I9J011110007-02
NOTE
• Cancellation of the system is possible whether or not the engine oil has been replaced.
Once the system has been activated,
SUZUKI strongly recommends that the engine oil be replaced before canceling the system.
• If the engine oil has been replaced with the system not activated, it is still necessary to perform the cancellation procedure to reset the Oil Change Reminder System.
I9J011110009-01
Action
Starting operation
(*1) (*4)
Indication
Indication
(*2)
(*3)
Cancellation
(*4)
Cancellation
(*4)
Indication
Indication
(*3)
Cancellation
(*4)
Cancellation
Repeat
I9J011110010-03
*1: Lapse of initial 20 hour’s operation
*2: Lapse of 80 hour’s operation
*3: Lapse of 100 hour’s operation
*4: When performing cancellation before system activation
Engine General Information and Diagnosis: 1A-15
Component Location
Engine Control System Components / Engine Electrical Device Location
Z9J0111103001
1 2 3 4 5
6
7
8
9
10
11
12
13
22
14
15
23
1. Flywheel
2. Starter motor
3. Oil pressure switch
4. Ex. manifold temp. sensor
5. Rectifier/Regulator
6. IAC valve
7. Throttle position sensor
8. Throttle body
9. IAT sensor
10. ECM
11. PTT motor relay
12. Electric parts holder
21
20 19
13. Fuse box
14. Starter relay
15. Main relay
16. Main fuse (40 amp.)
17. Spare fuse (30 amp.)
18. Spare fuse (10 amp.)
18
16
13
17
I9J011110012-03
19. Starter motor fuse (30 amp.)
20. PTT switch fuse (10 amp.)
21. ECM, Ign, etc., fuse (30 amp.)
22. IAC fuse (10 amp.)
23. Spare fuse (40 amp.)
1A-16 Engine General Information and Diagnosis:
1
2
5
4
3
1. Battery charge coil
2. MAP sensor
3. IAC valve
4. CKP sensor
5. Cylinder temp. sensor
I9J011110013-02
2 1
Engine General Information and Diagnosis: 1A-17
5 4
3
1. IAC valve
2. Throttle position sensor
3. Throttle body
4. Battery charge coil
5. CKP sensor
I9J011110014-01
1A-18 Engine General Information and Diagnosis:
3
5
4
1
2
1. Ignition coil
2. Fuel injector
3. CMP sensor
4. Rectifier/Regulator
5. Main harness capacitor
I9J011110015-01
4
Engine General Information and Diagnosis: 1A-19
5
2
3
1. Neutral switch
2. Shift position sensor
1
3. Trim and tilt sensor
4. High pressure fuel filter
5. Fuel vapor separator
I9J011110016-02
1A-20 Engine General Information and Diagnosis:
Diagnostic Information and Procedure
ECM Power and Ground Circuit Check
Wiring Diagram
2
1
R
4 3
5
Z9J0111104001
7
W
6
Gr 12
B/Bl 36
ECM
B/G 15
R/B 35
8
BATT
IG
GND
W
Gr
B
Gr
B
I9J011110018-03
1. Starter motor
2. Main battery cable
3. 40 amp. fuse
4. 30 amp. fuse
5. ECM main relay
6. 15 amp. fuse
7. Sub-battery cable
8. Battery
Circuit Description
When the ignition switch is turned “ON”, the main relay turns “ON” (the contact point closes) and the main power is supplied to the ECM.
Engine General Information and Diagnosis: 1A-21
Troubleshooting
Step Action
1
Is operation of the main relay heard when the ignition switch is turned “ON”?
2
Are the main fuses (40 amp. and 30 amp.), (for Ignition and
ECM), and the sub battery cable fuse (15 amp.) in good condition?
3 1) Disconnect the ECM connector at the ECM with the ignition switch “OFF”.
4
5
6
2) Measure the voltage between the No. 35 terminal of the
ECM connector and body ground.
Is the voltage 12 V (Battery Voltage)?
1) Turn the ignition switch “OFF”.
2) Connect the 36 pin test cord set between the ECM and the main wire harness.
3) Turn the ignition switch “ON”.
4) Measure the voltage between the No. 36 terminal and body ground, and the No. 15 terminal and body ground.
Is the voltage 12 V (Battery Voltage)?
1) Turn the ignition switch “OFF”.
2) Connect the 36 pin test cord set between the ECM and the main wire harness.
3) Turn the ignition switch “ON”.
4) Measure the voltage between the No. 35 terminal and body ground.
Is the voltage approx. 0.5 V?
1) Turn the ignition switch “ON”.
2) Measure the voltage between the No. 12 terminal and body ground.
Is the voltage 12 V (Battery Voltage)?
Yes
Go to step 4.
Go to step 3.
Go to step 4.
Go to step 5.
Go to step 6.
No
Go to step 2.
Replace.
• Check the ECM main relay.
• Poor ECM main relay connection.
• R/B wire open, shorted or poor connection.
• Check the ignition switch. Refer to
• Gr, B/Bl, B/G wire open circuit or poor connection.
• R/B wire open, shorted or poor connection.
ECM power and ground circuit are in good condition.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
• Gr wire open, shorted or poor connection.
• Faulty ECM main relay.
Troubleshooting with Self-Diagnostic Code
Z9J0111104002
!
WARNING
Before troubleshooting, read and follow the “Precautions on Engine Diagnosis” (Page 1A-1).
In this section, troubleshooting procedures are based on the assumption that the “low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.
1A-22 Engine General Information and Diagnosis:
Self-Diagnostic Code “3 – 4” MAP Sensor
Wiring Diagram
Z9J0111104003
ECM
5V
1
W
B/W
R
5V
C
P
U
B
I9J011110019-02
2 1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in
Is it in good condition?
1. MAP sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the MAP sensor connector.
2) With the ignition switch “ON”, Check the voltage at the
“R” wire terminal of the MAP sensor connector.
Is the voltage approx. 4 – 5 V?
Yes
Go to step 2.
• Substitute a good
ECM and recheck.
No
• “R” wire open, “R” wire shorted to ground or a poor wire connection.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
• Faulty MAP sensor.
• “R” wire shorted to
“W” wire, “B/W” wire open, poor “B/W” wire connection, poor
“W” wire connection,
“W” wire open or poor
MAP sensor connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
For step 1
I9J011110043-02
Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor
Wiring Diagram
Engine General Information and Diagnosis: 1A-23
Z9J0111104004
ECM
5V
1
B
B
Lg/W
B/W
C
P
U
I9J011110021-03
1. Cylinder temp. sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the Cylinder
Temp. Sensor connector.
2) With the ignition switch “ON”, check the voltage at the
“Lg/W” wire terminal of the Cylinder Temp. Sensor connector.
Is the voltage 4 V or more?
2 1) Check the Cylinder Temp. Sensor.
Refer to “Cylinder Temp. Sensor Inspection” in Section
Is it in good condition?
Yes
Go to step 2.
Poor Cylinder Temp.
Sensor connection, intermittent trouble or a faulty ECM may be the cause.
No
• “Lg/W” wire shorted to the “B/W” wire or ground circuit.
• If the wiring is OK, substitute a knowngood ECM and recheck.
Faulty Cylinder Temp.
Sensor.
For step 1
I9J011110045-02
1A-24 Engine General Information and Diagnosis:
Self-Diagnostic Code “2 – 3” IAT Sensor
Wiring Diagram
1
Lg/B
B/W
ECM
5V
C
P
U
Z9J0111104005
I9J011110024-03
1. IAT sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the IAT sensor connector.
2
2) With the ignition switch “ON”, check the voltage at the
“Lg/B” wire terminal of the IAT sensor connector.
Is the voltage 4 V more?
1) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C
Is it in good condition?
Yes
Go to step 2.
Poor IAT sensor connection, intermittent trouble or a faulty ECM may be cause.
No
• “Lg/B” wire shorted to
“B/W” wire or ground circuit.
• If the wiring is OK, substitute a knowngood ECM and recheck.
Faulty IAT sensor.
For step 1
I9J011110046-01
Self-Diagnostic Code “4 – 2” CKP Sensor
Wiring Diagram
R/B
B/G
R/B
B/W
Engine General Information and Diagnosis: 1A-25
Z9J0111104006
ECM
C
P
U
1
I9J011110025-03
1. CKP sensor
Troubleshooting
Step Action
1 1) Check the CKP sensor air gap.
Refer to “CKP Sensor Removal and Installation” in
Yes
Go to step 2.
No
Incorrectly adjusted air gap.
Is it in good condition?
2 1) Check the CKP sensor resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-7).
Is it in good condition?
Open wire between the
CKP sensor and the
ECM, poor lead wire connection or sensor lead wires are shorted to each other. If lead wire and connection are ok, intermittent trouble or a faulty ECM may be the cause.
Faulty CKP sensor.
1A-26 Engine General Information and Diagnosis:
Self-Diagnostic Code “2 – 4” CMP Sensor
Wiring Diagram
1
B/Bl
2
Y/Bl
B/W
ECM
C
P
U
Z9J0111104007
1. CMP sensor
I9J011110055-01
2. + 12 V (From Ign. switch)
Troubleshooting
Step Action
1
Is the CMP sensor installed properly and the wire harness connected securely?
2 1) Disconnect the connector from the CMP sensor.
2) Check for proper connection to the CMP sensor at “B/
Bl”, “Y/Bl” and “B/W” wire terminals.
3) If OK, turn the ignition switch “ON” and check the voltage at the “B/Bl”, “Y/Bl” and “B/W” wire terminals of the CMP sensor connector.
Yes
Go to step 2.
Go to step 5.
CMP sensor voltage
Terminal “B/Bl”: 10 – 14 V
Terminal “Y/Bl”: 4 – 5 V
Terminal “B/W”: 0 V
Correct.
No
Go to step 3.
3
4
5
Is the voltage satisfactory?
Was terminal “Y/Bl” voltage in step 2 within specification?
Was terminal “B/Bl” voltage in step 2 within specification?
Check the CMP sensor and sensor trigger vane.
Refer to “CMP Sensor Inspection” in Section 1C (Page 1C-
Go to step 4.
Go to step 5.
Substitute a knowngood ECM and recheck.
“Y/Bl” wire open or shorted to ground / power supply circuit. If the wiring and connection is OK, substitute a knowngood ECM and recheck.
“B/Bl” wire open circuit.
If the wiring and connection is OK, substitute a knowngood ECM and recheck.
Replace CMP sensor.
Is check result satisfactory?
For step 2
B / W
Y / B l
B / B l
I9J011110056-01
Self-Diagnostic Code “2 – 2” Air Intake System
Wiring Diagram
1
R
Br/Y
B/W
Engine General Information and Diagnosis: 1A-27
Z9J0111104008
ECM
5V
C
P
U
I9J011110057-01
1. TPS
Troubleshooting
Step
1 connector.
Action
1) With the ignition switch “OFF”, disconnect the TPS
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of TPS connector.
Is the voltage approx. 4 – 5 V?
Yes
Go to step 2.
No
• “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
• Faulty TPS.
2 1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-15).
Is it in good condition?
Go to step 3.
• “R” wire shorted to
“Br/Y” wire, “B/W” wire open, poor “B/
W” wire connection, poor “Br/Y” wire connection, “Br/Y” wire open or poor
TPS connection.
3 1) Check the MAP sensor, IAC system and intake manifold
(system) for air leakage.
Is the result OK?
Intermittent trouble or faulty ECM. Substitute a known-good ECM and recheck.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
Faulty air intake system.
For step 1
B/W
Br/Y
R
I9J011110058-01
1A-28 Engine General Information and Diagnosis:
Self-Diagnostic Code “3 – 2” MAP Sensor 2
Wiring Diagram
Z9J0111104009
1
+ 5V
ECM
5V
R
Br/Y
B/W
2
W
B/W
R
B
1. TPS 2. MAP sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the MAP sensor connector.
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of the MAP sensor connector.
Is the voltage approx 4 – 5 V?
Yes
Go to step 2.
5V
C
P
U
I9J011110029-03
No
• “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
Faulty MAP sensor.
2 1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in
Is it in good condition?
3 1) With the ignition switch “OFF”, disconnect the TPS connector.
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?
Go to step 3.
Go to step 4.
• “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
Engine General Information and Diagnosis: 1A-29
Step Action
4 1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-15).
Is it in good condition?
Yes
Intermittent trouble, substitute a knowngood ECM and recheck.
No
• Faulty TPS.
• “R” wire shorted to
“Br/Y” wire, “B/W” wire open, poor “B/
W” wire connection, poor “Br/Y” wire connection, “Br/Y” wire open or poor
TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
For step 1
W
B/W
R
I9J011110048-02
1A-30 Engine General Information and Diagnosis:
Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor
Wiring Diagram
1
B
B
V/W
B/W
ECM
5V
C
P
U
Z9J0111104010
I9J011110030-02
1. Ex. manifold temp. sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the Ex.
Manifold Temp sensor connector.
2) With the ignition switch “ON”, check the voltage at the
“V/W” wire terminal of the Ex. Manifold Temp. sensor connector.
Is the voltage 4 V or more?
2 1) Check the Ex. Manifold Temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Inspection” in
Is it in good condition?
Yes
Go to step 2.
Poor Ex. Manifold
Temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.
No
• “V/W” wire shorted to
“B/W” wire or ground circuit.
• If the wiring is OK, substitute a knowngood ECM and recheck.
Faulty Ex. manifold temp sensor.
For step 1
I9J011110049-01
Self-Diagnostic Code “4 – 3” Fuel Injector
Wiring Diagram
12 V (From main relay)
1
#1
O/B
#2
#3
B/Br
R/W
#4
Lg
Engine General Information and Diagnosis: 1A-31
Z9J0111104011
ECM
C
P
U
I9J011110040-04
1. Fuel injector
Troubleshooting
Step
1
Action
1) Using a sound scope, check that each injector has an operating sound when the engine is cranking.
Do all injectors make an operating sound?
2 1) Check the fuel injector, the wiring connection and the wire harness of the fuel injector not making the operating sound.
Yes
Fuel injector and its circuit are in good condition.
Substitute a knowngood ECM and recheck.
No
Go to step 2.
Faulty injector or its circuit.
Are all of the above OK?
3 1) With the ignition switch “OFF”, disconnect the connector from the fuel injector.
Go to step 4.
2) Check the voltage at “Gr” wire terminal with the ignition switch “ON”.
Power circuit open.
Is the voltage 12 V (battery voltage)?
4 1) Disconnect the ECM connector with the ignition switch
“OFF”, and check all of the injectors for resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-7).
Substitute a knowngood ECM and recheck.
Faulty injector or its circuit.
Is the resistance 10 – 14
Ω
for each injector?
For step 3
Gr
I9J011110023-02
1A-32 Engine General Information and Diagnosis:
Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor)
Wiring Diagram
1
ECM
5V
R
Br/Y
B/W
C
P
U
Z9J0111104012
I9J011110059-01
1. TPS
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the TPS connector.
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?
2 1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-15)
Is it in good condition?
Yes
Go to step 2.
No
• “R” wire open, “R” wire shorted to ground circuit or poor connection.
Substitute a knowngood ECM and recheck.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
• Faulty TPS.
• “R” wire shorted to
“Br/Y” wire, “B/W” wire open, poor “B/
W” wire connection, poor “Br/Y” wire connection, “Br/Y” wire open or poor
TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
For step 1
B/W
Br/Y
R
I9J011110060-01
Self-Diagnostic Code “1 – 2” Shift Position Sensor
Wiring Diagram
1
R
P/Bl
B/W
Engine General Information and Diagnosis: 1A-33
Z9J0111104013
ECM
5V
C
P
U
I9J011110061-01
1. Shift position sensor
Troubleshooting
Step
1
Action
1) With the ignition switch “OFF”, disconnect the shift position sensor connector.
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of the shift position sensor connector.
Is the voltage approx. 4 – 5 V?
Yes
Go to step 2.
2 1) Check the shift position sensor output voltage change.
Refer to “Shift Position Sensor Inspection” in Section 1C
Is it in good condition?
Poor shift position sensor connection, intermittent trouble or a faulty ECM may be the cause.
No
• “R” wire open, “R” wire shorted to ground circuit or poor connection.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
• “R” wire shorted to
“P/Bl” wire, “B/W” wire open, poor “B/
W” wire connection, poor “P/Bl” wire connection, “P/Bl” wire open or poor shift position sensor connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.
• Faulty shift position sensor.
For step 1
P/Bl
R
B/W
I9J011110062-01
1A-34 Engine General Information and Diagnosis:
Self-Diagnostic Code “3 – 3” Neutral Switch
Wiring Diagram
1
Y/G
Br
Y/G
B/Bl
ECM
C
P
U
Z9J0111104014
12V (From Ign. switch)
I9J011110033-04
1. Neutral switch
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect the neutral switch connector.
2) With the ignition switch “ON”, check the voltage at the
“B/Bl” wire terminal of the neutral switch connector.
Is the voltage 12 V or more?
2 1) Check the Neutral Switch.
Refer to “Neutral Switch Inspection” in Section 1I
Is it in good condition?
Yes
Go to step 2.
• Poor neutral switch connection, intermittent trouble or a faulty ECM.
• If the wiring and connection is OK, substitute a knowngood ECM and recheck.
Faulty neutral switch.
• Shift position sensor lever damage.
No
• “B/Bl” wire shorted to
“Y/G” wire or ground circuit.
For step 1
Y/G
B/Bl
I9J011110051-02
Engine General Information and Diagnosis: 1A-35
Self-Diagnostic Code “1 – 1” Rectifier/Regulator (Over Charging)
NOTE
Z9J0111104015
• This self-diagnostic code indication may be canceled when turning the ignition switch “ON” (engine not running), because ECM detects battery voltage.
• It is difficult to thoroughly check the rectifier/regulator. Before replacing it with new one, check that the ground point has good electrical contact.
Troubleshooting
Step Action
1 1) Check the Rectifier/Regulator resistance.
Refer to “Rectifier/Regulator Inspection” in Section 1K
Yes
Go to step 2.
No
Faulty Rectifier/
Regulator.
Is the result OK?
2 1) With the engine running, check charging voltage at idle speed.
Faulty Rectifier/
Regulator.
Is the result 16 V or higher?
Faulty ECM or wire continuity / connection failure.
Self-Diagnostic Code “5 – 3” Oil Pressure Switch
Wiring Diagram
Z9J0111104016
ECM
1
Bl
C
P
U
I9J011110063-01
1. Oil pressure switch
Troubleshooting
Step
1
Action
1) With the ignition switch “OFF”, remove the oil pressure switch wire.
2 1) Check the oil pressure switch operation.
Refer to “Oil Pressure Switch Inspection” in Section 1E
Yes
Go to step 2.
No
• Oil pressure switch wire open or poor connection.
2) With the ignition switch “ON”, check the voltage between the oil pressure switch wire terminal and body ground.
Is the voltage approx. 5 V?
Is it in good condition?
Poor oil pressure switch wire connection, intermittent trouble or a faulty ECM may be the cause.
• If wire and connection are OK, substitute a knowngood ECM and recheck.
Faulty oil pressure switch.
For step 1
I9J011110064-01
1A-36 Engine General Information and Diagnosis:
Self-Diagnostic Code “3 – 7” Trim Sensor
Wiring Diagram
1
R
W/Y
B/W
ECM
5V
C
P
U
Z9J0111104017
I9J011110065-01
1. Trim sensor
Troubleshooting
Step Action
1 1) With the ignition switch “OFF”, disconnect trim sensor connector.
2) With the ignition switch “ON”, check the voltage at the
“R” wire terminal of trim sensor connector.
Is the voltage approx. 4 – 5 V?
2 1) Check the trim sensor output voltage change.
Refer to “Trim Sensor Inspection” in Section 1C
Is it in good condition?
Yes
Go to step 2.
Poor trim sensor connection, intermittent trouble or a faulty ECM.
No
• “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wire and connection is OK, substitute a knowngood ECM and recheck.
• “R” wire shorted to
“W/Y” wire, “B/W” wire open, poor “B/
W” wire connection, poor “W/Y” wire connection, “W/Y” wire open or poor trim sensor connection.
• If the wire and connection is OK, intermittent trouble or a faulty ECM may be the cause.
• Faulty trim sensor.
For step 1
W/Y
R
B/W
I9J011110066-01
Engine General Information and Diagnosis: 1A-37
Troubleshooting Without Self-Diagnostic Code
Z9J0111104018
Before troubleshooting, make sure that there is not a self-diagnostic code indication.
Condition
Unstable idling / trolling
(or engine tends to stall)
Possible cause
Clogged MAP sensor vacuum passage.
Check the vacuum passage.
Malfunctioning TPS.
Faulty IAC system.
Fuel pressure out of specification.
Faulty injector or its circuit.
Poor performance of the IAT sensor,
TPS or MAP sensor.
Faulty ECM.
Faulty spark plug.
Faulty ignition coil or its circuit.
Correction / Reference Item
Check the TPS sensor.
Check the IAC system.
Check the fuel pressure.
Check the injector and its circuit.
Check each sensor.
Replace.
Replace.
Check the ignition coil and its circuit.
1A-38 Engine General Information and Diagnosis:
IAC System Troubleshooting
Wiring Diagram
12V (From Main relay)
1
B
A
1
2
3
4
ECM
Z9J0111104019
I9J011110036-02
1. IAC valve
Troubleshooting
Step Action
1 1) Warm up the engine to normal operating temperature and keep it idling.
2) Using the SDS tool, check the IAC duty cycle and idle speed.
Idle speed (IAC duty cycle):
550 – 650 r/min (approx. 0 – 30%)
Is result OK?
2 1) Disconnect the IAC connector at the IAC valve with ignition switch “OFF”.
2) Check the resistance between following terminals.
/ IAC “1” terminal – “B” terminal
/ IAC “2” terminal – “B” terminal
/ IAC “3” terminal – “A” terminal
/ IAC “4” terminal – “A” terminal
Is the resistance 25 – 34
Ω
for each test?
Yes
IAC system is in good condition.
No
Go to step 2.
Proceed to “Unstable
Idling / Trolling” in
and check items except for “Faulty IAC System”.
• Faulty IAC valve.
• Poor connection.
• Open wire harness.
For step 2
4 A 3
2 B 1
I9J011110041-01
Engine General Information and Diagnosis: 1A-39
Service Instructions
How to Use the 36 Pin Test Cord Set
Z9J0111106001
This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring harness.
To take a measurement, connect the tester probe to the relevant terminal of the test cord.
Special tool
(A): 09930–88730 (36-pin test cord set)
ECM
2
1
(White connector)
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
(A)
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
(White connector)
(A)
(Black connector)
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
3
3
I9J011110037-02
1. Black connector side 2. Gray connector side 3. Wire harness
Inspection of the ECM and Its Circuit
CAUTION
The ECM cannot be bench checked. It is strictly prohibited to connect any tester (voltmeter or ohmmeter) to an ECM which has been disconnected from the engine wiring harness.
Z9J0111106002
Special tool
: 09930–88730 (36-pin test cord set)
: 09930–99320 (Digital tester)
Tester knob indication
Voltage ( )
1) Turn the ignition switch “OFF”.
2) Pull and remove the fuse box from electric parts holder.
3) Connect the 36-pin test cord set between the ECM and wire harness as shown in figure.
4) Turn the ignition switch “ON”.
1A-40 Engine General Information and Diagnosis:
ECM
2
1
(White connector)
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
(A)
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
(White connector)
3
1. Black connector side
3
2. Gray connector side 3. Wire harness
(A)
(Black connector)
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
I9J011110037-02
Circuit Voltage Table
“B”
48 47 46 45 44 43 42 41 40 39 38 37
60 59 58 57 56 55 54 53 52 51 50 49
72 71 70 69 68 67 66 65 64 63 62 61
12 11 10 9 8 7 6 5 4 3 2 1
24 23 22 21 20 19 18 17 16 15 14 13
36 35 34 33 32 31 30 29 28 27 26 25
“A”
I9J011110017-02
“A”: Black connector
Terminal
1
2
Wire color
—
Circuit
—
G Starter relay control
7
8
9
10
11
12
13
14
15
3
4
5
6
P/W PTT relay DN
— —
Bl/B Water pressure sensor
Br/Y Throttle position sensor
W/Y Trim and Tilt sensor
Lg/B IAT sensor
Bl/W Speedo sensor
R/W Power source #2 for sensor
Bl Oil pressure switch
Gr ECM power source
— —
— —
B/G Ignition switch key
“B”: Gray connector
Standard Voltage Condition / Remarks
—
Approx. 0.5 V
Approx. 12 V
Approx. 0 V
Approx. 12 V
—
0.5 – 4.5 V
Approx. 3.8 V
—
—
Approx. 12 V
—
Ignition switch ON, Cranking.
Ignition switch ON, Normal.
PTT switch DN, free.
PTT switch DN, Push.
—
Ignition switch ON.
Ignition switch ON, Throttle WOT.
Approx. 0.7 V Ignition switch ON, Throttle FCT.
Approx. 0.9 – 4.0 V Ignition switch ON.
0.04 – 4.46 V
0.5 – 4.5 V
Ignition switch ON.
Ignition switch ON.
Approx. 5 V
Approx. 5 V
Approx. 0 V
Approx. 12 V
Ignition switch ON.
While engine running.
Engine stopped (Ignition switch ON.)
Ignition switch ON.
Ignition switch ON.
—
—
22
23
24
25
26
27
28
29
30
31
32
33
34
35
40
41
42
43
36
37
38
39
44
45
46
47
48
49
58
59
60
61
62
63
54
55
56
57
50
51
52
53
Terminal
16
17
18
19
20
Wire color
Circuit
Bl/R Emergency stop switch
—
—
—
—
— —
Lg/W Cylinder temp. sensor
21 P/Bl Shift position sensor
P PTT switch DOWN
Lbl PTT switch UP
B Ground for ECM
B/W Ground for sensor
— —
Lg/W PTT relay UP
—
—
—
—
— —
V/W Ex-manifold temp. sensor
W MAP sensor
R Power source #1 for sensor
— —
R/B Ground for ECM main relay
B/Bl Ignition switch
— —
Y PC communication line (B)
— —
Y/Bl CMP sensor
Gr/Y No.3 Ignition coil (–)
O No.1 Ignition coil (–)
W/Y Trim gauge
Bl/W Buzzer
O/B No.1 Fuel injector (–)
— —
R/W No.3 Fuel injector (–)
W/Bl IAC valve #4
Y/G Neutral switch
R/B CKP sensor
B Ground for ECM power
— —
Lg/R No.4 Ignition coil (–)
Bl No.2 Ignition coil (–)
P/W REV-LIMIT lamp
Y/B Tachometer
G/Y TEMP lamp
R/G IAC valve #3
Lg No.4 Fuel injector (–)
W/B IAC valve #1
— —
O/Y PC communication line (A)
B Ground for power
Engine General Information and Diagnosis: 1A-41
Standard Voltage Condition / Remarks
Approx. 5 V
Approx. 0 V
—
—
—
0.14 – 4.75 V
Approx. 2.5 V
Approx. 3.7 V
Ignition switch ON, Stop switch plate IN.
Ignition switch ON, Stop switch plate OUT.
—
—
—
Ignition switch ON.
Ignition switch ON, shift in Neutral.
Ignition switch ON, shift in Forward.
Ignition switch ON, shift in Reverse.
Approx. 1.2 V
Approx. 12 V
Approx. 0 V
Approx. 12 V
Approx. 0 V
—
—
—
Approx. 0 V
Approx. 12 V
—
—
—
0.14 – 4.75 V
0.79 – 4.2 V
Approx. 5 V
—
Approx. 12 V
Ignition switch ON, PTT DN switch ON.
Ignition switch ON, PTT DN switch OFF.
Ignition switch ON, PTT UP switch ON.
Ignition switch ON, PTT UP switch OFF.
—
—
PTT switch UP free.
—
PTT switch UP Push.
Ignition switch ON.
Ignition switch ON.
Ignition switch ON.
—
—
—
—
Ignition switch OFF.
• Ignition switch ON.
Approx. 0.5 V
Approx. 12 V
—
—
—
• Engine cranking.
Ignition switch ON.
—
—
—
Approx. 0.3 V or 5 V Ignition switch ON.
Approx. 0 V Ignition switch ON.
Approx. 0 V
—
Ignition switch ON.
—
Approx. 12 V
Approx. 12 V
Approx. 0 V
Ignition switch ON.
—
Approx. 12 V Ignition switch ON.
Approx. 12 V or 0 V Ignition switch ON.
Reverse.
—
—
—
Ignition switch ON, Shift into Neutral.
Ignition switch ON, Shift into Forward or
—
—
—
Approx. 0 V
Approx. 0 V
—
—
—
Ignition switch ON.
Ignition switch ON.
—
—
—
—
—
—
Approx. 12 V or 0 V Ignition switch ON.
Approx. 12 V Ignition switch ON.
Approx. 12 V or 0 V Ignition switch ON.
—
—
—
—
—
—
1A-42 Engine General Information and Diagnosis:
Terminal
64
Wire color
Circuit
O/W Buzzer cancel
65
66
67
68
69
70
71
Br Starter switch
Bl/B OIL lamp
—
—
—
—
G/W CHECK ENGINE lamp
R/Y IAC Valve #2
B/Br No.2 Fuel injector (–)
72 B/R High pressure fuel pump (–)
Standard Voltage Condition / Remarks
Approx. 12 V
Approx. 0 V
Approx. 2.5 V
Approx. 12 V
—
—
—
—
Ignition switch ON. Key pushed in.
Ignition switch ON. Key not pushed in.
Ignition switch ON.
Ignition switch START position.
—
—
—
—
Approx. 12 V or 0 V Ignition switch ON.
Approx. 12 V Ignition switch ON.
Approx. 0 V
• Stop switch plate IN, Shift into
NEUTRAL.
For 3 sec after ignition switch ON.
Approx. 12 V
• While engine running.
Engine stopped. Ignition switch ON.
Stop switch plate IN, Shift into NEUTRAL.
ECM Main Relay Inspection
Z9J0111106003
Inspect the ECM main relay using the following procedures:
1) Disconnect the ECM main relay from the fuse box.
ECM main relay function
12 V power applied
12 V power not applied
Continuity
Yes
No
2 3
1
5
I9J011110054-02
1. ECM main relay
2) Check continuity between terminal (2) and (3) each time 12 V power supply is applied to terminal (4) and
(5).
Connect the positive (+) lead to terminal (5), and negative (–) lead to terminal (4).
CAUTION
Be careful not to touch 12 V power supply wires to each other or with other terminals.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
12 V
CONT
4
(A)
I9J011110038-02
3) Measure the resistance between relay terminals (4) and (5).
If out of specification, replace ECM main relay.
Tester knob indication
Resistance (
Ω
)
ECM Main relay solenoid coil resistance
Standard: 145 – 190
Ω
(A)
I9J011110039-01
Engine Electrical Devices: 1C-1
Power Head
Engine Electrical Devices
Precautions
Precaution for Engine Electrical Device
Z9J0111300001
General Description
Sensor and Switch Description
Z9J0111301001
CKP Sensor
• There is one CKP sensor installed below the flywheel rotor.
When the reluctor bars on the flywheel pass the sensor, a signal (voltage pulse) is generated and sent to the ECM. This is the fundamental signal used to judge engine speed and crankshaft angle.
• There are 32 reluctor bars. They are located 10 degrees apart, except at two positions where they are
30 degrees apart.
During one crankshaft rotation, 32 signals are input to the ECM.
•
Failure symptom:
Without the CKP sensor signal input, the ECM does not output the ignition and fuel injection signals.
CMP Sensor
• The CMP sensor is mounted on the cylinder head cover and the trigger vanes are pressed onto the end of the exhaust camshaft.
This sensor is used to detect piston position.
• Signals received from this sensor are also used by the
ECM to determine sequential fuel injection and ignition control.
• The 12 V power to the CMP sensor is supplied through the Ign (Gr) line of the ignition switch.
1
I9J011130027-01
1. CMP sensor
1. CKP sensor
1
2. Reluctor bar
2
I9J011130026-01
1C-2 Engine Electrical Devices:
• The CMP sensor is a GMR (Giant Magnet Resistive) semiconductor type sensor.
The GMR semiconductor has the property of varying the electrical resistance depending on the intensity of the magnetic force applied.
When the line of magnetic force from the magnet to the GMR semiconductor is increased or decreased, the electrical resistance of the GMR semiconductor will change. The changes in resistance as the magnets pass create the sensors waveform.
When a trigger vane on the camshaft reluctor aligns with the sensors internal magnet, the electrical resistance of the GMR will decrease.
When a trigger vane moves away from the sensor, the electrical resistance of the GMR will increase.
When the GMR semiconductor voltage becomes higher than the standard value, the sensors signal will be lower. And when the voltage becomes lower than the standard value, the sensors signal will be higher.
The six camshaft trigger vanes provide six high voltage signals from the CMP sensor to the ECM during one camshaft rotation (two rotations of crankshaft).
1
•
Failure symptom:
Without the CMP sensor signal input, the ECM does not output the ignition and fuel injection signals.
•
ECM cylinder identification:
The cylinders are identified by a calculation of two signals; one from the CKP sensor and one from the
CMP sensor.
The ECM measures the time interval of the signals inputted from the CKP sensor.
When the ECM detects a signal interval that is longer than normal, it determines that the wide space between the reluctor bars (30 degree spaced apart section) has passed through the CKP sensor.
The ECM identifies the cylinder by the number of
CMP sensor signal inputs and the input timing
(pattern) within the gap of the widely spaced reluctors that have passed the CKP sensor. There are 2 CMP sensor signal inputs to the ECM when the #1 or #4 cylinders are on the compression stroke, but the input timing (pattern) is different.
Thus the cylinder identification is established.
When a compression stroke takes place either in the
#2 or the #3 cylinder, the number of CMP sensor signal inputs is 1. Likewise, the cylinder identification is established by the CMP sensor input timing
(pattern).
Signal
High
Low
2
4
3
1. Camshaft
2. Trigger vane
3. Magnet resistive semiconductor
5
4. Magnet
5. CMP sensor
I9J011130001-01
32 signals / crankshaft 1 rotation
CKP sensor signal
10°
140°
30°
220°
40°
CMP sensor signal
No.1 cylinder
No.3 cylinder
No.4 cylinder
No.2 cylinder
Cm.
In.
Ex.
Ep.
180°
100°
40°
Ep.
Cm.
In.
Ex.
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC
Ex.
In.
TDC
TDC
Ep.
Ex.
TDC
Cm.
Ep.
TDC TDC
In.
Cm.
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake
Cm.
In.
Ex.
Ep.
140°
TDC
Ep.
TDC
Cm.
In.
Ex.
I9J011130002-04
Cylinder Temperature Sensor
The cylinder temperature sensor is installed on the cylinder (top side) and is used to detect the cylinder temperature.
This is a thermistor type sensor (resistance of which changes depending on temperature) and inputs a signal to the ECM as a voltage value. This signal is used to compensate the fuel injection duration, ignition timing, etc.
This sensor is also used to detect engine over-heat as the ECM detects both the temperature and temperature change rate (gradient temp.-temperature rise vs. time).
Engine Electrical Devices: 1C-3
Exhaust Manifold Temperature Sensor
The exhaust manifold temperature sensor is installed on the exhaust manifold and used to detect exhaust manifold temperature.
This sensor is the same type as the cylinder temperature sensor, and inputs a signal to the ECM as a voltage value.
This signal is also used to detect engine over-heat.
1
1. Cylinder temp. sensor
(k )
1
I9J011130028-01
I9J011130029-01
1. Exhaust manifold temp. sensor
IAT Sensor
The IAT sensor is installed on the air intake silencer case and is used to detect the intake air temperature.
This sensor is the same type as the cylinder temperature sensor, and inputs a signal to the ECM as a voltage value.
This signal is used to compensate the fuel injection duration.
Temperature (C°)
I9J011130003-02
1
1. IAT sensor
I9J011130030-01
1C-4 Engine Electrical Devices:
MAP Sensor
The MAP sensor is installed on the intake manifold and used to detect the intake manifold pressure.
This sensor inputs the intake manifold pressure to the
ECM as a voltage value.
This input signal is used as the fundamental signal to determine fuel injection duration, ignition timing, etc.
1
Neutral Switch
The neutral switch is installed on the clutch lever holder and is used to detect the shift position.
This switch is “ON” in neutral and “OFF” in forward or reverse.
The ECM performs the following control based on the neutral switch signal:
• When the shift lever is in forward or reverse at the time of engine start, the ECM will not supply power to the starter motor relay, thus preventing starter motor engagement.
(Start-in-gear protection. Refer to “Start-In-Gear
Protection System Description” in Section 1I (Page 1I-
I9J011130031-01
1. MAP sensor
Throttle Position Sensor (TPS)
The TPS is installed on the throttle body and detects the degree of throttle opening. The throttle shaft is interlocked with the TPS shaft.
This sensor is a variable resistor, changing resistance
(Ohms) in accordance with the throttle opening.
The varying resistance value is converted to voltage and input to the ECM.
Based on the TPS voltage, the ECM calculates the idle and throttle opening positions to determine the control modes of the various controls systems (Idle air control, fuel injection control system, etc.).
1
1
I9J011130033-01
1. Neutral switch
Shift Position Sensor (SPS)
The SPS is installed on the clutch lever holder and detects the shift position. The clutch lever is interlocked with the SPS shaft.
This sensor is a variable resistor that changes resistance
(Ohms) in accordance with the shift position.
The varying resistance value is converted to voltage and input to the ECM.
Based on the SPS voltage, the ECM determines the shift position and executes the following controls.
• When the shift lever is in neutral, fuel injection is controlled to prevent engine speed from exceeding 3
000 r/min.
• After shifting into forward or reverse from neutral, the
IAC valve is controlled to increase intake air to prevent unstable engine idle or stalling.
I9J011130032-01
1. TPS
1
1. SPS
I9J011130034-01
Trim Sensor
The trim sensor is variable resistor type.
With the sensor signal received, the ECM performs the learning of the trim/tilt position and it controls the position of both the trim down limit and the tilt up limit.
The trim sensor signal also operates the trim meter through the ECM.
Engine Electrical Devices: 1C-5
Cranking Switch Signal
The ECM detects if the engine is being started by the position of ignition switch. When the ignition key is turned to ST position, a voltage (12 V) signal is input to the ECM.
The ECM in turn sets the ignition, fuel injection, IAC, etc. to the starting mode.
When the key is turned to the IG position, after the engine has been started, the input voltage becomes approx. 2.5 V.
2 3
+12V 1
1
OFF
IG
ST
I9J011130035-01
1. Trim sensor
•
Failure symptom:
In the event of sensor failure:
– The ECM performs the control on the assumption that the sensor output is 3.9 V.
– The control of the trim down limit and the tilt up limit becomes inoperative.
– The trim gauge indicates a full trim position.
NOTE
When the ECM has been replaced, the trim sensor removed/reinstalled, or the mid unit overhauled, resetting of both the tilt up limit and trim down limit must be performed.
ECM Main Relay
The ECM main relay is installed in the fuse box.
When energized by turning the ignition switch “ON”, battery voltage is supplied to the ECM, fuel injector, ignition coil, IAC valve and high pressure fuel pump.
With the ignition switch in the “OFF” position, and the UP or DOWN button of the PTT switch pressed, the main relay turns “ON” to supply 12 V power to the ECM, which then performs the on / off control of the PTT motor relay.
ECM
1. Ignition switch
2. Neutral switch
I9J011130004-03
3. Starter motor relay
Ignition switch Signal
The ECM receives a power signal when the ignition switch is turned “ON”, then sets the IAC valve to the standard starting position.
+12V 1
OFF
IG
1. Ignition switch
15
ECM
I9J011130037-01
1
1. ECM main relay
I9J011130036-02
1C-6 Engine Electrical Devices:
ECM Power Source Line
Z9J0111301002
The ECM is battery dependent and must be provided with its own dedicated 12 V power supply. The electrical circuits which provide this supply are:
1. The sub battery cable to the white lead wire in the remote control extension harness to the ignition switch.
When the ignition switch is turned “ON”, battery power passes from the white lead wire, through the ignition switch contacts to the gray output lead wire to the No. 15 and 36 terminals of the ECM.
NOTE
Ensure that the battery cable connections are clean and secure.
A failure at the battery connection will cause incorrect operation of the ECM and starter motor cranking system.
2. The engine wiring harness to the main relay.
When the ECM main relay is energized, by turning the ignition switch “ON”, battery voltage is supplied to the No. 12 terminal of the ECM.
2
1
R
4 3
5
Main Harness Capacitor
This capacitor stabilizes the voltage in the engine control system circuit.
• If a “short” occurs in this circuit, the sub battery cable fuse will blow causing the engine control system to be inoperative.
• If an “open” occurs in this circuit, the cranking system will not function.
1
1. Main harness capacitor
I9J011130038-01
7
W
6
Gr
B/Bl
B/G
R/B
12
36
ECM
15
35
8
BATT
IG
W
Gr
GND
B
Gr
B
1. Starter motor
2. Main battery cable
3. 40 amp. fuse
4. 30 amp. fuse
I9J011130005-03
5. ECM main relay
6. 15 amp. fuse
7. Sub-battery cable
8. Battery
Engine Electrical Devices: 1C-7
Component Location
Location of Sensor and Switch
Z9J0111303001
Service Instructions
Resistance Check
Z9J0111306001
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (
Ω
)
NOTE
Make sure ignition switch is always OFF when measuring resistance.
1) Turn ignition switch OFF.
2) Disconnect battery cables from battery.
3) Disconnect wire harness connector from ECM.
37 38 39 40 41 42 43 44 45 46 47 48
49 50 51 52 53 54 55 56 57 58 59 60
61 62 63 64 65 66 67 68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12
13 14 15 16 17 18 19 20 21 22 23 24
25 26 27 28 29 30 31 32 33 34 35 36
3 1
2
I9J011130006-04
1. Engine main wire harness
Resistance Table
Circuit
CKP sensor
Fuel injector No. 1
Fuel injector No. 2
Fuel injector No. 3
Fuel injector No. 4
IAC Valve #1
IAC Valve #2
IAC Valve #3
IAC Valve #4
IAT sensor
Cylinder temperature sensor
Ex-manifold temperature sensor
2. Black connector
Terminal for Tester Probe
Connection
50 (R/B) to 25 (B/W)
45 (O/B) to 12 (Gr)
71 (B/Br) to 12 (Gr)
47 (R/W) to 12 (Gr)
59 (Lg) to 12 (Gr)
60 (W/B) to 12 (Gr)
70 (R/Y) to 12 (Gr)
58 (R/G) to 12 (Gr)
48 (W/Bl) to 12 (Gr)
8 (Lg/B) to 25 (B/W)
20 (Lg/W) to 25 (B/W)
31 (V/W) to 25 (B/W)
3. Gray connector
Standard Resistance (at 20
°
C)
168 – 252
Ω
10 – 14
Ω
25 – 34
Ω
(Including IAC fuse 10 amp resistance)
0
°
C (32
°
F): 5.3 – 6.6 k
Ω
25
°
C (77
°
F): 1.8 – 2.3 k
Ω
50
°
C (122
°
F): 0.73 – 0.96 k
Ω
75
°
C (135
°
F): 0.33 – 0.45 k
Ω
(Thermistor characteristic)
1C-8 Engine Electrical Devices:
Cylinder Temp. Sensor Removal and
Installation
Z9J0111306002
Removal
1) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
2) Remove the thermostat cover.
Refer to “Thermostat Removal and Installation” in
3) Disconnect the cylinder temp. sensor lead wire connector.
Loosen and remove the cylinder temp. sensor (1).
Cylinder Temp. Sensor Inspection
Z9J0111306003
1) Remove the cylinder temperature sensor.
Refer to “Cylinder Temp. Sensor Removal and
2) Immerse temperature sensing part of cylinder temp. sensor in water.
3) Measure resistance between sensor terminals while heating water gradually.
4) If measured resistance does not change in the proportion indicated, replace sensor.
Cylinder temp. sensor specification
Water temperature:
°
C (
°
F)
Resistance
(k
Ω
)
0 (32) 25 (77)
5.3 – 6.6 1.8 – 2.3
50 (122) 75 (135)
0.73 –
0.96
0.33 –
0.45
1
1
I9J011130039-01
Installation
Installation is reverse order of removal.
• Clean mating surface of sensor and cylinder.
• Tighten sensor to specified torque.
Tightening torque
Cylinder temp. sensor (a): 8 N·m (0.8 kgf-m, 5.8 lbf-ft)
1. Thermometer
2
2. Heater
I9J011130051-01
(a)
I9J011130040-01
• Connect connector to sensor securely.
• Check to ensure that all removed parts are back in original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
Temperature
I9J011130008-02
5) Reinstall the cylinder temp. sensor.
Refer to “Cylinder Temp. Sensor Removal and
Ex. Manifold Temp. Sensor Removal and
Installation
Z9J0111306004
Removal
1) Disconnect the Ex. manifold temp. sensor lead wire connector.
2) Loosen and remove the Ex. manifold temp. sensor
(1).
1
Engine Electrical Devices: 1C-9
Ex. Manifold Temp. Sensor Inspection
Z9J0111306005
1) Remove the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Removal and
2) Immerse temperature sensing part of Ex. manifold temp. sensor in water.
3) Measure resistance between sensor terminals while heating water gradually.
4) If measured resistance does not change in the proportion indicated, replace sensor.
Ex. manifold temp. sensor specification
Water temperature:
°
C (
°
F)
Resistance
(k
Ω
)
0 (32) 25 (77)
5.3 – 6.6 1.8 – 2.3
50 (122) 75 (135)
0.73 –
0.96
0.33 –
0.45
I9J011130041-01
Installation
Installation is reverse order of removal.
• Clean mating surface of sensor and exhaust cover.
• Tighten sensor to specified torque.
Tightening torque
Ex. manifold temp. sensor (a): 8 N·m (0.8 kgf-m,
5.8 lbf-ft)
1
1. Thermometer
2
2. Heater
I9J011130051-01
(a)
• Connect connector to sensor securely.
I9J011130042-01
Temperature
I9J011130008-02
5) Reinstall the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Removal and
1C-10 Engine Electrical Devices:
CKP Sensor Removal and Installation
Z9J0111306006
Removal
1) Remove the ring gear cover and air intake silencer case.
Refer to “Ring Gear Cover Removal and Installation”
in Section 1D (Page 1D-2) and “Air Intake Silencer
Case Removal and Installation” in Section 1D
2) Disconnect the CKP sensor lead wire connector.
3) Remove the two screws and CKP sensor (1).
CKP Sensor Inspection
Inspect the CKP sensor.
Refer to “Resistance Check” (Page 1C-7).
Z9J0111306007
IAT Sensor Removal and Installation
Z9J0111306008
Removal
1) Remove the ring gear cover and air intake silencer case.
Refer to “Ring Gear Cover Removal and Installation”
in Section 1D (Page 1D-2) and “Air Intake Silencer
Case Removal and Installation” in Section 1D
2) Disconnect the IAT sensor lead wire connector.
3) Remove IAT sensor (1).
1
I9J011130043-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Install CKP sensor with air gap of 0.75 mm between sensor and reluctor bar on flywheel, then tighten sensor mounting screws securely.
CKP sensor air gap “a”
0.75 mm (0.030 in.)
1
I9J011130045-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Check to ensure that all removed parts are back in original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
2
3
“ a ”
1
1. CKP sensor
2. Reluctor bar
3. Thickness gauge
I9J011130044-01
• Check to ensure that all removed parts are back in original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
IAT Sensor Inspection
Z9J0111306009
1) Remove the IAT sensor.
Refer to “IAT Sensor Removal and Installation”
2) Immerse temperature sensing part of IAT sensor in water.
3) Measure resistance between sensor terminals while heating water gradually.
4) If measured resistance does not change in the proportion indicated, replace sensor.
IAT sensor specification
Water temperature:
°
C (
°
F)
Resistance
(k
Ω
)
0 (32) 25 (77)
5.3 – 6.6 1.8 – 2.3
50 (122) 75 (135)
0.73 –
0.96
0.33 –
0.45
Engine Electrical Devices: 1C-11
CMP Sensor Removal and Installation
Z9J0111306010
Removal
1) Disconnect the CMP sensor lead wire connector at sensor.
2) Remove the bolt and CMP sensor (1).
1
1
1. Thermometer
2
2. Heater
I9J011130007-03
I9J011130046-01
Installation
Installation is reverse order of removal.
• Install CMP sensor, then tighten mounting screw securely.
• Connect sensor lead wire connector to CMP sensor.
CMP Sensor Inspection
Z9J0111306011
1) Turn ignition switch OFF.
2) Remove the bolt and CMP sensor.
3) Connect the 36-pin test cord set between ECM and wire harness as shown in figure.
Special tool
(A): 09930–88730 (36-pin test cord set)
ECM
(A)
(A)
2
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
3
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
Temperature
I9J011130008-02
5) Reinstall the IAT sensor.
Refer to “IAT Sensor Removal and Installation”
1
1. Wire harness
2. White connector
3. Black connector
I9J011130052-02
4) Connect the tester probe (“+”, Red) to No. 40 terminal.
5) Connect the tester probe (“–”, Black) to No. 25 terminal (or to body ground).
Special tool
: 09930–99320 (Digital tester)
1C-12 Engine Electrical Devices:
Tester knob indication
DC Voltage ( )
36-pin test cord (White connector)
2
40
MAP Sensor Removal and Installation
Z9J0111306012
Removal
1) Remove the flywheel.
Refer to “Flywheel Removal and Installation” in
2) Disconnect lead wire connector at MAP sensor.
3) Remove the two screws and MAP sensor (1).
I9J011130011-03
36-pin test cord (Black connector)
3
1
25
I9J011130012-02
6) Turn Ignition switch ON.
7) Measure the voltage when the tip of a steel screwdriver is brought near and then pulled away from the sensor tip.
When screwdriver is brought near
Approx. 5.0 V
When screwdriver is pulled away
Approx. 0.3 V
I9J011130047-01
Installation
Installation is reverse order of removal.
• Install MAP sensor, then tighten mounting screw securely.
• Connect sensor lead wire connector to MAP sensor.
• Install flywheel and tighten flywheel bolts to specified torque.
Refer to “Flywheel Removal and Installation” in
Tightening torque
Flywheel bolt: 196 N·m (19.7 kgf-m, 142 lbf-ft)
5
4
I9J011130013-03
4. Screw driver 5. CMP sensor
8) If the voltage does not change in the above test, check wire harnesses for open and short.
If wire harnesses are in good condition, replace CMP sensor and recheck.
9) Reinstall CMP sensor.
MAP Sensor Output Voltage Inspection
Z9J0111306013
1) Remove the flywheel.
Refer to “Flywheel Removal and Installation” in
2) Connect the 36-pin test cord set between ECM and wire harness as shown in figure.
Special tool
(A): 09930–88730 (36-pin test cord set)
ECM
Engine Electrical Devices: 1C-13
4) Install MAP sensor into special tool.
5) Connect vacuum pump gauge (with hose) to MAP sensor (special tool) as shown in figure.
Special tool
(B): 09917–49610 (Vacuum pump adapter)
(C): 09917–47011 (Vacuum pump gauge)
(C)
(A)
(A)
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
2
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
1
1. Wire harness 2. Black connector
I9J011130048-02
3) Remove the screws and MAP sensor (1) from intake manifold.
(B)
I9J011130015-01
6) Turn ignition switch ON.
7) While applying negative pressure (vacuum) to MAP sensor, measure “32” terminal voltage.
MAP sensor output voltage change
Negative pressure: kPa (kg/cm 2 , mmHg)
“32” terminal voltage (V)
0
(0, 0)
4.00
40
(0.4, 300)
2.42
80
(0.8, 600)
0.84
(at 759.8 mmHg, 101.3 kPa, 29.91 inHg barometric pressure.)
36-pin test cord (Black connector)
2
(A)
32
1
I9J011130014-02
I9J011130016-02
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DC Voltage ( )
8) If out of specification, Check wire harnesses for open and short. If wire harnesses are in good condition, replace MAP sensor and recheck.
9) Reinstall MAP sensor.
Refer to “MAP Sensor Removal and Installation”
1C-14 Engine Electrical Devices:
IAC Valve Removal and Installation
Z9J0111306014
Removal
1) Remove the flywheel.
Refer to “Flywheel Removal and Installation” in
2) Disconnect IAC valve lead wire connector at IAC valve (1).
3) Remove the MAP sensor.
Refer to “MAP Sensor Removal and Installation”
4) Remove screws (2) and IAC valve.
IAC Valve Inspection
Z9J0111306015
1) Disconnect connector from IAC valve.
2) Check each coil of IAC valve for resistance.
IAC valve resistance
Terminals
Between “1” and “2”
Between “3” and “2”
Between “4” and “5”
Between “6” and “5”
Resistance
25 – 34
Ω
If out of specification, replace IAC valve.
2
1
I9J011130049-02
Installation
Installation is reverse order of removal.
• Install IAC valve, then tighten mounting screw securely.
• Connect IAC valve lead wire connector to IAC valve.
• Install the MAP sensor.
Refer to “MAP Sensor Removal and Installation”
• Install flywheel and tighten flywheel bolts to specified torque.
Refer to “Flywheel Removal and Installation” in
1 2 3
4
5
6
I9J011130017-04
3) Remove the flywheel.
Refer to “Flywheel Removal and Installation” in
4) Remove the screws securing IAC valve, then detach the IAC valve from intake manifold.
5) Connect the connector to IAC valve.
6) When the ignition switch is turned “ON” and “OFF”, check that the rotary valve turns to open and returns to closed.
I9J011130018-01
7) If the valve does not turn, check the wiring harness for continuity (between ECM and IAC valve and connector contact condition.
8) Reinstall IAC valve.
Refer to “IAC Valve Removal and Installation”
TPS Inspection
Z9J0111306016
1) Turn ignition switch OFF.
2) Connect the 36-pin test cord set between ECM and wire harness as shown in figure.
Special tool
(A): 09930–88730 (36-pin test cord set)
Engine Electrical Devices: 1C-15
3) Connect tester probe (“+”, Red) to No. 6 terminal.
4) Connect tester probe (“–”, Black) to No. 25 terminal
(or to body ground).
36-pin test cord (White connector)
3
6
1
I9J011130019-02
I9J011130021-02
36-pin test cord (Black connector)
4
25
1. TPS
ECM
(A)
(A)
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
3
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
4
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
2
2. Wire harness
3. White connector
4. Black connector
I9J011130020-03
I9J011130022-02
5) Turn the ignition switch ON.
6) Check for sensor output voltage.
Slowly move the throttle lever to open, and check if voltage changes linearly within specification, according to throttle valve opening angle.
Sensor output voltage
FCT position: Approx. 0.7 V
WOT position: Approx. 3.8 V
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DC Voltage ( )
NOTE
Do not try to adjust or remove any of the throttle body component parts (Throttle position sensor, throttle valve, throttle stop screw, etc.). These components have been factory adjusted to precise specifications.
7) If out of specification, check wire harnesses for open and short. If wire harnesses are in good condition, replace the throttle body and recheck.
1C-16 Engine Electrical Devices:
Shift Position Sensor Inspection
Z9J0111306017
1) Turn ignition switch OFF.
2) Connect 3-pin test cord between shift position sensor and wire harness as shown in figure.
3) Turn the ignition switch ON.
4) Connect tester probe as shown in the illustration and check for sensor power source voltage.
Sensor power source voltage
Standard: Approx. 5 V
2
1
5) Connect tester probe as shown in the illustration.
Check for sensor output voltage while operating remo-con handle.
Sensor output voltage
Shift position
Forward
Neutral
Reverse
Output voltage
Approx. 3.7 V
Approx. 2.5 V
Approx. 1.2 V
Output voltage
Bl
(A)
1
(B)
Y
B
W R B/W
3
(A)
1. Shift position sensor
2. Adjust screw
3. Clutch lever
Power source voltage
Bl
(A)
I9J011130023-02
1
(B)
Y
B
W R B/W
I9J011130054-01
If out of specification:
• 1st; Check remo-con cable adjustment, readjust if necessary.
• 2nd; Check wire harnesses for open and short.
If wire harnesses are in good condition, replace shift position sensor and recheck.
NOTE
After installing shift position sensor, check for proper correct function by operating remo-con handle.
I9J011130053-01
Special tool
(A): 09930–89220 (3-pin connector test cord)
(B): 09930–99320 (Digital tester)
Tester knob indication
DC Voltage ( )
Trim Sensor Inspection
Z9J0111306018
1) Turn ignition switch OFF.
2) Connect 3-pin test cord between trim sensor and wire harness as shown in figure.
1
(A)
I9J011130050-03
1. Trim sensor
3) Turn the ignition switch ON.
4) Connect tester probe as shown in the illustration and check for sensor power source voltage.
Sensor power source voltage
Standard: Approx. 5 V
Special tool
(A): 09930–89220 (3-pin connector test cord)
(B): 09930–99320 (Digital tester)
Tester knob indication
DC Voltage
Power source voltage
Bl
(A)
Engine Electrical Devices: 1C-17
5) Connect tester probe as shown in the illustration.
Check for sensor output voltage.
Operate the PTT switch, and check if voltage changes linearly within specification, according to trim/tilt position.
Sensor output voltage
Trim/Tilt position
Full trim down
Full tilt up
Output voltage
Approx. 0.9 V
Approx. 4.0 V
Output voltage
(A)
Bl
1
Y
B
W R B/W
(B)
I9J011130025-03
6) If out of specification, check wire harnesses for open and short. If wire harnesses are in good condition, replace trim sensor and recheck.
1
Y
B
W R B/W
(B)
I9J011130024-03
1D-1 Power Unit Mechanical:
Power Head
Power Unit Mechanical
General Description
Power Unit Construction Description
Z9J0111401001
The power unit is direct water cooled, in line 4 cylinder, 4 stroke gasoline unit with its DOHC (Double overhead camshaft) valve mechanism for “V” type valve configuration and 16 valves (4 valves/one cylinder).
The double overhead camshaft is mounted over the cylinder head, it is driven from crankshaft through driven gear and timing chain, and no pushed rods are provided in the valve train system.
These gears are located beneath the powerhead in the same oil bath location as the camshaft chain.
As the rotational direction of the driven gear will be opposite of the drive gear, a left-hand rotation powerhead design was adopted to retain a conventional, standard rotation (right-hand) propeller shaft output.
Cylinder Number
Cylinder number is as mentioned in figure.
Powerhead Direction of Rotation
This outboard motor is designed with a L.H. (left-hand) rotation powerhead utilizing an offset crankshaft.
This design has the advantage of reducing the size of the motor and keeping the overall motor's weight closer to the boat transom and therefore closer to the boat C/G
(Center of Gravity).
Rotation of the driveshaft is accomplished through a crankshaft drive gear and a driveshaft driven gear.
No.1
No.2
No.3
No.4
I9J011140077-01
Diagnostic Information and Procedures
Cylinder Compression Check
Refer to “Cylinder Compression Pressure Check” in Section 0B (Page 0B-21).
Oil Pressure Check
Refer to “Oil Pressure Check” in Section 0B (Page 0B-20).
Z9J0111404001
Z9J0111404002
Power Unit Mechanical: 1D-2
Service Instructions
Tappet Clearance Inspection
Z9J0111406028
Refer to “Tappet Clearance Inspection and Adjustment” in Section 0B (Page 0B-8).
3) Loosen the clamp securing breather hose (2), then remove the breather hose from cylinder head cover.
Ring Gear Cover Removal and Installation
Z9J0111406001
Removal
Prior to removing ring gear cover, disconnect battery cables from battery.
1) Loosen the four bolts securing ring gear cover (1).
I9J011140080-01
4) Disconnect ignition coil connectors (3).
Remove the bolts securing the ignition coils (4).
Remove all ignition coils and spark plugs.
I9J011140078-01
2) Remove the ring gear cover.
Installation
Installation is reverse order of removal.
Cylinder Head Cover Removal and Installation
Z9J0111406002
Removal
Before removing cylinder head cover, disconnect battery cables from battery.
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Remove the two bolts securing fuel pump guard (1).
I9J011140081-01
5) Disconnect inlet hose (5) and outlet hose (6) from low pressure fuel pump (7).
Remove bolts and low pressure fuel pump.
I9J011140082-01
I9J011140079-01
1D-3 Power Unit Mechanical:
6) Remove the two bolts securing filter bracket (8), then remove low pressure fuel filter (9) and filter bracket.
9) Disconnect fuel injector lead wire connector at all fuel injectors (12).
Cut the cable tie (13) binding injector lead wire to fuel delivery pipe (14).
Disconnect high pressure fuel pump lead wire connector (15).
I9J011140083-01
7) Remove the bolt and joint connector bracket (10).
I9J011140086-01
10) Remove the twelve bolts securing cylinder head cover (16) to the cylinder head, then remove the cylinder head cover.
I9J011140084-01
8) Disconnect CMP sensor lead wire connector at CMP sensor (11).
Remove bolt and CMP sensor.
I9J011140087-01
I9J011140085-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Clean sealing surface on cylinder head and cover.
• Remove oil, old sealant, and dust from sealing surfaces.
• After cleaning, apply sealant to cylinder head sealing surface area as shown in figure.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
Power Unit Mechanical: 1D-4
• Install cylinder head cover (2) to cylinder head, then tighten cylinder head cover bolts to specified torque.
Tightening torque
Cylinder head cover bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
I9J011140090-01
I9J011140088-01
• Install new cylinder head cover gasket (1) to head cover.
NOTE
Examine cylinder head cover gasket for damage.
Always replace gasket with new one.
I9J011140091-01
• Perform the following final assembly checks to ensure proper and safe operation.
– All parts removed have been returned to their original positions.
– Wire and hose routing matches service manual
illustration. Refer to “Fuel Hose Routing” in Section
4B (Page 4B-1) and “Water Hose Routing” in
– No oil leakage is evident during final test running.
I9J011140089-01
1D-5 Power Unit Mechanical:
Air Intake Silencer Case Removal and
Installation
Z9J0111406003
Removal
1) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation”
2) Remove the two bolts securing air intake silencer case (1).
3) Remove the air intake silencer case.
Electric Parts Holder Removal and Installation
Z9J0111406004
Removal
Before removing electric parts holder, disconnect battery cables from battery.
1) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation”
2) Remove the air intake silencer case (1).
Refer to “Air Intake Silencer Case Removal and
I9J011140092-01
I9J011140095-01
3) Pull and remove the fuse box (2) from electric parts holder.
I9J011140093-01
4) Disconnect the intake air temp. sensor lead wire connector (2) at sensor.
I9J011140096-01
4) Disconnect lead wire connectors from ECM (3).
Installation
Installation is reverse order of removal.
I9J011140094-01
I9J011140097-01
5) Remove the three bolts (4) securing electric parts holder to cylinder block.
6) Remove ECM from electric parts holder.
Power Unit Mechanical: 1D-6
b) Remove the bolt (9) securing negative (–) battery cable (10).
Pull battery cable out of electric parts holder.
I9J011140099-01
I9J011140102-01 c) Remove the bolt (11) securing PTT motor relay
GND lead wire.
I9J011140100-01
7) To remove the electric parts holder, refer to following.
a) Remove nut (5), positive (+) battery cable (6) and positive lead wire (7) from magnetic switch
(8) of starter motor.
I9J011140103-04 d) Remove PTT motor relay (12) and joint connectors (13) from electric parts holder.
I9J011140101-01
I9J011140104-01
Installation
Installation is reverse order.
Perform the following final assembly checks to ensure proper and safe operation.
• All parts removed have been returned to their original positions.
• Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3) and “Fuel Hose Routing” in Section
1D-7 Power Unit Mechanical:
Intake Manifold and Throttle Body Components
1
2
Z9J0111406005
3
I9J011140001-01
1. Intake manifold assembly 2. Throttle body assembly
Intake Manifold Removal and Installation
Z9J0111406006
Removal
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
2) Disconnect battery cables from battery.
3) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
4) Remove the ring gear cover (1).
Refer to “Ring Gear Cover Removal and Installation”
5) Remove the air intake silencer case (2).
Refer to “Air Intake Silencer Case Removal and
6) Disconnect the IAC valve lead wire connector (3) at
IAC valve.
3. Bolt
7) Disconnect the MAP sensor lead wire connector (4) at sensor.
I9J011140105-01
8) Disconnect the throttle position sensor lead wire connector (5) at sensor.
I9J011140106-01
9) Remove the bolts (6) securing throttle body bracket
(7) to crankcase.
Power Unit Mechanical: 1D-8
13) Disconnect fuel inlet hose (12) from low pressure fuel filter.
14) Disconnect fuel outlet hose (13) from low pressure fuel pump.
10) Remove the throttle link rod (8).
I9J011140108-01
I9J011140112-01
15) Disconnect fuel outlet hose (14) from high pressure fuel filter (15).
I9J011140109-01
11) Remove the fuel injector (9) and fuel delivery pipe
(10).
Refer to “Fuel Injector Removal and Installation” in
I9J011140113-01
16) Remove the bolt and oil level dipstick tube (16).
I9J011140110-01
12) Disconnect the high pressure fuel pump lead wire connector (11).
I9J011140114-01
17) Disconnect fuel return hose (17) from fuel cooler.
I9J011140115-01
I9J011140111-01
1D-9 Power Unit Mechanical:
18) Disconnect the fuel cooler water inlet hose (18) from the pilot water indicator (19).
• Install gaskets (1) into groove of intake manifold assembly (2).
I9J011140116-01
19) Disconnect the fuel cooler water outlet hose (20) from the water return union.
I9J011140119-01
• Install the intake manifold assembly (2), then tighten bolts and nuts securely.
Tightening torque
Intake manifold bolt / nut (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
“4” “8”
(a)
I9J011140117-01
20) Remove the six bolts and two nuts and then remove the intake manifold assembly (21).
“1”
21
“5”
“2”
“1”
“3”
“7”
“8”
“6”
“3”
“2”
“4”
I9J011140118-01
Installation
Installation is reverse order of removal with special attention to the following steps.
CAUTION
Do not reuse gasket once removed.
Always use a new gasket.
“6”
(a)
“7”
(a)
“5”
I9J011140002-02
• Install fuel injectors and fuel delivery pipe.
Refer to “Fuel Injector Removal and Installation” in
• Perform the following final assembly checks to ensure proper and safe operation.
– All parts removed have been returned to their original positions.
– Wire and hose routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-3) and “Fuel Hose Routing” in
– No fuel leakage is evident during final test running.
Throttle Body Removal and Installation
Z9J0111406007
Removal
1) Remove the Intake manifold assembly.
Refer to “Intake Manifold Removal and Installation”
2) Remove the flame arrester (1).
Power Unit Mechanical: 1D-10
Installation
Installation is reverse order of removal with special attention to the following steps.
CAUTION
Do not reuse gaskets, always replace with new one.
• Clean mating surface and install the seal ring (1).
I9J011140120-01
3) Remove the four bolts (2) securing throttle body to intake manifold.
I9J011140123-01
• Install the throttle body (2), then securely tighten the four throttle body bolts to specified torque.
Tightening torque
Throttle body bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbfft)
4) Remove the bolt (3) securing bracket (4).
I9J011140121-01
I9J011140124-01
• Install the intake manifold.
Refer to “Intake Manifold Removal and Installation”
I9J011140122-01
1D-11 Power Unit Mechanical:
Throttle Body Inspection
Z9J0111406008
CAUTION
Do not try to adjust or remove any of the throttle body component parts (Throttle position sensor, throttle valve, throttle stop screw, etc.).
These components have been factory adjusted to precise specifications.
• Clean throttle body bore by compressed air.
• Check that throttle lever and throttle valve moves smoothly.
• Replace throttle body if necessary.
Power Unit Removal and Installation
Z9J0111406009
Removal
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
2) Drain engine oil.
3) Disconnect battery cables from battery.
4) Remove the fuel injectors and intake manifold assembly (1).
Refer to “Intake Manifold Removal and Installation”
I9J011140125-01
I9J011140127-01
5) Remove the fuel vapor separator (2).
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-17).
I9J011140126-01
6) Remove the high pressure fuel filter (3).
I9J011140128-01
I9J011140129-01
7) Disconnect ignition coil connectors (4).
Remove the bolts securing the ignition coils (5).
Remove all ignition coils and spark plugs.
Power Unit Mechanical: 1D-12
10) Remove the starter motor (8).
Refer to “Starter Motor Removal and Installation” in
I9J011140130-01
8) Remove the cylinder head cover (6).
Refer to “Cylinder Head Cover Removal and
I9J011140133-01
11) Remove the flywheel (9).
Refer to “Flywheel Removal and Installation” in
Special tool
: 09930–48720 (Flywheel holder)
: 09930–39411 (Flywheel remover)
: 09930–39420 (Flywheel remover bolts)
I9J011140131-01
9) Remove the electric parts holder (7).
Refer to “Electric Parts Holder Removal and
I9J011140134-01
12) Remove the battery charge coil (10).
Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-6).
I9J011140132-01
I9J011140135-01
1D-13 Power Unit Mechanical:
13) Remove the bolts and rectifier/regulator (11).
Remove the bolt securing lead wire clamp plate (12).
Refer to “Rectifier/Regulator Removal and
Installation” in Section 1K (Page 1K-7).
17) Disconnect water flush hose (17) from cylinder block.
I9J011140136-01
14) Disconnect EX. manifold temperature sensor lead wire connector.
Remove EX. manifold temperature sensor (13).
15) Loosen screw and disconnect blue lead wire (14) from oil pressure switch (15).
I9J011140139-01
18) Remove the two bolts securing front panel (18).
I9J011140137-01
16) Remove screws and CKP sensor (16).
Disconnect CKP sensor lead wire connector.
I9J011140140-01
19) Remove the screws securing the hose and harness holder (19).
I9J011140141-01
20) Remove the bolt and throttle lever holder (20).
I9J011140138-01
I9J011140142-01
21) Remove the side cover seal (21).
Power Unit Mechanical: 1D-14
24) Remove the two bolts and clutch link holder assembly (28).
I9J011140143-01
22) Disconnect shift position sensor lead wire connector
(22).
Disconnect neutral switch lead wire connector (23).
Remove the bolt and lead wire clamp plate (24).
I9J011140146-03
25) Disconnect the water return hose (29), then remove the thermostat cover (30) and thermostat.
I9J011140144-01
23) Remove the cotter pin (25) and washer (26).
Remove the clutch lever link (27) from the clutch link holder assembly.
I9J011140147-01
26) Remove the two bolts and breather pipe (31).
I9J011140148-01
I9J011140145-01
1D-15 Power Unit Mechanical:
27) Remove the cylinder temperature sensor (32).
30) Remove the fourteen bolts (35).
I9J011140149-01
28) Remove the bolt and water return union (33).
I9J011140152-03
I9J011140150-01
29) Remove the two bolts and oil filter adapter case (34).
I9J011140151-01
I9J011140153-03
31) Lift up and remove power unit from engine holder.
Installation
Installation is reverse order of removal with special attention to the following step.
CAUTION
Do not reuse gaskets, O-rings and seals.
Always replace with new parts.
Power unit
• Install dowel pins (1), gasket (2).
Apply water resistant grease to driveshaft splines.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
I9J011140154-01
• Install the engine holder seal (3).
NOTE
Install seal (3) with lip facing upward.
Power Unit Mechanical: 1D-16
• Apply suzuki silicone seal to power unit mounting bolts and tighten bolts to specified torque.
: Sealant 99000–31120 (SUZUKI Silicone
Seal (50 g))
Tightening torque
Power unit mounting bolt (8 mm): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Power unit mounting bolt (10 mm): 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
I9J011140155-01
NOTE
Before installing power unit, apply sealant to the four hatched areas shown in the illustration at below.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
I9J011140156-03
I9J011140157-03
Thermostat
• Assemble thermostat, seal and thermostat cover to cylinder block and secure with bolts.
Refer to “Thermostat Removal and Installation” in
• Lower the power unit onto engine holder.
NOTE
Rotate crankshaft to aid alignment of driveshaft and counter shaft splines.
I9J011140022-02
I9J011140158-01
1D-17 Power Unit Mechanical:
Flywheel
• Install CKP sensor (1).
Refer to “CKP Sensor Removal and Installation” in
Cylinder head cover
• Install cylinder head cover.
Refer to “Cylinder Head Cover Removal and
• Install battery charge coil (2).
Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-6).
I9J011140159-01 I9J011140162-02
Vapor separator
• Install vapor separator.
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-17).
I9J011140160-01
• Install flywheel (3) and tighten flywheel bolts to specified torque.
Refer to “Flywheel Removal and Installation” in
Tightening torque
Flywheel bolt (a): 196 N·m (19.7 kgf-m, 142 lbf-ft)
Special tool
(A): 09930–48720 (Flywheel holder)
I9J011140163-01
I9J011140161-01
Intake manifold
• Install gaskets and intake manifold, then tighten bolts and nuts to specified torque.
Refer to “Intake Manifold Removal and Installation”
Tightening torque
Intake manifold bolt / nut (8 mm) (a): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
Power Unit Mechanical: 1D-18
Fuel injectors
• Install fuel injectors and fuel delivery pipe.
Refer to “Fuel Injector Removal and Installation” in
(a)
(a)
(a)
I9J011140164-01
I9J011140165-01
Perform the following final assembly checks to ensure proper and safe operation.
• All parts removed have been returned to their original positions.
• Fuel and water hose routing matches service manual illustration.
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
• Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in Section
• No fuel leakage is evident when fuel system is pressurized.
Refer to “Fuel Leakage Check Procedure” in Section
• No water leakage is evident during final test running.
1D-19 Power Unit Mechanical:
Timing Chain, Chain Tensioner and Camshaft Sprockets Components
Z9J0111406010
9
10
11
12
13
(a)
4
5
6
11
1. Timing chain
2. Bolt
3. Chain guide
4. Bolt
5. Spacer
14
2
3
8
7
1
6. Chain tensioner
7. Bolt
8. Tensioner adjuster
9. Bolt
10. Exhaust camshaft sprocket
11. Dowel pin
12. Intake camshaft sprocket
13. Bolt (L.H. thread)
14. Driven gear
15. Crankshaft
15
I9J011140003-04
: 78 N
⋅ m (7.8 kgf-m, 56 lbf-ft)
: Apply oil.
: Apply thread lock.
Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation
Z9J0111406011
Removal
1) Remove the oil pump.
Refer to “Oil Pump Removal and Installation” in
2) Turn the crankshaft in its normal running direction
(LH direction) until the match mark “A” on the crankshaft drive gear points to 12 o’clock position
(toward cylinder head).
CAUTION
When timing chain has been removed, never turn crankshaft or camshaft.
Special tool
: 09911–49910 (Crankshaft holder)
Power Unit Mechanical: 1D-20
4) Remove the two bolts (3) and chain tensioner adjuster (4).
I9J011140167-01
5) Remove bolt (5) and timing chain tensioner (6).
“A”
1
I9J011140007-05
1. Engine normal running direction
3) Remove two bolts (1) and timing chain guide (2).
I9J011140168-01
6) Loosen and remove the bolt (7) securing IN. camshaft timing sprocket to camshaft.
NOTE
• Intake sprocket bolt is LH thread.
• Hold camshaft by placing a wrench on the hexagon area of the camshaft.
I9J011140169-01
I9J011140166-01
1D-21 Power Unit Mechanical:
7) Remove timing chain (8), IN. camshaft timing sprocket (9) and dowel pin (10).
Installation
Installation is reverse order of removal with special attention to the following steps.
1) Check that match mark “A” on the crankshaft drive gear points to 12 o’clock position (towards cylinder head).
“A”
I9J011140170-02
8) Remove three bolts (11) and EX. camshaft timing sprocket (12) and dowel pin (13).
I9J011140171-01
I9J011140023-05
2) Install the driven gear (1) on the cylinder block so that match mark “A” aligns with match mark “B” on the driven gear as shown in illustration.
1
“B”
“A”
9) Remove driven gear (14).
I9J011140024-04
I9J011140172-01
3) Fit the dowel pin (2) onto EX. camshaft.
Install EX. camshaft timing sprocket (3), then tighten sprocket bolts, pre-coated with thread lock, to specified torque.
Check that engraved line “C” on sprocket is correctly aligned with mating face of cylinder head cover.
Tightening torque
EX. timing sprocket bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
: Thread lock cement 99000–32050
(SUZUKI Thread Lock 1342 (50 g))
Power Unit Mechanical: 1D-22
I9J011140175-02
I9J011140173-01
I9J011140176-03
5) As shown in figure, position timing chain on driven gear sprocket with yellow plate “H” of chain aligned with match mark “B” on driven gear.
“H”
“B”
I9J011140174-02
4) Install dowel pin (4) and IN. camshaft timing sprocket
(5), then tighten sprocket bolt to specified torque.
Check that engraved line “D” on sprocket is correctly aligned with mating face of cylinder head cover.
NOTE
When installing camshaft sprocket, position side of sprocket with two engraved lines facing down toward engine holder as shown figure.
Tightening torque
IN. timing sprocket bolt (b): 78 N·m (7.8 kgf-m,
56 lbf-ft)
I9J011140026-01
6) As shown in figure, engage timing chain with exhaust sprocket with one BLUE plate “I” of chain aligned with match mark (arrow) “E” of exhaust sprocket.
7) As shown in figure, engage timing chain with intake sprocket with another BLUE plate “I” of chain aligned with match mark (
•
) “F” of intake sprocket.
1D-23 Power Unit Mechanical:
“I” “I”
11) Install timing chain tensioner adjuster (10), then tighten bolts (11) to specified torque.
Tightening torque
Tensioner adjuster bolt (c): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
“E”
“F”
I9J011140025-01
8) Install timing chain guide (6), then tighten bolt securely.
I9J011140177-01
9) Insert the spacer (7) into the chain tensioner (8).
Install chain tensioner, then tighten bolt (9) securely.
Apply engine oil to chain tensioner.
I9J011140180-01
12) Apply engine oil to timing chain.
13) Remove the stopper from tensioner adjuster to release plunger.
14) Turn crankshaft in normal running direction two complete turns and check that crankshaft match mark “A” points toward the top and at the same time, engraved lines “C” and “D” on sprockets aligns with cylinder head cover mating face “G”.
“G” “G”
“C” “D”
I9J011140178-01
10) With latch of tensioner adjuster (10) pushed in 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.
1 2
2
4
3
“A”
I9J011140179-02
I9J011140008-04
15) Install oil pump.
Refer to “Oil Pump Removal and Installation” in
1. Plunger
2. Latch
3. Body
4. Stopper
Timing Chain, Chain Tensioner and Camshaft
Sprockets Inspection
Z9J0111406012
NOTE
If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced.
Timing Chain
Inspect timing chain for wear or damage.
If excessive wear or other damage is found, replace it.
Power Unit Mechanical: 1D-24
Timing Chain Tensioner/Chain Guide
• Check chain tensioner shoe for wear or damage.
If excessive wear or other damage is found, replace it.
• Check chain guide shoe for wear or damage.
If excessive wear or other damage is found, replace it.
I9J011140181-01
Tensioner Adjuster
Inspect tensioner adjuster for smooth operation.
Replace if fault is noted.
Check oil delivery passage to tensioner.
I9J011140183-01
Camshaft Timing Sprocket
Check teeth of sprocket for wear or damage.
If excessive wear or other damage is found, replace it.
1. Latch
2. Tooth surface
3. Oil passage
I9J011140182-01
I9J011140184-01
Driven Gear and Driven Gear Bearing
• Inspect driven gear.
Replace gear if damaged or worn excessively.
• Check driven gear bearing.
Replace bearing if pitted, noisy, or rough condition.
I9J011140185-01
1D-25 Power Unit Mechanical:
Camshaft, Tappet and shim Removal and
Installation
Z9J0111406013
Removal
1) Remove the oil pump.
Refer to “Oil Pump Removal and Installation” in
2) Remove the timing chain and chain tensioner.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
3) Remove the bolts securing camshaft housing (1) to cylinder head, then remove each camshaft housing.
NOTE
For ease of assembly, note position of each individual camshaft housing.
5) Remove tappets and tappet shims.
NOTE
All tappets and tappet shims must be installed in their original positions.
For ease of assembly, lay out tappets and record shim thickness for each individual cylinder / valve position.
I9J011140188-01
Installation
1) Apply engine oil around tappets and install them.
2) Install tappet shims.
4) Remove intake and exhaust camshaft.
I9J011140186-01
I9J011140189-01
I9J011140187-01
3) Apply engine oil to surface of each camshaft lobe and journal, then install them.
NOTE
• Before installing camshafts, turn crankshaft until the match mark “A” on the crankshaft drive gear points to 12 o’clock
(toward cylinder head).
• Install camshaft so that dowel pin hole “B” on the camshaft is positioned as shown.
Power Unit Mechanical: 1D-26
4) Install camshaft housing pins as shown figure.
1
I9J011140190-01
I9J011140193-05
1. Pin
5) Check position of camshaft housing.
NOTE
Embossed marks are provided on each camshaft housing indicating position and direction of installation.
6) Install housing as indicated by these marks.
2
3
4
I9J011140191-01
2. I: Intake side E: Exhaust side
3. Position from flywheel magneto side
4. pointing to flywheel magneto side
I9J011140194-03
I9J011140192-01
1D-27 Power Unit Mechanical:
7) Apply engine oil lightly to housing bolts.
8) Lightly seat all housing bolts.
According to numerical order in figure, tighten bolts to 1/3 of specified torque, then 2/3 of specified torque and finally to full specified torque.
Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
“20” “10”
“17”
“18”
“9”
“19”
“11”
“21” “12”
“2”
“1”
“3”
“4”
“6”
“5”
“7”
“8”
(a)
“14”
“13”
“15”
“16”
9) Install timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
10) Adjust tappet clearance.
I9J011140195-04
11) Install oil pump.
Refer to “Oil Pump Removal and Installation” in
Camshaft, Tappet and Shim Inspection
Z9J0111406014
NOTE
If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced.
Cam Face
Inspect cam face for scratches and wear.
If any of the above conditions are found, replace camshaft.
Cam Wear
Using micrometer, measure cam height.
If measurement exceeds service limit, replace camshaft.
Cam height “a” (for DF70A)
Standard
IN
38.620 – 38.780 mm
(1.5205 – 1.5268 in)
EX
40.920 – 41.080 mm
(1.6110 – 1.6173 in)
Service limit
38.520 mm
(1.5165 in)
40.820 mm
(1.6071 in)
Cam height “a” (for DF80A)
Standard
IN
39.620 – 39.780 mm
(1.5598 – 1.5661 in)
EX
40.920 – 41.080 mm
(1.6110 – 1.6173 in)
Cam height “a” (for DF90A)
Standard
IN
41.120 – 41.280 mm
(1.6189 – 1.6252 in)
EX
40.920 – 41.080 mm
(1.6110 – 1.6173 in)
Service limit
39.520 mm
(1.5559 in)
40.820 mm
(1.6071 in)
Service limit
41.020 mm
(1.6150 in)
40.820 mm
(1.6071 in)
I9J011140196-01
Camshaft Identification
DF70A, DF80A and DF90A camshafts differ as indicated below.
Identification mark
Model
DF70A
DF80A
DF90A
Identification mark
Intake Exhaust
2
0
1
0
0
1
Power Unit Mechanical: 1D-28
Camshaft Journal Wear
Check camshaft journals and camshaft housings for pitting, scratches, wear or damage.
If any of the above conditions are found, replace camshaft or cylinder head with housing.
NOTE
Camshaft housing and cylinder head must be replaced as a set.
I9J011140197-01
1. Identification mark
Camshaft Runout
Support camshaft on a surface plate using a set of Vblocks.
Measure runout using a dial gauge.
If measurement exceeds service limit, replace camshaft.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Camshaft runout
Service limit: 0.10 mm (0.0039 in.)
I9J011140030-01
Camshaft Journal Oil Clearance
Check journal oil clearance using Plastigauge as follows.
1) Clean housing and camshaft journals.
2) Install camshaft to cylinder head.
3) Place Plastigauge across the full width of camshaft journal (parallel to camshaft).
Special tool
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))
(A)
(B)
I9J011140199-02
I9J011140198-02
1D-29 Power Unit Mechanical:
4) Install camshaft housing. Tighten housing bolts in 3 steps (1/3 of specification, 2/3 of specification, full torque specification) in the indicated order.
Tightening torque
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
NOTE
Do not rotate camshaft while Plastigauge is installed.
(a)
“20” “10”
“17”
“18”
“9”
“19”
“11”
“21” “12”
“2”
“1”
“3”
“4”
“6”
“5”
“7”
“8”
“14”
“13”
“15”
“16”
I9J011140195-04
5) Remove camshaft housing.
6) Using scale on Plastigauge envelope, measure
Plastigauge at its widest point.
Camshaft journal oil clearance
Standard: 0.045 – 0.087 mm (0.0018 – 0.0034 in.)
Service limit: 0.120 mm (0.0047 in.)
1
2
If journal oil clearance exceeds the service limit, measure camshaft journal (outside dia.) and camshaft housing (inner dia.). Based on measurements, replace camshaft and/or cylinder head with camshaft housing.
Camshaft journal outside diameter No. 1 – No. 4
Standard: 22.934 – 22.955 mm (0.9029 – 0.9037 in.)
Camshaft journal outside diameter No. 5
Standard: 25.936 – 25.957 mm (1.0211 – 1.0219 in.)
Camshaft journal (housing) inside diameter No. 1
– No. 4
Standard: 23.000 – 23.021 mm (0.9055 – 0.9063 in.)
Camshaft journal (housing) inside diameter No. 5
Standard: 26.000 – 26.021 mm (1.0236 – 1.0244 in.)
Special tool
(B): 09900–20202 (Micrometer (25 – 50 mm))
(B): 09900–20205 (Micrometer (0 – 25 mm))
I9J011140200-02
1. Plastigauge 2. Scale
I9J011140075-01
I9J011140201-01
Wear of Tappet and Shim
Check tappet and shim for pitting, scratches, or damage.
If any above conditions are found, replace component.
I9J011140076-01
Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance.
If clearance exceeds service limit, replace tappet or cylinder head.
Special tool
: 09900–20202 (Micrometer (25 – 50 mm))
Cylinder head bore to tappet clearance
Standard: 0.025 – 0.062 mm (0.0010 – 0.0024 in.)
Service limit: 0.150 mm (0.0059 in.)
Tappet outer diameter
Standard: 27.959 – 27.975 mm (1.1007 – 1.1014 in.)
Cylinder head tappet bore
Standard: 28.000 – 28.021 mm (1.1024 – 1.1032 in.)
Power Unit Mechanical: 1D-30
I9J011140031-01
I9J011140032-01
1D-31 Power Unit Mechanical:
Cylinder Head Assembly Components
12
(b)
1. Intake valve
2. Exhaust valve
3. Valve guide
4. Valve spring seat
Z9J0111406015
11
(a)
10
9
7
8
6
5
4
2
5. Valve stem seal
6. Valve spring
7. Valve spring retainer
8. Valve cotter
1
9. Tappet
10. Tappet shim
11. Cylinder head bolt (10 mm)
12. Cylinder head bolt (8 mm)
3
I9J011140004-04
: 70 N
⋅ m (7.0 kgf-m, 50.5 lbf-ft)
: 23 N
⋅ m (2.3 kgf-m, 16.5 lbf-ft)
: Apply engine oil.
Cylinder Head Removal and Installation
Z9J0111406016
Removal
1) Prior to removing cylinder head assembly;
• Remove the power unit.
Refer to “Power Unit Removal and Installation”
• Remove the timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
• Remove the IN. and EX. camshafts.
Refer to “Camshaft, Tappet and shim Removal and Installation” (Page 1D-25).
2) Loosen and remove fifteen cylinder head bolts in the order indicated in figure.
Remove cylinder head assembly and head gasket.
NOTE
Use special tool (10 mm deep socket wrench) when loosening cylinder head bolts.
Special tool
(A): 09919–16010 (Deep socket wrench (10 mm))
“1” “3”
“5” “4” “2”
Power Unit Mechanical: 1D-32
Installation
Installation is in reverse order of removal paying special attention to the following steps.
CAUTION
Do not reuse gasket. Always use a new gasket.
1) Insert the dowel pins (1) and place a new cylinder head gasket (2) into position on the cylinder.
NOTE
Before installing cylinder head gasket, apply sealant to both surfaces of the hatched areas shown in illustration.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
I9J011140027-02
“6” “12” “14” “10” “8”
“9” “11” “15” “13” “7”
I9J011140202-01
I9J011140203-01
I9J011140204-01
2) Position cylinder head on cylinder.
NOTE
Use special tool (10 mm deep socket wrench) when tightening cylinder head bolts.
Special tool
: 09919–16010 (Deep socket wrench (10 mm))
1D-33 Power Unit Mechanical:
3) Apply engine oil to cylinder head bolts and tighten them gradually as follows.
a) Tighten all cylinder head bolts to 50 percent (%) of specified torque according to sequence in figure.
Tightening torque
Cylinder head bolt (1st step) [10 mm]: 35
N·m (3.5 kgf-m, 25.5 lbf-ft)
Cylinder head bolt (1st step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft)
“15” “13”
“11”
“12”
“14”
4) Install the IN. and EX. camshafts.
Refer to “Camshaft, Tappet and shim Removal and
5) Install the timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
Cylinder Head Disassembly and Assembly
Z9J0111406017
Disassembly
1) Using valve lifter and attachment, remove valve cotters (1) while compressing valve spring.
Special tool
(A): 09916–19030 (Valve lifter)
(B): 09916–14521 (Valve lifter attachment)
(C): 09916–84511 (Tweezers)
“10” “4” “2” “6” “8”
“7” “5” “1” “3” “9”
I9J011140205-01 b) Loosen all cylinder head bolts to 0 N
⋅ m (0 kgf-m,
0 lbf-ft.) according to reverse sequence in figure.
c) Again tighten all cylinder head bolts to 50 percent (%) of specified torque according to sequence in figure.
Tightening torque
Cylinder head bolt (3rd step) [10 mm]: 35
N·m (3.5 kgf-m, 25.5 lbf-ft)
Cylinder head bolt (3rd step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft)
d) Finally tighten all cylinder head bolts to specified torque according to sequence in figure.
Tightening torque
Cylinder head bolt (Final step) [10 mm]: 70
N·m (7.0 kgf-m, 50.5 lbf-ft)
Cylinder head bolt (Final step) [8 mm]: 23
N·m (2.3 kgf-m, 16.5 lbf-ft)
(C)
I9J011140207-01
(A)
(B)
1
I9J011140209-01
2) Remove valve spring retainer (2), valve spring (3) and valve (4).
1 2 3 5 6 4
1
I9J011140210-01
I9J011140206-01
Power Unit Mechanical: 1D-34
3) Remove valve stem seal (5) and valve spring seat
(6).
NOTE
Reassemble each valve and valve spring in their original positions.
(B)
2
(A)
5
6
I9J011140211-02
Assembly
Reassemble in reverse order of disassembly paying special attention to the following steps.
5
6
4
2
1
3) Apply engine oil to stem seal, valve guide bore and valve stem.
4) Install valve (3) to valve guide.
I9J011140033-03
NOTE
Reassemble each valve and valve spring to their original position.
3
I9J011140212-03
1) Install valve spring seat (1) to cylinder head.
2) After applying engine oil to stem seal (2) and spindle of special tool (A), fit stem seal to spindle.
Then, pushing special tool by hand, install stem seal to valve guide.
Check to be sure that seal is properly fixed to valve guide.
CAUTION
Do not reuse stem seal once removed.
Always install new seal.
Special tool
(A): 09917–98221 (Valve guide stem seal installer attachment)
(B): 09916–58210 (Valve guide installer handle)
I9J011140034-01
5) Install valve spring (4), and valve retainer (5).
NOTE
Set valve spring in place with narrow spiral area facing valve seat.
“C”
“A”
“A”: Large-pitch
“B”: Small-pitch
“B”
“D”
I9J011140035-01
“C”: Valve spring retainer side
“D”: Valve spring seat side
1D-35 Power Unit Mechanical:
6) Hold valve spring compressed with special tool and install valve cotters (6).
Make sure valve cotters are properly seated in groove “A”.
NOTE
When compressing the valve spring, be careful not to damage the tappet hole.
Special tool
(C): 09916–19030 (Valve lifter)
(D): 09916–14521 (Valve lifter attachment)
(E): 09916–84511 (Tweezers)
(C)
(D)
Cylinder Head Components Inspection and
Servicing
Z9J0111406018
NOTE
If cracks, excessive wear or other damage is found on any component, replace component.
Cylinder Head
• Remove all carbon from combustion chambers.
NOTE
• Do not use any sharp edged tool to scrape carbon off cylinder head or its components.
• Be careful not to scuff or nick metal surfaces when decarbonizing.
“A”
6
(E)
6
I9J011140213-02
(C)
(D)
I9J011140037-01
• Check cylinder head for cracks in intake and exhaust ports, combustion chambers, and head surface.
• Check valve seat, if cracks or other damage is found, replace cylinder head.
I9J011140036-02
I9J011140214-01
• Check water jackets. If clogged or obstructed, clean water jackets.
Power Unit Mechanical: 1D-36
Manifold seating faces distortion
Using a straightedge and thickness gauge, check cylinder head to manifold seating faces.
If measurement exceeds service limit, resurface or replace cylinder head.
Special tool
(A): 09900–20803 (Thickness gauge)
Manifold seating faces distortion
Service limit: 0.10 mm (0.004 in.)
I9J011140215-01
Cylinder head distortion
• Using a straightedge and thickness gauge, measure cylinder head distortion (gasket surface) at a total of six locations as shown.
If measurement exceeds service limit, resurface or replace cylinder head.
Special tool
(A): 09900–20803 (Thickness gauge)
Cylinder head distortion
Service limit: 0.03 mm (0.001 in.)
I9J011140216-03
(A)
I9J011140038-01
Valve and 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.
If measurement exceeds service limit, replace valve and/
or valve guide. Refer to “Valve guide replacement”
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
Valve stem outside diameter
Using micrometer, measure valve stem outside diameter.
Valve stem outside diameter
Standard (IN.): 5.465 – 5.480 mm (0.2152 – 0.2157 in.)
Standard (EX.): 5.440 – 5.455 mm (0.2142 – 0.2148 in.)
(A)
I9J011140217-01
(A)
I9J011140039-02
1D-37 Power Unit Mechanical:
Valve guide inside diameter
Using a small bore gauge, measure valve guide inside diameter.
Valve guide inside diameter
Standard (IN.): 5.500 – 5.512 mm (0.2165 – 0.2170 in.)
Standard (EX.): 5.500 – 5.512 mm (0.2165 – 0.2170 in.)
Valve stem end
Inspect valve stem end face for pitting and wear.
If pitting or wear is found, valve stem end may be resurfaced.
Use caution when resurfacing, do not grind away stem end chamfer.
When chamfer has been worn away, replace valve.
I9J011140040-01
Valve guide to valve stem clearance
Standard (IN.): 0.020 – 0.047 mm (0.0008 – 0.0019 in.)
Standard (EX.): 0.045 – 0.072 mm (0.0018 – 0.0028 in.)
Service limit (IN.): 0.070 mm (0.0028 in.)
Service limit (EX.): 0.090 mm (0.0035 in.)
Valve stem deflection
If unable to measure valve guide inside diameter, check
“Valve stem deflection”.
If measurement exceeds service limit, replace valve.
If measurement still exceeds service limit with new valve, replace valve guide.
Measure valve stem deflection as follows;
1) Install valve into valve guide.
2) Position valve head at approx. 5 mm away from valve seat.
3) Move valve head in the direction “a” – “b”, and measure deflection.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Valve stem deflection
Service limit (IN.): 0.14 mm (0.0055 in.)
Service limit (EX.): 0.18 mm (0.0071 in.)
I9J011140041-01
Valve stem runout
Measure valve stem runout.
If measurement exceeds service limit, replace valve.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
(C): 09900–21304 (Steel “V” block set)
Valve stem runout
Service limit: 0.05 mm (0.0020 in.)
(C)
(A)
(B)
I9J011140042-02
(B)
“ b ”
“ a ”
(A)
I9J011140218-01
Valve head radial runout
Measure valve head radial runout.
To measure runout, rotate valve slowly.
If measurement exceeds service limit, replace valve.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–21304 (Steel “V” block set)
: 09900–20701 (Magnetic stand)
Valve head radial runout
Service limit: 0.08 mm (0.0031 in.)
(A)
Power Unit Mechanical: 1D-38
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 (or equivalent).
3) Install valve into valve guide.
4) Put valve lapper on valve.
Special tool
(A): 09916–10911 (Valve lapper)
(B)
I9J011140043-03
Valve head thickness
Measure thickness “a” of valve head.
If measurement exceeds service limit, replace valve.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve head thickness
Standard (IN.): 0.75 mm (0.03 in.)
Standard (EX.): 0.95 mm (0.04 in.)
Service limit (IN.): 0.5 mm (0.02 in.)
Service limit (EX.): 0.7 mm (0.03 in.)
I9J011140219-01
5) Rotate valve while gently tapping valve contact area against seat.
6) Continue until a pattern is on valve seat face with prussian blue.
7) Measure valve seat contact width “b”.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve seat contact width “b”
Standard (IN., EX.): 1.1 – 1.3 mm (0.0433 – 0.0512 in.)
If measurement exceeds specification, repair valve
seat. Refer to “Valve seat servicing” (Page 1D-39).
45 °
“ a ”
I9J011140044-01
“ b ”
I9J011140045-01
1D-39 Power Unit Mechanical:
Valve seat servicing
If valve seat contact width is out of specification, reface valve seat as follows:
Valve seat angle
Intake side: 30
°
/ 45
°
/ 60
°
Exhaust side: 15
°
/ 45
°
IN.
• If width “a” is too high (or wide), reface valve seat using small angle cutter (Intake side: 30 side: 15
°
).
• If width “a” is too low (or narrow), reface valve seat using 60
°
angle cutter (Intake side).
• If width “a” is too low (or narrow), reface valve seat using 45
°
angle cutter (Exhaust side).
°
, Exhaust
45°
60°
45°
30° 15°
I9J011140046-02
To reface a valve seat, use the following valve seat cutting tool.
• Valve seat cutter 45
°
(Neway 122)
• Valve seat cutter 30
°
(Neway 126)
• Valve seat cutter 15
°
(Neway 120)
• Valve seat cutter 60
°
(Neway 111)
• Solid pilot (Neway, N-100-5.52) (09916-24450)
• Handle (Neway, N-505) (09916-54910)
NOTE
Turn cutter clockwise, never counterclockwise.
1) Remove all carbon from valve and valve seat.
2) Using 45
°
angle cutter, reface valve seat.
3) Check valve seat contact width “a”.
Refer to “Valve seat contact width” (Page 1D-38).
Too high (wide)
“ a ”
I9J011140049-01
4) Clean up any burrs using 45
°
angle cutter very lightly.
CAUTION
Cut seat areas minimally only.
Do not cut more than necessary.
5) Lap valve on seat in two steps, first with coarse grit lapping compound applied to face and the second with fine grit compound.
6) Recheck valve seat contact width “a”.
NOTE
Clean and assemble cylinder head and valve components.
Fill intake and exhaust ports with solvent to check for leaks between valve seat and valve.
If any leaks occur, inspect valve seat and face for burrs or other things that could prevent valve from sealing.
I9J011140047-01
Too low (narrow)
“ a ”
I9J011140220-01
I9J011140048-01
Valve guide replacement
CAUTION
Be careful not to damage cylinder head when replacing valve guide.
1) Using valve guide remover, drive valve guide out from combustion chamber side towards valve spring side.
NOTE
Do not reuse valve guide once it has been removed.
Always use a new valve guide (oversize) when assembling.
Special tool
(A): 09916–44310 (Valve guide remover)
Power Unit Mechanical: 1D-40
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 installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion “a”.
Special tool
(D): 09916–58210 (Valve guide installer handle)
(E): 09917–87010 (Valve guide installer attachment)
Valve guide protrusion “a”
Standard (IN., EX.): 10.8 – 11.6 mm (0.43 – 0.46 in.)
(A)
“ a ”
(D)
(E)
I9J011140050-01
2) Ream valve guide hole with
φ
10.5 mm reamer to true hole and remove burrs.
NOTE
Turn reamer clockwise, never counterclockwise.
Special tool
(B): 09916–37320 (Valve guide reamer (
φ
10.5 mm))
(C): 09916–34542 (Valve guide reamer handle)
I9J011140052-01
4) Ream valve guide bore with
φ
5.5 mm reamer.
NOTE
Clean and oil valve guide bore after reaming.
Special tool
(F): 09916–34550 (Valve guide reamer (
φ
5.5 mm))
(C): 09916–34542 (Valve guide reamer handle)
(C)
(F)
(C)
(B)
I9J011140053-02
I9J011140051-01
1D-41 Power Unit Mechanical:
Valve spring free length
Check spring strength by measuring free length.
If lower than service limit, replace valve spring.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Valve spring free length
Standard (IN., EX.): 33.1 mm (1.30 in.)
Service limit (IN., EX.) 31.8 mm (1.25 in.)
Valve spring squareness
Use a square and surface plate to check each spring for squareness (clearance between end of valve spring and square).
If measurement exceeds service limit, replace valve spring.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve spring squareness “a”
Service limit (IN., EX.): 2.0 mm (0.079 in.)
“ a ”
(A)
I9J011140054-02
Valve spring preload
Measure valve spring preload.
If lower than service limit, replace valve spring.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve spring preload
Standard (IN., EX.): 95 – 111 N (9.6 – 11.2 kg, 21.1 –
24.6 lbs.) at 28.5 mm (1.22 in.)
Service limit (IN., EX.): 87 N (8.8 kg, 19.4 lbs.) at 28.5 mm (1.22 in.)
I9J011140056-02
I9J011140055-01
Power Unit Mechanical: 1D-42
Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components
Z9J0111406019
1. Cylinder block
2. Piston ring set
3. Piston
4. Piston pin
5. Circlip
6. Conrod
12
12
13
7. Conrod bearing
8. Conrod cap
9. Conrod bolt
10. Oil seal
11. Crankshaft
12. Crankshaft main bearing
17
5
13. Dowel pin
14. Crankcase
15. Bolt, inside
16. Bolt, outside
17. Thrust bearing
: 47 N
⋅ m (4.7 kgf-m, 34 lbf-ft)
1
2
6
7
5
3
4
11
10
7
8
9
(a)
16
(b)
14
15
(c)
I9J011140005-03
: 25 N
⋅ m (2.5 kgf-m, 18.1 lbf-ft)
: 52 N
⋅ m (5.2 kgf-m, 37.5 lbf-ft)
: Apply engine oil.
: Apply Molybdenum oil solution.
1D-43 Power Unit Mechanical:
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and
Assembly
Z9J0111406020
Disassembly
1) Before performing service work in this section:
• Remove power unit.
Refer to “Power Unit Removal and Installation”
• Remove timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
• Remove cylinder head.
Refer to “Cylinder Head Removal and Installation”
2) Remove oil pressure switch (1).
NOTE
For proper assembly, mark cylinder number on all pistons, conrods, and conrod caps, using quick drying paint.
I9J011140223-03
4) Remove all conrod cap bolts (5) and conrod caps
(6).
1
I9J011140221-02
3) Remove ten bolts (2).
Remove ten bolts (3).
Remove crankcase (4) from cylinder block.
5) Remove crankshaft (7).
Remove oil seal (8) from crankshaft.
I9J011140224-01
I9J011140222-02
I9J011140225-01
6) Mark cylinder number on pistons using quick dry paint.
Push piston (with conrod) out through the top of cylinder bore.
NOTE
• To prevent damage to piston rings, decarbon top of cylinder bore wall before removing piston.
• Reassemble each conrod cap to its original position after removing piston from bore.
Power Unit Mechanical: 1D-44
8) Remove piston pin circlips (9) as shown.
9
I9J011140057-01
9) Remove piston pin from conrod.
NOTE
Reassemble each piston, piston pin and conrod in their original combination and position.
I9J011140226-02
7) Remove two compression rings (top and 2nd) and oil ring from piston. Mark cylinder number on conrod using quick dry paint.
I9J011140058-01
10) Remove the bolts and exhaust cover (10) (if necessary.).
I9J011140227-01
I9J011140228-01
1D-45 Power Unit Mechanical:
Assembly
Assembly is reverse order of disassembly paying special attention to the following steps.
CAUTION
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 oil to piston pin (1), piston pin bore and conrod (2).
• Assemble conrod (2) to piston (3) as shown in figure and insert piston pin (1) through piston and conrod.
• Install piston pin circlips (4).
NOTE
• “87L” mark on conrod and up mark “A” on piston dome must face toward flywheel side.
• Always use new piston pin circlip.
• Install so that circlip end gap comes within such range as indicated by arrow.
End gap of the circlip should not be aligned with the cutaway in the piston pin bore.
Flywheel side
“A”
Piston ring to piston
1) Install the oil ring.
• Apply engine oil to piston rings.
• Install spacer (1) first, then side rails (2) to piston.
“A”
“B”
2
2
1
I9J011140011-01
CAUTION
When installing spacer, do not allow spacer ends to overlap in groove.
I9J011140012-01
“A”: Incorrect “B”: Correct
“B”
I9J011140009-01
“B”: Circlip end gap direction “A”: Up mark
1
3
4
4
2
I9J011140010-01
2) Install the piston rings.
• Apply engine oil to piston ring.
• Install 2nd ring (3) and 1st ring (4) to piston.
“C”
“RN”
“R”
4
3
Power Unit Mechanical: 1D-46
Piston to cylinder
1) Install conrod bearing (1) to conrod (2) and cap (3).
CAUTION
• Assemble each conrod bearing to it’s original position.
• Do not apply oil between conrod and bearing or between bearing cap and bearing.
I9J011140013-02
NOTE
• 1st ring (4) and 2nd ring (3) differ in shape and color as shown in figure.
• Also indicated in figure, the 1st and 2nd ring are marked “C” with the letter “R” or
“RN” which must face towards top of piston.
4
4
2
1
1
3
I9J011140229-03
2) Apply engine oil to piston and cylinder walls.
3) Insert piston and conrod assembly (4) into cylinder bore from cylinder head side using special tool.
NOTE
Position the circle mark “A” on piston head to flywheel side “B”.
Special tool
(A): 09916–77310 (Piston ring compressor)
3
3
I9J011140014-02
3) Position piston rings so gaps are staggered at approximately 90 degree angles as shown.
CAUTION
Failure to stagger piston ring gaps may result in crankcase oil dilution.
“G”
“D”
“H”
I9J011140230-01
“F”
“D”: Up mark
“E”: 1st ring
“F”: Oil ring lower side rail
“E”
I9J011140016-01
“G”: 2nd ring
“H”: Oil ring upper side rail
I9J011140231-01
1D-47 Power Unit Mechanical:
Crankshaft to cylinder
Install crankshaft main bearings (1) in cylinder and crankcase.
Apply molybdenum oil solution to bearings.
CAUTION
• Assemble each bearing to its original position.
• Assemble main bearing half containing oil groove / hole to cylinder block.
Assemble the main bearing half without oil groove to crankcase.
• Do not apply molybdenum oil solution between crank bearing holder and crank main bearing.
NOTE
Align bearing tab “A” with notch in cylinder and crankcase.
Thrust bearing
Apply molybdenum oil solution to the thrust bearing and install in cylinder block overlapping both sides of the
No.4 main journal.
Oil groove on the thrust bearing must face towards crank webs.
1
I9J011140232-01
2
I9J011140059-03
1. Thrust bearing 2. Oil groove
Crankshaft
CAUTION
Do not reuse seal removed. Be sure to use new seal.
NOTE
Install upper oil seal with its spring / lipped side facing inward.
1) Apply engine oil to upper oil seal lip.
Install upper oil seal (1) to crankshaft.
2) Apply molybdenum oil solution to crank pin and crankshaft main journal and install crankshaft in cylinder.
NOTE
When installing crankshaft to cylinder, be sure to fit tab of seal in groove of cylinder.
1. Oil hole 2. Oil groove
I9J011140233-01
I9J011140234-01
I9J011140235-02
3) Install conrod cap.
a) Apply molybdenum oil solution to crank pin and conrod bearing.
b) Install dowel pins (2) and conrod cap (3) (with bearing) to conrod with embossed mark on the cap toward flywheel side.
CAUTION
Reassemble each conrod cap to its original position.
Do not mix them in position.
Power Unit Mechanical: 1D-48
4) Apply engine oil to conrod bolts.
Tighten conrod cap bolts in three steps as follows. a) Lightly seat all conrod bolts at first, then tighten bolts 12 N
⋅ m (1.2 kgf-m, 8.7 lbf-ft) of specified torque.
Tightening torque
Conrod cap bolt (1st step): 12 N·m (1.2 kgfm, 8.7 lbf-ft)
b) Tighten bolts 17 N
⋅ m (1.7 kgf-m, 12.3 lbf-ft) of specified torque.
Tightening torque
Conrod cap bolt (2nd step): 17 N·m (1.7 kgfm, 12.3 lbf-ft)
I9J011140236-01
I9J011140238-01 c) Finally tighten bolts 60 degrees turn from the point of step (b) using an angular torque gauge.
Tightening torque
Conrod cap bolt (Final step): 60 degrees (47
N
⋅
m, 4.7 kgf-m, 34 lbf-ft)
NOTE
Purchase a commercially available angular torque gauge for this step of tightening bolts.
1. Flywheel side
2. Embossed mark
3. Conrod cap
I9J011140237-01
I9J011140239-03 d) Pour approx. 2 ml of engine oil to each side surface of the conrod big end for initial lubrication.
1D-49 Power Unit Mechanical:
Crankcase to cylinder
1) Clean mating surface of cylinder and crankcase.
Apply suzuki bond to mating surface of crankcase as shown.
CAUTION
Apply bond to mating surface only.
Do not allow bond to contact surface of bearing.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
“A”
“A”
3) Install crankcase to cylinder.
Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three steps following the order indicated below.
NOTE
Tighten 10 mm (0.394 in.) thread diameter bolts first (following the order shown in figure), then tighten 8 mm (0.315 in.) thread diameter bolts.
Tightening torque
Crankcase inside bolt (10 mm thread diameter)
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
Crankcase inside bolt (10 mm thread diameter)
[2nd step]: 45 N·m (4.5 kgf-m, 32.5 lbf-ft)
Crankcase inside bolt (10 mm thread diameter)
[Final step]: 52 N·m (5.2 kgf-m, 37.5 lbf-ft)
Tightening torque
Crankcase outside bolt (8 mm thread diameter)
[1st step]: 6 N·m (0.6 kgf-m, 4.3 lbf-ft)
Crankcase outside bolt (8 mm thread diameter)
[2nd step]: 21 N·m (2.1 kgf-m, 15.0 lbf-ft)
Crankcase outside bolt (8 mm thread diameter)
[Final step]: 25 N·m (2.5 kgf-m, 18.1 lbf-ft)
“A”: Apply bond “–” marked line.
2) Install five dowel pins (1).
I9J011140017-03
“9”
“9”
“5”
“5”
“1”
“1”
I9J011140240-01
“3”
“3”
“7”
“7”
“10”
“10”
“6”
“6”
“2”
“2”
“4”
“4”
“8”
“8”
I9J011140018-03
Power Unit Mechanical: 1D-50
NOTE
After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand.
I9J011140242-03
I9J011140241-01
Cylinder head
Refer to “Cylinder Head Removal and Installation”
Timing chain
Refer to “Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation” (Page 1D-20).
Oil pump
Refer to “Oil Pump Removal and Installation” in Section
Powerhead
Refer to “Power Unit Removal and Installation”
Cylinder, Piston and Piston Ring Inspection and
Servicing
Z9J0111406021
NOTE
If cracks, excessive wear or other damage is found on any component, replace component.
Cylinder Distortion
Using a straightedge and thickness gauge, measure cylinder distortion (gasket surface) at a total of six locations as shown.
If measurement exceeds service limit, resurface or replace cylinder.
Special tool
(A): 09900–20803 (Thickness gauge)
Cylinder distortion
Service limit: 0.03 mm (0.0011 in.)
(A)
I9J011140244-01
Water Jackets
Check water jackets.
If clogged or obstruction is found, clean water jacket.
I9J011140245-01
Driven Gear Bearing
Inspect driven gear bearing. Replace bearing if pitted, noisy or rough.
I9J011140246-01
1D-51 Power Unit Mechanical:
Cylinder Bore
Inspect cylinder walls for scratches, roughness, or ridges which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged, bore cylinder and use oversize piston.
Cylinder Bore Wear (Difference)
Using telescoping gauge (1), measure cylinder bore in both axial (vertical line, following crankshaft) and transverse (horizontal line across crankshaft) directions at two positions as shown in figure.
NOTE
Purchase a commercially available telescoping gauge for this measurement.
Check the following:
• Difference between measurements at the two positions (taper).
• Difference between axial and transverse measurement (out-of-round).
If measurement exceeds service limit, bore or replace cylinder.
Cylinder bore wear (difference)
Service limit: 0.10 mm (0.039 in.)
Piston to Cylinder Clearance
1) Measure the piston diameter at a point 13 mm
(0.512 in.) above the piston skirt at a right angle to the piston pin bore.
Special tool
(A): 09900–20203 (Micrometer (50 – 75 mm))
Piston skirt diameter
Standard: 74.970 – 74.990 mm (2.9516 – 2.9524 in.)
“ a ”
(A)
I9J011140061-02
“a”: 13 mm
2) Measure the cylinder bore at 50 mm (1.969 in.) below the cylinder head gasket surface at a right angle to the crankshaft pin.
NOTE
Purchase a commercially available telescoping gauge (1) for this measurement.
Cylinder bore diameter
Standard: 75.000 – 75.020 mm (2.9528 – 2.9535 in.)
50 mm
I9J011140247-01
“ a ”
“a”: 50 mm (1.96 in)
“ b ”
“b”: 90 mm (3.54 in)
I9J011140060-01
I9J011140248-02
3) Calculate the piston / cylinder clearance (Clearance equals difference between piston diameter and cylinder bore measurements).
If clearance exceeds service limit, replace piston and/or cylinder or bore cylinder.
Piston to cylinder clearance
Standard: 0.020 – 0.040 mm (0.0008 – 0.0016 in.)
Service limit: 0.100 mm (0.0039 in.)
Identification of Oversize Piston / Piston Ring
One oversize piston / piston ring components, 0.50 mm is available. Oversize piston / piston ring are marked as shown, below.
Piston
Oversize
0.50 mm
I.D. mark
50
“A”
I9J011140062-02
“A”: I.D. mark: 50
1st and 2nd Piston ring
Oversize
0.50 mm
I.D. mark
50
1st, 2nd ring
“B”
Power Unit Mechanical: 1D-52
Piston
Visual inspection
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 of carbon.
Fit piston ring into piston groove, and measure clearance between ring and ring groove using thickness gauge.
If measurement exceeds service limit, replace piston and/or piston ring.
Special tool
(A): 09900–20803 (Thickness gauge)
Piston ring to groove clearance
Standard (1st): 0.030 – 0.070 mm (0.0012 – 0.0028 in.)
Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024 in.)
Service limit (1st): 0.12 mm (0.0047 in.)
Service limit (2nd): 0.10 mm (0.0039 in.)
1
(A)
“C”
“C”: I.D. mark
I9J011140063-03
“B”: I.D. mark
Oil ring
Oversize
0.50 mm
I.D. mark
One Red paint
Oil ring spacer
I9J011140064-02
I9J011140065-03
1. Piston ring
Piston ring groove width
Standard (1st): 1.02 – 1.04 mm (0.040 – 0.041 in.)
Standard (2nd): 1.21 – 1.23 mm (0.048 – 0.048 in.)
Standard (Oil): 2.01 – 2.03 mm (0.079 – 0.080 in.)
Piston ring thickness
Standard (1st): 0.97 – 0.99 mm (0.038 – 0.039 in.)
Standard (2nd): 1.17 – 1.19 mm (0.046 – 0.047 in.)
Piston Ring
Piston ring end gap
Measure piston ring end gap with piston ring in the lowest position of cylinder bore.
If measurement exceeds service limit, replace piston ring.
Special tool
(A): 09900–20803 (Thickness gauge)
1D-53 Power Unit Mechanical:
Piston ring end gap
Standard (1st): 0.15 – 0.30 mm (0.0059 – 0.0118 in.)
Standard (2nd): 0.30 – 0.45 mm (0.0118 – 0.0177 in.)
Service limit (1st): 0.70 mm (0.028 in.)
Service limit (2nd): 1.00 mm (0.039 in.)
1
(A)
2
I9J011140066-02
1. Cylinder 2. Piston ring
Piston ring free end gap
Measure piston ring free end gap using vernier calipers.
If measurement exceeds service limit, replace piston ring.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Piston ring free end gap
Standard (1st): Approx. 9.9 mm (0.3898 in.)
Standard (2nd): Approx. 9.7 mm (0.3819 in.)
Service limit (1st): 7.9 mm (0.311 in.)
Service limit (2nd): 7.8 mm (0.307 in.)
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.
Measure the following item:
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
Piston pin outside diameter
Standard: 17.995 – 18.000 mm (0.7085 – 0.7087 in.)
Service limit: 17.980 (0.7079 in.)
Piston pin hole diameter
Standard: 18.006 – 18.014 mm (0.7089 – 0.7092 in.)
Service limit: 18.030 (0.7098 in.)
Conrod small end bore
Standard: 18.003 – 18.011 mm (0.7088 – 0.7091 in.)
Pin clearance in piston pin hole
Standard: 0.006 – 0.019 mm (0.0002 – 0.0007 in.)
Service limit: 0.05 (0.0019 in.)
Pin clearance in conrod small end
Standard: 0.003 – 0.016 mm (0.0001 – 0.0006 in.)
Service limit: 0.05 (0.0020 in.)
(A)
I9J011140068-02
(A)
I9J011140067-02
Piston Pin and Conrod Inspection
Z9J0111406022
Piston Pin
Visual inspection
• Check piston pin, conrod small end bore and piston pin hole for wear or damage.
If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin can move smoothly in the piston pin hole.
If improper condition is found, replace the piston pin and/or piston.
(B)
(B)
I9J011140069-02
I9J011140070-02
Conrod big end side clearance
Measure conrod big end side clearance with conrod installed on crank pin as shown.
If measurement exceeds service limit, replace conrod and/or crankshaft.
Special tool
(A): 09900–20803 (Thickness gauge)
Conrod big end side clearance
Standard: 0.100 – 0.250 mm (0.0039 – 0.0098 in.)
Service limit: 0.35 mm (0.0138 in.)
Conrod big end width
Standard: 21.950 – 22.000 mm (0.8642 – 0.8661 in.)
Crank pin width
Standard: 22.100 – 22.200 mm (0.8071 – 0.8740 in.)
Power Unit Mechanical: 1D-54
Conrod Bearing Visual Inspection
Inspect bearing shell for proper contact pattern and signs of fusion, pitting, burning or flaking.
Bearing shells found in defective condition must be replaced.
I9J011140071-01
Conrod Big End Oil Clearance
Check conrod big end oil clearance as follows:
1) Clean surface of conrod, conrod cap, conrod bearing, and crank pin.
2) Install conrod bearing onto conrod and conrod cap.
NOTE
• Reassemble each bearing and conrod cap to their original position.
• Do not apply oil to bearing.
I9J011140249-01
Crank Pin and Conrod Bearing Inspection
Z9J0111406023
Crank Pin Diameter
Inspect crank pin for uneven wear or damage.
Measure crank pin for out-of-round “a” – “b” or taper “c” –
“d” with micrometer.
If crank pin is damaged, out-of-round “a” – “b” or taper
“c” – “d” is out of service limit, replace crankshaft.
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm))
Crank pin diameter
Standard: 41.982 – 42.000 mm (1.6528 – 1.6535 in.)
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.)
I9J011140251-01
1. Conrod bearing 2. Dowel pin
3) Place a piece of Plastigauge on crank pin parallel to crankshaft. Avoid placing Plastigauge over oil hole.
Special tool
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))
I9J011140250-01
I9J011140252-02
1D-55 Power Unit Mechanical:
4) Install conrod cap (with bearing) to conrod with the embossed mark on cap toward flywheel side.
c) Finally tighten bolts 60 degrees turn from the point of step b) using an angular torque gauge.
Tightening torque
Conrod cap bolt (Final step): 60 degrees (47
N
⋅
m, 4.7 kgf-m, 34 lbf-ft)
NOTE
Purchase a commercially available angular torque gauge for this step of tightening bolts.
I9J011140253-01
1. Embossed mark 2. Flywheel side
5) Apply engine oil to conrod bolts.
Tighten conrod cap bolts in three steps as follows.
a) Lightly seat all conrod bolts at first, then tighten bolts 12 N
⋅ m (1.2 kgf-m, 8.7 lbf-ft) of specified torque.
Tightening torque
Conrod cap bolt (1st step): 12 N·m (1.2 kgfm, 8.7 lbf-ft)
b) Tighten bolts 17 N
⋅ m (1.7 kgf-m, 12.3 lbf-ft) of specified torque.
Tightening torque
Conrod cap bolt (2nd step) (a): 17 N·m (1.7 kgf-m, 12.3 lbf-ft)
I9J011140255-03
NOTE
Do not rotate conrod with plastigauge in place.
6) Remove conrod and conrod cap from crank pin.
7) Using scale on plastigauge envelope, measure plastigauge width at its widest point.
If measurement exceeds service limit, replace conrod bearing.
Conrod big end oil clearance
Standard: 0.032 – 0.050 mm (0.0013 – 0.0020 in.)
Service limit: 0.080 mm (0.0031 in.)
I9J011140254-01
I9J011140256-01
1. Plastigauge 2. Scale
NOTE
For bearing replacement, see the “Selection of Conrod Bearing” (Page 1D-56).
Selection of Conrod Bearing
NOTE
Z9J0111406029
• If bearing is in malfunction, or bearing clearance is not in specification, select a new standard bearing according to the following procedure.
• When replacing crankshaft, conrod and its bearing due to any reason, select a new standard bearing to be installed by referring to numbers stamped on conrod and its cap and alphabets stamped on crank web No.1.
1) Check stamped numbers on conrod and its cap as shown.
Three kinds of number (“1”, “2” or “3”) represent the conrod big end inside diameter.For example, stamped number “1” indicates that corresponding its big end inside diameter is 45.000 – 45.006 mm
(1.7717 – 1.7719 in.).
Conrod big end inside diameter
Stamped No.
Conrod big end inside diameter
1
45.0000 – 45.0060 mm
(1.7717 – 1.7719 in.)
2
3
45.0061 – 45.0120 mm
(1.7719 – 1.7721 in.)
45.0121 – 45.0180 mm
(1.7721 – 1.7723 in.)
Power Unit Mechanical: 1D-56
2) Next, check crankshaft pin outside diameter. On crank web No.1, four alphabets are stamped as shown in the figure.
Three kinds of alphabet (“A”, “B” or “C”) represent the crankshaft pin diameter respectively. For example, stamped “A” indicates that corresponding crankshaft pin diameter is 41.994 – 42.000 mm
(1.6533 – 1.6535 in.).
Crankshaft pin outside diameter
Stamped alphabet
Crank pin diameter
A
41.9940 – 42.0000 mm
(1.6533 – 1.6535 in.)
B
C
41.9880 – 41.9939 mm
(1.6531 – 1.6533 in.)
41.9820 – 41.9879 mm
(1.6528 – 1.6531 in.)
“A”
“A”: Conrod big end inside dia. code
I9J011140266-01
“B”
“C”
“B”: No.1 Crank pin dia. code
“C”: No.2 Crank pin dia. code
“E”
“D”
I9J011140267-01
“D”: No.3 Crank pin dia. code
“E”: No.4 Crank pin dia. code
3) There are five kinds of standard bearing differing in thickness available. To distinguish them, they are painted in four colors at the position indicated in the figure.
Each color indicates the following thickness at the center of bearing.
Size of conrod bearing thickness
Color painted Bearing thickness
Blue
1.4990 – 1.5020 mm
(0.05901 – 0.05913 in.)
Yellow
Nothing
1.4960 – 1.4990 mm
(0.05890 – 0.05901 in.)
1.4930 – 1.4960 mm
(0.05878 – 0.05889 in.)
Black
Green
1.4900 – 1.4930 mm
(0.05867 – 0.05877 in.)
1.4870 – 1.4900 mm
(0.05854 – 0.05866 in.)
1D-57 Power Unit Mechanical:
(A)
(B)
“F”
I9J011140268-01
“F”: Color mark
4) From number stamped on conrod and its cap and alphabets stamped on crank web No.1, Determine new standard bearing to be installed into conrod big end, by referring to the table.
For example, if number stamped on conrod and its cap is “1” and alphabet stamped on crank web No.1 is “B”, install the bearing painted “Black” as a new standard bearing to conrod big end.
Matching chart of conrod bearing
Number stamped on conrod and its
Alphabet stamped on crank web No.1
A
B
C cap (Big end diameter)
1
Green
2
Black
3
Nothing
Black
Nothing
Nothing
Yellow
Yellow
Blue
(Crank pin diameter)
NOTE
Measure conrod big end oil clearance again after installing new bearing selected.
Refer to “Conrod Big End Oil Clearance”
under “Crank Pin and Conrod Bearing
Crankshaft Inspection
Z9J0111406024
Crankshaft Runout
Using a dial gauge, measure runout at center journal.
If measurement exceeds service limit, replace crankshaft.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Crankshaft runout
Service limit: 0.04 mm (0.0016 in.)
I9J011140257-02
Crankshaft Thrust Play
1) Measure thrust play with crankshaft, thrust bearing, journal bearing and crankcase / cylinder block assembled in a normal manner.
Tighten crankcase bolts to specified torque.
Tightening torque
Crankcase bolt (Inside 10 mm): 52 N·m (5.2 kgfm, 37.5 lbf-ft)
Crankcase bolt (Outside 8 mm): 25 N·m (2.5 kgfm, 18.1 lbf-ft)
2) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If measurement exceeds service limit, replace crankshaft thrust bearing.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.0043 – 0.0122 in.)
Service limit: 0.35 mm (0.0138 in.)
Crankshaft thrust bearing thickness
Standard: 2.47 – 2.52 mm (0.0972 – 0.0992 in.)
I9J011140258-02
Out-of-Round and Taper (Uneven Wear) of Journals
An unevenly worn crankshaft journal shows up as a difference in diameter at a cross section or along its length (or both).
This difference, if any, is determined by taking micrometer readings.
If any journal is badly damaged or if measurements exceed service limit, replace crankshaft.
Special tool
(A): 09900–20203 (Micrometer (50 – 75 mm))
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.)
Out-of-round: A – B
Taper: a – b
Crankshaft journal outside diameter
Standard: 51.994 – 52.012 mm (2.0470 – 2.0477 in.)
Power Unit Mechanical: 1D-58
Crankshaft Journal Oil Clearance
Check clearance using Plastigauge according to the following procedure.
NOTE
Assemble each bearing in its original position before checking clearance.
1) Clean surface of bearing holder (crankcase, and cylinder), bearing, and main bearing journal.
2) Install main bearing (1) to cylinder and crankcase.
NOTE
• Align tab “A” of bearing with notch in cylinder and crankcase.
• Do not apply engine oil to bearing.
• Install lower bearing half with oil hole / groove towards cylinder side.
I9J011140072-02
Crankshaft Main Bearing Inspection
Crankshaft Main Bearing Visual Inspection
Z9J0111406025
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 replace only one half of a bearing set.
I9J011140259-01
1. Oil hole / groove
I9J011140260-01
I9J011140073-01
1D-59 Power Unit Mechanical:
3) Install crankshaft to cylinder.
4) Place a piece of Plastigauge across full width of bearing (parallel to crankshaft) on journal.
Do not place Plastigauge over oil hole.
Special tool
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))
NOTE
Do not rotate crankshaft while Plastigauge is installed.
NOTE
Crankcase must be torqued to specification in order to assure proper compression of plastigauge and accurate reading of clearance.
“9”
“9”
“5”
“5”
“10”
“10”
“6”
“6”
“1”
“1” “2”
“2”
I9J011140261-02
5) Assemble crankcase to cylinder.
6) Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three steps following the order indicated below.
NOTE
Tighten 10 mm (0.394 in.) thread diameter bolts first (following the order shown in figure), then tighten 8 mm (0.315 in.) thread diameter bolts.
Tightening torque
Crankcase inside bolt (10 mm thread diameter)
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
Crankcase inside bolt (10 mm thread diameter)
[2nd step]: 45 N·m (4.5 kgf-m, 32.5 lbf-ft)
Crankcase inside bolt (10 mm thread diameter)
[Final step]: 52 N·m (5.2 kgf-m, 37.5 lbf-ft)
Tightening torque
Crankcase outside bolt (8 mm thread diameter)
[1st step]: 6 N·m (0.6 kgf-m, 4.3 lbf-ft)
Crankcase outside bolt (8 mm thread diameter)
[2nd step]: 21 N·m (2.1 kgf-m, 15.0 lbf-ft)
Crankcase outside bolt (8 mm thread diameter)
[Final step]: 25 N·m (2.5 kgf-m, 18.1 lbf-ft)
“3”
“7”
“3”
“7”
“4”
“8”
7) Remove crankcase from cylinder.
“4”
“8”
I9J011140018-03
I9J011140262-01
8) Using scale on Plastigauge envelope, measure plastigauge width at its widest point.
Crankshaft journal oil clearance
Standard: 0.016 – 0.036 mm (0.0012 – 0.0020 in.)
Service limit: 0.056 mm (0.0022 in.)
Power Unit Mechanical: 1D-60
2) Next, check bearing holder inside diameter without bearing.
As shown in figure, the cylinder block PORT side has five stamped code letters or numerals.
The letters (A, B and C) or numerals (1, 2 and 3) represent the bearing holder inside diameters shown below.
Code
A or 1
B or 2
C or 3
Crank bearing holder inside diameter (w/o bearing)
56.000 – 56.006 mm
(2.2047 – 2.2050 in.)
56.006 – 56.012 mm
(2.2050 – 2.2052 in.)
56.012 – 56.018 mm
(2.2052 – 2.2054 in.)
I9J011140263-01
2. Plastigauge 3. Scale
9) If measurement exceeds service limit, replace crankshaft main bearing.
NOTE
For bearing replacement, see the “Selection of Main Bearings” (Page 1D-60).
Selection of Main Bearings
Whenever a bearing requires replacement, select a new bearing according to following procedure.
1) First, check journal diameter.
As shown in figure, upper (flywheel side) crank web of No.1 cylinder has five stamped code numerals.
The numerals (1, 2 and 3) represent the journal diameters shown below.
Numeral stamped
1
2
3
Journal diameter
52.006 – 52.012 mm
(2.0475 – 2.0477 in.)
52.000 – 52.006 mm
(2.0472 – 2.0475 in.)
51.994 – 52.000 mm
(2.0470 – 2.0472 in.)
“A”
“B”
“C”
“D”
“E”
“J”
“I”
“F”: No. 1 Holder code
“G”: No. 2 Holder code
“H”: No. 3 Holder code
“H”
“G”
“F”
I9J011140029-01
“I”: No. 4 Holder code
“J”: No. 5 Holder code
3) There are five main bearings available, each of differing 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
Purple
Brown
Green
Black
No color mark
Bearing thickness
1.992 – 1.996 mm
(0.0784 – 0.0786 in.)
1.995 – 1.999 mm
(0.0785 – 0.0787 in.)
1.998 – 2.002 mm
(0.0787 – 0.0788 in.)
2.001 – 2.005 mm
(0.0788 – 0.0789 in.)
2.004 – 2.008 mm
(0.0789 – 0.0791 in.)
“A”: No. 1 Journal code
“B”: No. 2 Journal code
“C”: No. 3 Journal code
I9J011140028-02
“D”: No. 4 Journal code
“E”: No. 5 Journal code
1D-61 Power Unit Mechanical:
“K”
I9J011140074-01
“K”: Color mark
4) Select crankshaft main bearing referring to the below table.
For example, If number stamped on crank web is “1” and alphabet stamped on cylinder block is “B”, install a new bearing painted in “Brown” to it’s journal.
Numeral stamped on crank web
(journal outside diameter)
1 2
Brown
Green
3
Green
Black
Code stamped on cylinder block
(Bearing holder inside diameter)
A or 1 Purple
B or 2 Brown
C or 3 Green Black No color
NOTE
Measure crankshaft journal oil clearance again after installing new bearing selected.
Refer to “Crankshaft Journal Oil Clearance”
Crankshaft Drive Gear Inspection
Z9J0111406026
Inspect drive gear. Replace gear if damaged or worn.
Crankshaft Oil Seal Inspection
Z9J0111406027
Inspect condition. If cracked, cut or damaged, replace.
I9J011140265-01
I9J011140264-01
Power Unit Lubrication: 1E-1
Power Head
Power Unit Lubrication
General Description
Engine Lubrication Description
Z9J0111501001
A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.
Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at a constant level.
From the main gallery, oil flow is directed through either drilled internal passages or by splash method to those surfaces requiring lubrication.
Engine Oil Lubrication Chart
Schematic and Routing Diagram
No.1 PISTON
No.2 PISTON
No.3 PISTON
No.4 PISTON
OIL PRESSURE
SWITCH
No.1 CRANKSHAFT
MAIN JOURNAL
No.1 CRANK PIN
No.2 CRANKSHAFT
MAIN JOURNAL
No.2 CRANK PIN
No.3 CRANKSHAFT
MAIN JOURNAL
No.3 CRANK PIN
No.4 CRANKSHAFT
MAIN JOURNAL
No.4 CRANK PIN
No.5 CRANKSHAFT
MAIN JOURNAL
No.5 CRANK PIN
No.1
CAM FACE
No.2
CAM FACE
No.3
CAM FACE
No.4
CAM FACE
No.1 CAMSHAFT
JOURNAL (IN)
No.2 CAMSHAFT
JOURNAL (IN)
No.3 CAMSHAFT
JOURNAL (IN)
No.4 CAMSHAFT
JOURNAL (IN)
No.5 CAMSHAFT
HOUSING
CYLINDER HEAD
OIL FILTER
OIL PUMP
OIL STRAINER
CHAIN TENSIONER
ADJUSTER
PRESSURE
REGULATOR
Z9J0111502001
No.1 CAMSHAFT
JOURNAL (EX)
No.2 CAMSHAFT
JOURNAL (EX)
No.3 CAMSHAFT
JOURNAL (EX)
No.4 CAMSHAFT
JOURNAL (EX)
No.1
CAM FACE
No.2
CAM FACE
No.3
CAM FACE
No.4
CAM FACE
OIL PAN
I9J011150001-02
1E-2 Power Unit Lubrication:
Diagnostic Information and Procedures
Oil Pressure Check
Refer to “Oil Pressure Check” in Section 0B (Page 0B-20).
Oil Change Reminder System
Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14).
Z9J0111504001
Z9J0111504003
Low Oil Pressure Caution System
Z9J0111504004
The system operates when the engine lubricating oil pressure drops below the correct level (100 kPa, 1.0 kg/cm 2 , 14 psi.). If this system activates, the red oil lamp will light and caution buzzer will begin a series of beeps.
In addition, when this system is activated at 1 000 r/min. or higher, engine speed will automatically be reduced to approx. 1 000 r/min with REV Limit lamp lit.
The engine automatically stops 3 minutes after the control of this CAUTION system starts the activation.
If this system activates, stop the engine immediately.
Check the engine oil level and add oil if necessary.
Refer to “Engine Oil Level Check” in Section 0B (Page 0B-3).
NOTE
In case that the engine is automatically stopped due to the CAUTION system, the engine can be started again. However the CAUTION system will repeatedly activate until eliminating the cause.
Powerhead Lubrication System Diagnosis
Condition
Low oil pressure
High oil pressure
Z9J0111504002
Possible cause
Clogged oil filter.
Leakage from oil passages.
Defective oil pump.
Replace.
Correction / Reference Item
Repair or replace.
Replace.
Defective oil pressure regulator.
Damaged O-ring.
Replace.
Replace.
Combination of above item.
Repair or replace.
Using an engine oil of too high viscosity.
Replace.
Clogged oil passage.
Clogged oil pressure regulator.
Combination of above items.
Clean or replace.
Replace.
Repair or replace
Power Unit Lubrication: 1E-3
Service Instructions
Oil Pump Removal and Installation
Z9J0111506001
Removal
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
2) Remove the four bolts securing oil pump (1), then remove the oil pump.
Oil Pump Disassembly and Assembly
Z9J0111506002
Disassembly
1) Remove the screw (1) securing oil pump rotor plate
(2) to the oil pump case, then remove oil pump rotor plate.
1
1
I9J011150004-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Install oil pump assembly (1), then tighten four bolts securely.
Tightening torque
Oil pump (a): 15 N·m (1.5 kgf-m, 11 lbf-ft)
2
2) Remove the shaft (3) and pin (4).
3
I9J011150006-01
4
3) Take out inner rotor (5) and outer rotor (6).
I9J011150007-01
(a)
1
I9J011150005-01
• Pour approx. 20 ml (0.7 oz.) of engine oil into pump case for initial lubrication.
6
5
I9J011150008-01
1E-4 Power Unit Lubrication:
Assembly
1) Wash, clean and then dry all disassembly parts.
2) Apply thin coat of engine oil to inner and outer rotors, inside surfaces of oil pump case and plate.
3) Install outer rotor (1) and inner rotor (2) to pump case.
NOTE
When installing outer and inner rotors, the punch mark “a” on each rotor must face original direction.
5) Install dowel pins (5) and rotor plate (6), and then tighten screw (7) securely.
After mounting the rotor plate, make sure that each rotor turns smoothly by hand.
6
5
5
2
I9J011150011-01
7
“ a ”
1
I9J011150009-02
4) Assemble the pin (3) to oil pump shaft (4), then install oil pump shaft.
3 4
I9J011150010-01
I9J011150012-01
6) Pour approx. 20 ml (0.7 oz.) of engine oil into pump case for initial lubrication.
Inspection Oil Pump Component Parts
Z9J0111506003
NOTE
If any repair is required on outer rotor, inner rotor and oil pump case / plate, replace them as an oil pump assembly.
Oil Pump Component Parts
Check outer and inner rotors, rotor plate and oil pump case for excessive wear or damage. Replace as necessary.
I9J011150013-01
Measuring Radial Clearance
Using a feeler gauge, measure radial clearance between outer rotor and case.
If measurement is not within specifications, replace oil pump assembly.
Radial clearance
Service limit: 0.31 mm (0.0122 in.)
Power Unit Lubrication: 1E-5
Oil Pressure Switch Removal and Installation
Z9J0111506004
Removal
1) Loosen screw (1) and disconnect blue lead wire (2) from oil pressure switch (3).
3
1
2
I9J011150014-01
Measuring Side Clearance
Using Straightedge and feeler gauge, measure side clearance.
If measurement is not within specifications, replace oil pump assembly.
Side clearance
Service limit: 0.15 mm (0.0059 in.)
I9J011150016-01
2) Remove oil pressure switch from cylinder block.
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 (1) then tighten switch to specified torque.
NOTE
Cut off any excess sealing tape from switch threads before installation.
Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5 lbfft)
1
I9J011150015-01
1
I9J011150002-01
(a)
I9J011150017-01
• Start engine and check oil pressure switch for oil leakage.
Reseal switch if oil leakage is found.
1E-6 Power Unit Lubrication:
Oil Pressure Switch Inspection
Z9J0111506005
NOTE
Before checking the oil pressure switch, make sure the engine oil pressure is within specification.
1) Remove the blue lead wire (1) from oil pressure switch (2).
Oil Strainer Removal and Installation
Z9J0111506006
Removal
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Disassembly” in Section 2A (Page 2A-6).
Installation
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly” in Section 2A (Page 2A-9).
Oil Strainer Related Parts Inspection
Z9J0111506007
• Inspect oil strainer. Replace strainer if cracked, damaged or other abnormal conditions.
If clog or obstruction, clean oil strainer.
• Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal condition.
1
2
I9J011150018-01
2) Check the continuity between the switch terminal and engine body ground.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Oil pressure switch continuity
Engine running: Infinity
Engine stopped: Continuity
I9J011150019-01
3) If measurement exceeds specification, replace oil pressure switch.
4) Reinstall parts removed earlier.
I9J011150003-01
Power Unit Cooling System: 1F-1
Power Head
Power Unit Cooling System
General Description
Water Cooling System Description
Z9J0111601001
The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead assembly.
To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine operation, there is a thermostat in the cylinder block.
Motor temperature and cooling system efficiency are monitored by cylinder temp. sensor and exhaust manifold temp. sensor in the cylinder. If temperature higher than normal is detected by a sensor, an advance caution of overheat condition is provided.
Displacement Type Water Pump Description
Z9J0111601002
In this displacement type water pump, the water pressure is increased by the change in volume between the impeller and the pump case. As a result, the increased water pressure enables the water pump to circulate the cooling water.
1
4
2
3
5
6
7
1. Water inlet
2. Water outlet
3. Key
4. Water pump case
5. Water pump impeller
6. Under panel
7. Driveshaft
Water Pressure Valve Description
If cylinder water pressure is high when thermostat is closed, the valve will open to relieve the pressure.
I9J011160003-01
Z9J0111601003
1
2
1. Water pressure valve cover
I9J011160004-01
2. Water pressure valve
1F-2 Power Unit Cooling System:
Schematic and Routing Diagram
Cooling Water Circulation Chart
Z9J0111602001
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic form below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or component damage.
Engine holder Return hose Thermostat open
Oil pan
Driveshaft housing
Fuel return pipe
Oil pan
Water jacket cover
Thermostat
Cylinder block
Engine holder
Oil pan
Water tube
Water pump
Cylinder head
Pressure valve
Pilot water hole
Propeller exhaust outlet
Water intake
WATER
I9J011160001-02
Power Unit Cooling System: 1F-3
Diagnostic Information and Procedures
Powerhead Cooling System Diagnosis
Z9J0111604001
Condition
Overheating powerhead
Possible cause
Water inlet screen obstructed.
Water passage obstructed.
Pump plate not sealing.
Water pump impeller damage.
Clean.
Correction / Reference Item
Clean or replace.
Check and repair.
Replace.
Water pump housing and/or plate worn.
Replace.
Water pump housing seal worn.
Water tube grommet damaged.
Replace.
Replace.
Thermostat damaged / defective.
Water pressure valve damaged / defective.
Overcooling powerhead
Thermostat damaged / defective.
Replace.
Replace.
Replace.
Service Instructions
Thermostat Removal and Installation
Z9J0111606001
Removal
1) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
2) Loosen the clip (1) and remove the water return hose (2) from thermostat cover (3).
4) Remove the thermostat (5) and cover seal (6) from thermostat cover.
3
1
2
I9J011160005-01
3) Remove the two bolts (4) securing the thermostat cover (3), then remove the cover with thermostat.
6
5
I9J011160007-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Assemble thermostat (1), cover seal (2) and thermostat cover (3).
3
4
2
1
4
I9J011160008-01
3
I9J011160006-01
1F-4 Power Unit Cooling System:
• Install the thermostat cover and thermostat assembly, then secure thermostat cover (3) with bolts (4).
Tightening torque
Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)
1
2
3
4
(a)
3
I9J011160009-03
• Check to ensure that all removed parts are back in place.
Thermostat Inspection
Z9J0111606002
Inspect the thermostat in the following procedures:
1) Remove the thermostat.
Refer to “Thermostat Removal and Installation”
2) Inspect the thermostat.
If salt deposits, corrosion, wear or other damage is found, clean or replace.
I9J011160002-01
1. Thermometer
2. Heater
3. Thermostat
4) Install the thermostat.
Refer to “Thermostat Removal and Installation”
Water Pressure Valve Removal and Installation
Z9J0111606003
Removal
1) Remove lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Remove two bolts (1), pressure valve cover (2) and water pressure valve (3).
1 1
2
I9J011160011-01
I9J011160010-01
3) Check thermostat opening temperature as follows: a) Insert a length of thread between thermostat valve / body and suspend thermostat in a container filled with water.
b) Place thermometer in container and heat water.
Observe water temperature when thermostat valve opens and releases thread.
Thermostat operating temperature
Standard: 58 – 62
°
C (136 – 144
°
F)
3
I9J011160012-01
Installation
1) Install O-ring (1) to pressure valve cover (2).
1
2
Power Unit Cooling System: 1F-5
2) Inspect the water pressure valve.
If salt deposits, corrosion, wear or other damage is found, clean or replace.
Inspect O-ring. Replace if nicked, cut or torn.
I9J011160013-01
2) Install pressure valve (3) and pressure valve cover
(2) to oil pan and secure with bolts (4).
3
4
2
3) Install lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
I9J011160014-01
Water Pressure Valve Related Item Inspection
Z9J0111606004
Inspect the water pressure valve in the following procedures:
1) Remove the water pressure valve.
Refer to “Water Pressure Valve Removal and
I9J011160015-01
3) Install the water pressure valve.
Refer to “Water Pressure Valve Removal and
Water Pump Removal and Installation
Z9J0111606005
Refer to “Water Pump Removal and Installation” in
Water Pump Related Item Inspection
Z9J0111606006
Refer to “Water Pump and Related Items Inspection” in
Water Tube Removal and Installation
Z9J0111606007
Removal
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Disassembly” in Section 2A (Page 2A-6).
Installation
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly” in Section 2A (Page 2A-9).
Water Tube Related Item Inspection
Z9J0111606008
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Related Component Inspection” in Section 2A
1G-1 Fuel System:
Power Head
Fuel System
Precautions
Precautions on Fuel System Service
Z9J0111700001
!
WARNING
Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system.
• Disconnect battery cables except when battery power is required for servicing / inspection.
• Keep the working area well ventilated and away from open flame (such as gas heater) or sparks.
• Do not smoke or allow anyone else to smoke near the working areas.
Post a “NO SMOKING” sign.
• Keep a fully charged CO
2
fire extinguisher readily available for use.
• Always use appropriate safety equipment and wear safety glasses when working around a pressurized fuel system.
• To avoid potential fire hazards, do not allow fuel to spill on hot engine parts or on operating electrical components.
• Wipe up fuel spills immediately.
• Fuel components and fuel hoses, after the high pressure fuel pump, remain pressurized at all times.
To protect against fuel spray, relieve fuel line pressure before disconnecting or removing components.
CAUTION
• Do not over bend (kink) or twist hoses when installing.
• When installing hose clamps, position tabs to avoid contact with other parts.
• Be sure hoses do not contact rods, levers or other components with engine either operating or at rest.
• Extreme care should be taken not to cut, abrade or cause any other damage to hoses.
• Use care not to excessively compress hoses when tightening clamps.
Fuel System: 1G-2
General Description
Electronic Fuel Injection System Description
Z9J0111701001
The fuel injection system used by the DF70 / 80 / 90 is a speed-density, multi-point, sequential, electronic fuel injection type.
The fuel injection system is composed of the fuel line components, air intake components, and components for system control (ECM, sensors, switches, etc.).
Fuel Injection Control System Outline
Sensors are mounted at precise locations on the motor to monitor the current conditions of engine operation and send signals to the ECM.
Based on these signals, the ECM determines the optimum fuel injection time duration (fuel amount), fuel injection timing (multi-point sequential timing) and controls the injector operating signals accordingly.
In regards to fuel injection timing, the fuel injection end timing is set depending on engine rpm. The ECM calculates the amount of fuel injection based on the engines operating conditions, and determines the fuel injection start timing.
In the injection timing chart below, the injection end timing is set at 0
°
BTCD on the exhaust stroke.
Basic sensors
MAP sensor:
Informs ECM of intake manifold pressure.
CKP sensor:
Informs ECM of engine speed and crankshaft angle.
Compensating sensors
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
Exhaust manifold temperature sensor:
Informs ECM of exhaust manifold temperature.
IAT sensor:
Informs ECM of intake air temperature.
TPS (Throttle position sensor):
Informs ECM of throttle opening angle.
Battery voltage:
Constantly monitored by the ECM.
Others
CMP sensor:
Informs ECM of camshaft angle.
Shift position sensor:
Informs ECM of shift position (neutral or in-gear).
ECM
Fuel injection time duration
(amount) is determined by a digital map designed in relation to intake manifold pressure and engine speed.
Fuel amount compensation
Multi-point sequential timing
Signal Signal Signal Signal
Injector
ECM
CPU
Sensor / switch signal input
Battery charge coil
Rectifier & regulator
ECM main relay
30A fuse
40A fuse
Battery
15A fuse
Ignition switch
A A A A
Injector
I9J011170001-02
1G-3 Fuel System:
Fuel Injection Timing Chart
32 signals / crankshaft 1 rotation
CKP sensor signal
140° 220°
40°
180°
100°
40°
140°
CMP sensor signal
No.1 cylinder
No.3 cylinder
No.4 cylinder
Cm.
In.
Ex.
Ep.
Ep.
Cm.
In.
Ex.
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC
Ex.
In.
TDC TDC
Ep.
Ex.
TDC
Cm.
Ep.
TDC TDC
In.
Cm.
Cm.
In.
Ex.
Ep.
TDC
Ep.
TDC
Cm.
In.
Ex.
No.2 cylinder
Injection end timing: 0° BTDC on Ex.stroke
Injection time duration
No.1 Injection
signal
No.3 Injection
signal
No.4 Injection
signal
No.2 Injection
signal
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake,
I9J011170002-05
Fuel Injection Control Mode
When cranking:
Fuel is injected in each cylinders according to the “Start up mode” map which is based on the cylinder temperature and intake air temperature (sequential injection).
After start (Fast-idle function):
The fuel injection amount is controlled so that the engine rpm stays within the fast idle speed map until the cylinder temperature reaches normal operating temperature.
When idling / trolling:
The fuel injection amount is controlled to maintain a stable engine speed at the specified idle / trolling rpm.
When accelerating:
The fuel injection amount is controlled to increase.
When decelerating:
The fuel injection amount is controlled to decrease.
The fuel injection is also cut off on very rapid engine deceleration.
Fuel System: 1G-4
Fuel Delivery System Components Description
Z9J0111701002
The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel injectors and hoses.
Fuel is supplied through the primer bulb, low pressure fuel filter, and low pressure fuel pump to the fuel vapor separator.
Fuel flow from the fuel vapor separator is pressurized by the high pressure fuel pump and supplied through the high pressure fuel filter and fuel delivery pipe to the fuel injectors.
The pressure regulator maintains fuel pressure in the feed line between the high pressure fuel pump and fuel injector.
This pressure, maintained at a constant level, is higher than the pressure in the vapor separator chamber.
When fuel feed line pressure exceeds vapor separator chamber pressure by more than approx. 250 kPa (2.55 kg/cm 2 ,
36.3 psi.), the valve in the fuel pressure regulator will open and return the excess fuel to the vapor separator chamber.
Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals supplied from the
ECM.
8 7
9
12
6
1
10
2
3
To atmosphere
15
11
5
4
1. High pressure fuel pump
2. High pressure fuel filter
3. Fuel cooler
4. Fuel delivery pipe
14
5. Fuel injector
6. Evaporation hose
7. Primer bulb
8. Low pressure fuel filter
13
9. Low pressure fuel pump
10. Fuel vapor separator
11. Fuel pressure regulator
12. Intake silencer
13. Intake manifold
14. Throttle body
15. Fuel tank
I9J011170003-03
1G-5 Fuel System:
Fuel Vapor Separator
The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber.
As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump.
The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator.
This vapor is routed through the evaporation hose to the atmosphere.
High Pressure Fuel Pump
The high pressure fuel pump is an “integral” type in which the pump mechanism is located within the fuel vapor separator.
To supply the optimum fuel amount, the pump is driven by the duty cycle signal from the ECM.
Fuel outlet
Evaporation
Fuel inlet
5
6
4
3
1
7
2
1. High pressure fuel pump
2. Suction filter
3. Needle valve
4. Valve seat
Fuel return
Fuel drain
5. Float
6. Chamber
7. Fuel pressure regulator
I9J011170016-03
Fuel System: 1G-6
Fuel Pressure Regulator
The fuel pressure regulator is located in the fuel vapor separator.
The regulator's function in the system is to maintain constant fuel pressure to the injectors while the engine is operating.
The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure balanced.
Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in the fuel vapor separator chamber by approx. 250 kPa (2.55 kg/cm 2 , 36.3 psi.).
By-pass fuel is returned to the fuel vapor separator chamber.
VALVE CLOSED
(below 250 kPa)
VALVE OPENED
(over 250 kPa)
To Fuel vapor separator chamber
(Fuel return)
From Delivery line From Delivery line
I9J011170004-02
Fuel Injector
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the solenoid coil is energized pulling up the plunger.
This opens the injector valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel injected is determined by the amount of time (duration) the electromagnetic valve is open.
1
4
2
1. Filter
2. Solenoid coil
3. Ball valve
4. Terminal
3
I9J011170005-02
1G-7 Fuel System:
High Pressure Fuel Pump Control System Description
Z9J0111701003
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON” / “OFF” signal, at a specified rate (1 000 times a second).
Based on engine speed and battery voltage, the ECM determines the optimum duty cycle (repeating “ON” time rate within a cycle) and sends this signal to the fuel pump.
CKP sensor:
Informs ECM of engine speed.
Battery voltage
Ignition switch:
Informs ECM of “START” signal.
Cylinder temp. sensor:
Informs ECM of cylinder temperature.
ECM Signal FP
Fuel pump
I9J011170006-01
7
ECM
CPU
3
8
4
6
1
5
FP
BATT
9
1. Sensor/switch signal input
2. Fuel pump
3. ECM main relay
4. 30 A fuse
5. 15 A fuse
2
I9J011170007-01
6. 40 A fuse
7. Battery charge coil
8. Rectifier/Regulator
9. Ignition switch
Duty cycle signal for fuel pump (example: 80% duty)
“ON” time
1 cycle time
× 100 = duty (%)
0.8 ms
OFF
ON
Time
1 ms (1cycle)
I9J011170008-01
Fuel System: 1G-8
Control Modes
Before start:
For 3 seconds after the ignition switch is turned “ON”, the fuel pump is controlled to operate at a 100% duty cycle to initially pressurize the high pressure fuel line.
When cranking:
The fuel pump is controlled to operate at a 50 – 100% duty cycle.
The duty cycle changes depending on cylinder temperature.
When running (normal operation):
The fuel pump is controlled to operate at a 50 – 100% duty cycle based on the current engine speed and battery voltage.
Air Intake Components Description
Z9J0111701004
Air, after entering through the silencer case, passes through the throttle body and flows into the surge tank where it is then distributed to the intake manifold.
Intake manifold pressure, monitored by the MAP sensor, is an indirect measurement of the intake air amount.
When the throttle is fully closed, the main supply of intake manifold air necessary to sustain engine idle passes through the by-pass air passage.
To maintain engine idle speed at specification, the ECM controlled IAC valve supplies a regulated amount of additional air through the IAC (Idle Air Control) passage.
3
1
2
7
1. Throttle body
2. IAC valve
6
4
Air flow
3. Intake manifold
4. Throttle position sensor
5
5. MAP sensor
6. IAT sensor
7. Air intake silencer
I9J011170009-01
1G-9 Fuel System:
Throttle Body
• The throttle body assembly consists of the main bore, throttle valve and TPS (Throttle Position Sensor).
• The throttle body adjusts the intake air amount with the throttle valve which is connected to the throttle lever linkage.
• The TPS installed on the throttle body informs the ECM of the throttle valve opening angle.
NOTE
Do not try to adjust or remove any of the throttle body component parts (Throttle Position Sensor, throttle valve, throttle stop screw, etc.).
These components have been factory adjusted to precise specifications.
2
1
I9J011170025-01
1. Throttle body assembly 2. TPS
Idle Air Control System Description
Z9J0111701005
IAC Valve/Passage
The IAC valve is a stepper motor type mounted on the intake manifold.
Its purpose is to control the amount of intake air flowing through the IAC passage.
The IAC valve consists of a stepper motor, rod, valve and other parts.
As the stepper motor is controlled by signals from the ECM, valve position changes will increase or decrease the air flow through the IAC passage.
1
1. IAC valve
I9J011170073-01
Fuel System: 1G-10
3
+12 V
ECM
4
Gr
IAC valve
W/B
R/Y
60 IAC1
70 IAC2
2 R/G
W/Bl
58 IAC3
48 IAC4
1
Air flow
I9J011170010-02
1. Valve pintle 2. Screw shaft 3. Rotor 4. Coil
Idle Air Control System Outline
The ECM controls the position of the IAC valve to regulate a portion of the intake air flow to the intake manifold.
This system is used for the following purposes:
• To keep idling / trolling at the specified speed.
• To improve drivability when decelerating. (dash-pot effect)
• To improve engine starting and warm-up performance. (fast-idle function)
The sensors and switch shown below monitor the current engine condition and send signals to the ECM.
Based on these signals, the ECM determines the IAC valve setting necessary to achieve the target engine speed and outputs the signal for actuating the stepper motor inside the IAC valve.
The rotor of the stepper motor then turns in an amount equal to the steps of the signal supplied from the ECM, moving the valve via a screw shaft.
CKP sensor:
Informs ECM of engine speed.
MAP sensor:
Informs ECM of intake manifold pressure.
TPS:
Informs ECM of throttle opening angle.
Cylinder temp. sensor:
Informs ECM of cylinder temperature.
IAT sensor:
Informs ECM of intake air temperature.
Shift position sensor:
Informs ECM of shift position and change.
ECM
Signal
IAC valve
I9J011170011-03
1G-11 Fuel System:
IAC Valve Control Mode
Before started:
The IAC valve is initialized at a 70% opening position when engine is not running. (Ignition switch “OFF”).
When cranking:
The IAC valve is controlled to operate at approx. 60 – 90% open position.
The open position changes depending on the cylinder temperature.
After start (fast-idle function):
The IAC valve is controlled to operate at approx. 60 – 90% open position until the timer, (set according to cylinder temperature at cranking) expires. Then the open position gradually decreases until the engine rpm slows to the preset idle speed.
When idling / trolling:
The IAC valve is controlled so that the engine speed is stable at the idling / trolling speed specified.
During this period, the IAC valve has an open position of approx. 0 – 30%, but will vary slightly as idling / trolling conditions change.
When running (normal operation):
The IAC valve is controlled to operate at a 0 – 90% open position, dependent on current engine operating conditions.
When decelerating (dash-pot effect):
When the throttle valve is suddenly returned to fully closed, and the throttle position sensor signal changes to “fully closed”, the IAC valve is controlled to gradually return to an idle / troll operating position to prevent engine stalling or unstable running.
NOTE
Due to the limited intake air flow from the IAC passage, and in order to effectively use both the “Dashpot effect” and the “Fast-idle function”, an IAC valve operating position of 0 – 30% at idling / trolling speed is required.
Diagnostic Information and Procedures
Fuel Pressure Inspection
Z9J0111704001
!
WARNING
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury.
1) Relieve fuel pressure in fuel feed line.
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
2) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
3) Disconnect the high pressure fuel feed hose (1) from the fuel delivery pipe upper union (2).
Loosen the delivery pipe upper plug (3).
3
2
1
I9J011170026-02
3
(a)
5) Ensure the emergency stop switch lock plate is in place.
Shift into “Neutral” position.
6) Squeeze fuel primer bulb until you feel resistance.
7) Turn ignition switch “ON” for 3 seconds (to operate the fuel pump), then turn it “OFF”.
8) Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system and then check the fuel pressure.
Fuel System: 1G-12
4) Connect special tools (pressure gauge, pressure hose and pressure joint) between fuel feed hose (1) and fuel delivery pipe upper union as shown in figure. Tighten the delivery pipe upper plug (3) to specified torque.
Clamp the hose securely to ensure that no leaks occur during checking.
CAUTION
A small amount of fuel may be released when the fuel feed hose is disconnected.
Place container under the fuel feed hose or fuel delivery pipe upper union with a shop cloth so that the released fuel is caught in the container or absorbed by the cloth. Place the fuel soaked cloth in an approved container.
Special tool
(A): 09912–58442 (Fuel pressure gauge)
(B): 09912–58432 (Fuel pressure hose)
(C): 09912–58490 (3-way joint & hose)
Tightening torque
Delivery pipe upper plug (a): 35 N·m (3.5 kgf-m,
25.5 lbf-ft)
3
2
1. High pressure fuel filter
2. Fuel delivery pipe
(A)
(B)
(C)
1
I9J011170027-03
I9J011170017-01
3. Delivery pipe upper union
OFF
ON
I9J011170018-01
9) Check for any signs of fuel leakage.
!
WARNING
When the engine is running, keep your hands, hair, clothing, etc., away from the engine.
10) Measure fuel pressure at cranking or idle speed operation.
Fuel pressure
Standard: Approx. 255 kPa (2.55 kg/cm 2 , 36.3 psi.)
11) Stop engine and wait 5 minutes.
Check the residual fuel pressure in line.
Residual fuel pressure
Standard: 200 kPa (2.0 kg/cm 2 , 28.4 psi.) or more
CAUTION
The fuel feed line is under high fuel pressure, make sure to release fuel pressure according to the fuel pressure relief procedures mentioned earlier.
Use the following procedures to remove the fuel pressure gauge.
• Place a container under the joint to catch the fuel.
• Cover the joint with rag and loosen joint nut slowly to gradually release any residual fuel pressure.
1G-13 Fuel System:
12) After checking fuel pressure, remove fuel pressure gauge.
13) Reconnect fuel line.
14) With the engine not running and ignition switch “ON”, check the fuel system for leaks.
4
I9J011170019-01
4. Joint nut
Fuel System Diagnosis
Z9J0111704002
Condition
Engine will not start or hard to start (Fuel does not reach the fuel delivery pipe).
Engine will not start or hard to start.
Unstable idling / trolling or engine tends to stall.
Possible cause
Clogging, bending or improper routing of fuel hose.
Fuel pump failure.
Fuel pressure regulator failure.
Fuel injector(s) failure.
Wiring connection failure.
Throttle position sensor failure.
MAP sensor failure.
ECM failure.
Cylinder temp. sensor failure.
IAT sensor failure.
High pressure fuel pump failure.
Fuel hose improperly routed.
Shift position sensor failure.
Throttle position sensor failure.
IAC control system failure.
IAC passage clogged.
ECM failure.
Wire continuity / connection failure.
Fuel injector(s) clogged.
Fuel pressure regulator failure.
High pressure fuel pump failure.
Fuel filter clogged.
Clogging, bending or improper routing of fuel hose.
Air leakage from air intake system.
Insufficient engine power in high speed range (Air intake system failure).
Insufficient engine power in high speed range
(Control circuit or sensor failure).
Insufficient engine power in high speed range
(Engine internal parts or electrical equipment failure).
Fuel pressure too low.
Throttle position sensor failure.
ECM failure.
Fuel injector(s) clogged.
Throttle position sensor failure.
ECM failure.
Correction / Reference Item
Clean, repair or replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Reroute properly.
Replace.
Replace.
Check idle air control system.
Clean.
Replace.
Repair or replace.
Clean.
Check fuel pressure. Replace if necessary.
Check fuel pump and its circuit. Replace.
Clean or replace.
Clean, reroute, repair or replace.
Repair or replace.
Check fuel pressure. Repair or replace.
Replace.
Replace.
Clean.
Replace.
Replace.
Fuel System: 1G-14
Fuel Injection System Troubleshooting
Before starting the troubleshooting, make sure that:
• There is no self-diagnostic code indication.
• Emergency stop switch plate is set in place.
Step Action
1
Check fuel injector operating sound.
• Check each injector for operating sound at engine cranking. (
Yes
Fuel injector circuit is in good condition.
No
Go to step 2.
Z9J0111704003
Do all 4 injector make operating sound?
2
Check fuel injector resistance.
• Turn ignition switch off, disconnect connectors from fuel injectors.
• Check for proper connection to fuel injector at each terminal.
• If good condition, check all fuel injector for resistance.
(
Are all injectors in good condition?
3
Check fuel injector power supply.
• Measure voltage between each “Gray” wire terminal of fuel injector connector and engine body ground with ignition switch turned “ON”.
Go to step 3.
Go to step 4.
Is voltage 10 – 14 V?
4
Check Wire circuit.
• Turn “OFF” ignition switch.
• Disconnect connector from ECM.
• Measure resistance between each “O/B”, “B/Br”, “R/W”,
“Lg” wire terminal of the fuel injector connector and body ground.
Go to step 5.
Is resistance infinity?
5
Check Wire circuit.
• Connect connector to ECM.
• Measure voltage between each “O/B”, “B/Br”, “R/W”, “Lg” wire terminal of fuel injector connector and body ground with ignition switch turned “ON”.
Go to step 6.
Faulty fuel injector.
• “Gray” wire open or shorted.
• If it is in good condition, check ECM power source and ground circuit.
“O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s) are shorted to ground.
“O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s) are shorted to power supply circuit.
6
Is voltage 0 V?
Check fuel injector operating signal.
• Connect connectors to each fuel injector and ECM with ignition switch turned “OFF”.
• Measure fuel injector operating signal between each “45”,
“71”, “47”, “59” terminal of ECM and body ground.
(
If check result is satisfactory, substitute a known-good ECM and recheck.
“O/B”, “B/Br”, “R/W”, and/or “Lg” wire(s) are open circuit.
Is voltage 6 – 10 V or over?
1G-15 Fuel System:
Service Instructions
Fuel Pressure Relief Procedure
Z9J0111706001
After making sure that engine is cold, relieve fuel pressure as follows:
1) Turn “OFF” ignition switch.
2) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
3) Disconnect the high pressure fuel pump lead wire connector at high pressure fuel pump.
7) Upon completion of servicing, connect the ignition coil primary lead wire and the high pressure fuel pump lead wire.
8) Install the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
I9J011170028-01
4) Disconnect the ignition coil primary lead wire connectors from all of the ignition coils.
I9J011170029-01
5) Crank the engine 5 – 10 times (3 seconds each time) to dissipate the fuel pressure in lines.
6) Make sure fuel pressure has been relieved by pinching the high pressure fuel hose between finger tips (the line should feel soft, without pressure).
Fuel Line Removal and Installation
Z9J0111706002
Pay special attention to the following points when removing or installing fuel hoses.
!
WARNING
Fuel components and fuel hoses after the high pressure fuel pump remain pressurized at all times.
To protect against fuel spray, relieve the fuel line pressure before disconnecting or removing components.
CAUTION
• Do not over bend (kink) or twist hoses when installing.
• When installing hose clamps, position the tabs to avoid contact with other parts.
• Be sure hoses do not contact rods, levers or other components with engine either operating or at rest.
• Extreme care should be taken not to cut, abrade or cause any other damage to hoses.
• Use care not to excessively compress hoses when tightening the clamps.
• The fuel feed line is under high pressure, use special care when servicing it.
• Spilled gasoline should be wiped off immediately.
• Perform the following checks to ensure proper and safe operation of the repaired unit.
– Check fuel hose routing.
Refer to “Fuel Hose Routing” in Section 4B
– Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure”
Fuel Line Inspection
Z9J0111706003
Visually inspect fuel lines for evidence of fuel leakage, cracking, deterioration, or damage. Make sure all clamps are secure. Replace parts as needed.
I9J011170030-01
Fuel Leakage Check Procedure
Z9J0111706004
After performing any fuel system service, always be sure there is no fuel leakage by checking as follows.
1) Squeeze fuel primer bulb until you feel resistance.
2) Shift into “Neutral” position.
3) Ensure emergency stop switch lock plate is in place.
4) Turn ignition switch “ON” for 3 seconds (to operate fuel pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system.
5) Once pressurized, check all connections and components for any signs of leakage.
Fuel System: 1G-16
• For type “C” pipe, hose must fit up against the flanged part of pipe.
Type “C”
“ a ”
I9J011170014-01
“a”: 3 – 7 mm (0.1 – 0.3 in)
• For type “D” pipe, the hose must cover the pipe by 20
– 30 mm (0.8 – 1.2 in.).
Type “D”
OFF
ON
I9J011170020-01
Inspection of Fuel Hose Connections
Z9J0111706005
Note that the fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly by referring to the figure.
• For type “A” (short barbed end) pipe, the hose must completely cover pipe.
Type “A”
1
2
1. Clamp (Clip)
2. Hose
“ a ”
3
I9J011170012-01
3. Joint pipe
“a”: 3 – 7 mm (0.1 – 0.3 in)
• For type “B” (bent end) pipe, hose must cover the straight part of pipe by 20 – 30 mm (0.8 – 1.2 in.).
Type “B”
“ b ”
“ a ”
“a”: 3 – 7 mm (0.1 – 0.3 in)
I9J011170015-01
“b”: 20 – 30 mm (0.8 – 1.2 in)
High Pressure Fuel Pump Operating Sound
Inspection
Z9J0111706006
1) Install the emergency stop switch lock plate into position.
2) Shift into “Neutral”.
3) Turn ignition switch “ON” and check for fuel pump operating sound.
NOTE
Fuel pump operating sound is low because the pump is inside the fuel vapor separator. If you cannot hear the pump sound clearly, use a sound scope or long blade screw driver.
Fuel pump operating sound
Sounds for approx. 3 seconds only
(each time the ignition is turned to the “ON” position)
“ b ”
“ a ”
“a”: 3 – 7 mm (0.1 – 0.3 in)
I9J011170013-01
“b”: 20 – 30 mm (0.8 – 1.2 in)
I9J011170031-01
1G-17 Fuel System:
4) If no pump operating sound is heard: a) Turn ignition key to the “OFF” position, check for contact failure in the lead wire connector.
b) Check that the drive voltage is outputting from the ECM and no abnormal conditions exist in the engine main wiring harness.
c) If inspection in steps “a” and “b” are OK, replace the high pressure fuel pump.
Fuel Vapor Separator Removal and Installation
Z9J0111706007
Removal
1) Remove the intake manifold assembly.
Refer to “Intake Manifold Removal and Installation” in Section 1D (Page 1D-7).
2) Remove the bolts and fuel vapor separator.
Disconnect fuel outlet hose and evaporation hose from fuel vapor separator.
Fuel Vapor Separator Disassembly and
Assembly
Z9J0111706008
Disassembly
1) Remove five screws (1).
Remove the separator cover (2) with the high pressure fuel pump from separator case (3).
2
1
3
2) Remove the float pin (4).
Remove the float (5) and needle valve (6).
I9J011170033-01
5
4
I9J011170032-01
Installation
Installation is in the reverse order of removal with special attention to the following steps.
• Install the fuel vapor separator, then tighten the bolts securely.
• Install the intake manifold assembly.
Refer to “Intake Manifold Removal and Installation” in
• Check to ensure that all removed parts are back in place.
• Check hose and wire routing.
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
• Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
5
6
I9J011170034-01
I9J011170035-01
3) Remove screw (7), plate (8) and valve seat (9).
8
9
7
I9J011170036-01
4) Remove screw and fuel pressure regulator (10) from the separator case.
Fuel System: 1G-18
Assembly
Assembly is in the reverse order of disassembly with special attention to the following steps.
High pressure fuel pump
Connect the pump lead wire connector, then install grommet (1) and fuel pump (2).
NOTE
Apply fuel to the grommet before installing.
1
2
I9J011170040-01
10
I9J011170037-01
Float / Float pin
Install the float (1) and float pin (2).
1
5) Remove suction filter (11).
11
I9J011170038-01
6) Remove the high pressure fuel pump (12) and grommet (13) from the separator cover and then disconnect the pump lead wire connector.
13
2
I9J011170041-01
NOTE
After assembling, check for smooth and free float movement.
12
I9J011170039-01
I9J011170042-01
1G-19 Fuel System:
Checking float height
Measure the float height.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Float height “a”
Standard: 43
±
3.0 mm
NOTE
Make sure that the float weight is not applied to the needle valve.
Fuel pressure regulator
Install the fuel pressure regulator (1) and tighten the screw securely.
NOTE
Apply fuel to the O-ring (2) before installing the regulator.
1
“ a ”
I9J011170043-02
Setting float height
To correct specification, bend only adjustment tab (1).
CAUTION
When adjusting the tab, do not bend to the point that it applies pressure to the needle and seat.
2
I9J011170045-01
Separator cover / Separator case
1) Install the seal ring (1) and then apply Suzuki Bond evenly to only the outside mating surface of the separator case as shown in figure.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
NOTE
• Clean mating surfaces before applying bond.
• Do not apply bond to seal ring, groove or inside mating surface.
Outside
1
I9J011170044-01
I9J011170046-01
2) Install the separator case and then tighten the screws securely.
NOTE
When installing the separator case, align suction hole “A” with hole “B” of separator case.
Fuel System: 1G-20
Inspection of Fuel Vapor Separator Component
Parts
Z9J0111706009
NOTE
If cracks, excessive wear or other damage is found on any component, replace the component.
Needle Valve / Valve Seat
Inspect the needle valve and valve seat for grooves, other damage or dirt.
Replace or clean if necessary.
“A”
“B”
I9J011170047-01
Float
Inspect the float for cracks or other damage.
Replace if necessary.
I9J011170049-01
I9J011170048-01
Final assembly check
• Check to ensure that all removed parts are back in place.
I9J011170050-01
Filter
Inspect the pump suction filter for clogging or other damage.
Replace or clean if necessary.
I9J011170051-01
1G-21 Fuel System:
Separator Cover and Case
Inspect the separator cover and case.
Replace if cracked, damaged or other abnormal conditions.
NOTE
Separator cover and case are a set.
If any repair is required on the cover or case, replace them as a fuel vapor separator assembly.
Fuel Injector Inspection with Injector in place
Z9J0111706010
1) Using a sound scope or equivalent, check the operating sound of the fuel injector when the engine is running or cranking.
Injector operating sound cycle should vary according to engine speed.
If no sound or an unusual sound is heard, check injector circuit (wire or connector) or injector.
“ c l i c k ”
1
I9J011170052-01
Fuel Pressure Regulator
Inspect the fuel pressure regulator for damage or corrosion.
Check the fuel pressure regulator operation.
Special tool
(A): 09952–99310 (Hand air pump)
(B): 09940–44121 (Air pressure gauge)
(C): 09940–44130 (Attachment)
(D): 09912–58490 (3-way joint & hose)
1) Connect the special tools to the inlet side of the regulator as shown in the figure.
2) Pump air into the regulator using pump until air is released through outlet side.
(B)
I9J011170053-03
1. Injector body
2) Disconnect the lead wire connector from the fuel injector.
3) Connect a digital tester between the terminals of the injector and measure resistance.
If out of specification, replace the fuel injector.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (
Ω
)
Fuel injector resistance
Standard: 10 – 14.0
Ω
(A)
(D)
(C)
I9J011170021-01
3) Read the pressure on the gauge when air is released.
If out of specification, replace regulator.
Regulator operating pressure
Standard: 240 – 270 kPa (2.4 – 2.7 kg/cm 2 , 34.1 –
38.4 psi.)
I9J011170054-01
4) Connect the lead wire connector to the fuel injector securely.
Individual Fuel Injector Operating Sound
Inspection
Z9J0111706011
1) Disconnect the ignition coil lead wire connectors from all of the ignition coils.
2) Disconnect the fuel injector lead wire connector and connect the test cord.
Special tool
(A): 09930–89260 (Injector test cord (A))
“ c l i c k ”
Fuel System: 1G-22
3) Connect the Gray wire to body ground.
4) Momentarily touch the Black/Yellow wire to the starter motor magnetic switch terminal “B”
(connected to battery positive (+) terminal) and check for injector operating sound.
If out of specification, replace fuel injector.
CAUTION
Connecting the fuel injector to battery positive for more than a few seconds may cause injector overheating and possible injector solenoid failure.
Fuel injector operating sound
“click”
(A)
1
I9J011170055-01
Fuel Injector Operating Signal Inspection
2
(A)
4
1
ECM
(A)
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
B/Y
Gr
1. Starter motor magnetic switch “B” terminal
I9J011170056-01
Z9J0111706012
1. Black connector
2. White connector
2 3
5
1
3. Peak voltmeter stevens CD-77
4. Gray test cord connector side
45 47 59
71
(A)
5. Starter motor magnetic switch “B” terminal
I9J011170022-03
1G-23 Fuel System:
Special tool
(A): 09930–88730 (36-pin test cord set)
: Stevens peak reading voltmeter CD-77
Tester knob indication
NEG 50
1) Disconnect all ignition coil connectors from the ignition coils.
2) Connect the test cord between the ECM and wire harness as shown in figure, then turn ignition switch “ON”.
3) Connect the tester probe (“–”, Black) to the starter motor magnetic switch terminal “B” (connected to battery positive (+) terminal) as shown in figure.
4) Connect the tester probe (“+”, Red) to each terminal.
Injector
No.1
No.2
No.3
No.4
Terminal
45
71
47
59
Wire color (Engine harness)
O/B
B/Br
R/W
Lg
5) Crank the engine and measure the voltage.
If out of specification, inspect the related parts as described in “Fuel System Diagnostic Information / Fuel Injection
System Troubleshooting”.
Fuel injector operating signal
Standard: Approx. 6 – 10 V or over
Fuel Injector Removal and Installation
Z9J0111706013
Removal
1) Relieve the fuel pressure in the fuel feed line according to “Fuel Pressure Relief Procedure”.
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
2) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
3) Loosen the clamp and place a large cloth over the end of the fuel feed hose (1).
Slowly pull the fuel feed hose from the fuel delivery pipe.
Drain any excess fuel in the hose into a small container.
4) Disconnect the four fuel injector connectors (2).
Cut the cable tie (3) binding the fuel injector lead wire to the fuel delivery pipe.
3
2
I9J011170058-02
1
I9J011170057-01
5) Remove the two bolts (4) and the fuel delivery pipe
(5) (with the fuel injectors).
CAUTION
A small amount of fuel may be released when the fuel injector is removed from delivery pipe.
Place a shop cloth under the fuel injector before removal to absorb any fuel released.
Dispose of the fuel soaked cloth in appropriate container.
Fuel System: 1G-24
Installation
Installation is in the reverse order of removal with special attention to the following steps.
CAUTION
Do not re-use O-ring and cushion once removed.
Always use new parts.
1) Replace the injector O-ring (1) with a new one using care to avoid nicks or cuts during installation.
1 2
4
5
4
I9J011170059-02
6) Remove each injector (6) from the delivery pipe.
“A”
I9J011170024-01
“A”: Apply fuel to O-ring.
2) Replace the injector cushion (2) with a new one and install to the cylinder head.
2
6
I9J011170060-01
I9J011170063-01
1G-25 Fuel System:
3) Apply a thin coat of fuel to injector O-rings, then install the injectors into the delivery pipe and cylinder head.
Make sure that the injectors rotate smoothly.
4) Tighten the delivery pipe bolts (3) and make sure that the injectors rotate smoothly.
Tightening torque
Fuel delivery pipe bolt (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
3
(a)
I9J011170064-01
7) Make sure the emergency stop switch lock plate is in place.
Shift into “Neutral” position.
8) Squeeze the fuel primer bulb until you feel resistance.
Turn ignition switch “ON” for 3 seconds (to operate fuel pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times to pressurize the fuel system.
Check for fuel leaks around the fuel injectors.
Low Pressure Fuel Pump Removal and
Installation
Z9J0111706014
NOTE
The low pressure fuel pump is a nonrepairable component.
Do not attempt to disassemble the low pressure fuel pump.
It must be replaced as a complete unit if it is defective.
Removal
1) Remove the two bolts securing the fuel pump guard
(1).
3
(a)
1
I9J011170065-01
5) Reconnect the fuel feed hose and fuel line securely.
6) Connect the lead wire connector to the injectors securely.
I9J011170067-01
2) Disconnect the inlet hose (3) and outlet hose (4) from low pressure fuel pump (5).
3) Remove two bolts (6).
6
5
4
3
I9J011170066-01
6
I9J011170068-01
4) Remove fuel pump. Note the position before removing the O-ring (7).
7
I9J011170069-01
Installation
Installation is in the reverse order of removal with special attention to the following steps.
CAUTION
• Before installing the fuel pump, rotate the crankshaft to bring the No.1 (top cylinder) piston to Top Dead Center on the compression stroke.
• Do not reuse O-ring once removed. Always use a new O-ring.
Tightening torque
Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-m,
7.0 lbf-ft)
Fuel System: 1G-26
Low Pressure Fuel Pump Inspection
Z9J0111706015
NOTE
The low pressure fuel pump is a nonrepairable component.
Do not attempt to disassemble the low pressure fuel pump.
It must be replaced as a complete unit if it is defective.
Fuel Pump Assembly
Inspect the fuel pump.
If leakage, cracks, damage or other abnormal condition is found, replace fuel pump assembly.
I9J011170071-01
(a)
I9J011170072-01
(a)
I9J011170070-01
1H-1 Ignition System:
Power Head
Ignition System
General Description
Ignition System Description
Z9J0111801001
The ignition system used by the DF70 / 80 / 90 is a fully transistorized, electronic microcomputer timing advanced type.
This system is battery powered, with the ECM controlling all of the ignition timing functions.
The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch etc.).
When the ignition switch is “ON”, battery voltage (12 V) is applied to the circuit as shown in the illustration.
The ECM determines the optimum ignition timing and duration of current flowing through the ignition coil primary winding based on the signals received from various sensors. The ECM interrupts the base current of the power transistor inside the ignition coil thereby controlling current flow (ignition) to the primary winding of the ignition coil.
In this way, a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated.
4
5
3
OFF
IG
2
1
12
ECM
IGT1
42
O
Ign.1
35
IGT2 54
Bl
Spark plug
Ign.2
Spark plug
IGT3
41
Ign.3
Gr/Y
36
Spark plug
Ign.4
Spark plug
15
Sensor / switch signal
1. Main relay
2. Ignition switch
3. Battery
4. Fuse 30 A
IGT4
53
Lg/R
5. Fuse 15 A
I9J011180001-05
Ignition System: 1H-2
Ignition Control Description
Z9J0111801002
Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM.
Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils.
Basic sensors
MAP sensor:
Informs ECM of intake manifold pressure.
CKP sensor:
Informs ECM of engine speed and crankshaft angle.
Compensating sensors
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
Throttle position sensor:
Informs ECM of throttle opening angle.
Shift position sensor:
Informs ECM of shift position and change.
IAT sensor:
Informs ECM of intake air temperature.
ECM
Ignition timing is determined by a digital map designed in relation to intake manifold pressure and engine speed.
Ignition timing compensation
Switch
Ignition switch:
Informs ECM of “START” signal.
Signal
Ign.coil
Spark plug
I9J011180002-01
Ignition specification
Ignition system
Advance
Ignition timing
Firing order
Full-transistorized ignition
Electronic microcomputer control
BTDC 0
° ±
5
°
– BTDC 26
° ±
5
°
(DF70 / 80)
BTDC 0
° ±
5
°
– BTDC 27
° ±
5
°
(DF90)
1 — 3 — 4 — 2
1H-3 Ignition System:
Ignition Timing Chart
The following chart is an example for ignition at 10
°
BTDC.
32 signals / crankshaft 1 rotation
CKP sensor signal
CMP sensor signal
No.1 cylinder
No.3 cylinder
No.4 cylinder
No.2 cylinder
Cm.
In.
Ex.
Ep.
140°
Ep.
Cm.
In.
Ex.
220°
40°
180°
CMP sensor - 6 signals / 720°(crankshaft 2 rotation)
100°
TDC
TDC
TDC
Ex.
Ep.
Cm.
In.
TDC
In.
Ex.
Ep.
Cm.
TDC
TDC
40°
Cm.
In.
Ex.
Ep.
140°
TDC
TDC
Ep.
Cm.
In.
Ex.
Spark timing
No.1 Ignition
signal
No.3 Ignition
signal
No.4 Ignition
signal
No.2 Ignition
signal
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake, TDC: Top Dead Center
I9J011180003-05
Ignition Timing Control Mode
•
When Cranking
The ignition timing is fixed at 5
°
BTDC until the engine starts.
•
When Idling / Trolling
The ignition timing is controlled within the range of 0
° ±
5
°
BTDC to provide stable engine operation at the specified idling / trolling speed.
•
When Running (Normal Operation)
The ignition timing ranges between 0
°
– 27
°
BTDC, depending on engine operating conditions.
Ignition System: 1H-4
Component Location
Ignition System Components Location
Z9J0111803001
Diagnostic Information and Procedures
Ignition System Symptom Diagnosis
Condition
Engine cranks, but will not start or weak spark.
(No spark)
Possible cause
Blown fuse for ignition system.
Loose connection or disconnection of lead wire.
Faulty spark plug(s).
Faulty ignition coil.
Faulty CKP sensor.
Faulty CMP sensor or sensor trigger vane of camshaft.
Faulty ECM.
Incorrect gasoline.
Incorrect spark plug.
Spark plug is wet or quickly becomes fouled with carbon.
Spark plug quickly become fouled with oil or carbon.
Spark plug electrodes overheat or burn.
Worn piston ring.
Worn piston.
Worn cylinder.
Excessive valve stem to valve guide clearance.
Worn valve stem seal.
Incorrect spark plug.
Overheated engine.
Loose spark plug.
Z9J0111804001
Replace.
Correction / Reference Item
Connect securely.
Replace.
Replace.
Replace.
Replace.
Replace.
Change.
Replace.
Replace.
Replace.
Replace.
Replace.
Replace.
Change.
Tune-up.
Tighten.
1H-5 Ignition System:
Ignition System Troubleshooting
Z9J0111804002
Before starting the troubleshooting, make sure that:
• There is not self-diagnostic code indication.
• Emergency stop switch plate is set in place.
Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system.
Step Action
1
Check the ignition system connector for poor connections. Is there connection in the ignition system connectors?
2
Check spark condition.
3
Check if the spark plugs are in good condition.
Yes
Go to step 2.
Go to step 3.
Go to step 4.
4
Check ignition coil assembly power supply and ground circuits for open and short. Are circuits in good condition?
5
Check ignition coil operating signal. Is result OK?
Go to step 5.
Go to step 6.
No
Poor connection of connectors.
No or weak sparks.
Replace spark plug with a new one.
Repair or replace.
6
Measure the battery voltage between input lead wire at ECM with the ignition switch in “ON” position. Is result OK?
Go to step 7.
7
Check CKP sensor. Refer to “CKP Sensor Inspection” in
Section 1C (Page 1C-10). Is result OK?
8
Check CMP sensor. Refer to “CMP Sensor Inspection” in
Section 1C (Page 1C-11). Is result OK?
Go to step 8.
Go to step 9.
9
Substitute a known-good ignition coil assembly then repeat step 2. Is check result of step 2 satisfactory?
Go to step 10.
10
Check the ignition timing by using timing light (2 at 1 000 r/min). Is result OK?
° ±
5
°
DTBC
System is in good condition.
Check ignition coil operating signal wire for open, short and poor connection.
• Faulty ignition switch.
• Faulty ECM main relay.
• Broken wire harness or poor connection of related circuit connector.
• Check air gap between CKP sensor and flywheel reluctor bars.
• Adjust CKP sensor air gap.
• Replace CKP sensor or flywheel.
• Check CMP sensor.
• Check CMP sensor trigger vane.
• Replace CMP sensor or Ex. camshaft.
Substitute a known good ECM, then repeat step 2.
Check input signals related to this system.
Ignition System: 1H-6
Spark Plug Inspection
Z9J0111806002
Refer to “Spark Plug Inspection and Cleaning” in Section
Ignition Coil Removal and Installation.
Z9J0111806003
Removal
1) Disconnect the battery cables at the battery.
2) Disconnect the ignition coil connector (1).
3) Remove the bolt (2) securing the ignition coil, then pull out the ignition coil (3).
2
Service Instructions
Spark Plug Removal and Installation
Z9J0111806001
Refer to “Spark Plug Removal and Installation” in
4) Turn the ignition key to the ON position. Check for battery voltage by measuring between the BAT (+) terminal and GND terminal on the wiring harness side connector.
5) Connect the wiring harness connector to the ignition coil and measure the ignition operating signal.
Refer to “Ignition Coil Operating Signal Inspection”
• If any failure exists, check for open circuit, short circuited battery, short circuited lead and connector’s contact condition for each circuit.
• If there is no spark even with the wiring harness and spark plug in sound condition, perform the inspection again using an ignition coil that is known to be in good condition (new or used from another cylinder that is operating properly).
• If there is still no spark even with the wiring harness, spark plug and ignition coil in sound condition, replace the ECM and perform the inspection again.
3
IGT
GND +BAT
1
I9J011180006-01
Installation
1) Install the ignition coil, then secure the ignition coil with its mounting bolt.
2) Connect the ignition coil connector.
3) Connect the battery cables to battery.
Ignition Coil Inspection
Z9J0111806004
NOTE
The ignition coil power transistor and high tension lead are an integral part of the coils internal circuit. Using resistance measurements to check for a defect on either the primary or secondary coil is not possible.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DCV
1) Turn the ignition key OFF.
2) Disconnect the ignition coil connector.
3) Check for continuity between the GND (–) terminal on the wiring harness side connector and the engine body ground.
I9J011180004-03
1H-7 Ignition System:
Ignition Coil Operating Signal Inspection
Z9J0111806009
Special tool
(A): 09930–88730 (36-pin test cord set)
: Stevens peak reading voltmeter CD-77
Tester knob indication
SEN 50
1) Disconnect all injector connectors from the fuel injectors.
2) Connect the test cord between the ECM and the wire harness as shown in figure then turn ignition switch
ON.
3) Connect the tester probe Red (+) to each terminal, one at a time to test each circuit.
No.1 Ignition coil
No.2 Ignition coil
No.3 Ignition coil
No.4 Ignition coil
Terminal
42
54
41
53
Wire color (engine harness)
O
Bl
Gr/Y
Lg/R
4) Connect the tester probe Black (–) to No. 51 terminal
(or to body ground).
5) Crank the engine and measure the voltage.
If out of specification, inspect the related parts.
Refer to “Ignition System Symptom Diagnosis”
(Page 1H-4) and “Ignition System Troubleshooting”
Ignition coil operating signal
Standard: Approx. 5 V
4
(A)
ECM
1
(A)
2
37 38 39 40 41 42 43 44 45 46 47 48 49
50 51 52 53 54
55 56 57 58 59 60 61 62 63 64 65 66 67
68 69 70 71 72
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18
19 20 21 22 23 24 25 26 27 28 29 30 31
32 33 34 35 36
CKP Sensor Inspection
Z9J0111806005
Refer to “CKP Sensor Inspection” in Section 1C
CMP Sensor Inspection
Z9J0111806006
Refer to “CMP Sensor Inspection” in Section 1C
Ignition Switch Inspection
Z9J0111806007
Refer to “Ignition Switch Inspection” in Section 1I
ECM Main Relay Inspection
Z9J0111806008
Refer to “ECM Main Relay Inspection” in Section 1A
51
41 42
53 54
2
1. Black connector
2. White connector
(A)
3
I9J011180007-03
3. Peak voltmeter stevens CD-77
4. Gray test cord connector side
Starting System: 1I-1
Power Head
Starting System
General Description
Electric Starter System Description
Z9J0111901001
The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay, ECM and related electrical wiring.
These components are connected electrically as shown in the figure below.
In the circuit shown in the figure below, the magnetic switch coils and starter relay coil are magnetized when the ignition switch is closed (turned to “START”).
The resulting plunger and pinion shift lever movement causes the pinion to engage the engine flywheel gear, the magnetic switch main contacts to close, and engine cranking to take place.
When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is opened, at which time the torsion spring causes the pinion to disengage.
1
4
6
5
3
R
8
7
G
W
19
1. Starter relay
2. Battery
3. Magnetic switch
4. Pull-in coil
5. Hold-in coil
9
10
2
11
20
12
15
13
14
W
Br
B/Bl
Y/G
Y/G
Br
16
Br
W
16
Br
B GND
W BATT
Gr IG
Br START
17
ECM
6. Plunger
7. Shift lever
11. 15 A Fuse
12. 30 A Fuse (Starter)
8. Ring gear
9. Starter motor
13. 30 A Fuse (ECM)
14. 40 A Fuse (Main)
10. Pinion and over-running clutch 15. Main relay
Bl/R
B
G
B
18
I9J011190001-06
16. Neutral switch
17. Ignition switch
18. Emergency stop switch
19. Capacitor
20. Sub battery cable
1I-2 Starting System:
Starter Motor Operation Condition Description
Z9J0111901002
The starter motor relay is controlled by the ECM.
• The starter motor relay will only engage when the ignition switch is turned to the “START” position if the all of the following conditions are satisfied.
– Lock plate is attached to emergency stop switch.
– Neutral switch is in the “ON” position.
– Engine is not already operating.
• After returning the ignition key to the “ON” position from “START”, the starter motor continues to run for 4 seconds until engine starts.
NOTE
If a failure exists in the sub-battery cable or the 15 amp. fuse in its circuit, the starter motor relay circuit will not function.
Start-In-Gear Protection System Description
Z9J0111901003
To avoid accidental movement of the boat at the time of engine starting, the system prohibits starter motor operation when the shift lever is “IN” gear.
Control by Neutral Switch
A switch to detect “Neutral” gear position is located on the clutch lever holder and operated by the clutch control lever.
This ON/OFF type switch is ON in “Neutral” and OFF in
“Forward” or “Reverse”.
When attempting to start the engine, the ECM detects the shift position using the neutral switch.
When the neutral switch is OFF, the ECM does not provide a starter motor relay operating signal.
“Reverse”
1. Clutch lever
“Neutral”
“Forward”
1 2
2. Neutral switch
I9J011190050-02
Control by Shift Position Sensor
A shift position sensor is installed on the clutch lever holder and detects the shift position as the clutch lever is interlocked with the SPS shaft.
This sensor is a variable resistor that changes resistance in accordance with the shift position.
The resistance changes (increase / decrease) the voltage signal output from the sensor to the ECM. Based on the sensor voltage, the ECM calculates and detects shift position.
When attempting to start the engine, the ECM does not provide an injector operating signal when a shift lever ingear position is detected.
“Neutral”
“Reverse” “Forward”
1
2
1. Clutch lever
I9J011190051-03
2. Shift position sensor
Operation by neutral switch on engine starting
Operation
Shift position
Fuel injection
Ignition
High pressure
Starter motor
Neutral
Forward /
Reverse
Yes
No
(*1:Yes)
Yes
No
(*1:Yes)
fuel pump
Yes
Yes
Yes
No
*1: If it is in neutral judged by the ECM according to the shift position sensor signal.
Operation by shift position sensor on engine starting
Shift position
Fuel injection
Operation
High
Ignition pressure fuel pump
Starter motor
Neutral
Forward /
Reverse
Yes
No
(*2:Yes)
Yes
No
(*2:Yes)
Yes
Yes
Yes
Yes
*2: If it is in neutral judged by the ECM according to ON signal from the neutral switch.
Starting System: 1I-3
Component Location
Starting System Components Location
Z9J0111903001
Diagnostic Information and Procedures
Starter System Troubleshooting
Z9J0111904001
CAUTION
If any abnormality is found, immediately disconnect the battery cables from the battery.
NOTE
Before troubleshooting the electric starter system, make sure of the following:
• Battery is fully charged.
• All cables / wires are securely connected.
• Shift is in “Neutral” position.
• Emergency stop switch lock plate is set in place.
Condition
Motor not running. (No operating sound of magnetic switch.)
Motor not running.
(Operating sound of magnetic switch heard.)
Starter motor running but too slow. (Low torque)
(If battery and wiring are satisfactory, inspect starting motor.)
Possible cause
Poor or broken battery connection.
Replace.
Correction / Reference Item
Loose or corroded battery connection.
Repair or retighten.
Weak or shorted battery.
Replace or recharge battery.
Defective neutral switch.
Fuse blown.
Defective ignition switch.
Open circuit between ignition switch and
Neutral switch inspection. Replace.
Replace.
Ignition switch inspection. Replace.
Repair.
magnetic switch.
Defective emergency stop switch.
Lead wire disconnected or loose.
Poor contacting action of ignition switch and magnetic switch.
Defective starter motor control relay.
Defective ECM and its circuit.
Open circuit in pull-in coil.
Replace. Emergency stop switch inspection.
Retighten.
Replace. Ignition switch inspection. Magnetic switch inspection.
Main relay and starter motor relay inspection.
Inspection of ECM and its circuit.
Replace magnetic switch. Magnetic switch inspection.
Brushes are seating poorly or worn.
Weak or shorted battery.
Battery voltage too low due to battery deterioration.
Repair or replace. Brushes inspection.
Replace or recharge battery.
Replace battery.
Loose or corroded battery connection.
Repair or retighten.
Burnt main contact point, or poor
Replace magnetic switch. Magnetic switch
contacting action of magnetic switch.
Brushes are seating poorly or worn.
inspection.
Replace or repair. Brushes inspection.
Weakened brush spring.
Burnt commutator.
Replace.
Replace armature. Commutator inspection.
Shorted or open winding in armature.
Replace. Armature inspection.
Excessive friction in engine.
Repair.
Insufficient contact of magnetic switch main contacts.
Shorted armature.
Dirty or corroded commutator.
Replace magnetic switch. Magnetic switch inspection.
Replace. Armature inspection.
Repair commutator or replace armature.
Worn brushes.
Weakened brush spring.
Armature inspection.
Replace brushes.
Replace.
1I-4 Starting System:
Condition
Starter motor running, but not cranking engine.
Starter motor does not stop running.
Possible cause
Worn pinion tip.
Poor sliding of over-running clutch.
Correction / Reference Item
Replace over-running clutch.
Repair.
Over-running clutch slipping.
Worn teeth of ring gear.
Replace over-running clutch.
Replace flywheel.
Broken contact point of magnetic switch.
Replace magnetic switch.
Short-circuit magnetic switch coil.
Replace magnetic switch.
Service Instructions
Starter Motor Removal and Installation
Z9J0111906001
Removal
CAUTION
Prior to removing the starter motor, disconnect the battery cables from the battery.
1) Remove the PORT lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Remove the ring gear cover and air intake silencer case.
Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-5).
3) Remove nut (1), positive (+) battery cable (2) and positive (Gray) cable (3) from the magnetic switch
(4) of starter motor.
5) Remove the three bolts securing the electric parts holder (8).
8
8
I9J011190054-02
3
4
1
I9J011190055-02
6) Remove the two bolts (9) securing the starter motor.
2
I9J011190052-01
4) Remove the two bolts (5), negative (–) battery cable
(6) and starter motor band (7).
6
9
9
I9J011190056-02
5
5
7
I9J011190053-01
7) Remove the starter motor (10), then disconnect the red lead wire (11) from “S” terminal of starter magnetic switch.
11
10
Starting System: 1I-5
Pull-In / Hold-In Test
NOTE
Before testing, disconnect the brush lead from terminal “M”.
Connect the battery to the magnetic switch as shown in the figure.
• Check that the plunger and pinion (over-running clutch) move outward.
If the plunger and pinion don’t move, replace the magnetic switch.
1
3
4
I9J011190057-01
Installation
Installation is in the reverse order of removal with special attention to the following steps.
• Install the starter motor and tighten starter motor mounting bolts securely.
Tightening torque
Starter motor mounting bolt (a): 23 N·m (2.3 kgfm, 16.5 lbf-ft)
2
I9J011190002-02
1. Terminal “S”
2. Terminal “M”
3. Terminal “B”
4. Brush lead
• While connected as above with the plunger out, disconnect the negative lead from terminal “M”.
Check that the plunger and pinion remain out. If the plunger and pinion return inward, replace the magnetic switch.
(a)
I9J011190058-01
• Check to ensure that all removed parts are back in place.
Starter Motor Test
Z9J0111906002
!
WARNING
When performing the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as original equipment.
CAUTION
Each test must be performed within 3 – 5 seconds to avoid coil damage from overheating.
I9J011190003-01
Plunger and Pinion Return Test
Disconnect the negative lead from the switch / motor body.
Check that the plunger and pinion return inward.
If the plunger and pinion don't return inward, replace the magnetic switch.
1I-6 Starting System:
1) Connect a battery and ammeter to the starter motor as shown.
2) Check that the starter rotates smoothly and steadily with the pinion moving out. Check that the ammeter indicates the specified current.
Specified current (No-load performance test)
Within 90 A at 11 V
I9J011190004-01
No-Load Performance Test
CAUTION
Before performing the following test, secure the starter motor to the test bench.
Starter Motor Components
1 3 4 5 6 7 8 9
10
2
(a)
I9J011190005-01
Z9J0111906003
20
19
21 26 24
25
24 23 22 28 27
12
(b)
1. Nut
2. Bolt
3. Magnetic switch
4. Gasket
5. Spring
6. Plunger
7. Torsion spring
8. Rubber packing
11 13 14
9. Shift lever
10. Front housing
11. Screw
12. Through bolt
13. Rear cover
14. Thrust washer
15. Brush holder
16. Yoke
15 16
17. Armature
18. Center cover plate
19. Internal gear
20. Planetary gear
21. Pinion shaft
22. Pinion
23. E-ring
24. Washer
17 18
I9J011190006-02
25. Center bracket
26. Rubber ring
27. Stopper ring
28. Pinion stopper
: 7 N
⋅ m (0.7 kgf-m, 5.1 lbf-ft)
: 5.5 N
⋅ m (0.55 kgf-m, 4.0 lbf-ft)
: Apply grease.
Starter Motor Disassembly and Assembly
Z9J0111906004
Disassembly
When overhauling the starting motor, it is recommended that the component parts be cleaned thoroughly.
However, the yoke assembly, armature coil, overrunning clutch assembly, magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent.
These parts should be cleaned with compressed air or wiped with clean cloth.
NOTE
Before disassembling the starting motor, be sure to put match marks at three locations
(“A”, “B” and “C”) as shown in the figure at right to avoid any possible component alignment mistakes.
Starting System: 1I-7
4) Remove screws (5), long through bolts (6) and the rear cover (7).
5
6
5
7
6
I9J011190010-01
5) Remove thrust washer (8) with a screwdriver.
8
“A”
“C”
“B”
I9J011190007-01
1) Remove nut (1) from the magnetic switch, then disconnect the connecting wire (2).
2) Remove two bolts (3) securing the magnetic switch.
3
1
2
I9J011190011-01
6) Pull the brush spring (9) up to separate the brush from the surface of the commutator, then remove the brush holder (10).
9
10
7) Remove the yoke (11) and armature (12).
I9J011190012-01
I9J011190008-01
3) Remove the magnetic switch (4).
11
4
12
I9J011190013-01
I9J011190009-01
1I-8 Starting System:
8) Remove the center cover plate (13).
9) Remove the planetary gears (14) and internal gear
(15).
14
12) Push the pinion stopper (21) down, then remove the stopper ring (22). Remove the pinion stopper and pinion (19).
22
21
21
19
15
13
I9J011190017-01
I9J011190014-01
10) Remove the center bracket (16) (with shift lever (18), pinion (19) and pinion shaft (20)) from front housing
(17).
13) Remove the E-ring (23).
18
19
17
20
16
11) Remove the shift lever (18).
I9J011190015-02
23
I9J011190019-01
14) Remove the pinion shaft (20), washers (24) and rubber ring (25) from the center bracket.
20
24
25
24
18
I9J011190020-01
I9J011190016-01
!
WARNING
Wear safety glasses when disassembling and assembling the stopper ring.
NOTE
Using a screw-driver, pry off the stopper ring.
Assembly
Assembly is in the reverse order of disassembly with special attention to the following steps.
Reassemble the starter motor, refer to “Starter Motor
CAUTION
When installing the armature, use care to avoid breaking the brushes.
Starting System: 1I-9
• Measure the commutator outside diameter. If the measurement exceeds the service limit, replace the armature.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Commutator outside diameter
Standard: 29.0 mm (1.14 in.)
Service limit: 28.0 mm (1.10 in.)
(A)
I9J011190021-01
Starter Motor Components Inspection and
Servicing
Z9J0111906005
Armature and Commutator
• Inspect the commutator surface. If surface is gummy or dirty, clean with # 500 grit emery paper (1).
1
I9J011190023-01
• Check that the mica (insulator) between the segments is undercut to specified depth.
If the measurement exceeds the service limit, cut to the specified depth.
!
WARNING
Wear safety glasses when using compressed air.
NOTE
Remove all particles of mica and metal using compressed air.
Commutator undercut “a”
Standard: 0.5 – 0.8 mm (0.02 – 0.03 in.)
Service limit: 0.2 mm (0.01 in.)
3
I9J011190022-01
“ a ”
2. Mica
2
3. Segment
I9J011190024-01
1I-10 Starting System:
• Check for continuity between the commutator (4) and the armature core (5) / shaft (6).
Replace the armature if continuity is indicated.
Special tool
(B): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
4
6
Brushes
Check the length of each brush (1).
If brushes are worn down to the service limit, they must be replaced.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Brush length
Standard: 16.0 mm (0.63 in.)
Service limit: 12.0 mm (0.47 in.)
(A)
5
1
(B)
(B)
I9J011190025-01
• Check for continuity between adjacent commutator segments. Replace armature if no continuity is indicated.
Tester knob indication
Continuity ( )
I9J011190026-01
I9J011190027-01
Brush Holder
Check brush holder continuity.
Replace the brush holder if the tester doesn't show the below.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Brush holder continuity
Brush holder positive (+) to brush holder negative (–)
Brush holder positive (+) to base plate (ground)
Continuity
No
No
( Ţ“ )
(–)
1
1. Base plate
I9J011190028-01
Shift Lever
Inspect the shift lever for wear. Replace if necessary.
Starting System: 1I-11
Gear
Inspect planetary gears and internal gear for wear, damage or other abnormal conditions.
Replace if necessary.
I9J011190029-01
Pinion and Over-Running Clutch
• Inspect the pinion for wear, damage or other abnormal conditions.
Check that the clutch locks up when turned in the direction of drive and rotates smoothly in reverse direction. Replace if necessary.
I9J011190032-01
Pinion Shaft / Pinion Shaft Bushing
• Inspect the pinion shaft for wear, damage or other abnormal conditions. Replace if necessary.
• Inspect the pinion shaft bushing for wear or other damage.
Replace if necessary.
I9J011190030-01
• Inspect spline teeth for wear or other damage.
Inspect the pinion for smooth movement. Replace if necessary.
I9J011190033-01
Front Housing
• Inspect the front housing for wear, damage or other abnormal conditions. Replace if necessary.
• Inspect the bushing for wear or other damage.
Replace if necessary.
I9J011190031-01
I9J011190034-01
1I-12 Starting System:
Armature Shaft Bush
Inspect the bushing for wear or other damage.
Replace if necessary.
Pull-in coil open circuit test
Check for continuity across the magnetic switch “S” terminal (1) and “M” terminal (2).
If no continuity exists, the coil is open and should be replaced.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
3
Plunger
Inspect the plunger for wear or other damage.
Replace if necessary.
I9J011190035-01
1
2
(A)
I9J011190036-01
Magnetic Switch
Push in the plunger and release. The plunger should return quickly to its original position.
Replace if necessary.
I9J011190038-02
1. Terminal “S”
2. Terminal “M”
3. Terminal “B”
Hold-in coil open circuit test
Check for continuity across the magnetic switch “S” terminal (1) and coil case (4).
If no continuity exists, the coil is open and should be replaced.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
4
(A)
1
3
2
1
1. Terminal “S”
2. Terminal “M”
3. Terminal “B”
4. Coil case
I9J011190039-01
I9J011190037-01
1. Plunger
Contact points test
Put the plunger on the under side and then push the magnetic switch down.
At this time, check for continuity between terminal “B” and terminal “M”.
Continuity indicates proper condition. If no continuity exists, replace the magnetic switch and/or plunger.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
(A)
Starting System: 1I-13
FREE
(OFF) (ON)
(START)
PUSH
W
Br
O
B
I9J011190040-01
Ignition Switch Inspection
Inspect the ignition switch using the following
Z9J0111906006 procedures:
1) Disconnect the ignition switch from remo-con box wiring harness.
2) Check continuity between wiring leads at the key positions shown in the chart.
3) If out of specification, replace the ignition switch.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
W/R
Bl
Gr
G
Br
Br
Bl
Gr
B
G
I9J011190042-02
Starter Motor Relay Inspection
Z9J0111906007
Inspect the starter motor relay using the following procedures:
1) Disconnect the starter motor relay from the fuse box.
1
Key position
B
OFF
ON
START
FREE
PUSH
G
Switch Lead Wires
W Gr Br O
: Continuity
I9J011190041-03
1. Starter motor relay
I9J011190059-02
1I-14 Starting System:
2) Check continuity between terminal (2) and (3) each time 12 V power supply is applied to terminal (4) and
(5).
Connect the positive (+) lead to terminal (5), and negative (–) lead to terminal (4).
CAUTION
Be careful not to touch 12 V power supply wires to each other or with other terminals.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Starter motor relay function
12 V power applied
12 V power not applied
Continuity
Yes
No
Neutral Switch Inspection
Z9J0111906008
Check for continuity / infinity of the neutral switch.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Neutral switch in remo-con box
1) Disconnect the neutral switch lead wire connector from the ignition switch.
2) Check continuity / infinity between the switch brown wire leads while operating the remo-con handle.
If out of specification, replace the neutral switch.
Neutral switch function
Shift position
Neutral
Forward
Reverse
Tester indicates
Continuity
Infinity
Infinity
2 3
5
(A)
“Reverse” “Forward”
12 V
CONT
4
(A)
I9J011190043-03
3) Measure the resistance between relay terminals (4) and (5).
If out of specification, replace starter motor relay.
Tester knob indication
Resistance (
Ω
)
Starter motor relay solenoid coil resistance
Standard: 145 – 190
Ω
Br
Br
I9J011190045-03
(A)
I9J011190044-02
Neutral switch on engine side
1) Disconnect the neutral switch lead wire connector.
2) Check continuity / infinity between the Yellow / Green and Brown lead wires while operating the remo-con handle.
Special tool
(A): 09930–99320 (Digital tester)
Neutral switch function
Shift position
Neutral
Forward
Reverse
Tester indicates
Continuity
Infinity
Infinity
Starting System: 1I-15
Emergency Stop Switch Inspection
Z9J0111906009
1) Disconnect the emergency stop switch lead wire.
2) Check the continuity / infinity between the wiring leads under the condition shown below.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Tester probe connection
Red (+) Black (–)
Lock plate installed
Lock plate removed
Green Black
Tester indicates
Infinity
Continuity
“Reverse”
“Neutral”
“Forward”
B
(A)
1. Clutch lever
1
2
2. Neutral switch
I9J011190046-02
G
I9J011190048-04
(A)
Y/G
Br
(A)
B
I9J011190047-03
3) If out of specification:
• 1st:
Check the remo-con cable adjustment, readjust if necessary.
• 2nd:
Check the wire harnesses for open and short circuits.
If the wire harnesses are in good condition, replace the neutral switch and recheck.
NOTE
After installing the neutral switch, check for correct function by operating the remo-con handle.
G
3) If out of specification, replace the switch.
I9J011190049-04
1K-1 Charging System:
Power Head
Charging System
General Description
Charging System Description
Z9J0111B01001
The battery charging system circuit is illustrated below.
It is composed of the Battery Charge Coil, Rectifier/regulator and Battery. The three phase AC current generated from the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the battery.
Battery Charge coil Output
Standard: 12 V 27 A (324 W) at 3 000 r/min
Regulated Voltage
Standard: 14.5 – 15.2 Volts
1
2
8
To ECM
From Ign. switch
P/B
W
W
Gr
To ECM
To Fuel injector
To Ign. coil
To Fuel pump
Other
7 6
Y
Y
Y
B
R
3
4
M
1. Alternator (Magneto)
2. Battery charge coil
3. Rectifier/Regulator
4. Starter motor
5. Battery
6. Main fuse 40 A
–
+
5
7. ECM fuse 30 A
8. Main relay
To Starter relay
I9J0111B0001-03
Battery Requirement Description
Z9J0111B01002
Suzuki recommends 12-volt cranking-type lead acid battery for the DF70 / 80 / 90.
Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below.
Recommended battery size
650 Marine Cranking Amps (MCA)/ABYC or 512 Cold Cranking Amps (CCA)/SAE or 160 Reserve Capacity (RC) Minutes/SAE or 12 V 100 AH
NOTE
• The specifications listed above are the minimum battery rating requirements for starting the engine.
• Additional electrical loads from the boat will require larger capacity batteries.
• Dual-purpose (Cranking / Deep-Cycle) batteries can be used if they meet the minimum specifications listed above
(MCA, CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or
Gel-Cell batteries is not recommended because they may not be compatible with
Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of similar age. When replacement is necessary, they should be replaced as a set.
• When connecting batteries, hex nuts must be used to secure battery leads to battery posts.
• It is recommended that the battery be installed in an enclosed case.
1
2
Charging System: 1K-2
3
1. Red lead
2. Sub battery cable
3. Black lead
I9J0111B0002-02
4
4. Hexagon-nut
I9J0111B0003-02
1K-3 Charging System:
Component Location
Charging System Components Location
Z9J0111B03001
Diagnostic Information and Procedures
Charging System Diagnosis
Z9J0111B04001
Condition
Alternator (Battery charge coil) does not charge.
Alternator (Battery charge coil) overcharge.
Unstable charging
Possible cause
Open or short circuit lead wires.
Correction / Reference Item
Repair or replace.
Open or short circuit battery charge coil.
Replace.
Rectifier/Regulator failure.
Replace.
Main fuse blown out.
Poor or broken battery connection.
Rectifier/Regulator failure.
Poorly grounded rectifier/regulator.
Replace.
Repair or Replace.
Replace.
Repair or Retighten.
Short circuit battery charge coil.
Loose lead wire connection.
Rectifier/regulator failure.
Poor or broken battery connection.
Replace.
Repair or replace.
Replace.
Repair or replace.
Charging System Construction
CAUTION
Flywheel bolt (1) is a left hand thread.
Service Instructions
18
19
22
21
23
20
24
25
26
Charging System: 1K-4
Z9J0111B06001
1
2
(a)
3
17
5
4
10
6
7
8
9
27
1. Bolt
2. washer
3. Flywheel
9. Clamp
10. Electric parts holder
11. Rectifier/Regulator
4. Key 12. Bolt
5. Battery charge coil 13. Cushion
6. Bolt
7. Bolt
8. Clamp
14. Washer
15. Bolt
16. Bolt
11
14
13
12
17. Wiring harness assembly
18. Fuse case upper cover
19. O-ring
20. Fuse (40 amp.)
21. Main relay
22. Starter motor relay
23. Fuse
24. Bolt
16
13
14
15
I9J0111B0004-04
25. Nut
26. washer
27. Battery cable
: 196 N
⋅ m (19.7 kgf-m, 142 lbf-ft)
: Apply engine oil.
: Apply SUZUKI Bond 1207B.
1K-5 Charging System:
Flywheel Removal and Installation
Removal
Z9J0111B06002
CAUTION
Prior to removing flywheel, disconnect battery cables from battery.
1) Remove the ring gear cover.
Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
2) Loosen flywheel bolt 2 – 3 turns in clockwise direction.
CAUTION
Flywheel bolt is LH thread.
NOTE
Do not remove flywheel bolt at this time.
This bolt prevents damage to the crankshaft when using flywheel remover tools.
Special tool
(A): 09930–48720 (Flywheel holder)
4) Remove the flywheel bolt (1), washer (2), flywheel
(3) and key (4).
1
2
3
4
I9J0111B0011-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Clean flywheel and crankshaft mating surfaces with cleaning solvent.
• Apply engine oil lightly to flywheel bolt before installing.
(A)
I9J0111B0009-01
3) Using special tools, loosen flywheel from crankshaft.
Special tool
(B): 09930–39411 (Flywheel remover)
(C): 09930–39420 (Flywheel remover bolt)
I9J0111B0013-01
• Tighten flywheel bolt to specified torque.
Special tool
(A): 09930–48720 (Flywheel holder)
Tightening torque
Flywheel bolt (a): 196 N·m (19.7 kgf-m, 142 lbf-ft)
(a)
(A)
(C)
(B)
I9J0111B0014-01
I9J0111B0010-02
Battery Charge Coil Removal and Installation
Z9J0111B06003
Removal
CAUTION
Prior to removing electrical parts, disconnect battery cables from battery.
1) Remove flywheel.
Refer to “Flywheel Removal and Installation”
2) Disconnect battery charge coil lead wire connector
(1) at rectifier/regulator.
1
I9J0111B0015-01
3) Disconnect the charge output (red) lead wire connector.
4) Remove the bolt securing rectifier GND lead wire.
Charging System: 1K-6
6) Remove the bolts securing lead wire clamp (4).
4
4
I9J0111B0018-01
7) Remove the battery charge coil (3).
Installation
Installation is reverse order of removal with special attention to the following steps.
Battery charge coil
• Apply suzuki bond No. 1207B to the coil securing screws.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
• Install battery charge coil, then tighten coil screws securely.
I9J0111B0016-01
5) Remove three screws (2) securing the battery charge coil (3).
2
I9J0111B0019-02
Wire routing
Secure coil lead wire with lead wire clamps, then check that coil lead wire is routed properly and away from hot or rotating parts.
For wire routing, refer to “Wiring Harness Routing
Diagram” in Section 4A (Page 4A-3).
3
I9J0111B0017-01
I9J0111B0020-01
1K-7 Charging System:
Flywheel
Install flywheel and tighten flywheel bolt to specified torque.
Refer to “Flywheel Removal and Installation” (Page 1K-
Special tool
: 09930–48720 (Flywheel holder)
Tightening torque
Flywheel bolt: 196 N·m (19.7 kgf-m, 142 lbf-ft)
Battery Charge Coil Inspection
Z9J0111B06004
Measure battery charge coil resistance in the following procedure.
1) Disconnect battery charge coil leads from rectifier/ regulator.
2) Measure resistance between leads in the combinations shown.
If measurement exceeds specification, replace battery charge coil.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (
Ω
)
Battery charge coil resistance
Terminal for tester probe connection Resistance
Yellow 1 to Yellow 2
Yellow 2 to Yellow 3 0.1 – 0.3
Ω
Yellow 3 to Yellow 1
Rectifier/Regulator Removal and Installation
Z9J0111B06005
Removal
CAUTION
Prior to removing electrical parts, disconnect battery cables from battery.
1) Disconnect lead wire connector (1) from rectifier/ regulator.
2) Remove the bolts (2) and rectifier/regulator (3).
3
2
1
I9J0111B0021-01
Installation
1) Install rectifier/regulator (1), then tighten bolts (2) securely.
2) Connect lead wire connector to rectifier/regulator.
Check that lead wire routed properly.
2
1
I9J0111B0022-01
Y
1
Y
2
Y
3
I9J0111B0005-02
Charging System: 1K-8
Rectifier/Regulator Inspection
Inspect the rectifier/regulator in the following procedures:
1) Disconnect all lead wires of rectifier/regulator.
2) Measure resistance between terminals in the combinations shown.
If measurement exceeds specification, replace rectifier/regulator.
Z9J0111B06006
NOTE
The values given below are for a SUZUKI pocket tester.
As thyristors, diodes, etc. are used inside this rectifier/regulator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.
A E
B C D
I9J0111B0006-02
Special tool
: 09930–25002 (Pocket tester)
Tester knob indication
Resistance (x 1 k
Ω
)
Rectifier and regulator resistance
A
Tester probe ( )
(Black) connection
A
B
C
D
E
B
Tester probe ( ) (Red) connection
C D
Main Fuse Inspection
Z9J0111B06007
Inspect the main fuse in the following procedures.
1) Remove the main fuse from fuse box.
2) Inspect continuity between both terminal of fuse.
If no continuity is indicated, replace fuse.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
CONT
Unit: k
E
: Infinity
I9J0111B0008-06
I9J0111B0023-01
1K-9 Charging System:
Table of Contents 2- i
Section 2
Mid Unit
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precaution for Mid Unit ......................................... 2-1
Housing and Bracket............................... 2A-1
Precautions...........................................................2A-1
Precaution for Housing and Bracket ................... 2A-1
Service Instructions.............................................2A-2
Lower Side Cover Components .......................... 2A-2
Lower Side Cover Removal and Installation ....... 2A-3
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Components....................................... 2A-4
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Disassembly....................................... 2A-6
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Assembly............................................ 2A-9
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Related Component Inspection........ 2A-13
Clutch Shaft Bearing and Oil Seal
Replacement...................................................2A-15
Driveshaft Upper Oil Seal Replacement ........... 2A-16
Driven Gear Bearing and Oil Seal
Replacement...................................................2A-16
Clamp / Swivel / Steering Brackets
Components.................................................... 2A-17
Clamp / Swivel / Steering Brackets
Disassembly.................................................... 2A-18
Clamp / Swivel / Steering Brackets Assembly ..2A-20
Clamp / Swivel / Steering Brackets Related
Components Inspection .................................. 2A-24
Power Trim and Tilt ................................. 2B-1
Precautions...........................................................2B-1
Precaution for Power Trim and Tilt......................2B-1
General Description .............................................2B-1
Power Trim and Tilt Description ..........................2B-1
Principles of Power Trim and Tilt Operation
Description ........................................................2B-3
Schematic and Routing Diagram........................2B-8
Power Trim and Tilt System Diagram .................2B-8
Diagnostic Information and Procedures............2B-9
Diagnose PTT System Malfunction.....................2B-9
Service Instructions...........................................2B-10
Checking PTT Fluid Level .................................2B-10
Air Bleeding from PTT Unit ...............................2B-10
Setting of Trim Down Position Limit ..................2B-11
Setting Tilt Up Limit Position .............................2B-12
Power Trim and Tilt Unit Removal and
Installation .......................................................2B-13
Power Trim and Tilt Unit Components ..............2B-17
Power Trim and Tilt Unit Disassembly ..............2B-18
Power Trim and Tilt Unit Reassembly...............2B-19
Power Trim and Tilt Unit Components
Cleaning and Inspecting..................................2B-21
Power Trim and Tilt Motor Removal and
Installation .......................................................2B-22
Power Trim and Tilt Motor Disassembly and
Assembly.........................................................2B-23
PTT Motor Related Items Inspection.................2B-24
PTT Motor Relay Inspection..............................2B-25
PTT Switch Inspection ......................................2B-26
2
2-1 Precautions:
Mid Unit
Precautions
Precautions
Precaution for Mid Unit
Refer to “General Precautions” in Section 00 (Page 00-1).
Z9J0112000001
Housing and Bracket: 2A-1
Mid Unit
Housing and Bracket
Precautions
Precaution for Housing and Bracket
Z9J0112100001
CAUTION
Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic corrosion or build up of static charges.
Replace any damaged wire.
NOTE
• When dismantling housing and bracket, inspect mountings and bolts for damage and wear. Replace if necessary.
• Check the condition of the zinc anodes on lower section of mid unit. Replace if necessary.
2A-2 Housing and Bracket:
Lower Side Cover Components
Service Instructions
Z9J0112106001
1
3
19
18
24
23
26
17
22
25
20
28
2
9
10
8
22
11
6
18
(a)
27
23
24
19
14
13
21
25
1. Side cover rubber
2. Side cover seal
3. Lower side cover STBD
4. Lower side cover PORT
5. Screw
6. Screw
7. Screw
8. Cushion
17
26
12
15
16
9. Side cover holder
10. Bolt
11. Front panel
12. Bolt
13. Washer
14. Cushion
15. Water plug
16. Gasket
5
(a)
4
7
(a)
17. Engine cover hook shaft
18. Engine cover hook
19. Bolt
20. Rear hook lever
21. Front hook lever
22. Hook lever latch
23. Washer
24. Wave washer
I9J011210003-05
25. Pin
26. Bush
27. Bolt
28. Bolt
: Apply water resistance grease.
: 7 N
⋅ m (0.7 kgf-m, 5.0 lbf-ft)
Lower Side Cover Removal and Installation
Z9J0112106002
Removal
1) Remove the side cover rubber (1).
Housing and Bracket: 2A-3
3) Remove three screws (4) and PORT side cover (5).
4
1
5
4) Disconnect PTT switch lead connector.
I9J011210008-02
I9J011210009-01
2) Remove ten screws (2) and STBD side cover (3).
3
2
I9J011210007-02
I9J011210010-01
Installation
Installation is reverse order of removal with special attention to the following step.
• Tighten side cover screws, pre-coated with thread lock, to specified torque.
Tightening torque
Side cover screw: 7 N·m (0.7 kgf-m, 5 lbf-ft)
2A-4 Housing and Bracket:
Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components
3
1
2
4
Z9J0112106003
1. Mount case cover
2. Gasket
3. Bolt
4. Gasket
5. Engine holder
6. Gasket
7. Plug
8. Dowel pin
9. Dowel pin
17
15
16
18
9
12
13
11
10
14
22
(a)
21
8
20
5
6
7
19
24
25
10. Driven gear seal
11. Oil seal
12. Clutch shaft bearing
13. Oil seal
14. Upper mount cover
15. Bolt
16. Bolt
17. Spacer
18. Upper mount bolt
27
19. Upper thrust mount
20. Upper mount
21. Washer
22. Nut
23. Bolt
24. Upper unit stopper
25. Bolt
26. O-ring
27. Oil strainer
23
26
30
29
(b)
28
I9J011210004-01
28. Bolt
29. Gasket
30. Oil relief valve
: 80 N
⋅ m (8.0 kgf-m, 57.8 lbf-ft)
: 27 N
⋅ m (2.7 kgf-m, 19.5 lbf-ft)
: Apply engine oil.
: Apply SUZUKI water resistant grease.
: Apply SUZUKI thread lock 1342.
Housing and Bracket: 2A-5
6
(a)
5
14
15
18
19
1
2
4
3
13
16
17
7
8
9
10
11
12
36
41
TRANSOM X TYPE
40
39
37
35
38
42
24
25
26
27
28
29
30
31
32
34
43
44
20
1. Gasket
2. Oil pan
3. Exhaust pipe
4. Gasket
5. Gasket
6. Oil drain plug
7. Bolt
8. Bolt
9. Gasket
10. Water jacket cover
11. Gasket
12. Water plug
(b)
21
22
23
13. Bolt
14. Gasket
15. Exhaust tube housing
16. Bolt
17. Dowel pin
18. Bolt
19. Driveshaft housing
20. Lower mount bolt
21. Washer
22. Lower mount bracket
23. Lower thrust mount
24. Washer
33
25. Lower mount spacer
26. Damper
27. Lower side mount FWD
28. Lower mount
29. Lower side mount
30. Damper
31. Washer
32. Nut
33. Lower mount cover
34. Bolt
35. Bolt
36. Bolt
I9J011210005-03
37. Seal
38. Exhaust tube Extension
39. Circlip
40. Bush
41. Dowel pin
42. Extension case
43. Anode
44. Bolt
: 13 N
⋅ m (1.3 kgf-m, 9.5 lbf-ft)
: 60 N
⋅ m (6.0 kgf-m, 43.4 lbf-ft)
: Apply SUZUKI thread lock 1342.
: Apply SUZUKI silicon seal.
2A-6 Housing and Bracket:
Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Disassembly
Z9J0112106004
1) Remove the power unit. Refer to “Power Unit
Removal and Installation” in Section 1D (Page 1D-
2) Remove the lower unit. Refer to “Lower Unit
Removal and Installation” in Section 3A (Page 3A-5).
3) Remove the screw and bonding wire (1).
5) Unscrew and remove the STBD / PORT lower mount bolts (3). Account for washers (4), (5), mount spacer
(6), forward damper (7), white side mount (8), lower mount (9), black side mount (10), damper (11), washer (12) and nut (13).
4 5
7 9
11
13
3 6 8 10 12
I9J011210013-02
1
I9J011210011-01
4) Remove the four bolts securing the STBD / PORT lower mount covers, then detach the mount covers
(2).
10
11
12
9
8
7
6
5
I9J011210014-01
6) Remove the eight bolts securing the driveshaft housing (14) to the oil pan, then remove the driveshaft housing.
2
I9J011210012-01
14
I9J011210015-02
14
I9J011210016-01
7) Remove the water tube (15).
Housing and Bracket: 2A-7
11) Remove five bolts and oil pan water jacket cover (19)
(if necessary).
19
15
I9J011210018-01
8) Remove five bolts and exhaust tube housing (16).
I9J011210023-01
12) Remove bolts, water pressure valve cover (20), and water pressure valve (21).
20
16
21
I9J011210019-01
9) Remove bolt and water indicator union (17) (if necessary).
I9J011210024-01
13) Loosen and remove the clutch shaft plug (22).
22
17
I9J011210020-01
10) Remove the three bolts securing exhaust pipe (18), then remove exhaust pipe (if necessary).
I9J011210025-01
14) Push the clutch rod (23) down to free it from the engine holder.
23
18
I9J011210022-01
I9J011210026-01
2A-8 Housing and Bracket:
15) Remove STBD / PORT upper mount nuts (24) and washers.
19) Remove the upper mounts (27), upper thrust mount
(28), damper (29) and mount bolts (30).
27
28
24
16) Remove engine holder with oil pan.
I9J011210027-01
27
I9J011210031-01
30
30
I9J011210028-01
17) Remove five bolts and the mount case cover (25).
29
I9J011210032-02
20) Remove the six bolts and the engine holder (31) from the oil pan.
25
I9J011210029-01
18) Remove three bolts and upper mount cover (26).
31
31
26
I9J011210030-01
I9J011210033-02
I9J011210034-02
21) Remove two bolts and oil strainer (32).
Housing and Bracket: 2A-9
• Install oil strainer to engine holder, then tighten bolts securely.
4
4
32
3
I9J011210035-01
22) Remove the oil relief valve (33) and gasket.
I9J011210038-01
• Install two dowel pins (5) and gasket (6) to oil pan.
CAUTION
Do not reuse gasket. Always assemble with a new gasket.
33
6
5
I9J011210036-02
Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly
Z9J0112106005
Assembly is in reverse order of disassembly with special attention to the following steps.
Engine Holder to Oil Pan
• Install the gasket (1) and oil relief valve (2) to the engine holder, then tighten the valve securely.
Tightening torque
Oil relief valve (a): 27 N·m (2.7 kgf-m, 19.5 lbf-ft)
5
I9J011210039-03
• Install engine holder (7) to oil pan (8), then securely tighten it with engine holder bolts (9).
7
2
(a)
9
8
I9J011210040-01
1
I9J011210037-01
• Apply engine oil to O-rings (3), then install O-rings to oil strainer (4).
7
9
8
I9J011210041-02
2A-10 Housing and Bracket:
Upper Mount and Mount Cover
• Assemble these items in the following sequence:
Place upper thrust mount (1) and upper mounts (2) on upper mount bolts (3).
• Install dampers (4) to thrust mount.
NOTE
Install upper thrust mount with the lettered mark “UP” facing upward.
• Install the upper mount cover (5).
• Tighten upper mount cover bolts, pre-coated with thread lock, to specified torque.
Tightening torque
Upper mount cover bolt (a): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
UP
3
5
(a)
2
4
1
4
I9J011210042-01
• Place upper mount / thrust mount assembly into position.
NOTE
Position the retaining pin hole on upper mount facing downward.
• Be sure the retaining pin “A” on the engine holder properly fits into the retaining pin hole “B” on the mount.
I9J011210045-02
Mount Case Cover
• Install the gasket and mount case cover (1), then tighten five cover bolts securely.
1
I9J011210046-01
“B”
“A”
I9J011210043-01
I9J011210044-01
Engine Holder / Oil Pan
• Position the clutch rod (1) into place.
1
Housing and Bracket: 2A-11
Clutch Rod
• Slide the clutch rod (1) into place.
1
I9J011210047-01
• Install engine holder / oil pan to steering bracket.
I9J011210050-01
• Tighten the clutch shaft plug (2), pre-coated with thread lock, to specified torque.
Tightening torque
Clutch shaft plug (a): 22 N·m (2.2 kgf-m, 16.0 lbfft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
2
(a)
I9J011210048-01
• Install washer (2) and upper mount nut (1), then tighten two nuts, pre-coated with thread lock, to specified torque.
Tightening torque
Upper mount nut (a): 80 N·m (8.0 kgf-m, 57.8 lbfft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
I9J011210051-01
Water Pressure Valve
• Install water pressure valve (1) and cover (2). Refer to
“Water Pressure Valve Removal and Installation” in
1
2
1
(a)
2
I9J011210049-01
I9J011210052-01
2A-12 Housing and Bracket:
Driveshaft Housing / Oil Pan
• Install the gasket and exhaust tube housing (1), then tighten bolts securely.
• Install driveshaft housing (5) to oil pan, then tighten eight bolts securely.
1
5
• Install water tube (2).
2
I9J011210053-01
I9J011210054-01
• Install two dowel pins (3) to driveshaft housing (4).
Apply sealant to mating surfaces of driveshaft housing and oil pan.
: Sealant 99000–31120 (SUZUKI Silicone
Seal (50 g))
I9J011210056-02
Lower Mount / Bolt / Nut
• Assemble the white lower side mount (1), lower thrust damper (2), black lower side mount (3) and damper
(4) to the lower mount (5) as shown in figure.
• Place the spacer (6) and lower mount assembly into driveshaft housing.
• Install the lower mount bolt (7), washer (8), washer
(9), washer (10) and nut (11), then tighten bolt, precoated with thread lock, to specified torque.
Tightening torque
Lower mount bolt (a): 60 N·m (6.0 kgf-m, 43.4 lbfft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
9
6
2
1
5
3
3
4
10
7
8
11
I9J011210057-01
4
3
I9J011210055-02
9
8
11
7
(a)
10
I9J011210058-02
• Install lower mount cover (12) and cover bolts (13), then tighten bolts, pre-coated with thread lock, to specified torque.
Tightening torque
Lower mount cover bolt (b): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
12
Housing and Bracket: 2A-13
Engine Holder
• Inspect the engine holder. Replace if cracked, damaged, or other abnormal conditions are noted.
• Check water passage. If clogged or obstructed, clean water passage.
• Visually check the clutch shaft bearing. Replace if pitted, noisy, rough or other abnormal conditions are found.
• Check the clutch shaft oil seal. Replace the oil seal if nicked, cut, worn or other abnormal conditions are found.
13
(b)
I9J011210059-01
Bonding Wire
• Reattach the bonding wire (1), then tighten screw securely.
I9J011210061-01
1
I9J011210060-01
Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Related Component Inspection
Z9J0112106006
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Disassembly” (Page 2A-6) and “Engine Holder /
Oil Pan / Driveshaft Housing / Mounts Assembly”
NOTE
If any component is found to be excessively worn, cracked, defective or damaged in any way, it must be replaced.
I9J011210062-01
Mount Case Cover
• Inspect the mount case cover. Replace the mount case cover if cracked, damaged or other abnormal conditions are found.
I9J011210063-01
2A-14 Housing and Bracket:
Oil Strainer
• Inspect the oil strainer. Replace the strainer if cracked, damaged or other abnormal conditions are found.
If clogged or obstructed, clean the oil strainer.
• Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal condition are found.
I9J011210064-01
Oil Pan / Driveshaft Housing
• Check oil pan, driveshaft housing.
If cracks, defects or other damage is found, replace it.
I9J011210067-01
Exhaust Tube Housing
• Inspect exhaust tube housing.
Replace housing if cracked, damaged or other abnormal conditions are found.
I9J011210065-01
Mount
• Check upper, lower and thrust mounts.
If excessive wear, corrosion or other damage is found, replace mount.
• Inspect mount cover. Replace mount cover if cracked, damaged or other abnormal conditions are found.
I9J011210069-01
Water Tube / Water Tube Grommet
• 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.
I9J011210070-01
I9J011210066-01
Housing and Bracket: 2A-15
Clutch Shaft Bearing and Oil Seal Replacement
Z9J0112106007
1) Remove the engine holder. Refer to “Engine Holder /
Oil Pan / Driveshaft Housing / Mounts Disassembly”
2) Extract oil seal (1) with oil seal remover.
CAUTION
Do not reuse oil seal once removed.
Always use a new oil seal.
Special tool
(A): 09913–50121 (Oil seal remover)
(A)
(C)
(B) 3
5) Apply engine oil to outer circumference of bearing
(3).
Install bearing into engine holder.
6) Install circlip (2).
I9J011210073-01
1
2
I9J011210071-01
3
3) Remove circlip (2).
2
I9J011210072-01
4) Remove bearing (3) with special tool and sliding hammer.
CAUTION
Do not reuse the bearing once removed.
Always use a new bearing.
Special tool
(B): 09923–73210 (Bearing remover)
(C): 09930–30104 (Sliding hammer)
I9J011210074-01
7) Apply water resistant grease to outer circumference of oil seal (1).
Drive oil seal into engine holder.
Apply water resistant grease to the seal lip.
NOTE
Install oil seal as shown in the figure.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
1
I9J011210075-02
8) Reassemble the engine holder. Refer to “Engine
Holder / Oil Pan / Driveshaft Housing / Mounts
2A-16 Housing and Bracket:
Driveshaft Upper Oil Seal Replacement
Z9J0112106008
1) Remove the engine holder. Refer to “Engine Holder /
Oil Pan / Driveshaft Housing / Mounts Disassembly”
2) Extract oil seals with oil seal remover.
Special tool
(A): 09913–50121 (Oil seal remover)
(A)
CAUTION
Do not re-use the bearing once removed.
Always use a new bearing.
Special tool
(A): 09941–64511 (Bearing remover)
(B): 09930–30104 (Sliding hammer)
(A)
1
I9J011210076-01
3) Apply water resistant grease to outer circumference of oil seal.
4) Drive the two oil seals (one at a time) into the engine holder.
NOTE
Install oil seal with lip (spring side) facing downward (oil pan side).
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
(B)
I9J011210078-01
3) Extract oil seal (2) with oil seal remover.
Special tool
(C): 09913–50121 (Oil seal remover)
(C)
2
I9J011210121-01
5) Reassemble the engine holder. Refer to “Engine
Holder / Oil Pan / Driveshaft Housing / Mounts
Driven Gear Bearing and Oil Seal Replacement
Z9J0112106009
1) Remove the engine holder. Refer to “Engine Holder /
Oil Pan / Driveshaft Housing / Mounts Disassembly”
2) Remove bearing (1) with special tool and sliding hammer.
4) Apply water resistant grease to outer circumference of oil seal.
5) Drive the oil seal into the engine holder.
I9J011210079-01
NOTE
Install oil seal with lip (spring side) facing upward (Driven gear bearing side).
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
I9J011210081-01
6) Apply engine oil to outer circumference of bearing
(1). Install bearing into engine holder.
Housing and Bracket: 2A-17
7) Reassemble the engine holder. Refer to “Engine
Holder / Oil Pan / Driveshaft Housing / Mounts
1
I9J011210080-03
Clamp / Swivel / Steering Brackets Components
Z9J0112106010
9
6
5
(a)
1
8
(c)
(b)
1. Clamp bracket STBD
2. Clamp bracket PORT
3. Clamp bracket shaft
4. Bolt
5. Washer
6. Nut
7. Lower clamp bracket
8. Bolt
9. Bolt
10. Anode
11. Bolt
12. Swivel bracket
24
42
41
40
39
25
14
13
12
16
7
15
18
17
25
26
10
11
36
38
38
37
38
13. Bush
14. Washer
15. Grease nipple
16. Steering bracket
17. Washer
18. Bush
19. Seal
20. Washer
21. Shim
22. Lower mount bracket
23. Circlip
24. Tilt lock lever
38
13
18
14
35
25. Bush
26. Spring
27. Tilt lock lever PORT
28. Pin
29. Washer
30. Nut
31. Tilt lock lever link
32. Spring
33. Screw
34. Bracket
35. Bonding wire
36. Bonding wire
34
33
32
31
19
20
21
22
23
27
30
28
29
2
3
4
I9J011210006-03
37. Bonding wire
38. Screw
39. Bolt
40. Steering bracket attachment
41. Washer
42. Nut
: 43 N
⋅ m (4.3 kgf-m, 31.0 lbf-ft)
: 50 N
⋅ m (5.0 kgf-m, 36.0 lbf-ft)
: 50 N
⋅ m (5.0 kgf-m, 36.0 lbf-ft)
: Apply SUZUKI water resistance grease.
: Apply SUZUKI thread lock 1342.
2A-18 Housing and Bracket:
Clamp / Swivel / Steering Brackets Disassembly
Z9J0112106011
1) Remove engine holder / oil pan and driveshaft
housing. Refer to “Engine Holder / Oil Pan /
Driveshaft Housing / Mounts Disassembly”
2) Remove screw and bonding wire from lower mount bracket.
5) Lift steering bracket (5) upward to remove from swivel bracket.
Remove washer (6) and upper bushing (7).
5
7
6
I9J011210084-01
6) Remove swivel bracket seal (8) and lower bushing
(9).
I9J011210082-01
3) Remove circlip (1).
1
9
8
I9J011210086-01
7) Remove bolt (10) and trim sensor assembly (11).
Cut the cable tie securing sensor lead wire.
I9J011210083-01
4) Remove lower mount bracket (2), shims (3), and washer (4) from the steering shaft.
10
11
3
4
2
I9J011210085-01
I9J011210087-01
8) Slide the lower trim sensor cam plate (12) off.
12
I9J011210088-01
9) Remove the upper trim sensor cam (13) from clamp bracket shaft.
Housing and Bracket: 2A-19
13) Remove the PTT unit (19) and lower clamp bracket
(20) from between the clamp brackets.
13
I9J011210089-01
10) Remove circlip (14) and push out tilt cylinder upper rod (15).
19
20
I9J011210093-01
14) Using flat blade screw driver, drive locking edge of lock washer (21) to clamp bracket side.
21
15
14
11) Remove bolts (16) and anode (17).
I9J011210090-01 I9J011210094-01
15) Remove the two STBD motor mounting bolts (22).
Remove the clamp bracket shaft nut (23) and washer.
Remove the screw and bonding wire (24) from swivel bracket.
24
23
17 16
I9J011210091-01
12) Remove the four bolts (18) securing lower clamp bracket to STBD and PORT clamp brackets.
22
I9J011210095-02
18
18
18
I9J011210092-02
2A-20 Housing and Bracket:
16) Slide STBD clamp bracket (25) off clamp bracket shaft.
25
I9J011210096-02
17) Remove the bolt (26) securing clamp bracket shaft to
PORT clamp bracket.
Clamp / Swivel / Steering Brackets Assembly
Z9J0112106012
Assembly is reverse order of disassembly with special attention to the following steps.
Clamp Bracket / Swivel Bracket
NOTE
Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings.
: Grease 99000–25161 (SUZUKI Water Resistant
Grease (250 g))
• Insert PORT and STBD bushings (2) into the swivel bracket (1).
26
1
2
2
I9J011210097-02
18) Pull PORT clamp bracket (27) outward to remove clamp bracket and bracket shaft (28) from swivel bracket (29). Remove washer (30) and bushing (31) from each side of swivel bracket.
I9J011210099-01
• Assemble port clamp bracket (3), washer (4), clamp bracket shaft (5) and swivel bracket (1).
3
1
29
27
30
31
5 4
I9J011210100-01
28
31
30
I9J011210098-02
• Apply Thread Lock 1342 to threads of shaft bolt (5) before threading it to PORT clamp bracket.
Install the shaft bolt (5), then tighten it securely.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
Housing and Bracket: 2A-21
• After tightening clamp bracket shaft nut to specified torque, bend lock washer edge toward nut to secure nut.
5
I9J011210101-01
• Install washer (6), STBD clamp bracket (7), lock washer (8) and clamp bracket shaft nut (9).
I9J011210104-01
• Install PTT unit and lower clamp bracket assembly
(10). Refer to “Power Trim and Tilt Unit Removal and
Installation” in Section 2B (Page 2B-13).
6
7
8
10
9
I9J011210102-01
• Tighten clamp bracket shaft nut (9) to specified torque.
Tightening torque
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
31.0 lbf-ft)
I9J011210105-01
• Tighten four lower clamp bracket bolts (11), precoated with thread lock, to specified torque.
Tightening torque
Lower clamp bracket bolt (b): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
11
(b)
9
(a)
I9J011210103-01
11
(b)
11
(b)
I9J011210106-01
2A-22 Housing and Bracket:
Trim Sensor and Trim Sensor Cam
• Install the upper trim sensor cam (1) engaging its locating pin “A” with the clamp bracket shaft hole “B”.
1
“A”
“B”
• Install the lower trim sensor cam plate (2).
I9J011210107-01
Steering Bracket
• Apply water resistant grease to steering bracket shaft.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
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 bracket seal (4) with oil seal lip (spring side) facing downward.
• Install steering bracket (5) to swivel bracket.
5
2
• Install the trim sensor assembly (3), then secure it with bolts (4).
• Secure switch lead wire with cable tie.
I9J011210108-01
3
4
I9J011210109-02
4
3
2
6
2
1
8
1. Upper bushing
2. Washer
3. Lower bushing
4. Swivel bracket seal
5. Steering bracket
7
“A”
I9J011210002-04
6. Shim
7. Lower mount bracket
8. Circlip
“A”: Seal lip
Housing and Bracket: 2A-23
Lower Mount Bracket
• Install lower thrust mount (1) to lower mount bracket
(2).
• Install washer (3) and shim (4), and then slide the lower mount bracket (2) upward on the splines until it contacts the shim.
1
• Install circlip (5) to retain bracket.
2
4
3
I9J011210110-01
I9J011210113-01
Lubrication
After completing reassembly of the mid unit, apply grease through each grease nipple.
: Grease 99000–25161 (SUZUKI Water Resistant
Grease (250 g))
5
I9J011210114-01
I9J011210111-01
Bonding Wire
Reattach bonding wire to swivel bracket and tighten screw securely.
I9J011210115-01
I9J011210112-01
I9J011210116-01
2A-24 Housing and Bracket:
Clamp / Swivel / Steering Brackets Related
Components Inspection
Z9J0112106013
Refer to “Clamp / Swivel / Steering Brackets
Disassembly” (Page 2A-18) and “Clamp / Swivel /
Steering Brackets Assembly” (Page 2A-20).
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.
Clamp Bracket Shaft
Check clamp bracket shaft.
If clamp bracket shaft is bent or twisted, replace shaft.
I9J011210120-01
Bracket
Check clamp brackets, steering bracket and swivel bracket.
If cracks or other damage is found, replace bracket (s).
I9J011210117-01
Oil Seal
Check swivel bracket seal. If excessive wear or other damage is found, replace seal.
I9J011210119-01
I9J011210118-01
Power Trim and Tilt: 2B-1
Mid Unit
Power Trim and Tilt
Precautions
Precaution for Power Trim and Tilt
!
WARNING
Before removing the PTT unit, the motor should be fully supported to prevent personal injury.
Z9J0112200001
CAUTION
• To prevent system malfunctions, ensure that all components are kept free from dirt or contamination.
• To unscrew the trim / tilt cylinder head, use only the special cylinder cap tool.
• Pull rams out by hand; do not attempt to leverage with a screwdriver blade etc.
NOTE
Reinstall all O-rings, seals, springs etc. with the component(s) to which they belong. This will prevent possible confusion and will ensure correct reassembly.
General Description
Power Trim and Tilt Description
Z9J0112201001
• The power trim and tilt system components are an electric motor, a pump unit, a fluid reservoir and one tilt cylinder.
The outboard can be trimmed “UP” or “DOWN” while under way, and can be tilted for beaching, operating in shallow water or trailering.
Trim and tilt “UP” or “DOWN” is obtained by supplying power to a permanent magnet type motor. This motor will rotate clockwise for “UP” or counterclockwise for “DOWN”, according to power delivered via the PTT relay, which is mounted on the electric part holder.
• The PTT relay is controlled by the ECM.
The ON/OFF signal for the PTT UP or DOWN is inputted to the ECM PTT relay drive circuit from ECM terminals No.
22 or 23 and the output signal from terminals No. 3 or 27.
NOTE
• A PTT relay control circuit has been added to the ECM for the tilt/trim function.
The PTT switch is powered by the main battery, the same as other models, but battery voltage must also be supplied to the ECM by the sub battery cable for the system to operate.
• With the ignition switch in the OFF position, and the PTT switch operated, the tilt/trim will operate.
With the ignition switch in the OFF position, operating the PTT switch will supply a 12 V power signal to the ECM.
When this signal is received, the ECM operates the main relay (ON), allowing the ECM drive signal to feedback to the ECM and the PTT relay circuit.
Thus the PTT system functions only if the PTT switch is operated.
When the PTT switch signal turns from ON to OFF and a predetermined time has elapsed, the ECM drive voltage will be interrupted automatically.
2B-2 Power Trim and Tilt:
Power Trim and Tilt Hydraulic Diagram
1
2
11
13
1. PTT motor
2. Tilt rod
3. Oil reservoir
4. Tilt cylinder Upper chamber
5. Floating tube
6. Trim cylinder upper chamber
7. Tilt piston
8. Trim piston
22
21
20 19
14
15 16
12
18 17
9. Free piston
10. Lower cylinder chamber
11. Manual release valve
12. Thermal valve
13. 2-way valve
14. Gear pump
15. “UP” pressure main check valve
16. “UP” relief valve
3
4
5
6
7
8
10
9
I9J011220001-02
17. “DOWN” relief valve
18. Spool valve No. 1
19. Check valve No. 1
20. Check valve No. 2
21. Spool valve No. 2
22. “DOWN” pressure main check valve
Power Trim and Tilt: 2B-3
Principles of Power Trim and Tilt Operation Description
Z9J0112201002
By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder.
Trim / Tilt Up Circuit
• When the PTT switch is operated “UP” position, the electric motor and gear pump (1) will operation on clockwise direction.
• Pressurized oil will open check valve (2), oil will flow from the reservoir to spool valve (3) via the pump and spool valve (4).
• Operation of spool valve (3) in the “DOWN” direction will cause the main check valve (5) to open.
• Oil in the upper chamber of the cylinder will return to the pump via a 2-way valve.
Then the oil pressure will rise and open the “UP” pressure main check valve (6), then allowing oil to flow to the lower chamber of cylinder.
This makes the piston rod push up and the engine tilt up.
• Oil flows from the reservoir to the pump through check valve (2).
Oil flows through the “DOWN” pressure main check valve (5) and returns to the pump.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check valve (6) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full tilt up position is attained, sustained operation of the “UP” relay will cause oil flow to be returned to the reservoir through the “UP” relief valve (7).
3
2
5 1
6
4
7
I9J011220002-01
2B-4 Power Trim and Tilt:
Trim / Tilt Down Circuit
• When the PTT switch is operated in the “DOWN” position, the electric motor will rotate in a counterclockwise direction and turn the gear pump.
• Check valve (1) will open; oil will flow from the reservoir to the spool valve (2).
This makes spool valve (3) move to downward, and causes the “UP” pressure main check valve (4) to open.
• Oil in the lower chamber will return to pump, and then oil pressure increase will open the “DOWN” pressure main check valve (5), allowing oil flow to the upper chamber of cylinder.
This makes the piston rod push down and the engine will tilt down.
• Oil flows from the reservoir to the pump through check valve (1).
Surplus oil in the pump flows through the “DOWN” relief valve (6) and returns to the reservoir.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check valve (4) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full trim/tilt down position is attained, sustained operation of the “DOWN” relay will cause oil to be returned to the reservoir through the “DOWN” relief valve (6).
5
2
4
1
3
6
I9J011220003-02
Power Trim and Tilt: 2B-5
Shock Absorber Circuit
Shock valve
Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
Return valve
When the point of impact has passed, propeller thrust and motor weight will force the tilt ram piston back downward.
The oil from between the ram piston (3) and the free piston (4) is then expelled through the return valve (5) before flowing into the upper cylinder chamber (1).
5
4
1
3
2
I9J011220004-01
2B-6 Power Trim and Tilt:
Manual Release Circuit (Manual Valve)
Turn the manual valve a maximum of three full turns counterclockwise.
When the manual release valve (1) is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again.
: Tilt “DOWN”
: Tilt “UP”
1
I9J011220005-02
Power Trim and Tilt: 2B-7
Thermal Valve
As temperature goes up, oil pressure will increase and the oil in PTT unit will expand.
High oil pressure in the upper cylinder chamber (1) caused by rising temperature will release the thermal valve (2) and make the oil flow to the reservoir to prevent damage to the PTT unit.
1
2
I9J011220006-01
2B-8 Power Trim and Tilt:
Schematic and Routing Diagram
Power Trim and Tilt System Diagram
R
10
11
2 12
13
9
M
3
Lbl
P
R
B
1
G Bl
BATT
8
6
7
4
W-tube
Lbl
W/R
P
Z9J0112202001
12
35
22 23
27
ECM
3
36
B/G
1. PTT switch (Remote control box)
2. PTT switch (Side cover)
3. PTT motor relay
4. PTT motor
5. Ignition switch
6. Battery
7. Sub battery cable
8. Sub battery cable fuse 15 amp.
9. Starter motor
10. ECM main relay
B GND
W BATT
Gr IGN
Br START
5
11. ECM fuse 30 amp.
12. PTT switch fuse 10 amp.
13. Main fuse 40 amp.
I9J011220007-04
Power Trim and Tilt: 2B-9
Diagnostic Information and Procedures
Diagnose PTT System Malfunction
Condition
Motor will not trim / tilt at all (no up, no down).
Z9J0112204001
Possible cause
Blown fuse for PTT system.
(Sub battery cable: 15 A, Main: 40 A,
PTT switch: 10 A, ECM: 30 A).
Defective PTT switch.
Open circuit between main fuse 40 A and PTT relay.
Defective main relay.
Replace.
Repair.
Correction / Reference Item
Inspection and replace.
Defective PTT relay.
Defective ECM and/or PTT system circuit.
Loose or corroded sub battery cable
Replace.
Replace.
Inspection of ECM and its circuit in section 1A.
Repair or retighten.
connection.
Open circuit between main fuse and
Repair.
starter motor magnetic switch.
Defective PTT motor armature.
Replace.
Defective PTT motor armature brushes.
Replace.
Defective PTT pump.
Manual release valve leaking.
Replace.
• Ensure that valve is fully closed.
Motor will not trim / tilt up.
Defective PTT switch.
Defective PTT relay.
Open light blue lead wire circuit.
Defective ECM.
Motor will not trim / tilt down.
Defective PTT switch.
Defective PTT relay.
Open pink lead wire circuit.
Defective ECM.
PTT motor operates, but no motor trim / tilt movement.
Low PTT fluid level.
Manual release valve leaking.
Motor will not retain selected trim and tilt setting, creeps downward.
PTT motor operates at higher than normal speed, or with high pitched
“squealing” sound. No trim / tilt action.
Debris in system.
Broken drive joint in PTT pump.
Broken PTT pump.
Tilt piston leaking.
Manual release valve leaking.
Tilt piston leaking.
Debris in system.
Low PTT fluid level.
Manual release valve leaking.
Broken drive joint in PTT pump.
• Inspect manual release valve.
Replace.
Replace.
Repair or replace.
Replace.
Replace.
Replace.
Repair or replace.
Replace.
Added PTT fluid.
• Ensure that valve is fully closed.
• Inspect manual release valve.
Inspect for debris.
Replace.
Replace.
Replace PTT unit assembly.
• Ensure that valve is fully closed.
• Inspect manual release valve.
Replace PTT unit assembly.
Inspect for debris.
Added PTT fluid.
• Ensure that valve is fully closed.
• Inspect manual release valve.
Replace.
2B-10 Power Trim and Tilt:
1
Service Instructions
Checking PTT Fluid Level
1) Raise the engine to a full-tilt up position.
2) Lower the manual tilt lock lever (1).
Z9J0112206001
Air Bleeding from PTT Unit
Z9J0112206002
1) Check that the manual release valve (1) is tightened to the specified torque.
CAUTION
Do not over tighten manual release valve.
Tightening torque
Manual release valve (a): 3.5 N·m (0.36 kgf-m,
2.6 lbf-ft)
Direction of rotation
Counterclockwise: Open
Clockwise: Close
I9J011220050-01
3) Remove the oil filler plug (2).
1
(a)
2
I9J011220051-01
4) If fluid can be seen at filler plug level, the reservoir is full.
5) If fluid level is low, refill with the recommended PTT fluid.
CAUTION
To ensure consistent pump operation, do not mix different types of fluid.
Recommended PTT fluid
Dexron III automatic transmission fluid or equivalent
I9J011220052-03
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.
I9J011220053-01
3) Check PTT fluid level, topping off if necessary.
4) Reinstall oil filler plug.
6) Reinstall oil filler plug.
I9J011220008-01
Setting of Trim Down Position Limit
Z9J0112206003
Once the ECM has been replaced or the trim sensor removed and reinstalled, the resetting of the trim lower position limit should be performed.
Perform this set-up after the current position setting has been cancelled, as explained in the following procedures.
Canceling Trim Down Position Limit Setting
1) Turn the ignition key to the “ON” position.
2) Pull out the emergency stop switch lock plate.
3) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in the “ON” position.)
I9J011220054-01
4)
Top mount type:
Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.
“NEUTRAL” “NEUTRAL”
Power Trim and Tilt: 2B-11
5) Press the “DOWN” side of the PTT switch for three seconds and the buzzer will sound two times briefly indicating the setting has been canceled.
1
DOWN
I9J011220056-03
1. PTT switch
6) Return the throttle to the fully closed position.
Setting Trim Down Position Limit
1) Press the “DOWN” side of the PTT switch so that the full trim down position is obtained.
2) Turn the ignition key to the “ON” position.
3) Pull out the emergency stop switch lock plate.
4) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in the “ON” position.)
5)
Top mount type:
Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time verifying the set mode is active.
Side mount type:
Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time verifying the set mode is active.
6) Press the “DOWN” side of the PTT switch three times within three seconds. The buzzer will sound one time briefly indicating the setting has been accepted.
7) With the throttle fully closed, install the lock plate on the emergency switch.
Press the “UP” side of the PTT switch to obtain the full tilt up position and then press the “DOWN” switch to obtain the full trim down position. Check that the positions are set.
I9J011220055-01
2B-12 Power Trim and Tilt:
Setting Tilt Up Limit Position
Z9J0112206012
If the outboard motor contacts the motor well of the boat during full tilt up operation, the upper limit setting should be reset. Perform this set-up after the current position setting has been canceled, as explained in the following procedure.
Canceling Tilt Up Position Limit Setting
1) Turn the ignition key to the “ON” position.
2) Pull out the emergency stop switch lock plate.
3) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in “ON” position.)
I9J011220057-01
4)
Top mount type:
Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.
“NEUTRAL” “NEUTRAL”
5) Press the “UP” side of the PTT switch for three seconds and the buzzer will sound twice briefly indicating the setting has been canceled.
UP
1
I9J011220059-02
1. PTT switch
6) Return the throttle to the fully closed position.
Setting Tilt Up Position Limit
1) Press the UP side of the PTT switch so that the optimum full tilt up position for the boat can be obtained.
2) Turn the ignition key to the “ON” position.
3) Pull out the emergency stop switch lock plate.
4) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in “ON” position.)
5)
Top mount type:
Using the throttle only function of the remote control box, move the control handle forward until the caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control box, move the warm-up lever upward until the caution buzzer sounds one time.
6) Press the “UP” side of PTT switch three times within three seconds.
The buzzer will sound one time briefly indicating the setting has been accepted.
7) Return the throttle to the fully closed position and install the lock plate on the emergency switch.
Operate the full tilt up and full trim down operations several times by pressing the PTT switch and check that the settings of both the trim down limit and tilt up limit is properly set.
I9J011220058-01
Power Trim and Tilt Unit Removal and
Installation
Z9J0112206004
Removal
1) Remove the lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Raise the engine to the full tilt up position and lower the manual tilt lock levers (1).
!
WARNING
During the following procedures, the engine must be firmly secured and its weight fully supported. (See below)
Power Trim and Tilt: 2B-13
3) Remove the tilt rod snap ring (2) and push the tilt cylinder upper shaft pin (3) out.
3
2
I9J011220062-01
4) Lower the tilt rod to the full down position and disconnect the battery cable.
1
I9J011220060-01
5) Remove the bolt (4) and cable clamp (5).
I9J011220063-01
I9J011220061-02
5
4
I9J011220064-01
2B-14 Power Trim and Tilt:
6) Disconnect the PTT motor cable wire connector from the PTT relay. Cut the cable tie binding PTT motor cable and trim sensor lead. Remove the PTT motor cable from engine lower cover.
9) Remove the PTT unit (9) and lower clamp bracket from between the clamp brackets.
9
I9J011220065-01
7) Remove two bolts and anode (6). Remove the screw securing bonding wire (7).
I9J011220069-01
10) Remove the snap ring (10) and push tilt cylinder lower shaft (11) out.
10
7
11
6
I9J011220066-01
8) Remove the four bolts (8) securing lower clamp bracket to STBD / PORT clamp brackets.
I9J011220070-01
11) Remove the PTT unit (12) from the lower clamp bracket (13).
12
13
8
I9J011220071-01
I9J011220067-01
8
I9J011220068-01
Installation
Installation is reverse order of removal with special attention to the following steps.
• Lower tilt rod to full down position.
• Apply water resistant grease to the tilt cylinder lower shaft and lower shaft bushings.
Install the lower shaft bushings (1) to PTT unit.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
Power Trim and Tilt: 2B-15
• Place the PTT unit (with lower clamp bracket) in position between the clamp brackets.
1 1
I9J011220072-01
• Fit the PTT unit (2) to the lower clamp bracket (3) as shown in figure and insert the tilt cylinder lower shaft
(4) through the lower clamp bracket and PTT unit.
Secure the tilt cylinder lower shaft with the snap rings
(5).
I9J011220075-01
• Tighten four lower clamp bracket bolts (6), pre-coated with thread lock, to specified torque.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
Tightening torque
Lower clamp bracket bolt (a): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
2
6
(a)
3
I9J011220076-01
4
I9J011220073-01
6
(a)
5
4
I9J011220077-01
I9J011220074-00
2B-16 Power Trim and Tilt:
• Install anode (7), then tighten bolts securely. Install bonding wire (8), then tighten screw securely.
• Apply water resistant grease to the PTT rod upper shaft (10), then insert the shaft through the swivel bracket and tilt rod.
Secure the upper shaft with the snap ring (11).
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
8
10
11
7
I9J011220078-01
• Apply water resistant grease to tilt rod upper bushings
(9), then install bushings 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.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
I9J011220080-01
• Route the PTT motor cable in through the lower cover and connect the PTT cable connector to the PTT relay.
Refer to “Wiring Harness Routing Diagram” in Section
9
9
I9J011220079-01
I9J011220081-01
• Final assembly check
Perform the following checks to ensure proper and safe operation of repaired unit:
– All parts removed have been returned to their original positions.
– Wire routing matchs service manual illustration.
Power Trim and Tilt Unit Components
Power Trim and Tilt: 2B-17
Z9J0112206005
5
1. Joint
2. Tank
3. Plug
4. O-ring
5. Bolt
6. Clamp
7. O-ring
6
7
8
1
(a)
2
4
3
9
10
8. Manifold assembly
9. Field case
10. O-ring
11. Armature
12. Brush set
13. Breaker assembly
14. Spring
21
22
20
19
18
23
24
15. Brush holder
16. Screw
17. Oil seal
18. Drive joint
19. Filter
20. O-ring
21. O-ring
26
11
14
13
12
14
15
16
17
25
I9J011220009-03
22. Pump assembly
23. Bolt
24. Bolt
25. Bolt
26. Manual valve
: 108 N
⋅ m (10.8 kgf-m, 78.0 lbf-ft)
: Apply thread lock to the thread area.
2B-18 Power Trim and Tilt:
Power Trim and Tilt Unit Disassembly
Z9J0112206006
NOTE
Before disassembly, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt. Dry the PTT body with compressed air.
1) Place the lower section 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.
4) Remove the manual release valve snap ring (1), then unscrew the manual release valve (2).
2
1
2
I9J011220012-01
5) Remove the PTT motor assembly (3).
Refer to “Power Trim and Tilt Motor Removal and
Note the position of drive joint (4) and O-ring (5), before removing them.
I9J011220010-02
2) Connect the PTT cable extension to PTT motor cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
3) Connect the PTT cable extension leads (G, Bl) to battery and operate PTT motor until tilt rod is at maximum stroke (full-tilt up position). Unscrew the filler plug and drain PTT oil into a suitable container.
3
5
4
I9J011220013-01
6) Remove the three screws securing the PTT pump assembly (6), then detach the PTT pump assembly from PTT cylinder body.
Note the position of O-rings (7), before removing them.
7
(A)
6
I9J011220014-01
I9J011220011-01
7) Using special tool, unscrew the upper eye (8).
Special tool
(B): 09945–69010 (PTT rod holder)
8
(B)
I9J011220016-01
8) Remove the four bolts securing the reservoir (9), then detach the reservoir from the PTT body.
9) Remove the O-ring (10).
Power Trim and Tilt: 2B-19
Power Trim and Tilt Unit Reassembly
Z9J0112206007
Assembly is reverse order of disassembly with special attention to following steps.
CAUTION
• Do not reuse O-rings and seals once removed.
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
• Do not reuse PTT fluid, always refill with new fluid.
Reservoir
• Apply PTT fluid to reservoir seal, then install reservoir.
• Tighten four bolts securely.
Tightening torque
Reservoir bolt (a): 5.0 N·m (0.5 kgf-m, 3.6 lbf-ft)
9
10
I9J011220015-01
I9J011220017-01
(a)
I9J011220018-01
Upper Eye
• Apply thread lock super 1333B to threads of upper eye before threading it onto tilt rod.
: Thread lock cement 99000–32020 (SUZUKI
Thread Lock Super 1333B (50 g))
• Tighten upper eye to specified torque.
Tightening torque
Upper eye (a): 108 N·m (10.8 kgf-m, 78.0 lbf-ft)
Special tool
(A): 09945–69010 (PTT rod holder)
(a)
(A)
I9J011220019-01
2B-20 Power Trim and Tilt:
PTT Pump Assembly
• Install four O-rings (1) to PTT body assembly.
NOTE
Lubricate O-rings with PTT fluid before installing.
• Install PTT pump assembly, then tighten three screws
(a) (b) to specified torque.
Tightening torque
PTT pump assembly bolt (a): 8.0 N·m (0.8 kgf-m,
5.8 lbf-ft)
PTT pump assembly bolt (b): 5.5 N·m (0.55 kgfm, 4.0 lbf-ft)
PTT Motor
• Install the PTT motor.
Refer to “Power Trim and Tilt Motor Removal and
PTT Fluid
• Pour recommended PTT fluid into reservoir to specified level.
Refer to “Checking PTT Fluid Level” (Page 2B-10).
Air Bleeding
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 fluid to the specified level, then install oil filler plug.
1
(a) (a)
(b)
I9J011220020-01
Manual Release Valve
• Oil and install the manual release valve (1).
Tighten the valve to specified torque.
• Install snap ring (2).
Tightening torque
Manual release valve (a): 3.6 N·m (0.36 kgf-m, 2.6 lbf-ft)
1
1
(a)
I9J011220022-01
3) Tighten the manual release valve to the specified torque.
4) Connect the PTT cable extension to the PTT motor cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
5) Connect the two extension cable lead wires (Bl to positive / G to negative) to the battery as shown in the illustration.
Operate the PTT motor until the PTT rod is in the fully trimmed down position (completely retracted).
If the rod does not come down completely, push it in by hand while operating the motor.
2
I9J011220021-01
(A)
I9J011220023-01
6) Reverse the two extension cable lead wires (G to positive / Bl to negative).
Operate the PTT motor until the PTT rod is in the full tilt up position (fully extended).
If the rod does not come up completely, pull it up by hand while operating the motor.
Power Trim and Tilt: 2B-21
• Inspect PTT pump assembly for cracks, nicks, stripped threads and any other imperfections.
Replace if necessary.
(A)
I9J011220024-01
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 level.
NOTE
Repeat the air bleeding procedure after the
PTT unit has been installed on the outboard
motor. Refer to “Air Bleeding from PTT Unit”
Power Trim and Tilt Unit Components Cleaning and Inspecting
Z9J0112206008
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.
• If excessive wear, cracks, defective or other damage is found on any component, replace component.
I9J011220025-01
• Inspect reservoir for cracks, nicks or damage.
Replace if necessary.
• Inspect reservoir seal for cuts, nicks or wear.
• Inspect all O-rings for cuts, nicks or tears.
I9J011220026-01
I9J011220027-01
2B-22 Power Trim and Tilt:
• Inspect manual release valve for damage. Replace if necessary.
• Inspect O-rings for cuts, nicks or tears.
2) Place the lower section 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.
I9J011220028-01
• Inspect lower shaft and upper shaft for bends, twists 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.
• Inspect upper and lower shaft for bent, twist or other damage. Replace if necessary.
I9J011220029-02
3) Remove the four screws securing the PTT motor (1) to the PTT pump assembly.
1
I9J011220082-01
Power Trim and Tilt Motor Removal and
Installation
Z9J0112206009
Removal
1) Remove Power Trim and Tilt unit.
Refer to “Power Trim and Tilt Unit Removal and
NOTE
Before removing PTT motor, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt. Dry the PTT body with compressed air.
I9J011220030-02
4) Detach the PTT motor from PTT pump assembly.
Note the position of drive joint (2) and O-ring (3) and remove them.
3
2
I9J011220031-01
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.
2
Power Trim and Tilt: 2B-23
Power Trim and Tilt Motor Disassembly and
Assembly
Z9J0112206010
Disassembly
1) For correct assembly, scribe an alignment mark on the field case and brush holder.
2) Slide cable protector tube upward.
3) Remove the screw securing the motor cable holder
(1), then slide motor cable holder and grommets (2) out as shown in figure.
2
1
4
1
3
I9J011220032-02
• Check the level of PTT fluid contained in the PTT pump assembly. 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 pump assembly (3), ensure that the tip of armature shaft (4) fits firmly into the drive joint (1).
• Tighten the four screws (a) to specified torque.
Tightening torque
PTT motor screw (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft)
1
I9J011220034-01
4) Remove the two screws (3) securing the field case to the brush holder.
3
(a) (a)
I9J011220033-02
• Pour recommended PTT fluid into reservoir until specified level.
• Perform the air bleeding procedure.
Refer to “Power Trim and Tilt Unit Reassembly”
I9J011220035-01
5) 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.
I9J011220036-01
2B-24 Power Trim and Tilt:
6) Disconnect PTT motor cables from brush holder.
Remove armature from field case. Note the position of the O-ring encircling the brush holder.
PTT Motor Related Items Inspection
Z9J0112206011
Armature and Commutator
• Check for continuity between the commutator and the armature core / shaft. Replace armature if continuity is indicated.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
I9J011220037-01
Assembly
Assembly is reverse of disassembly with special attention to following steps.
• Install O-ring (1).
• Install armature (2) to brush holder first. When installing the armature, use care to avoid breaking the brushes.
2
1
(A)
I9J011220040-01
• Check continuity between adjacent commutator segments.
Replace armature if no continuity is indicated.
(A)
I9J011220038-01
• Match up previously scribed alignment marks.
• When assembling field case to brush holder, pull out on the PTT motor cables as the field case is assembled into position.
• Apply silicone seal to PTT motor cable holder and grommets and install cable holder screw.
: Sealant 99000–31120 (SUZUKI Silicone
Seal (50 g))
I9J011220041-01
• Inspect the commutator surface.
If surface is gummy or dirty, clean with 400 grit emery paper (1).
• Measure commutator outside diameter.
If measurement exceeds service limit, replace armature.
Special tool
(B): 09900–20101 (Vernier calipers (150 mm))
Commutator outside diameter
Standard: 22.0 mm (0.87 in)
Service limit: 21.0 mm (0.83 in)
I9J011220039-01
Power Trim and Tilt: 2B-25
O-ring
• Inspect the O-ring between the PTT motor and PTT pump assembly. Replace if cuts, nicks or tears are found.
1
(B)
I9J011220042-01
• Ensure that the mica (insulator) between commutator segments are undercut “a” to specified depth.
If undercut is less than service limit, cut to specified depth.
!
WARNING
Wear safety glasses when using compressed air.
NOTE
Remove all particles of mica and metal using compressed air.
Commutator undercut
Standard: 1.6 – 1.9 mm (0.06 – 0.07 in.)
Service limit: 1.0 mm (0.04 in.)
“A”
I9J011220045-01
PTT Motor Relay Inspection
Z9J0112206013
1) Remove the PTT motor relay from the electric parts holder.
Refer to “Electric Parts Holder Removal and
Installation” in Section 1D (Page 1D-5).
2) Check the resistance between each two lead wires.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Resistance (
Ω
)
PTT relay coil resistance
Between “P” wire and “B” wire: 25 – 37
Ω
Between “Lbl” wire and “B” wire: 25 – 37
Ω
“ a ”
“B”
I9J011220043-01
“A”: Segment “B”: Mica
Brushes
• Check the length of each brush.
If brushes are worn down to the service limit, they must be replaced.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Brush length
Standard: 9.8 mm (0.39 in.)
Service limit: 5.5 mm (0.22 in.)
B
Lbl
P
R
Bl
G
(A)
I9J011220046-01
(A)
I9J011220044-01
2B-26 Power Trim and Tilt:
3) Connect the “R” (red) wire to positive (+) terminal, and the “B” (black) wire to negative (–) terminal of a
12 V battery.
CAUTION
Each operation test must be performed within 3 to 5 seconds to avoid overheat damage to the relay coil.
4) Temporarily connect a jumper wire (1) from the “P” lead wire to the battery positive (+) terminal, then check the voltage between the “G” wire and the “B” wire.
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Voltage ( )
Voltage between “G” wire and “B” wire
12 V (Battery voltage)
PTT Switch Inspection
Z9J0112206014
Test continuity between the switch lead wires at each of the three switch positions.
If out of specification, replace PTT switch.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Tester probe connection
Red (+) Black (–)
DN side depressed
UP side depressed
Not depressed
Terminal (2)
Terminal (3)
Tester indicates
Terminal (2) Terminal (1) Continuity
Terminal (3) Terminal (1) Continuity
Terminal (1) Infinity
2
(P)
1
(W/R)
3
(Lbl)
1 (Lg)
I9J011220048-02
3 (Lbl)
2 (R)
B
Lbl
P
R
1
BATT.
12 V
Bl
G
(A)
I9J011220047-01
5) Temporarily connect a jumper wire from the “Lbl” lead wire to the battery positive (+) terminal, then check the voltage between the “Bl” wire and the “B” wire.
Voltage between “Bl” wire and “B” wire
12 V (Battery voltage)
6) If inspection in step 2 and/or step 4, 5 fails, replace
PTT motor relay.
7) Install the PTT motor relay to the electric parts holder.
Refer to “Electric Parts Holder Removal and
Installation” in Section 1D (Page 1D-5).
I9J011220049-03
Table of Contents 3- i
Section 3
Lower Unit
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
General Precautions ............................................. 3-1
Precaution for Lower Unit ..................................... 3-1
Right Hand Rotation Unit........................ 3A-1
Diagnostic Information and Procedures............3A-1
Diagnose Lower Unit Malfunction ....................... 3A-1
Service Instructions.............................................3A-2
Lower Unit Components ..................................... 3A-2
Propeller Removal and Installation ..................... 3A-4
Propeller / Nut / Cotter Pin Inspection................. 3A-5
Lower Unit Removal and Installation...................3A-5
Water Pump Removal and Installation................3A-6
Water Pump and Related Items Inspection.........3A-8
Lower Unit Disassembly......................................3A-8
Pinion Bearing Removal and Installation ..........3A-11
Lower Unit Related Items Inspection ................3A-12
Propeller Shaft Oil Seal Replacement...............3A-15
Driveshaft Oil Seal Replacement ......................3A-16
Lower Unit Assembly ........................................3A-16
Trim Tab Adjustment.........................................3A-23
Lower Unit Gears - Shimming and Adjustment ..3A-24
3
3-1 Precautions:
Lower Unit
Precautions
Precautions
General Precautions
Refer to “General Precautions” in Section 00 (Page 00-1).
Z9J0113000001
Precaution for Lower Unit
!
WARNING
Z9J0113000002
• When installing or removing the propeller, shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally.
• Wear safety glasses if using compressed air.
CAUTION
• When draining lower unit gear oil, check the following points.
– Water ingress (white, milky appearance)
– Overheating or burning (black appearance, charred smell)
– Metal filings or deposits
• If reassembling with original components and gears, do not omit or add any shims or thrust washers.
NOTE
To simplify reassembly and to prevent confusion, note the positions and quantities of all shims and thrust washers. Retain these items next to the gears or bearings to which they belong.
Right Hand Rotation Unit: 3A-1
Lower Unit
Right Hand Rotation Unit
Diagnostic Information and Procedures
Diagnose Lower Unit Malfunction
Z9J0113104001
Trouble Check Chart
Condition
Engine stalls when engaging gear
Engaging gear(s) has no effect on propulsion
Possible cause
Idling speed set too low.
Propeller shaft bearings damaged, lacking lubrication or seized.
Correction / Reference Item
Adjustment.
Replace.
Clutch out of adjustment.
Adjustment.
Driveshaft broken or splines damaged.
Replace.
Chipped or worn dog clutches.
Propeller not secured correctly (fallen
Replace.
Inspection or retighten.
Loss of power. (Assuming engine is OK)
off).
Propeller bush slipping.
Bent or worn propeller.
Engine shakes the boat
Failed propeller bush.
Bent driveshaft or propeller shaft.
Damaged propeller.
Clutch will not engage or disengage
Replace.
Repair or replace.
Replace.
Replace.
Seized shift rod.
Clutch shaft and clutch rod have
Replace.
Inspection.
Inspection.
become detached.
Seized / broken remote control cable.
Replace.
Problem at control box end.
Inspection or replace.
3A-2 Right Hand Rotation Unit:
Service Instructions
Lower Unit Components
10
1. Cover
2. Bolt
3. Shift rod guide housing
4. O-ring
5. Oil seal
6. E-ring
7. Shift rod
8. Magnet
9. Shifter yoke
10. Nipple
11. Dowel pin
Z9J0113106001
28
(d)
2
7
1
3
4
5
6
31
29
30
30
32
33
34
35
37
36
9
6
8
6
13
12
11
14
19
11
18
(a)
16
17
15
22
21
20
26
19
18
(a)
25
(b)
23 24
12. Exhaust tube housing seal
13. Exhaust seal plate
14. Gearcase
15. Trim tab
16. Washer
17. Bolt
18. Plug
19. Gasket
20. Anode
21. Bolt
22. Water filter STBD
23. Water filter PORT
24. Screw
25. Bolt
26. Washer
27. Bolt
28. Bolt
29. Water pump case
30. Dowel pin
31. Case sealing
32. Inner sleeve
33. Key
27
(c)
25
26
(b)
I9J011310019-07
34. Water pump impeller
35. Under panel
36. Gasket
37. Bush
: 10 N
⋅ m (1.1 kgf-m, 7.2 lbf-ft)
: 55 N
⋅ m (5.5 kgf-m, 40 lbf-ft)
: 55 N
⋅ m (5.5 kgf-m, 40 lbf-ft)
: 17 N
⋅ m (1.7 kgf-m, 12.3 lbf-ft)
: Apply SUZUKI Water Resistant Grease.
: Apply SUZUKI Silicon seal.
Right Hand Rotation Unit: 3A-3
1
7
8
9
10
10
11
12
38
39
40
44
41
42
43
(c)
2
6
(a)
3
4
5
30
32
33
(b)
35
35
32
33
34
(b)
36
37
31
28
1. Driveshaft
2. Pin
3. Driveshaft collar
4. Pinion bearing
5. Pinion gear
6. Pinion nut
7. Bolt
8. Driveshaft oil seal housing
9. O-ring
10. Oil seal
11. Shim
12. Driveshaft bearing
13. Shim
29
16
27
26
25
15
24
14. Forward gear bearing
15. Bearing
16. Forward gear
17. Thrust washer
18. Connector pin
19. Small detent ball
20. Large detent ball
21. Spring
22. Dog spring
23. Clutch dog shifter
24. Dog pin
25. Propeller shaft
26. Thrust washer
13
14
19
20
20
17
19
18
21
22
23
27. Reverse gear
28. Shim
29. Bearing
30. O-ring
31. Propeller shaft bearing housing
32. Washer
33. Bolt
34. Bearing
35. Oil seal
36. Protector
37. Ring
38. Stopper
39. Propeller
I9J011310020-03
40. Propeller bush
41. Spacer
42. Washer
43. Nut
44. Pin
: 120 N
⋅ m (12 kgf-m, 86.8 lbf-ft)
: 23 N
⋅ m (2.3 kgf-m, 16.6 lbf-ft)
: 55 N
⋅ m (5.5 kgf-m, 40 lbf-ft)
: Apply SUZUKI Water Resistant Grease.
: Apply SUZUKI Outboard Motor Gear Oil.
: Apply SUZUKI Thread Lock 1342.
3A-4 Right Hand Rotation Unit:
Propeller Removal and Installation
!
WARNING
Z9J0113106002
• When installing or removing the propeller, shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally.
• 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 before attempting to remove or install propeller nut.
Removal
1) Shift to “Neutral” position.
2) Remove cotter pin (1) from propeller nut and remove propeller nut (2).
3) Remove washer (3), spacer (4), propeller (5) and stopper (6) from the propeller shaft.
Installation
1) Coat the propeller shaft splines liberally with Suzuki water resistant grease.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
2) Install propeller stopper (1) onto propeller shaft, then slide on the propeller (2).
3) Fit spacer (3), washer (4) and nut (5), then tighten nut to specified torque.
4) Push cotter pin (6) through nut and shaft, then bend to secure.
Tightening torque
Propeller nut (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
3
2
1
4
5
6
I9J011310017-01
6
5
4
I9J011310001-01
3
2
1
I9J011310002-02
(a)
I9J011310003-04
Propeller / Nut / Cotter Pin Inspection
Z9J0113106010
Refer to “Propeller / Propeller Nut and Cotter Pin
Inspection” in Section 0B (Page 0B-16).
Lower Unit Removal and Installation
Removal
Z9J0113106020
!
WARNING
Always disconnect the battery cable, before removing lower unit.
1) Shift to “Neutral” position. Remove bolt and trim tab
(1) (if necessary).
Right Hand Rotation Unit: 3A-5
Installation
1) Ensure that shift rod (1) is at “Neutral” position.
NOTE
Before installing lower unit assembly, bring shift to Neutral position by turning shift rod right or left.
1
1
I9J011310021-01
2) Remove five bolts (2) and separate gearcase (3) from driveshaft housing.
NOTE
Before gearcase is removed completely, disconnect speedometer pick up tube (4) from gearcase.
I9J011310024-01
2) Insert two dowel pins (2).
3) Apply water resistant grease to driveshaft and shift rod splines.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
4) Apply a light coating of suzuki silicone seal to mating surfaces of gearcase and driveshaft housing.
: Sealant 99000–31120 (SUZUKI Silicone
Seal (50 g))
2
2
3
2
I9J011310025-01
I9J011310022-01
4
I9J011310023-01
3A-6 Right Hand Rotation Unit:
5) Set the clutch control lever (3) at “Neutral” position, then slide the lower unit (4) into place, ensuring that the top of driveshaft engages properly with driven gear shaft and that water tube locates in water pump case outlet.
NOTE
In order for shift rod and clutch rod splines to be aligned correctly, clutch rod may need to be turned slightly right or left.
Water Pump Removal and Installation
Z9J0113106012
Removal
1) Remove the lower unit. Refer to “Lower Unit
Removal and Installation” (Page 3A-5).
2) Loosen four bolts (1), then remove water pump case
(2).
1
N
2
3
I9J011310026-01
6) Apply suzuki silicone seal to five gearcase bolts and tighten them to specified torque.
: Sealant 99000–31120 (SUZUKI Silicone
Seal (50 g))
Tightening torque
Gearcase bolt (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
I9J011310028-01
3) Remove impeller (3), impeller key (4), pump under plate (5) and dowel pins (6).
Keep impeller key (4) for reuse and discard the plate gasket.
(a)
4
3
6
4
6
5
I9J011310029-01
NOTE
To facilitate the removal of inner sleeve from pump case, warm up the entire case using a heater like hair dryer.
4) Remove inner sleeve (7) and rubber seal ring (8).
I9J011310027-01
7) Shift the clutch control lever to “Forward” and
“Reverse” position from “Neutral” position to check proper gear engagement.
8
7
I9J011310030-01
Installation
1) Place the dowel pins (1), under panel gasket (2) and under panel (3) into position.
2) Insert the key (4) in the driveshaft and slide the impeller (5) onto driveshaft, ensuring that key and keyway is aligned.
Right Hand Rotation Unit: 3A-7
8
5
1
4
3
2
1
I9J011310031-01
3) Place the seal ring (7) into groove of the pump case
(6).
CAUTION
Do not reuse seal ring once removed.
Always use new ring.
I9J011310033-01
NOTE
Before installing water pump case assembly, apply water resistant grease lightly on pump case inner sleeve and under panel for initial lubrication.
7
6
I9J011310032-01
NOTE
Before installing pump inner sleeve, apply water resistant grease lightly between inner sleeve and pump case mating surfaces.
4) Install inner sleeve (8) into the pump case, ensuring that projection of inner sleeve and groove of pump case are aligned.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
I9J011310034-01
5) Install the pump case assembly (9) while rotating driveshaft clockwise to flex the impeller vanes in the correct direction.
Securely tighten the four pump case bolts (10) to the specified torque.
Tightening torque
Water pump case bolt (a): 17 N·m (1.7 kgf-m,
12.3 lbf-ft)
10
(a)
9
I9J011310035-01
3A-8 Right Hand Rotation Unit:
6) Install the Lower Unit. Refer to “Lower Unit Removal and Installation” (Page 3A-5).
Water Pump and Related Items Inspection
Z9J0113106021
Inspect the following parts.
• Inspect impeller. Replace if vanes are cut, torn, worn or other abnormal conditions.
• Inspect pump case. Replace if cracked, distorted or other abnormal conditions are noted.
• Inspect pump inner sleeve. Replace if worn, cracked, distorted, corroded or other abnormal conditions are noted.
• Inspect under panel. Replace if cracked, distorted, corroded or other abnormal conditions are noted.
CAUTION
Do not reuse seal ring once removed.
Always use new ring.
4) Place a drain pan under oil drain plug. Remove oil drain plug (1) first then oil level plug (2) and allow gear oil to drain.
Inspect oil for water, contaminates or metal.
2
1
I9J011310038-01
5) Remove the exhaust tube housing seal (3) and seal plate (4).
3
4
I9J011310036-01
I9J011310039-01
6) Remove the bolt (5) and shift rod guide housing assembly (6).
6
I9J011310037-01
Lower Unit Disassembly
Z9J0113106022
1) Remove the lower unit. Refer to “Lower Unit
Removal and Installation” (Page 3A-5).
2) Remove the propeller. Refer to “Propeller Removal and Installation” (Page 3A-4).
3) Remove the water pump and related parts. Refer to
“Lower Unit Removal and Installation” (Page 3A-5)
and “Water Pump Removal and Installation”
5
I9J011310040-01
7) Remove two bolts (7) securing the propeller shaft bearing housing to the gearcase.
7
7
I9J011310041-01
Right Hand Rotation Unit: 3A-9
8) Using special tools, pull out the propeller shaft bearing housing.
Remove the propeller shaft and bearing housing assembly (8).
Special tool
(A): 09930–30104 (Sliding hammer)
(B): 09930–30161 (Propeller shaft remover)
11
(A)
I9J011310046-01
12) Remove the pin (12) and driveshaft collar (13) from driveshaft (if necessary).
(B)
8
I9J011310042-01
9) Hold the pinion nut securely, then fit special tool to the driveshaft and loosen the pinion nut. Remove pinion nut (9).
Special tool
(C): 09921–28710 (Driveshaft holder)
(C)
12
13
I9J011310045-01
13) Remove the pinion gear (14).
Remove the forward gear (15) (with thrust washer
(16)).
Remove the forward gear bearing outer race (17) and back-up shim (18).
9
I9J011310043-01
10) Remove the four bolts securing driveshaft oil seal housing (10), then remove oil seal housing and pinion shim.
14
I9J011310047-01
11) Lift out driveshaft assembly (11).
10
I9J011310044-01
18 17 15 16
I9J011310048-01
3A-10 Right Hand Rotation Unit:
14) To disassemble propeller shaft components, refer to following.
a) Slide propeller shaft away from reverse gear (19) and bearing housing assembly (20).
Account for the reverse gear back-up shim (21) and reverse gear thrust washer (22).
d) Remove clutch dog shifter (24) and connector pin (25) from propeller shaft.
25
22
21
19
20
I9J011310049-01 b) Remove spring (23) from clutch dog shifter (24).
24
I9J011310052-01 e) Remove large detent ball (26), detent spring
(27), large detent ball (28) and two small detent balls (29) from connector pin (25).
26
25
24
23
I9J011310050-01 c) Use special tool to push the dog pin (25) out of the clutch dog shifter.
Special tool
(D): 09922–89810 (Shift lock pin remover)
27
28
29
I9J011310053-01
15) To disassemble shift rod components, refer to following.
a) Remove oil seal cover (30).
b) Slide shift rod (31) out of shift rod guide housing
(32).
25
(D)
31
30
32
I9J011310054-01
I9J011310051-01
c) Remove E-ring (33) and shifter yoke (34).
34
Right Hand Rotation Unit: 3A-11
Removal
1) Disassemble the lower unit. Refer to “Lower Unit
2) Place the attachment (D) inside the pinion bearing.
3) Insert the removal shaft (A) into attachment (D).
4) Thread sliding hammer (E) into top of removal shaft
(A).
5) Put wood block under pinion bearing.
6) Drive the pinion bearing out downwards by striking top of shaft (A) with sliding hammer (E).
33
I9J011310055-01
Pinion Bearing Removal and Installation
Z9J0113106023
CAUTION
• When removing the pinion bearing, use care to avoid damaging the gearcase.
• Do not reuse pinion bearing once removed. Always use a new pinion bearing.
Removal and Installation Tools
To remove the pinion bearing from the gearcase, use the following special tools.
Special tool
(A): 09951–59910 (Shaft (removal and installation))
(B): 09951–38710 (Plate)
(C): 01500–08403 (Bolt)
(D): 09951–18730 (Attachment)
(E): 09930–30104 (Sliding hammer)
(B)
(E)
(A)
1
(E)
(A)
(D)
2
I9J011310005-03
1. Pinion bearing 2. Wood block
Installation
CAUTION
• Before installing bearing, ensure that inside of gearcase is clean and free of debris.
• Ensure that the bearing stamped mark faces upward.
1) Set the installer shaft (A), plate (B), attachment (D) and pinion bearing as shown in the figure.
(C)
(D)
I9J011310018-03
3A-12 Right Hand Rotation Unit:
2) Place the installer shaft (A) (with pinion bearing on end of installer shaft) into the gearcase.
3) Secure the plate (B) by tightening the bolt (C).
4) Thread the sliding hammer (E) into the top of the installer shaft (A).
5) Drive the pinion bearing down into position by gently striking the installer shaft (A) until the coupler touches plate.
6) Assemble the lower unit. Refer to “Lower Unit
(A)
(E)
(B)
(C)
I9J011310056-01
Lower Unit Related Items Inspection
Z9J0113106024
!
WARNING
Wear safety glasses when using compressed air.
NOTE
• If any component is worn excessively, cracked, defective or damaged in any way, it must be replaced.
• Thoroughly wash all metal components with cleaning solvent and dry with compressed air.
Gearcase
• Inspect the gearcase. Replace if cracked, damaged or other abnormal conditions are noted.
• Visually check the pinion bearing. Replace bearing if pitted, rough or other abnormal conditions are noted.
NOTE
For the removal and installation of pinion bearing, refer to Pinion bearing removal and installation.
(E)
(A)
(C)
(B)
(D)
1
1. Pinion bearing
I9J011310006-04
I9J011310057-01
Gears / Bearing
• Inspect forward, reverse and pinion gear teeth and engaging dogs.
Replace gears if damaged worn or other abnormal conditions are noted.
• Inspect propeller shaft forward bearing, forward gear bearing.
Replace bearing if pitted, noisy, rough or other abnormal conditions are noted.
Right Hand Rotation Unit: 3A-13
• Inspect dog pin. Replace if bent, worn or other abnormal conditions are noted.
• Inspect propeller shaft / splines. Replace if worn, twisted, damaged or other abnormal conditions are noted.
I9J011310060-01
I9J011310058-01
I9J011310059-01
Propeller Shaft Components
• Inspect connector pin. Replace if worn, damaged or other abnormal conditions are noted.
• Inspect detent balls. Replace if wear, damage or other abnormal conditions are noted.
• Inspect clutch dog shifter. Replace if chipped, worn, damaged or other abnormal conditions are noted.
I9J011310061-01
• Check detent spring by measuring its free length. If free length is not within specifications, replace detent spring.
Detent spring free length “a”
Standard: 24.8 mm (0.98 in.)
Service limit: 24 mm (0.94 in.)
“ a ”
I9J011310062-01
3A-14 Right Hand Rotation Unit:
Propeller Shaft Bearing Housing
• Inspect housing. Replace if cracked, damaged or other abnormal conditions are noted.
• Inspect reverse gear bearing and propeller shaft bearing. Replace bearing if pitted, noisy, rough or other abnormal conditions are noted.
• Check condition of oil seal and O-ring. Replace oil seal and O-ring if nicked, cut, worn or other abnormal conditions are noted.
• Inspect oil seal and oil seal cover. Replace if nicked, cut, worn or other abnormal conditions are noted.
I9J011310065-01
I9J011310063-01
I9J011310064-01
Shift Rod Guide Housing Components
• Inspect shift rod guide housing.
Replace if cracked, damaged or other abnormal conditions are noted.
• Inspect shifter yoke. Replace if worn, damaged or other abnormal conditions are noted.
• Inspect shift rod / splines. Replace if worn, twisted, damaged or other abnormal conditions are noted.
• Inspect O-ring. Replace if nicked, cut, torn, swollen or other abnormal conditions are noted.
I9J011310066-01
Driveshaft Oil Seal Housing
• Inspect housing. Replace if cracked, damaged or other abnormal conditions are noted.
• Check condition of oil seals. Replace if nicked, cut, worn or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other abnormal conditions are noted.
I9J011310067-01
Driveshaft
• Inspect driveshaft / splines. Replace if worn, twisted, damaged or other abnormal conditions are noted.
• Inspect driveshaft bearing, replace if pitted, noisy, rough or other abnormal conditions are noted.
Right Hand Rotation Unit: 3A-15
3) Extract seals (3) with oil seal remover.
CAUTION
Do not reuse oil seal once removed.
Always use new oil seal.
Special tool
(A): 09913–50121 (Oil seal remover)
(A)
I9J011310068-01
I9J011310069-01
Propeller Shaft Oil Seal Replacement
Z9J0113106025
1) Remove the propeller shaft bearing housing. Refer
to “Lower Unit Disassembly” (Page 3A-8).
2) Remove retaining ring (1) and washer (2).
1
4) Apply water resistant grease to the inner circumference of the housing.
I9J011310071-01
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
5) Using an oil seal installer, drive the two oil seals (one at a time) into the propeller shaft bearing housing.
The lipped portion of the seal must face towards the propeller. Apply water resistant grease to the seal lips.
2
I9J011310070-02
I9J011310072-02
6) Install the washer and retaining ring.
7) Assemble the propeller shaft bearing housing. Refer
to “Lower Unit Assembly” (Page 3A-16).
3A-16 Right Hand Rotation Unit:
Driveshaft Oil Seal Replacement
Z9J0113106026
1) Remove the driveshaft oil seal housing. Refer to
“Lower Unit Disassembly” (Page 3A-8).
2) Using special tool, remove two oil seals out of the driveshaft oil seal housing.
Special tool
(A): 09913–50121 (Oil seal remover)
(A)
I9J011310073-01
3) Apply water resistant grease to inner circumference of driveshaft oil seal housing.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
4) Grease the inner lips of oil seal.
With the lips facing away from driveshaft bearing, place seal in position and drive it into the oil seal housing.
Lower Unit Assembly
Z9J0113106027
Assembly is in reverse order of disassembly with special attention to the following steps.
CAUTION
• Make sure that all parts used in assembly are clean and lubricated.
• It is recommended that all seals, gaskets and O-rings be replaced with new on assembly.
• After assembly, check parts for tightness and smoothness of operation.
• Before final assembly, be absolutely certain that all gear contact, shim adjustments and tolerances are correct.
Failure to correctly adjust these areas will result in lower unit damage. Refer to
“Lower Unit Gears - Shimming and
Forward Gear
Place the forward gear back-up shim (1), forward gear bearing outer race (2) in position, then install forward gear (3) with forward gear bearing (4).
2
1
I9J011310075-01
Direction of water pump case
I9J011310074-02
5) Assemble the driveshaft oil seal housing. Refer to
“Lower Unit Assembly” (Page 3A-16).
4
3
I9J011310076-01
Pinion Gear
Place pinion gear (1) in gearcase.
Right Hand Rotation Unit: 3A-17
• Install the bearing outer race (4) and pinion shim (5) to driveshaft.
5
4
1
I9J011310077-01
Driveshaft
• Assemble the driveshaft collar (1) to driveshaft.
• Install the pin (2).
I9J011310080-01
Driveshaft Oil Seal Housing
• Apply water resistant grease to the driveshaft oil seal.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
• Apply water resistant grease to O-ring (1), then install
O-ring into groove on the driveshaft oil seal housing
(2).
2
1
2
I9J011310078-01
• Lower the driveshaft assembly (3) down into the gearcase until the bottom of shaft protrudes through center of pinion.
1
I9J011310081-01
• Install the driveshaft oil seal housing on the gearcase, then tighten four bolts (3) securely.
3
I9J011310079-01
3
I9J011310082-01
3A-18 Right Hand Rotation Unit:
Pinion Nut
• Apply thread lock 1342 to the threads of pinion nut (1) before threading it onto driveshaft.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
• Tighten pinion nut to specified torque.
NOTE
It is recommended the original pinion nut be used for the purposes of shimming during repair. A new pinion nut should be used on final assembly.
Special tool
(A): 09921–28710 (Driveshaft holder)
Tightening torque
Pinion nut (a): 120 N·m (12.0 kgf-m, 86.8 lbf-ft)
Checking Driveshaft Thrust Play
Before installing reverse gear, driveshaft thrust play
should checked. Refer to “Lower Unit Gears - Shimming and Adjustment” (Page 3A-24).
Special tool
(A): 09951–09530 (Gear adjusting gauge)
(A)
(A)
I9J011310085-01
Propeller Shaft
• Slide the clutch dog shifter (2) onto the propeller shaft
(1).
NOTE
The side of the clutch dog shifter marked with the letter “R” must face towards reverse gear.
I9J011310083-02
“R”
2
1
1
(a)
I9J011310084-02
I9J011310086-01
• Insert two small detent balls (3), large detent ball (4), detent spring (5) and large detent ball (6) into connector pin (7). Then depress detent ball (6) and temporarily insert stopper pin “a” into dog pin hole of connector pin, as shown in figure.
Right Hand Rotation Unit: 3A-19
• Install the dog pin retaining spring (9), ensuring that it fits snugly into the groove on the dog shifter.
7
7
8
3
1
I9J011310089-01
6 5 4
I9J011310087-01
NOTE
Temporarily insert a water pump case dowel pin into the connector pin to prevent the detent ball from falling out.
“ a ”
I9J011310088-01
• Insert the connector pin (7) (with detent balls) into propeller shaft (1).
• Align the holes in the shifter dog and connector pin and then slide the dog pin (8) through both dog and connector pin. (save the temporarily installed dowel pin pushed out as the dog pin is inserted.)
9
I9J011310090-01
Propeller Shaft / Bearing Housing
• Place the forward thrust washer (1) and reverse thrust washer (2) on the propeller shaft.
• Install back-up shim (3) and reverse gear (4) to propeller shaft bearing housing (5).
• Slide propeller shaft into reverse gear and propeller shaft bearing housing.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
: Gear Oil 99000–22540 (SUZUKI Outboard
Motor Gear Oil)
5
1
2
4
3
I9J011310091-02
3A-20 Right Hand Rotation Unit:
• Apply water resistant grease to the bearing housing
O-ring (6).
Rechecking Driveshaft Thrust Play
Recheck the driveshaft thrust play. This should not be less than previously checked. If less, reduce the number
/ thickness of the reverse gear back-up shims. Refer to
“Lower Unit Gears - Shimming and Adjustment”
Special tool
(A): 09951–09530 (Gear adjusting gauge)
6
I9J011310092-01
NOTE
Before installing the propeller shaft / bearing housing assembly, move the shifter dog to bring the connector pin to the “Neutral” position.
• Install the propeller shaft and housing assembly in the gearcase.
• When the housing is fully seated, tighten both retaining bolts to the specified torque.
Tightening torque
Bearing housing bolt (a): 23 N·m (2.3 kgf-m, 16.6 lbf-ft)
(A)
I9J011310085-01
Checking Propeller Shaft Thrust Play
Check propeller shaft thrust play. Refer to “Lower Unit
Gears - Shimming and Adjustment” (Page 3A-24).
(A)
(a)
I9J011310094-02
I9J011310093-01
Shift Rod Guide Housing
• Using an oil seal installer, drive the oil seal (1) into the shift rod guide housing (2). The lipped portion of oil seal must face towards the driveshaft housing.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
Right Hand Rotation Unit: 3A-21
• Install the E-ring (7) to the shift rod, then slide the shift rod guide housing onto the shift rod.
7
2
1
I9J011310095-01
• Install the E-ring (3), shifter yoke (4) and E-ring (5) to shift rod (6).
NOTE
E-ring should be installed with gap facing as shown in the figure.
I9J011310097-01
• Install the oil seal cover (8) to the shift rod guide housing.
NOTE
Be sure the connector pin is in the “Neutral” position before installing the shift unit (shift rod guide housing assembly).
8
5
6
4
3
I9J011310099-01
I9J011310096-01
4
5
4
5 3
6
I9J011310007-03
3A-22 Right Hand Rotation Unit:
• Apply water resistant grease to the shift rod guide housing O-ring.
: Grease 99000–25161 (SUZUKI Water
Resistant Grease (250 g))
• Install the shift rod guide housing assembly (9) by aligning the shifter yoke with the groove in the connector pin, then tighten the housing bolt (10) securely.
9
I9J011310098-01
NOTE
Before installing the shift rod guide housing assembly, bring the shifter yoke to the
“Neutral” position by turning the shift rod right or left.
I9J011310101-02
10
9
I9J011310100-01
I9J011310102-01
• Turn the shift rod from the “Neutral” position to the
“Forward” and “Reverse” position to check proper gear engagement.
Leakage Check
Check for leakage of oil seal and O-ring when applying specified pressure inside of the gearcase.
1) Install the test tool into the oil level hole.
2) Connect the air pump to the tester.
3) Rotate driveshaft and propeller shaft clockwise several times and then apply specified pressure for the test.
CAUTION
Do not exceed pressure of 110 kPa (1.1 kg/ cm 2 , 15.6 psi.) or damage to oil seals will result.
NOTE
Apply low initial pressure of 20 – 40 kPa (0.2
– 0.4 kg/cm 2 , 2.8 – 5.7 psi.) first, then apply specified pressure.
Special tool
(A): 09950–69512 (Gearcase oil leakage tester)
(B): 09952–99310 (Hand air pump)
Leakage pressure test
100 kPa (1.0 kg/cm 2 , 14.2 psi.)
Right Hand Rotation Unit: 3A-23
Lower Unit
Install the Lower Unit.
Refer to “Lower Unit Removal and Installation”
Trim Tab Adjustment
Z9J0113106028
The trim tab counteracts or minimizes propeller torque pull felt through the steering system.
If the steering is pulls to the starboard or port side, adjust the trim tab with the following procedure.
1) Loosen the trim tab bolt (1).
1
(A)
I9J011310009-03
2) Changing the trim tab setting.
• To compensate for a veer to starboard, set the trailing edge of tab (2) to the right (as viewed from behind).
• To compensate for a veer to port, set the trailing edge of tab to the left.
(B)
I9J011310103-01
4) Once stabilized, pressure should remain steady for at least 5 min.
If pressure does not fall, sealing performance is correct.
Water Pump
Install the water pump and related parts.
Refer to “Lower Unit Removal and Installation”
(Page 3A-5) and “Water Pump Removal and Installation”
Propeller
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3A-
2
I9J011310010-03
3) Tighten the bolt of trim tab.
4) Test drive the boat and repeat the procedure 1 – 3 to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be neutral and there should be no tendency for the steering to be pulled to either port or starboard.
3A-24 Right Hand Rotation Unit:
Lower Unit Gears - Shimming and Adjustment
Z9J0113106029
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim / Washer and Mounting Position
Item
Design specification thickness
(mm)
Pinion gear back up shim
Forward gear back up shim
Forward gear thrust washer
Propeller shaft reverse thrust washer
Reverse gear back up shim
Available thickness (mm)
0.50, 0.55, 0.60, 0.65, 0.70, 0.75,
0.80, 0.85, 0.90, 0.95, 1.00, 1.05,
1.10, 1.15
0.55, 0.60, 0.65, 0.70, 0.75, 0.80,
0.85, 0.90, 0.95, 1.00
3.0
0.5, 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6,
1.7
0.55, 0.60, 0.65, 0.70, 0.75, 0.80,
0.85, 0.90, 0.95, 1.00, 1.05
1.0
1.0
3.0
1.3
1.0
1
5
1. Pinion gear back up shim
2. Forward gear back up shim
2
3
4
3. Forward gear thrust washer
4. Propeller shaft reverse thrust washer
5. Reverse gear back up shim
I9J011310011-04
Forward Gear / Pinion Gear Back-Up Shim
Adjustment
Follow the procedure below to adjust forward gear / pinion gear.
Prior to adjustment
1) Install standard pinion gear back-up shim thickness according to
±
design specification mark on the gear.
Right Hand Rotation Unit: 3A-25
Checking driveshaft thrust play
1) Affix the gear adjusting gauge to driveshaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)
2) To check driveshaft thrust play, push the forward gear inward and hold it in this position. Slowly push the driveshaft downward completely, then slowly pull the driveshaft up and read the maximum thrust play.
Driveshaft thrust play
0.4 – 0.6 mm (0.016 – 0.023 in.)
“A”
I9J011310012-01
“A”:
±
design spec. mark
2) Correctly assemble driveshaft oil seal housing, driveshaft, forward gear, pinion gear and related
components. Refer to “Lower Unit Assembly”
Do not install reverse gear at this time.
(A)
I9J011310085-01
I9J011310104-01
3) Tighten pinion nut to specified torque.
Tightening torque
Pinion nut: 120 N·m (12.0 kgf-m, 86.8 lbf-ft)
I9J011310105-01
• If thrust play is larger than specified, the forward gear back-up shim thickness must be increased.
• If thrust play is smaller than specified, the forward gear back-up shim thickness must be decreased.
3A-26 Right Hand Rotation Unit:
Checking and adjusting tooth contact pattern
(Pinion and Forward gear)
Check tooth contact pattern using the following procedure.
1) To assess tooth contact, apply a light coat of prussian blue on the convex surface of the forward gear.
2) Install the propeller shaft and housing assembly
(minus reverse gear and internal components).
3) Push the propeller shaft inward and hold it in position.
I9J011310105-01
4) Using the driveshaft holder tool, rotate the driveshaft
5 – 6 times.
Special tool
(A): 09921–28710 (Driveshaft holder)
5) Carefully remove the propeller shaft and housing to check the tooth contact pattern.
“A”
“B”
“C”
“a”
“F”
“G”
“D”
“E”
“A”: Concave side
“B”: Convex side
“C”: Heel
“D”: Tooth top
I9J011310013-02
“E”: Tooth bottom
“F”: Toe
“G”: Tooth contact pattern
“a”: Tooth width
Optimum tooth contact
The optimum tooth contact is shown in the figure. A shim adjustment may be necessary to obtain this contact pattern.
CAUTION
The driveshaft thrust play should be checked when increasing or decreasing shim thickness to adjust tooth contact.
Optimum tooth contact
“ a ”
“ b ”
“A”
(A)
I9J011310106-01
“A”: Heel
“B”: Convex side
“C”: Toe
“B”
“C”
I9J011310014-02
“a”: Approx. 1/3 of tooth width
“b”: Approx. 1 mm
Example [A]
Incorrect topside toe contact.
Correction measures.
• Decrease thickness of forward gear shim.
• Slightly increase pinion gear shim thickness.
CAUTION
Do not set tooth contact in this position (top side toe contact). Damage and chipping of the forward and pinion gears may result.
Example of incorrect
Rechecking driveshaft thrust play
After obtaining optimum tooth contact, driveshaft thrust play should be measured.
1) Affix the gear adjusting gauge to the driveshaft.
Special tool
Right Hand Rotation Unit: 3A-27
(A): 09951–09530 (Gear adjusting gauge)
(A)
“C”
“A”
I9J011310015-01
Example [B]
Incorrect bottom side toe contact.
Correction measures.
• Increase thickness of forward gear shim.
• Slightly decrease pinion gear shim thickness.
CAUTION
Do not set the tooth contact in this position
(bottom side toe contact). Chipping of the pinion gear may result.
Example of incorrect
I9J011310085-01
2) To check driveshaft thrust play, push the forward gear inward and hold it in this position.
Push the driveshaft down completely, then slowly pull the driveshaft up and read the maximum thrust play.
Designate this amount of play as “A”.
NOTE
Driveshaft thrust play “A” must be known to adjust reverse gear shim.
Driveshaft thrust play
0.4 – 0.6 mm (0.016 – 0.023 in.)
“A”
“C”
I9J011310016-01
3A-28 Right Hand Rotation Unit:
Reverse Gear Back-Up Shim Adjustment
After adjusting the forward gear tooth contact pattern, follow the procedure below to adjust the reverse gear.
1) Correctly assemble and install reverse gear, propeller shaft, propeller shaft bearing housing and related components.
2) Screw a slide hammer assembly onto the propeller shaft and strike it a few gentle outward taps.
Special tool
(A): 09930–30161 (Propeller shaft remover)
(B): 09930–30104 (Sliding hammer)
(B)
(A)
I9J011310107-01
3) Affix the gear adjusting gauge to driveshaft.
Special tool
(C): 09951–09530 (Gear adjusting gauge)
4) Slowly push the driveshaft downward completely, then slowly pull the driveshaft up and read the maximum thrust play. Designate this measurement as play “B”.
5) Compare play “B” to play “A”.
Refer to “Rechecking driveshaft thrust play”
6) Reverse gear back-up shim adjustment is correct if
“B” is equal to “A”.
If “B” is less than “A”, reduce reverse gear back-up shim thickness.
Checking propeller shaft thrust play
After adjusting all gear positions, measure the propeller shaft thrust play. If not within the following specification, a shim adjustment is required.
NOTE
Maintain the forward gear thrust washer at standard thickness (3.0 mm) and use only the reverse gear thrust washer to adjust thrust play.
Propeller shaft thrust play
Approx. 0.2 – 0.4 mm (0.01 – 0.02 in.)
1) Assemble the gear adjusting gauge to the propeller shaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)
(A)
(C)
I9J011310108-01
I9J011310094-02
2) Push propeller shaft inward.
3) Hold the shaft in and set the dial gauge pointer to zero.
4) Slowly pull the shaft outward and read the maximum thrust play on the dial gauge.
• If the measurement is more than the specification, increase the reverse gear thrust washer thickness.
• If the measurement is less than the specification, reduce the reverse gear thrust washer thickness.
Section 4
Wire / Hose Routing
CONTENTS
Table of Contents 4- i
Precautions .................................................4-1
Precautions............................................................. 4-1
Precautions for Wire / Hose Routing..................... 4-1
Component Location ............................................. 4-1
Electrical Component Location ............................. 4-1
Wire Routing ............................................ 4A-1
Schematic and Routing Diagram........................4A-1
Wiring Diagram ................................................... 4A-1
Wiring Harness Routing Diagram........................4A-3
Fuel / Water Hose Routing...................... 4B-1
Precautions...........................................................4B-1
Precautions for Fuel / Water Hose Routing.........4B-1
Schematic and Routing Diagram........................4B-1
Fuel Hose Routing ..............................................4B-1
Water Hose Routing............................................4B-5
4
4-1 Precautions:
Wire / Hose Routing
Precautions
Precautions
Precautions for Wire / Hose Routing
Refer to “General Precautions” in Section 00 (Page 00-1).
Z9J0114000001
Component Location
Electrical Component Location
Z9J0114003001
Wire / Hose Routing
Wire Routing
Schematic and Routing Diagram
Wiring Diagram
Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
Wire Routing: 4A-1
Z9J0114102004
4A-2 Wire Routing:
DF70A / 80A / 90A
B B/W Gr
R
R
R
B
R/B R/B R/B
B/G B/G B/G
R/B R/B R/B
B/W B/W B/W
W/R W/R W/R
W W
R R
R
G G
Y/G
R R
Gr Gr Gr
W W
W W
Gr Gr
W
Gr
W
W W
W W
Gr/R
Gr Gr Gr
Gr/R Gr/R
R/B R/B R/B
Y
Br Br Br
Bl/W
O/Y O/Y O/Y
B B
P/W P/W P/W
Lg Lg Lg
B/Br B/Br B/Br
O/B O/B
O/B
Gr/Y Gr/Y Gr/Y
O O
Bl/W Bl/W
G/Y G/Y G/Y
Y/G Y/G Y/G
Lg/B Lg/B Lg/B
P/Bl P/Bl P/Bl
P P
B B
Bl/R Bl/R Bl/R
Br/Y Br/Y Br/Y
R/W R/W
Lg/W
R/W
Lg/W Lg/W
V/W V/W V/W
G G
Bl/B
Lg/W
Bl/B
Lg/W Lg/W
Bl/B
W/Bl W/Bl W/Bl
R/B R/B R/B
R/Y R/Y R/Y
W W
B B
Y
B
Y
W/YW/
Lb Lbl
Gr Gr
Bl Bl
W/Y
Lbl
Gr
Bl
G/W
B/R B/R
Bl Bl
G/W
B/R
Bl
R R R
Y/B Y/B
Bl/B Bl/B
R/W R/W
Y/Bl Y/Bl
Y/B
Bl/B
R/W
Y/Bl
B/Bl B/Bl
B/W B/W
P/W P/W
R/B R/B
B/Bl
B/W
P/W
R/B
W/BW/B
R/G R/G
W/YW/Y
O/W O/W
Lg/R Lg/R
W/B
R/G
W/Y
O/W
Lg/R
B/G B/G
Bl/W Bl/W
B/G
Bl/W
B B
Y Y
Bl Bl Bl
B B
Y Y
Bl Bl Bl
B B
Y Y
Bl Bl Bl
B B
Y Y
Bl Bl Bl
B/W
P/Bl P/Bl
G
Br Br Br
Y/GY/ Y/G
R
B/W B/W B/W
W/Y W/Y W/Y
R R R
B/Bl B/Bl B/Bl
Y/G Y/G Y/G
B/W B/W B/W
R R R
Bl/W Bl/W Bl/W
NEUTRAL SWITCH N ON F
P
Lbl Lb Lbl
P P
W/RW/R W/R W/R W/R W/R
P P
Lbl Lb Lbl
B/G B/G B/G
B B
O/Y O/Y
Y
O/Y
Y
Lg/W Lg/W Lg/W
P/W P/W P/W
G/W G/W G/W
Bl/B Bl/B Bl/B
P/W P/W P/W
Bl/B Bl/B Bl/B
G/W G/W G/W
P/W P/W P/W
B B
Bl/B Bl/B Bl/B
P/W
G/W G/W G/W
Bl/B Bl/B Bl/B
G/W G/W G/W
P/W P/W
Lbl Lb Lbl
P P P
P/W P/W P/W
B/G B/G B/G
B B
Y Y
O/Y O/Y O/Y
B/Bl B/Bl B/Bl
B B
W W
B/G B/G B/G
W W W W
B B B
R R
W W
B B B
B B
R/G R/G R/G
R/G R/G R/G R/G R/G R/G
B B
R/G R/G R/G
SUZUKI
I9J011410001-04
Wiring Harness Routing Diagram
3
2
1
Wire Routing: 4A-3
Z9J0114102003
1
5
4
1. Electric parts holder
2. ECM
3. Cushion
4. Fuse box
5. PTT motor relay
I9J011410002-01
4A-4 Wire Routing:
25
29
26
28
(a)
27
23
1
2
3
4
5
6
7
View “A”
8
5
24
23
22
21
19
20
“A”
6
9
16
18
17
15
14
13
1. Flywheel
2. Starter motor
3. Oil pressure switch
: Cover the oil pressure switch with cap.
4. Ex. mani. temp. sensor
5. Rectifier/Regulator
6. Main harness capacitor
7. Clamp
8. Clamp
9. Clamp
: Bind the main harness, rectifier lead wire and capacitor harness.
10. Bolt
: Tighten bolt with harness GND lead and
Rectifier GND lead wire.
11. Rectifier/Regulator GND lead wire
12. Main harness GND lead wire
13. Bolt
14. Cushion
15. Washer
16. Cap
17. Main harness (Red)
18. PTT relay lead wire (Red)
19. Fuse box
20. Electric parts holder
10
12 11
I9J011410003-03
21. ECM
22. IAT sensor
23. Battery cable (+)
24. Battery cable (–)
25. IAC valve
26. MAP sensor
27. Cap
28. Nut
29. Main harness (Red)
: 8.6 N
⋅ m (0.86 kgf-m, 6.2 lbf-ft)
Wire Routing: 4A-5
1
3
6
5
1. Battery charge coil
2. Battery charge coil lead wire
2 4 4
3. Cylinder temp. sensor lead wire
4. Clamp
5. MAP sensor
6. IAC valve
I9J011410004-02
4A-6 Wire Routing:
1
2
3
4
3
1. Clamp
: Fix the harness with clamp.
2. High pressure fuel pump sub lead wire
3. Shift position sensor
4. Shift position sensor lever
5
5. Neutral switch
6. Clamp
6
I9J011410005-04
Wire Routing: 4A-7
1
13
12
11
3
7
2
6
8
9
10
1. CMP sensor
2. No.1 Ign. coil
3. No.2 Ign. coil
4. No.3 Ign. coil
5. No.4 Ign. coil
6. No.1 fuel injector
7. No.2 fuel injector
8. No.3 fuel injector
5 4
9. Clamp
: Fix the harness with clamp.
10. Clamp
11. Main harness capacitor
12. Rectifier/Regulator
I9J011410006-02
13. Ex. mani. temp. sensor
4A-8 Wire Routing:
2
1
4
3
9 7
8
6
5
21
20
19
13
18
18
10
10
17
16
14
15
1. CKP sensor
2. IAC valve
3. Harness clamp
4. TPS
5. PTT relay GND lead wire
6. Clamp
: Bind CKP sensor lead wire and main harness.
7. Bolt
12
15
8. Cushion
9. Washer
10. Battery cable
11. PTT cable
: Set the taping position “a” as shown.
12. Grommet
13. Trim sensor lead wire
14. Neutral switch and shift sensor lead wire
11
11
12
“ a ”
I9J011410007-05
15. Remote control harness connector
16. 3-pin connector
17. 2-pin connector
18. Cable holder
19. Screw
20. Holder
21. Washer
Wire Routing: 4A-9
1
2
3
4
1. Trim sensor
2. Trim sensor cam
6
5
3. Clamp
: Fix the trim sensor lead wire at white taping position.
4. Clamp
I9J011410008-03
5. Clamp
6. PTT motor cable
4B-1 Fuel / Water Hose Routing:
Wire / Hose Routing
Fuel / Water Hose Routing
Precautions
Precautions for Fuel / Water Hose Routing
CAUTION
Z9J0114200001
• 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.
• Extreme care should be taken not to cut, abrade or cause any other damage on hoses.
• Care should be taken not to cause hoses to be compressed excessively by any clamp when fitted.
Schematic and Routing Diagram
Fuel Hose Routing
Z9J0114202001
8
3
4
10
2
11
1
12
7
5
1. Fuel hose (Filter to fuel pump)
2. Fuel hose / protector (Pump to fuel vapor separator)
3. Breather hose / protector
4. Fuel hose (High pressure fuel filter to 3-way joint)
9
6
5. Evaporation hose / protector
6. Fuel hose (Fuel cooler to fuel vapor separator)
7. Clamp
8. Clamp
: Clamp the fuel hose (2) and (3).
I9J011420001-02
9. Fuel vapor separator
10. High pressure fuel filter
11. Low pressure fuel pump
12. Low pressure fuel filter
Fuel / Water Hose Routing: 4B-2
10
11
12
13
14
9
8
7
6
2 1
3
1. Clamp
2. Fuel hose (Joint to low pressure fuel filter)
3. Clamp
4. Clamp
5. Fuel hose protector
5
4
6. Low pressure fuel filter
7. Fuel hose (Filter to fuel pump)
8. Low pressure fuel pump
9. Fuel hose / protector (Fuel pump to fuel vapor separator)
10. Clamp
: Clamp the fuel hose (9) and breather hose (11).
I9J011420002-02
11. Breather hose
12. Fuel hose (3-way joint to fuel delivery pipe)
13. 3-way joint
14. Fuel hose (High pressure fuel filter to 3way joint)
4B-3 Fuel / Water Hose Routing:
5
6
4
3
1
2
1. Fuel hose (Joint to low pressure fuel filter)
2. Fuel hose protector
3. Low pressure fuel filter
4. Fuel hose (Fuel filter to fuel pump)
11
10
9 12 8 7
5. Low pressure fuel pump
6. Breather hose/protector
7. Fuel hose (Fuel pump to fuel vapor separator)
8. High pressure fuel filter
I9J011420003-01
9. Fuel hose (High pressure fuel filter to 3-way joint)
10. 3-way joint
11. Fuel hose (3-way joint to fuel delivery pipe)
12. Clip
Fuel / Water Hose Routing: 4B-4
3
4
2
1
5
1. Fuel hose / protector (Joint to low pressure fuel filter)
2. Fuel hose (Fuel filter to fuel pump)
3. Fuel hose (Fuel pump to fuel vapor separator)
4. Low pressure fuel pump
I9J011420004-01
5. Low pressure fuel filter
4B-5 Fuel / Water Hose Routing:
Water Hose Routing
Z9J0114202002
1
3
2
7
1. Water return hose
2. Fuel cooler
3. Water hose (Fuel cooler to water return union)
6
5
4
4. Water hose (Union to fuel cooler)
5. Water hose protector
6. Water union
7. Water return union
I9J011420005-02
Fuel / Water Hose Routing: 4B-6
2
1. Thermostat cover
1
2. Water return hose
I9J011420006-02
4B-7 Fuel / Water Hose Routing:
3
1
1. Water flush hose
3
2
2. Speed meter hose 3. Clamp
I9J011420007-01
2
3
1. Water flush hose
1
2. Speed meter hose
I9J011420008-01
3. Front panel
Prepared by
Marine Design Department
October, 2008
Manual No. 99500-87L00-01E
Printed in Japan
344
TOP
99500-87L00-01E DF70A/80A/90A Service Manual Cover for PS printing (13mm) 5/0 2008/10/29
BOTTOM
DIC502 Pantone 303C Pantone 485 Pantone 294 Black
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Key features
- 80 horsepower for powerful performance
- Lightweight and compact design for easy handling
- Advanced fuel injection system for improved fuel economy
- Electronic ignition system for quick and reliable starting
- Power trim and tilt for easy adjustment of the motor angle
- Freshwater flushing system for easy maintenance