Suzuki DF200 Service manual

PRE - PRODUCTION
ISSUE
1
FOREWORD
This manual contains an introductory description of
the SUZUKI DF200/225/250 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.
GROUP INDEX
GENERAL INFORMATION
1
PERIODIC MAINTENANCE
2
ENGINE CONTROL SYSTEM
3
ENGINE ELECTRICAL
4
FUEL SYSTEM
5
POWER UNIT
6
MID UNIT
7
POWER TRIM AND TILT
8
LOWER UNIT
9
[Standard rotation (Right-hand) model]
LOWER UNIT
[Counter rotation (Left-hand) model]
10
WIRE/HOSE ROUTING
11
12
!
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.
NOTE:
This manual is compiled based on 2004 (K4) model.
© COPYRIGHT SUZUKI MOTOR CORPORATION 2003
Marine & Power Products Division
2
HOW TO USE THIS MANUAL
TO LOCATE WHAT YOU ARE LOOKING FOR:
1. The text of this manual is divided into sections.
2. The section titles are listed on the previous page in a
GROUP INDEX. Select the section needed for reference.
3. Holding the manual as shown at the right will allow you to
find the first page of the section easily.
4. The first page of each section contains a table of contents to
easily locate the item and page you need.
COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS
Under the name of each system or unit, an exploded view is provided with work instructions and other service information such as the tightening torque, lubrication and locking agent points.
Example:
1. Flywheel bolt
2. Flywheel
3. Dowel pin
4. CKP sensor
5. Bolt
6. CMP sensor
7. Bolt
1
118 N·m (11.8 kg-m, 85.3 lb-ft)
7
6
2
5
3
7
6
NOTE:
Clean flywheel and crankshaft
mating surfaces with cleaning
solvent.
4
3
SYMBOL
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
SYMBOL
DEFINITION
Torque control required.
Data beside it indicates specified
torque.
Apply THREAD LOCK “1342”.
Apply oil. Use the engine oil unless otherwise specified.
Apply THREAD LOCK SUPER “1333B”.
Apply SUZUKI OUTBOARD MOTOR
GEAR OIL.
Measure in DC voltage range.
Apply SUZUKI SUPER GREASE “A”.
Measure in resistance range.
Apply SUZUKI WATER RESISTANT
GREASE.
Measure in continuity test range.
Apply SUZUKI BOND “1104”.
Use peak voltmeter “Stevens CD-77”.
Apply SUZUKI BOND “1207B”.
Use special tool.
Apply SUZUKI SILICONE SEAL.
4
ABBREVIATIONS
Abbreviations used in this service manual are as follows:
BTDC
: Before Top Dead Center
CKP
CMP
CTP
: Crankshaft position
: Camshaft position
: Close Throttle position
DC
DOHC
: Direct Current
: Double Over Head Camshaft
ECM
: Engine Control Module
EX (Ex.) : Exhaust
IAC
IAT
IN (In.)
: Idle Air Control
: Intake Air Temperature
: Intake
MAP
: Manifold absolute pressure
OCV
: Oil control valve
PCV
PORT
PTT
: Positive Crankcase Ventilation
: Port
: Power Trim & Tilt
SPS
STBD
: Shift Position Sensor
: Starboard
TPS
: Throttle Position Sensor
VSV
VVT
: Vacuum switching valve
: Variable Valve Timing
5
GENERAL INFORMATION
1-1
GENERAL INFORMATION
1
CONTENTS
WARNING/CAUTION/NOTE .........................................................................1- 2
GENERAL PRECAUTIONS ...........................................................................1- 2
IDENTIFICATION NUMBER LOCATION ......................................................1- 4
FUEL AND OIL ..............................................................................................1- 5
GASOLINE RECOMMENDATION .........................................................1- 5
ENGINE OIL ...........................................................................................1- 5
ENGINE BREAK-IN .......................................................................................1- 6
WARM-UP RECOMMENDATION ..........................................................1- 6
THROTTLE RECOMMENDATION .........................................................1- 6
PROPELLERS ...............................................................................................1- 7
POWERHEAD DIRECTION OF ROTATION .................................................1- 8
CYLINDER NUMBER ....................................................................................1- 8
* SPECIFICATIONS .......................................................................................1- 9
* SERVICE DATA ..........................................................................................1-13
TIGHTENING TORQUE .................................................................................1-21
SPECIAL TOOLS ..........................................................................................1-23
MATERIALS REQUIRED ..............................................................................1-27
6
1-2
GENERAL INFORMATION
WARNING/CAUTION/NOTE
Please read this manual and follow its instructions carefully. To emphasize special information, the symbol
and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.
!
Indicates a potential hazard that could result in death or injury.
"
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 judgement and observe basic mechanical safety
principles.
GENERAL PRECAUTIONS
!
• 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 goggles when filing metals, working on a grinder,
or doing other work, which could cause flying material particles.
• 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 and on a boat, 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 wellventilated 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 dishwashing 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 fuel, oil/engine cooling system and 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.
7
GENERAL INFORMATION
1-3
"
• 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 when 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 and batteries.
• To protect the Earth’s natural resources, properly dispose of used motor parts.
8
1-4
GENERAL INFORMATION
IDENTIFICATION NUMBER LOCATION
MODEL, PRE-FIX, SERIAL NUMBER
The MODEL, PRE-FIX and SERIAL NUMBER of motor are
stamped on a plate attached to the clamp bracket.
Example
MODEL
DF 250
25001F
PRE-FIX
SERIAL NUMBER
ENGINE SERIAL NUMBER
A second engine serial number plate is pressed into a boss on
the cylinder block.
1
XXXXXX
1. Serial number plate
9
GENERAL INFORMATION
1-5
FUEL AND OIL
GASOLINE RECOMMENDATION
Suzuki highly recommends that you use alcohol-free unleaded
gasoline with a minimum pump octane rating of 87 (R/2+M/2
method) or 91 (Research method). However, blends of
unleaded gasoline and alcohol with equivalent octane content
may be used.
Allowable maximum blend of a single additive (not combination):
5% Methanol, 10% Ethanol, 15% MTBE
"
If leaded gasoline is used, engine damage may result.
Use only unleaded gasoline.
ENGINE OIL
Use only oils that are rated SE, SF, SG, SH or SJ under the API
(American Petroleum Institute) classification system.
The viscosity rating should be SAE 10W-40.
If SAE 10W-40 motor oil is not available, select an alternative
according to the chart at right.
10
1-6
GENERAL INFORMATION
ENGINE BREAK-IN
The first 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt. How the motor is operated during this time
will have direct bearing on its life span and long-term durability.
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 by varying the
throttle position occasionally.
1. FIRST 2 HOURS
For 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 planing.
2. NEXT 1 HOUR
Operate the engine in-gear at less than 3/4 (three-quarter)
throttle (4 000 r/min).
3. LAST 7 HOURS
Operate the engine in-gear at desired engine speed.
However, do not operate continuously at full throttle for more
than 5 minutes.
11
GENERAL INFORMATION
1-7
PROPELLERS
An outboard motor is designed to develop its rated power within
a specified engine speed range. The maximum rated power
delivered by the DF200/225/250 models are shown below.
Recommended full
throttle speed range
DF200
DF225
DF250
5 000 – 6 000 r/min
5 000 – 6 000 r/min
5 500 – 6 100 r/min
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 selection chart
Right-hand rotation models
Blade × Diam. (in.) × Pitch (in.)
3 ×
16
× 17
3 ×
16
× 18 and 1/2
3 ×
16
× 20
3 ×
16
× 21 and 1/2
3 ×
16
× 23
3 ×
16
× 24 and 1/2
Counter rotation models
Blade × Diam. (in.) × Pitch (in.)
3 ×
16
× 17
3 ×
16
× 18 and 1/2
3 ×
16
× 20
3 ×
16
× 21 and 1/2
3 ×
16
× 23
3 ×
16
× 24 and 1/2
"
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.
NOTE:
In case of twin installation, always use on both engines, the
same size right-hand rotation and counter-rotation propellers.
12
1-8
GENERAL INFORMATION
POWERHEAD DIRECTION OF ROTATION
This outboard motor is designed with a L.H. (left hand) rotation
powerhead utilizing an offset crankshaft.
This design has the advantage of reducing the size of the motor
and keeping the overall motor’s weight closer to the boat 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.
CYLINDER NUMBER
Cylinder number is as mentioned in the right figure.
No. 1
No. 2
No. 3
No. 4
No. 5
No. 6
13
GENERAL INFORMATION
1-9
* SPECIFICATIONS
* These specifications are subject to change without notice.
For DF200Z/225Z/250Z specification, see page 1-11.
Item
Unit
PRE-FIX
DF200T
Data
DF225T
DF250T
20001F
22501F
25001F
DIMENSIONS & WEIGHT
Overall length
(front to back)
mm (in.)
897 (35.3)
Overall width
(side to side)
mm (in.)
572 (22.5)
UL
mm (in.)
1 834 (72.2)
XX
mm (in.)
1 961 (77.2)
UL
kg (lbs)
263 (580)
XX
kg (lbs)
268 (591)
UL
mm (in. type)
632 (25)
XX
mm (in. type)
759 (30)
Overall height
Weight
(without engine oil)
Transom height
PERFORMANCE
Maximum output
kW (PS)
147 (200)
165 (225)
184 (250)
Recommended operating range
r/min
5 000 – 6 000
5 000 – 6 000
5 500 – 6 100
Idle speed
r/min
650 ± 50 (in-gear: Approx. 650)
POWER HEAD
Engine type
4-stroke DOHC
Number of cylinders
V-6
Bore
mm (in.)
95 (3.74)
Stroke
mm (in.)
85 (3.35)
Total displacement
cm (cu. in)
3 614 (220.5)
Compression ratio
:1
9.5
NGK
BKR6E
Spark plug
Ignition system
Fuel supply system
3
Full-transistorized ignition
Multi-point sequential electronic fuel injection
Exhaust system
Through prop exhaust
Cooling system
Water cooled
Lubrication system
Wet sump by trochoid pump
Starting system
Electric
Throttle control
Remote control
14
1-10
GENERAL INFORMATION
Item
Unit
Data
DF225T
DF200T
DF250T
FUEL & OIL
Fuel
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.
Engine oil
Engine oil amounts
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
L (US/lmp. qt)
Gear oil
Gearcase oil capacity
8.0 (8.5/7.0) : Oil change only
8.2 (8.7/7.2) : Oil filter change
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
ml
(US/lmp. oz)
1 100 (37.2/38.7)
degree
0 – 19 (PTT system)
BRACKET
Trim angle
Number of trim position
Maximum tilt angle
PTT system
degree
70
LOWER UNIT
Reversing system
Transmission
Gear
Forward-Neutral-Reverse
Reduction system
Bevel gear
Gear ratio
Drive line impact protection
12 : 22 (1.83)
Spline drive rubber hub
Propeller shaft rotation (when shift into forward)
Propeller
Clockwise
Blade × Diam. (in.) × Pitch (in.)
3
3
3
3
3
3
×
×
×
×
×
×
16
16
16
16
16
16
×
×
×
×
×
×
17
18 and 1/2
20
21 and 1/2
23
24 and 1/2
REDUCTION SYSTEM
1st reduction gear ratio
(Crankshaft drive gear: Driven gear)
32 : 40 (1.25)
2nd reduction gear ratio (Lower unit gear)
12 : 22 (1.83)
Total reduction gear ratio
2.29 (40/32 × 22/12)
15
GENERAL INFORMATION
1-11
* These specifications are subject to change without notice.
For DF200T/225T/250T specification, see page 1-9.
Item
Unit
PRE-FIX
DF200Z
Data
DF225Z
DF250Z
20001Z
22501Z
25001Z
DIMENSIONS & WEIGHT
Overall length
(front to back)
mm (in.)
897 (35.3)
Overall width
(side to side)
mm (in.)
572 (22.5)
UL
mm (in.)
1 834 (72.2)
XX
mm (in.)
1 961 (77.2)
UL
kg (lbs)
263 (580)
XX
kg (lbs)
268 (591)
UL
mm (in. type)
632 (25)
XX
mm (in. type)
759 (30)
Overall height
Weight
(without engine oil)
Transom height
PERFORMANCE
Maximum output
kW (PS)
147 (200)
165 (225)
184 (250)
Recommended operating range
r/min
5 000 – 6 000
5 000 – 6 000
5 500 – 6 100
Idle speed
r/min
650 ± 50 (in-gear: Approx. 650)
POWER HEAD
Engine type
4-stroke DOHC
Number of cylinders
V-6
Bore
mm (in.)
95 (3.74)
Stroke
mm (in.)
85 (3.35)
Total displacement
cm (cu. in)
3 614 (220.5)
Compression ratio
:1
9.5
NGK
BKR6E
Spark plug
Ignition system
Fuel supply system
3
Full-transistorized ignition
Multi-point sequential electronic fuel injection
Exhaust system
Through prop exhaust
Cooling system
Water cooled
Lubrication system
Wet sump by trochoid pump
Starting system
Electric
Throttle control
Remote control
16
1-12
GENERAL INFORMATION
Item
Unit
Data
DF225Z
DF200Z
DF250Z
FUEL & OIL
Fuel
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.
Engine oil
Engine oil amounts
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
L (US/lmp. qt)
Gear oil
Gearcase oil capacity
8.0 (8.5/7.0) : Oil change only
8.2 (8.7/7.2) : Oil filter change
SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil)
ml
(US/lmp. oz)
1 100 (37.2/38.7)
degree
0 – 19 (PTT system)
BRACKET
Trim angle
Number of trim position
Maximum tilt angle
PTT system
degree
70
LOWER UNIT
Reversing system
Transmission
Gear
Forward-Neutral-Reverse
Reduction system
Bevel gear
Gear ratio
Drive line impact protection
12 : 22 (1.83)
Spline drive rubber hub
Propeller shaft rotation (when shift into forward)
Propeller
Counterclockwise
Blade × Diam. (in.) × Pitch (in.)
3
3
3
3
3
3
×
×
×
×
×
×
16
16
16
16
16
16
×
×
×
×
×
×
17
18 and 1/2
20
21 and 1/2
23
24 and 1/2
REDUCTION SYSTEM
1st reduction gear ratio
(Crankshaft drive gear: Driven gear)
32 : 40 (1.25)
2nd reduction gear ratio
(Lower unit gear)
12 : 22 (1.83)
Total reduction gear ratio
2.29 (40/32 × 22/12)
17
GENERAL INFORMATION
1-13
* SERVICE DATA
* These service data are subject to change without notice.
Item
Unit
DF200T/Z
Data
DF225T/Z
DF250T/Z
5 000 – 6 000
5 000 – 6 000
5 500 – 6 100
POWERHEAD
Recommended operating range
r/min
Idle speed
r/min
650 ± 50 (in-gear: Approx. 650)
**Cylinder compression
kPa
(kg/cm 2, psi)
1 100 – 1 700 (11 – 17, 156 – 242)
**Cylinder compression max. difference between any other cylinders
kPa
(kg/cm 2, psi)
100 (1.0, 14)
**Engine oil pressure
kPa
(kg/cm 2, psi)
400 – 600 (4.0 – 6.0, 57 – 85) at 3 000 r/min
(at normal operating temp.)
Engine oil
Engine oil amounts
Thermostat operating temperature
API classification SE, SF, SG, SH, SJ
Viscosity rating SAE 10W-40
L (US/lpm. qt))
8.0 (8.5/7.0) : Oil change only
8.2 (8.7/7.2) : Oil filter change
°C (°F)
58 – 62 (136 – 144)
** Figures shown are guidelines only, not absolute service limits.
18
1-14
GENERAL INFORMATION
Item
Unit
DF200T/Z
Data
DF225T/Z
DF250T/Z
CYLINDER HEAD/CAMSHAFT
Cylinder head distortion
Limit
mm (in.)
0.03 (0.001)
Manifold seating faces distortion
Limit
mm (in.)
0.10 (0.004)
STD
mm (in.)
43.020 – 43.180
(1.6937 – 1.7000)
42.420 – 42.580
(1.6701 – 1.6764)
44.920 – 45.080
(1.7685 – 1.7748)
Limit
mm (in.)
42.920 (1.6898)
42.320 (1.6661)
44.820 (1.7646)
STD
mm (in.)
43.620 – 43.780
(1.7173 – 1.7236)
43.620 – 43.780
(1.7173 – 1.7236)
44.420 – 44.580
(1.7488 – 1.7551)
Limit
mm (in.)
43.520 (1.7134)
43.520 (1.7134)
44.320 (1.7449)
Top, STD
2nd,
3rd,
Limit
4th
mm (in.)
0.043 – 0.085 (0.0017 – 0.0033)
mm (in.)
0.120 (0.0047)
Camshaft journal
Top, STD
(housing) inside diam- 2nd,
eter
3rd,
Limit
4th
mm (in.)
26.000 – 26.021 (1.0236 – 1.0244)
mm (in.)
—
Camshaft journal outside diameter
Top, STD
2nd,
3rd,
Limit
4th
mm (in.)
25.936 – 25.957 (1.0211 – 1.0219)
mm (in.)
—
Camshaft runout
Limit
mm (in.)
0.10 (0.004)
Cylinder head bore to tappet
clearance
STD
mm (in.)
0.025 – 0.066 (0.0010 – 0.0026)
Limit
mm (in.)
0.150 (0.0059)
Tappet outer diameter
STD
mm (in.)
33.959 – 33.975 (1.3370 – 1.3376)
Cylinder head bore
STD
mm (in.)
34.000 – 34.025 (1.3386 – 1.3396)
Cam height
IN
EX
Camshaft journal oil
clearance
19
GENERAL INFORMATION
Item
Unit
DF200T/Z
Data
DF225T/Z
1-15
DF250T/Z
VALVE/VALVE GUIDE
Valve diameter
Tappet clearance
(Cold engine condition)
Valve seat angle
Valve guide to valve
stem clearance
IN
mm (in.)
35.9 (1.4)
EX
mm (in.)
31.4 (1.2)
IN
STD
mm (in.)
0.23 – 0.27 (0.009 – 0.011)
EX
STD
mm (in.)
0.33 – 0.37 (0.013 – 0.015)
IN
—
15°, 45°, 60°
EX
—
15°, 45°, 60°
STD
mm (in.)
0.020 – 0.047 (0.0008 – 0.0019)
Limit
mm (in.)
0.070 (0.0028)
STD
mm (in.)
0.045 – 0.072 (0.0018 – 0.0028)
Limit
mm (in.)
0.090 (0.0035)
IN
EX
Valve guide inside
diameter
IN,
EX
STD
mm (in.)
5.500 – 5.512 (0.2165 – 0.2170)
Valve guide protrusion
IN,
EX
STD
mm (in.)
11.4 – 11.8 (0.45 – 0.46)
Valve stem outside
diameter
IN
STD
mm (in.)
5.465 – 5.480 (0.2152 – 0.2157)
EX
STD
mm (in.)
5.440 – 5.455 (0.2142 – 0.2148)
IN
Limit
mm (in.)
0.14 (0.006)
EX
Limit
mm (in.)
0.18 (0.007)
Valve stem runout
IN,
EX
Limit
mm (in.)
0.05 (0.002)
Valve head radial
runout
IN,
EX
Limit
mm (in.)
0.08 (0.003)
STD
mm (in.)
1.1 (0.04)
Limit
mm (in.)
0.7 (0.03)
STD
mm (in.)
1.05 (0.04)
Limit
mm (in.)
0.7 (0.03)
IN
STD
mm (in.)
1.1 – 1.3 (0.04 – 0.05)
EX
STD
mm (in.)
1.1 – 1.3 (0.04 – 0.05)
STD
mm (in.)
40.2 (1.58)
Limit
mm (in.)
38.6 (1.52)
STD
N (kg, lbs)
147 – 173 (15.0 – 17.7, 33.1 – 39.0) for 31.1 mm (1.22 in)
Limit
N (kg, lbs)
136 (13.9, 30.6) for 31.1 mm (1.22 in)
Limit
mm (in.)
2.0 (0.08)
Valve stem deflection
Valve head thickness
IN
EX
Valve seat contact
width
Valve spring free length
Valve spring tension
Valve spring squareness
20
1-16
GENERAL INFORMATION
Item
Unit
DF200T/Z
Data
DF225T/Z
DF250T/Z
CYLINDER/PISTON/PISTON RING
Cylinder distortion
Limit
mm (in.)
0.03 (0.001)
Piston to cylinder clearance
STD
mm (in.)
0.020 – 0.040 (0.0008 – 0.0016)
Limit
mm (in.)
0.100 (0.0039)
STD
mm (in.)
95.000 – 95.020 (3.0472 – 3.7409)
mm (in.)
50 (1.969) from cylinder top surface
mm (in.)
94.970 – 94.990 (3.7390 – 3.7398)
mm (in.)
8 (0.31) from piston skirt end
Limit
mm (in.)
0.10 (0.039)
STD
mm (in.)
0.20 – 0.33 (0.008 – 0.013)
Limit
mm (in.)
0.70 (0.028)
STD
mm (in.)
0.33 – 0.48 (0.013 – 0.019)
Limit
mm (in.)
1.00 (0.039)
STD
mm (in.)
Approx. 11.7 (0.46)
Limit
mm (in.)
9.3 (0.366)
STD
mm (in.)
Approx. 13.2 (0.52)
Limit
mm (in.)
10.5 (0.413)
STD
mm (in.)
0.030 – 0.070 (0.0012 – 0.0028)
Limit
mm (in.)
0.12 (0.005)
STD
mm (in.)
0.020 – 0.060 (0.0008 – 0.0024)
Limit
mm (in.)
0.10 (0.004)
1st
STD
mm (in.)
1.22 – 1.24 (0.048 – 0.049)
2nd
STD
mm (in.)
1.21 – 1.23 (0.048 – 0.048)
Oil
STD
mm (in.)
2.51 – 2.53 (0.099 – 0.100)
1st
STD
mm (in.)
1.17 – 1.19 (0.046 – 0.047)
2nd
STD
mm (in.)
1.17 – 1.19 (0.046 – 0.047)
STD
mm (in.)
0.006 – 0.017 (0.0002 – 0.0007)
Limit
mm (in.)
0.040 (0.0016)
STD
mm (in.)
21.996 – 22.000 (0.8660 – 0.8661)
Limit
mm (in.)
21.980 (0.8654)
STD
mm (in.)
22.006 – 22.014 (0.8664 – 0.8667)
Limit
mm (in.)
22.030 (0.8673)
STD
mm (in.)
0.003 – 0.014 (0.0001 – 0.0006)
Limit
mm (in.)
0.050 (0.0020)
STD
mm (in.)
22.003 – 22.011 (0.8663 – 0.8666)
Cylinder bore
Cylinder measuring position
Piston skirt diameter
STD
Piston measuring position
Cylinder bore wear
Piston ring end gap
1st
2nd
Piston ring free end
gap
1st
2nd
Piston ring to groove
clearance
1st
2nd
Piston ring groove
width
Piston ring thickness
Pin clearance in piston pin
hole
Piston pin outside diameter
Piston pin hole diameter
Pin clearance in conrod
small end
Conrod small end bore
21
GENERAL INFORMATION
Item
Unit
DF200T/Z
Data
DF225T/Z
1-17
DF250T/Z
CRANKSHAFT/CONROD
Conrod small end inside
diameter
STD
mm (in.)
22.003 – 22.011 (0.8663 – 0.8666)
Conrod big end oil clearance STD
mm (in.)
0.045 – 0.063 (0.0018 – 0.0025)
Limit
mm (in.)
0.080 (0.0031)
Conrod big end inside diameter
STD
mm (in.)
57.000 – 57.018 (2.2441 – 2.2448)
Crank pin outside diameter
STD
mm (in.)
53.982 – 54.000 (2.1253 – 2.1260)
Crank pin outside diameter
difference (out of round and
taper)
Limit
mm (in.)
0.010 (0.0004)
Conrod bearing thickness
STD
mm (in.)
1.482 – 1.497 (0.0583 – 0.0589)
Conrod big end side clearance
STD
mm (in.)
0.300 – 0.450 (0.0118 – 0.0177)
Limit
mm (in.)
0.550 (0.0217)
Conrod big end width
STD
mm (in.)
20.750 – 20.800 (0.8169 – 0.8189)
Crank pin width
STD
mm (in.)
21.100 – 21.200 (0.8307 – 0.8346)
Crankshaft center journal
runout
Limit
mm (in.)
0.04 (0.002)
STD
mm (in.)
0.024 – 0.044 (0.0009 – 0.0017)
Limit
mm (in.)
0.065 (0.0026)
Crankcase bearing holder
inside diameter
STD
mm (in.)
70.000 – 70.018 (2.7559 – 2.7566)
Crankshaft journal outside
diameter
STD
mm (in.)
64.988 – 65.006 (2.5586 – 2.5593)
Crankshaft journal outside
diameter difference (out of
round and taper)
Limit
mm (in.)
0.010 (0.0004)
Crankshaft bearing thickness
STD
mm (in.)
2.496 – 2.512 (0.0983 – 0.0989)
Crankshaft thrust play
STD
mm (in.)
0.11 – 0.31 (0.004 – 0.012)
Limit
mm (in.)
0.35 (0.014)
STD
mm (in.)
2.425 – 2.475 (0.0955 – 0.0974)
Crankshaft journal oil clearance
Crankshaft thrust bearing
thickness
22
1-18
GENERAL INFORMATION
Item
Unit
DF200T/Z
Data
DF225T/Z
DF250T/Z
BTDC 0 – 26 ± 3
BTDC 0 – 25 ± 3
BTDC 0 – 26 ± 3
ELECTRICAL
Ignition timing
Degrees
at r/min
Over revolution limiter
r/min
CKP sensor resistance
Ω at 20°
168 – 252
CMP sensor resistance
Ω at 20°
—
Primary
Ω at 20°
—
Secondary
kΩ at 20°
—
Ω at 20°
0.32 – 0.48
Battery charge coil output (12V)
Watt
648
Standard spark plug
Type
NGK
BKR6E
Gap
mm (in.)
0.7 – 0.8 (0.028 – 0.031)
A
Main fuse: 60
Sub fuse: 30
Ah (kC)
100 (360) or larger
Fuel injector resistance
Ω at 20 °C
10 – 14
IAC valve resistance
Ω at 20 °C
25 – 34
IAT sensor/Cylinder temp. sensor/
Ex. mani. temp. sensor (Thermistor
characteristic)
kΩ at 25 °C
1.8 – 2.3
ECM main relay resistance
Ω at 20 °C
145 – 190
Starter relay coil resistance
Ω at 20 °C
145 – 190
PTT motor relay coil resistance
Ω at 20 °C
25 – 37
Max. continuous time of use
Sec.
30
Motor output
kW
1.4
STD
mm (in.)
16.0 (0.63)
Limit
mm (in.)
12.0 (0.47)
STD
mm (in.)
0.5 – 0.8 (0.02 – 0.03)
Limit
mm (in.)
0.2 (0.01)
STD
mm (in.)
29.0 (1.14)
Limit
mm (in.)
28.0 (1.10)
STD
mm (in.)
0.05 (0.002)
Limit
mm (in.)
0.40 (0.016)
Ignition coil resistance
Battery charge coil resistance
Fuse amp. rating
Recommended battery capacity
(12V)
6 200
6 300
STARTER MOTOR
Brush length
Commutator undercut
Commutator outside diameter
Commutator outside diameter difference
23
GENERAL INFORMATION
1-19
PTT MOTOR
Brush length
Commutator outside diameter
STD
mm (in.)
9.8 (0.39)
Limit
mm (in.)
5.5 (0.22)
STD
mm (in.)
22.0 (0.87)
Limit
mm (in.)
21.0 (0.83)
SELF-DIAGNOSTIC SYSTEM INDICATION
When the abnormality occurs in a signal from sensor, switch, etc., the “CHECK ENGINE” lamp on the monitor-tachometer flashes (lights intermittently) according to the each code pattern with buzzer sounding.
PRIORITY
*
FAILED ITEM
CODE
LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM
ACTIVATING
1
MAP sensor 1
3–4
on
off
YES
2
IAC valve/By-pass air
screw adjustment
3–1
on
off
NO
3
Cylinder temp. sensor
1–4
on
off
YES
4
IAT sensor
2–3
on
off
YES
5
CKP sensor
4–2
on
off
YES
6
CMP sensor
2–4
on
off
YES
7
Air intake system
2–2
on
off
YES
8
MAP sensor 2
(Pressure detect passage)
3–2
on
off
NO
9
Rectifier & regulator
(Over-charging)
1–1
on
off
NO
10
Exhaust manifold temp.
sensor (STBD)
1–5
on
off
YES
11
Exhaust manifold temp.
sensor (PORT)
1–6
on
off
YES
12
Fuel injector
4–3
on
off
NO
13
Throttle position sensor
2–1
on
off
YES
14
Shift position sensor
1–2
on
off
YES
24
1-20
GENERAL INFORMATION
PRIORITY
*
FAILED ITEM
CODE
15
CMP sensor (VVT·STBD)
2–5
on
off
YES
16
CMP sensor (VVT·PORT)
2–6
on
off
YES
17
VVT advance (STBD)
5–1
on
off
YES
18
VVT advance (PORT)
5–2
on
off
YES
19
Neutral switch
3–3
on
off
NO
20
Model discrimination
4–1
on
off
YES
21
Oil control valve (STBD)
6–1
on
off
NO
22
Oil control valve (PORT)
6–2
on
off
NO
LAMP FLASHING PATTERN
FAIL-SAFE SYSTEM ACTIVATING
* If more than two items fail at once, the self-diagnostic indication appears according to priority order.
The indication repeats three times.
25
GENERAL INFORMATION
1-21
TIGHTENING TORQUE
Tightening torque – Important fasteners
ITEM
Cylinder head cover bolt
Cylinder head bolt
Crankcase bolt
Crankshaft drive gear bolt
Conrod cap bolt
Camshaft housing bolt
Piston cooling jet
Oil pump bolt
VVT
model
IN. camshaft timing sprocket
Non VVT
model
EX. camshaft timing sprocket
OCV
Chain tensioner adjuster bolt
Timing chain guide bolt
Collector cover
Funnel bracket
Engine holder cover bolt
Intake manifold bolt/nut
Oil pressure switch
Fuel delivery pipe bolt
Upper
Fuel delivery pipe plug/
union bolt
Lower
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
Driveshaft housing bolt
Upper mount bolt/nut
Upper mount cover bolt
Lower mount bolt/nut
Clamp bracket shaft nut
Water pump case bolt
Driveshaft oil seal housing
THREAD
DIAMETER
6 mm
8 mm
11 mm
8 mm
10 mm
10 mm
9 mm
6 mm
—
8 mm
TIGHTENING TORQUE
N·m
kg-m
11
1.1
23
2.3
86
8.6
27
2.7
52
5.2
48
4.8
63
6.3
12
1.2
20
2.0
23
2.3
lb-ft
8.0
16.6
62.0
19.5
37.6
34.7
45.6
8.7
14.5
16.6
—
60
6.0
43.4
—
78
7.8
56.0
—
6 mm
6 mm
6 mm
8 mm
8 mm
8 mm
8 mm
—
8 mm
12 mm
12 mm
6 mm
6 mm
12 mm
8 mm
—
12 mm
8 mm
10 mm
10 mm
14 mm
10 mm
14 mm
22 mm
8 mm
—
78
12
11
10
23
23
23
23
13
23
35
35
10
10
118
23
14
13
23
50
50
100
50
100
43
17
98
7.8
1.2
1.1
1.0
2.3
2.3
2.3
2.3
1.3
2.3
3.5
3.5
1.0
1.0
11.8
2.3
1.4
1.3
2.3
5.0
5.0
10.0
5.0
10.0
4.3
1.7
10.0
56.0
8.7
8.0
7.0
16.6
16.6
16.6
16.5
9.5
16.5
25.5
25.5
7.0
7.0
85.3
16.6
10.0
9.5
16.5
36.0
36.0
72.3
36.0
72.3
31.0
12.3
72.3
26
1-22
GENERAL INFORMATION
ITEM
Gearcase bolt
Propeller shaft bearing housing bolt
Pinion gear nut
Propeller nut
THREAD
DIAMETER
10 mm
12 mm
8 mm
14 mm
18 mm
TIGHTENING TORQUE
N·m
kg-m
54
5.5
83
8.3
23
2.3
144
14.5
55
5.5
lb-ft
40.0
60.0
16.6
105.0
40.0
Tightening torque – General bolt
NOTE:
These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners”
table.
TYPE OF BOLT
(Conventional or “4” marked bolt)
(Stainless steel bolt)
(7 marked or
marked bolt)
THREAD
DIAMETER
5 mm
6 mm
8 mm
10 mm
5 mm
6 mm
8 mm
10 mm
5 mm
6 mm
8 mm
10 mm
TIGHTENING TORQUE
N·m
kg-m
lb-ft
2–4
0.2 – 0.4
1.5 – 3.0
4–7
0.4 – 0.7
3.0 – 5.0
10 – 16
1.0 – 1.6
7.0 – 11.5
22 – 35
2.3 – 3.5
16.0 – 25.5
2–4
0.2 – 0.4
1.5 – 3.0
6 – 10
0.6 – 1.0
4.5 – 7.0
15 – 20
1.5 – 2.0
11.0 – 14.5
34 – 41
3.4 – 4.1
24.5 – 29.5
3–6
0.3 – 0.6
2.0 – 4.5
8 – 12
0.8 – 1.2
6.0 – 8.5
18 – 28
1.8 – 2.8
13.0 – 20.0
40 – 60
4.0 – 6.0
29.0 – 43.5
27
GENERAL INFORMATION
1-23
SPECIAL TOOLS
1.
2.
3.
4.
5.
(A)
(B)
09900-00411
Hexagon socket
09900-00410
(included in
Hexagon wrench set 09900-00410)
09900-00413 (5 mm)
09900-00414 (6 mm)
09900-00415 (8 mm)
(A) 09900-06107
Hexagon bit (included (B) 09900-06108
in 09900-00410)
Snap ring pliers
09900-20101 (150 mm)
09900-20102 (200 mm)
Vernier calipers
6.
7.
8.
9.
10.
09900-20202
Micrometer
(25 – 50 mm)
09900-20203
(50 – 75 mm)
09900-20204
(75 – 100 mm)
Micrometer
09900-20205
Micrometer
(0 – 25 mm)
09916-99310
Flywheel holder
09900-20605
Dial calipers
(10 – 34 mm)
11.
12.
13.
14.
15.
09900-21304
Steel “V” block set
09900-22302
(0.051 – 0.125 mm)
09900-22301
(0.025 – 0.076 mm)
Plastigauge
09900-20602
Dial gauge
09900-20701
Magnetic stand
09900-20803
Thickness gauge
28
1-24
GENERAL INFORMATION
16.
17.
18.
19.
(3)
(1)
(2)
09900-26006
Engine tachometer
09900-28403
Hydrometer
09912-58413: Fuel pressure gauge set
(1) 09912-58442: Fuel pressure gauge
(2) 09912-58432: Fuel pressure hose
(3) 09912-58490: 3-way joint & hose
20.
21.
22.
23.
09951-09310
Gear adjust spring
set
09921-29410
Driveshaft holder
09915-47341
Oil filter wrench
09915-67010
Compression gauge
09915-64512
Compression gauge hose attachment
25.
26.
27.
28.
29.
09915-64530
Compression gauge 09915-77311
hose
Oil pressure gauge
09915-78211
Oil pressure gauge
adapter
09916-10911
Valve lapper
09916-14510
Valve lifter
30.
31.
32.
33.
34.
09916-14521
Valve lifter attachment
09916-24450
Solid pilot
(N-100-5.52)
09916-54910
Handle (N-505)
09916-22420
Valve seat cutter (60°) Valve seat cutter (45°)
(N-114)
(Neway 634)
09913-50121
Oil seal remover
24.
29
GENERAL INFORMATION
35.
36.
1-25
37.
38.
39.
09916-34550
Valve seat cutter (15°) Valve guide reamer
(# 5.5 mm)
(Neway 217)
09916-34542
Valve guide reamer
handle
09916-37320
Valve guide reamer
(# 10.5 mm)
09916-44310
Valve guide remover
40.
41.
42.
43.
44.
09916-69310
Tappet holder
09916-77310
Piston ring com09916-57330
Valve guide installer pressor
09916-84511
Tweezers
09917-47011
Vacuum pump
gauge
45.
46.
48.
49.
47.
(A)
(B)
(A) 09922-59410
Propeller shaft
housing installer
09917-98221
09922-89810
(B) 09922-59420
09916-56011
Valve guide stem
Housing installer Shift lock pin
Valve guide installer seal installer attachremover
handle
attachment
ment
09930-30104
Sliding hammer
50.
51.
52.
53.
54.
09930-30161
Propeller shaft
remover
09926-29310
Driveshaft housing
remover
09951-99310
Gear holder
09945-79310
09930-76420
PTT cable extension Timing light
30
1-26
GENERAL INFORMATION
55.
56.
57.
58.
59.
09930-89240
09930-89220
3-pin connector test 4-pin connector test 09930-89260
cord
Injector test cord A
cord
09930-89340
26-pin & 34-pin test
cord
09930-99320
Digital tester
60.
61.
62.
63.
64.
09932-79910
Diagnostic harness
09932-89910
SDS adapter
09940-44121
Air pressure gauge
09940-44130
Attachment
09951-09511
09950-69512
Gearcase oil leakage Gear adjusting
gauge
tester
65.
66.
67.
68.
69.
(A)
(B)
09952-09310
Back lash indicator
tool
09930-89350
H·T cord adapter
09900-25002
Pocket tester
(A) 18213-74F00
O2 sensor
(B) 18498-99E70
Protector
70.
71.
72.
73.
99954-53008-820*
Digital voltmeter
99954-53873*
Stevens CD-77
Peak reading voltmeter
99954-53883*
Gear oil filler
09952-99310
hand air pump
09944-09420
PTT cylinder cap
tool
NOTE:
* Marked part No. is in U.S. market only.
31
GENERAL INFORMATION
1-27
MATERIALS REQUIRED
SUZUKI OUTBOARD SUZUKI SUPER
MOTOR GEAR OIL
GREASE “A”
WATER RESISTANT SUZUKI SILICONE
GREASE
SEAL
SUZUKI BOND
“1104”
99000-22540
(400 ml × 24 pcs)
SUZUKI BOND
“1207B”
99000-25030*
99000-25010
(500 g)
THREAD LOCK
“1342”
99000-25160
(250 g)
THREAD LOCK
SUPER “1333B”
99000-31120
(50 g)
4-Stroke Motor Oil
99000-31030
(100 g)
99104-33140*
99000-31140
(100 g)
99000-32050
(50 g)
99000-32020
(50 g)
API: SE, SF, SG, SH, SJ
SAE: 10W-40
NOTE:
* Marked part No. is in U.S. market only.
32
PERIODIC MAINTENANCE
2-1
PERIODIC MAINTENANCE
CONTENTS
PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2
PERIODIC MAINTENANCE CHART .....................................................2- 2
MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 3
ENGINE OIL/ENGINE OIL FILTER ........................................................2- 3
GEAR OIL ...............................................................................................2- 6
LUBRICATION .......................................................................................2- 7
SPARK PLUG ........................................................................................2- 8
TAPPET CLEARANCE ..........................................................................2- 9
IDLE SPEED ...........................................................................................2-16
IGNITION TIMING ..................................................................................2-17
FUEL LINE .............................................................................................2-18
LOW PRESSURE FUEL FILTER ...........................................................2-19
HIGH PRESSURE FUEL FILTER ..........................................................2-19
PCV SYSTEM .........................................................................................2-20
LOW PRESSURE FUEL PUMP FILTER ...............................................2-21
WATER PUMP/WATER PUMP IMPELLER ...........................................2-21
PROPELLER/NUT/COTTER PIN ...........................................................2-21
BONDING WIRES ..................................................................................2-21
ANODES .................................................................................................2-22
BATTERY ...............................................................................................2-23
BOLTS AND NUTS ................................................................................2-25
FUEL MIXTURE CHECK (O2 FEEDBACK) ..........................................2-25
OIL PRESSURE ..............................................................................................2-26
CYLINDER COMPRESSION ...........................................................................2-28
ENGINE VACUUM CHECK .............................................................................2-29
2
6
33
2-2
PERIODIC MAINTENANCE
PERIODIC MAINTENANCE SCHEDULE
The chart below lists the recommended intervals for all the required periodic service work necessary to keep
the motor operating at peak performance and economy.
Maintenance intervals should be judged by number of hours or months, whichever comes first.
NOTE:
More frequent servicing should be performed on outboard motors that are used under severe conditions.
PERIODIC MAINTENANCE CHART
Item to be serviced
Spark plug
Interval Initial 20 hrs. or Every 50 hrs. or
1 month
3 months
Fuel line
PCV system
Engine oil [NOTE]
Gear oil
Lubrication
Anodes & Bonding wires
Battery
Fuel mixture check
(O2 feedback)
Engine oil filter
Low pressure fuel filter
Low pressure fuel pump filter
High pressure fuel filter
Ignition timing
Idle speed
Tappet clearance
Water pump
Water pump impeller
Propeller nut & pin
Bolt & Nuts
—
I
I
R
R
—
—
—
Every 100 hrs.
or 6 months
—
I
I
I
Replace every 2 years.
I
I
Replace every 2 years.
—
R
—
R
I
I
I
I
I
I
Every 200 hrs.
or 12 months
R
I
I
R
R
I
I
I
Perform every 2 years.
R
—
—
I
I
—
—
I
T
—
—
I
I
Replace every 400 hours or 2 years.
Replace every 1 000 hours.
Replace every 1 000 hours.
—
—
—
—
—
—
—
—
—
—
—
I
—
T
I: Inspect and clean, adjust, lubricate or replace, if necessary
R
I
I
I
I
I
R
I
T
T: Tighten R: Replace
NOTE:
OIL CHANGE REMINDER SYSTEM
• Refer to page 3-45 for function and operation.
• See page 2-5 for reset information.
34
PERIODIC MAINTENANCE
2-3
MAINTENANCE AND TUNE-UP PROCEDURES
This section describes servicing procedures for each periodic
maintenance requirement.
ENGINE OIL/ENGINE OIL FILTER
ENGINE OIL LEVEL CHECK
Inspect oil level before every use.
1.
2.
3.
4.
Place outboard motor upright on a level surface.
Remove motor cover.
Remove oil level dipstick and wipe it clean.
Reinsert dipstick fully into dipstick tube, then remove to
check oil level.
Oil level dipstick
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 hole (Max.).
Recommended oil:
• 4 stroke motor oil
• API classification SE, SF, SG, SH, SJ
• Viscosity rating
SAE 10W-40
Full level
line
Low level
line
35
2-4
PERIODIC MAINTENANCE
ENGINE OIL CHANGE/ENGINE OIL FILTER
REPLACEMENT
ENGINE OIL
Change initially after 20 hours (1 month) and every
100 hours (6 months).
ENGINE OIL FILTER
Replace 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.
1.
2.
3.
4.
Place outboard motor upright on a level surface.
Remove oil filler cap.
Place a container under engine oil drain plug.
Remove engine oil drain plug and gasket to drain engine oil.
OilOilfiller
filtercap
cap
Oil drain plug
5. ENGINE OIL FILTER REPLACEMENT
NOTE:
For engine oil change only, go to step 6.
To replace engine oil filter:
(1) Place a shop cloth under oil filter before removal to
absorb any oil released.
(2) Using oil filter wrench to loosen the oil filter, then remove
filter and O-ring.
! 09915-47341: Oil filter wrench
NOTE:
Before fitting new oil filter, be sure to oil O-ring.
Gasket
PERIODIC MAINTENANCE
(3) Screw new filter on by hand until filter O-ring contacts the
mounting surface.
(4) Tighten filter 3/4 turn from point of contact with mounting
surface using an oil filter wrench.
" Engine oil filter: 14 N·m (1.4 kg-m, 10.0 lb-ft), 3/4 turn
6. Install new gasket and oil drain plug.
Tighten engine oil drain plug to specified torque.
" Engine oil drain plug: 13 N·m (1.3 kg-m, 9.5 lb-ft)
#
Do not re-use gasket once removed. Always use a new
gasket.
7. Pour recommended engine oil into oil filler opening, then
install oil filler cap.
Engine oil amounts
Oil change only: 8.0 L (8.5/7.0 US/Imp. qt)
Oil filter change: 8.2 L (8.7/7.2 US/Imp. qt)
8. To reset oil change reminder system’s operation time to zero
(cancellation);
(1) Turn ignition key to “ON” position.
(2) Pull out emergency stop switch plate 1.
(3) Pull up emergency stop switch knob 2 three times in ten
seconds. A short beep will be heard if cancellation is successfully finished.
(4) Turn ignition key to “OFF” position, then set emergency
stop switch plate 1 in original position.
NOTE:
See “OIL CHANGE REMINDER SYSTEM” section on page
3-45.
9. 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.
Full level
line
Low level
line
2-5
2-6
PERIODIC MAINTENANCE
GEAR OIL
Change 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 first, then remove gear oil
level plug and drain gear oil.
1 Oil level plug
2 Oil drain plug
4. Fill with recommended gear oil through oil drain hole until oil
just starts to flow out from oil level hole.
Gear oil amount: 1 100 ml (37.2/38.7 US/Imp. oz)
Recommended oil:
SUZUKI OUTBOARD MOTOR GEAR OIL or
SAE #90 HYPOID GEAR OIL
5. Install oil level plug before removing oil filler tube from drain
hole.
6. Install oil drain plug.
#
Do not re-use 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.
PERIODIC MAINTENANCE
LUBRICATION
Inspect every 50 hours (3 months).
Apply SUZUKI Water Resistant Grease to the following points.
$ 99000-25160: SUZUKI WATER RESISTANT GREASE
Throttle cable/link
Shift link
Throttle cable/link
Swivel bracket
Propeller shaft
Swivel bracket
2-7
2-8
PERIODIC MAINTENANCE
SPARK PLUG
• Inspect every 100 hours (6 months).
• Replace every 200 hours (12 months).
Standard spark plug: NGK BKR6E
#
Only resistor (R) type spark plugs must be used with
this engine. Using a non-resistor spark plug will cause
ignition and fuel injection system malfunctions.
REMOVAL
• Disconnect ignition coil connector, then remove the bolt
securing the ignition coil.
• Remove the ignition coil and spark plug.
CARBON DEPOSIT
Inspect for a carbon deposit on spark plug base.
If carbon is present, remove it with a spark plug cleaning
machine or by carefully using a pointed tool.
SPARK PLUG GAP
Measure spark plug gap with a thickness gauge.
Adjust to within specified range if gap is out of specification.
Spark plug gap: 0.7 – 0.8 mm (0.028 – 0.031 in)
! 09900-20803: Thickness gauge
CONDITION OF ELECTRODE
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.
#
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.
Gap
PERIODIC MAINTENANCE
INSTALLATION
Installation is reverse order of removal.
" Spark plug: 28 N·m (2.8 kg-m, 20.0 lb-ft)
TAPPET CLEARANCE
Inspect initially after 20 hours (1 month) and every
200 hours (12 months).
The tappet clearance specification is different for intake and
exhaust valves.
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.
CHECKING AND ADJUSTING TAPPET CLEARANCE
1. Remove following parts:
• Engine side lower cover (See page 7-2.)
• Ring gear cover and air intake silencer case
• Ignition coils
• Spark plugs
• Collector assembly (See page 6-3, 6-5.)
2. Remove PORT and STBD cylinder head covers. (See page
6-8.)
2-9
2-10
PERIODIC MAINTENANCE
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.
90˚
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)
! 09900-20803: Thickness gauge
#
This is 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.
5. If out of specification, adjust tappet clearance by changing
shim.
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.
Cut section of the tappet
Plug hole
! Shim
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.
! 09916-69310: Tappet holder
Camshaft housing bolt
Plug hole
PERIODIC MAINTENANCE
2-11
4. Rotate top of cam 90 degree counterclockwise and remove
shim from cut-away at tappet.
(Two tappets can be adjusted at the same time.)
#
• Do not put your finger between camshaft and tappet
while the tappet is being held with the tappet holder.
• Use a magnet to remove and install shim.
• When installing shim, identification mark on the
shim should face down (towards tappet).
Magnet
Shim
5. After removing shim, measure thickness of original shim and
determine correct thickness of shim for proper tappet clearance as calculated by following formula.
! 09900-20205: Micrometer
IN. side:
A = B + (C – 0.25 mm)
EX. side:
A = B + (C – 0.32 mm)
Removed shim
A: Correct thickness of shim for proper tappet
clearance (mm)
B: Thickness of original shim (mm)
C: Original tappet clearance (mm)
I.D No.
Thickness
(mm)
I.D No.
Thickness
(mm)
I.D No.
Thickness
(mm)
218
220
223
225
228
230
233
235
238
240
243
245
2.18
2.20
2.23
2.25
2.28
2.30
2.33
2.35
2.38
2.40
2.43
2.45
248
250
253
255
258
260
263
265
268
270
273
275
2.48
2.50
2.53
2.55
2.58
2.60
2.63
2.65
2.68
2.70
2.73
2.75
278
280
283
285
288
290
293
295
298
300
2.78
2.80
2.83
2.85
2.88
2.90
2.93
2.95
2.98
3.00
I.D No.
2.50 mm
250
2-12
PERIODIC MAINTENANCE
6. Install shim. Identification number should face down
(towards tappet).
7. Rotate crankshaft to be open (lift up) valve.
8. Remove tappet holder 1 and tighten camshaft housing bolts
to specified torque.
" Camshaft housing bolt: 12 N·m (1.2 kg-m, 8.7 lb-ft)
Special tool
Tappet
! Camshaft
9. Recheck tappet clearance.
NOTE:
After completing tappet clearance adjustment and securing
camshaft housing bolts, inspect tappet clearance again.
REASSEMBLY
After checking and adjusting all valves, reinstall parts removed
earlier.
Installation is reverse order of removal.
Cylinder head cover
Install the cylinder head cover. (See page 6-10.)
NOTE:
Examine cylinder head cover gasket for damage.
Always replace gasket if sealing performance is suspect.
1
• Tighten cylinder head cover bolts to specification.
" Cylinder head cover bolts: 11 N·m (1.1 kg-m, 8.0 lb-ft)
1. Head cover gasket
PERIODIC MAINTENANCE
OCV (Oil control valve)
• On the DF250 model, install gasket and OCV, and then
tighten bolts securely.
NOTE:
Position the projection of OCV gasket as shown the right.
1
#
Do not re-use OCV gasket. Always replace with new
one.
1. OCV gasket
" OCV bolt: 12 N·m (1.2 kg-m, 8.6 lb-ft)
Collector assembly
• Install the collector assembly. (See page 6-5, 6-7.)
1
1. Collector assembly
Checking
• All parts removed have been returned to their original positions.
• Check hose and wire routing. (See page - .)
• Check oil leakage.
2-13
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293
220 223 225 225 228 230 233 235 240 240 245 245 250 250 255 255 260 260 263 265 270 270 273 278 280 280 283 285 290 290 293 295
0.10 – 0.14
0.15 – 0.19
0.20 – 0.22
0.88 – 0.92 283 285 288 290 293 295 298 300
0.83 – 0.87 278 280 283 285 288 290 293 295 298 300
0.78 – 0.82 273 275 278 280 283 285 288 290 293 295 298 300
0.73 – 0.77 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.68 – 0.72 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.63 – 0.67 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.58 – 0.62 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.53 – 0.57 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.48 – 0.52 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
Tappet clearance is — 0.35 mm
Present shim size
— 2.40 mm
Shim size to be used — 2.50 mm
1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
3. Match clearance in vertical column with
present shim size in horizontal column.
0.43 – 0.47 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.38 – 0.42 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.33 – 0.37 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.28 – 0.32 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
SPECIFIED CLEARANCE/NO. ADJUSTMENT REQUIRED
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283
0.05 – 0.09
0.23 – 0.27
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278
2.18 2.20 2.23 2.25 2.28 2.30 2.33 2.35 2.38 2.40 2.43 2.45 2.48 2.50 2.53 2.55 2.58 2.60 2.63 2.65 2.68 2.70 2.73 2.75 2.78 2.80 2.83 2.85 2.88 2.90 2.93 2.95 2.98 3.00
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.00 – 0.04
Tappet
clearance
(mm)
Present shim
size (mm)
Shim
I.D. No.
TAPPET SHIM SELECTION CHART [IN. side]
2-14
PERIODIC MAINTENANCE
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295
0.10 – 0.14
0.15 – 0.19
0.20 – 0.24
0.25 – 0.29
0.30 – 0.32
0.90 – 0.94
275 278 280 283 285 288 290 293 295 298 300
0.85 – 0.89 270 273 275 278 280 283 285 288 290 293 295 298 300
0.80 – 0.84 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.75 – 0.79 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.70 – 0.74 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.65 – 0.69 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.60 – 0.64 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.55 – 0.59 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
Tappet clearance is — 0.40 mm
Present shim size
— 2.40 mm
Shim size to be used — 2.48 mm
1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
3. Match clearance in vertical column with
present shim size in horizontal column.
0.50 – 0.54 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.45 – 0.49 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.40 – 0.44 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.38 – 0.39 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
SPECIFIED CLEARANCE/NO. ADJUSTMENT REQUIRED
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273
0.05 – 0.09
0.33 – 0.37
220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268
2.18 2.20 2.23 2.25 2.28 2.30 2.33 2.35 2.38 2.40 2.43 2.45 2.48 2.50 2.53 2.55 2.58 2.60 2.63 2.65 2.68 2.70 2.73 2.75 2.78 2.80 2.83 2.85 2.88 2.90 2.93 2.95 2.98 3.00
218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
0.00 – 0.04
Tappet
clearance
(mm)
Present shim
size (mm)
Shim
ID No.
TAPPET SHIM SELECTION CHART [EX. side]
PERIODIC MAINTENANCE
2-15
2-16
PERIODIC MAINTENANCE
IDLE SPEED
Inspect initially after 20 hours (1 month) and every
200 hours (12 months).
NOTE:
• Before checking idle speed, engine must be warmed up.
• Check and/or adjust idle speed after engine speed has stabilized.
• Before checking idle speed, check throttle link mechanism and
throttle valve for smooth operation.
No. 1 Ign. coil
1. Remove bolt and No. 1 ignition coil.
2. Connect special tool (H·T cord with plug cap adapter)
between No. 1 ignition coil and spark plug.
! 09930-89350: H·T cord with plug cap adapter
3. Start engine and allow to warm up.
4. Attach engine tachometer to the special tool.
! 09900-26006: Engine tachometer
5. Check engine speed.
Idle speed (in neutral gear): 600 – 700 r/min.
ADJUSTMENT:
If engine idle speed is out of specification, the following adjustment procedure must be performed.
6. Shift into Neutral and close the throttle fully (this will cause
the fully close throttle signal to be input to the ECM).
7. To set the IAC valve duty to constant 30%, turn the ignition
key from ON to START five times within ten seconds.
At this time, caution buzzer will sound to notify that IAC duty
is in fixed mode.
NOTE:
• The ignition key operation to set the IAC valve into the fixed
mode should be performed with the engine running at idle.
• While IAC valve duty is at a fixed 30% duty, the caution buzzer
will sound in a repeating pattern of 0.5 second on with an interval of 3 seconds off.
• The 30% fixed mode of IAC valve duty will continue for 5 minutes after which it will automatically cancel.
8. During this fixed mode of IAC valve duty, adjust engine
speed to 650 ± 50 r/min. by turning by-pass air screw.
Turning air screw counterclockwise:
Engine speed will increase.
Turning air screw clockwise:
Engine speed will decrease.
1
2
1. PORT throttle body
2. By-pass air screw
PERIODIC MAINTENANCE
9. When finished adjusting the idle speed, opening the throttle
will automatically cancel the IAC fixed mode.
NOTE:
The fixed mode of IAC can also be canceled manually by shifting to Forward or Reverse or raising the engine speed (causes
the fully close throttle signal of TPS to be OFF ).
10. Return the throttle to full close and check engine speed. It
should now be stable at 600 – 700 r/min.
NOTE:
Idling/trolling speed of 600 – 700 r/min. is controlled by IAC (idle
air control) system.
If engine speed does not return to specification, IAC passage
may be clogged or IAC system may not be operating correctly.
See “IDLE AIR CONTROL SYSTEM” section on page 3-28.
NOTE:
Trolling speed (in-gear idle speed) is same as idle speed.
IGNITION TIMING
Inspect every 200 hours (12 months).
NOTE:
Before checking the ignition timing, make sure idle speed is
adjusted within the specification.
1. Start the engine and allow to warm up.
2. Attach the timing light cord to the No. 1 ignition coil primary
wire.
! 09930-76420: Timing light
09900-26006: Engine tachometer
3. Check the ignition timing while operating the engine in neutral gear at 1 000 r/min.
Ignition timing: Approx. BTDC 0° ± 5° at 1 000 r/min.
2-17
2-18
PERIODIC MAINTENANCE
FUEL LINE
• Inspect initially after 20 hours (1 month) and every
50 hours (3 months).
• Replace every 2 years.
If leakage, cracks, swelling or other damage is found, replace
the fuel line.
PERIODIC MAINTENANCE
2-19
LOW PRESSURE FUEL FILTER
1
• Inspect before every use.
• Inspect every 50 hours (3 months).
• Replace every 400 hours or 2 years.
If leakage, cracks or other damage is found, replace the fuel filter.
NOTE:
When water is present in the fuel supply, the red indicator float
surrounding the filter element rises.
Whenever the red float is up, remove filter cap and drain the
water.
1. Fuel filter
Inspect and Cleaning
%
Spring
• 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.
Red float
1. Turn the engine “off”.
2. Remove the two (2) bolts securing low pressure fuel filter to
filter bracket and remove fuel filter.
3. Remove the ring nut 2.
4. Separate the filter cap 3 from filter body 1, then remove
large O-ring 4, filter element 5 and small O-ring 6.
5. Inspect filter element and O-rings for damage.
Replace if damaged.
6. Wash the filter element with cleaning solvent.
7. Assemble the small O-ring 6 and filter element 5 to filter
body 1.
8. Install large O-ring 4 and filter cap 3, then thread the ring
nut 2 into position.
9. Install low pressure fuel filter and tighten bolts securely.
10. Restart the engine and check that there are no leaks around
the fuel filter.
HIGH PRESSURE FUEL FILTER
1
Replace every 1 000 hours.
SUZUKI recommends that replacing the high pressure fuel filter
every 1 000 operating hours.
1. High pressure fuel filter
2-20
PERIODIC MAINTENANCE
PCV SYSTEM
2
• Inspect initially after 20 hours (1 month) and every
50 hours (3 months).
• Replace every 2 years.
NOTE:
Be sure to check for any obstruction in the PCV valve or its hose
before checking engine idle speed/IAC duty.
An obstructed PCV valve or hose prevents proper operation of
these items.
1
1. PCV valve
2. PCV hose
PCV HOSE
Check crank case ventilation hoses (breather hose) and PCV
hoses for connection, leakage, cracks, clog or deterioration.
Check for sticking or clogged PCV valve. Replace as necessary.
3
3. Breather hose
PCV valve inspection
1. Disconnect PCV valve from cylinder head cover.
2. Run engine at idle.
3. Place your finger over end of PCV valve to check for vacuum.
If there is no vacuum, check for clogged valve. Replace as
necessary.
4. After checking vacuum, stop engine and remove PCV valve
from hose.
Shake valve and listen for the rattle of check needle inside
the valve.
If valve does not rattle, replace valve.
1
1. PCV valve
5. After checking, connect PCV valve, PCV hose and tighten
clamps securely.
1
1. PCV valve
PERIODIC MAINTENANCE
LOW PRESSURE FUEL PUMP FILTER
1
Replace every 1 000 hours.
SUZUKI recommends that replacing the low pressure fuel pump
filter every 1 000 operating hours.
1. Low pressure fuel pump filter
WATER PUMP/WATER PUMP IMPELLER
WATER PUMP
Inspect every 200 hours (12 months).
Inspect water pump case, inner sleeve and under panel.
Replace if wear, cracks, distortion or corrosion is found.
WATER PUMP IMPELLER
Replace every 200 hours (12 months).
Inspect water pump impeller.
Replace if vanes are cut, torn or worn.
PROPELLER/NUT/COTTER PIN
Inspect initially after 20 hours (1 month) and every
100 hours (6 months).
• Inspect propeller for bent, chipped or broken blades.
Replace propeller if damage noticeably affects operation.
• Inspect propeller splines. Replace propeller if splines are
worn, damaged or twisted.
• Inspect propeller bush for slippage.
Replace if necessary.
• Make sure that propeller nut is torqued to specification and
cotter pin is installed securely.
BONDING WIRES
• If breakage or other damage is found on bonding wire,
replace the wire.
• If rust, corrosion or other damage is found on terminal, clean
with cleaning solvent or replace wire.
2-21
2-22
PERIODIC MAINTENANCE
ANODES
Inspect every 50 hours (3 months).
ANODES
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.
STBD cylinder
NOTE:
The anode cover may be separated from the power unit body by
inserting and turning a 10 mm bolt it to function as a screw jack.
1
2
1. Screw jack
2. Anode cover
#
Anode
Never paint the anode.
NOTE:
The anode securing bolt should be covered with SUZUKI SILICONE SEAL.
& 99000-31120: SUZUKI SILICONE SEAL
PORT cylinder
PERIODIC MAINTENANCE
BATTERY
Inspect every 50 hours (3 months).
%
• Never expose battery to open flame or electric spark
as batteries generate gas, which is flammable and
explosive.
• Battery acid is poisonous and corrosive. Avoid 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
CONNECTING BATTERY
Upon completion of connection, lightly apply grease to battery
terminals.
How to connect:
1. Connect positive (+) terminal first.
2. Connect negative (–) terminal second.
How to disconnect:
1. Disconnect negative (–) terminal first.
2. Disconnect positive (+) terminal second.
#
If the battery leads are loose, incorrectly connected or
reversed, the electrical system could be damaged.
2-23
2-24
PERIODIC MAINTENANCE
BATTERY SOLUTION LEVEL CHECK
Battery solution level should be between UPPER level and
LOWER level.
If level is low, add distilled water only.
#
Once the battery has been initially serviced, NEVER
add diluted sulfuric acid or battery damage will occur.
Follow the battery manufacture’s instructions for specific maintenance procedures.
BATTERY SOLUTION GRAVITY CHECK
Measure the gravity of battery solution using a hydrometer.
Battery solution gravity: 1.28 at 20 °C
! 09900-28403: Hydrometer
PERIODIC MAINTENANCE
BOLTS AND NUTS
Inspect 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.
ITEM
Cylinder head cover bolt
Collector
Flywheel bolt
Power unit mounting bolt
Clamp bracket shaft nut
Lower mount bolt/nut
Gearcase bolt
Propeller nut
THREAD
DIAMETER
6 mm
8 mm
12 mm
8 mm
10 mm
22 mm
14 mm
10 mm
12 mm
18 mm
N·m
11
23
118
23
50
43
100
54
83
55
FUEL MIXTURE CHECK (O2 FEEDBACK)
Perform every 2 years.
To perform fuel mixture check (O2 feedback) operation, a battery powered personal computer and the Suzuki Diagnostic System software/hardware must be used.
For fuel mixture check (O2 feedback) operation, refer to “Suzuki
Diagnostic System Operation Manual”.
NOTE:
See “O2 FEEDBACK SYSTEM” section on page 3-47 before
starting O2 feedback operation.
TIGHTENING TORQUE
kg-m
1.1
2.3
11.8
2.3
5.0
4.3
10.0
5.5
8.3
5.5
lb-ft
8.0
16.6
85.3
16.5
36.0
31.0
72.3
40.0
60.0
40.0
2-25
2-26
PERIODIC MAINTENANCE
OIL PRESSURE
Oil pressure (at normal operating temp.):
400 – 600 kPa (4.0 – 6.0 kg/cm2, 57 – 85 psi)
at 3000 r/min.
NOTE:
The figure shown above is a guideline only, not an absolute service limit.
If oil pressure is lower or higher than specification, the following
causes may be considered.
(See page 6-98 for oil passage locations.)
Low oil pressure
• Clogged oil filter
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
• Damage 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
TEST PROCEDURE
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.
3. Install oil pressure gauge adaptor into oil pressure swicth
hole in place of oil pressure switch.
! 09915-77311: Oil pressure gauge
09915-78211: Oil pressure gauge adapter
PERIODIC MAINTENANCE
4. Start engine and allow to warm up as follows:
Summer : 5 min. at 2 000 r/min.
Winter
: 10 min. at 2 000 r/min.
5. After warming up, shift into forward gear and increase
engine speed to 3 000 r/min., then compare pressure indicated on gauge to specifications.
6. After testing, reinstall oil pressure switch.
(See page 3-69.)
Monitor-tachometer
2-27
2-28
PERIODIC MAINTENANCE
CYLINDER COMPRESSION
Cylinder compression:
Standard: 1 100 – 1 700 kPa
(11 – 17 kg/cm2, 156 – 242 psi)
Max. difference between any other cylinders:
100 kPa (1.0 kg/cm2, 14 psi)
NOTE:
Figures shown are guidelines only, not absolute service limits.
Low compression pressure can indicate one or more of the following:
• Excessively worn cylinder wall
• Worn piston or piston rings
• Stuck piston rings
• Poor seating of valves
• Ruptured or otherwise damaged cylinder head gasket
TEST PROCEDURE
1. Start engine and allow to warm up, then shut engine off.
2. Disconnect all ignition coil connectors.
3. Remove the bolts securing the ignition coil, then remove all
spark plugs.
4. Install compression gauge hose attachment into spark plug
hole, then connect compression gauge hose to gauge hose
attachment and compression gauge.
1. Compression gauge
2. Compression gauge hose
3. Compression gauge hose
attachment
1
2
! 09915-64512: Compression gauge
09915-64530: Compression gauge hose
09915-67010: Compression gauge hose attachment
5. Disconnect remote control throttle cable from throttle lever.
6. Move and hold throttle lever in full-open position.
7. While cranking engine with starter motor, note maximum
compression pressure reading on gauge for each cylinder.
8. Reinstall parts removed earlier. (spark plugs, ignition coils,
etc.)
Throttle lever
3
PERIODIC MAINTENANCE
ENGINE VACUUM CHECK
Engine vacuum is required for proper operation of the
Multi-Stage Induction system used on the DF225 & DF250.
Engine vacuum is also an indicator of general engine condition.
1. Warm up engine to normal operating temperature.
Make sure engine idle speed is within specification.
2. Stop engine and disconnect vacuum outlet hose from PORT
side of intake manifold outer cover (collector cover).
3. Connect special tools (vacuum gauge, hose and 3-way joint)
between engine vacuum hose and collector cover hose connection.
2
! 09915-67311: Vacuum Gauge
09918-08210: Hose joint
09355-35754-601: Hose
09367-04002: 3-way joint
1
1. Intake manifold outer cover
(Collector cover)
2. Check valve
4. Start engine and run at idle speed. Vacuum reading on
gauge should be within specification.
Vacuum specification (idle speed at sea level)
61 – 71 kPa (457 – 533 mmHg, 18 – 21 inHg)
To collector cover
Check
valve.
5. If vacuum is not within specification, further testing (leakdown test, compression test, etc.) and evaluation of engine
condition is required.
To vacuum tank
Possible causes of incorrect engine vacuum
• Piston ring leakage
• Incorrect valve timing
• Poor valve/valve seat/valve guide condition
• Intake leakage
• Cylinder head gasket leakage
• Restricted exhaust
2-29
ENGINE CONTROL SYSTEM
3-1
ENGINE CONTROL SYSTEM
CONTENTS
ENGINE CONTROL SYSTEM STRUCTURE ..................................................... 3- 2
SYSTEM STRUCTURE 1 .......................................................................... 3- 2
SYSTEM STRUCTURE 2 .......................................................................... 3- 3
COMPONENTS FOR SYSTEM CONTROL ....................................................... 3- 5
ENGINE CONTROL MODULE (ECM) ...................................................... 3- 5
ECM CONNECTOR/TERMINALS LAYOUT ............................................. 3- 6
ECM INTERNAL STRUCTURE ................................................................ 3- 7
LOCATION OF SENSOR AND SWITCH .................................................. 3- 8
SENSOR AND SWITCH ............................................................................ 3-10
IGNITION SYSTEM ............................................................................................ 3-17
IGNITION CONTROL SYSTEM ................................................................ 3-18
ELECTRONIC FUEL INJECTION SYSTEM ....................................................... 3-20
FUEL INJECTION CONTROL SYSTEM ................................................... 3-20
FUEL DELIVERY SYSTEM COMPONENTS ............................................ 3-22
HIGH PRESSURE FUEL PUMP CONTROL SYSTEM ............................. 3-25
LOW PRESSURE FUEL PUMP CONTROL SYSTEM ............................. 3-26
EVAPORATION PURGE SYSTEM ........................................................... 3-26
AIR INTAKE COMPONENTS ................................................................... 3-27
IDLE AIR CONTROL SYSTEM ................................................................. 3-28
MULTI-STAGE INDUCTION ............................................................................... 3-31
OUTLINE ................................................................................................... 3-31
SYSTEM COMPOSITION ......................................................................... 3-31
SYSTEM OPERATION .............................................................................. 3-32
VVT (Variable Valve Timing) SYSTEM ............................................................. 3-33
CAUTION SYSTEM ............................................................................................ 3-35
OVER-REVOLUTION CAUTION SYSTEM ............................................... 3-35
LOW OIL PRESSURE CAUTION SYSTEM ............................................. 3-36
OVERHEAT CAUTION ............................................................................. 3-37
LOW BATTERY VOLTAGE CAUTION SYSTEM ..................................... 3-38
SELF-DIAGNOSTIC SYSTEM ............................................................................ 3-39
PRIORITY/CODE/PATTERN FOR SELF-DIAGNOSTIC
SYSTEM OPERATION .............................................................................. 3-39
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION .............. 3-41
FAIL-SAFE SYSTEM .......................................................................................... 3-43
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM ...................... 3-43
OPERATING HOUR INDICATION SYSTEM ...................................................... 3-44
OIL CHANGE REMINDER SYSTEM .................................................................. 3-45
START-IN-GEAR PROTECTION SYSTEM ........................................................ 3-46
O2 FEEDBACK SYSTEM ................................................................................... 3-47
INSPECTION ...................................................................................................... 3-48
PRECAUTION ON SYSTEM INSPECTION .............................................. 3-48
26-PIN & 34-PIN TEST CORD .................................................................. 3-48
INSPECTION FOR ECM CIRCUIT VOLTAGE ......................................... 3-49
INSPECTION FOR RESISTANCE ............................................................ 3-52
COMPONENT INSPECTIONS .................................................................. 3-53
MULTI-STAGE INDUCTION ..................................................................... 3-63
REMOVAL/INSTALLATION ............................................................................... 3-66
FLYWHEEL ............................................................................................... 3-66
CKP SENSOR ........................................................................................... 3-68
CMP SENSOR ........................................................................................... 3-69
IAC VALVE ................................................................................................ 3-69
OIL PRESSURE SWITCH ......................................................................... 3-69
OCV (Oil control valve) ............................................................................ 3-70
THROTTLE CONTROL ...................................................................................... 3-71
SYNCHRONIZING THROTTLE BODIES .................................................. 3-71
THROTTLE CONTROL CABLE ............................................................... 3-72
3
6
3-2
ENGINE CONTROL SYSTEM
ENGINE CONTROL SYSTEM STRUCTURE
The DF200/DF225/DF250 models employ an integrated control system which performs the control functions
for fuel injection, ignition, idle/trolling speed (idle air), etc. through the ECM (Engine Control Module).
SYSTEM STRUCTURE 1
INPUT
(sensor/switch)
CONTROL
(ECM)
OUTPUT
(actuator etc.)
CKP sensor
Fuel injection system
Fuel injector
CMP sensor #1
Ignition system
Ignition coil
CMP sensor #2
Idle air control system
IAC valve
CMP sensor #3
VVT system
Oil control valve
MAP sensor
Low pressure fuel pump
Fuel pump system
IAT sensor
Cylinder temp. sensor
High pressure fuel pump
Multi-stage induction system
VSV (Vacuum switching valve)
Evaporation purge system
Purge valve
Caution system
Caution Buzzer
Exhaust manifold temp. sensor #1
Exhaust manifold temp. sensor #2
Throttle position sensor
Self diagnostic system
Monitor-tachometer
Neutral switch
Fail safe system
Shift position sensor
Oil pressure switch
Operating hour indication system
Oil changing reminder system
Emergency stop switch
Ignition switch
Start-in-gear protection system
Starter motor relay control system
O2 sensor (Optional)
O2 feedback system
NOTE:
• DF200/225 models are not equipped with CMP sensor #2·3 and VVT system.
• DF200 model is not equipped with Multi-stage induction system.
Starter motor relay,
(Starter motor)
Fuse
Main relay
Starter relay
E.C.M.
Filter
IAT sensor
Throttle body
Fuel
cooler
CKP sensor
MAP sensor
Cylinder
temp. sensor
Ex. manifold
temp. sensor
CMP sensor
Flywheel
magneto
*O2 sensor
Spark plug
Fuel
injector
Ignition coil
High
pressure
fuel filter
High
pressure
fuel
pump
Intake
manifold
By-pass
air screw
IAC valve
Fuel pressure
regulator
Evaporation
hose
Float
Fuel vapor separator
Throttle position sensor
Silencer
Purge control valve
Low pressure
fuel pump
Squeeze pump
Low pressure
fuel filter
SYSTEM STRUCTURE 2
* : O2 Sensor must be installed when performing
“O2 feedback operation” only.
Emergency ST
stop switch
OFF
Ignition
IG switch
Neutral switch
Shift position
sensor
Battery
Fuel tank
ENGINE CONTROL SYSTEM
[DF200]
3-3
OFF
Fuse
Main relay
Starter relay
E.C.M.
Filter
Throttle position sensor
IAT sensor
Silencer
High
pressure
fuel
pump
High
pressure
fuel filter
By-pass
air screw
Throttle body
IAC valve
VSV
Intake manifold
MAP sensor
Fuel
Fuel pressure regulator cooler
Fuel injector
Evaporation
hose
Float
Fuel vapor separator
Low pressure
fuel filter
Purge control valve
Low pressure
fuel pump
Squeeze pump
* : O2 Sensor must be installed when performing
“O2 feedback operation” only.
** : DF225 model is not equipped with OCV and VVT system.
Emergency ST
stop switch
Ignition
IG switch
Neutral switch
Shift position
sensor
Battery
Fuel tank
Cylinder temp. sensor
Ex. manifold
temp. sensor
CMP sensor
*O2 sensor
Spark plug
**OCV
Ignition coil
CKP
sensor
Flywheel
magneto
3-4
ENGINE CONTROL SYSTEM
[DF225/DF250]
ENGINE CONTROL SYSTEM
3-5
COMPONENTS FOR SYSTEM CONTROL
ENGINE CONTROL MODULE (ECM)
The ECM sends signals to control the actuators based on the information inputs from each sensor/switch.
Major controls are as follows:
NAME OF CONTROL
Fuel injection control
Ignition control
Idle air control
VVT system
Fuel pump control
•
•
•
Multi-stage induction system
•
•
•
•
Evaporation purge system
•
Caution system control
•
•
•
•
Self-diagnostic system control
Fail-safe system control
Total operating hour indication
system control
Oil changing reminder system
control
Start-in-gear protection system
control
Starter motor relay control
system
O2 feedback system control
•
DESCRIPTION
Controls fuel injection amount and timing.
Controls ignition timing.
Controls idling/trolling speed by adjusting intake air amount through
IAC valve.
Controls intake cam valve timing through OCV (Oil control valve).
Controls high pressure fuel pump drive.
Controls Low pressure fuel pump drive.
Changing the length of intake manifold pipes according to engine
speed.
Discharges vapor generated within fuel vapor separator to air intake
silencer case by controlling purge valve.
Informs operator of abnormal engine condition.
Controls engine speed.
Informs operator of sensor/switch malfunction.
Allows operation with back-up system during sensor/switch
malfunction.
Informs operator of total operating time.
• Informs operator of time for replacing engine oil on the basis of the
maintenance schedule.
• Prevents engine start when shift is positioned in forward or reverse.
• Prevents starter motor operation when engine is already operating.
• Controls and performs O2 feedback operation using optional O2 sensor.
NOTE:
The information related to the Caution system, Self-Diagnostic System, Total operating hour indication system and O2 feedback system are retained in ECM memory.
ECM
3-6
ENGINE CONTROL SYSTEM
ECM CONNECTOR/TERMINALS LAYOUT
27
28
36
44
52
29
37
45
53
30
38
46
54
31
39
47
55
32
40
48
56
33
41
49
57
34
42
50
58
1
35
51
59
2
8
43
14
60
20
3
9
15
21
4
10
16
22
5
11
17
23
6
12
18
24
7
13
19
25
26
(FRONT VIEW)
TERMI- WIRE
CIRCUIT
NAL
COLOR
1
Dg
Starter relay control
2
B/G
O2 Feedback
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
R/B
Y/Bl
B/O
O/G
V/W
Lg/W
G/R
P/Bl
W
B
R
Bl/R
Br/Y
P/B
Br
Bl
Gr
Y
O/Y
B/Bl
O
Lg/B
—
O/Bl
R/W
Y/R
Br/W
CKP sensor
CMP sensor #1
CMP sensor #3 (VVT_ STBD)
CMP sensor #2 (VVT_ PORT)
Ex-manifold temp. sensor #1
Cylinder temp. sensor
Ex-manifold temp. sensor #2
Shift position sensor
MAP sensor
Model distinction (DF200 only)
Power source for sensor
Emergency stop switch
Throttle position sensor
Ground for ECM main relay
Neutral/Cranking switch
Oil pressure switch
ECM power source
PC communication
PC communication
Engine switch
Buzzer cancel
IAT sensor
—
No. 5 Fuel injector (–)
No. 3 Fuel injector (–)
No. 6 Fuel injector (–)
No. 1 OCV (–)
TERMI- WIRE
CIRCUIT
NAL
COLOR
31
Br/R No. 2 OCV (–)
32
O/W Purge valve (–)
Variable intake control valve
33
Gr/R
(VSV)
34
P
Rev-Limit lamp
35
Y/B
Tachometer
36
B/Br
No. 2 Fuel injector (–)
37
W/G No. 5 Ignition coil (–)
38
Bl/Y
No. 6 Ignition coil (–)
39
Gr/Y No. 3 Ignition coil (–)
40
—
—
41
—
—
42
O
No. 1 Ignition coil (–)
43
Bl/W Buzzer
44
B/Y
Low pressure fuel pump (–)
45
Lg/R No. 4 Ignition coil (–)
46
B
Ground for power
47
B
Ground for power
48
B
Ground for ECM
49
B/W
Ground for sensor
50
Bl
No. 2 Ignition coil (–)
51
Bl/B
Oil lamp
52
B/R
High pressure fuel pump (–)
53
Lg
No. 4 Fuel injector (–)
54
O/B
No. 1 Fuel injector (–)
55
W/B
IAC valve #1
56
R/Y
IAC valve #2
57
W/Bl IAC valve #4
58
R/G
IAC valve #3
59
G/W CHECK ENGINE lamp
60
G/Y
TEMP lamp
Battery
Reset
switch
40
41
21
22
15
19
26
49
13
10
8
9
25
11
16
12
14
5
7
6
4
24
1
18
Starter
relay
20
48
SDS & Tool
23
17
Neutral
switch
ST.
OFF
IG.
Main relay
ECM POWER
Com. line
Com. line
Emergency stop switch
Oil pressure switch
Tester terminal
Sensor GND
Model distinction
EX. mani. temp. sensor #2
EX. mani. temp. sensor #1
CYL temp. sensor
IAT sensor
Shift sensor
Throttle sensor
MAP sensor
Sensor power
5V
CMP sensor #1
CMP sensor #2
VVT PORT
CMP sensor #3
VVT STBD
CKP sensor
Buzzer cancel switch
Relay control
Neutral/Cranking switch
ECM GND
ECM PWR
Main relay
Engine switch
RELAY CONTROL
CPU
Power GND
Power GND
O2 sensor
Tachometer
Over REV LED
Oil pressure LED
CHECK Eng. LED
TEMP. LED
Buzzer
Ignition coil #6
Ignition coil #4
Ignition coil #2
Ignition coil #5
Ignition coil #3
Ignition coil #1
F/P (L)
F/P (H)
IAC #2
IAC #4
IAC #3
IAC #1
Purge valve
Variable intake
control valve
OCV #2
OCV #1
Injector #6
Injector #5
Injector #4
Injector #3
Injector #2
Injector #1
47
46
2
35
34
51
59
60
43
38
45
50
37
39
42
44
52
56
57
58
55
32
33
31
30
29
27
53
28
36
54
IGT
IGT
PLUG
ENG
IGT
PLUG
ENG
IGT
M
ENG
IGT
PLUG
ENG
IGT
PLUG
PLUG
ENG
ENG
PLUG
ENGINE CONTROL SYSTEM
3-7
ECM INTERNAL STRUCTURE
3-8
ENGINE CONTROL SYSTEM
LOCATION OF SENSOR AND SWITCH
EX. temp. sensor (STBD)
Fuel injector
Ignition coil
IAC valve
MAP sensor
Cylinder temp. sensor
IAT sensor
TPS
VSV
Purge valve
EX. temp. sensor (PORT)
CMP sensor
CKP sensor
Ground cable bolt
60 A fuse
Starter motor reray
ECM main relay
Fuel pump (High pressure)
Battery cable
30 A fuse
To neutral switch
Fuel pump (Low pressure)
To shift sensor
Ground cable bolt
To trim sender, tilt limit switch & PTT motor
To PTT switch
ENGINE CONTROL SYSTEM
3-9
Shift position sensor
Neutral switch
Oil pressure swtich
Parts holder
Battery cable
CMP sensor (DF250)
CMP sensor STBD (DF250)
CMP sensor (DF200/225)
CMP sensor PORT (DF250)
Ignition coil
Fuel injector
OCV
OCV
3-10
ENGINE CONTROL SYSTEM
SENSOR AND SWITCH
CKP (Crankshaft Position) SENSOR
There is one (1) 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 34 reluctor bars, spaced 10 degrees apart, followed
by a 20 degree index space. During one crankshaft rotation, 34
signals are input to the ECM.
CMP (Camshaft Position) SENSOR #1
• For DF250 model:
CMP sensor #1 is mounted on the PORT cylinder head cover
with trigger vanes pressed onto the end of the PORT exhaust
camshaft. This sensor detects piston position.
• For DF200/225 models:
CMP sensor #1 is mounted on the STBD cylinder head cover
with trigger vanes pressed onto the end of the Intake camshaft. This sensor detects piston position.
• Signals received from this sensor are also used by the ECM
to determine sequential fuel injection control.
The CMP sensor contains a “Hall Effect” semiconductor and a
magnet. The semiconductor generates a voltage in proportion to
the line of magnetic force passed through it. When a trigger
vane on the camshaft reluctor aligns with the sensor’ internal
magnet, a large amount of magnetic force is generated allowing
a high voltage to pass through the semiconductor. When the
trigger vane moves away from the sensor, no magnetic force is
generated and low voltage passes through the semiconductor.
These generated voltages are rectified to create “ON” (high voltage) & “OFF” (low voltage) signals to the ECM.
The four camshaft trigger vanes provid four high voltage signals
from CMP sensor to ECM during one rotation of camshaft (two
rotations of crankshaft).
1
1. CKP sensor
2. Reluctor bar
2
1
DF225
1. CMP sensor
2
DF200/DF225
2. CMP sensor
Camshaft
Trigger vane
“Hall Effect” semiconductor
Magnet
CMP sensor
High voltage
Low voltage
ENGINE CONTROL SYSTEM
3-11
ECM cylinder identification:
Cylinders are identified by a calculation combined from two signals; one from the CKP sensor and one from
the CMP sensor.
#1 Cyl.
Cm.
#3 Cyl.
#4 Cyl.
#5 Cyl.
#6 Cyl.
Ep.
Ex.
Ep.
#2 Cyl.
Ex.
Ex.
Ex.
In.
In.
In.
In.
In.
Cm.
Cm.
Cm.
Cm.
Ep.
Ep.
Ep.
Ep.
34-signals/360˚
CKP
sensor
signal
Cm.
Cm.
Ex.
Ex.
In.
4-signals/720˚
CMP
sensor
signal #1
CMP
sensor
signal #2
CMP
sensor
signal #3
In.: Intake,
Cm.: Compression,
Ep.: Explosion,
CMP (Camshaft position) SENSOR #2
• For DF250 model:
CMP sensor #2 is mounted on the PORT cylinder head cover
with trigger vanes pressed onto the end of the PORT intake
camshaft. This sensor detects camshaft position.
• This sensor is the same type as the CMP sensor #1, and
inputs signals to ECM. This signal is used to control PORT
intake camshaft valve timing through OCV (Oil control valve).
Ex.: Exhaust
2
1
1. CMP sensor #1
2. CMP sensor #2
CMP (Camshaft position) SENSOR #3
• For DF250 model:
CMP sensor #3 is mounted on the STBD cylinder head cover
with trigger vanes pressed onto the end of the STBD intake
camshaft. This sensor detects camshaft position.
• This sensor is the same type as the CMP sensor #1, and
inputs signals to ECM. This signal is used to control STBD
intake camshaft valve timing through OCV (Oil control valve).
3
3. CMP sensor #3
3-12
ENGINE CONTROL SYSTEM
CYLINDER TEMPERATURE SENSOR
The cylinder temperature sensor is installed on the cylinder (top
side) and used to detect the cylinder temperature.
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 time duration, ignition timing, evaporation purge system,
etc.
This sensor is also used to detect engine over-heat as the ECM
detects both the temperature and temperature change gradient
(temperature rise vs time).
Cylinder
temp. sensor
Resistance
(k9
Temperature
EXHAUST MANIFOLD TEMPERATURE SENSOR
Two exhaust manifold temperature sensor are used, one
installed on each exhaust manifold (PORT and STBD) 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 and control
evaporation purge system.
(C˚)
Ex. manifold
temp. sensor
(PORT)
Ex. manifold
temp. sensor
(STBD)
ENGINE CONTROL SYSTEM
IAT (Intake Air Temperature) SENSOR
The IAT sensor is installed on the bottom of the ring gear cover
and air intake silencer case and used to detect the intake air
temperature.
This sensor is the same type as the cylinder temperature sensor, and inputs a signal to the ECM as a voltage value.
This signal is used to compensate the fuel injection time duration.
MAP (Manifold Absolute Pressure) SENSOR
The MAP sensor is installed on the collector assembly (top side)
and used to detect the intake manifold (surge tank) pressure.
It also detects the barometric pressure before starting the
engine. This sensor inputs the intake manifold (surge tank) pressure to the ECM as a voltage value.
This input signal is used as the fundamental signal to determine
fuel injection time duration, ignition timing, etc.
TPS (Throttle Position Sensor)
The TPS is installed on the PORT side throttle body and detects
the throttle opening with the throttle shaft interlocked.
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 position
and throttle opening and determines the control modes of various controls systems (Idle air control, VVT system control, Fuel
injection control system, etc.).
NEUTRAL SWITCH
The neutral switch is installed on the throttle lever holder and
used to detect the shift position.
This switch is “ON” in neutral and “OFF” in forward or reverse.
Based on the switch’ shift position signal input, the ECM performs the following controls:
• When the shift is in forward or reverse at the time of engine
start, no power is supplied to starter motor relay preventing
starter motor engagement.
(Start-in-gear protection. See page 3-46.)
2
1
1. IAT sensor
2. Air intake silencer case
MAP sensor
Throttle position
sensor
Neutral switch
3-13
3-14
ENGINE CONTROL SYSTEM
SPS (Shift Position Sensor)
The SPS is installed on the throttle lever holder and detects the
shift position with the clutch lever operation interlocked.
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 calculates and determines
the change of shift position and executes the following controls.
• When the shift 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 for 0.1 second to prevent unstable engine idle or stalling.
ECM MAIN RELAY
The ECM main relay is installed in the electric parts holder.
When energized by turning the ignition switch ON, a circuit is
formed which supplies battery voltage to the ECM, fuel injector,
ignition coil, IAC valve, CMP sensor, high/low pressure fuel
pump, purge valve, OCV (Oil control valve) and VSV (Vacuum
switching valve).
CRANKING SWITCH SIGNAL
The ECM detects the engine being started by the position of
ignition switch key. When the ignition key is turned to ST position, a voltage (12 V) signal is input to the ECM.
The ECM in turn controls the actuators for ignition, fuel injection,
IAC, etc. to the starting mode.
With the key is turned to IG position after the engine has been
started, the input voltage becomes approx. 1.4 V.
Shift position sensor
ECM
main relay
+12V
1
OFF
ON
ST
ECM
2
3
1. Ignition switch
2. Neutral switch
3. To starter motor relay
ENGINE CONTROL SYSTEM
SUB BATTERY CABLE
The ECM power source is through the gray lead wire which supplies power directly from the battery.
The white lead wire in the remote control extension harness carries battery power to the ignition switch. When the ignition switch
is turned ON, battery power passes from the white lead wire,
through the ignition switch contacts to the gray output lead wire
to the ECM.
NOTE:
Ensure battery cable connections are clean and secure.
Failure at the battery connection will cause incorrect operation of
the ECM and starter motor cranking system.
Sub battery cable
15 amp. fuse
BATTERY
3-15
3-16
ENGINE CONTROL SYSTEM
O2 SENSOR (Optional item)
The O2 sensor is installed in the exhaust manifold only when the
O2 feedback operation is performed.
This sensor is a zirconia element (platinum plated) which
changes output voltage depending on the oxygen concentration
difference between its internal and external surfaces. The voltage change reflects the concentration of the oxygen in the
exhaust gas and is used to perform the O2 feedback operation.
The terminal voltage change (0 – 1 V) is dependent on the concentration of oxygen in the exhaust gas.
This detected voltage value therefore represents the oxygen
concentration. The terminal voltage decreases when the oxygen
concentration is high, and increases when it is low.
NOTE:
As the Zirconia element is not conductive below 250 °C, the O2
sensor will not function properly until the engine is at normal
operating temperature.
NOTE:
Zirconia element:
The zirconia element produces a potential difference (voltage)
when there is a difference in the oxygen concentration of the
gases which contact the two sides of the element.
Since the inner surface of the Zirconia element (inside the sensor) is exposed to atmospheric air and the outer surface
exposed to the exhaust gas, there is a difference in oxygen concentration on each side and thus a difference in the potential
generated.
Zirconia element
Housing
ENGINE CONTROL SYSTEM
3-17
IGNITION SYSTEM
The ignition system used by the DF200/DF225/DF250 is a fully transistorized, electronic microcomputer timing advanced type.
This system is totally battery powered, with the ECM controlling all ignition timing functions.
The ignition system is composed of the ignition coil, spark plug and components for system control (ECM,
sensor, switch etc.)
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 controling current flow (ignition) to the primary winding of
ignition coil.
In this way, a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated.
ECM
+12 V
+12 V
Ign.1
Ign.2
Spark
plug
Spark
plug
+12 V
+12 V
Ign.3
IGT1 42
Bl
IGT2 50
Gr/Y
IGT3 39
Lg/R
IGT4 45
W/G
IGT5 37
Bl/Y
IGT6 38
Ign.4
Spark
plug
Ignition coil
IGT
Spark
plug
+12 V
+12 V
Ign.6
Spark
plug
Spark
plug
O
Ign.5
GND
+BAT
3-18
ENGINE CONTROL SYSTEM
IGNITION CONTROL SYSTEM
OUTLINE
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 collector assembly (surge tank) 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.
Switch
Ignition switch:
Informs ECM of “START” signal.
ECM
Ignition timing is determined by a
digital map designed in relation to
collector assembly (surge tank)
pressure and engine speed.
Ignition timing compensation
Signal
Ign.coil
Spark plug
SPECIFICATION
Ignition system
Advance
Ignition timing
Firing order
Full-transistorized ignition
Electronic microcomputer control
BTDC 0° – BTDC 26° (DF200)
BTDC 0° – BTDC 25° (DF225)
BTDC 0° – BTDC 26° (DF250)
1–6–5–4–3–2
ENGINE CONTROL SYSTEM
3-19
IGNITION TIMING CHART
The following chart is an example for ignition at BTDC 10°.
34-signals/360˚
CKP
sensor
signal
4-signals/720˚
CMP
sensor
#1 signal
Spark timing
Ig. coil #1
Cm. TDC
Ep.
Ex.
TDC
In.
Cm.
TDC
Ep.
Ex.
TDC
Ig. coil #6
Cm.
Ep.
TDC
Ex.
TDC
In.
Cm.
TDC
Ep.
Ex.
Ig. coil #5
In.
Cm.
TDC
Ep.
Ex.
TDC
In.
Cm.
TDC
Ep.
Ig. coil #4
TDC
In.
Cm.
TDC
Ep.
Ex.
TDC
In.
Cm.
TDC
Ig. coil #3
In.
TDC
Cm.
TDC
Ep.
Ex.
TDC
In.
Ig. coil #2
Ex.
TDC
In.: Intake,
In.
Cm.
Cm.: Compression,
TDC
Ep.
Ep.: Explosion,
Ex.
TDC
Ex.: Exhaust
CONTROL MODE
WHEN CRANKING:
The ignition timing is fixed at BTDC 5° (STBD bank) or BTDC 0° (PORT bank) until the engine starts.
WHEN IDLING/TROLLING:
The ignition timing is controlled within the range of BTDC 0° ± 5° to provide stable engine operation at the
specified idling/trolling speed.
WHEN RUNNING (NORMAL OPERATION):
The ignition timing ranges between BTDC 0° – 26° (DF200), BTDC 0° – 25° (DF225) or BTDC 0° – 26°
(DF250), depending on current engine operating conditions.
3-20
ENGINE CONTROL SYSTEM
ELECTRONIC FUEL INJECTION SYSTEM
The fuel injection system used by the DF200/DF225/DF250 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.
Fuel injection start timing is set at a constant of ATDC 280° (640° of crankshaft rotation) on the exhaust stroke.
Basic sensors
MAP sensor:
Informs ECM of collector assembly (surge tank) pressure.
ECM
Fuel injection time duration
(amount) is determined by
a digital map designed in
relation to collector assembly
(surge tank) pressure and
engine speed.
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.
Fuel amount compensation
IAT sensor:
Informs ECM of intake air temperature.
TPS (Throttle position sensor):
Informs ECM of throttle opening angle.
Multi-point sequential timing
MAP sensor:
Informs ECM of barometric pressure at time of engine start.
Battery voltage:
Constantly monitored by the ECM.
Signal
Signal
Signal
Signal
Signal
Signal
Others
CMP sensor:
Informs ECM of camshaft angle.
Shift position sensor:
Informs ECM of shift position (neutral or in-gear).
Injector
ECM
Battery
charge
coil
Rectifier &
regulator
30A fuse
A
A
A
60A fuse
15A fuse
Ignition
switch
Battery
Sensor/switch
signal input
CPU
ECM
main
relay
Injector
A
A
A
ENGINE CONTROL SYSTEM
3-21
FUEL INJECTION TIMING CHART
CKP
sensor
signal
CMP
sensor
#1 signal
34-signals/360˚
4-signals/720˚
ATDC 280˚ on Ex. stroke
OFF
#1
Injection ON
signal
240˚
TDC
Injection time duration
280˚
Ep.
Ex.
In.
TDC
Cm.
TDC
Ep.
Ex.
TDC
#6
Injection
signal
Cm.
Ep.
TDC
Ex.
In.
TDC
Cm.
TDC
Ep.
Ex.
#5
Injection
signal
In.
Cm.
TDC
Ep.
Ex.
TDC
In.
Cm.
TDC
Ep.
#4
Injection
signal
Ex.
TDC
In.
Cm.
TDC
Ep.
Ex.
TDC
In.
Cm.
TDC
#3
Injection
signal
Ex.
In.
TDC
Cm.
Ep.
TDC
Ex.
TDC
In.
Cm.
#2
Injection
signal
Ep.
Ex.
TDC
In.: Intake,
In.
Cm.
Cm.: Compression,
TDC
Ep.: Explosion,
Ep.
Ex.
TDC
In.
Ex.: Exhaust
CONTROL MODE
BEFORE START:
When the ignition switch is turned “ON”, the ECM receives a MAP sensor signal, indicating the static barometric pressure of the collector assembly (surge tank). This signal is used to compensate the fuel injection
map for altitude.
WHEN CRANKING:
Fuel is simultaneously injected to all cylinders according to the “Start up mode” map in relation to crankshaft
angle.
AFTER START (FAST-IDLE FUNCTION):
The fuel injection amount is controlled to remain increased until the timer, set according to cylinder temperature at the time of engine start, expires.
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.
3-22
ENGINE CONTROL SYSTEM
FUEL DELIVERY SYSTEM COMPONENTS
The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.),
fuel vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in
the fuel vapor separator), delivery pipe, fuel injector and hoses.
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/cm2, 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.
Low pressure
fuel filter
Primer bulb
Fuel vapor separator
Fuel tank
Low pressure
fuel pump
Evaporation
hose
Fuel pressure regulator
1 Relief valve
2 Low pressure fuel pump filter
3 High pressure fuel pump
4 High pressure fuel filter
5 Fuel cooler
6 Fuel delivery pipe
7 Fuel injector
8 Purge valve
Intake silencer
Intake manifold
Throttle body
ENGINE CONTROL SYSTEM
3-23
FUEL VAPOR SEPARATOR
The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator
chamber.
As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump.
The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel
returned from the fuel pressure regulator.
This vapor is routed through the evaporation purge system to the air intake silencer case. (See page 3-26
for the Evaporation purge system.)
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 ECM.
Needle valve
Valve seat
Float
Chamber
High pressure
fuel pump
Fuel pressure
regulator
Suction filter
Vent screw
Evaporation
Fuel outlet
Fuel inlet
Fuel return
Fuel drain screw
Fuel drain
Fuel
return
3-24
ENGINE CONTROL SYSTEM
FUEL PRESSURE REGULATOR
The fuel pressure regulator is located in the fuel vapor separator.
The regulator’s function in the system is to maintain a constant fuel pressure relative to the injector while the
engine is operating.
The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure 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/cm2, 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
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 valve
is open.
From Delivery line
1
4
2
1. Filter
2. Solenoid coil
3. Ball valve
4. Terminal
3
ENGINE CONTROL SYSTEM
3-25
HIGH PRESSURE FUEL PUMP CONTROL SYSTEM
OUTLINE
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated ON/OFF
signal, at a specified rate (1 000 times a second).
Based on engine speed and battery voltage, the ECM determines the optimum duty (repeating “ON” time
rate within a cycle) and sends this signal to the fuel pump.
CKP sensor:
Informs ECM of engine speed.
Battery voltage
ECM
Signal
Ignition switch:
Informs ECM of “START” signal.
Fuel pump
Duty cycle signal for fuel pump
(example: 80% duty)
ECM
Battery
charge
coil
Rectifier &
regulator
CPU
“ON” time × 100 = duty (%)
1 cycle time
ECM
main
relay
0.8 ms
30A fuse
OFF
60A fuse
15A fuse
Ignition
switch
Battery
FP
FP
Sensor/switch
signal input.
Fuel pump
Time
ON
1 ms (1cycle)
CONTROL MODES
BEFORE START:
For 6 seconds after the ignition switch is turned “ON”, the pump is controlled to operate at 100% duty in
order to initially pressurize the high pressure line.
WHEN CRANKING:
The pump is controlled to operate at 100% duty.
WHEN RUNNING (NORMAL OPERATION):
The pump is controlled to operate at 50 – 100% duty based on the current engine speed and battery voltage.
3-26
ENGINE CONTROL SYSTEM
LOW PRESSURE FUEL PUMP CONTROL SYSTEM
!
Fuel flowing through the pump is the pump coolant.
The fuel pump should never be run dry for long periods or it will become damaged.
The low pressure fuel pump is an electrically operated type that
supplies fuel from the fuel tank to the vapor separator.
The pump is controlled by the ECM and operates with at approx.
100% duty under any of the conditions below.
• Six (6) seconds after the ignition switch has been turned ON.
• Whenever the ECM receives a signal input from the CKP sensor.
EVAPORATION PURGE SYSTEM
The evaporation purge system connects the vapor separator
and the air intake silencer case with a hose in which the purge
valve is installed. This system’ function is to prevent hard starting of the engine during hot soak periods by controlling the discharge of vapors from the vapor separator into the air intake
case.
The ECM outputs a signal to the purge valve for opening/closing
on the basis of signals from IAT sensor, cylinder temp. sensor,
exhaust manifold temp. sensor and CKP sensor. (Normally, the
purge valve closes when the engine in shut off and opens after
the engine has been started.)
NOTE:
• The purge valve is driven by a duty cycle control signal from
the ECM.
During the engines “hot soak period”, the valve opens at
approx. 2000 r/min. and a 40 – 50% duty control takes place.
Otherwise, the valve opens after the engine has started and a
30 – 50% duty control takes place.
• Evaporative emissions can occur when fuel heats up and
evaporates from the vapor separator. They are also released
from a hot engine when it is running and/or idling.
After the engine is turned off, engine heat rises slightly as the
cooling system water flow ceases, causing a small portion of
the fuel in the vapor separator to vaporize. This is generally
termed the “hot soak period.” Vapors are also released during
engine operation as new fuel enters the vapor separator pushing air and fuel vapors out.
• See page 5-17 for the evaporation purge system check.
Low pressure
fuel pump
1
3
2
1. Purge valve
2. Hose (Vapor separator to purge valve)
3. Hose (Purge valve to air intake case)
ENGINE CONTROL SYSTEM
3-27
AIR INTAKE COMPONENTS
Air, after entering through the silencer case, passes through the throttle bodies and flows into the collector
assembly (surge tank) where it is then distributed to the cylinder intake manifold.
Collector assembly (surge tank) pressure, monitored by the MAP sensor, is an indirect measure of the
intake air amount.
When the throttle is fully closed, the main supply of collector assembly (surge tank) 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
5
1
7
2
Air flow
8
6
1. PORT throttle body
2. STBD throttle body
3. IAC valve
4. By-pass air screw
5. Collector assembly
6. Throttle position sensor
7. MAP sensor
8. IAT sensor
9. Air intake silencer
4
9
THROTTLE BODY
• Two throttle bodies are located on top of the collector assembly.
• The PORT throttle body assembly consists of the main bore,
throttle valve, by-pass air passage, by-pass air screw and
TPS (Throttle position sensor).
• The STBD throttle body assembly consists of the main bore
and throttle valve.
• 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 PORT throttle body informs of throttle valve opening angle.
9
1
2
1. PORT throttle body
2. STBD throttle body
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.
1
2
1. TPS
2. PORT throttle body
3-28
ENGINE CONTROL SYSTEM
BY-PASS AIR SCREW/PASSAGE
Since the throttle valve is almost fully closed when idling/trolling,
the main flow of air necessary to maintain idling/trolling speed
passes through the by-pass air passage.
The by-pass air screw controls the flow of air through the passage and provides a means of partially adjusting the total
amount of air necessary for idling/trolling.
NOTE:
See page 2-16 for the by-pass air screw adjustment procedure.
1
2
1. PORT throttle body
2. By-pass air screw
IAC VALVE/PASSAGE
The IAC valve is a stepper motor type mounted on the collector
assembly.
Its purpose is to control the amount of intake air flowing from 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.
IAC valve
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 collector
assembly.
This system is used for the following purposes:
• To keep idling/trolling at specified speed.
• To improve driveability when decelerating. (Dash-pot effect)
• To improve engine starting and warm-up performance. (Fast-idle function)
The sensors/switch shown below monitor current engine condition and send signals to the ECM.
Based on these signals, the ECM determines the IAC valve opening necessary to achieve the target engine
revolution 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 collector (surge tank) pressure.
Throttle position sensor:
Informs ECM of throttle opening angle.
Signal
ECM
Cylinder temp. sensor:
Informs ECM of cylinder temperature.
IAC valve
Shift position sensor:
Informs ECM of shift position and change.
ENGINE CONTROL SYSTEM
3-29
IAC VALVE
• The IAC valve uses a stepper type motor.
• The IAC valve is installed on the intake collector assembly.
• The IAC valve controls the volume of bypass air to stabilize the idling/trolling speed.
• The transistor driving the IAC is inside the ECM and turns ON/OFF when a signal (command) is received
from the CPU.
This signal operates the stepper motor inside the IAC valve, causing it to be driven equal to the number of
command signal steps. Through this procedure, the system is able to attain a very precise target
idling/trolling speed.
• The stepper motor rotates by means of magnetic attraction between the stator and rotor. More specifically, shifting the stator excitation in State (1) of below illustration to that in State (2) will develop a magnetic torque to cause the rotor to rotate and then stabilize in State (3). (The illustration at below shows the
operating principle of a simple stepper motor. This example differs slightly from the 2-phase excitation
method used in the actual application). This operation is repeated equal to the number of command signal
steps from the ECM resulting in rotation of the rotor. With the screw shaft installed, this rotation is converted to a linier motion of the valve pintle that changes the volume of IAC air flow.
• Battery voltage is applied to the center tap of each coil through the ECM main relay when the ignition
switch is turned on. The Each coil end connects to one of the ECM terminals “IAC 1-4”.
The terminal voltage at ECM terminals “IAC 1-4” is 1 V MAX when current flows and battery voltage at all
other times.
+12 V
3
ECM
Gr
W/B
55
IAC1
5
R/G
58
IAC3
W/Bl
57
IAC4
R/Y
56
IAC2
2
1. Valve pintle
2. Screw shaft
3. Rotor
4. Coil
5. Bearing
N
1
Air flow
6
8
S
S
Attraction
S
N
7
N
Attraction
S
N
S
9
6
State 1
N
N
S
6. Stator
7. Rotor
8. IAC valve
9. Throttle valve
IAC valve
4
State 2
Pole shifting
State 3
Rotor rotation
3-30
ENGINE CONTROL SYSTEM
CONTROL MODE
BEFORE START:
The IAC valve is initialized at 70% opening position when engine is not running (Ignition switch OFF).
WHEN CRANKING:
The IAC valve is controlled to operate at approx. 50 – 100% duty.
Duty change depends on cylinder temperature.
AFTER START (FAST-IDLE FUNCTION):
The IAC valve is controlled to operate at approx. 40 – 70% duty until the timer, (set according to cylinder
temperature at cranking) expires, then decrease duty gradually to reach the set rpm at idle.
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 a duty of approx. 30% but will vary slightly as idling/trolling conditions
change.
WHEN RUNNING (NORMAL OPERATION):
The IAC valve is controlled to operate at 20 – 90% duty, dependent on current engine conditions.
WHEN DECELERATING (DASH-POT EFFECT):
When the throttle valve is suddenly returned to full close and the throttle position sensor signal changes to
“fully closed”, the IAC valve operates at a controlled gradual return to idle/troll operating duty 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 “Dash-pot
effect” and “Fast-idle function”, the by-pass air screw must be adjusted to provide IAC valve operation at
approx. 30 ± 5% duty at the engine idling/trolling specification. See page 2-16 for the by-pass air screw
adjustment procedure.
ENGINE CONTROL SYSTEM
MULTI-STAGE INDUCTION
OUTLINE
The multi-stage induction system is designed to improve the
intake efficiency by changing the intake tract volume in accordance with the engine speed.
This system improves low and mid range torque and increases
power output at the higher rpm ranges.
SYSTEM COMPOSITION
Located between the STBD and PORT banks, a collector
assembly provides air for the low/mid range intake tract and high
speed range tracts. Mounted on the collector are two throttle
bodies, VSV (Vacuum Switching Valve), vacuum tank, depression chamber for operating the system and the shut off valve for
switching the intake tract. System connection components
include one check valve and hose to form the vacuum passage.
• VACUUM TANK
The vacuum tank stores vacuum created during engine operation. The vacuum tank’ purpose is to supply a stable vacuum to
the depression chamber under the varying vacuum conditions
normally occurring within the collector, thereby making it possible to control the shut off valve accurately.
A hose and check valve connects one side of the vacuum tank
to the collector. The other side of the tank is connected to the
VSV with a hose.
• VSV (Vacuum switching valve)
One side of the VSV is connected via hose to the vacuum tank,
the other side is connected via hose to the depression chamber.
The VSV receives operating signals from the ECM. When the
ECM signals OFF, the VSV releases vacuum to the atmosphere.
When the ECM signals ON, the VSV supplies vacuum to the
depression chamber.
1
1. Collector assembly
2
1
1. Vacuum tank
2. Check valve
1
1. VSV (Vacuum switching valve)
• DEPRESSION CHAMBER
The depression chamber is designed to open/close the shut off
valve.
When vacuum is applied to the depression chamber, the rod in
the chamber is pulled in closing the shut off valve.
When vacuum is not applied to the chamber, the rod returns to
the original position, opening the shut off valve.
1
1. Depression chamber
3-31
3-32
ENGINE CONTROL SYSTEM
SYSTEM OPERATION
This system is operated by the vacuum created during engine
operation and controlled by the ECM.
To operate the system (open/close the shut off valve to change
the intake tract), the collector, check valve, vacuum tank, VSV
and depression chamber are connected with hoses as shown in
the illustration.
A rod is used to connect the shut off valve and depression
chamber for opening and closing the valve.
LOW & MID SPEED
Shut off valve closed
• LOW & MID SPEED RANGE
When engine speed is below the preset value (*), the ECM generates a signal to turn the VSV ON, applying vacuum to the
depression chamber which closes the shut off valve.
With the valve closed during the engines low to mid speed
range, intake air is supplied through the low/mid speed intake
tract only.
In this operating mode, intake air speed is boosted and, combined with the resonance effect, increases low and mid speed
range engine torque.
*: Preset value;
DF225: approx. 4 200 r/min DF250: approx. 4 800 r/min
• HIGH SPEED RANGE
When the engine speed is above the preset value (*), the ECM
generates a signal to turn the VSV OFF, and vacuum is no
longer applied to the depression chamber.
Without vacuum the shut off valve return spring returns and
holds the valve in its normal open position.
In this operating mode, intake air is supplied to the engine
through the high speed intake tract only.
This enlarges the intake tract volume, improves intake inertia
and efficiency, which increases the engines output power.
HIGH SPEED
Shut off valve opened
ENGINE CONTROL SYSTEM
3-33
VVT (Variable Valve Timing) SYSTEM
• The VVT system is designed to continuously vary intake valve timing to best fit the engines current operating condition.
• The intake cam timing sprocket assembly (VVT actuator) is located at the front end of the intake camshaft. The timing sprocket’ internal rotor is operated by engine oil pressure. Since the rotor and intake
camshaft are bolted together, the rotor and camshaft move together. Varying the intake valve timing is
accomplished by changing the intake camshaft phase angle relative to the intake cam timing sprocket
using pressurized engine oil applied to the rotor through an ECM controlled oil control valve.
• The oil control valve (OCV) directs engine oil pressure to the advance chamber or retard chamber inside
the intake cam timing sprocket assembly (VVT actuator). The oil control valve operates on a duty cycle
controlled by the ECM.
• The ECM determines the optimum valve timing (advance angle) under various operating conditions
based on engine speed, throttle opening and cylinder wall temperature. These input values are then
used to control the position of the oil control valve (OCV). The ECM also detects the actual advance angle
from the CMP sensor inputs to perform feedback control and accurately maintain the target advance
angle.
Rotation direction
VVT actuator
In.
camshaft
CMP sensor
Ex. camshaft
In. camshaft
Retard
Crankshaft
Advance
CKP sensor
Drain
ECM
Crank
position
Throttle sensor
Cylinder temp. sensor
MAP sensor
Throttle opening angle
Cylinder temp.
Cam position
Manifold pressure
Target
advance
Oil
pump
Duty
control
Oil control valve (OCV)
Oil pan
Feed
back
Actual valve
timing
ECM
Oil
filter
Engine oil pressure
Signal
+12 V
Advance
40˚ movable angle
Valve lift
In. valve
Ex. valve
OCV
Retard
30
Crank angle
46
Valve overlap
3-34
ENGINE CONTROL SYSTEM
OCV (Oil Control Valve)
Two OCV are used, one installed on each (PORT/STBD) lower
camshaft housing.
RETARD OPERATION
When the duty ratio of the ECM is small, the OCV spool valve is
pushed away from the coil by spring force and engine oil pressure is applied to the retard chamber.
Engine oil remaining in the advance chamber is drained out
through the spool valve.
Retard operation
Advance chamber
Engine oil pressure
Drain
Retard chamber
Coil
Spool valve
Spring
ADVANCE OPERATION
When the duty ratio of the ECM is large, the spool valve is
towards the coil by magnetic force, compressing the spring and
applying engine oil pressure to the advance chamber side.
Engine oil remaining in the retard chamber side is drained out
through the spool valve.
RETAINING OPERATION
When the duty ratio of the ECM is medium, the OCV coil magnetic and return spring forces are equal. This positions the spool
valve between the advance and retard chamber, closing both oil
passages.
INTAKE CAM TIMING SPROCKET ASSY
Inside the intake cam timing sprocket assembly (VVT actuator),
there are separate advance chamber and retard chamber
formed by partition of the rotor.
The rotor moves inside the housing as engine oil pressure is
applied to the advance or retard chamber.
The intake cam timing sprocket is part of the sprocket housing
assembly. Since the rotor and intake camshaft are bolted
together, when the rotor moves inside the housing, a change of
phase angle takes place in the relative position between the
intake camshaft and intake cam timing sprocket. The rotor has a
spring pressured lock pin which engages with the housing when
spring force is greater than oil pressure, locking the rotor in the
most retarded position. This prevents a change of phase angle
between the intake camshaft and intake cam timing sprocket
when the engine oil pressure is low at engine start.
When the engine is started and the engine oil pressure is
applied to the advance chamber, the lock pin is forced up, compressing the return spring, releasing the rotor and allowing the
VVT actuator to function.
Advance chamber
Intake cam
timing sprocket
Housing
Retard
chamber
Rotor
Spring
Lock pin
Seal
ENGINE CONTROL SYSTEM
3-35
CAUTION SYSTEM
The following four caution systems alert the operator when an
abnormality occurs on the engine.
•
•
•
•
MONITOR-TACHOMETER
OVER-REVOLUTION CAUTION
LOW OIL PRESSURE CAUTION
OVERHEAT CAUTION
LOW BATTERY VOLTAGE CAUTION
CAUTION
TYPE
Over-revolution
Low oil pressure
Overheat
Low battery voltage
CAUTION
LAMP
CAUTION
BUZZER
Yes 1
Yes 2 (1)
Yes 3 (1)
Yes 4
No
Yes
Yes
Yes
OVER-REV
LIMITER
(3000 r/min)
Yes
Yes
Yes
No
“REV LIMIT” lamp
“OIL” lamp
! “TEMP” lamp
" “CHECK ENGINE” lamp
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
DF200/DF225 : 6 200 r/min
DF250
: 6 300 r/min
ACTION:
Engine speed
Caution lamp
Caution buzzer
Automatically reduced to approx. 3 000 r/min by intermittent fuel injection signal.
“REV-LIMIT” lamp lights continuously.
No buzzer sounds.
RESET:
Close throttle to reduce engine speed below approx. 3 000 r/min for one second.
3-36
ENGINE CONTROL SYSTEM
LOW OIL PRESSURE CAUTION SYSTEM
CONDITION:
Immediate activation of system when the oil pressure switch is turned “ON” due to an engine oil pressure
drop below 100 kPa (1.0 kg/cm2, 14 psi).
ACTION:
Engine speed
Caution lamps
Caution buzzer
Automatically reduced to approx. 3 000 r/min by intermittent fuel injection signal if the
system is activated at 3 000 r/min or higher.
“OIL” lamp lights continuously.
“REV-LIMIT” lamp lights continuously during engine speed rev-limiter activation.
Sounds in a series of long (1.5 sec) beeps.
RESET:
Stop engine and check engine oil level. Refill engine oil to the correct level if below the low oil 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 is reset when the oil pressure is restored to over 1.0 kg/cm2 with approx.
3 000 r/min or less engine speed operation.
However, the engine must be stopped and checked immediately once the system is activated.
ENGINE CONTROL SYSTEM
3-37
OVERHEAT CAUTION
CONDITION 1 (Maximum temperature)
Immediate activation of system when:
• Cylinder temperature reaches 120 °C (248 °F)
• Exhaust manifold temperature reaches 114 °C (237.2 °F)
CONDITION 2 (Temp. rise vs Time)
Immediate activation of system when:
• The average temperature difference during 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 (46 °F)
Approx. 1.5 °C (35 °F)
• The average temperature difference during 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 (57.2 °F)
Approx. 1.7 °C (35 °F)
ACTION:
Engine speed
Caution lamps
Caution buzzer
Automatically reduced to approx. 3 000 r/min by intermittent fuel injection and ignition
signals if the system is activated at 3 000 r/min or higher.
“TEMP” lamp lights continuously.
“REV-LIMIT” lamp lights continuously during engine speed rev-limiter activation.
Sounds in a series of long (1.5 sec) beeps.
RESET:
Close throttle completely and then shift into neutral.
System reset will occur when 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.
Caution cause
Condition 1
(Maximum temperature)
Condition 2
(Temperature rise vs Time)
Reset temperature
Approx. 78 °C (172 °F)
Approx. 76 °C (169 °F)
3-38
ENGINE CONTROL SYSTEM
LOW BATTERY VOLTAGE CAUTION SYSTEM
CONDITION 1:
System activated when battery voltage decreases to less than 9 volts for 30 seconds.
CONDITION 2:
System activated if battery voltage is less than 2 V for more than 2 seconds with the ignition switch turned
“ON” and engine 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:
This 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 deteriorated battery, poor battery
cable connection, battery switch in OFF condition, etc. must be inspected.
To cancel the caution system activation for these conditions, check all power source related items and eliminate the problem.
ENGINE CONTROL SYSTEM
3-39
SELF-DIAGNOSTIC SYSTEM
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from sensor, switch, etc.
When the system is activated, the “CHECK ENGINE” lamp
flashes (lights intermittently) according to each code pattern
along with a buzzer sound.
When engine is running, the buzzer sounds a series of short
(0.2 sec) beeps.
When engine is not running, the buzzer sounds according to
each code pattern, but not simultaneous with the lamp flash.
The buzzer sound, activated by the self-diagnostic system, can
be temporally canceled by pushing the ignition key in.
MONITOR-TACHOMETER
“CHECK ENGINE” lamp
PRIORITY/CODE/PATTERN FOR SELF-DIAGNOSTIC SYSTEM OPERATION
PRIORITY
FAILED ITEM
CODE
LAMP FLASHING
PATTERN
FAIL-SAFE SYSTEM
ACTIVE
1
MAP sensor 1
3–4
ON
OFF
YES
2
IAC valve/By-pass
air screw adjustment
3–1
ON
OFF
NO
3
Cylinder temp. sensor
1–4
ON
OFF
YES
4
IAT sensor
2–3
ON
OFF
YES
YES
5
CKP sensor [NOTE 1]
4–2
ON
OFF
6
CMP sensor
2–4
ON
OFF
YES
7
Air intake system
2–2
ON
OFF
YES
3–2
ON
OFF
NO
1–1
ON
OFF
NO
STBD
1–5
ON
OFF
PORT
1–6
ON
OFF
8
9
10
MAP sensor 2
(Pressure detect passage)
Rectifier & regulator
(Over-charging) [NOTE 2]
11
Exhaust manifold
temp. sensor
12
Fuel injector
4–3
ON
OFF
NO
13
Throttle position sensor
2–1
ON
OFF
YES
1–2
ON
OFF
YES
YES
14
Shift position sensor
YES
15
CMP sensor (VVT·STBD)
2–5
ON
OFF
16
CMP sensor (VVT·PORT)
2–6
ON
OFF
YES
17
VVT advance (STBD)
5–1
ON
OFF
YES
5–2
ON
OFF
YES
NO
18
VVT advance (PORT)
19
Neutral switch
3–3
ON
OFF
20
Model discrimination/
Check code wire [NOTE 3]
4–1
ON
OFF
YES
21
Oil control valve (STBD)
6–1
ON
OFF
NO
22
Oil control valve (PORT)
6–2
ON
OFF
NO
3-40
ENGINE CONTROL SYSTEM
NOTE:
• If more than two items fail at once, the self-diagnostic indication appears according to priority order. The
indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition switch
“ON”.
• After correcting failed item, the self-diagnostic indication appears until the ECM receives the proper signal
with the engine running.
• For cylinder temp. sensor, exhaust manifold temp. sensor or IAT sensor the self-diagnostic indication will
be canceled after corrective action by turning the ignition switch “ON”.
(The ECM will require 10 – 20 seconds after turning the ignition switch “ON” to cancel the self-diagnostic
indication.)
NOTE 1:
To cancel the diagnostic display of CKP sensor, perform the following procedures after the failure has been
corrected:
(1) Start the engine. The diagnostic code for CKP sensor failure will continue to be displayed until a normal
signal sequence is received by the ECM. Thereafter only the display being conceled. At this stage of the
diagnostic system reset process the diagnostic code for a failed CKP sensor is not displayed but the
engine is still controlled using the CMP sensor signal.
(2) Stop the engine and restart. At the second restart, complete canceling of the CKP sensor failure code
will occur.
NOTE 2:
This self-diagnostic indication may not display (be canceled) by turning the ignition switch “ON” because the
ECM detects only battery voltage, not charging output. Under this condition the buzzer will not sound a 1-1
code.
However, if the rectifier & regulator have failed, the self diagnostic indication will again appear after starting
the engine.
NOTE 3:
The diagnostic code for model discrimination is displayed when a failure (either open or short circuit) exists
in No.13 terminal of the wiring harness connector.
When this code is displayed, the first check should be for a failure in the wiring harness.
When this code is displayed, do not replace the ECM.
Replacing the ECM may cause improper execution of the self-diagnostic for model discrimination possibly
leading to engine trouble.
ENGINE CONTROL SYSTEM
3-41
CONDITION FOR SELF-DIAGNOSTIC SYSTEM OPERATION
FAILED ITEM
MAP sensor 1
•
•
IAC valve/By-pass air screw
adjustment
•
Cylinder temp. sensor
•
•
IAT sensor
•
•
CKP sensor
CMP sensor
Air intake system
•
•
•
MAP sensor 2
(Pressure detect passage)
Rectifier & Regulator.
(Over-charging)
Exhaust manifold temp. sensor
(PORT or STBD)
•
Fuel injector
Throttle position sensor
Shift position sensor
CMP sensor
(VVT PORT or STBD)
VVT advance
(PORT or STBD)
Neutral switch
Model discrimination
Oil control valve
(PORT or STBD)
•
CONDITION
No signal (With engine running)
Receiving an out of range “37 – 860 mmHg (1.46 – 33.86 inHg)
(0.50 – 4.84 V)” signal (With engine running)
IAC valve operates at 80% duty or higher when ECM receives fully
closed position signal from throttle position sensor.
[NOTE 1]
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, 34 signals are not input to ECM.
During two crankshaft rotation, 4 signals are not input to the ECM.
During the ECM’s receiving input of the complete close signal from the
throttle position sensor, the engine operates at an abnormally high
speed. (Criterion: 2 500 r/min MIN)
Receiving unchanging signal regardless engine speed change.
[NOTE 2]
Receiving 16 volts or higher signal
• 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
• No signal
• During two crankshaft rotation, 4 signals are not input to ECM.
• There is a large difference between the target advance angle and the
actual advance angle.
• While the shift sensor outputs the forward or reverse signal, the ECM
receives input of the neutral signal from the neutral switch.
• There is discrepancy of signal between the ECM memory storage and
the model discrimination terminal.
• [No.13 terminal open. (DF200)]
• [No.13 terminal short circuit. (DF225/250)]
• OCV not operating.
3-42
ENGINE CONTROL SYSTEM
NOTE 1:
These conditions will be caused by IAC valve failure or incorrect
by-pass air screw adjustment. If IAC valve is always closed or
by-pass air is too low, the ECM controls the IAC valve duty to
increase to maintain the idling/trolling speed specified.
NOTE 2:
This condition will be caused by clogged pressure detect passage in collector assembly.
O-ring
Passage
MAP sensor
ENGINE CONTROL SYSTEM
3-43
FAIL-SAFE SYSTEM
The fail-safe system is closely related to the self-diagnostic system.
When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a
pre-programmed value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.
PRE-PROGRAMMED VALUE FOR FAIL-SAFE SYSTEM
FAILED ITEM
MAP sensor 1
CKP sensor
CMP sensor
Air intake system
Cylinder temp. sensor
IAT sensor
Exhaust manifold temp. sensor
Throttle position sensor
Shift position sensor
CMP sensor (VVT)
VVT advance
Model discrimination
PRE-PROGRAMMED VALUE
• 280 – 560 mmHg (11.02 – 22.05 inHg)/(The control takes place in
accordance with the engine speed.) [NOTE 1]
Based on signals from CMP sensor:
• The ignition timing is controlled in 0 – 10 degree range in accordance
with the engine condition.
• Normal sequential fuel injection.
Based on signals from CKP sensor:
(a) Failed with engine running
• Normal ignition timing.
• Normal sequential fuel injection.
• VVT advance is fixed at the most retarded angle.
(b) Failed prior to engine start
• The ignition timing is controlled in 0 – 10 degree range in accordance
with the engine condition.
• 1 simultaneous injection for all cylinders per 2 crankshaft rotations.
• VVT advance is fixed at the most retarded angle.
• The control is executed with the maximum engine speed as 2000 r/min.
• 60 °C (140 °F)
• 45 °C (113 °F)
• 60 °C (140 °F)
• The control is executed with the throttle opening as 5 degrees.
• VVT advance is fixed at the most retarded angle.
• The shift position whether neutral or other is detected with the neutral
switch signal.
• The IAC control is operated in the forward map.
• VVT advance is fixed at the most retarded angle.
• VVT advance is fixed at the most retarded angle.
• The ECM cyclically outputs the drive and stop signals for the OCV and
when the difference between the VVT’s target advance angle and the
actual advance angle has come to the normal range, the diagnostic
code display is canceled.
• The original model discrimination is retained.
NOTE:
There is no back-up system for the ECM itself. The engine will stop if it has failed.
NOTE 1:
This value will change according to the current engine speed.
3-44
ENGINE CONTROL SYSTEM
OPERATING HOUR INDICATION SYSTEM
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 actual engine
operation, not ignition switch “ON” time.
CHART OF TOTAL OPERATING HOURS INDICATION
Total operating
hours
0 h – (49 h)
50 h
60 h
1 time
2 times
5400 r/min
500 r/min
···
···
2030 h
2040 h or over
No
5400 r/min
500 r/min
···
···
1540 h
1550 h
5400 r/min
500 r/min
600 r/min
···
···
1040 h
1050 h
No
500 r/min
600 r/min
···
···
540 h
550 h
560 h
MONITOR-TACHOMETER
Needle 1
REV-LIMIT lamp 2
indication
flashing *
5300 r/min
5400 r/min
* : One flashing is corresponded to 500 hours.
3 times
3 time
MONITOR-TACHOMETER
ENGINE CONTROL SYSTEM
OIL CHANGE REMINDER SYSTEM
This system informs the operator of the time for replacing
ENGINE OIL on the basis of the recommended maintenance
schedule. When the total motor operating hours have reached
the preprogrammed hours, the “OIL” lamp will flash, and the
buzzer will begin a series of double beeps if engine is not running (but ignition switch is ON). The above mentioned indication
will repeat until the activated system is manually cancelled.
3-45
Action
Starting operation
(*1)
(*4)
Indication
Cancellation
(*2)
Indication
(*4)
Cancellation
(*3)
Indication
NOTE:
This system will activate up to 2 100 hour’s operation.
(*4)
Cancellation
(*3)
Indication
(*4)
Cancellation
INDICATION OF SYSTEM ACTIVATION
Buzzer
OIL lamp
Repeat
*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
OFF
Ign. switch
ON
ON
Buzzer
OFF
ON
Oil Lamp
OFF
: Indicator check (No relation to OIL CHANGE REMINDER SYSTEM)
CANCELLATION
Procedure
1. Turn the ignition key to “ON” position.
2. Pull out the emergency stop switch plate 1.
3. Pull up the emergency stop switch knob 2 three times in ten
seconds. A short beep will be heard if cancellation is successfully finished.
4. Turn the ignition key to “OFF” position.
5. Set the switch plate 1 in original position.
NOTE:
• Canceling of the system activation is possible regardless of whether or not the engine oil has been
replaced. Once the system has operated, however, SUZUKI strongly recommends that the engine oil be
replaced before canceling the system activation.
• Even if the engine oil has been replaced with the system not operating, it is still necessary to perform the
cancellation.
3-46
ENGINE CONTROL SYSTEM
START-IN-GEAR PROTECTION SYSTEM
■ Control by Neutral switch
A switch to detect neutral gear position is located on the throttle lever holder and operated by the clutch control lever.
This ON/OFF type switch is ON in neutral and OFF in forward or reverse.
On starting the engine, the ECM detects the shift position using the neutral switch.
When the neutral switch is OFF, the ECM does not provide starter motor relay operating signal.
■ Control by Shift position sensor
A shift position sensor is installed on the throttle lever holder and detects the shift position with the clutch
lever operation interlocked.
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.
On starting the engine, the ECM does not provide an injector operating signal when a shift lever in-gear
position is detected.
ENGINE CONTROL SYSTEM
3-47
O2 FEEDBACK SYSTEM
After extended usage, the engine components may become deteriorated or worn out.
This might make the A/F (air/fuel mixture ratio) incorrect which could affect exhaust emissions. To correct
the A/F, an O2 sensor must be temporally installed in the exhaust manifold. This sensor is used to measure
the concentration of oxygen in the exhaust gas at engine speeds of 3 000, 4 000, and 5 000 r/min.
The ECM uses the input data from the O2 sensor to correct the compensation coefficient of the fuel injection
duration map within the ECM itself.
O2 sensor:
Informs ECM of concentration of oxygen in exhaust gas.
ECM
Feedback
" 18213-74F00: O2 sensor
NOTE:
For fuel mixture check (O2 feedback) operation procedure, refer to “Suzuki Diagnostic System Operation
Manual”.
3-48
ENGINE CONTROL SYSTEM
INSPECTION
PRECAUTION ON SYSTEM INSPECTION
#
To prevent any unexpected engine start, perform the following before proceeding with any
CRANKING tests.
• When performing tests not related to fuel injector operation:
•Disconnect all fuel injector wire connectors.
• When performing tests related to fuel injector operation:
•Relieve fuel pressure in line. (See page 5-3.)
•Disconnect high pressure fuel pump wire connector located on fuel vapor separator.
!
• Always turn ignition switch “OFF” and disconnect battery cables when wires are being disconnected or connected.
• Hold and pull connector pieces when disconnecting. Do not pull wires.
NOTE:
• The self-diagnostic codes memory in ECM will remain even if battery is disconnected.
• As each terminal voltage is affected by battery voltage, use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires/cables are securely connected.
26-PIN & 34-PIN TEST CORD
This test cord is used when checking the circuit for voltage, etc. and connected between ECM and the wiring
harness.
To measure, connect the tester probe to the relevant terminal of the test cord.
" 09930-89340: 26-pin & 34-pin test cord
34 pin test cord
ECM
26 pin test cord
(White connector)
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
60
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
(White connector)
Wire harness
(Black connector)
14 15 16 17 18 19 20 21 22 23 24 25 26
ENGINE CONTROL SYSTEM
INSPECTION FOR ECM CIRCUIT VOLTAGE
!
ECM cannot be bench checked. It is strictly prohibited
to connect any tester (voltmeter or ohmmeter) to an
ECM which has been disconnected from the engine
wiring harness.
" 09930-89340: 26-pin & 34-pin test cord
09930-99320: Digital tester
$ Tester range: % DCV (See chart for range.)
1. Turn ignition switch OFF.
2. Connect the 26-pin & 34-pin test cord between ECM and
wire harness as shown in figure.
3. Turn ignition switch ON.
4. Connect the tester probe (“-”, Black) to body ground, and
measure voltage according to the “CIRCUIT VOLTAGE
TABLE”.
34 pin test cord
26 pin test cord
(White connector)
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
60
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
(Black connector)
14 15 16 17 18 19 20 21 22 23 24 25 26
(White connector)
26 pin test cord
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
White connector
Black connector
34 pin test cord
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
White connector
60
Black connector
3-49
3-50
ENGINE CONTROL SYSTEM
CIRCUIT VOLTAGE TABLE
27
28
36
44
52
29
37
45
53
30
38
46
54
31
39
47
55
32
40
48
56
33
41
49
57
34
42
50
58
1
35
51
59
2
8
43
14
60
20
3
9
15
21
4
10
16
22
5
11
17
23
6
12
18
24
7
13
19
25
26
(FRONT VIEW)
TERMINAL
WIRE COLOR
1
Dg
2
B/G
CIRCUIT
Starter relay control
O2 Feedback
—
STANDARD VOLTAGE
CONDITION/REMARKS
Approx. 1.3 V
Ignition switch ON, stop switch plate OUT
Approx. 0.5 V
Ignition switch ON, stop switch plate IN
—
—
—
—
3
—
4
R/B
CKP sensor
5
Y/Bl
CMP sensor #1
Approx. 0.3 V or 5 V
Ignition switch ON
6
B/O
CMP sensor #3 (VVT_STBD)
Approx. 0.3 V or 5 V
Ignition switch ON
—
—
7
O/G
CMP sensor #2 (VVT_PORT)
Approx. 0.3 V or 5 V
Ignition switch ON
8
V/W
Ex. manifold temp. sensor #1
0.14 – 4.75 V
Ignition switch ON
9
Lg/W
Cylinder temp. sensor
0.14 – 4.75 V
Ignition switch ON
10
G/R
Ex. manifold temp. sensor #2
0.14 – 4.75 V
Ignition switch ON
11
P/Bl
Shift position sensor
12
13
W
MAP sensor
B
Model distinction
Approx. 2 V
Ignition switch ON, Shift in Neutral
Approx. 4 V
Ignition switch ON, Shift in Forward
Approx. 0.6 V
Ignition switch ON, Shift in Reverse
0.20 – 4.53 V
Ignition switch ON
Approx. 5 V
Ignition switch ON
(DF200 only)
14
R
Power source for sensor
Approx. 5 V
Ignition switch ON
15
Bl/R
Emergency stop switch
Approx. 11 V
Ignition switch ON,
Stop switch plate IN
Approx. 0 V
Ignition switch ON,
Stop switch plate OUT
16
Br/Y
17
P/B
18
Br
19
20
Bl
Gr
Throttle position sensor
Ground for ECM main relay
Neutral/Cranking switch
Oil pressure switch
ECM power source
Approx. 3.8 V
Ignition switch ON, Throttle WOT
Approx. 0.7 V
Ignition switch ON, Throttle FCT
—
—
Approx. 0.7 V
Ignition switch ON,
Engine stopped shift into NEUTRAL
Approx. 2.5 V
Ignition switch ON,
Shift into FOWARD or REVERSE
Approx. 10 V
While engine cranking
Approx. 5 V
While engine running
Approx. 0 V
Engine stopped (Ignition switch ON)
Approx. 12 V
Ignition switch ON
21
Y
PC communication
—
—
22
O/Y
PC communication
—
—
23
B/Bl
Engine switch
Approx. 12 V
Ignition switch ON
24
O
Buzzer cancel
Approx. 12 V
Ignition switch ON, Key pushed in
Approx. 0 V
Ignition switch ON,
Key not pushed in
0.04 – 4.46 V
Ignition switch ON
25
Lg/B
IAT sensor
ENGINE CONTROL SYSTEM
TERMINAL
WIRE
COLOR
CIRCUIT
—
STANDARD VOLTAGE
CONDITION/REMARKS
26
—
27
O/Bl
28
R/W
No. 3 Fuel injector
Approx. 12 V
Ignition switch ON
29
Y/R
No. 6 Fuel injector
Approx. 12 V
Ignition switch ON
30
Br/W
No. 1 OCV
Approx. 12 V
Ignition switch ON
31
Br/R
No. 2 OCV
Approx. 12 V
Ignition switch ON
No. 5 Fuel injector
—
Approx. 12 V
—
Ignition switch ON
32
O/W
Purge valve
Approx. 12 V
Ignition switch ON
33
Gr/R
Variable intake control valve
(VSV)
Approx. 12 V
Ignition switch ON
34
P
REV-LIMIT lamp
—
35
Y/B
Tachometer
—
36
B/Br
No. 2 Fuel injector
Approx. 12 V
Ignition switch ON
37
W/G
No. 5 Ignition coil
Approx. 0 V
Ignition switch ON
38
Bl/Y
No. 6 Ignition coil
Approx. 0 V
Ignition switch ON
39
Gr/Y
No. 3 Ignition coil
Approx. 0 V
Ignition switch ON
40
—
—
—
—
41
—
—
—
—
42
O
43
Bl/W
Buzzer
No. 1 Ignition coil
44
B/Y
Low pressure fuel pump (–)
Approx. 0 V
—
—
Ignition switch ON
—
—
Approx. 0 V
• Stop switch plate IN, For 6 sec after
ignition switch ON
• While engine running
Approx. 12 V
Engine stopped, Ignition switch ON, stop
switch plate IN
Ignition switch ON
45
Lg/R
No. 4 Ignition coil
Approx. 0 V
46
B
Ground for power
—
—
47
B
Ground for power
—
—
48
B
Ground for ECM
—
—
49
B/W
50
Bl
51
Bl/B
Oil lamp
52
B/R
High pressure fuel pump (–)
Ground for sensors
No. 2 Ignition coil
3-51
—
Approx. 0 V
—
Ignition switch ON
—
—
Approx. 0 V
• Stop switch plate IN, For 6 sec after
ignition switch ON
• While engine running
Approx. 12 V
Engine stopped, Ignition switch ON, stop
switch plate IN
53
Lg
No. 4 Fuel injector
Approx. 12 V
Ignition switch ON
54
O/B
No. 1 Fuel injector
Approx. 12 V
Ignition switch ON
55*
W/B
IAC valve #1
Approx. 12 V or 0 V
Ignition switch ON
56*
R/Y
IAC valve #2
Approx. 12 V or 0 V
Ignition switch ON
57*
W/Bl
IAC valve #4
Approx. 12 V or 0 V
Ignition switch ON
58*
R/G
IAC valve #3
Approx. 12 V or 0 V
Ignition switch ON
59
G/W
“CHECK ENGINE” lamp
—
—
60
G/Y
“TEMP” lamp
—
—
* :When 12 V is displayed at No. 55 (57) terminal, 0 (zero) V is displayed at No. 58 (56) terminal. Conversely, if 0 V is displayed at No. 55 (57) terminal, 12 V will be displayed at No. 58 (56) terminal.
3-52
ENGINE CONTROL SYSTEM
INSPECTION FOR RESISTANCE
" 09930-99320: Digital tester
& Tester range: Ω (Resistance, See chart for range.)
NOTE:
Make sure ignition switch is always OFF when measuring resistance.
1.
2.
3.
4.
Turn ignition switch OFF.
Disconnect battery cables from battery.
Disconnect wire harness connector from ECM.
Connect the tester probes to terminal (wire harness side)
and measure resistance according to the “RESISTANCE
TABLE”.
35 34 33 32 31 30 29 28 27
7 6 5 4 3 2 1
43 42 41 40 39 38 37 36
13 12 11 10 9 8
51 50 49 48 47 46 45 44
19 18 17 16 15 14
60 59 58 57 56 55 54 53 52
26 25 24 23 22 21 20
Wire harness
NOTE 1:
Pull out ECM main relay, and connect tester probe to terminal
( “A”, Gray wire) of ECM main relay.
• Gray wire
ECM main relay
NOTE 2:
Disconnect remote control wire harness and connect tester
probe to terminal ( “B”, White wire).
16 Pin connector
B White
lead wire
ENGINE CONTROL SYSTEM
3-53
RESISTANCE TABLE
CKP sensor
TERMINAL FOR TESTER
PROBE CONNECTION
4 (R/B) to 49 (B/W)
Fuel injector No. 1
54 (O/B) to Terminal A [NOTE 1]
ITEM
Fuel injector No. 2
36 (B/Br) to Terminal A [NOTE 1]
Fuel injector No. 3
28 (R/W) to Terminal A [NOTE 1]
Fuel injector No. 4
53 (Lg) to Terminal A [NOTE 1]
Fuel injector No. 5
27 (O/Bl) to Terminal A [NOTE 1]
Fuel injector No. 6
29 (Y/R) to Terminal A [NOTE 1]
IAC valve #1
55 (W/B) to Terminal A [NOTE 1]
IAC valve #2
56 (R/Y) to Terminal A [NOTE 1]
IAC valve #3
58 (R/G) to Terminal A [NOTE 1]
IAC valve #4
57 (W/Bl) to Terminal A [NOTE 1]
OCV (Oil control valve) #1
30 (Br/W) to Terminal A [NOTE 1]
OCV (Oil control valve) #2
31 (Br/R) to Terminal A [NOTE 1]
Purge valve
32 (O/W) to Terminal A [NOTE 1]
VSV (Vacuum switching valve)
33 (Gr/R) to Terminal A [NOTE 1]
STANDARD RESISTANCE
(at 20 °C)
168 – 252 Ω
10 – 14 Ω
25 – 34 Ω
6.0 – 8.3
28 – 35
34 – 46
IAT sensor
25 (Lg/B) to 49 (B/W)
Cylinder temperature sensor
9 (Lg/W) to 49 (B/W)
Ex-manifold temperature sensor #1 8 (V/W) to 49 (B/W)
0 °C (32 °F): 5.3 – 6.6 kΩ
25 °C (77 °F): 1.8 – 2.3 kΩ
50 °C (122 °F): 0.73 – 0.96 kΩ
Ex-manifold temperature sensor #2 10 (G/R) to 49 (B/W)
75 °C (135 °F): 0.33 – 0.45 kΩ
(Thermistor characteristic)
ECM main relay
17 (P/B) to Terminal B [NOTE 2]
145 – 190 Ω
COMPONENT INSPECTIONS
FUEL PUMP 6 SEC OPERATING SOUND
[High pressure side]
1. Install the emergency stop switch lock plate in position.
2. Turn ignition switch ON and check for fuel pump operating
sound.
Fuel pump operating sound:
Sounds for approx. 6 seconds only
NOTE:
Fuel pump operating sound is low because pump is inside fuel
vapor separator. If you cannot hear pump sound clearly, use a
sound scope or long blade screw driver.
1
1. Fuel vapor separator/
High pressure fuel pump
3-54
ENGINE CONTROL SYSTEM
[Low pressure side]
1. Install the emergency stop switch lock plate in position.
2. Turn ignition switch ON and check for fuel pump operating
sound.
1
Fuel pump operating sound:
Sounds for approx. 6 seconds only
1. Low pressure fuel pump
FUEL INJECTOR OPERATING SOUND (CRANKING)
1. Remove the collector assembly. (See page 6-3, 6-6)
2. Touch a sound scope or long blade screw driver to fuel injector body as shown.
3. Crank engine and check for injector operating sound.
Click
Injector body
Injector operating sound: “Click”
4. Reinstall the collector assembly. (See page 6-5, 6-7.)
FUEL INJECTOR OPERATING SOUND (INDIVIDUAL)
1. Remove the collector assembly. (See page 6-3, 6-6)
2. Disconnect fuel injector wire and connect test cord.
Click
" 09930-89260: Injector test cord A
3. Connect Gray wire to body ground.
4. Momentarily touch Black/Yellow wire to starter motor magnetic switch “B” terminal (connected to battery positive +
terminal) and check for injector operating sound.
Injector operating sound: “Click”
!
Connecting fuel injector to battery positive for more
than a few seconds may cause injector overheating
and possible injector solenoid failure.
1
5. Reinstall the collector assembly. (See page 6-5, 6-7.)
1. Magnetic switch “B” terminal
ENGINE CONTROL SYSTEM
3-55
FUEL INJECTOR OPERATING SIGNAL
ECM
34 pin test cord
26 pin test cord
(White connector)
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
60
(Black connector)
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
(White connector)
Wire harness
Starter motor magnetic
switch “B” terminal
27 28 29
36
53 54
(Black connector)
(White connector)
34 pin test cord
" 09930-89340: 26-pin & 34-pin test cord
Peak voltmeter Stevens CD-77
' Tester range: NEG 50
1. Connect test cord between ECM and wire harness as shown
in figure then turn ignition switch ON.
2. Connect the tester probe (“-”, Black) to starter motor magnetic switch “B” terminal (connected to battery positive +
terminal) as shown in figure.
3. Connect the tester probe (“+”, Red) to each terminal.
(Voltage)
Injector
No.
No.
No.
No.
No.
No.
1
2
3
4
5
6
Terminal
54
36
28
53
27
29
Wire color
(engine harness)
O/B
B/Br
R/W
Lg
O/Bl
Y/R
4. Crank engine and measure voltage.
Fuel injector operating signal: 6 – 10 V
12 V
) Peak voltage reading (NEG)
* 0 V level for peak voltmeter
(Time)
3-56
ENGINE CONTROL SYSTEM
IGNITION COIL OPERATING SIGNAL
ECM
34 pin test cord
26 pin test cord
(White connector)
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
60
(Black connector)
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
(White connector)
37 38 39
45 46
50
42
(White connector)
(Black connector)
34 pin test cord
" 09930-89340: 26-pin & 34-pin test cord
Peak voltmeter Stevens CD-77
' Tester range: SEN 50
1. Connect test cord between ECM and wire harness as shown
in figure then turn ignition switch ON.
2. Connect the tester probe (“+”, Red) to each terminal.
Ignition coil
No.
No.
No.
No.
No.
No.
1
2
3
4
5
6
Terminal
42
50
39
45
37
38
Wire color
(engine harness)
O
Bl
Gr/Y
Lg/R
W/G
Bl/Y
3. Connect the tester probe (“-” Black) to No. 46 terminal (or
to body ground).
4. Crank engine and measure voltage.
Ignition coil operating signal: Approx. 5 V
ENGINE CONTROL SYSTEM
IGNITION COIL ASSEMBLY
" 09930-99320: Digital tester
$ Tester range: % DCV (See chart for range.)
NOTE:
The ignition coil power transistor and high-tension lead are an
integral part of the coil’ internal circuit. Using resistance measurements to check for a defect on either the primary or secondary coil is not possible.
1. Turn ignition key OFF.
2. Disconnect ignition coil connector.
3. Check for continuity between GND - terminal on the wiring
harness side connector and the engine body ground.
4. Turn the ignition key to ON position. Check for battery voltage by measureing 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. (See page 3-56.)
6. If any failure exists, check for open circuit, short-circuited
battery, short-circuited lead and connector’s contact condition for each circuit.
7. If there is no spark even with the wiring harness and spark
plug in sound condition, perform inspection again using an
ignition coil that is known to be in good condition (new or
used from another cylinder that is operating properly).
8. If there is still no spark even with the wiring harness, spark
plug and ignition coil in sound condition, replace the ECM
and perform inspection again.
IGT
GND
+BAT
3-57
3-58
ENGINE CONTROL SYSTEM
CMP SENSOR SIGNAL
ECM
" 09930-89340: 26-pin & 34-pin test cord
09930-99320: Digital tester
$ Tester range: % DCV (See chart for range.)
(White connector)
27 28 29 30 31 32 33 34 35 36 37 38 39
44 45 46 47 48 49 50 51 52 53 54 55 56
40 41 42
57 58 59
43
60
(Black connector)
(Black connector)
1 2 3 4 5 6 7 8 9 10 11 12 13
(White connector)
1. Turn ignition switch OFF.
2. Remove CMP sensor. (See page 3-69.)
3. Connect the 26-pin & 34-pin test cord between ECM and
wire harness as shown in figure.
4. Connect the tester probe (“+”, Red) to each terminal.
CMP sensor
No. 1
No. 2 (VVT_PORT)
No. 3 (VVT_STBD)
Terminal
5
7
6
Wire color
(engine harness)
Y/Bl
O/G
B/O
Wire harness
26 pin test cord
5 6 7
(White connector)
5. Connect the tester probe (“-”, Black) to No. 49 terminal (or
to body ground).
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.
34 pin test cord
When screwdriver is brought near: Approx. 5 V
When screwdriver is pulled away: Approx. 0.3 V
49
If the voltage does not change in the above test, replace the
sensor.
(Black connector)
2
1
1. Screw driver
2. CMP sensor
14 15 16 17 18 19 20 21 22 23 24 25 26
ENGINE CONTROL SYSTEM
MAP SENSOR OUTPUT VOLTAGE CHANGE
" 09917-47011: Vacuum pump gauge
09930-89340: 26-pin & 34-pin test cord
09930-99320: Digital tester
$ Tester range: % DCV (See chart for range.)
1. Remove ring gear cover and silencer case. (See page 6-2.)
2. Remove bolts and MAP sensor from collector assembly.
MAP sensor
3. Connect vacuum pump gauge (with hose) to MAP sensor as
shown in figure.
4. Turn ignition switch ON.
5. While applying negative pressure (vacuum) to MAP sensor,
measure “12” terminal voltage. (See page 3-49 and 3-50 for
procedure.)
MAP sensor output voltage change:
Negative pressure
kPa (kg/cm2, mmHg)
“12” terminal
voltage (V)
26 pin test cord
0
(0, 0)
40
(0.4, 300)
80
(0.8, 600)
4.00
2.42
0.84
(at 759.8 mmHg, 29.91 inHg, 1013 hPa barometric pressure)
12
(White connector)
3-59
3-60
ENGINE CONTROL SYSTEM
TPS (Throttle position sensor)
" 09930-99320: Digital tester
09930-89220: 3-pin test cord
$ Tester range: %(DCV (See chart for range.)
1. Turn ignition switch OFF.
2. Remove ring gear cover and silencer case. (See page 6-2.)
3. Connect 3-pin test cord between TPS and wire harness as
shown in figure.
4. Turn the ignition switch ON.
5. Connect tester probe as shown in the illustration and check
for sensor power source voltage.
TPS
Sensor power source voltage: Approx. 5 V
6. Connect tester probe as shown in the illustration and 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.
Power source voltage
Bl
TPS
Y
W R B/W
B
Sensor output voltage:
FCT position : Approx. 0.7 V
WOT position : Approx. 3.8 V
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.
Out put voltage
Bl
TPS
Y
B
W R B/W
ENGINE CONTROL SYSTEM
SHIFT POSITION SENSOR
" 09930-99320: Digital tester
09930-89220: 3-pin test cord
$ Tester range: %(DCV (See chart for range.)
1. Turn ignition switch OFF.
2. Connect 3-pin test cord between shift position sensor and
wire harness as shown in figure.
3. 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: Approx. 5 V
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. 4.1 V
Approx. 2.3 V
Approx. 0.8 V
If out of specification:
• 1st Check sensor position adjustment, readjust if necessary.
• 2nd Replace shift position sensor.
NOTE:
After installing shift position sensor, check for proper correct
function by operating remo-con handle.
2
3
1
1. Shift position sensor
2. Adjust screw
3. Clutch lever
Power source voltage
Bl
Y
Shift position
sensor
W R B/W
B
Out put voltage
Bl
Y
Shift position
sensor
B
W R B/W
3-61
3-62
ENGINE CONTROL SYSTEM
OIL PRESSURE SWITCH
NOTE:
Before checking the oil pressure switch, make sure the engine
oil pressure is within specification.
1. Remove the blue lead wire from oil pressure switch.
2. Check the continuity between the switch terminal and engine
body ground.
" 09930-99320: Digital tester
) Tester range: *( (Continuity)
Engine running
Engine stopped
Infinity
Continuity
1
1. Oil pressure switch
If measurement exceeds specification, replace oil pressure
switch.
3. Reinstall parts removed earlier.
ECM MAIN RELAY
" 09930-99320: Digital tester
) Tester range: *( (Continuity)
1
1. Disconnect ECM main relay from wire harness.
2. Check continuity between terminal 1 and 2 each time 12 V
is applied. Connect positive + probe to terminal 4, and
negative - probe to terminal 3.
1. ECM main relay
ECM main relay function:
12 V power
Applied
Not applied
Continuity
Yes
No
!
Do not touch 12 V power supply wires to each other or
with other terminals.
12 V
CONT
ENGINE CONTROL SYSTEM
IAC VALVE
1. Remove IAC valve. (See page 3-69.)
2. When the ignition switch is turned ON and OFF, check that
the rotary valve turns to open and returns to closed.
3. If the valve does not turn, check the wiring harness for continuity (between ECM and IAC valve) and connector contact
condition.
3-63
1
1. IAC valve
OCV (Oil control valve)
1. Remove OCV. (See page 3-70.)
2. Check for operating sound (ticking sound) when battery voltage applied to and removed from the terminals of oil control
valve.
3. Check resistance between the two OCV terminals.
OCV
OCV resistance: 6.0 – 8.0 Ω
MULTI-STAGE INDUCTION
SYSTEM INSPECTION
• Ensure the depression chamber rod pulls the shut off valves
to the complete close position after engine start.
• Ensure the shut off valve return spring returns the shut off
valves to the full open position when the engine is turned off.
DEPRESSION CHAMBER
" 09917-47011: Vacuum pump gauge
• Ensure the shut off valve fully close when vacuum is applied
to the depression chamber with a vacuum pump tool.
Operation start vacuum: 1 – 8 mmHg
Operation end vacuum: 18 – 20 mmHg
Depression chamber
Rod
3-64
ENGINE CONTROL SYSTEM
VACUUM PASSAGE INSPECTION
1. Disconnect vacuum hose 1 from vacuum switching valve
2.
2. Start engine and run it at idle speed.
Place a finger over vacuum hose end 1 and engine vacuum
is present.
3. If vacuum is not present, clean vacuum passage with compressed air, start engine and check again for vacuum.
CHECK VALVE
Inspection
1. Remove check valve 1.
2. Blow air (moderate pressure) through hose fitting on black
side of check valve. Air should not pass through valve from
collector assembly (black side 3) to orange side 2.
3. Blow air (low pressure) through hose fitting on orange side of
check valve. Air should pass through to black side.
4. If air passes through valve in Step 2) or high pressure is
required to cause air to pass in Step 3), replace check valve.
#
DO NOT SUCK air through check valve.
Fuel vapor inside the valve is harmful.
5. Install check valve.
NOTE:
The check valve is directional. Refer to the figure for correct
installation.
4 To vacuum tank
5 From collector assembly
6 Vacuum tank
ENGINE CONTROL SYSTEM
3-65
VSV (Vacuum switching valve)
1. With ignition switch OFF, disconnect connector from VSV.
2. Check resistance between VSV terminals.
Resistance of VSV: 37 – 44 Ω
3. Disconnect two hoses from VSV.
4. With 12 V applied between the VSV terminals, check that
port (E) connects to port (F) but not to the filter section.
5. Without voltage applied to the VSV terminals, check that port
(E) connects to the filter section but not to port (F).
F
Filter
E
VSV AIR PASSAGE CONTINUITY
Passage continuity
between ports
VSV electrical power
E
F
Filter
section
F
Filter
Power ON
Power OFF
E
: Air passage
NOTE:
Before removing hoses to check VSV, mark each hose for position to ensure correct hose connection on assembly.
E: To depression chamber
F: To vacuum tank
3-66
ENGINE CONTROL SYSTEM
REMOVAL/INSTALLATION
FLYWHEEL
1. Flywheel bolt
2. Flywheel
3. Dowel pin
4. CKP sensor
5. Bolt
6. CMP sensor
7. Bolt
1
118 N·m (11.8 kg-m, 85.3 lb-ft)
7
6
2
5
3
4
REMOVAL
Prior to removing flywheel:
• Disconnect battery cables from battery.
1. Remove ring gear cover and air intake silencer case.
(See page 6-2.)
2. Remove screws 1 and battery charge coil connector holder
2 from cylinder.
3. To lock the flywheel 3, use special tool shown in figure.
Use screws and threaded holes on top of cylinder to attach
special tool.
" 09916-99310: Flywheel holder
7
6
NOTE:
Clean flywheel and crankshaft
mating surfaces with cleaning
solvent.
ENGINE CONTROL SYSTEM
4. Remove eight (8) flywheel bolts 4.
5. Remove flywheel 3 and dowel pin 5.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Install dowel pin 5.
• Install flywheel 3 onto crankshaft making sure to align dowel
pin hole.
NOTE:
Before installing the flywheel magneto, wipe the crankshaft and
flywheel clean.
!
Before tightening flywheel bolts, make sure the flywheel dowel pin hole and crankshaft dowel pin align
or severe damage may result.
• Apply THREAD LOCK “1342” to flywheel bolts 4 before
installing.
• Tighten flywheel bolts 4 to specified torque. To lock flywheel,
use special tool as shown in figure.
+ Flywheel bolt: 118 N·m (11.8 kg-m, 85.3 lb-ft)
" 09916-99310: Flywheel holder
, 99000-32050: THREAD LOCK “1342”
• After installing flywheel and torquing bolts to specification,
check air gap between CKP sensor and reluctor bars on flywheel.
Air gap: 0.75 mm (0.030 in)
• Check to ensure that all removed parts are back in original
position.
CKP sensor
0.75 mm
3-67
3-68
ENGINE CONTROL SYSTEM
CKP SENSOR
REMOVAL
Prior to removing CKP sensor:
• Disconnect battery cables from battery.
1. Remove ring gear cover and air intake silencer case. (See
page 6-2.)
2. Disconnect CKP sensor lead wire connector in electric parts
holder.
3. Remove two (2) screws 1 and CKP sensor 2.
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Apply THREAD LOCK “1342” to the sensor mounting screws.
, 99000-32050: THREAD LOCK “1342”
• Install CKP sensor with air gap of 0.75 mm between sensor
and reluctor bar on flywheel, then tighten sensor mounting
screws securely.
Air gap: 0.75 mm (0.030 in)
CKP sensor
0.75 mm
ENGINE CONTROL SYSTEM
CMP SENSOR
REMOVAL
1. Remove collector assembly. (See page 6-3, 6-6.)
2. Disconnect CMP sensor lead wire connector at sensor.
3. Remove bolt and CMP sensor.
1
1. CMP sensor
2. CMP sensor
INSTALLATION
Installation is reverse order of removal.
• Install CMP sensor, then tighten sensor mounting screw
securely.
• Connect sensor lead wire connector to CMP sensor.
• Check to ensure that all removed parts are back in original
position.
2
3
3. CMP sensor
IAC VALVE
REMOVAL
1. Remove the ring gear cover and air intake silencer case.
(See page 6-2.)
2. Disconnect IAC valve lead wire connector at IAC valve.
3. Remove screws and IAC valve.
1
1. IAC valve
INSTALLATION
Installation is reverse order of removal.
• Install IAC valve, then tighten mounting screw securely.
• Connect IAC valve lead wire connector to IAC valve.
• Check to ensure that all removed parts are back in original
position.
OIL PRESSURE SWITCH
REMOVAL
1. Loosen screw 1 and disconnect blue lead wire 2 from
switch.
2. Remove oil pressure switch from cylinder block.
Oil pressure switch
3-69
3-70
ENGINE CONTROL SYSTEM
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Before installing oil pressure switch, wrap screw threads with
sealing tape then tighten switch to specified torque.
NOTE:
Cut off any excess sealing tape from switch threads before
installation.
1
1. Sealing tape
+ Oil pressure switch: 13 N·m (1.3 kg-m, 9.5 lb-ft)
• Start engine and check oil pressure switch for oil leakage.
Reseal switch if oil leakage is found.
OCV (Oil control valve)
REMOVAL
1. Remove collector assembly. (See page 6-3, 6-6.)
2. Disconnect OCV lead wire connector at OCV.
3. Remove the four (4) bolts securing OCV, then remove OCV
and discard OCV gasket.
1. OCV
INSTALLATION
Installation is reverse order of removal with special attention to
the following steps.
• Install gasket and OCV, then tighten bolts securely.
NOTE:
Position the projection of OCV gasket as shown the right.
1
!
Do not re-use the OCV gasket, always replace with
new one.
+ OCV bolt: 12 N·m (1.2 kg-m, 8.6 lb-ft)
• Install collector assembly.
Refer to “Collector assembly” in this section for assembly.
• Check to ensure that all removed parts are back in original
position.
1. OCV gasket
1
ENGINE CONTROL SYSTEM
THROTTLE CONTROL
SYNCHRONIZING THROTTLE BODIES
1. Check that the throttle link operates smoothly.
Throttle lever
2. Loosen screw 1.
3. Check that the tip of both the STBD and PORT throttle stop
screws 2 contacts the throttle lever stop 3.
This condition indicates the throttle valve is completely
closed.
!
Do not attempt to adjust the throttle stop screw.
4. In the condition of step 3, insert a thickness gauge of 0.2 mm
(0.008 in) between the throttle stop screw 2 and throttle
lever stop 3.
With the link rod 4 pushed up lightly, tighten screw 1
securely.
5. Operate the throttle lever from complete close position to full
open position 2 – 3 times repeatedly and check that both the
STBD and PORT throttle valves open and close completely.
Also check that both the throttle valves start to open simultaneously when the throttle lever is gradually opened from the
complete close position.
6. As necessary, repeat steps 2 – 5.
: Thickness gauge. 0.2 mm
3-71
3-72
ENGINE CONTROL SYSTEM
THROTTLE CONTROL CABLE
Installation and Adjustment
1. Lightly push throttle lever to bring the throttle to full close.
Throttle lever
2. Align the match mark a (▲) on throttle cam 1 with the center of throttle lever roller 2 and hold this position.
3. Install throttle control cable 3 to throttle drum 4 and cable
holder 5.
4. Turn lock nut 6 in the appropriate direction to install cable
with no sag.
5. Tighten the lock nuts 6 to secure throttle cable to cable
holder.
6. Turn throttle cam 1 to the position where the clearance b
between throttle lever roller 2 and throttle cam becomes 0
(zero) mm.
Hold this condition unmoved and install throttle cable 7 to
throttle drum 4 and cable holder 5.
Turn the lock nut 8 so as to remove play on the inner cable.
Tighten lock nut securely.
7. Pull and push the throttle lever from fully closed position to
fully open position several times.
With the throttle lever in complete close position, check that
the tip of throttle stop screw 9 contacts throttle lever stop 0
and the clearance b is 0 (zero) mm.
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