Page 2 CAUTION stated, you must also use good judgment and observe basic mechanical safety principles. WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual.
Page 3 * This manual is intended for use by technicians who already possess the basic knowledge and skills to ser- vice 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 Out- board motor dealer.
Page 4 TABLE OF CONTENTS Precautions............... 00-i Precautions ............00-1 General Information ........... 0-i General Information ..........0A-1 Maintenance and Tune-Up........0B-1 Power Head..............1-i Precautions .............. 1-1 Engine General Information and Diagnosis ... 1A-1 Engine Electrical Devices........1C-1 Power Unit Mechanical ..........1D-1 Power Unit Lubrication ...........
Page 5 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions ..........00-1 Precautions............00-1 General Precautions ........... 00-1...
Page 6 00-1 Precautions: Precautions Precautions Precautions General Precautions Z9J0110000002 WARNING • Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor. • To avoid eye injury, always wear protective glasses when filing metals, working on a grinder, or doing other work, which could cause debris.
Page 7 00-2 CAUTION • If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. • When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.
Page 8 00-3 Precautions:...
Page 9 Table of Contents 0- i Section 0 General Information CONTENTS General Information ........ 0A-1 Scheduled Maintenance ........0B-1 Periodic Maintenance Schedule Chart....0B-1 General Description ..........0A-1 Lubrication Point ..........0B-2 Symbols .............. 0A-1 Service Instructions ..........0B-3 Abbreviations ............0A-1 Engine Oil Level Check........0B-3 Wire Color Symbols ..........
Page 10 Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI Outboard Motor Gear Oil. Apply SUZUKI Super Grease A. Apply SUZUKI Moly Paste.
Page 11 General Information: 0A-2 Wire Color Symbols Z9J0110101010 There are two kinds of colored wire used in this product. One is single colored wire and the other is dual colored (striped) wire. The single colored wire uses only one color symbol. example: B (Black). The dual colored wire uses two color symbols.
Page 12 Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of a SAE 10 W – 40 NMMA certified oil. If NMMA certified FC-W oil is not available, select a good...
Page 13 General Information: 0A-4 Break-In Procedures Propeller Selection Guide Z9J0110101016 Z9J0110101017 The first 10 hours are critically important to ensure An outboard motor is designed to develop its rated correct running of either a brand new motor or a motor power within a specified engine speed range. The that has been reconditioned or rebuilt.
Page 14 Powerhead Direction of Rotation Description Z9J0110101018 Z9J0110101019 Suzuki recommends a 12 volt cranking type lead acid This outboard motor is designed with a L.H. (left hand) battery for the DF70A / 80A / 90A. rotation powerhead utilizing an offset crankshaft. This...
Page 15 Unit DF70AT DF80AT DF90AT Suzuki highly recommends the use of alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R/2+M/2 method) or 91 Fuel (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used.
Page 16 4.0 (4.2 / 3.5): Oil change only Engine oil amounts L (US/lmp. qt) 4.3 (4.5 / 3.8): Oil filter change SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API Gear oil classification GL-5. Gearcase oil capacity ml (US/lmp. oz) 850 (28.7/30.0)
Page 17 General Information: 0A-8 Service Data Z9J0110107002 NOTE These service data are subject to change without notice. Powerhead Data Item Unit DF70AT DF80AT DF90AT Recommended operating range r/min 5 000 – 6 000 5 000 – 6 000 5 500 – 6 300 600 ±...
Page 18 0A-9 General Information: Valve / Valve Guide Data Item Unit DF70AT DF80AT DF90AT mm (in.) 27.5 (1.08) Valve diameter mm (in.) 22.9 (0.90) Tappet clearance std. mm (in.) 0.23 – 0.27 (0.009 – 0.011) (Cold engine condition) std. mm (in.) 0.30 –...
Page 19 General Information: 0A-10 Cylinder / Piston / Piston Ring Data Item Unit DF70AT DF80AT DF90AT Cylinder distortion Limit mm (in.) 0.03 (0.001) std. mm (in.) 0.020 – 0.040 (0.0008 – 0.0016) Piston to cylinder clearance Limit mm (in.) 0.100 (0.0039) Cylinder bore std.
Page 20 0A-11 General Information: Crankshaft / Conrod Data Item Unit DF70AT DF80AT DF90AT Conrod small end inside diameter std. mm (in.) 18.003 – 18.011 (0.7088 – 0.7091) std. mm (in.) 0.032 – 0.050 (0.0013 – 0.0020) Conrod big end oil clearance Limit mm (in.) 0.080 (0.0031)
Page 21 General Information: 0A-12 Starter Motor Data Item Unit DF70AT DF80AT DF90AT Max. continuous time of use Sec. Motor output std. mm (in.) 16.0 (0.63) Brush length Limit mm (in.) 12.0 (0.47) std. mm (in.) 0.5 – 0.8 (0.02 – 0.03) Commutator undercut Limit mm (in.)
Page 22 0A-13 General Information: Fail-safe system Failed item Code Lamp flashing pattern activating Trim sensor 3 – 7 MCODE00D37-0-01 Oil pressure switch 5 – 3 MCODE00D53-0-01 Rectifier/Regulator (Over-charging) 1 – 1 MCODE00D11-0-01 Tightening Torque Specifications Z9J0110107003 Important Fasteners Thread Tightening Torque Item Diameter N⋅m...
Page 23 Special Tools and Equipment Recommended Service Material Z9J0110108001 99000–22540 99000–25161 99000–31120 99000–31140 99000–32020 SUZUKI Outboard SUZUKI Water SUZUKI Silicone Seal SUZUKI Bond 1207B SUZUKI Thread Lock Motor Gear Oil Resistant Grease (250 (50 g) (100 g) 1333B (50 g) 99000–32050 99000–25140...
Page 24 0A-15 General Information: Special Tool Z9J0110108002 01500–08403 09900–20101 09900–20202 09900–20203 09900–20205 Bolt Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (0 – 25 09900–20605 09900–20606 09900–20701 09900–20803 09900–21304 Dial calipers (10 – 34 Dial gauge Magnetic stand Thickness gauge Steel “V”...
Page 25 General Information: 0A-16 09916–34542 09916–34550 09916–37320 09916–44310 09916–58210 Valve guide reamer Valve guide reamer (φ Valve guide reamer (φ Valve guide remover Valve guide installer handle 5.5 mm) 10.5 mm) handle 09916–68710 09916–77310 09916–84511 09917–47011 09917–49610 Tappet holder Piston ring Tweezers Vacuum pump gauge Vacuum pump adapter...
Page 26 0A-17 General Information: 09930–89260 09930–99320 09940–44121 09940–44130 09941–64511 Injector test cord (A) Digital tester Air pressure gauge Attachment Bearing remover 09945–69010 09945–79310 09950–69512 09951–09530 09951–18730 PTT rod holder PTT cable extension Gearcase oil leakage Gear adjusting gauge Attachment tester 09951–38710 09951–59910 09952–99310 99954–53873*...
Page 27 Maintenance and Tune-Up: 0B-1 Maintenance and Tune-Up General Information Precautions Precautions for Maintenance Z9J0110200001 The “Periodic Maintenance Schedule Chart” lists the recommended intervals for all the required periodic service work necessary to keep the motor operating at peak performance and economy. Maintenance intervals should be judged by number of hours or months, whichever comes first.
Page 28 Lubrication Point Z9J0110205002 Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor. Apply Suzuki Water Resistant Grease to the following point. Lubricate Every 50 hours (3 months) : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011020034-04 1.
Page 29 Maintenance and Tune-Up: 0B-3 Service Instructions Engine Oil Level Check Z9J0110206039 Inspect oil level Before every use 1) Place outboard motor upright on a level surface. 2) Remove motor cover. 3) Remove oil level dipstick (1) and wipe it clean. I9J011020036-01 Engine Oil Change and Engine Oil Filter Replacement...
Page 30 0B-4 Maintenance and Tune-Up: 3) Place a container under engine oil drain plug. 6) Pour the recommended engine oil into oil filler opening, then install oil filler cap. 4) Remove engine oil drain plug (2) and gasket (3) to drain engine oil. Recommended Engine Oil •...
Page 31 Maintenance and Tune-Up: 0B-5 Engine Oil Filter Replacement 6) Tighten the filter 3/4 turn from the point of contact with mounting surface using an oil filter wrench. 1) Drain engine oil in the same manner of engine oil change procedure. Tightening torque 2) Remove STBD and PORT side covers.
Page 32 Recommended Gear Oil 1) Disconnect wiring harness connector from ignition • Suzuki Outboard Motor Gear Oil or API coil (1), then remove the bolt (2) securing the ignition classification GL5, Viscosity rating SAE # 90 coil.
Page 33 Maintenance and Tune-Up: 0B-7 Installation Installation is reverse order of removal. Pay attention to the following: • Tighten the spark plug to specified torque. Tightening torque Spark plug (a): 18 N·m (1.8 kgf-m, 13 lbf-ft) I9J011020006-01 Spark Plug Gap Measure spark plug gap with a thickness gauge. Adjust to within specified range if gap is out of specification.
Page 34 0B-8 Maintenance and Tune-Up: Tappet Clearance Inspection and Adjustment 3) Rotate crankshaft counterclockwise to bring cam Z9J0110206041 nose vertical to shim surface. Inspect tappet clearance 4) Measure tappet clearances by inserting thickness Every 200 hours (12 months) gauge between cam and shim surface. Inspection CAUTION The tappet clearance specification is different for intake...
Page 35 Maintenance and Tune-Up: 0B-9 Adjustment 4) Rotate top of cam 90 degree counterclockwise and Tappet clearances are adjusted by replacing tappet remove shim from cut- away at tappet. shim. (Two tappets can be adjusted at the same time) 1) With cam nose vertical to valve, turn tappet cut-away towards center of cylinder head as shown in figure.
Page 36 0B-10 Maintenance and Tune-Up: NOTE “C” After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again. “ a ” I9J011020013-01 “C”: I.D No. “a”: 2.50 mm Shim size chart Thickness Thickness I.D. No. I.D. No. (mm) (mm) 2.080 2.500...
Page 37 Maintenance and Tune-Up: 0B-11 Tappet shim selection chart (IN. side) I9J011020016-06...
Page 38 0B-12 Maintenance and Tune-Up: Tappet shim selection chart (EX. side) I9J011020017-05...
Page 39 Maintenance and Tune-Up: 0B-13 Idle Speed and Idle Air Control (IAC) Duty 5) Shift into forward, Check in-gear idle speed. If not, check idle air control system. Inspection Z9J0110206030 NOTE Inspect idle speed and IAC Duty Initially after 20 hours (1 month) and every 200 hours •...
Page 40 0B-14 Maintenance and Tune-Up: Breather Line and Fuel Line Inspection Z9J0110206043 Inspect breather line and fuel line Initially after 20 hours (1 month) and every 50 hours (3 months) Replace breather line and fuel line Every 2 years If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line. Fuel line check point I9J011020019-04...
Page 41 • Stop the motor before cleaning the fuel Every 1 000 hours filter. • Do not smoke and keep open flames and SUZUKI recommends that replacing the high pressure sparks away while working near any part of fuel filter every 1 000 operating hours. the fuel system.
Page 42 I9J011020021-01 3) Inspect water pump impeller. Replace if vanes are cut, torn or worn. SUZUKI recommends that replacing the water pump impeller every 200 hours (12 months). 4) Assemble the water pump related items. Refer to “Water Pump Removal and Installation” in Section 3A (Page 3A-6).
Page 43 10 mm bolt (2) to function as a screw jack. I9J011020058-01 I9J011020022-04 NOTE The anode (3) securing bolt should be covered with suzuki silicone seal. : Sealant 99000–31120 (SUZUKI Silicone Seal I9J011020025-02 (50 g)) NOTE To access the anode in the gearcase, remove the water inlet filter.
Page 44 0B-18 Maintenance and Tune-Up: Bonding Wires Inspection Battery Inspection Z9J0110206049 Z9J0110206050 Inspect bonding wires Inspect battery Every 50 hours (3 months) Every 50 hours (3 months) 1) If breakage or other damage is found on bonding WARNING wire (1), replace the wire. •...
Page 45 Maintenance and Tune-Up: 0B-19 Connecting Battery Battery Solution Level Check CAUTION CAUTION Once the battery has been initially serviced, • If the battery leads are loose, incorrectly NEVER add diluted sulfuric acid or battery connected or reversed, the electrical damage will occur. system could be damaged.
Page 46 0B-20 Maintenance and Tune-Up: Bolts and Nuts Inspection Z9J0110206025 Inspect bolts and nuts Initially after 20 hours (1 month) and every 100 hours (6 months) Check that all bolts and nuts listed below are tightened to their specified torque. Refer to “Tightening Torque Specifications” in Section 0A (Page 0A-13).
Page 47 Maintenance and Tune-Up: 0B-21 High oil pressure 6) Disconnect remote control throttle cable from throttle lever. • Using an engine oil of too high viscosity 7) Move and hold throttle lever (1) in full-open position. • Clogged oil passage • Clogged oil pressure regulator •...
Page 48 0B-22 Maintenance and Tune-Up:...
Page 49: Table Of Contents
Table of Contents 1- i Section 1 Power Head CONTENTS Precautions ..........1-1 Self-Diagnostic Code “3 – 7” Trim Sensor ..1A-36 Troubleshooting Without Self-Diagnostic Precautions............. 1-1 Code..............1A-37 Precautions for Powerhead........1-1 IAC System Troubleshooting ......1A-38 Engine General Information and Service Instructions ...........1A-39 Diagnosis ..........
Page 50 1-ii Table of Contents Service Instructions..........1D-2 Oil Strainer Removal and Installation ....1E-6 Tappet Clearance Inspection ......1D-2 Oil Strainer Related Parts Inspection ....1E-6 Ring Gear Cover Removal and Installation..1D-2 Power Unit Cooling System.....1F-1 Cylinder Head Cover Removal and Installation ............1D-2 General Description ..........1F-1 Air Intake Silencer Case Removal and Water Cooling System Description .....
Page 51 Table of Contents 1-iii Low Pressure Fuel Pump Removal and Component Location ..........1I-3 Installation ............1G-25 Starting System Components Location....1I-3 Low Pressure Fuel Pump Inspection ....1G-26 Diagnostic Information and Procedures ..... 1I-3 Starter System Troubleshooting......1I-3 Ignition System........1H-1 Service Instructions ..........
Page 52: Precautions
1-1 Precautions: Precautions Power Head Precautions Precautions for Powerhead Z9J0111000001 Refer to “General Precautions” in Section 00 (Page 00-1).
Page 53: Engine General Information And Diagnosis
NOTE • To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use the Suzuki Diagnostic System. • The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected. • Each electrical circuit is affected by battery voltage, always use a full-charged battery.
Page 54: General Description
1A-2 Engine General Information and Diagnosis: General Description Engine Control System Description Z9J0111101001 The DF70 / 80 / 90 models employ an integrated system which performs the control functions for fuel injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine Control Module). System Structure INPUT CONTROL...
Page 55 Engine General Information and Diagnosis: 1A-3 Engine Control System Flow Diagram I9J011110002-04 1. Flywheel 11. IAC valve 21. PTT relay 31. Low pressure fuel pump 2. CKP sensor 12. PTT switch 22. PTT motor 32. Fuel vapor separator 3. Ex. manifold temp. sensor 13.
Page 56: Description
1A-4 Engine General Information and Diagnosis: Engine Control Module (ECM) Z9J0111101002 The ECM sends signals to control the actuators based on the information inputs from each sensor / switch. Major controls are as follows: Name of Control Description Fuel injection control •...
Page 57 Engine General Information and Diagnosis: 1A-5 ECM Input / Output Circuit Diagram I9J011110011-04...
Page 58 1A-6 Engine General Information and Diagnosis: ECM Connector / Terminals Layout 48 47 46 45 44 43 42 41 40 39 38 37 12 11 10 9 8 7 6 5 4 3 2 1 60 59 58 57 56 55 54 53 52 51 50 49 24 23 22 21 20 19 18 17 16 15 14 13 72 71 70 69 68 67 66 65 64 63 62 61 36 35 34 33 32 31 30 29 28 27 26 25...
Page 59 Engine General Information and Diagnosis: 1A-7 Caution System Description Z9J0111101003 The following four caution systems alert the operator when an abnormality occurs on the engine. • OVER-REVOLUTION CAUTION • LOW OIL PRESSURE CAUTION • OVERHEAT CAUTION • LOW BATTERY VOLTAGE CAUTION Monitor-Tachometer “A”...
Page 60 1A-8 Engine General Information and Diagnosis: Low Oil Pressure Caution System Condition: Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop below 100 kPa (1.0 kg/cm , 14 psi.) while the engine is running. Action: Engine speed •...
Page 61 Engine General Information and Diagnosis: 1A-9 Action: Engine speed • Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel injection and ignition signals. • The engine automatically stops 3 minutes after the caution system is activated. Caution lamp •...
Page 62 1A-10 Engine General Information and Diagnosis: Self-Diagnostic System Description Z9J0111101004 The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or switch, etc. When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code pattern, along with a buzzer sound.
Page 63 Engine General Information and Diagnosis: 1A-11 Priority Failed Item Code Lamp Flashing Pattern Fail-Safe System Active Rectifier/Regulator 1 – 1 (Over-charging) MCODE00D11-0-01 Oil pressure switch 5 – 3 MCODE00D53-0-01 Trim sensor 3 – 7 MCODE00D37-0-01 NOTE • If two or more items fail at once, the self-diagnostic indication appears according to the priority order.
Page 64 1A-12 Engine General Information and Diagnosis: Failed Item Condition • While the shift sensor outputs a forward or reverse signal, the ECM Neutral switch receives a neutral signal from the neutral switch. Rectifier/Regulator • Receiving 16 volts or higher signal. (Over-charging) •...
Page 65 Engine General Information and Diagnosis: 1A-13 Operating Hour Indication System Description Z9J0111101006 When the ignition switch is initially turned “ON” (from “OFF”), the ECM tests the caution system by turning on all four lamps in the monitor-tachometer and sounding the caution buzzer for an initial two seconds. For the next three seconds, the ECM indicates the total operating hours, using a combination of the tachometer needle and “REV-LIMIT”...
Page 66: Oil Change Reminder System Description
Oil lamp replaced. Once the system has been activated, SUZUKI strongly recommends that the engine oil be replaced before canceling the system. • If the engine oil has been replaced with the...
Page 67: Component Location
Engine General Information and Diagnosis: 1A-15 Component Location Engine Control System Components / Engine Electrical Device Location Z9J0111103001 20 19 I9J011110012-03 1. Flywheel 7. Throttle position sensor 13. Fuse box 19. Starter motor fuse (30 amp.) 2. Starter motor 8. Throttle body 14.
Page 68 1A-16 Engine General Information and Diagnosis: I9J011110013-02 1. Battery charge coil 3. IAC valve 5. Cylinder temp. sensor 2. MAP sensor 4. CKP sensor...
Page 69 Engine General Information and Diagnosis: 1A-17 I9J011110014-01 1. IAC valve 3. Throttle body 5. CKP sensor 2. Throttle position sensor 4. Battery charge coil...
Page 70 1A-18 Engine General Information and Diagnosis: I9J011110015-01 1. Ignition coil 3. CMP sensor 5. Main harness capacitor 2. Fuel injector 4. Rectifier/Regulator...
Page 71 Engine General Information and Diagnosis: 1A-19 I9J011110016-02 1. Neutral switch 3. Trim and tilt sensor 5. Fuel vapor separator 2. Shift position sensor 4. High pressure fuel filter...
Page 72: Diagnostic Information And Procedure
1A-20 Engine General Information and Diagnosis: Diagnostic Information and Procedure ECM Power and Ground Circuit Check Z9J0111104001 Wiring Diagram B/Bl BATT I9J011110018-03 1. Starter motor 3. 40 amp. fuse 5. ECM main relay 7. Sub-battery cable 2. Main battery cable 4.
Page 73: Troubleshooting With Self-Diagnostic Code
Engine General Information and Diagnosis: 1A-21 Troubleshooting Step Action Is operation of the main relay heard when the ignition switch Go to step 4. Go to step 2. is turned “ON”? Are the main fuses (40 amp. and 30 amp.), (for Ignition and Go to step 3.
Page 74: Self-Diagnostic Code "3 - 4" Map Sensor
1A-22 Engine General Information and Diagnosis: Self-Diagnostic Code “3 – 4” MAP Sensor Z9J0111104003 Wiring Diagram I9J011110019-02 1. MAP sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the MAP Go to step 2. • “R” wire open, “R” sensor connector.
Page 75: Self-Diagnostic Code "1 - 4" Cylinder Temp
Engine General Information and Diagnosis: 1A-23 Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor Z9J0111104004 Wiring Diagram Lg/W I9J011110021-03 1. Cylinder temp. sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the Cylinder Go to step 2. • “Lg/W” wire shorted Temp.
Page 76: Self-Diagnostic Code "2 - 3" Iat Sensor
1A-24 Engine General Information and Diagnosis: Self-Diagnostic Code “2 – 3” IAT Sensor Z9J0111104005 Wiring Diagram Lg/B I9J011110024-03 1. IAT sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the IAT sensor Go to step 2. • “Lg/B” wire shorted to connector.
Page 77: Self-Diagnostic Code "4 - 2" Ckp Sensor
Engine General Information and Diagnosis: 1A-25 Self-Diagnostic Code “4 – 2” CKP Sensor Z9J0111104006 Wiring Diagram I9J011110025-03 1. CKP sensor Troubleshooting Step Action 1) Check the CKP sensor air gap. Go to step 2. Incorrectly adjusted air Refer to “CKP Sensor Removal and Installation” in gap.
Page 78: Self-Diagnostic Code "2 - 4" Cmp Sensor
1A-26 Engine General Information and Diagnosis: Self-Diagnostic Code “2 – 4” CMP Sensor Z9J0111104007 Wiring Diagram B/Bl Y/Bl I9J011110055-01 1. CMP sensor 2. + 12 V (From Ign. switch) Troubleshooting Step Action Is the CMP sensor installed properly and the wire harness Go to step 2.
Page 79: Self-Diagnostic Code "2 - 2" Air Intake System
Engine General Information and Diagnosis: 1A-27 Self-Diagnostic Code “2 – 2” Air Intake System Z9J0111104008 Wiring Diagram Br/Y I9J011110057-01 1. TPS Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the TPS Go to step 2. • “R” wire open, “R” connector.
Page 80: Self-Diagnostic Code "3 - 2" Map Sensor 2
1A-28 Engine General Information and Diagnosis: Self-Diagnostic Code “3 – 2” MAP Sensor 2 Z9J0111104009 Wiring Diagram Br/Y I9J011110029-03 1. TPS 2. MAP sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the MAP Go to step 2. •...
Page 81 Engine General Information and Diagnosis: 1A-29 Step Action 1) Check the TPS output voltage change. Intermittent trouble, • Faulty TPS. Refer to “TPS Inspection” in Section 1C (Page 1C-15). substitute a known- • “R” wire shorted to good ECM and recheck. “Br/Y”...
Page 82: Self-Diagnostic Code "1 - 5" Ex. Manifold Temp. Sensor
1A-30 Engine General Information and Diagnosis: Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor Z9J0111104010 Wiring Diagram I9J011110030-02 1. Ex. manifold temp. sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the Ex. Go to step 2. •...
Page 83: Self-Diagnostic Code "4 - 3" Fuel Injector
Engine General Information and Diagnosis: 1A-31 Self-Diagnostic Code “4 – 3” Fuel Injector Z9J0111104011 Wiring Diagram 12 V (From main relay) B/Br I9J011110040-04 1. Fuel injector Troubleshooting Step Action 1) Using a sound scope, check that each injector has an Fuel injector and its Go to step 2.
Page 84: Self-Diagnostic Code "2 - 1" Tps
1A-32 Engine General Information and Diagnosis: Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor) Z9J0111104012 Wiring Diagram Br/Y I9J011110059-01 1. TPS Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the TPS Go to step 2. • “R” wire open, “R” connector.
Page 85: Position Sensor)
Engine General Information and Diagnosis: 1A-33 Self-Diagnostic Code “1 – 2” Shift Position Sensor Z9J0111104013 Wiring Diagram P/Bl I9J011110061-01 1. Shift position sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the shift Go to step 2. • “R” wire open, “R” position sensor connector.
Page 86: Self-Diagnostic Code "3 - 3" Neutral Switch
1A-34 Engine General Information and Diagnosis: Self-Diagnostic Code “3 – 3” Neutral Switch Z9J0111104014 Wiring Diagram B/Bl 12V (From Ign. switch) I9J011110033-04 1. Neutral switch Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect the neutral Go to step 2. •...
Page 87: Self-Diagnostic Code "1 - 1" Rectifier
Engine General Information and Diagnosis: 1A-35 Self-Diagnostic Code “1 – 1” Rectifier/Regulator (Over Charging) Z9J0111104015 NOTE • This self-diagnostic code indication may be canceled when turning the ignition switch “ON” (engine not running), because ECM detects battery voltage. • It is difficult to thoroughly check the rectifier/regulator. Before replacing it with new one, check that the ground point has good electrical contact.
Page 88: Self-Diagnostic Code "3 - 7" Trim Sensor
1A-36 Engine General Information and Diagnosis: Self-Diagnostic Code “3 – 7” Trim Sensor Z9J0111104017 Wiring Diagram I9J011110065-01 1. Trim sensor Troubleshooting Step Action 1) With the ignition switch “OFF”, disconnect trim sensor Go to step 2. • “R” wire open, “R” connector.
Page 89 Engine General Information and Diagnosis: 1A-37 Troubleshooting Without Self-Diagnostic Code Z9J0111104018 Before troubleshooting, make sure that there is not a self-diagnostic code indication. Condition Possible cause Correction / Reference Item Unstable idling / trolling Clogged MAP sensor vacuum passage. Check the vacuum passage. (or engine tends to stall) Malfunctioning TPS.
Page 90: Troubleshooting Without Self-Diagnostic
1A-38 Engine General Information and Diagnosis: IAC System Troubleshooting Z9J0111104019 Wiring Diagram 12V (From Main relay) I9J011110036-02 1. IAC valve Troubleshooting Step Action 1) Warm up the engine to normal operating temperature IAC system is in good Go to step 2. and keep it idling.
Page 91: Service Instructions
Engine General Information and Diagnosis: 1A-39 Service Instructions How to Use the 36 Pin Test Cord Set Z9J0111106001 This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring harness. To take a measurement, connect the tester probe to the relevant terminal of the test cord.
Page 92 1A-40 Engine General Information and Diagnosis: (White connector) 40 41 42 43 44 45 46 47 48 49 58 59 60 61 62 63 64 65 66 67 (Black connector) (Black connector) 1 2 3 4 5 6 7 8 9 10 11 12 13 19 20 21 22 23 24 25 26 27 28 29 30 31 14 15 16 17 18...
Page 93 Engine General Information and Diagnosis: 1A-41 Wire Terminal Circuit Standard Voltage Condition / Remarks color Approx. 5 V Ignition switch ON, Stop switch plate IN. Bl/R Emergency stop switch Approx. 0 V Ignition switch ON, Stop switch plate OUT. — —...
Page 94: Ecm Main Relay Inspection
1A-42 Engine General Information and Diagnosis: Wire Terminal Circuit Standard Voltage Condition / Remarks color Approx. 12 V Ignition switch ON. Key pushed in. O/W Buzzer cancel Approx. 0 V Ignition switch ON. Key not pushed in. Approx. 2.5 V Ignition switch ON.
Page 95: Engine Electrical Devices
Engine Electrical Devices: 1C-1 Engine Electrical Devices Power Head Precautions Precaution for Engine Electrical Device Z9J0111300001 Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Engine Diagnosis” in Section 1A (Page 1A-1). General Description Sensor and Switch Description CMP Sensor Z9J0111301001 •...
Page 96 1C-2 Engine Electrical Devices: • The CMP sensor is a GMR (Giant Magnet Resistive) • Failure symptom: semiconductor type sensor. Without the CMP sensor signal input, the ECM does not output the ignition and fuel injection signals. The GMR semiconductor has the property of varying the electrical resistance depending on the intensity of •...
Page 97 Engine Electrical Devices: 1C-3 Cylinder Temperature Sensor Exhaust Manifold Temperature Sensor The cylinder temperature sensor is installed on the The exhaust manifold temperature sensor is installed on cylinder (top side) and is used to detect the cylinder the exhaust manifold and used to detect exhaust temperature.
Page 98 1C-4 Engine Electrical Devices: MAP Sensor Neutral Switch The MAP sensor is installed on the intake manifold and The neutral switch is installed on the clutch lever holder used to detect the intake manifold pressure. and is used to detect the shift position. This sensor inputs the intake manifold pressure to the This switch is “ON”...
Page 99 Engine Electrical Devices: 1C-5 Trim Sensor Cranking Switch Signal The trim sensor is variable resistor type. The ECM detects if the engine is being started by the position of ignition switch. When the ignition key is With the sensor signal received, the ECM performs the turned to ST position, a voltage (12 V) signal is input to learning of the trim/tilt position and it controls the position of both the trim down limit and the tilt up limit.
Page 100: Ecm Power Source Line
1C-6 Engine Electrical Devices: ECM Power Source Line Main Harness Capacitor Z9J0111301002 This capacitor stabilizes the voltage in the engine control The ECM is battery dependent and must be provided system circuit. with its own dedicated 12 V power supply. The electrical •...
Page 101: Component Location
Engine Electrical Devices: 1C-7 Component Location Location of Sensor and Switch Z9J0111303001 Refer to “Engine Control System Components / Engine Electrical Device Location” in Section 1A (Page 1A-15). Service Instructions Resistance Check Z9J0111306001 Special tool : 09930–99320 (Digital tester) Tester knob indication Resistance (Ω) NOTE Make sure ignition switch is always OFF when measuring resistance.
Page 102: Cylinder Temp. Sensor Removal And Installation
1C-8 Engine Electrical Devices: Cylinder Temp. Sensor Removal and Cylinder Temp. Sensor Inspection Z9J0111306003 Installation 1) Remove the cylinder temperature sensor. Z9J0111306002 Removal Refer to “Cylinder Temp. Sensor Removal and Installation” (Page 1C-8). 1) Remove the ring gear cover. Refer to “Ring Gear Cover Removal and Installation” 2) Immerse temperature sensing part of cylinder temp.
Page 103: Ex. Manifold Temp. Sensor Removal And Installation
Engine Electrical Devices: 1C-9 Ex. Manifold Temp. Sensor Removal and Ex. Manifold Temp. Sensor Inspection Z9J0111306005 Installation 1) Remove the Ex. manifold temp. sensor. Z9J0111306004 Removal Refer to “Ex. Manifold Temp. Sensor Removal and Installation” (Page 1C-9). 1) Disconnect the Ex. manifold temp. sensor lead wire connector.
Page 104: Ckp Sensor Removal And Installation
1C-10 Engine Electrical Devices: CKP Sensor Removal and Installation CKP Sensor Inspection Z9J0111306006 Z9J0111306007 Removal Inspect the CKP sensor. Refer to “Resistance Check” (Page 1C-7). 1) Remove the ring gear cover and air intake silencer case. IAT Sensor Removal and Installation Refer to “Ring Gear Cover Removal and Installation”...
Page 105: Iat Sensor Inspection
Engine Electrical Devices: 1C-11 IAT Sensor Inspection CMP Sensor Removal and Installation Z9J0111306009 Z9J0111306010 Removal 1) Remove the IAT sensor. Refer to “IAT Sensor Removal and Installation” 1) Disconnect the CMP sensor lead wire connector at (Page 1C-10). sensor. 2) Immerse temperature sensing part of IAT sensor in 2) Remove the bolt and CMP sensor (1).
Page 106: Map Sensor Removal And Installation
1C-12 Engine Electrical Devices: Tester knob indication MAP Sensor Removal and Installation DC Voltage ( Z9J0111306012 Removal 1) Remove the flywheel. 36-pin test cord (White connector) Refer to “Flywheel Removal and Installation” in Section 1K (Page 1K-5). 2) Disconnect lead wire connector at MAP sensor. 3) Remove the two screws and MAP sensor (1).
Page 107: Map Sensor Output Voltage Inspection
Engine Electrical Devices: 1C-13 MAP Sensor Output Voltage Inspection 4) Install MAP sensor into special tool. Z9J0111306013 5) Connect vacuum pump gauge (with hose) to MAP 1) Remove the flywheel. sensor (special tool) as shown in figure. Refer to “Flywheel Removal and Installation” in Special tool Section 1K (Page 1K-5).
Page 108: Iac Valve Removal And Installation
1C-14 Engine Electrical Devices: IAC Valve Removal and Installation IAC Valve Inspection Z9J0111306014 Z9J0111306015 Removal 1) Disconnect connector from IAC valve. 1) Remove the flywheel. 2) Check each coil of IAC valve for resistance. Refer to “Flywheel Removal and Installation” in IAC valve resistance Section 1K (Page 1K-5).
Page 109: Tps Inspection
Engine Electrical Devices: 1C-15 TPS Inspection 3) Connect tester probe (“+”, Red) to No. 6 terminal. Z9J0111306016 4) Connect tester probe (“–”, Black) to No. 25 terminal 1) Turn ignition switch OFF. (or to body ground). 2) Connect the 36-pin test cord set between ECM and 36-pin test cord (White connector) wire harness as shown in figure.
Page 110: Shift Position Sensor Inspection
1C-16 Engine Electrical Devices: Shift Position Sensor Inspection 5) Connect tester probe as shown in the illustration. Z9J0111306017 Check for sensor output voltage while operating 1) Turn ignition switch OFF. remo-con handle. 2) Connect 3-pin test cord between shift position Sensor output voltage sensor and wire harness as shown in figure.
Page 111: Trim Sensor Inspection
Engine Electrical Devices: 1C-17 Trim Sensor Inspection 5) Connect tester probe as shown in the illustration. Z9J0111306018 Check for sensor output voltage. 1) Turn ignition switch OFF. Operate the PTT switch, and check if voltage changes linearly within specification, according to 2) Connect 3-pin test cord between trim sensor and trim/tilt position.
Page 112: 1D-1 Power Unit Mechanical
1D-1 Power Unit Mechanical: Power Unit Mechanical Power Head General Description Power Unit Construction Description These gears are located beneath the powerhead in the Z9J0111401001 same oil bath location as the camshaft chain. The power unit is direct water cooled, in line 4 cylinder, 4 As the rotational direction of the driven gear will be stroke gasoline unit with its DOHC (Double overhead opposite of the drive gear, a left-hand rotation...
Page 113: Service Instructions
Power Unit Mechanical: 1D-2 Service Instructions Tappet Clearance Inspection 3) Loosen the clamp securing breather hose (2), then Z9J0111406028 remove the breather hose from cylinder head cover. Refer to “Tappet Clearance Inspection and Adjustment” in Section 0B (Page 0B-8). Ring Gear Cover Removal and Installation Z9J0111406001 Removal Prior to removing ring gear cover, disconnect...
Page 114 1D-3 Power Unit Mechanical: 6) Remove the two bolts securing filter bracket (8), then 9) Disconnect fuel injector lead wire connector at all remove low pressure fuel filter (9) and filter bracket. fuel injectors (12). Cut the cable tie (13) binding injector lead wire to fuel delivery pipe (14).
Page 115 • Remove oil, old sealant, and dust from sealing 8.0 lbf-ft) surfaces. • After cleaning, apply sealant to cylinder head sealing surface area as shown in figure. : Sealant 99000–31140 (SUZUKI Bond 1207B (100 g)) I9J011140090-01 I9J011140088-01 • Install new cylinder head cover gasket (1) to head cover.
Page 116: Air Intake Silencer Case Removal And Installation
1D-5 Power Unit Mechanical: Air Intake Silencer Case Removal and Electric Parts Holder Removal and Installation Z9J0111406004 Installation Removal Z9J0111406003 Before removing electric parts holder, disconnect Removal battery cables from battery. 1) Remove the ring gear cover. 1) Remove the ring gear cover. Refer to “Ring Gear Cover Removal and Installation”...
Page 117 Power Unit Mechanical: 1D-6 5) Remove the three bolts (4) securing electric parts b) Remove the bolt (9) securing negative (–) battery holder to cylinder block. cable (10). Pull battery cable out of electric parts holder. 6) Remove ECM from electric parts holder. I9J011140102-01 I9J011140099-01 c) Remove the bolt (11) securing PTT motor relay...
Page 118: Intake Manifold And Throttle Body Components
1D-7 Power Unit Mechanical: Intake Manifold and Throttle Body Components Z9J0111406005 I9J011140001-01 1. Intake manifold assembly 2. Throttle body assembly 3. Bolt Intake Manifold Removal and Installation 7) Disconnect the MAP sensor lead wire connector (4) Z9J0111406006 at sensor. Removal 1) Relieve fuel pressure.
Page 119 Power Unit Mechanical: 1D-8 9) Remove the bolts (6) securing throttle body bracket 13) Disconnect fuel inlet hose (12) from low pressure (7) to crankcase. fuel filter. 14) Disconnect fuel outlet hose (13) from low pressure fuel pump. I9J011140108-01 10) Remove the throttle link rod (8). I9J011140112-01 15) Disconnect fuel outlet hose (14) from high pressure fuel filter (15).
Page 120 1D-9 Power Unit Mechanical: 18) Disconnect the fuel cooler water inlet hose (18) from • Install gaskets (1) into groove of intake manifold the pilot water indicator (19). assembly (2). I9J011140116-01 I9J011140119-01 19) Disconnect the fuel cooler water outlet hose (20) •...
Page 121: Throttle Body Removal And Installation
Power Unit Mechanical: 1D-10 Throttle Body Removal and Installation Installation Z9J0111406007 Installation is reverse order of removal with special Removal attention to the following steps. 1) Remove the Intake manifold assembly. CAUTION Refer to “Intake Manifold Removal and Installation” (Page 1D-7). Do not reuse gaskets, always replace with 2) Remove the flame arrester (1).
Page 122: Throttle Body Inspection
1D-11 Power Unit Mechanical: Throttle Body Inspection Power Unit Removal and Installation Z9J0111406008 Z9J0111406009 Removal CAUTION 1) Relieve fuel pressure. Do not try to adjust or remove any of the Refer to “Fuel Pressure Relief Procedure” in Section throttle body component parts (Throttle 1G (Page 1G-15).
Page 123 Power Unit Mechanical: 1D-12 7) Disconnect ignition coil connectors (4). 10) Remove the starter motor (8). Remove the bolts securing the ignition coils (5). Refer to “Starter Motor Removal and Installation” in Remove all ignition coils and spark plugs. Section 1I (Page 1I-4). I9J011140130-01 I9J011140133-01 8) Remove the cylinder head cover (6).
Page 124 1D-13 Power Unit Mechanical: 13) Remove the bolts and rectifier/regulator (11). 17) Disconnect water flush hose (17) from cylinder Remove the bolt securing lead wire clamp plate (12). block. Refer to “Rectifier/Regulator Removal and Installation” in Section 1K (Page 1K-7). I9J011140139-01 18) Remove the two bolts securing front panel (18).
Page 125 Power Unit Mechanical: 1D-14 21) Remove the side cover seal (21). 24) Remove the two bolts and clutch link holder assembly (28). I9J011140143-01 22) Disconnect shift position sensor lead wire connector I9J011140146-03 (22). 25) Disconnect the water return hose (29), then remove Disconnect neutral switch lead wire connector (23).
Page 126 CAUTION Do not reuse gaskets, O-rings and seals. Always replace with new parts. Power unit • Install dowel pins (1), gasket (2). Apply water resistant grease to driveshaft splines. I9J011140151-01 : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011140154-01...
Page 127 Power Unit Mechanical: 1D-16 • Install the engine holder seal (3). • Apply suzuki silicone seal to power unit mounting bolts and tighten bolts to specified torque. NOTE : Sealant 99000–31120 (SUZUKI Silicone Install seal (3) with lip facing upward.
Page 128 1D-17 Power Unit Mechanical: Flywheel Cylinder head cover • Install CKP sensor (1). • Install cylinder head cover. Refer to “CKP Sensor Removal and Installation” in Refer to “Cylinder Head Cover Removal and Section 1C (Page 1C-10). Installation” (Page 1D-2). I9J011140159-01 I9J011140162-02 •...
Page 129 Power Unit Mechanical: 1D-18 Intake manifold Fuel injectors • Install gaskets and intake manifold, then tighten bolts • Install fuel injectors and fuel delivery pipe. and nuts to specified torque. Refer to “Fuel Injector Removal and Installation” in Refer to “Intake Manifold Removal and Installation” Section 1G (Page 1G-23).
Page 130: Timing Chain, Chain Tensioner And Camshaft Sprockets Components
1D-19 Power Unit Mechanical: Timing Chain, Chain Tensioner and Camshaft Sprockets Components Z9J0111406010 I9J011140003-04 1. Timing chain 6. Chain tensioner 11. Dowel pin : 78 N⋅m (7.8 kgf-m, 56 lbf-ft) 2. Bolt 7. Bolt 12. Intake camshaft sprocket : Apply oil. 3.
Page 131: Timing Chain, Chain Tensioner And Camshaft Sprockets Removal And Installation
Power Unit Mechanical: 1D-20 Timing Chain, Chain Tensioner and Camshaft 4) Remove the two bolts (3) and chain tensioner adjuster (4). Sprockets Removal and Installation Z9J0111406011 Removal 1) Remove the oil pump. Refer to “Oil Pump Removal and Installation” in Section 1E (Page 1E-3).
Page 132 1D-21 Power Unit Mechanical: 7) Remove timing chain (8), IN. camshaft timing Installation sprocket (9) and dowel pin (10). Installation is reverse order of removal with special attention to the following steps. 1) Check that match mark “A” on the crankshaft drive gear points to 12 o’clock position (towards cylinder head).
Page 133 Tightening torque EX. timing sprocket bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) I9J011140175-02 I9J011140173-01 I9J011140176-03 5) As shown in figure, position timing chain on driven gear sprocket with yellow plate “H”...
Page 134 1D-23 Power Unit Mechanical: 11) Install timing chain tensioner adjuster (10), then tighten bolts (11) to specified torque. “I” “I” Tightening torque Tensioner adjuster bolt (c): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) “E” “F” I9J011140025-01 8) Install timing chain guide (6), then tighten bolt securely.
Page 135: Timing Chain, Chain Tensioner And Camshaft Sprockets Inspection
Power Unit Mechanical: 1D-24 Timing Chain, Chain Tensioner and Camshaft Timing Chain Tensioner/Chain Guide Sprockets Inspection • Check chain tensioner shoe for wear or damage. Z9J0111406012 If excessive wear or other damage is found, replace it. NOTE • Check chain guide shoe for wear or damage. If any component is worn excessively, If excessive wear or other damage is found, replace it.
Page 136: Camshaft, Tappet And Shim Removal And Installation
1D-25 Power Unit Mechanical: Camshaft, Tappet and shim Removal and 5) Remove tappets and tappet shims. Installation NOTE Z9J0111406013 Removal All tappets and tappet shims must be 1) Remove the oil pump. installed in their original positions. Refer to “Oil Pump Removal and Installation” in For ease of assembly, lay out tappets and Section 1E (Page 1E-3).
Page 137 Power Unit Mechanical: 1D-26 3) Apply engine oil to surface of each camshaft lobe 4) Install camshaft housing pins as shown figure. and journal, then install them. NOTE • Before installing camshafts, turn crankshaft until the match mark “A” on the crankshaft drive gear points to 12 o’clock (toward cylinder head).
Page 138: Camshaft, Tappet And Shim Inspection
If any of the above conditions are found, replace camshaft. Cam Wear Using micrometer, measure cam height. If measurement exceeds service limit, replace camshaft. “20” “10” “2” “6” “14” Cam height “a” (for DF70A) “17” Standard Service limit “9” “1” “5” “13” 38.620 – 38.780 mm 38.520 mm “11”...
Page 139 Power Unit Mechanical: 1D-28 Camshaft Identification Camshaft Journal Wear DF70A, DF80A and DF90A camshafts differ as indicated Check camshaft journals and camshaft housings for below. pitting, scratches, wear or damage. If any of the above conditions are found, replace Identification mark camshaft or cylinder head with housing.
Page 140 1D-29 Power Unit Mechanical: 4) Install camshaft housing. Tighten housing bolts in 3 If journal oil clearance exceeds the service limit, steps (1/3 of specification, 2/3 of specification, full measure camshaft journal (outside dia.) and torque specification) in the indicated order. camshaft housing (inner dia.).
Page 141 Power Unit Mechanical: 1D-30 Wear of Tappet and Shim Check tappet and shim for pitting, scratches, or damage. If any above conditions are found, replace component. I9J011140031-01 I9J011140076-01 Measure cylinder head bore and tappet outside diameter to determine cylinder head to tappet clearance. If clearance exceeds service limit, replace tappet or cylinder head.
Page 142: Cylinder Head Assembly Components
1D-31 Power Unit Mechanical: Cylinder Head Assembly Components Z9J0111406015 I9J011140004-04 1. Intake valve 5. Valve stem seal 9. Tappet : 70 N⋅m (7.0 kgf-m, 50.5 lbf-ft) 2. Exhaust valve 6. Valve spring 10. Tappet shim : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft) 3.
Page 143: Cylinder Head Removal And Installation
Installation” (Page 1D-25). shown in illustration. 2) Loosen and remove fifteen cylinder head bolts in the order indicated in figure. : Sealant 99000–31140 (SUZUKI Bond Remove cylinder head assembly and head gasket. 1207B (100 g)) NOTE Use special tool (10 mm deep socket wrench) when loosening cylinder head bolts.
Page 144: Cylinder Head Disassembly And Assembly
1D-33 Power Unit Mechanical: 3) Apply engine oil to cylinder head bolts and tighten 4) Install the IN. and EX. camshafts. them gradually as follows. Refer to “Camshaft, Tappet and shim Removal and Installation” (Page 1D-25). a) Tighten all cylinder head bolts to 50 percent (%) of specified torque according to sequence in 5) Install the timing chain.
Page 145 Power Unit Mechanical: 1D-34 3) Remove valve stem seal (5) and valve spring seat (6). NOTE Reassemble each valve and valve spring in their original positions. I9J011140033-03 3) Apply engine oil to stem seal, valve guide bore and valve stem. 4) Install valve (3) to valve guide.
Page 146: Cylinder Head Components Inspection And Servicing
1D-35 Power Unit Mechanical: 6) Hold valve spring compressed with special tool and Cylinder Head Components Inspection and install valve cotters (6). Servicing Make sure valve cotters are properly seated in Z9J0111406018 NOTE groove “A”. If cracks, excessive wear or other damage is NOTE found on any component, replace When compressing the valve spring, be...
Page 147 Power Unit Mechanical: 1D-36 • Check water jackets. If clogged or obstructed, clean Manifold seating faces distortion water jackets. Using a straightedge and thickness gauge, check cylinder head to manifold seating faces. If measurement exceeds service limit, resurface or replace cylinder head. Special tool (A): 09900–20803 (Thickness gauge) Manifold seating faces distortion...
Page 148 1D-37 Power Unit Mechanical: Valve guide inside diameter Valve stem end Using a small bore gauge, measure valve guide inside Inspect valve stem end face for pitting and wear. If pitting or wear is found, valve stem end may be diameter.
Page 149 Power Unit Mechanical: 1D-38 Valve head radial runout Valve seat contact width Measure valve head radial runout. Measure valve seat contact width as follows: To measure runout, rotate valve slowly. 1) Remove all carbon from valve and seat. If measurement exceeds service limit, replace valve. 2) Coat valve seat evenly with prussian blue (or Special tool equivalent).
Page 150 1D-39 Power Unit Mechanical: Valve seat servicing • If width “a” is too high (or wide), reface valve seat If valve seat contact width is out of specification, reface using small angle cutter (Intake side: 30°, Exhaust side: 15°). valve seat as follows: •...
Page 151 Power Unit Mechanical: 1D-40 Valve guide replacement 3) Install valve guide to cylinder head. • Heat cylinder head to a temperature of 80 – 100 CAUTION °C (176 – 212 °F). Be careful not to damage cylinder head when Apply heat uniformly so that head will not be replacing valve guide.
Page 152 1D-41 Power Unit Mechanical: Valve spring free length Valve spring squareness Check spring strength by measuring free length. Use a square and surface plate to check each spring for If lower than service limit, replace valve spring. squareness (clearance between end of valve spring and square).
Page 153 Power Unit Mechanical: 1D-42 Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components Z9J0111406019 I9J011140005-03 1. Cylinder block 7. Conrod bearing 13. Dowel pin : 25 N⋅m (2.5 kgf-m, 18.1 lbf-ft) 2. Piston ring set 8. Conrod cap 14. Crankcase : 52 N⋅m (5.2 kgf-m, 37.5 lbf-ft) 3.
Page 154: Pistons, Piston Rings, Connecting Rods, Cylinder And Crankshaft Disassembly And Assembly
1D-43 Power Unit Mechanical: Pistons, Piston Rings, Connecting Rods, NOTE Cylinder and Crankshaft Disassembly and For proper assembly, mark cylinder number Assembly on all pistons, conrods, and conrod caps, Z9J0111406020 using quick drying paint. Disassembly 1) Before performing service work in this section: •...
Page 155 Power Unit Mechanical: 1D-44 6) Mark cylinder number on pistons using quick dry 8) Remove piston pin circlips (9) as shown. paint. Push piston (with conrod) out through the top of cylinder bore. NOTE • To prevent damage to piston rings, decarbon top of cylinder bore wall before removing piston.
Page 156 1D-45 Power Unit Mechanical: Assembly Piston ring to piston Assembly is reverse order of disassembly paying special 1) Install the oil ring. attention to the following steps. • Apply engine oil to piston rings. • Install spacer (1) first, then side rails (2) to piston. CAUTION If original components are not replaced, each piston, piston pin and conrod is to be...
Page 157 Power Unit Mechanical: 1D-46 2) Install the piston rings. Piston to cylinder • Apply engine oil to piston ring. 1) Install conrod bearing (1) to conrod (2) and cap (3). • Install 2nd ring (3) and 1st ring (4) to piston. CAUTION •...
Page 158 1D-47 Power Unit Mechanical: Crankshaft to cylinder Thrust bearing Install crankshaft main bearings (1) in cylinder and Apply molybdenum oil solution to the thrust bearing and crankcase. install in cylinder block overlapping both sides of the Apply molybdenum oil solution to bearings. No.4 main journal.
Page 159 Power Unit Mechanical: 1D-48 4) Apply engine oil to conrod bolts. Tighten conrod cap bolts in three steps as follows. a) Lightly seat all conrod bolts at first, then tighten bolts 12 N⋅m (1.2 kgf-m, 8.7 lbf-ft) of specified torque. Tightening torque Conrod cap bolt (1st step): 12 N·m (1.2 kgf- m, 8.7 lbf-ft)
Page 160 3) Install crankcase to cylinder. Apply engine oil to crankcase bolts. 1) Clean mating surface of cylinder and crankcase. Tighten crankcase bolts in three steps following the Apply suzuki bond to mating surface of crankcase as order indicated below. shown. NOTE CAUTION Tighten 10 mm (0.394 in.) thread diameter...
Page 161: Cylinder, Piston And Piston Ring Inspection And Servicing
Power Unit Mechanical: 1D-50 NOTE After tightening crankcase bolts, check to be sure that crankshaft rotates smoothly when turned by hand. I9J011140242-03 I9J011140241-01 Cylinder head Refer to “Cylinder Head Removal and Installation” (Page 1D-32). Timing chain Refer to “Timing Chain, Chain Tensioner and Camshaft I9J011140244-01 Sprockets Removal and Installation”...
Page 162 1D-51 Power Unit Mechanical: Cylinder Bore Piston to Cylinder Clearance Inspect cylinder walls for scratches, roughness, or ridges 1) Measure the piston diameter at a point 13 mm which indicate excessive wear. (0.512 in.) above the piston skirt at a right angle to If cylinder bore is very rough, deeply scratched or ridged, the piston pin bore.
Page 163 Power Unit Mechanical: 1D-52 Identification of Oversize Piston / Piston Ring Piston One oversize piston / piston ring components, 0.50 mm Visual inspection is available. Oversize piston / piston ring are marked as Inspect piston for faults, cracks or other damage. shown, below.
Page 164: Piston Pin And Conrod Inspection
1D-53 Power Unit Mechanical: Piston ring end gap Piston pin clearance Standard (1st): 0.15 – 0.30 mm (0.0059 – 0.0118 in.) Check the piston pin clearance in the conrod small end. Standard (2nd): 0.30 – 0.45 mm (0.0118 – 0.0177 in.) Replace the conrod if its small end is badly worn or Service limit (1st): 0.70 mm (0.028 in.) damaged or if clearance exceeds service limit.
Page 165: Crank Pin And Conrod Bearing Inspection
Power Unit Mechanical: 1D-54 Conrod big end side clearance Conrod Bearing Visual Inspection Measure conrod big end side clearance with conrod Inspect bearing shell for proper contact pattern and installed on crank pin as shown. signs of fusion, pitting, burning or flaking. If measurement exceeds service limit, replace conrod Bearing shells found in defective condition must be and/or crankshaft.
Page 166 1D-55 Power Unit Mechanical: 4) Install conrod cap (with bearing) to conrod with the c) Finally tighten bolts 60 degrees turn from the embossed mark on cap toward flywheel side. point of step b) using an angular torque gauge. Tightening torque Conrod cap bolt (Final step): 60 degrees (47 N⋅m, 4.7 kgf-m, 34 lbf-ft) NOTE...
Page 167: Selection Of Conrod Bearing
Power Unit Mechanical: 1D-56 Selection of Conrod Bearing 2) Next, check crankshaft pin outside diameter. On Z9J0111406029 crank web No.1, four alphabets are stamped as NOTE shown in the figure. Three kinds of alphabet (“A”, “B” or “C”) represent • If bearing is in malfunction, or bearing the crankshaft pin diameter respectively.
Page 168: Crankshaft Inspection
1D-57 Power Unit Mechanical: “F” I9J011140268-01 “F”: Color mark I9J011140257-02 Crankshaft Thrust Play 4) From number stamped on conrod and its cap and alphabets stamped on crank web No.1, Determine 1) Measure thrust play with crankshaft, thrust bearing, new standard bearing to be installed into conrod big journal bearing and crankcase / cylinder block end, by referring to the table.
Page 169: Crankshaft Main Bearing Inspection
Power Unit Mechanical: 1D-58 Out-of-Round and Taper (Uneven Wear) of Journals Crankshaft Journal Oil Clearance An unevenly worn crankshaft journal shows up as a Check clearance using Plastigauge according to the difference in diameter at a cross section or along its following procedure.
Page 170 1D-59 Power Unit Mechanical: 3) Install crankshaft to cylinder. NOTE 4) Place a piece of Plastigauge across full width of Crankcase must be torqued to specification bearing (parallel to crankshaft) on journal. in order to assure proper compression of Do not place Plastigauge over oil hole. plastigauge and accurate reading of clearance.
Page 171 Power Unit Mechanical: 1D-60 8) Using scale on Plastigauge envelope, measure 2) Next, check bearing holder inside diameter without plastigauge width at its widest point. bearing. As shown in figure, the cylinder block PORT side has Crankshaft journal oil clearance five stamped code letters or numerals.
Page 172: Crankshaft Drive Gear Inspection
1D-61 Power Unit Mechanical: Crankshaft Oil Seal Inspection Z9J0111406027 Inspect condition. If cracked, cut or damaged, replace. “K” I9J011140074-01 “K”: Color mark 4) Select crankshaft main bearing referring to the below table. I9J011140265-01 For example, If number stamped on crank web is “1” and alphabet stamped on cylinder block is “B”, install a new bearing painted in “Brown”...
Page 173: Power Unit Lubrication
Power Unit Lubrication: 1E-1 Power Unit Lubrication Power Head General Description Engine Lubrication Description Z9J0111501001 A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication. Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the main oil gallery.
Page 174: Diagnostic Information And Procedures
1E-2 Power Unit Lubrication: Diagnostic Information and Procedures Oil Pressure Check Z9J0111504001 Refer to “Oil Pressure Check” in Section 0B (Page 0B-20). Oil Change Reminder System Z9J0111504003 Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14). Low Oil Pressure Caution System Z9J0111504004 The system operates when the engine lubricating oil pressure drops below the correct level (100 kPa, 1.0 kg/cm , 14...
Page 175: Service Instructions
Power Unit Lubrication: 1E-3 Service Instructions Oil Pump Removal and Installation Oil Pump Disassembly and Assembly Z9J0111506001 Z9J0111506002 Removal Disassembly 1) Remove the power unit. 1) Remove the screw (1) securing oil pump rotor plate Refer to “Power Unit Removal and Installation” in (2) to the oil pump case, then remove oil pump rotor Section 1D (Page 1D-11).
Page 176: Inspection Oil Pump Component Parts
1E-4 Power Unit Lubrication: Assembly 5) Install dowel pins (5) and rotor plate (6), and then tighten screw (7) securely. 1) Wash, clean and then dry all disassembly parts. After mounting the rotor plate, make sure that each 2) Apply thin coat of engine oil to inner and outer rotors, rotor turns smoothly by hand.
Page 177: Oil Pressure Switch Removal And Installation
Power Unit Lubrication: 1E-5 Measuring Radial Clearance Oil Pressure Switch Removal and Installation Using a feeler gauge, measure radial clearance between Z9J0111506004 Removal outer rotor and case. 1) Loosen screw (1) and disconnect blue lead wire (2) If measurement is not within specifications, replace oil from oil pressure switch (3).
Page 178: Oil Pressure Switch Inspection
1E-6 Power Unit Lubrication: Oil Pressure Switch Inspection Oil Strainer Removal and Installation Z9J0111506005 Z9J0111506006 NOTE Removal Refer to “Engine Holder / Oil Pan / Driveshaft Housing / Before checking the oil pressure switch, Mounts Disassembly” in Section 2A (Page 2A-6). make sure the engine oil pressure is within specification.
Page 179: Power Unit Cooling System
Power Unit Cooling System: 1F-1 Power Unit Cooling System Power Head General Description Water Cooling System Description Z9J0111601001 The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead assembly. To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine operation, there is a thermostat in the cylinder block.
Page 180: Schematic And Routing Diagram
1F-2 Power Unit Cooling System: Schematic and Routing Diagram Cooling Water Circulation Chart Z9J0111602001 The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water pressure valve, power unit water passages and thermostat. This system cools both the power unit and exhaust and is shown in schematic form below.
Page 181: Diagnostic Information And Procedures
Power Unit Cooling System: 1F-3 Diagnostic Information and Procedures Powerhead Cooling System Diagnosis Z9J0111604001 Condition Possible cause Correction / Reference Item Overheating powerhead Water inlet screen obstructed. Clean. Water passage obstructed. Clean or replace. Pump plate not sealing. Check and repair. Water pump impeller damage.
Page 182: Thermostat Inspection
1F-4 Power Unit Cooling System: • Install the thermostat cover and thermostat assembly, then secure thermostat cover (3) with bolts (4). Tightening torque Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft) I9J011160002-01 1. Thermometer 3. Thermostat 2. Heater 4) Install the thermostat.
Page 183: Water Pressure Valve Related Item Inspection
Power Unit Cooling System: 1F-5 Installation 2) Inspect the water pressure valve. If salt deposits, corrosion, wear or other damage is 1) Install O-ring (1) to pressure valve cover (2). found, clean or replace. Inspect O-ring. Replace if nicked, cut or torn. I9J011160013-01 2) Install pressure valve (3) and pressure valve cover I9J011160015-01...
Page 184: Fuel System
1G-1 Fuel System: Fuel System Power Head Precautions Precautions on Fuel System Service Z9J0111700001 WARNING Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system. • Disconnect battery cables except when battery power is required for servicing / inspection. •...
Page 185: General Description
Fuel System: 1G-2 General Description Electronic Fuel Injection System Description Z9J0111701001 The fuel injection system used by the DF70 / 80 / 90 is a speed-density, multi-point, sequential, electronic fuel injection type. The fuel injection system is composed of the fuel line components, air intake components, and components for system control (ECM, sensors, switches, etc.).
Page 186 1G-3 Fuel System: Fuel Injection Timing Chart 32 signals / crankshaft 1 rotation CKP sensor signal 40° 40° 140° 220° 180° 100° 140° CMP sensor signal CMP sensor - 6 signals / 720° (crankshaft 2 rotation) No.1 cylinder No.3 cylinder No.4 cylinder No.2 cylinder Injection end timing: 0°...
Page 187: Fuel Delivery System Components Description
Fuel System: 1G-4 Fuel Delivery System Components Description Z9J0111701002 The fuel delivery system is composed of the low pressure fuel line components (fuel tank, filter, pump etc.), fuel vapor separator, high pressure fuel pump, high pressure fuel filter, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel injectors and hoses.
Page 188 1G-5 Fuel System: Fuel Vapor Separator The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber. As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump. The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator.
Page 189 Fuel System: 1G-6 Fuel Pressure Regulator The fuel pressure regulator is located in the fuel vapor separator. The regulator's function in the system is to maintain constant fuel pressure to the injectors while the engine is operating. The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure balanced. Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in the fuel vapor separator chamber by approx.
Page 190: High Pressure Fuel Pump Control System Description
1G-7 Fuel System: High Pressure Fuel Pump Control System Description Z9J0111701003 To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON” / “OFF” signal, at a specified rate (1 000 times a second). Based on engine speed and battery voltage, the ECM determines the optimum duty cycle (repeating “ON”...
Page 191: Air Intake Components Description
Fuel System: 1G-8 Control Modes Before start: For 3 seconds after the ignition switch is turned “ON”, the fuel pump is controlled to operate at a 100% duty cycle to initially pressurize the high pressure fuel line. When cranking: The fuel pump is controlled to operate at a 50 – 100% duty cycle. The duty cycle changes depending on cylinder temperature.
Page 192: Idle Air Control System Description
1G-9 Fuel System: Throttle Body • The throttle body assembly consists of the main bore, throttle valve and TPS (Throttle Position Sensor). • The throttle body adjusts the intake air amount with the throttle valve which is connected to the throttle lever linkage. •...
Page 193 Fuel System: 1G-10 +12 V IAC valve IAC1 IAC2 IAC3 W/Bl IAC4 Air flow I9J011170010-02 1. Valve pintle 2. Screw shaft 3. Rotor 4. Coil Idle Air Control System Outline The ECM controls the position of the IAC valve to regulate a portion of the intake air flow to the intake manifold. This system is used for the following purposes: •...
Page 194: Diagnostic Information And Procedures
1G-11 Fuel System: IAC Valve Control Mode Before started: The IAC valve is initialized at a 70% opening position when engine is not running. (Ignition switch “OFF”). When cranking: The IAC valve is controlled to operate at approx. 60 – 90% open position. The open position changes depending on the cylinder temperature.
Page 195 Fuel System: 1G-12 4) Connect special tools (pressure gauge, pressure 5) Ensure the emergency stop switch lock plate is in hose and pressure joint) between fuel feed hose (1) place. and fuel delivery pipe upper union as shown in Shift into “Neutral” position. figure.
Page 196: Fuel System Diagnosis
1G-13 Fuel System: 12) After checking fuel pressure, remove fuel pressure 13) Reconnect fuel line. gauge. 14) With the engine not running and ignition switch “ON”, check the fuel system for leaks. I9J011170019-01 4. Joint nut Fuel System Diagnosis Z9J0111704002 Condition Possible cause Correction / Reference Item...
Page 197: Fuel Injection System Troubleshooting
Fuel System: 1G-14 Fuel Injection System Troubleshooting Z9J0111704003 Before starting the troubleshooting, make sure that: • There is no self-diagnostic code indication. • Emergency stop switch plate is set in place. Step Action Check fuel injector operating sound. Fuel injector circuit is in Go to step 2.
Page 198: Service Instructions
1G-15 Fuel System: Service Instructions Fuel Pressure Relief Procedure 7) Upon completion of servicing, connect the ignition Z9J0111706001 coil primary lead wire and the high pressure fuel After making sure that engine is cold, relieve fuel pump lead wire. pressure as follows: 8) Install the ring gear cover.
Page 199: Fuel Leakage Check Procedure
Fuel System: 1G-16 Fuel Leakage Check Procedure • For type “C” pipe, hose must fit up against the flanged Z9J0111706004 part of pipe. After performing any fuel system service, always be sure Type “C” there is no fuel leakage by checking as follows. 1) Squeeze fuel primer bulb until you feel resistance.
Page 200: Fuel Vapor Separator Removal And Installation
1G-17 Fuel System: 4) If no pump operating sound is heard: Fuel Vapor Separator Disassembly and Assembly a) Turn ignition key to the “OFF” position, check for Z9J0111706008 contact failure in the lead wire connector. Disassembly b) Check that the drive voltage is outputting from 1) Remove five screws (1).
Page 201 Fuel System: 1G-18 3) Remove screw (7), plate (8) and valve seat (9). Assembly Assembly is in the reverse order of disassembly with special attention to the following steps. High pressure fuel pump Connect the pump lead wire connector, then install grommet (1) and fuel pump (2).
Page 202 “ a ” I9J011170045-01 Separator cover / Separator case 1) Install the seal ring (1) and then apply Suzuki Bond evenly to only the outside mating surface of the I9J011170043-02 separator case as shown in figure.
Page 203: Inspection Of Fuel Vapor Separator Component Parts
Fuel System: 1G-20 2) Install the separator case and then tighten the Inspection of Fuel Vapor Separator Component screws securely. Parts Z9J0111706009 NOTE NOTE When installing the separator case, align If cracks, excessive wear or other damage is suction hole “A” with hole “B” of separator found on any component, replace the case.
Page 204: Fuel Injector Inspection With Injector In Place
1G-21 Fuel System: Separator Cover and Case Fuel Injector Inspection with Injector in place Inspect the separator cover and case. Z9J0111706010 1) Using a sound scope or equivalent, check the Replace if cracked, damaged or other abnormal operating sound of the fuel injector when the engine conditions.
Page 205: Individual Fuel Injector Operating Sound Inspection
Fuel System: 1G-22 Individual Fuel Injector Operating Sound 3) Connect the Gray wire to body ground. Inspection 4) Momentarily touch the Black/Yellow wire to the Z9J0111706011 starter motor magnetic switch terminal “B” 1) Disconnect the ignition coil lead wire connectors (connected to battery positive (+) terminal) and from all of the ignition coils.
Page 206: Fuel Injector Removal And Installation
1G-23 Fuel System: Special tool (A): 09930–88730 (36-pin test cord set) : Stevens peak reading voltmeter CD-77 Tester knob indication NEG 50 1) Disconnect all ignition coil connectors from the ignition coils. 2) Connect the test cord between the ECM and wire harness as shown in figure, then turn ignition switch “ON”. 3) Connect the tester probe (“–”, Black) to the starter motor magnetic switch terminal “B”...
Page 207 Fuel System: 1G-24 5) Remove the two bolts (4) and the fuel delivery pipe Installation (5) (with the fuel injectors). Installation is in the reverse order of removal with special attention to the following steps. CAUTION CAUTION A small amount of fuel may be released when the fuel injector is removed from delivery Do not re-use O-ring and cushion once pipe.
Page 208: Low Pressure Fuel Pump Removal And Installation
1G-25 Fuel System: 3) Apply a thin coat of fuel to injector O-rings, then 7) Make sure the emergency stop switch lock plate is in install the injectors into the delivery pipe and cylinder place. head. Shift into “Neutral” position. Make sure that the injectors rotate smoothly.
Page 209: Low Pressure Fuel Pump Inspection
Fuel System: 1G-26 4) Remove fuel pump. Note the position before Low Pressure Fuel Pump Inspection removing the O-ring (7). Z9J0111706015 NOTE The low pressure fuel pump is a non- repairable component. Do not attempt to disassemble the low pressure fuel pump. It must be replaced as a complete unit if it is defective.
Page 210: Ignition System
1H-1 Ignition System: Ignition System Power Head General Description Ignition System Description Z9J0111801001 The ignition system used by the DF70 / 80 / 90 is a fully transistorized, electronic microcomputer timing advanced type. This system is battery powered, with the ECM controlling all of the ignition timing functions. The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor, switch etc.).
Page 211: Ignition Control Description
Ignition System: 1H-2 Ignition Control Description Z9J0111801002 Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM. Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils. Basic sensors MAP sensor: Ignition timing is determined by a...
Page 212 1H-3 Ignition System: Ignition Timing Chart The following chart is an example for ignition at 10° BTDC. 32 signals / crankshaft 1 rotation CKP sensor signal 40° 40° 140° 220° 180° 100° 140° CMP sensor signal CMP sensor - 6 signals / 720°(crankshaft 2 rotation) No.1 cylinder No.3 cylinder No.4 cylinder...
Page 213: Component Location
Ignition System: 1H-4 Component Location Ignition System Components Location Z9J0111803001 Refer to “Engine Control System Components / Engine Electrical Device Location” in Section 1A (Page 1A-15). Diagnostic Information and Procedures Ignition System Symptom Diagnosis Z9J0111804001 Condition Possible cause Correction / Reference Item Engine cranks, but will Blown fuse for ignition system.
Page 214: Ignition System Troubleshooting
1H-5 Ignition System: Ignition System Troubleshooting Z9J0111804002 Before starting the troubleshooting, make sure that: • There is not self-diagnostic code indication. • Emergency stop switch plate is set in place. Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system.
Page 215: Service Instructions
Ignition System: 1H-6 Service Instructions Spark Plug Removal and Installation 4) Turn the ignition key to the ON position. Check for Z9J0111806001 battery voltage by measuring between the BAT (+) Refer to “Spark Plug Removal and Installation” in terminal and GND terminal on the wiring harness Section 0B (Page 0B-6).
Page 216: Ignition Coil Operating Signal Inspection
1H-7 Ignition System: Ignition Coil Operating Signal Inspection CKP Sensor Inspection Z9J0111806009 Z9J0111806005 Refer to “CKP Sensor Inspection” in Section 1C Special tool (Page 1C-10). (A): 09930–88730 (36-pin test cord set) : Stevens peak reading voltmeter CD-77 CMP Sensor Inspection Tester knob indication Z9J0111806006 Refer to “CMP Sensor Inspection”...
Page 217: Starting System
Starting System: 1I-1 Starting System Power Head General Description Electric Starter System Description Z9J0111901001 The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay, ECM and related electrical wiring. These components are connected electrically as shown in the figure below. In the circuit shown in the figure below, the magnetic switch coils and starter relay coil are magnetized when the ignition switch is closed (turned to “START”).
Page 218: Starter Motor Operation Condition Description
1I-2 Starting System: Starter Motor Operation Condition Description Control by Shift Position Sensor Z9J0111901002 A shift position sensor is installed on the clutch lever The starter motor relay is controlled by the ECM. holder and detects the shift position as the clutch lever is •...
Page 219: Component Location
Starting System: 1I-3 Component Location Starting System Components Location Z9J0111903001 Refer to “Engine Control System Components / Engine Electrical Device Location” in Section 1A (Page 1A-15). Diagnostic Information and Procedures Starter System Troubleshooting Z9J0111904001 CAUTION If any abnormality is found, immediately disconnect the battery cables from the battery. NOTE Before troubleshooting the electric starter system, make sure of the following: •...
Page 220: Service Instructions
1I-4 Starting System: Condition Possible cause Correction / Reference Item Starter motor running, but Worn pinion tip. Replace over-running clutch. not cranking engine. Poor sliding of over-running clutch. Repair. Over-running clutch slipping. Replace over-running clutch. Worn teeth of ring gear. Replace flywheel.
Page 221: Starter Motor Test
Starting System: 1I-5 7) Remove the starter motor (10), then disconnect the Pull-In / Hold-In Test red lead wire (11) from “S” terminal of starter NOTE magnetic switch. Before testing, disconnect the brush lead from terminal “M”. Connect the battery to the magnetic switch as shown in the figure.
Page 222: Starter Motor Components
1I-6 Starting System: 1) Connect a battery and ammeter to the starter motor as shown. 2) Check that the starter rotates smoothly and steadily with the pinion moving out. Check that the ammeter indicates the specified current. Specified current (No-load performance test) Within 90 A at 11 V I9J011190004-01 No-Load Performance Test...
Page 223: Starter Motor Disassembly And Assembly
Starting System: 1I-7 Starter Motor Disassembly and Assembly 4) Remove screws (5), long through bolts (6) and the Z9J0111906004 rear cover (7). Disassembly When overhauling the starting motor, it is recommended that the component parts be cleaned thoroughly. However, the yoke assembly, armature coil, over- running clutch assembly, magnetic switch assembly and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent.
Page 224 1I-8 Starting System: 8) Remove the center cover plate (13). 12) Push the pinion stopper (21) down, then remove the stopper ring (22). Remove the pinion stopper and 9) Remove the planetary gears (14) and internal gear pinion (19). (15). I9J011190017-01 I9J011190014-01 13) Remove the E-ring (23).
Page 225: Starter Motor Components Inspection And Servicing
Starting System: 1I-9 Assembly • Measure the commutator outside diameter. If the Assembly is in the reverse order of disassembly with measurement exceeds the service limit, replace the special attention to the following steps. armature. Reassemble the starter motor, refer to “Starter Motor Special tool Components”...
Page 226 1I-10 Starting System: • Check for continuity between the commutator (4) and Brushes the armature core (5) / shaft (6). Check the length of each brush (1). Replace the armature if continuity is indicated. If brushes are worn down to the service limit, they must be replaced.
Page 227 Starting System: 1I-11 Shift Lever Gear Inspect the shift lever for wear. Replace if necessary. Inspect planetary gears and internal gear for wear, damage or other abnormal conditions. Replace if necessary. I9J011190029-01 Pinion and Over-Running Clutch I9J011190032-01 • Inspect the pinion for wear, damage or other abnormal Pinion Shaft / Pinion Shaft Bushing conditions.
Page 228 1I-12 Starting System: Armature Shaft Bush Pull-in coil open circuit test Inspect the bushing for wear or other damage. Check for continuity across the magnetic switch “S” Replace if necessary. terminal (1) and “M” terminal (2). If no continuity exists, the coil is open and should be replaced.
Page 229: Ignition Switch Inspection
Starting System: 1I-13 Contact points test Put the plunger on the under side and then push the magnetic switch down. (OFF) (ON) At this time, check for continuity between terminal “B” FREE and terminal “M”. (START) Continuity indicates proper condition. If no continuity exists, replace the magnetic switch and/or plunger.
Page 230: Neutral Switch Inspection
1I-14 Starting System: 2) Check continuity between terminal (2) and (3) each Neutral Switch Inspection time 12 V power supply is applied to terminal (4) and Z9J0111906008 Check for continuity / infinity of the neutral switch. (5). Connect the positive (+) lead to terminal (5), and Special tool negative (–) lead to terminal (4).
Page 231: Emergency Stop Switch Inspection
Starting System: 1I-15 Neutral switch on engine side Emergency Stop Switch Inspection Z9J0111906009 1) Disconnect the neutral switch lead wire connector. 1) Disconnect the emergency stop switch lead wire. 2) Check continuity / infinity between the Yellow / Green 2) Check the continuity / infinity between the wiring and Brown lead wires while operating the remo-con leads under the condition shown below.
Page 232: Charging System
1K-1 Charging System: Charging System Power Head General Description Charging System Description Z9J0111B01001 The battery charging system circuit is illustrated below. It is composed of the Battery Charge Coil, Rectifier/regulator and Battery. The three phase AC current generated from the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the battery.
Page 233: Battery Requirement Description
Charging System: 1K-2 Battery Requirement Description Z9J0111B01002 Suzuki recommends 12-volt cranking-type lead acid battery for the DF70 / 80 / 90. Minimum battery requirement for starting the engine is provided below. The battery must satisfy one of the specifications described below.
Page 234: Component Location
1K-3 Charging System: Component Location Charging System Components Location Z9J0111B03001 Refer to “Engine Control System Components / Engine Electrical Device Location” in Section 1A (Page 1A-15). Diagnostic Information and Procedures Charging System Diagnosis Z9J0111B04001 Condition Possible cause Correction / Reference Item Alternator (Battery charge Open or short circuit lead wires.
Page 235: Service Instructions
: 196 N⋅m (19.7 kgf-m, 142 lbf-ft) 5. Battery charge coil 13. Cushion 21. Main relay : Apply engine oil. 6. Bolt 14. Washer 22. Starter motor relay : Apply SUZUKI Bond 1207B. 7. Bolt 15. Bolt 23. Fuse 8. Clamp 16. Bolt 24. Bolt...
Page 236: Flywheel Removal And Installation
1K-5 Charging System: Flywheel Removal and Installation 4) Remove the flywheel bolt (1), washer (2), flywheel Z9J0111B06002 (3) and key (4). Removal CAUTION Prior to removing flywheel, disconnect battery cables from battery. 1) Remove the ring gear cover. Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2).
Page 237: Battery Charge Coil Removal And Installation
7) Remove the battery charge coil (3). Installation Installation is reverse order of removal with special attention to the following steps. Battery charge coil • Apply suzuki bond No. 1207B to the coil securing screws. : Sealant 99000–31140 (SUZUKI Bond 1207B (100 g)) I9J0111B0015-01 3) Disconnect the charge output (red) lead wire •...
Page 238: Battery Charge Coil Inspection
1K-7 Charging System: Flywheel Rectifier/Regulator Removal and Installation Install flywheel and tighten flywheel bolt to specified Z9J0111B06005 Removal torque. Refer to “Flywheel Removal and Installation” (Page 1K- CAUTION Prior to removing electrical parts, disconnect Special tool battery cables from battery. : 09930–48720 (Flywheel holder) 1) Disconnect lead wire connector (1) from rectifier/ Tightening torque...
Page 239: Rectifier/Regulator Inspection
If measurement exceeds specification, replace rectifier/regulator. NOTE The values given below are for a SUZUKI pocket tester. As thyristors, diodes, etc. are used inside this rectifier/regulator, the resistance values will differ when an ohmmeter other than SUZUKI pocket tester is used.
Page 240 1K-9 Charging System:...
Page 241 Table of Contents 2- i Section 2 Mid Unit CONTENTS Precautions ..........2-1 Power Trim and Tilt ......... 2B-1 Precautions............. 2-1 Precautions............2B-1 Precaution for Mid Unit ......... 2-1 Precaution for Power Trim and Tilt......2B-1 General Description ..........2B-1 Housing and Bracket....... 2A-1 Power Trim and Tilt Description ......2B-1 Precautions............2A-1 Principles of Power Trim and Tilt Operation...
Page 242: Precautions
2-1 Precautions: Precautions Mid Unit Precautions Precaution for Mid Unit Z9J0112000001 Refer to “General Precautions” in Section 00 (Page 00-1).
Page 243: Housing And Bracket
Housing and Bracket: 2A-1 Housing and Bracket Mid Unit Precautions Precaution for Housing and Bracket Z9J0112100001 CAUTION Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic corrosion or build up of static charges. Replace any damaged wire.
Page 244: Service Instructions
2A-2 Housing and Bracket: Service Instructions Lower Side Cover Components Z9J0112106001 I9J011210003-05 1. Side cover rubber 9. Side cover holder 17. Engine cover hook shaft 25. Pin 2. Side cover seal 10. Bolt 18. Engine cover hook 26. Bush 3. Lower side cover STBD 11.
Page 245: Lower Side Cover Removal And Installation
Housing and Bracket: 2A-3 Lower Side Cover Removal and Installation 3) Remove three screws (4) and PORT side cover (5). Z9J0112106002 Removal 1) Remove the side cover rubber (1). I9J011210008-02 4) Disconnect PTT switch lead connector. I9J011210009-01 2) Remove ten screws (2) and STBD side cover (3). I9J011210010-01 Installation Installation is reverse order of removal with special...
Page 246: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components
15. Bolt 24. Upper unit stopper : Apply engine oil. 7. Plug 16. Bolt 25. Bolt : Apply SUZUKI water resistant grease. 8. Dowel pin 17. Spacer 26. O-ring : Apply SUZUKI thread lock 1342. 9. Dowel pin 18. Upper mount bolt...
Page 247 10. Water jacket cover 22. Lower mount bracket 34. Bolt : 60 N⋅m (6.0 kgf-m, 43.4 lbf-ft) 11. Gasket 23. Lower thrust mount 35. Bolt : Apply SUZUKI thread lock 1342. 12. Water plug 24. Washer 36. Bolt : Apply SUZUKI silicon seal.
Page 248: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly
2A-6 Housing and Bracket: Engine Holder / Oil Pan / Driveshaft Housing / 5) Unscrew and remove the STBD / PORT lower mount bolts (3). Account for washers (4), (5), mount spacer Mounts Disassembly (6), forward damper (7), white side mount (8), lower Z9J0112106004 1) Remove the power unit.
Page 249 Housing and Bracket: 2A-7 7) Remove the water tube (15). 11) Remove five bolts and oil pan water jacket cover (19) (if necessary). I9J011210018-01 8) Remove five bolts and exhaust tube housing (16). I9J011210023-01 12) Remove bolts, water pressure valve cover (20), and water pressure valve (21).
Page 250 2A-8 Housing and Bracket: 15) Remove STBD / PORT upper mount nuts (24) and 19) Remove the upper mounts (27), upper thrust mount washers. (28), damper (29) and mount bolts (30). I9J011210027-01 I9J011210031-01 16) Remove engine holder with oil pan. I9J011210032-02 20) Remove the six bolts and the engine holder (31) I9J011210028-01...
Page 251: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Assembly
Housing and Bracket: 2A-9 21) Remove two bolts and oil strainer (32). • Install oil strainer to engine holder, then tighten bolts securely. I9J011210035-01 22) Remove the oil relief valve (33) and gasket. I9J011210038-01 • Install two dowel pins (5) and gasket (6) to oil pan. CAUTION Do not reuse gasket.
Page 252 • Install dampers (4) to thrust mount. Upper mount cover bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft) NOTE : Thread lock cement 99000–32050 (SUZUKI Install upper thrust mount with the lettered Thread Lock 1342 (50 g)) mark “UP” facing upward.
Page 253 • Tighten the clutch shaft plug (2), pre-coated with thread lock, to specified torque. Tightening torque Clutch shaft plug (a): 22 N·m (2.2 kgf-m, 16.0 lbf- : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) I9J011210048-01 • Install washer (2) and upper mount nut (1), then tighten two nuts, pre-coated with thread lock, to specified torque.
Page 254 Tightening torque Lower mount bolt (a): 60 N·m (6.0 kgf-m, 43.4 lbf- I9J011210054-01 : Thread lock cement 99000–32050 (SUZUKI • Install two dowel pins (3) to driveshaft housing (4). Thread Lock 1342 (50 g)) Apply sealant to mating surfaces of driveshaft housing and oil pan.
Page 255: Engine Holder / Oil Pan / Driveshaft Housing / Mounts Related Component Inspection
Housing and Bracket: 2A-13 • Install lower mount cover (12) and cover bolts (13), Engine Holder then tighten bolts, pre-coated with thread lock, to • Inspect the engine holder. Replace if cracked, specified torque. damaged, or other abnormal conditions are noted. Tightening torque •...
Page 256 2A-14 Housing and Bracket: Oil Strainer • Inspect the oil strainer. Replace the strainer if cracked, damaged or other abnormal conditions are found. If clogged or obstructed, clean the oil strainer. • Check condition of O-ring. Replace O-ring if nicked, cut, worn or other abnormal condition are found.
Page 257: Clutch Shaft Bearing And Oil Seal Replacement
Drive oil seal into engine holder. Apply water resistant grease to the seal lip. NOTE Install oil seal as shown in the figure. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011210072-01 4) Remove bearing (3) with special tool and sliding hammer.
Page 258: Driveshaft Upper Oil Seal Replacement
4) Drive the two oil seals (one at a time) into the engine holder. NOTE Install oil seal with lip (spring side) facing downward (oil pan side). : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011210079-01 4) Apply water resistant grease to outer circumference of oil seal.
Page 259: Clamp / Swivel / Steering Brackets Components
21. Shim 33. Screw : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft) 10. Anode 22. Lower mount bracket 34. Bracket : Apply SUZUKI water resistance grease. 11. Bolt 23. Circlip 35. Bonding wire : Apply SUZUKI thread lock 1342. 12. Swivel bracket 24.
Page 260: Clamp / Swivel / Steering Brackets Disassembly
2A-18 Housing and Bracket: Clamp / Swivel / Steering Brackets Disassembly 5) Lift steering bracket (5) upward to remove from Z9J0112106011 swivel bracket. 1) Remove engine holder / oil pan and driveshaft Remove washer (6) and upper bushing (7). housing. Refer to “Engine Holder / Oil Pan / Driveshaft Housing / Mounts Disassembly”...
Page 261 Housing and Bracket: 2A-19 9) Remove the upper trim sensor cam (13) from clamp 13) Remove the PTT unit (19) and lower clamp bracket bracket shaft. (20) from between the clamp brackets. I9J011210089-01 I9J011210093-01 10) Remove circlip (14) and push out tilt cylinder upper 14) Using flat blade screw driver, drive locking edge of rod (15).
Page 262: Clamp / Swivel / Steering Brackets Assembly
NOTE Before installing clamp bracket to swivel bracket, apply grease to clamp bracket shaft and bushings. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011210096-02 • Insert PORT and STBD bushings (2) into the swivel 17) Remove the bolt (26) securing clamp bracket shaft to bracket (1).
Page 263 Install the shaft bolt (5), then tighten it securely. nut. : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) I9J011210104-01 • Install PTT unit and lower clamp bracket assembly (10).
Page 264 • Install the upper trim sensor cam (1) engaging its • Apply water resistant grease to steering bracket shaft. locating pin “A” with the clamp bracket shaft hole “B”. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) NOTE Apply grease to bushings, oil seal lip and pilot shaft portion of steering bracket.
Page 265 (2) upward on the splines until it contacts the shim. I9J011210113-01 Lubrication After completing reassembly of the mid unit, apply grease through each grease nipple. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011210110-01 • Install circlip (5) to retain bracket. I9J011210114-01 I9J011210111-01...
Page 266: Clamp / Swivel / Steering Brackets Related Components Inspection
2A-24 Housing and Bracket: Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft Check clamp bracket shaft. Components Inspection Z9J0112106013 If clamp bracket shaft is bent or twisted, replace shaft. Refer to “Clamp / Swivel / Steering Brackets Disassembly” (Page 2A-18) and “Clamp / Swivel / Steering Brackets Assembly”...
Page 267: Power Trim And Tilt
Power Trim and Tilt: 2B-1 Power Trim and Tilt Mid Unit Precautions Precaution for Power Trim and Tilt Z9J0112200001 WARNING Before removing the PTT unit, the motor should be fully supported to prevent personal injury. CAUTION • To prevent system malfunctions, ensure that all components are kept free from dirt or contamination.
Page 268 2B-2 Power Trim and Tilt: Power Trim and Tilt Hydraulic Diagram I9J011220001-02 1. PTT motor 9. Free piston 17. “DOWN” relief valve 2. Tilt rod 10. Lower cylinder chamber 18. Spool valve No. 1 3. Oil reservoir 11. Manual release valve 19.
Page 269: Principles Of Power Trim And Tilt Operation Description
Power Trim and Tilt: 2B-3 Principles of Power Trim and Tilt Operation Description Z9J0112201002 By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder. Trim / Tilt Up Circuit •...
Page 270 2B-4 Power Trim and Tilt: Trim / Tilt Down Circuit • When the PTT switch is operated in the “DOWN” position, the electric motor will rotate in a counterclockwise direction and turn the gear pump. • Check valve (1) will open; oil will flow from the reservoir to the spool valve (2). This makes spool valve (3) move to downward, and causes the “UP”...
Page 271 Power Trim and Tilt: 2B-5 Shock Absorber Circuit Shock valve Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
Page 272 2B-6 Power Trim and Tilt: Manual Release Circuit (Manual Valve) Turn the manual valve a maximum of three full turns counterclockwise. When the manual release valve (1) is loosened, oil will flow unimpeded (without resistance) through the internal pump tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the manual valve must be closed again.
Page 273 Power Trim and Tilt: 2B-7 Thermal Valve As temperature goes up, oil pressure will increase and the oil in PTT unit will expand. High oil pressure in the upper cylinder chamber (1) caused by rising temperature will release the thermal valve (2) and make the oil flow to the reservoir to prevent damage to the PTT unit.
Page 274: Schematic And Routing Diagram
2B-8 Power Trim and Tilt: Schematic and Routing Diagram Power Trim and Tilt System Diagram Z9J0112202001 BATT W-tube B GND W BATT Gr IGN Br START I9J011220007-04 1. PTT switch (Remote control box) 6. Battery 11. ECM fuse 30 amp. 2.
Page 275: Diagnostic Information And Procedures
Power Trim and Tilt: 2B-9 Diagnostic Information and Procedures Diagnose PTT System Malfunction Z9J0112204001 Condition Possible cause Correction / Reference Item Motor will not trim / tilt at Blown fuse for PTT system. Inspection and replace. all (no up, no down). (Sub battery cable: 15 A, Main: 40 A, PTT switch: 10 A, ECM: 30 A).
Page 276: Service Instructions
2B-10 Power Trim and Tilt: Service Instructions Checking PTT Fluid Level Air Bleeding from PTT Unit Z9J0112206001 Z9J0112206002 1) Raise the engine to a full-tilt up position. 1) Check that the manual release valve (1) is tightened to the specified torque. 2) Lower the manual tilt lock lever (1).
Page 277: Setting Of Trim Down Position Limit
Power Trim and Tilt: 2B-11 Setting of Trim Down Position Limit 5) Press the “DOWN” side of the PTT switch for three Z9J0112206003 seconds and the buzzer will sound two times briefly Once the ECM has been replaced or the trim sensor indicating the setting has been canceled.
Page 278: Setting Tilt Up Limit Position
2B-12 Power Trim and Tilt: Setting Tilt Up Limit Position 5) Press the “UP” side of the PTT switch for three Z9J0112206012 seconds and the buzzer will sound twice briefly If the outboard motor contacts the motor well of the boat indicating the setting has been canceled.
Page 279: Power Trim And Tilt Unit Removal And Installation
Power Trim and Tilt: 2B-13 Power Trim and Tilt Unit Removal and 3) Remove the tilt rod snap ring (2) and push the tilt cylinder upper shaft pin (3) out. Installation Z9J0112206004 Removal 1) Remove the lower side cover. Refer to “Lower Side Cover Removal and Installation”...
Page 280 2B-14 Power Trim and Tilt: 6) Disconnect the PTT motor cable wire connector from 9) Remove the PTT unit (9) and lower clamp bracket the PTT relay. Cut the cable tie binding PTT motor from between the clamp brackets. cable and trim sensor lead. Remove the PTT motor cable from engine lower cover.
Page 281 Resistant Grease (250 g)) I9J011220075-01 • Tighten four lower clamp bracket bolts (6), pre-coated with thread lock, to specified torque. : Thread lock cement 99000–32050 (SUZUKI Thread Lock 1342 (50 g)) Tightening torque Lower clamp bracket bolt (a): 50 N·m (5.0 kgf-m, 36.0 lbf-ft)
Page 282 (10), then insert the shaft through the swivel bracket and tilt rod. Secure the upper shaft with the snap ring (11). : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011220078-01 • Apply water resistant grease to tilt rod upper bushings (9), then install bushings in tilt rod.
Page 283: Power Trim And Tilt Unit Components
Power Trim and Tilt: 2B-17 Power Trim and Tilt Unit Components Z9J0112206005 I9J011220009-03 1. Joint 8. Manifold assembly 15. Brush holder 22. Pump assembly 2. Tank 9. Field case 16. Screw 23. Bolt 3. Plug 10. O-ring 17. Oil seal 24.
Page 284: Power Trim And Tilt Unit Disassembly
2B-18 Power Trim and Tilt: Power Trim and Tilt Unit Disassembly 4) Remove the manual release valve snap ring (1), Z9J0112206006 then unscrew the manual release valve (2). NOTE Before disassembly, wash the PTT body with a stiff bristle brush and hot, soapy water to remove sand or dirt.
Page 285: Power Trim And Tilt Unit Reassembly
Upper Eye • Apply thread lock super 1333B to threads of upper eye before threading it onto tilt rod. : Thread lock cement 99000–32020 (SUZUKI Thread Lock Super 1333B (50 g)) • Tighten upper eye to specified torque. Tightening torque Upper eye (a): 108 N·m (10.8 kgf-m, 78.0 lbf-ft)
Page 286 2B-20 Power Trim and Tilt: PTT Pump Assembly PTT Motor • Install four O-rings (1) to PTT body assembly. • Install the PTT motor. Refer to “Power Trim and Tilt Motor Removal and NOTE Installation” (Page 2B-22). Lubricate O-rings with PTT fluid before PTT Fluid installing.
Page 287: Power Trim And Tilt Unit Components Cleaning And Inspecting
Power Trim and Tilt: 2B-21 6) Reverse the two extension cable lead wires (G to • Inspect PTT pump assembly for cracks, nicks, positive / Bl to negative). stripped threads and any other imperfections. Operate the PTT motor until the PTT rod is in the full Replace if necessary.
Page 288: Power Trim And Tilt Motor Removal And Installation
2B-22 Power Trim and Tilt: • Inspect manual release valve for damage. Replace if 2) Place the lower section of the PTT unit in a vise. necessary. Tighten the vise only enough to secure the PTT unit, DO NOT OVER TIGHTEN. •...
Page 289: Power Trim And Tilt Motor Disassembly And Assembly
Power Trim and Tilt: 2B-23 Installation Power Trim and Tilt Motor Disassembly and Installation is reverse of removal with special attention to Assembly following steps. Z9J0112206010 Disassembly • Ensure that the drive joint (1) is aligned and firmly 1) For correct assembly, scribe an alignment mark on inserted into the gear pump assembly.
Page 290: Ptt Motor Related Items Inspection
If surface is gummy or dirty, clean with 400 grit emery grommets and install cable holder screw. paper (1). • Measure commutator outside diameter. : Sealant 99000–31120 (SUZUKI Silicone If measurement exceeds service limit, replace Seal (50 g)) armature. Special tool (B): 09900–20101 (Vernier calipers (150...
Page 291: Ptt Motor Relay Inspection
Power Trim and Tilt: 2B-25 O-ring • Inspect the O-ring between the PTT motor and PTT pump assembly. Replace if cuts, nicks or tears are found. I9J011220042-01 • Ensure that the mica (insulator) between commutator segments are undercut “a” to specified depth. If undercut is less than service limit, cut to specified depth.
Page 292: Ptt Switch Inspection
2B-26 Power Trim and Tilt: 3) Connect the “R” (red) wire to positive (+) terminal, PTT Switch Inspection and the “B” (black) wire to negative (–) terminal of a Z9J0112206014 Test continuity between the switch lead wires at each of 12 V battery.
Page 293 Table of Contents 3- i Section 3 Lower Unit CONTENTS Precautions ..........3-1 Lower Unit Removal and Installation....3A-5 Water Pump Removal and Installation....3A-6 Precautions............. 3-1 Water Pump and Related Items Inspection..3A-8 General Precautions ..........3-1 Lower Unit Disassembly........3A-8 Precaution for Lower Unit ........3-1 Pinion Bearing Removal and Installation ..3A-11 Right Hand Rotation Unit......
Page 294: Precautions
3-1 Precautions: Precautions Lower Unit Precautions General Precautions Z9J0113000001 Refer to “General Precautions” in Section 00 (Page 00-1). Precaution for Lower Unit Z9J0113000002 WARNING • When installing or removing the propeller, shift into “Neutral” and remove the emergency stop switch lock plate so that the motor cannot be started accidentally. •...
Page 295: Right Hand Rotation Unit
Right Hand Rotation Unit: 3A-1 Right Hand Rotation Unit Lower Unit Diagnostic Information and Procedures Diagnose Lower Unit Malfunction Z9J0113104001 Trouble Check Chart Condition Possible cause Correction / Reference Item Engine stalls when Idling speed set too low. Adjustment. engaging gear Propeller shaft bearings damaged, Replace.
Page 296: Service Instructions
19. Gasket 30. Dowel pin : 17 N⋅m (1.7 kgf-m, 12.3 lbf-ft) 9. Shifter yoke 20. Anode 31. Case sealing : Apply SUZUKI Water Resistant Grease. 10. Nipple 21. Bolt 32. Inner sleeve : Apply SUZUKI Silicon seal. 11. Dowel pin 22.
Page 297 35. Oil seal : Apply SUZUKI Water Resistant Grease. 10. Oil seal 23. Clutch dog shifter 36. Protector : Apply SUZUKI Outboard Motor Gear Oil. 11. Shim 24. Dog pin 37. Ring : Apply SUZUKI Thread Lock 1342. 12. Driveshaft bearing 25.
Page 298: Propeller Removal And Installation
3A-4 Right Hand Rotation Unit: Propeller Removal and Installation Installation Z9J0113106002 1) Coat the propeller shaft splines liberally with Suzuki WARNING water resistant grease. • When installing or removing the propeller, : Grease 99000–25161 (SUZUKI Water shift into “Neutral” and remove the...
Page 299: Propeller / Nut / Cotter Pin Inspection
: Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011310021-01 4) Apply a light coating of suzuki silicone seal to mating 2) Remove five bolts (2) and separate gearcase (3) surfaces of gearcase and driveshaft housing. from driveshaft housing.
Page 300: Water Pump Removal And Installation
(5) and dowel pins (6). Keep impeller key (4) for reuse and discard the plate I9J011310026-01 gasket. 6) Apply suzuki silicone seal to five gearcase bolts and tighten them to specified torque. : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) Tightening torque Gearcase bolt (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
Page 301 4) Install inner sleeve (8) into the pump case, ensuring that projection of inner sleeve and groove of pump case are aligned. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011310035-01...
Page 302: Water Pump And Related Items Inspection
3A-8 Right Hand Rotation Unit: 6) Install the Lower Unit. Refer to “Lower Unit Removal 4) Place a drain pan under oil drain plug. Remove oil and Installation” (Page 3A-5). drain plug (1) first then oil level plug (2) and allow gear oil to drain.
Page 303 Right Hand Rotation Unit: 3A-9 8) Using special tools, pull out the propeller shaft bearing housing. Remove the propeller shaft and bearing housing assembly (8). Special tool (A): 09930–30104 (Sliding hammer) (B): 09930–30161 (Propeller shaft remover) I9J011310046-01 12) Remove the pin (12) and driveshaft collar (13) from driveshaft (if necessary).
Page 304 3A-10 Right Hand Rotation Unit: 14) To disassemble propeller shaft components, refer to d) Remove clutch dog shifter (24) and connector following. pin (25) from propeller shaft. a) Slide propeller shaft away from reverse gear (19) and bearing housing assembly (20). Account for the reverse gear back-up shim (21) and reverse gear thrust washer (22).
Page 305: Pinion Bearing Removal And Installation
Right Hand Rotation Unit: 3A-11 c) Remove E-ring (33) and shifter yoke (34). Removal 1) Disassemble the lower unit. Refer to “Lower Unit Disassembly” (Page 3A-8). 2) Place the attachment (D) inside the pinion bearing. 3) Insert the removal shaft (A) into attachment (D). 4) Thread sliding hammer (E) into top of removal shaft (A).
Page 306: Lower Unit Related Items Inspection
3A-12 Right Hand Rotation Unit: 2) Place the installer shaft (A) (with pinion bearing on Lower Unit Related Items Inspection end of installer shaft) into the gearcase. Z9J0113106024 WARNING 3) Secure the plate (B) by tightening the bolt (C). 4) Thread the sliding hammer (E) into the top of the Wear safety glasses when using compressed installer shaft (A).
Page 307 Right Hand Rotation Unit: 3A-13 Gears / Bearing • Inspect dog pin. Replace if bent, worn or other abnormal conditions are noted. • Inspect forward, reverse and pinion gear teeth and engaging dogs. • Inspect propeller shaft / splines. Replace if worn, Replace gears if damaged worn or other abnormal twisted, damaged or other abnormal conditions are conditions are noted.
Page 308 3A-14 Right Hand Rotation Unit: Propeller Shaft Bearing Housing • Inspect oil seal and oil seal cover. Replace if nicked, cut, worn or other abnormal conditions are noted. • Inspect housing. Replace if cracked, damaged or other abnormal conditions are noted. •...
Page 309: Propeller Shaft Oil Seal Replacement
I9J011310071-01 4) Apply water resistant grease to the inner circumference of the housing. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) 5) Using an oil seal installer, drive the two oil seals (one at a time) into the propeller shaft bearing housing.
Page 310: Driveshaft Oil Seal Replacement
Forward Gear of driveshaft oil seal housing. Place the forward gear back-up shim (1), forward gear : Grease 99000–25161 (SUZUKI Water bearing outer race (2) in position, then install forward Resistant Grease (250 g)) gear (3) with forward gear bearing (4).
Page 311 • Assemble the driveshaft collar (1) to driveshaft. • Apply water resistant grease to the driveshaft oil seal. • Install the pin (2). : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) • Apply water resistant grease to O-ring (1), then install O-ring into groove on the driveshaft oil seal housing (2).
Page 312 • Apply thread lock 1342 to the threads of pinion nut (1) should checked. Refer to “Lower Unit Gears - Shimming before threading it onto driveshaft. and Adjustment” (Page 3A-24). : Thread lock cement 99000–32050 (SUZUKI Special tool Thread Lock 1342 (50 g)) (A): 09951–09530 (Gear adjusting gauge) •...
Page 313 (1). Resistant Grease (250 g)) • Align the holes in the shifter dog and connector pin : Gear Oil 99000–22540 (SUZUKI Outboard and then slide the dog pin (8) through both dog and Motor Gear Oil) connector pin. (save the temporarily installed dowel pin pushed out as the dog pin is inserted.)
Page 314 3A-20 Right Hand Rotation Unit: • Apply water resistant grease to the bearing housing Rechecking Driveshaft Thrust Play O-ring (6). Recheck the driveshaft thrust play. This should not be less than previously checked. If less, reduce the number / thickness of the reverse gear back-up shims. Refer to “Lower Unit Gears - Shimming and Adjustment”...
Page 315 • Using an oil seal installer, drive the oil seal (1) into the shift rod guide housing (2). The lipped portion of oil seal must face towards the driveshaft housing. : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) I9J011310097-01 •...
Page 316 • Install the shift rod guide housing assembly (9) by housing O-ring. aligning the shifter yoke with the groove in the connector pin, then tighten the housing bolt (10) : Grease 99000–25161 (SUZUKI Water securely. Resistant Grease (250 g)) I9J011310101-02...
Page 317: Trim Tab Adjustment
Right Hand Rotation Unit: 3A-23 3) Rotate driveshaft and propeller shaft clockwise Lower Unit several times and then apply specified pressure for Install the Lower Unit. the test. Refer to “Lower Unit Removal and Installation” (Page 3A-5). CAUTION Trim Tab Adjustment Do not exceed pressure of 110 kPa (1.1 kg/ Z9J0113106028 , 15.6 psi.) or damage to oil seals will...
Page 318: Lower Unit Gears - Shimming And Adjustment
3A-24 Right Hand Rotation Unit: Lower Unit Gears - Shimming and Adjustment Z9J0113106029 If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash will have to be checked and/or adjusted to ensure smooth, reliable operation. Shim / Washer and Mounting Position Design specification thickness Item...
Page 319 Right Hand Rotation Unit: 3A-25 Forward Gear / Pinion Gear Back-Up Shim Checking driveshaft thrust play Adjustment 1) Affix the gear adjusting gauge to driveshaft. Follow the procedure below to adjust forward gear / Special tool pinion gear. (A): 09951–09530 (Gear adjusting gauge) Prior to adjustment 2) To check driveshaft thrust play, push the forward 1) Install standard pinion gear back-up shim thickness...
Page 320 3A-26 Right Hand Rotation Unit: Checking and adjusting tooth contact pattern 5) Carefully remove the propeller shaft and housing to (Pinion and Forward gear) check the tooth contact pattern. Check tooth contact pattern using the following procedure. “A” “a” 1) To assess tooth contact, apply a light coat of “B”...
Page 321 Right Hand Rotation Unit: 3A-27 Example [A] Rechecking driveshaft thrust play Incorrect topside toe contact. After obtaining optimum tooth contact, driveshaft thrust Correction measures. play should be measured. • Decrease thickness of forward gear shim. 1) Affix the gear adjusting gauge to the driveshaft. •...
Page 322 3A-28 Right Hand Rotation Unit: Reverse Gear Back-Up Shim Adjustment 5) Compare play “B” to play “A”. After adjusting the forward gear tooth contact pattern, Refer to “Rechecking driveshaft thrust play” follow the procedure below to adjust the reverse gear. (Page 3A-27).
Page 323 Table of Contents 4- i Section 4 Wire / Hose Routing CONTENTS Precautions ..........4-1 Wiring Harness Routing Diagram......4A-3 Precautions............. 4-1 Fuel / Water Hose Routing ...... 4B-1 Precautions for Wire / Hose Routing..... 4-1 Precautions............4B-1 Component Location ..........4-1 Precautions for Fuel / Water Hose Routing..4B-1 Electrical Component Location ......
Page 324: Precautions
4-1 Precautions: Precautions Wire / Hose Routing Precautions Precautions for Wire / Hose Routing Z9J0114000001 Refer to “General Precautions” in Section 00 (Page 00-1). Component Location Electrical Component Location Z9J0114003001 Refer to “Engine Control System Components / Engine Electrical Device Location” in Section 1A (Page 1A-15).
Page 325: Wire Routing
Wire Routing: 4A-1 Wire Routing Wire / Hose Routing Schematic and Routing Diagram Wiring Diagram Z9J0114102004 Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).
Page 326 4A-2 Wire Routing: DF70A / 80A / 90A I9J011410001-04...
Page 327: Wiring Harness Routing Diagram
Wire Routing: 4A-3 Wiring Harness Routing Diagram Z9J0114102003 I9J011410002-01 1. Electric parts holder 3. Cushion 5. PTT motor relay 2. ECM 4. Fuse box...
Page 328 4A-4 Wire Routing: View “A” “A” I9J011410003-03 1. Flywheel 11. Rectifier/Regulator GND lead wire 21. ECM 2. Starter motor 12. Main harness GND lead wire 22. IAT sensor 3. Oil pressure switch 13. Bolt 23. Battery cable (+) : Cover the oil pressure switch with cap. 4.
Page 329 Wire Routing: 4A-5 I9J011410004-02 1. Battery charge coil 3. Cylinder temp. sensor lead wire 5. MAP sensor 2. Battery charge coil lead wire 4. Clamp 6. IAC valve...
Page 330 4A-6 Wire Routing: I9J011410005-04 1. Clamp 3. Shift position sensor 5. Neutral switch : Fix the harness with clamp. 2. High pressure fuel pump sub lead wire 4. Shift position sensor lever 6. Clamp...
Page 331 Wire Routing: 4A-7 I9J011410006-02 1. CMP sensor 5. No.4 Ign. coil 9. Clamp 13. Ex. mani. temp. sensor : Fix the harness with clamp. 2. No.1 Ign. coil 6. No.1 fuel injector 10. Clamp 3. No.2 Ign. coil 7. No.2 fuel injector 11.
Page 332 4A-8 Wire Routing: “ a ” I9J011410007-05 1. CKP sensor 8. Cushion 15. Remote control harness connector 2. IAC valve 9. Washer 16. 3-pin connector 3. Harness clamp 10. Battery cable 17. 2-pin connector 4. TPS 11. PTT cable 18. Cable holder : Set the taping position “a”...
Page 333 Wire Routing: 4A-9 I9J011410008-03 1. Trim sensor 3. Clamp 5. Clamp : Fix the trim sensor lead wire at white taping position. 2. Trim sensor cam 4. Clamp 6. PTT motor cable...
Page 334: Fuel / Water Hose Routing
4B-1 Fuel / Water Hose Routing: Fuel / Water Hose Routing Wire / Hose Routing Precautions Precautions for Fuel / Water Hose Routing Z9J0114200001 CAUTION • Do not over-bend (kink) or twist hoses when installing. • When installing hose clips, position tabs to avoid contact with other parts. •...
Page 335 Fuel / Water Hose Routing: 4B-2 I9J011420002-02 1. Clamp 6. Low pressure fuel filter 11. Breather hose 2. Fuel hose (Joint to low pressure fuel 7. Fuel hose (Filter to fuel pump) 12. Fuel hose (3-way joint to fuel delivery filter) pipe) 3.
Page 336 4B-3 Fuel / Water Hose Routing: I9J011420003-01 1. Fuel hose (Joint to low pressure fuel filter) 5. Low pressure fuel pump 9. Fuel hose (High pressure fuel filter to 3-way joint) 2. Fuel hose protector 6. Breather hose/protector 10. 3-way joint 3.
Page 337 Fuel / Water Hose Routing: 4B-4 I9J011420004-01 1. Fuel hose / protector (Joint to low pressure fuel filter) 3. Fuel hose (Fuel pump to fuel vapor separator) 5. Low pressure fuel filter 2. Fuel hose (Fuel filter to fuel pump) 4.
Page 338: Water Hose Routing
4B-5 Fuel / Water Hose Routing: Water Hose Routing Z9J0114202002 I9J011420005-02 1. Water return hose 4. Water hose (Union to fuel cooler) 7. Water return union 2. Fuel cooler 5. Water hose protector 3. Water hose (Fuel cooler to water return union) 6.
Page 339 Fuel / Water Hose Routing: 4B-6 I9J011420006-02 1. Thermostat cover 2. Water return hose...
Page 340 4B-7 Fuel / Water Hose Routing: I9J011420007-01 1. Water flush hose 2. Speed meter hose 3. Clamp I9J011420008-01 1. Water flush hose 2. Speed meter hose 3. Front panel...
Page 341 Prepared by Marine Design Department October, 2008 Manual No. 99500-87L00-01E Printed in Japan...

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Df90a Df80a

Suzuki DF70A Service Manual

Section 1 Power Head

Precautions

Engine General Information and Diagnosis

Precautions

General Description

Component Location

Diagnostic Information and Procedure

Service Instructions

Engine Electrical Devices

Precautions

General Description

Component Location

Service Instructions

1D-1 Power Unit Mechanical

General Description

Diagnostic Information and Procedures

Service Instructions

Power Unit Lubrication

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Service Instructions

Power Unit Cooling System

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Service Instructions

Fuel System

Precautions

General Description

Diagnostic Information and Procedures

Service Instructions

Ignition System

General Description

Component Location

Diagnostic Information and Procedures

Service Instructions

Starting System

General Description

Component Location

Diagnostic Information and Procedures

Service Instructions

Charging System

General Description

Component Location

Diagnostic Information and Procedures

Service Instructions

Section 2 MID Unit

Precautions

Precautions

Housing and Bracket

Service Instructions

Power Trim and Tilt

Precautions

General Description

Schematic and Routing Diagram

Diagnostic Information and Procedures

Service Instructions

Section 3 Lower Unit

Precautions

Right Hand Rotation Unit

Diagnostic Information and Procedures

Service Instructions

Section 4 Wire / Hose Routing

Precautions

Component Location

Wire Routing

Schematic and Routing Diagram

Fuel / Water Hose Routing

Precautions

Schematic and Routing Diagram

Quick Links

Chapters

Troubleshooting

Need help?

Questions and answers

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Summary of Contents for Suzuki DF70A