df70a.pdf

TOP 99500-87L00-01E DF70A/80A/90A Service Manual Cover for PS printing (13mm) 5/0 2008/10/29 BOTTOM DIC502 Pantone 303C Pantone 485 Pantone 294 Black IMPORTANT NOTICE WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol...

TOP 99500-87L00-01E DF70A/80A/90A Service Manual Cover for PS printing (13mm) 5/0 2008/10/29 BOTTOM DIC502 Pantone 303C Pantone 485 Pantone 294 Black IMPORTANT NOTICE WARNING / CAUTION / NOTE Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words ! WARNING , CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words. ! WARNING Indicates a potential hazard that could result in death or injury. CAUTION Indicates a potential hazard that could result in motor damage. NOTE: Indicates special information to make maintenance easier or instructions clearer. Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the ! WARNING and CAUTION stated, you must also use good judgment and observe basic mechanical safety principles. ! WARNING This service manual is intended for authorized Suzuki outboard motor dealers and qualified service technicians only. Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers. FOREWORD This manual contains an introductory description of the SUZUKI DF70/80/90 Outboard motors and procedures for inspection, service and overhaul of their main components. General knowledge information is not included. Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures. This manual will help you better understand these outboard motors, assisting you in providing your customers with optimum and quick service. * This manual has been prepared using the latest information available at the time of publication. Differences may exist between the content of this manual and the actual outboard motor. * Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the actual outboard motor in exact detail. * This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Outboard motor dealer. NOTE: This manual is compiled based on 2009 (K9) model. © COPYRIGHT SUZUKI MOTOR CORPORATION 2008 TABLE OF CONTENTS 00 0 Precautions............................................................... 00-i Precautions............................................................ 00-1 1 General Information................................................... 0-i General Information............................................... 0A-1 Maintenance and Tune-Up..................................... 0B-1 Power Head................................................................. 1-i Precautions.............................................................. 1-1 Engine General Information and Diagnosis........... 1A-1 Engine Electrical Devices.......................................1C-1 Power Unit Mechanical..........................................1D-1 Power Unit Lubrication........................................... 1E-1 Power Unit Cooling System................................... 1F-1 Fuel System...........................................................1G-1 Ignition System.......................................................1H-1 Starting System....................................................... 1I-1 Charging System.................................................... 1K-1 Mid Unit....................................................................... 2-i Precautions.............................................................. 2-1 Housing and Bracket.............................................. 2A-1 Power Trim and Tilt................................................ 2B-1 2 3 4 5 Lower Unit................................................................... 3-i Precautions.............................................................. 3-1 Right Hand Rotation Unit....................................... 3A-1 6 Wire / Hose Routing................................................... 4-i Precautions.............................................................. 4-1 Wire Routing.......................................................... 4A-1 Fuel / Water Hose Routing..................................... 4B-1 7 8 9 10 11 Table of Contents 00- i Section 00 Precautions CONTENTS Precautions...............................................00-1 Precautions........................................................... 00-1 General Precautions........................................... 00-1 00 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. When two or more persons work together, pay attention to the safety of each other. When it is necessary to run the outboard motor indoors, make sure that exhaust gas is vented outdoors. When testing an outboard motor in the water, ensure that the necessary safety equipment is on board. Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first aid kit, emergency starter rope, etc. When working with toxic or flammable materials, make sure that the area you work in is well ventilated and that you follow all of the material manufacturer’s instructions. Never use gasoline as a cleaning solvent. To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly after engine operation. Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and moisture-proof gloves (such as latex gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil. After servicing the fuel, lubrication, cooling and/or the exhaust system, check all lines and fittings related to the system for leaks. Carefully adhere to the battery handling instructions laid out by the battery supplier. Precautions: 00-2 CAUTION If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent. When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation. Be sure to use special tools where instructed. Make sure that all parts used in assembly are clean and also lubricated when specified. When use of a certain type of lubricant, bond, or sealant is specified, be sure to use the specified type. When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable. When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery. Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter. Always tighten from inside to outside diagonally to the specified tightening torque. Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips, and certain other parts as specified, always replace them with new. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces. Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted. Use a torque wrench to tighten fasteners to the torque values when specified. Remove grease or oil from screw / bolt threads unless a lubricant is specified. After assembly, check parts for tightness and operation. To protect the environment, do not unlawfully dispose of used motor oil, other fluids or batteries. To protect the Earth's natural resources, properly dispose of used motor parts. 00-3 Precautions: Table of Contents 0- i Section 0 General Information CONTENTS General Information................................ 0A-1 General Description.............................................0A-1 Symbols.............................................................. 0A-1 Abbreviations...................................................... 0A-1 Wire Color Symbols............................................ 0A-2 Warning, Caution and Information Label Locations........................................................... 0A-2 Genuine Parts Description.................................. 0A-3 Outboard Motor Identification Number Location............................................................ 0A-3 Fuel and Oil Recommendations.......................... 0A-3 Break-In Procedures........................................... 0A-4 Propeller Selection Guide................................... 0A-4 Battery Requirement........................................... 0A-5 Powerhead Direction of Rotation Description..... 0A-5 Specifications.......................................................0A-6 Specifications...................................................... 0A-6 Service Data....................................................... 0A-8 Tightening Torque Specifications...................... 0A-13 Special Tools and Equipment...........................0A-14 Recommended Service Material....................... 0A-14 Special Tool...................................................... 0A-15 Maintenance and Tune-Up...................... 0B-1 Precautions...........................................................0B-1 Precautions for Maintenance.............................. 0B-1 General Description.............................................0B-1 Recommended Oil and Lubricants...................... 0B-1 Scheduled Maintenance......................................0B-1 Periodic Maintenance Schedule Chart................0B-1 Lubrication Point.................................................0B-2 Service Instructions.............................................0B-3 Engine Oil Level Check.......................................0B-3 Engine Oil Change and Engine Oil Filter Replacement.....................................................0B-3 Gear Oil Change.................................................0B-6 Spark Plug Removal and Installation..................0B-6 Spark Plug Inspection and Cleaning...................0B-7 Tappet Clearance Inspection and Adjustment....0B-8 Idle Speed and Idle Air Control (IAC) Duty Inspection........................................................0B-13 Ignition Timing Inspection.................................0B-13 Breather Line and Fuel Line Inspection............0B-14 Low Pressure Fuel Filter Inspection..................0B-15 High Pressure Fuel Filter Replacement............0B-15 Water Pump and Water Pump Impeller Inspection........................................................0B-16 Propeller / Propeller Nut and Cotter Pin Inspection........................................................0B-16 Anodes Inspection.............................................0B-17 Bonding Wires Inspection.................................0B-18 Battery Inspection.............................................0B-18 Bolts and Nuts Inspection.................................0B-20 Oil Pressure Check...........................................0B-20 Cylinder Compression Pressure Check............0B-21 0 0A-1 General Information: General Information General Information General Description Symbols Z9J0110101001 Listed in the table below are the symbols indicating instructions and other important information necessary for proper servicing. Please note the definition for each symbol. You will find these symbols used throughout this manual. Refer back to this table if you are not sure of any symbol (s) meanings. Symbol Definition Torque control required. Data beside it indicates specified torque. Apply oil. Use engine oil unless otherwise specified. Apply molybdenum oil solution. (Mixture of engine oil and SUZUKl MOLY PASTE in a ratio of 1 : 1) Apply SUZUKI Outboard Motor Gear Oil. Apply SUZUKI Super Grease A. Apply SUZUKI Moly Paste. 99000-25140 Apply SUZUKI Water Resistant Grease. Apply SUZUKI Bond 1207B. Apply SUZUKI Silicone Seal. Apply SUZUKI Thread Lock 1342. Apply SUZUKI Thread Lock Super 1333B. Use special tool. Do not reuse. Note on reassembly. Use peak voltmeter Stevens CD-77. Abbreviations Z9J0110101002 Abbreviations used in this service manual are as follows: A: ATDC: After Top Dead Center AC: Alternating Current B: BTDC: Before Top Dead Center C: CKP Sensor: Crankshaft Position sensor CMP Sensor: Camshaft Position sensor CTP: Close Throttle Position D: DC: Direct Current DOHC: Double Over Head Camshaft E: ECM: Engine Control Module EX (Ex.): Exhaust F: FP: Fuel Pump G: GND: Ground I: IAC: Idle Air Control IAT: Intake Air Temperature IG: Ignition Ign.: Ignition IN (In.): Intake L: LPS: Lever Position Sensor M: MAP: Manifold Absolute Pressure P: PCV: Positive Crankcase Ventilation PORT: Port PTT: Power Trim and Tilt S: SPS: Shift Position Sensor STBD: Starboard SIGP: Start-In-Gear Protection T: TPS: Throttle Position Sensor General Information: Wire Color Symbols 0A-2 Z9J0110101010 There are two kinds of colored wire used in this product. One is single colored wire and the other is dual colored (striped) wire. The single colored wire uses only one color symbol. example: B (Black). The dual colored wire uses two color symbols. example: Bl/B. The first symbol represents the base color of the wire and the second symbol represents the color of the stripe. Example: Bl/B (Blue with Black stripe). Symbol Wire color Symbol Wire color B Black Lg Light green Bl Blue O Orange Br Brown P Pink Dg Dark green R Red G Green V Violet Gr Gray W White Lbl Light blue Y Yellow B (Base Color) Bl (Blue Color) Black (Stripe Color) Bl/B I9J011010001-02 Warning, Caution and Information Label Locations Z9J0110101011 The figure shows main labels among others that are attached to outboard motor. When servicing outboard motor, refer to WARNING / CAUTION instructions printed on labels. If any WARNING / CAUTION label is found stained or damage, clean or replace it as necessary. Do not reuse a label after it has been removed. Always use new label. 1 3 2 I9J011010004-02 1. Label, engine cover 2. Label, mag cover 3. Label S.I.G.P. 0A-3 General Information: Genuine Parts Description Z9J0110101012 Fuel and Oil Recommendations Z9J0110101015 If parts replacement is necessary, Suzuki strongly recommends that you use genuine Suzuki parts or their equivalent. They are precision-made to ensure high quality and correct fit. Gasoline Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R+M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used. Outboard Motor Identification Number Location Allowable maximum blend of a single additive (not combination) 5% Methanol, 10% Ethanol, 15% MTBE Z9J0110101013 Model, Pre-fix, Serial number The Model, Pre-fix and Serial number of motor are stamped on a plate attached to the clamp bracket. CAUTION If leaded gasoline is used, engine damage may result. Use only unleaded gasoline. 1 I9J011010005-01 1. Identification number plate Example API Classification DF 90 09002F TEMP. 2 SAE Viscosity Grade SG SH SJ SL SM 1 3 I9J011010002-03 1. Model Engine oil Oil quality is a major contributor to your engine’s performance and life. Always select good quality engine oil. Suzuki recommends the use of a SAE 10 W – 40 NMMA certified oil. If NMMA certified FC-W oil is not available, select a good quality 4-cycle motor oil from the following chart according to the average temperatures in your area. 3. Serial number 10W–40 10W–30 C –20 –10 0 10 20 30 F –4 14 32 50 68 86 40 104 I9J011010003-02 Gear oil Suzuki recommends the use of SUZUKI Outboard Motor Gear Oil. If it is not available, use SAE 90 hypoid gear oil which is rated GL-5 under the API classification system. 2. Pre-fix Engine Serial Number Location A second engine serial number plate is pressed into a boss on the cylinder block. 1 I9J011010012-02 1. Serial number plate http://SelfFixer.com XXXXXX General Information: Break-In Procedures Z9J0110101016 The first 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long-term durability. Break-in period 10 hours Warm-up recommendation Allow sufficient idling time (more than 5 minutes) for the engine to warm up after cold engine starting. Throttle recommendation NOTE Avoid maintaining a constant engine speed for an extended period at any time during the engine break-in period by varying the throttle position occasionally. First 2 hours For the first 15 minutes, operate the engine in-gear at idling speed. During the remaining 1 hour and 45 minutes, operate the engine in-gear at less than 1/2 (half) throttle (3 000 r/min). NOTE The throttle may be briefly opened beyond the recommended setting to plane the boat, but must be reduced to the recommended setting immediately after planning. Next 1 hour Operate the engine in-gear at less than 3/4 (three quarter) throttle (4 000 r/min). Propeller Selection Guide 0A-4 Z9J0110101017 An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF70 / 80 / 90 models are shown below. Recommended full throttle speed range DF70 5 000 – 6 000 r/min DF80 5 000 – 6 000 r/min DF90 5 500 – 6 300 r/min CAUTION Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor. If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified above. Propeller size chart Blade x Dia. (in.) x Pitch (in.) 3 x 14 x 13 3 x 13 and 7/8 x 15 3 x 13 and 3/4 x 17 3 x 13 and 3/4 x 19 3 x 13 and 3/4 x 21 3 x 13 and 3/4 x 23 3 x 13 and 1/2 x 15 3 x 14 x 17 3 x 14 x 19 3 x 14 x 21 3 x 14 x 23 http://SelfFixer.com Last 7 hours Operate the engine in-gear at a desired engine speed. However, do not operate continuously at full throttle for more than 5 minutes. 0A-5 General Information: Battery Requirement Z9J0110101018 Suzuki recommends a 12 volt cranking type lead acid battery for the DF70A / 80A / 90A. Minimum battery requirement for starting the engine is provided below. The battery must satisfy one of the specifications described below. NOTE The specifications listed below are the minimum battery rating requirements for starting the engine. Additional electrical loads from the boat will require larger capacity batteries. Dual-purpose (Cranking / Deep Cycle) batteries can be used if they meet the minimum specifications listed below (MCA, CCA, or RC). Do not use a Deep Cycle battery for the main cranking battery. The use of Maintenance-Free, sealed, or Gel-Cell batteries is not recommended because they may not be compatible with Suzuki’s charging system. When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of similar age. When replacement is necessary, they should be replaced as a set. It is recommended that the battery be installed in an enclosed case. When connecting batteries, hexagon nuts must be used to secure battery leads to battery terminals. Powerhead Direction of Rotation Description Z9J0110101019 This outboard motor is designed with a L.H. (left hand) rotation powerhead utilizing an offset crankshaft. This design has the advantage of reducing the size of the motor and keeping the overall motor’s weight closer to the boat transom and therefore closer to the boat C/G (Center of Gravity). Rotation of the driveshaft is accomplished through a crankshaft drive gear and a driveshaft driven gear. These gears are located beneath the powerhead in the same oil bath location as the camshaft chain. As the rotational direction of the driven gear will be opposite of the drive gear, a left hand rotation powerhead design was adopted to retain a conventional, standard rotation (right hand) propeller shaft output. http://SelfFixer.com Battery Specification 650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold Cranking Amps (CCA)/SAE or 160 Reserve Capacity (RC) Minutes/SAE or 12 V 100 AH General Information: 0A-6 Specifications Specifications Z9J0110107001 NOTE These specifications are subject to change without notice. Model Pre-fix Item Unit DF70AT 07002F PRE-FIX Data DF80AT 08001F DF90AT 09002F Dimensions and Weight Item Unit Overall length (front to back) Overall width (side to side) Overall height Weight (without engine oil) Transom height L X L X L X DF70AT mm (in.) mm (in.) mm (in.) mm (in.) kg (lbs) kg (lbs) mm (in. type) mm (in. type) Data DF80AT 724 (28.5) 459 (18.1) 1 480 (58.2) 1 607 (63.3) 155 (341) 158 (348) 510 (20) 637 (25) DF90AT Performance Item Maximum output Recommended operating range Idle speed kW (PS) DF70AT 51.5 (70) Data DF80AT 58.8 (80) DF90AT 66.2 (90) r/min 5 000 – 6 000 5 000 – 6 000 5 500 – 6 300 Unit 600 ± 50 (in-gear: Approx. 600) r/min Powerhead Item Engine type Number of cylinders Bore Stroke Total displacement Compression ratio Spark plug Ignition system Fuel supply system Exhaust system Cooling system Lubrication system Starting system Throttle control Unit mm (in.) mm (in.) cm3 (cu. in) :1 NGK Data DF80AT DF90AT 4-stroke DOHC 4 75 (2.95) 85 (3.35) 1 502 (91.6) 9.5 DCPR6E Full-transistorized ignition Multi-point sequential electronic fuel injection Through prop exhaust Water cooled Wet sump by trochoid pump Electric Remote control DF70AT Item Fuel Unit Data 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 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used. http://SelfFixer.com Fuel and Oil 0A-7 General Information: Item Engine oil Engine oil amounts Gear oil Gearcase oil capacity Data DF70AT DF80AT DF90AT API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40 4.0 (4.2 / 3.5): Oil change only 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 classification GL-5. ml (US/lmp. oz) 850 (28.7/30.0) Unit Bracket Item Trim angle Number of trim position Maximum tilt angle Unit DF70AT degree degree Data DF80AT 0 – 20 (–6 to 14) PTT system 75 (–6 to 69) DF90AT Lower unit Item Unit DF70AT Reversing system Transmission Reduction system Gear ratio Drive line impact protection Propeller shaft rotation (when shift into forward) Data DF80AT Gear Forward-Neutral-Reverse Bevel gear 12 : 25 (2.08) Spline drive rubber hub DF90AT Clockwise Blade x Dia. (in.) x Pitch (in.) 3 x 14 x 13 3 x 13 and 7/8 x 15 3 x 13 and 3/4 x 17 3 x 13 and 3/4 x 19 3 x 13 and 3/4 x 21 3 x 13 and 3/4 x 23 3 x 13 and 1/2 x 15 3 x 14 x 17 3 x 14 x 19 3 x 14 x 21 3 x 14 x 23 Propeller Reduction system Unit 1st reduction gear ratio (Crankshaft drive gear: Driven gear) 2nd reduction gear ratio (Lower unit gear) Total reduction gear ratio DF70AT Data DF80AT DF90AT 29 : 36 (1.24) 12 : 25 (2.08) 2.59 (36/29 x 25/12) http://SelfFixer.com Item General Information: Service Data 0A-8 Z9J0110107002 NOTE These service data are subject to change without notice. Powerhead Item Unit Recommended operating range Idle speed **Cylinder compression pressure **Cylinder compression pressure max. difference between cylinders r/min r/min kPa (kgf/cm2, psi.) kPa (kgf/cm2, psi.) kPa (kgf/cm2, psi.) Data DF70AT DF80AT DF90AT 5 000 – 6 000 5 000 – 6 000 5 500 – 6 300 600 ± 50 (in-gear: Approx. 600) 1 200 – 1 800 (12 – 18, 171 – 256) 100 (1.0, 14) 400 – 600 (4.0 – 6.0, 57 – 85) at 3 000 r/min (at normal operating temp.) API classification: SG, SH, SJ, SL, SM or NMMA FC-W classification: SG, SH, SJ, SL, SM Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40 4.0 (4.2 / 3.5): Oil change only L (US/lpm. qt) 4.3 (4.5 / 3.8): Oil filter change °C (°F) 58 – 62 (136 – 144) **Engine oil pressure Engine oil Engine oil amounts Thermostat operating temperature **Figures shown are guidelines only, not absolute service limits. Cylinder Head / Camshaft Limit Limit mm (in.) mm (in.) std. mm (in.) Limit mm (in.) std. mm (in.) Limit Top, std. 2nd, 3rd, Limit 4th, 5th Top, std. 2nd, 3rd, Limit 4th std. 5th Limit Top, std. 2nd, 3rd, Limit 4th std. 5th Limit Limit std. Limit std. std. mm (in.) mm (in.) Data DF80AT DF90AT 0.03 (0.001) 0.10 (0.004) 38.620 – 38.780 39.620 – 39.780 41.120 – 41.280 (1.5205 – 1.5268) (1.5598 – 1.5661) (1.6189 – 1.6252) 38.520 (1.5165) 39.520 (1.5559) 41.020 (1.6150) 40.920 – 41.080 (1.6110 – 1.6173) 40.820 (1.6071) 0.045 – 0.087 (0.0018 – 0.0034) mm (in.) 0.120 (0.0047) mm (in.) 23.000 – 23.021 (0.9055 – 0.9063) mm (in.) — mm (in.) mm (in.) mm (in.) 26.000 – 26.021 (1.0236 – 1.0244) — 22.934 – 22.955 (0.9029 – 0.9037) mm (in.) — mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 25.936 – 25.957 (1.0211 – 1.0291) — 0.10 (0.004) 0.025 – 0.062 (1.0010 – 1.0024) 0.150 (0.0059) 27.959 – 27.975 (1.1007 – 1.1014) 28.000 – 28.021 (1.1024 – 1.1032) Unit Cylinder head distortion Manifold seating faces distortion IN Cam height EX Camshaft journal oil clearance Camshaft journal (housing) inside diameter Camshaft journal outside diameter Camshaft runout Cylinder head bore to tappet clearance Tappet outer diameter Cylinder head tappet bore DF70AT http://SelfFixer.com Item 0A-9 General Information: Valve / Valve Guide std. Limit std. Limit mm (in.) mm (in.) mm (in.) mm (in.) — — mm (in.) mm (in.) mm (in.) mm (in.) Data DF80AT DF90AT 27.5 (1.08) 22.9 (0.90) 0.23 – 0.27 (0.009 – 0.011) 0.30 – 0.34 (0.012 – 0.013) 30°, 45°, 60° 15°, 45° 0.020 – 0.047 (0.0008 – 0.0019) 0.070 (0.0028) 0.045 – 0.072 (0.0018 – 0.0028) 0.090 (0.0035) std. mm (in.) 5.500 – 5.512 (0.2165 – 0.2170) std. mm (in.) 10.8 – 11.6 (0.43 – 0.46) std. std. Limit Limit mm (in.) mm (in.) mm (in.) mm (in.) 5.465 – 5.480 (0.2152 – 0.2157) 5.440 – 5.455 (0.2142 – 0.2148) 0.14 (0.006) 0.18 (0.007) Limit mm (in.) 0.05 (0.002) Limit mm (in.) 0.08 (0.003) std. Limit std. Limit std. std. std. Limit std. Limit Limit mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) N (kg, lbs) N (kg, lbs) mm (in.) 0.75 (0.03) 0.5 (0.02) 0.95 (0.04) 0.7 (0.03) 1.1 – 1.3 (0.04 – 0.05) 1.1 – 1.3 (0.04 – 0.05) 33.1 (1.30) 31.8 (1.25) 95 – 111 (9.6 – 11.2, 21.1 – 24.6) at 28.5 mm (1.12 in) 87 (8.8, 19.4) at 28.5 mm (1.12 in) 2.0 (0.08) Unit Valve diameter Tappet clearance (Cold engine condition) Valve seat angle Valve guide to valve stem clearance Valve guide inside diameter Valve guide protrusion Valve stem outside diameter Valve stem deflection Valve stem runout Valve head radial runout IN EX IN EX IN EX IN, EX IN, EX IN EX IN EX IN, EX IN, EX IN Valve head thickness EX Valve seat contact width Valve spring free length Valve spring preload Valve spring squareness IN EX IN EX std. std. DF70AT http://SelfFixer.com Item General Information: 0A-10 Cylinder / Piston / Piston Ring Unit Cylinder distortion Limit std. Limit std. Piston to cylinder clearance Cylinder bore Cylinder measuring position Piston skirt diameter Piston measuring position Cylinder bore wear std. 1st Piston ring end gap 2nd 1st Piston ring free end gap 2nd Piston ring to groove clearance Piston ring groove width Piston ring thickness 1st 2nd 1st 2nd Oil 1st 2nd Pin clearance in piston pin hole Piston pin outside diameter Piston pin hole diameter Pin clearance in conrod small end Conrod small end bore Limit std. Limit std. Limit std. Limit std. Limit std. Limit std. Limit std. std. std. std. std. std. Limit std. Limit std. Limit std. Limit std. mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) Data DF80AT DF90AT 0.03 (0.001) 0.020 – 0.040 (0.0008 – 0.0016) 0.100 (0.0039) 75.000 – 75.020 (2.9598 – 2.9535) 50 (1.969) from cylinder top surface 74.970 – 74.990 (2.9516 – 2.9524) 13 (0.512) from piston skirt end 0.10 (0.039) 0.15 – 0.30 (0.0059 – 0.0118) 0.70 (0.028) 0.30 – 0.45 (0.0118 – 0.0177) 1.00 (0.039) Approx 9.9 (0.3898) 7.9 (0.3110) Approx 9.7 (0.3819) 7.8 (0.3070) 0.030 – 0.070 (0.0012 – 0.0028) 0.12 (0.005) 0.020 – 0.060 (0.0008 – 0.0024) 0.10 (0.004) 1.02 – 1.04 (0.040 – 0.041) 1.21 – 1.23 (0.048 – 0.048) 2.01 – 2.03 (0.079 – 0.080) 0.97 – 0.99 (0.038 – 0.039) 1.17 – 1.19 (0.046 – 0.047) 0.006 – 0.019 (0.0002 – 0.0007) 0.005 (0.0019) 17.995 – 18.000 (0.7085 – 0.7087) 17.980 (0.7079) 18.006 – 18.014 (0.7089 – 0.7092) 18.030 (0.7098) 0.003 – 0.016 (0.0001 – 0.0006) 0.050 (0.0020) 18.003 – 18.011 (0.7088 – 0.7091) DF70AT http://SelfFixer.com Item 0A-11 General Information: Crankshaft / Conrod std. std. Limit std. std. mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) Data DF70AT DF80AT DF90AT 18.003 – 18.011 (0.7088 – 0.7091) 0.032 – 0.050 (0.0013 – 0.0020) 0.080 (0.0031) 45.000 – 45.018 (1.7717 – 1.7724) 41.982 – 42.000 (1.6528 – 1.6535) Limit mm (in.) 0.010 (0.0004) std. std. Limit std. std. Limit std. Limit mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) 1.487 – 1.502 (0.0585 – 0.0591) 0.100 – 0.250 (0.0039 – 0.0098) 0.350 (0.0138) 21.950 – 22.000 (0.8642 – 0.8661) 22.100 – 22.200 (0.8071 – 0.8740) 0.04 (0.002) 0.016 – 0.032 (0.0006 – 0.0014) 0.056 (0.0022) mm (in.) 56.000 – 56.018 (2.2047 – 2.2054) mm (in.) 51.994 – 52.012 (2.0470 – 2.0477) mm (in.) 0.010 (0.0004) mm (in.) mm (in.) mm (in.) mm (in.) 1.992 – 2.008 (0.0784 – 0.0791) 0.11 – 0.31 (0.004 – 0.012) 0.35 (0.014) 2.47 – 2.52 (0.0972 – 0.0992) Item Unit Conrod small end inside diameter Conrod big end oil clearance Conrod big end inside diameter Crank pin outside diameter Crank pin outside diameter difference (out-of-round and taper) Conrod bearing thickness Conrod big end side clearance Conrod big end width Crank pin width Crankshaft center journal runout Crankshaft journal oil clearance Crankcase bearing holder inside std. diameter Crankshaft journal outside diameter std. Crankshaft journal outside diameter Limit difference (out-of-round and taper) Crankshaft bearing thickness std. std. Crankshaft thrust play Limit Crankshaft thrust bearing thickness std. Electrical Unit Ignition timing Over revolution limiter CKP sensor resistance CMP sensor resistance Ignition coil resistance Primary Secondary Battery charge coil resistance Battery charge coil output (12 V) Standard spark plug Type Gap Fuse amp. rating Recommended battery capacity (12 V) Fuel injector resistance IAC valve resistance IAT sensor / Cylinder temp. sensor / Ex. mani. temp. sensor (Thermistor characteristic) ECM main relay coil resistance Starter motor relay coil resistance PTT motor relay coil resistance Degrees at r/ min r/min Ω at 20 °C Ω at 20 °C Ω at 20 °C kΩ at 20 °C Ω at 20 °C Watt NGK mm (in.) Data DF80AT DF70AT BTDC 0 – 26 DF90AT BTDC 0 – 27 Ah (kC) Ω at 20 °C Ω at 20 °C 6 400 168 – 252 — — — 0.10 – 0.30 324 DCPR6E 0.8 – 0.9 (0.031 – 0.035) Main fuse: 40 Starter motor: 30 Ignition coil, Injector, ECM, Fuel pump: 30 PTT switch: 10 IAC: 10 100 (360) or larger 10 – 14 25 – 34 kΩ at 25 °C 1.8 – 2.3 Ω at 20 °C Ω at 20 °C Ω at 20 °C 145 – 190 145 – 190 25 – 37 A 6 200 http://SelfFixer.com Item General Information: 0A-12 Starter Motor Item Unit Max. continuous time of use Motor output Brush length Commutator undercut Commutator outside diameter std. Limit std. Limit std. Limit Data DF80AT 30 1.4 16.0 (0.63) 12.0 (0.47) 0.5 – 0.8 (0.02 – 0.03) 0.2 (0.01) 29.0 (1.14) 28.0 (1.10) DF70AT Sec. kW mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) mm (in.) DF90AT PTT Motor Item Brush length Commutator outside diameter Unit std. Limit std. Limit Data DF80AT 9.8 (0.39) 5.5 (0.22) 22.0 (0.87) 21.0 (0.83) DF70AT mm (in.) mm (in.) mm (in.) mm (in.) DF90AT Self-Diagnostic Code 0: OFF, 1: ON Failed item Code Lamp flashing pattern Fail-safe system activating 1 MAP sensor 1 3–4 YES 0 MCODE00D34-0-01 1 Cylinder temp. sensor 1–4 YES 0 MCODE00D14-0-01 1 IAT sensor 2–3 YES 0 MCODE00D23-0-01 1 CKP sensor 4–2 NO 0 MCODE00D42-0-01 1 CMP sensor 2–4 NO 0 MCODE00D24-0-01 1 Air intake system 2–2 YES 0 MCODE00D22-0-01 1 MAP sensor 2 3–2 NO 0 MCODE00D32-0-01 1 Exhaust manifold temp. sensor 1–5 YES 0 MCODE00D15-0-01 1 Fuel injector 4–3 NO 0 MCODE00D43-0-01 1 Throttle position sensor 2–1 YES 0 MCODE00D21-0-01 1 Shift position sensor 1–2 YES 0 1 Neutral switch 3–3 NO 0 MCODE00D33-0-01 http://SelfFixer.com MCODE00D12-0-01 0A-13 General Information: Failed item Code Lamp flashing pattern Fail-safe system activating 1 Trim sensor 3–7 NO 0 MCODE00D37-0-01 1 Oil pressure switch 5–3 NO 0 MCODE00D53-0-01 1 Rectifier/Regulator (Over-charging) 1–1 NO 0 MCODE00D11-0-01 Tightening Torque Specifications Z9J0110107003 Item Cylinder head cover bolt Cylinder head bolt Crankcase bolt Conrod cap bolt Camshaft housing bolt Oil pump bolt IN. camshaft timing sprocket EX. camshaft timing sprocket Chain tensioner adjuster bolt Timing chain guide bolt Intake manifold bolt / nut Oil pressure switch Fuel delivery pipe bolt Fuel delivery pipe plug / union bolt Low pressure fuel pump bolt Thermostat cover bolt Flywheel bolt Starter motor mounting bolt Engine oil filter Engine oil drain plug Outside Inside Upper Lower Power unit mounting bolt Driveshaft housing bolt Upper mount nut Upper mount cover bolt Lower mount bolt Clamp bracket shaft nut Water pump case bolt Driveshaft oil seal housing Gearcase bolt Propeller shaft bearing housing bolt Pinion gear nut Propeller nut Thread Diameter 6 mm 8 mm 10 mm 8 mm 10 mm 9 mm 6 mm 6 mm — 6 mm 6 mm 8 mm 8 mm — 8 mm 14 mm 14 mm 6 mm 6 mm 16 mm 8 mm — 12 mm 8 mm 10 mm 10 mm 12 mm 10 mm 12 mm 7/8-14 UNF 8 mm 8 mm 10 mm 8 mm 14 mm 18 mm N⋅m 11 23 70 25 52 47 11 15 78 11 11 23 23 13 23 35 35 10 10 196 23 14 13 23 50 50 80 50 60 43 17 23 55 23 120 55 Tightening Torque kgf-m 1.1 2.3 7.0 2.5 5.2 4.7 1.1 1.5 7.8 1.1 1.1 2.3 2.3 1.3 2.3 3.5 3.5 1.0 1.0 19.7 2.3 1.4 1.3 2.3 5.0 5.0 8.0 5.0 6.0 4.3 1.7 2.3 5.5 2.3 12.0 5.5 lbf-ft 8.0 16.6 51.0 18.0 37.5 40.0 8.0 11.0 56.0 8.0 8.0 16.6 16.5 9.5 16.5 25.5 25.5 7.0 7.0 142.0 16.6 10.0 9.5 16.5 36.0 36.0 57.8 36.0 43.4 31.0 12.3 16.5 40.0 16.6 86.8 40.0 http://SelfFixer.com Important Fasteners General Information: 0A-14 General Bolt NOTE These value are only applicable when torque for a general bolt is not listed in the “Important Fasteners” table. Type of Bolt I9J011010014-01 (Conventional or “4” marked bolt) I9J011010015-01 (Stainless steel bolt) I9J011010016-01 (“7” marked bolt) Thread Diameter 5 mm 6 mm 8 mm N⋅m 2–4 4–7 10 – 16 Tightening Torque kgf-m 0.2 – 0.4 0.4 – 0.7 1.0 – 1.6 lbf-ft 1.5 – 3.0 3.5 – 5.0 7.0 – 11.5 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5 5 mm 6 mm 8 mm 2–4 6 – 10 15 – 20 0.2 – 0.4 0.6 – 1.0 1.5 – 2.0 1.5 – 3.0 4.5 – 7.0 11.0 – 14.5 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5 5 mm 6 mm 8 mm 3–6 8 – 12 18 – 28 0.3 – 0.6 0.8 – 1.2 1.8 – 2.8 2.0 – 4.5 6.0 – 8.5 13.0 – 20.0 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5 Special Tools and Equipment Recommended Service Material 99000–22540 SUZUKI Outboard Motor Gear Oil Z9J0110108001 99000–25161 99000–31120 99000–31140 99000–32020 SUZUKI Water SUZUKI Silicone Seal SUZUKI Bond 1207B SUZUKI Thread Lock Resistant Grease (250 (50 g) (100 g) 1333B (50 g) g) http://SelfFixer.com 99000–32050 99000–25140 SUZUKI Thread Lock SUZUKI Moly Paste 1342 (50 g) (50g) 0A-15 General Information: Special Tool 09900–20101 Vernier calipers (150 mm) 09900–20605 09900–20606 Dial calipers (10 – 34 Dial gauge mm) 09900–20202 Micrometer (25 – 50 mm) 09900–20203 Micrometer (50 – 75 mm) 09900–20205 Micrometer (0 – 25 mm) 09900–20701 Magnetic stand 09900–20803 Thickness gauge 09900–21304 Steel “V” block set 09900–22301 Plastigauge (0.025 – 0.076 mm) 09900–28403 Hydrometer 09911–49910 Crankshaft holder 09912–58432 Fuel pressure hose 09912–58442 Fuel pressure gauge 09912–58490 3-way joint & hose 09913–50121 Oil seal remover 09915–47341 Oil filter wrench 09915–64512 Compression gauge 09915–69910 Compression gauge attachment 09915–77311 Oil pressure gauge 09915–78211 Oil pressure gauge adapter 09916–10911 Valve lapper 09916–14521 09916–19030 Valve lifter attachment Valve lifter http://SelfFixer.com 01500–08403 Bolt Z9J0110108002 General Information: 0A-16 09916–34542 Valve guide reamer handle 09916–34550 09916–37320 09916–44310 Valve guide reamer (φ Valve guide reamer (φ Valve guide remover 5.5 mm) 10.5 mm) 09916–68710 Tappet holder 09916–77310 Piston ring compressor 09917–87010 Valve guide installer attachment 09917–98221 09919–16010 Valve guide stem seal Deep socket wrench (10 mm) installer attachment 09921–28710 Driveshaft holder 09922–89810 Shift lock pin remover 09923–73210 Bearing remover 09930–25002 Pocket tester 09930–30104 Sliding hammer 09930–30161 Propeller shaft remover 09930–39411 Flywheel remover 09930–39420 Flywheel remover bolts 09930–48720 Flywheel holder 09930–76420 Timing light 09930–88730 36-pin test cord set 09930–89220 3-pin connector test cord 09917–47011 09917–49610 Vacuum pump gauge Vacuum pump adapter http://SelfFixer.com 09916–84511 Tweezers 09916–58210 Valve guide installer handle 0A-17 General Information: 09930–89260 Injector test cord (A) 09930–99320 Digital tester 09940–44121 Air pressure gauge 09940–44130 Attachment 09941–64511 Bearing remover 09945–69010 PTT rod holder 09945–79310 PTT cable extension 09950–69512 09951–09530 09951–18730 Gearcase oil leakage Gear adjusting gauge Attachment tester 09951–38710 Plate 09951–59910 Shaft (removal and installation) 09952–99310 Hand air pump 99954–53873* 99954–53008–820* Stevens peak reading Digital voltmeter voltmeter CD-77 99954–53883* Gear oil filler NOTE http://SelfFixer.com * Marked part No. is in U.S. market only. 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. NOTE More frequent servicing should be performed on outboard motors that are used under severe conditions. General Description Recommended Oil and Lubricants Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-3). Z9J0110201001 Scheduled Maintenance Periodic Maintenance Schedule Chart Z9J0110205001 NOTE I = Inspect and clean, adjust, lubricate or replace, if necessary T = Tighten R = Replace Spark plug Breather hose and fuel line Engine oil Gear oil Lubrication Anodes and bonding wires Battery Engine oil filter Low pressure fuel filter High pressure fuel filter Ignition timing Idle speed Tappet clearance Water pump Water pump impeller Propeller nut and pin Bolt and Nuts Interval Initial 20 hrs. Every 50 hrs. Every 100 hrs. Every 200 hrs. or 1 month or 3 months or 6 months or 12 months — — I R I I I I Replace every 2 years. R — R R R — R R — I I I — I I I — I I I R — — R — I I I Replace every 400 hours or 2 years. Replace every 1000 hours. — — — I I — — I — — — I — — — I — — — R I — I I T — T T http://SelfFixer.com Item to serviced 0B-2 Maintenance and Tune-Up: Lubrication Point Z9J0110205002 Proper lubrication is important for the safe, smooth operation and long life of each working part of the outboard motor. Apply Suzuki Water Resistant Grease to the following point. Lubricate Every 50 hours (3 months) : Grease 99000–25161 (SUZUKI Water Resistant Grease (250 g)) 1 1 1 5 2 2 2 3 4 I9J011020034-04 3. Grease nipple, swivel bracket 2. Grease nipple, swivel bracket 4. Propeller shaft 5. Grease nipple, shift lever http://SelfFixer.com 1. Throttle and shift linkage 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 Z9J0110206008 1 Change engine oil Initially after 20 hours (1 month) and every 100 hours (6 months) I9J011020002-02 4) Reinsert dipstick fully into dipstick tube, then remove it to check oil level. 5) Oil level should be between full level Max. mark (hole) and low level Min. mark (hole). If level is low, add recommended oil to full level Max. mark. Recommended Engine Oil 4 stroke motor oil NMMA FC-W classification: SG, SH, SJ, SL, SM. or API classification: SG, SH, SJ, SL, SM. Viscosity rating: NMMA FC-W 10W-40 or SAE 10W-40 Replace Engine oil filter Initially after 20 hours (1 month) and every 200 hours (12 months) NOTE Engine oil should be changed while engine is warm. When replacing engine oil filter, change engine oil at the same time. Engine Oil Change 1) Place outboard motor upright on a level surface. 2) Remove oil filler cap (1). 1 I9J011020037-01 “A” “B” I9J011020035-01 “B”: Min. mark (hole) http://SelfFixer.com “A”: Max. mark (hole) 0B-4 Maintenance and Tune-Up: 3) Place a container under engine oil drain plug. 4) Remove engine oil drain plug (2) and gasket (3) to drain engine oil. 2 6) Pour the recommended engine oil into oil filler opening, then install oil filler cap. Recommended Engine Oil 4 stroke motor oil NMMA FC-W classification: SG, SH, SJ, SL, SM. or API classification: SG, SH, SJ, SL, SM. Viscosity rating: NMMA FC-W 10W-40 or SAE 10W-40 Engine oil amounts Oil change only: 4.0 L (4.2/3.5 US/Imp.qt) Oil filter change: 4.3 L (4.5/3.8 US/Imp.qt) 3 I9J011020038-01 5) Install new gasket and oil drain plug. Tighten engine oil drain plug to specified torque. CAUTION To avoid water entry into oil pan or oil leakage into the environment do not reuse gasket once removed. Always use a new gasket. I9J011020039-01 Tightening torque Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.5 lbf-ft) 7) To reset oil change reminder system’s operation time to zero (cancellation). NOTE Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14). I9J011020042-01 a) Turn ignition key to “ON” position. b) Pull out emergency stop switch plate (4). c) Pull up emergency stop switch knob (5) three times in ten seconds. A short beep will be heard if cancellation is successfully finished. d) Turn ignition key to “OFF” position, then set emergency stop switch plate (4) in original position. 4 5 I9J011020003-01 8) Start engine and allow it to run for several minutes at idle speed. Check oil drain plug for oil leakage. Turn off engine and wait for approx. two minutes, then recheck engine oil level. http://SelfFixer.com (a) Maintenance and Tune-Up: Engine Oil Filter Replacement 1) Drain engine oil in the same manner of engine oil change procedure. 2) Remove STBD and PORT side covers. Refer to “Lower Side Cover Removal and Installation” in Section 2A (Page 2A-3). 3) Place a shop cloth under the oil filter before removal to absorb any oil released. 4) Using an oil filter wrench to loosen the oil filter, then remove the filter and O-ring. Special tool (A): 09915–47341 (Oil filter wrench) 0B-5 6) Tighten the filter 3/4 turn from the point of contact with mounting surface using an oil filter wrench. Tightening torque Engine oil filter (a): 14 N·m (1.4 kgf-m, 10.0 lbf-ft) (a) I9J011020044-01 7) Install PORT and STBD side covers. Refer to “Lower Side Cover Removal and Installation” in Section 2A (Page 2A-3). 8) Pour the recommended engine oil into the oil filler opening, then install oil filler cap. Check the oil level in the same manner of engine oil change procedure. (A) I9J011020043-01 NOTE Before fitting a new oil filter, be sure to oil the O-ring. Recommended Engine Oil 4 stroke motor oil NMMA FC-W classification: SG, SH, SJ, SL, SM. or API classification: SG, SH, SJ, SL, SM. Viscosity rating: NMMA FC-W 10W-40 or SAE 10W-40 Engine oil amounts Oil change only: 4.0 L (4.2/3.5 US/Imp.qt) Oil filter change: 4.3 L (4.5/3.8 US/Imp.qt) http://SelfFixer.com I9J011020004-01 5) Screw the new filter on by hand until filter O-ring contacts the mounting surface. 9) Reset oil change reminder system’s operation time to zero (cancellation). Refer to “Engine Oil Change” (Page 0B-3). 10) Start engine and allow it to run for several minutes at idle speed. Check oil filter for oil leakage. Turn off engine and wait for approx. two minutes, then recheck engine oil level. 0B-6 Maintenance and Tune-Up: Gear Oil Change Z9J0110206040 Change gear oil Initially after 20 hours (1 month) and every 100 hours (6 months) 1) Place outboard motor upright on a level surface. 2) Place a container under the lower unit. 3) Remove lower gear oil drain plug (1) first, then remove gear oil level plug (2) and drain gear oil. Spark Plug Removal and Installation Z9J0110206004 Inspect spark plug Every 100 hours (6 months) Replace spark plug Every 200 hours (12 months) Standard spark plug NGK DCPR6E CAUTION Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition and fuel injection system malfunctions. 2 Removal 1 ! I9J011020040-01 4) Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole. Recommended Gear Oil Suzuki Outboard Motor Gear Oil or API classification GL5, Viscosity rating SAE # 90 Hypoid gear oil. Gear oil amount 850 ml (28.7/30.0 US/Imp. oz) WARNING The hot engine can burn you. Wait until the engine is cool enough to touch. 1) Disconnect wiring harness connector from ignition coil (1), then remove the bolt (2) securing the ignition coil. 2 1 I9J011020041-01 5) Install oil level plug before removing oil filler tube from drain hole. 6) Install oil drain plug. I9J011020045-01 2) Remove the ignition coil and spark plug. CAUTION Do not reuse gaskets once removed. Always use a new gasket. NOTE I9J011020046-01 http://SelfFixer.com To avoid a possible low gear oil level, recheck gear oil level 10 minutes after doing procedure in step 6. If oil level is low, add additional gear oil until level is correct. Maintenance and Tune-Up: 0B-7 Installation Installation is reverse order of removal. Pay attention to the following: Tighten the spark plug to specified torque. Tightening torque Spark plug (a): 18 N·m (1.8 kgf-m, 13 lbf-ft) (A) I9J011020006-01 Spark Plug Gap Measure spark plug gap with a thickness gauge. Adjust to within specified range if gap is out of specification. Special tool : 09900–20803 (Thickness gauge) (a) Spark plug gap “a” (Standard) 0.8 – 0.9 mm (0.031 – 0.035 in.) I9J011020047-01 Spark Plug Inspection and Cleaning Z9J0110206005 CAUTION Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition and fuel injection system malfunctions. “a” Inspect spark plug Every 100 hours (6 months) I9J011020007-01 Condition of Electrodes Inspect electrode for a worn or burnt condition. If it is extremely worn or burnt, replace spark plug. Also, be sure to replace spark plug if it has a broken insulator, damaged thread, etc. Replace spark plug Every 200 hours (12 months) Standard spark plug NGK DCPR6E Carbon Deposits Inspect for carbon deposits on spark plug base. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool. CAUTION Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage. http://SelfFixer.com I9J011020005-01 0B-8 Maintenance and Tune-Up: Tappet Clearance Inspection and Adjustment Z9J0110206041 Inspect tappet clearance Every 200 hours (12 months) Inspection The tappet clearance specification is different for intake and exhaust valves. Too small a tappet clearance may reduce engine power, too large a tappet clearance increases valve noise and hastens valve and seat wear. When the tappets are set to the specified clearance, the engine will run without excessive noise from the valve mechanism and will deliver full power. In this engine, the tappet clearance is increased or decreased by replacing the shim disc, made of a special wear resistant material, fitted to the top of the tappet. Using the proper tools provides for easy removal and installation of the shim disc. Tappet clearance adjustment should be checked and adjusted: During scheduled periodic inspection. When valve mechanism is serviced. When camshafts are disturbed by removing them for inspection. 1) Remove following parts: Engine lower side cover. Refer to “Lower Side Cover Removal and Installation” in Section 2A (Page 2A-3). Ring gear cover. Refer to “Ring Gear Cover Removal and Installation” in Section 1D (Page 1D-2). Ignition coils and spark plugs. Refer to “Spark Plug Removal and Installation” (Page 0B-6) and “Spark Plug Inspection and Cleaning” (Page 0B-7). 2) Remove the cylinder head cover (1). Refer to “Cylinder Head Cover Removal and Installation” in Section 1D (Page 1D-2). 3) Rotate crankshaft counterclockwise to bring cam nose vertical to shim surface. 4) Measure tappet clearances by inserting thickness gauge between cam and shim surface. CAUTION This is a left hand (LH) rotation powerhead. Rotate crankshaft counterclockwise to prevent water pump impeller damage. NOTE Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface. All tappet clearances can be measured during two crankshaft rotations. Special tool (A): 09900–20803 (Thickness gauge) Tappet clearance (cold engine condition) IN.: 0.23 – 0.27 mm (0.009 – 0.011 in.) EX.: 0.30 – 0.34 mm (0.012 – 0.013 in.) “a” (A) I9J011020008-01 “a”: 90° 5) If out of specification, adjust tappet clearance by changing shim. 1 http://SelfFixer.com I9J011020048-01 Maintenance and Tune-Up: Adjustment Tappet clearances are adjusted by replacing tappet shim. 1) With cam nose vertical to valve, turn tappet cut-away towards center of cylinder head as shown in figure. 0B-9 4) Rotate top of cam 90 degree counterclockwise and remove shim from cut- away at tappet. (Two tappets can be adjusted at the same time) 3 1 “B” 1 I9J011020011-01 “A” I9J011020009-01 1. Shim 3. Magnet 1. Shim “A”: Cut section of the tappet “B”: Spark plug hole CAUTION 2) Rotate crankshaft to open (lift up) valve and then remove camshaft housing bolts where shim is to be replaced. 3) Install special tool with camshaft housing bolts as shown in figure. Special tool (A): 09916–68710 (Tappet holder) Do not put your finger between camshaft and tappet while the tappet is being held with the tappet holder. Use a magnet to remove and install shim. When installing shim, identification mark on the shim should face down (towards tappet). 5) After removing shim, measure thickness of original shim and determine correct thickness of shim for proper tappet clearance as calculated by following formula. 2 Special tool (B): 09900–20205 (Micrometer (0 – 25 mm)) “B” (A) I9J011020010-01 2. Camshaft housing bolt “B”: Spark plug hole (B) I9J011020012-01 http://SelfFixer.com Tappet clearance specifications IN. side: A = B + (C – 0.25 mm) EX. side: A = B + (C – 0.32 mm) A: Correct thickness of shim for proper tappet clearance (mm) B: Thickness of original shim (mm) C: Original tappet clearance (mm) 0B-10 Maintenance and Tune-Up: NOTE “C” After completing tappet clearance adjustment and securing camshaft housing bolts, inspect tappet clearance again. 250 “a” I9J011020013-01 “C”: I.D No. “a”: 2.50 mm Shim size chart Thickness I.D. No. (mm) 208 2.080 210 2.100 212 2.120 214 2.140 216 2.160 218 2.180 220 2.200 222 2.220 224 2.240 226 2.260 228 2.280 230 2.300 232 2.320 234 2.340 236 2.360 238 2.380 240 2.400 242 2.420 244 2.440 246 2.460 248 2.480 Thickness (mm) 2.500 2.520 2.540 2.560 2.580 2.600 2.620 2.640 2.660 2.680 2.700 2.720 2.740 2.760 2.780 2.800 2.820 2.840 2.860 2.880 2.900 I.D. No. 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 6) Install shim with the identification number facing down (towards tappet). 7) Rotate crankshaft to open (lift up) valve. 8) Remove tappet holder (A) and tighten camshaft housing bolts (a) to specified torque. I9J011020015-02 10) After checking and adjusting all valves, reinstall parts removed earlier. Installation is reverse order of removal. a) Cylinder Head Cover Installation. Install the cylinder head cover. Refer to “Cylinder Head Cover Removal and Installation” in Section 1D (Page 1D-2). NOTE Examine cylinder head cover gasket for damage. Always replace gasket if sealing performance is suspect. Tightening torque Cylinder head cover bolts (b): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) (b) Tightening torque Camshaft housing bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) I9J011020049-01 b) Final assembly check All parts removed have been returned to their original positions. Check hose and wire routing. Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3). Check oil leakage. 4 (A) (a) I9J011020014-01 4. Tappet 5. Camshaft 9) Recheck tappet clearance. http://SelfFixer.com 5 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 290 268 293 270 272 274 276 278 280 282 284 286 0.10 – 0.14 0.15 – 0.19 0.20 – 0.22 I9J011020016-06 http://SelfFixer.com 0.88 – 0.92 272 274 276 278 280 282 284 286 288 290 0.83 – 0.87 268 270 272 274 276 278 280 282 284 286 288 290 0.78 – 0.82 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.73 – 0.77 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.68 – 0.72 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.63 – 0.67 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.58 – 0.62 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.53 – 0.57 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 [ EXAMPLE ] Tappet clearance is — 0.35 mm Present shim size — 2.40 mm Shim size to be used — 2.50 mm 1. Measure tappet clearance “Engine cold”. 2. Measure present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 0.48 – 0.52 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.43 – 0.47 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.38 – 0.42 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.33 – 0.37 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.28 – 0.32 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 Specified clearance / No adjustment required. 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 0.05 – 0.09 0.23 – 0.27 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32 2.34 2.36 2.38 2.40 2.42 2.44 2.46 2.48 2.50 2.52 2.54 2.56 2.58 2.60 2.62 2.64 2.66 2.68 2.70 2.72 2.74 2.76 2.78 2.80 2.82 2.84 2.86 2.88 2.90 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.00 – 0.04 clearance (mm) Tappet Present shim size (mm) Shim I.D. No. TAPPET SHIM SELECTION CHART [IN. side] Maintenance and Tune-Up: 0B-11 Tappet shim selection chart (IN. side) 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 0.10 – 0.14 0.15 – 0.19 0.20 – 0.24 0.25 – 0.29 I9J011020017-05 http://SelfFixer.com 0.90 – 0.94 268 270 272 274 276 278 280 282 284 286 288 290 0.85 – 0.89 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.80 – 0.84 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.75 – 0.79 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.70 – 0.74 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.65 – 0.69 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.60 – 0.64 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 [ EXAMPLE ] Tappet clearance is — 0.40 mm Present shim size — 2.40 mm Shim size to be used — 2.50 mm 1. Measure tappet clearance “Engine cold”. 2. Measure present shim size. 3. Match clearance in vertical column with present shim size in horizontal column. 0.55 – 0.59 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.50 – 0.54 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.45 – 0.49 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.40 – 0.44 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.35 – 0.39 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 Specified clearance / No adjustment required. 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 0.05 – 0.09 0.30 – 0.34 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 2.08 2.10 2.12 2.14 2.16 2.18 2.20 2.22 2.24 2.26 2.28 2.30 2.32 2.34 2.36 2.38 2.40 2.42 2.44 2.46 2.48 2.50 2.52 2.54 2.56 2.58 2.60 2.62 2.64 2.66 2.68 2.70 2.72 2.74 2.76 2.78 2.80 2.82 2.84 2.86 2.88 2.90 208 210 212 214 216 218 220 222 224 226 228 230 232 234 236 238 240 242 244 246 248 250 252 254 256 258 260 262 264 266 268 270 272 274 276 278 280 282 284 286 288 290 0.00 – 0.04 Tappet clearance (mm) Present shim size (mm) Shim ID No. TAPPET SHIM SELECTION CHART [EX. side] 0B-12 Maintenance and Tune-Up: Tappet shim selection chart (EX. side) Maintenance and Tune-Up: Idle Speed and Idle Air Control (IAC) Duty Inspection Z9J0110206030 Inspect idle speed and IAC Duty Initially after 20 hours (1 month) and every 200 hours (12 months) NOTE Before checking idle speed / IAC duty, make sure of the following. Engine must be warmed up. Check idle speed after engine speed has stabilized. Check throttle link mechanism and throttle valve for smooth operation. Lead wire and hoses of electronic fuel injection and engine control systems are connected securely. Ignition timing is within specification. Tappet clearance is checked according to maintenance schedule. No abnormal air drawn in from air intake system. After all items are confirmed, check idle speed and IAC duty. 0B-13 5) Shift into forward, Check in-gear idle speed. If not, check idle air control system. NOTE Trolling speed (in-gear idle speed) is same as idle speed. Idling / trolling speed of 550 – 650 r/min. is controlled by IAC system. Idle speed in gear (IAC duty) 550 – 650 r/min (Duty: Approx. 0 – 30%) Ignition Timing Inspection Z9J0110206042 Inspect ignition timing Every 200 hours (12 months) NOTE Before checking the ignition timing, make sure idle speed is adjusted within specification. 1) Start the engine and allow to warm up. 2) Attach the timing light cord to the No.1 ignition coil (1) primary wire. Special tool (A): 09930–76420 (Timing light) 1 (A) 1 2 I9J011020050-01 2. Throttle body Check idle speed and IAC duty as follows. To perform idle speed and IAC duty inspection, use personal computer and SDS tool. 1) Connect SDS tool to engine. Refer to SDS operation manual for the step 1 procedure. 2) Start engine and allow to warm up. 3) Check engine speed and IAC duty by using “Service data / Engine data” mode on SDS. 4) If IAC duty and / or idle speed is out of specification, inspect idle speed control system referring to “Idle air control system check”. I9J011020051-02 3) Check the ignition timing while operating the engine in neutral gear at 1 000 r/min. Ignition timing Approx. BTDC 2° ± 5° at 1 000 r/min (A) Idle speed in neutral gear (IAC duty) 550 – 650 r/min (Duty: Approx. 0 – 30%) I9J011020018-02 http://SelfFixer.com 1. IAC valve 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 Fuel line check point I9J011020019-04 http://SelfFixer.com If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line. Maintenance and Tune-Up: Low Pressure Fuel Filter Inspection Z9J0110206044 Inspect low pressure fuel filter Every 50 hours (3 months) 0B-15 3) Remove the fuel filter (3) from filter bracket (4). 4) Remove the cap (5), then drain and clean fuel filter. 5) Install the cap, then secure it with clamp (6). Replace low pressure fuel filter Every 400 hours or 2 years If leakage, cracks or other damage is found, replace the fuel filter. 4 5 3 6 I9J011020054-01 1 I9J011020052-01 1. Low pressure fuel filter ! 6) Install fuel filter to filter bracket properly. 7) Connect the fuel inlet and outlet hose to fuel filter, then secure the fuel hoses to the fuel filter with the hose clamp. 8) Restart the engine and check that there are no leaks around the fuel filter. High Pressure Fuel Filter Replacement WARNING Z9J0110206045 Stop the motor before cleaning the fuel filter. Do not smoke and keep open flames and sparks away while working near any part of the fuel system. Replace high pressure fuel filter Every 1 000 hours SUZUKI recommends that replacing the high pressure fuel filter every 1 000 operating hours. 1) Turn the engine off. 2) Disconnect the inlet hose (1) and outlet hose (2) from fuel filter. 1 2 1 I9J011020055-01 1. High pressure fuel filter http://SelfFixer.com I9J011020053-01 0B-16 Maintenance and Tune-Up: Water Pump and Water Pump Impeller Inspection Z9J0110206046 Inspect water pump Every 200 hours (12 months) Propeller / Propeller Nut and Cotter Pin Inspection Z9J0110206047 Inspect propeller / propeller nut and cotter pin Initially after 20 hours (1 month) and every 100 hours (6 months). Replace water pump impeller Every 200 hours (12 months) 1) Inspect propeller for bent, chipped or broken blades. Replace propeller if damage noticeably affects operation. 2) Remove the propeller. Refer to “Propeller Removal and Installation” in Section 3A (Page 3A-4). 3) Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted. 4) Inspect propeller bush for slippage. Replace if necessary. I9J011020020-02 I9J011020021-01 I9J011020056-01 5) Install the propeller and related parts. Refer to “Propeller Removal and Installation” in Section 3A (Page 3A-4). 6) Make sure that propeller nut is torqued to specification and cotter pin is installed securely. Tightening torque Propeller nut: 55 N·m (5.5 kgf-m, 40.0 lbf-ft) http://SelfFixer.com 1) Remove the lower unit and water pump case. Refer to “Water Pump Removal and Installation” in Section 3A (Page 3A-6). 2) Inspect water pump case, inner sleeve and under panel. Replace if wear, cracks, distortion or corrosion is found. 3) Inspect water pump impeller. Replace if vanes are cut, torn or worn. SUZUKI recommends that replacing the water pump impeller every 200 hours (12 months). 4) Assemble the water pump related items. Refer to “Water Pump Removal and Installation” in Section 3A (Page 3A-6). 5) Install the lower unit assembly. Refer to “Lower Unit Removal and Installation” in Section 3A (Page 3A-5). Maintenance and Tune-Up: Anodes Inspection 0B-17 Z9J0110206048 Inspect anodes Every 50 hours (3 months) 1 If 2/3 of zinc anode has corroded away, replace anode. The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness. CAUTION 1 Never paint the anode. I9J011020057-01 NOTE The anode cover (1) may be separated from the power unit body by inserting and turning a 10 mm bolt (2) to function as a screw jack. 1 2 1 I9J011020058-01 I9J011020022-04 NOTE The anode (3) securing bolt should be covered with suzuki silicone seal. 3 : Sealant 99000–31120 (SUZUKI Silicone Seal (50 g)) I9J011020025-02 NOTE To access the anode in the gearcase, remove the water inlet filter. 3 I9J011020023-01 3 http://SelfFixer.com I9J011020026-02 0B-18 Maintenance and Tune-Up: Bonding Wires Inspection Z9J0110206049 Inspect bonding wires Every 50 hours (3 months) Battery Inspection Z9J0110206050 Inspect battery Every 50 hours (3 months) 1) If breakage or other damage is found on bonding wire (1), replace the wire. 2) If rust, corrosion or other damage is found on terminal, clean with cleaning solvent or replace wire. 1 I9J011020027-02 1 ! WARNING Never expose battery to open flame or electric spark as batteries generate gas, which is flammable and explosive. Battery acid is poisonous and corrosive. Avoid contact with eyes, skin, clothing, and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention. Batteries should always be kept out of reach of children. When checking or servicing the battery, disconnect the negative (black) cable. Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the motor at the same time. Wear approved eye protection. Recommended battery 12 V 100 AH (360 kC) or larger I9J011020028-01 Refer to “Battery Requirement” in Section 0A (Page 0A5). http://SelfFixer.com 1 Maintenance and Tune-Up: Connecting Battery 0B-19 Battery Solution Level Check CAUTION CAUTION If the battery leads are loose, incorrectly connected or reversed, the electrical system could be damaged. Wing nuts must not be used and hexagon nuts must be used to secure sub battery cable to the battery terminals to avoid loss of electrical power. Once the battery has been initially serviced, NEVER add diluted sulfuric acid or battery damage will occur. Follow the battery manufacture's instructions for specific maintenance procedures. How to connect 1) Connect positive (+) terminal first. 2) Connect negative (–) terminal second. 3) Upon completion of connection, lightly apply grease to battery terminals. Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only. 1 2 I9J011020031-01 3 Battery Solution Specific Gravity Check Measure the specific gravity of battery solution using a hydrometer. I9J011020029-03 Battery solution specific gravity (temperature) 1.28 (20 °C) Special tool : 09900–28403 (Hydrometer) 1. Red lead 2. Sub battery cable 3. Black lead How to disconnect 1) Disconnect negative (–) terminal first. 2) Disconnect positive (+) terminal second. 1 2 I9J011020032-01 3 I9J011020030-02 1. Red lead 2. Sub battery cable http://SelfFixer.com 3. Black lead 0B-20 Maintenance and Tune-Up: Bolts and Nuts Inspection Z9J0110206025 Inspect bolts and nuts Initially after 20 hours (1 month) and every 100 hours (6 months) Check that all bolts and nuts listed below are tightened to their specified torque. Refer to “Tightening Torque Specifications” in Section 0A (Page 0A-13). Cylinder head cover bolts Intake manifold bolts and nuts Exhaust manifold cover bolts Flywheel bolt ECM ground bolt Power unit mounting bolts Clamp bracket shaft nut Gearcase bolts Propeller nut Oil Pressure Check (B) (A) I9J011020060-02 4) Start engine and warm up. Engine warm up (engine speed) Summer: 5 min. (2 000 r/min.) Winter: 10 min. (2 000 r/min.) Z9J0110206027 Check the engine oil pressure periodically. 1) Check the engine oil level. 2) Loosen screw and disconnect blue lead wire (1) from oil pressure switch (2). Remove the oil pressure switch. I9J011020033-01 5) After warming up, shift into forward gear and increase engine speed to 3 000 r/min, then compare pressure indicated on gauge to specifications. NOTE 2 The figure shown below is a guideline only, not an absolute service limit. 1 Oil pressure 400 – 600 kPa (4.0 – 6.0 kg/cm2, 57 – 85 psi.) Special tool (A): 09915–77311 (Oil pressure gauge) (B): 09915–78211 (Oil pressure gauge adapter) http://SelfFixer.com I9J011020059-01 3) Install oil pressure gauge adaptor into oil pressure switch hole in place of oil pressure switch. 6) If oil pressure is lower or higher than specification, the following causes may be considered. Low oil pressure Clogged oil filter Leakage from oil passages Defective oil pump Defective oil pressure regulator Damaged O-ring Combination of above items Maintenance and Tune-Up: High oil pressure Using an engine oil of too high viscosity Clogged oil passage Clogged oil pressure regulator Combination of above items 7) After testing, reinstall oil pressure switch. Refer to “Oil Pressure Switch Removal and Installation” in Section 1E (Page 1E-5). 0B-21 6) Disconnect remote control throttle cable from throttle lever. 7) Move and hold throttle lever (1) in full-open position. 1 Cylinder Compression Pressure Check Z9J0110206026 The compression pressure reading of cylinder is good indicator of its internal condition. The decision to overhaul the power unit is often based on the results of a compression test. Periodic maintenance records kept at your dealership should include compression readings for each maintenance service. 1) Start engine and allow to warm up, then shut engine off. 2) Disconnect all fuel injector connectors at fuel injector. 3) Disconnect all ignition coil connectors. 4) Remove the bolts securing the ignition coil, then remove all ignition coils and spark plugs. 5) Install compression gauge attachment into spark plug hole, then connect compression gauge attachment to compression gauge. Special tool (A): 09915–64512 (Compression gauge) (B): 09915–69910 (Compression gauge attachment) (A) I9J011020063-02 8) While cranking engine with starter motor, note maximum compression pressure reading on gauge for each cylinder. NOTE Figures shown are guidelines only, not absolute service limits. Cylinder compression pressure Standard: 1 200 – 1 800 kPa (12 – 18 kgf/cm2, 171 – 256 psi.) Cylinder compression pressure max. difference between cylinders 100 kPa (1.0 kgf/cm2, 14 psi.) Low compression pressure can indicate one or more of following: Excessively worn cylinder wall Worn piston or piston rings Stuck piston rings Poor seating of valves Ruptured or otherwise damaged cylinder head gasket 9) Reinstall parts removed earlier (spark plugs, ignition coils, etc.). (B) I9J011020062-01 http://SelfFixer.com I9J011020061-01 http://SelfFixer.com 0B-22 Maintenance and Tune-Up: Table of Contents 1- i Section 1 Power Head CONTENTS 1 Precautions............................................................. 1-1 Precautions for Powerhead................................... 1-1 Engine General Information and Diagnosis................................................. 1A-1 Precautions...........................................................1A-1 Precautions on Engine Diagnosis....................... 1A-1 General Description.............................................1A-2 Engine Control System Description.................... 1A-2 Engine Control Module (ECM)............................ 1A-4 Caution System Description................................ 1A-7 Self-Diagnostic System Description.................. 1A-10 Fail-Safe System Description............................ 1A-12 Operating Hour Indication System Description...................................................... 1A-13 Oil Change Reminder System Description........ 1A-14 Component Location.........................................1A-15 Engine Control System Components / Engine Electrical Device Location............................... 1A-15 Diagnostic Information and Procedure............1A-20 ECM Power and Ground Circuit Check............. 1A-20 Troubleshooting with Self-Diagnostic Code...... 1A-21 Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-22 Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor............................................................. 1A-23 Self-Diagnostic Code “2 – 3” IAT Sensor.......... 1A-24 Self-Diagnostic Code “4 – 2” CKP Sensor........ 1A-25 Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-26 Self-Diagnostic Code “2 – 2” Air Intake System............................................................ 1A-27 Self-Diagnostic Code “3 – 2” MAP Sensor 2..... 1A-28 Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor................................................. 1A-30 Self-Diagnostic Code “4 – 3” Fuel Injector........ 1A-31 Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor).............................................. 1A-32 Self-Diagnostic Code “1 – 2” Shift Position Sensor............................................................. 1A-33 Self-Diagnostic Code “3 – 3” Neutral Switch..... 1A-34 Self-Diagnostic Code “1 – 1” Rectifier/ Regulator (Over Charging).............................. 1A-35 Self-Diagnostic Code “5 – 3” Oil Pressure Switch............................................................. 1A-35 Self-Diagnostic Code “3 – 7” Trim Sensor........1A-36 Troubleshooting Without Self-Diagnostic Code................................................................1A-37 IAC System Troubleshooting............................1A-38 Service Instructions...........................................1A-39 How to Use the 36 Pin Test Cord Set...............1A-39 Inspection of the ECM and Its Circuit................1A-39 ECM Main Relay Inspection..............................1A-42 Engine Electrical Devices....................... 1C-1 Precautions...........................................................1C-1 Precaution for Engine Electrical Device..............1C-1 General Description.............................................1C-1 Sensor and Switch Description...........................1C-1 ECM Power Source Line.....................................1C-6 Component Location...........................................1C-7 Location of Sensor and Switch............................1C-7 Service Instructions.............................................1C-7 Resistance Check...............................................1C-7 Cylinder Temp. Sensor Removal and Installation.........................................................1C-8 Cylinder Temp. Sensor Inspection......................1C-8 Ex. Manifold Temp. Sensor Removal and Installation.........................................................1C-9 Ex. Manifold Temp. Sensor Inspection...............1C-9 CKP Sensor Removal and Installation..............1C-10 CKP Sensor Inspection.....................................1C-10 IAT Sensor Removal and Installation................1C-10 IAT Sensor Inspection.......................................1C-11 CMP Sensor Removal and Installation.............1C-11 CMP Sensor Inspection....................................1C-11 MAP Sensor Removal and Installation..............1C-12 MAP Sensor Output Voltage Inspection............1C-13 IAC Valve Removal and Installation..................1C-14 IAC Valve Inspection.........................................1C-14 TPS Inspection..................................................1C-15 Shift Position Sensor Inspection.......................1C-16 Trim Sensor Inspection.....................................1C-17 Power Unit Mechanical........................... 1D-1 General Description.............................................1D-1 Power Unit Construction Description..................1D-1 Diagnostic Information and Procedures............1D-1 Cylinder Compression Check..............................1D-1 Oil Pressure Check.............................................1D-1 http://SelfFixer.com Precautions.................................................1-1 1-ii Table of Contents Power Unit Lubrication............................1E-1 General Description............................................. 1E-1 Engine Lubrication Description........................... 1E-1 Schematic and Routing Diagram........................ 1E-1 Engine Oil Lubrication Chart............................... 1E-1 Diagnostic Information and Procedures............ 1E-2 Oil Pressure Check............................................. 1E-2 Oil Change Reminder System............................. 1E-2 Low Oil Pressure Caution System...................... 1E-2 Powerhead Lubrication System Diagnosis.......... 1E-2 Service Instructions............................................. 1E-3 Oil Pump Removal and Installation..................... 1E-3 Oil Pump Disassembly and Assembly................ 1E-3 Inspection Oil Pump Component Parts............... 1E-4 Oil Pressure Switch Removal and Installation.... 1E-5 Oil Pressure Switch Inspection........................... 1E-6 Oil Strainer Removal and Installation..................1E-6 Oil Strainer Related Parts Inspection..................1E-6 Power Unit Cooling System.....................1F-1 General Description............................................. 1F-1 Water Cooling System Description..................... 1F-1 Displacement Type Water Pump Description..... 1F-1 Water Pressure Valve Description...................... 1F-1 Schematic and Routing Diagram........................ 1F-2 Cooling Water Circulation Chart.......................... 1F-2 Diagnostic Information and Procedures............ 1F-3 Powerhead Cooling System Diagnosis............... 1F-3 Service Instructions............................................. 1F-3 Thermostat Removal and Installation.................. 1F-3 Thermostat Inspection......................................... 1F-4 Water Pressure Valve Removal and Installation......................................................... 1F-4 Water Pressure Valve Related Item Inspection.......................................................... 1F-5 Water Pump Removal and Installation................ 1F-5 Water Pump Related Item Inspection................. 1F-5 Water Tube Removal and Installation................. 1F-5 Water Tube Related Item Inspection................... 1F-5 Fuel System............................................. 1G-1 Precautions.......................................................... 1G-1 Precautions on Fuel System Service................. 1G-1 General Description............................................ 1G-2 Electronic Fuel Injection System Description..... 1G-2 Fuel Delivery System Components Description....................................................... 1G-4 High Pressure Fuel Pump Control System Description....................................................... 1G-7 Air Intake Components Description.................... 1G-8 Idle Air Control System Description................... 1G-9 Diagnostic Information and Procedures......... 1G-11 Fuel Pressure Inspection................................. 1G-11 Fuel System Diagnosis.................................... 1G-13 Fuel Injection System Troubleshooting............ 1G-14 Service Instructions.......................................... 1G-15 Fuel Pressure Relief Procedure....................... 1G-15 Fuel Line Removal and Installation.................. 1G-15 Fuel Line Inspection......................................... 1G-15 Fuel Leakage Check Procedure....................... 1G-16 Inspection of Fuel Hose Connections.............. 1G-16 High Pressure Fuel Pump Operating Sound Inspection....................................................... 1G-16 Fuel Vapor Separator Removal and Installation...................................................... 1G-17 Fuel Vapor Separator Disassembly and Assembly........................................................ 1G-17 Inspection of Fuel Vapor Separator Component Parts........................................... 1G-20 Fuel Injector Inspection with Injector in place.. 1G-21 Individual Fuel Injector Operating Sound Inspection....................................................... 1G-22 Fuel Injector Operating Signal Inspection........ 1G-22 Fuel Injector Removal and Installation............. 1G-23 http://SelfFixer.com Service Instructions.............................................1D-2 Tappet Clearance Inspection..............................1D-2 Ring Gear Cover Removal and Installation.........1D-2 Cylinder Head Cover Removal and Installation.........................................................1D-2 Air Intake Silencer Case Removal and Installation.........................................................1D-5 Electric Parts Holder Removal and Installation....1D-5 Intake Manifold and Throttle Body Components......................................................1D-7 Intake Manifold Removal and Installation...........1D-7 Throttle Body Removal and Installation............1D-10 Throttle Body Inspection...................................1D-11 Power Unit Removal and Installation................1D-11 Timing Chain, Chain Tensioner and Camshaft Sprockets Components...................................1D-19 Timing Chain, Chain Tensioner and Camshaft Sprockets Removal and Installation................1D-20 Timing Chain, Chain Tensioner and Camshaft Sprockets Inspection.......................................1D-24 Camshaft, Tappet and shim Removal and Installation.......................................................1D-25 Camshaft, Tappet and Shim Inspection............1D-27 Cylinder Head Assembly Components.............1D-31 Cylinder Head Removal and Installation...........1D-32 Cylinder Head Disassembly and Assembly......1D-33 Cylinder Head Components Inspection and Servicing.........................................................1D-35 Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components............1D-42 Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Disassembly and Assembly........................................................1D-43 Cylinder, Piston and Piston Ring Inspection and Servicing..................................................1D-50 Piston Pin and Conrod Inspection.....................1D-53 Crank Pin and Conrod Bearing Inspection........1D-54 Selection of Conrod Bearing.............................1D-56 Crankshaft Inspection.......................................1D-57 Crankshaft Main Bearing Inspection.................1D-58 Crankshaft Drive Gear Inspection.....................1D-61 Crankshaft Oil Seal Inspection..........................1D-61 Table of Contents 1-iii Ignition System........................................ 1H-1 General Description.............................................1H-1 Ignition System Description................................1H-1 Ignition Control Description.................................1H-2 Component Location...........................................1H-4 Ignition System Components Location...............1H-4 Diagnostic Information and Procedures............1H-4 Ignition System Symptom Diagnosis...................1H-4 Ignition System Troubleshooting.........................1H-5 Service Instructions.............................................1H-6 Spark Plug Removal and Installation..................1H-6 Spark Plug Inspection.........................................1H-6 Ignition Coil Removal and Installation.................1H-6 Ignition Coil Inspection........................................1H-6 Ignition Coil Operating Signal Inspection............1H-7 CKP Sensor Inspection.......................................1H-7 CMP Sensor Inspection......................................1H-7 Ignition Switch Inspection...................................1H-7 ECM Main Relay Inspection................................1H-7 Starting System.........................................1I-1 General Description.............................................. 1I-1 Electric Starter System Description...................... 1I-1 Starter Motor Operation Condition Description......................................................... 1I-2 Start-In-Gear Protection System Description....... 1I-2 Component Location............................................ 1I-3 Starting System Components Location................ 1I-3 Diagnostic Information and Procedures............. 1I-3 Starter System Troubleshooting........................... 1I-3 Service Instructions.............................................. 1I-4 Starter Motor Removal and Installation................ 1I-4 Starter Motor Test................................................ 1I-5 Starter Motor Components................................... 1I-6 Starter Motor Disassembly and Assembly........... 1I-7 Starter Motor Components Inspection and Servicing............................................................ 1I-9 Ignition Switch Inspection................................... 1I-13 Starter Motor Relay Inspection........................... 1I-13 Neutral Switch Inspection................................... 1I-14 Emergency Stop Switch Inspection.................... 1I-15 Charging System..................................... 1K-1 General Description.............................................1K-1 Charging System Description..............................1K-1 Battery Requirement Description........................1K-2 Component Location...........................................1K-3 Charging System Components Location.............1K-3 Diagnostic Information and Procedures............1K-3 Charging System Diagnosis................................1K-3 Service Instructions.............................................1K-4 Charging System Construction...........................1K-4 Flywheel Removal and Installation......................1K-5 Battery Charge Coil Removal and Installation....1K-6 Battery Charge Coil Inspection...........................1K-7 Rectifier/Regulator Removal and Installation......1K-7 Rectifier/Regulator Inspection.............................1K-8 Main Fuse Inspection..........................................1K-8 http://SelfFixer.com Low Pressure Fuel Pump Removal and Installation.......................................................1G-25 Low Pressure Fuel Pump Inspection................1G-26 1-1 Precautions: Precautions Power Head Precautions Refer to “General Precautions” in Section 00 (Page 00-1). Z9J0111000001 http://SelfFixer.com Precautions for Powerhead Engine General Information and Diagnosis: 1A-1 Engine General Information and Diagnosis Power Head Precautions Precautions on Engine Diagnosis ! Z9J0111100001 WARNING To prevent any unexpected engine starting, perform the following before proceeding with any CRANKING tests. When performing tests not related to fuel injector operation: – Disconnect all fuel injector wire connectors. When performing tests related to fuel injector operation: – Relieve the fuel pressure in the fuel lines. Refer to “Fuel Pressure Relief Procedure” in Section 1G (Page 1G-15). – Disconnect the high pressure fuel pump wire connector located on the fuel vapor separator. CAUTION Always turn the ignition switch “OFF” and disconnect the battery cables when wires are being disconnected or connected. Hold and pull the connectors when disconnecting. Do not pull the wires. NOTE http://SelfFixer.com To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use the Suzuki Diagnostic System. The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected. Each electrical circuit is affected by battery voltage, always use a full-charged battery. Make sure all ground points have good electrical contact. Make sure all wires / cables are securely connected. 1A-2 Engine General Information and Diagnosis: General Description Engine Control System Description Z9J0111101001 The DF70 / 80 / 90 models employ an integrated system which performs the control functions for fuel injection, ignition, idle / trolling speed (idle air), etc. through the ECM (Engine Control Module). System Structure INPUT (sensor/switch) CONTROL (ECM) OUTPUT (actuator etc.) CKP sensor Fuel injection system Fuel injector CMP sensor Ignition system Ignition coil Idle air control system IAC valve Fuel pump system High pressure fuel pump Exhaust manifold temp. sensor Caution system Caution Buzzer Throttle position sensor Self diagnostic system MAP sensor IAT sensor Cylinder temp. sensor Neutral switch Monitor-tachometer Fail safe system Shift position sensor Oil pressure switch Operating hour indication system Oil changing reminder system Emergency stop switch Ignition switch Start-in-gear protection system Starer motor relay, (Starter motor) Starter motor relay control system PTT switch Trim/Tilt sensor Power trim and tilt relay control system PTT motor relay Trim gauge Water pressure gauge Speedo sensor (Optional) Speedometer I9J011110001-02 http://SelfFixer.com Water pressure sensor (Optional) Engine General Information and Diagnosis: 1A-3 Engine Control System Flow Diagram 28 30 29 32 23 2 22 35 1 21 33 19 34 31 20 36 37 17 15 11 26 14 7 24 27 18 6 25 8 13 3 12 4 16 10 5 9 I9J011110002-04 11. IAC valve 21. PTT relay 2. CKP sensor 12. PTT switch 22. PTT motor 32. Fuel vapor separator 3. Ex. manifold temp. sensor 13. ECM main relay 23. Battery 33. Float 4. Cylinder temp. sensor 14. Ignition switch 24. Fuel injector 34. High pressure fuel pump 5. Spark plug 15. Fuse (30 amp.) 25. Air intake silencer 35. High pressure fuel filter 6. Ignition coil 16. Fuse (15 amp.) 26. Throttle body 36. Fuel cooler 37. Fuel pressure regulator 7. CMP sensor 17. Starter relay 27. Intake manifold 8. MAP sensor 18. Neutral switch 28. Fuel tank 9. Throttle position sensor 19. Trim/Tilt sensor 29. Fuel primer bulb 20. Shift position sensor 30. Low pressure fuel filter 10. IAT sensor 31. Low pressure fuel pump http://SelfFixer.com 1. Flywheel 1A-4 Engine General Information and Diagnosis: Engine Control Module (ECM) Z9J0111101002 The ECM sends signals to control the actuators based on the information inputs from each sensor / switch. Major controls are as follows: Name of Control Fuel injection control Ignition control Idle air control Description Controls fuel injection amount and timing. Controls ignition timing. Controls idling / trolling speed by adjusting the intake air volume through the IAC valve. Controls the high pressure fuel pump drive. Informs the operator of abnormal engine conditions. Controls engine speed, if activated. Informs the operator of sensor / switch malfunction. Allows engine operation with a back-up system during sensor / switch malfunction. Informs the operator of the total operating time. Informs the operator that it is time to replace the engine oil, based on the maintenance schedule. Prevents engine starting when the shift lever is positioned in forward or reverse. Prevents starter motor operation when the engine is already operating. Controls On / Off for the PTT relay’s up and down circuits. Fuel pump control Caution system control Self-diagnostic system control Fail-safe system control Total operating hour indication system control. Oil changing reminder system control Start-in-gear protection system control Starter motor relay control system Power trim and tilt relay control system NOTE Information related to the Caution System, Self-Diagnostic System, and Total Operating Hours System is retained in the ECM memory. 1 I9J011110042-01 http://SelfFixer.com 1. ECM http://SelfFixer.com PTT SW PTT SW BATTERY ON RESET SW START SW NEUTRAL SW PTT RELAY IG. OFF ST RELAY Main relay IPS IPS CMP SENSOR #1 CKP SENSOR PTT RELAY DN PTT RELAY UP PTT DN SW PTT UP SW BUZZER RESET SW START SW STARTER RELAY CTRL NEUTRAL SW KEY SW MAIN RELAY BATTERY PWR IG SWITCH TPS SPS MAP SENSOR 16 11 25 31 20 8 9 5 7 EMERGENCY STOP SW OIL PRESSURE SW SENSOR GND EX-MANI TEMP SENSOR CYL TEMP SENSOR IAT SENSOR SPEEDO SENSOR WATER PRESSURE SENSOR TRIM/TILT SENSOR 10 SENSOR PWR #2 6 21 32 33 SENSOR PWR #1 40 50 3 27 22 23 64 65 2 49 15 35 12 36 VB MONITOR ECM POWER CPU 56 55 43 66 69 57 44 63 51 53 41 54 42 48 58 70 60 72 59 47 71 45 ECM GND 24 COMMUNICATION LINE B 38 COMMUNICATION LINE A 62 TACHOMETER OVER REV LED TRIM GAUGE Oil pressure LED DIAG LED OVER HEAT LED BUZZER PWR GND PWR GND IGN COIL #4 IGN COIL #3 IGN COIL #2 IGN COIL #1 IAC #4 IAC #3 IAC #2 IAC #1 F/P (H) INJECTOR #4 INJECTOR #3 INJECTOR #2 INJECTOR #1 IGT IGT PLUG GND IGT PLUG GND IGT M GND PLUG GND PLUG Engine General Information and Diagnosis: 1A-5 ECM Input / Output Circuit Diagram I9J011110011-04 1A-6 Engine General Information and Diagnosis: ECM Connector / Terminals Layout 48 47 46 45 44 43 42 41 40 39 38 37 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 “A” “B” I9J011110003-02 Terminal 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 Wire Color — G P/W — Bl/B Br/Y W/Y Lg/B Bl/W R/W Bl Gr — — B/G Bl/R — — — Lg/W P/Bl P Lbl B B/W — Lg/W — — — V/W W R — R/B B/Bl Circuit — Starter relay control PTT relay DN — Water pressure sensor Throttle position sensor Trim / Tilt sensor IAT sensor Speedo sensor Power source for sensor Oil pressure switch Power source for ECM — — Ignition key switch Emergency stop switch — — — Cylinder temp. sensor Shift position sensor PTT switch “DN” PTT switch “UP” Ground for ECM Ground for Sensor — PTT relay UP — — — Ex. Manifold temp. sensor MAP sensor Power source #1 for sensor — Ground for ECM main relay Ignition switch “B”: Black connector Terminal 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67 68 69 70 71 72 Wire Color — Y — Y/Bl Gr/Y O W/Y Bl/W O/B — R/W W/Bl Y/G R/B B — Lg/R Bl P/W Y/B G/Y R/G Lg W/B — O/Y B O/W Br Bl/B — — G/W R/Y B/Br B/R Circuit — PC communication line (B) — CMP sensor No.3 Ignition coil No.1 Ignition coil Trim gauge Buzzer No.1 Fuel injector — No.3 Fuel injector IAC valve #4 Neutral switch CKP sensor Ground for power — No.4 Ignition coil No.2 Ignition coil Rev – Limit lamp Tachometer TEMP lamp IAC valve #3 No.4 Fuel injector IAC valve #1 — PC communication line (A) Ground for power Buzzer cancel Start switch Oil lamp — — CHECK ENGINE lamp IAC valve #2 No.2 Fuel injector High pressure fuel pump (–) http://SelfFixer.com “A”: Gray connector Engine General Information and Diagnosis: Caution System Description The following four caution systems alert the operator when an abnormality occurs on the engine. OVER-REVOLUTION CAUTION LOW OIL PRESSURE CAUTION OVERHEAT CAUTION LOW BATTERY VOLTAGE CAUTION Monitor-Tachometer 1A-7 Z9J0111101003 “A” “D” “C” “B” I9J011110004-02 Caution Type Over-revolution Low oil pressure Overheat Low battery voltage “A”: “REV LIMIT” lamp “C”: “TEMP” lamp “B”: “OIL” lamp “D”: “CHECK ENGINE” lamp Caution Lamp Yes “A” Yes “B” (“A”) Yes “C” (“A”) Yes “D” Caution Buzzer No Yes Yes Yes Engine RPM Limited Yes Yes Yes No Lamp check / Buzzer Check When the ignition key is turned to the “ON” position: Four Caution lamps turns on for two seconds. Caution buzzer sounds for two seconds. Over-Revolution Caution System Condition: The ECM controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed. Over revolution limiter DF70 / 80: 6 200 r/min. DF90: 6 400 r/min. Action: Engine speed Caution lamp Caution buzzer Automatically reduced to approx. 3 000 r/min. by an intermittent fuel injection signal. If the operator decreases the engine speed below the over revolution system maximum preset value, within 10 seconds, the over-revolution caution control will be canceled. “REV-LIMIT” lamp lights continuously. No buzzer sounds. http://SelfFixer.com Reset: Close the throttle to reduce the engine speed below approx. 3 000 r/min. for one second. 1A-8 Engine General Information and Diagnosis: Low Oil Pressure Caution System Condition: Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop below 1