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99500-92J00-01E

99500-92J00-01E
2013

DIC502 Pantone 303C Pantone 485 Pantone 294 Black

No. 667 99500-92J00-01E DF100A/115A/140A Service Manual Cover for PS printing (14mm) 5/0 2013/01/23 BOTTOM
 IMPORTANT NOTICE

WARNING / CAUTION / NOTICE / NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and
the words ! WARNING , ! CAUTION , NOTICE 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 serious injury.

! CAUTION
Indicates a potential hazard that could result in minor or moderate injury.

NOTICE
Indicates a potential hazard that could result in damage to the motor or boat.

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 poten-
tial hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the ! WARNING ,
! CAUTION , and NOTICE stated, you must also use good judgment and observe basic mechanical safety prin-

ciples.

! 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 DF100A/115A/140A Outboard motors and proce-
dures 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 ser-
vice SUZUKI Outboard motors. Persons without such knowledge and skills should not attempt to service
Suzuki Outboard engines by relying on this manual only and should contact an authorized SUZUKI Out-
board motor dealer.

NOTE:
This manual is compiled with the production model manufactured in August, 2012.

© COPYRIGHT SUZUKI MOTOR CORPORATION 2012

 00
TABLE OF CONTENTS

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
2
Precautions .............................................................. 1-1
Engine Control ....................................................... 1A-1
Engine Electrical Devices.......................................1C-1
Power Unit Mechanical ..........................................1D-1 3
Power Unit Lubrication ........................................... 1E-1
Power Unit Cooling System ................................... 1F-1
Fuel System ...........................................................1G-1
Ignition System.......................................................1H-1
Starting System....................................................... 1I-1 4
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1
Housing and Bracket.............................................. 2A-1 5
Power Trim and Tilt ................................................ 2B-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Right Hand Rotation Unit ....................................... 3A-1 6
Left Hand Rotation Unit.......................................... 3B-1
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1 7
Fuel / Water Hose Routing..................................... 4B-1

10

11

12
 Table of Contents 00- i

Section 00
00

Precautions
CONTENTS

Precautions ...............................................00-1 Precautions........................................................... 00-1

General Precautions ........................................... 00-1
00-1 Precautions:

Precautions
Precautions

Precautions
General Precautions
CENDG2110000001
The WARNING, CAUTION and NOTICE messages below describe some general precautions that you should observe
when servicing the outboard motor. These general precautions apply to many of the service procedures, but they will
not necessarily be repeated for every procedure to which they apply.

! WARNING
Failure to take proper precautions when servicing the outboard motor can cause severe personal
injury.
• 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.
• Whenever handling toxic or flammable materials, wear safety glasses to protect your eyes. Any
toxic or flammable materials getting into your eye may cause inflammation. Also wear
moistureproof gloves to protect your skin.
• Do not swallow any toxic or flammable materials. Swallowing them could cause diarrhea, nausea or
other health problems. Be especially careful not to allow children and pets to swallow these
materials.
• Keep all toxic or flammable materials out of reach of children and pets.
• 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.
• Avoid contact with new and used oil. Prolonged contact with used oil has been shown to cause skin
cancer in laboratory animals. Brief contact with used oil may irritate the skin. 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.
• Never disconnect any of the fuel lines between the fuel pump and injectors without first releasing
the fuel pressure, or fuel can be sprayed out under pressure.
• 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

NOTICE
Failure to take proper precautions when servicing the outboard motor can cause damage to the parts
or the outboard motor.
To prevent the parts or the outboard motor from damage, be sure to take the following precautions:
• 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.
• Do not expose connectors and electrical parts to water, which will cause electrical systems
problems.
• Always be careful not to drop electrical components (ECM, relays, etc.) or handle them in a rough
manner.
• 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 ones. 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 proper operation.

NOTE
• 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.

Replacement Parts

NOTICE
Use of replacement parts which are not equivalent in quality to genuine SUZUKI parts can lead to
performance problems and damage.
Use only genuine SUZUKI replacement parts or their equivalent. Genuine SUZUKI parts are high
quality parts which are designed and built specially for SUZUKI outboard motors.

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.
00-3 Precautions:

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
Outboard Motor Identification Number
Location ............................................................ 0A-3
Fuel and Oil Recommendations.......................... 0A-3
Break-In Procedures ........................................... 0A-4
Propeller Selection Guide ................................... 0A-5
Battery Requirement ........................................... 0A-5
Powerhead Direction of Rotation Description ..... 0A-5
Specifications.......................................................0A-6
Specifications ...................................................... 0A-6
Service Data ....................................................... 0A-9
Tightening Torque Specifications...................... 0A-14
Special Tools and Equipment ...........................0A-15
Recommended Service Material ....................... 0A-15
Special Tool ...................................................... 0A-16
Maintenance and Tune-Up...................... 0B-1
Precautions...........................................................0B-1
Precautions for Maintenance .............................. 0B-1
General Description .............................................0B-1
Recommended Oil and Lubricants...................... 0B-1
Table of Contents 0- i
0
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-5
Spark Plug Removal and Installation ..................0B-6
Spark Plug Inspection and Cleaning ...................0B-6
Tappet Clearance Inspection and Adjustment ....0B-7
Idle Speed and Idle Air Control (IAC) Duty
Inspection........................................................0B-12
Ignition Timing Inspection .................................0B-12
Breather Line and Fuel Line Inspection ............0B-13
Low Pressure Fuel Filter Inspection..................0B-14
Water Pump and Water Pump Impeller
Inspection........................................................0B-15
Propeller / Propeller Nut and Cotter Pin
Inspection........................................................0B-15
Anode Inspection ..............................................0B-16
Bonding Wire Inspection ...................................0B-17
Battery Inspection .............................................0B-17
Bolts and Nuts Inspection .................................0B-18
Oil Pressure Check ...........................................0B-19
Cylinder Compression Pressure Check ............0B-20
0A-1 General Information:

General Information
General Information

General Description
Symbols
CENDG2110101001
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 I:
CENDG2110101002 IAC: Idle Air Control
Abbreviations used in this service manual are as follows:
IAT: Intake Air Temperature
A:
IG: Ignition
ATDC: After Top Dead Center
Ign.: Ignition
AC: Alternating Current
IN (In.): Intake
B:
L:
BTDC: Before Top Dead Center
LPS: Lever Position Sensor
C:
M:
CKP Sensor: Crankshaft Position sensor
MAP: Manifold Absolute Pressure
CMP Sensor: Camshaft Position sensor
P:
CTP: Close Throttle Position
PCV: Positive Crankcase Ventilation
D:
PORT: Port
DC: Direct Current
PTT: Power Trim and Tilt
DOHC: Double Over Head Camshaft
S:
E:
SPS: Shift Position Sensor
ECM: Engine Control Module
STBD: Starboard
EX (Ex.): Exhaust
SIGP: Start-In-Gear Protection
F:
T:
FP: Fuel Pump
TPS: Throttle Position Sensor
G:
GND: Ground
 General Information: 0A-2

Wire Color Symbols

CENDG2110101003
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) Bl/B

Black (Stripe Color)

I9J011010001-02

Warning, Caution and Information Label Locations

CENDG2110101004
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
WARNING
AVERTISSEMENT
• Fuel can leak creating a fire hazard if
you lay motor on its side. Drain fuel
completely from vapor separator or
carburetor before laying motor on its side.
• See owner’s manual for details.
• Le carburant risque de fuir et de
présenter un danger d’incendie si le
moteur est placé sur le côté.
Vidanger entičrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.

IDG211010001-03

1. Label, engine cover 2. Label, mag cover 3. Label S.I.G.P.

0A-3 General Information:

Outboard Motor Identification Number Location Fuel and Oil Recommendations

CENDG2110101006 CENDG2110101007
Model, Pre-Fix, Serial Number Gasoline
The Model, Pre-fix and Serial number of motor are
stamped on a plate attached to the clamp bracket. NOTICE
Use of leaded gasoline can cause engine
damage.
Use of improper or poor quality fuel can
affect performance and may damage the
motor and fuel system.
1
Use only unleaded gasoline. Do not use fuel
having lower than the recommended octane,
or fuel that may be stale or contaminated by
dirt/water etc.
IDG211010002-02

1. Identification number plate Suzuki highly recommends that you use alcohol-free
unleaded gasoline with a minimum pump octane rating
Example of 87 (R/2+M/2 method) or 91 (Research method).
However, blends of unleaded gasoline and alcohol with
1 equivalent octane content may be used.
Allowable maximum blend of a single additive (Not
DF 115A combination)
5% Methanol, 10% Ethanol, 15% MTBE
11503F
Engine Oil

NOTICE
2 3 Use of a poor quality engine oil can adversely
IDG211010003-02 affect engine performance and life.
1. Model 3. Serial number
2. Pre-fix Suzuki recommends that you use Suzuki
Marine 4-Cycle Engine Oil or its equivalent.
Engine Serial Number Location
A second engine serial number plate is pressed into a Oil quality is a major contributor to your engine’s
boss on the cylinder block. performance and life. Always select good quality engine
oil.
Suzuki recommends the use of SAE 10W-40 SUZUKI
1
MARINE 4-CYCLE ENGINE OIL.
If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
XXXXXX available, select a NMMA certified FC-W oil or good
quality 4-cycle motor oil from the following chart
according to the average temperatures in your area.

API Classification SAE Viscosity Grade

SG
SH 10W–40

IDG211010004-01
SJ
SL
1. Serial number plate 10W–30
SM

C –20 –10 0 10 20 30 40
TEMP.
F –4 14 32 50 68 86 104
I9J011010003-02

Gear Oil
Suzuki recommends the use of SUZUKI Outboard Motor
Gear Oil. If it is not available, use SAE 90 hypoid gear oil
which is rated GL-5 under the API classification system.

Break-In Procedures
CENDG2110101008
NOTICE
Failure to follow the break-in procedures
described below can result in severe engine
damage.
Be sure to follow the engine break-in
procedures described below.
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
NOTICE
Running at high speed without sufficient
warm-up may cause severe engine damage
such as piston seizure.
Always allow sufficient idling time (5
minutes) for the engine to warm-up before
running at high speed.
Allow sufficient idling time (more than 5 minutes) for the
engine to warm up after cold engine starting.
General Information: 0A-4
Throttle Recommendation
NOTE
Avoid maintaining a constant engine speed
for an extended period at any time during the
engine break-in period by varying the throttle
position occasionally.
First 2 hours
For the first 15 minutes, operate the engine in-gear at
idling speed. During the remaining 1 hour and 45
minutes, operate the engine in-gear at less than 1/2
(half) throttle (3 000 r/min).
NOTE
The throttle may be briefly opened beyond
the recommended setting to plane the boat,
but must be reduced to the recommended
setting immediately after planning.
Next 1 hour
Operate the engine in-gear at less than 3/4 (three -
quarter) throttle (4 000 r/min).
Last 7 hours
Operate the engine in-gear at a desired engine speed.
However, do not operate continuously at full throttle for
more than 5 minutes.
NOTICE
Running continuously at full throttle for more
than 5 minutes at a time during the last 7
hours of break-in operation may cause
severe engine damage such as seizure.
During the last 7 hours of break-in operation,
do not operate at wide open throttle for more
than 5 minutes at a time.
0A-5 General Information:

Propeller Selection Guide Battery Requirement

CENDG2110101009 CENDG2110101010
An outboard motor is designed to develop its rated Suzuki recommends a 12 V cranking type lead acid
power within a specified engine speed range. The battery for the DF100A/115A/140A.
maximum rated power delivered by the DF100A/115A/ Minimum battery requirement for starting the engine is
140A models are shown below. provided below.
The battery must satisfy one of the specifications
Recommended full throttle speed range described below.
DF100A
5 000 – 6 000 r/min NOTE
DF115A
DF140A 5 600 – 6 200 r/min • The specifications listed below are the
minimum battery rating requirements for
NOTICE starting the engine.
Installing a propeller with either too much or • Additional electrical loads from the boat
too little pitch will cause incorrect maximum will require larger capacity batteries.
engine speed, which may result in severe • Dual-purpose (Cranking/Deep Cycle)
damage to the motor. batteries can be used if they meet the
minimum specifications listed below
Select a propeller that will allow the engine to (MCA, CCA, or RC).
reach the recommended operating range at
full throttle with the maximum boat load. • Do not use a Deep Cycle battery for the
main cranking battery.
If the standard propeller fails to meet the above • The use of Maintenance-Free, sealed, or
requirement, use another pitch propeller to hold the Gel-Cell batteries is not recommended
engine speed within the range specified above. because they may not be compatible with
Suzuki’s charging system.
Propeller size chart • When connecting batteries in parallel, they
Right-hand rotation propeller must be of the same type, capacity,
Blade x Dia. (in.) x Pitch (in.) manufacturer, and of similar age. When
3 x 13 and 1/2 x 15 replacement is necessary, they should be
3 x 14 x 17 replaced as a set.
3 x 14 x 19
• It is recommended that the battery be
3 x 14 x 21
installed in an enclosed case.
3 x 14 x 23
3 x 13 and 7/8 x 15 • When connecting batteries, hexagon nuts
3 x 13 and 7/8 x 17 must be used to secure battery leads to
3 x 13 and 7/8 x 19 battery terminals.
3 x 13 and 7/8 x 21
Battery specification
3 x 13 and 7/8 x 23
650 Marine Cranking Amps (MCA)/ABYC, or 512 Cold
3 x 13 and 7/8 x 25
Cranking Amps (CCA)/SAE or 160 Reserve Capacity
3 x 14 and 1/4 x 18
(RC) Minutes/SAE or 12 V 100 AH
3 x 14 and 1/4 x 20
3 x 14 and 1/4 x 22
3 x 14 and 1/4 x 24 Powerhead Direction of Rotation Description
CENDG2110101011
This outboard motor is designed with a L.H. (left hand)
Left-hand rotation propeller rotation powerhead utilizing an offset crankshaft. This
Blade x Dia. (in.) x Pitch (in.) design has the advantage of reducing the size of the
3 x 13 and 7/8 x 17 motor and keeping the overall motor’s weight closer to
3 x 13 and 7/8 x 19 the boat transom and therefore closer to the boat C/G
3 x 13 and 7/8 x 21 (Center of Gravity).
3 x 13 and 7/8 x 23 Rotation of the driveshaft is accomplished through a
3 x 14 and 1/4 x 18 crankshaft drive gear and a driveshaft driven gear.
3 x 14 and 1/4 x 20 These gears are located beneath the powerhead in the
3 x 14 and 1/4 x 22 same oil bath location as the camshaft chain.
3 x 14 and 1/4 x 24 As the rotational direction of the driven gear will be
opposite of the drive gear, a left hand rotation
powerhead design was adopted to retain a conventional,
standard rotation (right hand) propeller shaft output.
 General Information: 0A-6

Specifications
Specifications
CENDG2110107001
NOTE
These specifications are subject to change without notice.

Model Pre-Fix
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
PRE-FIX 10003F 11503F/11503Z 14003F/14003Z

Dimensions and Weight

Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Overall length (front to back) mm (in.) 779 (30.7)
Overall width (side to side) mm (in.) 489 (19.3)
L mm (in.) 1 615 (63.6)
Overall height
X mm (in.) 1 742 (68.6)
L kg (lbs) 182 (401.3) 179 (395.7)
Weight (without engine oil)
X kg (lbs) 187 (412.3) 184 (406.8)
L mm (in. type) 534 (20)
Transom height
X mm (in. type) 661 (25)

Performance
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Maximum output kW (PS) 73.6 (100) 84.6 (115) 103 (140)
Recommended operating
r/min 5 000 – 6 000 5 000 – 6 000 5 600 – 6 200
range
Idle speed r/min 700 ± 50 (in-gear: Approx. 700)

Powerhead
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Engine type 4-stroke DOHC
Number of cylinders 4
Bore mm (in.) 86 (3.39)
Stroke mm (in.) 88 (3.46)
Total displacement cm3 (cu. in) 2 044 (124.7)
Compression ratio :1 9.7
Spark plug NGK BKR6E
Ignition system Full-transistorized ignition
Fuel supply system Multi-point sequential electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Electric
Throttle control Remote control
0A-7 General Information:

Fuel and Oil

Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Suzuki highly recommends the use of alcohol-free unleaded gasoline
with a minimum pump octane rating of 87 (R/2+M/2 method) or 91
Fuel
(Research method). However, blends of unleaded gasoline and
alcohol with equivalent octane content may be used.
• API classification: SG, SH, SJ, SL, SM or NMMA FC-W
Engine oil classification: SG, SH, SJ, SL, SM
• Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
5.5 (5.8/4.8): Oil change only
Engine oil amounts L (US/lmp. qt)
5.7 (6.0/5.0): Oil filter change
SUZUKI Outboard Motor Gear Oil or SAE 90 hypoid gear oil, API
Gear oil
classification GL-5.
Gearcase oil capacity ml (US/lmp. oz) 1 050 (35.5/37.0)

Bracket
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Trim angle degree 0 – 22 (–6 to 16) 0 – 21 (–6 to 15)
Number of trim position PTT system
Maximum tilt angle degree 75 (–6 to 69)
 General Information: 0A-8

Lower Unit
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
Reversing system Gear
Transmission Forward-Neutral-Reverse
Reduction system Bevel gear
Gear ratio 12 : 25 (2.08)
Drive line impact protection Spline drive rubber hub
Propeller shaft rotation (When shift into DF100AT/115AT/140AT: Clockwise
forward) DF115AZ/140AZ: Counterclockwise
Right-hand rotation propeller
Blade x Dia. (in.) x Pitch (in.)
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
3 x 13 and 7/8 x 15
3 x 13 and 7/8 x 17
3 x 13 and 7/8 x 19
3 x 13 and 7/8 x 21
Propeller 3 x 13 and 7/8 x 23
3 x 13 and 7/8 x 25
3 x 14 and 1/4 x 18
3 x 14 and 1/4 x 20
3 x 14 and 1/4 x 22
3 x 14 and 1/4 x 24
Left-hand rotation propeller
Blade x Dia. (in.) x Pitch (in.)
3 x 13 and 7/8 x 17
3 x 13 and 7/8 x 19
3 x 13 and 7/8 x 21
3 x 13 and 7/8 x 23
3 x 14 and 1/4 x 18
3 x 14 and 1/4 x 20
3 x 14 and 1/4 x 22
3 x 14 and 1/4 x 24

Reduction System
Data
Item Unit
DF100AT DF115AT/DF115AZ DF140AT/DF140AZ
1st reduction gear ratio
29 : 36 (1.24)
(Crankshaft drive gear: Driven gear)
2nd reduction gear ratio (Lower unit gear) 12 : 25 (2.08)
Total reduction gear ratio 2.59 (36/29 x 25/12)
0A-9 General Information:

Service Data
CENDG2110107002
NOTE
These service data are subject to change without notice.

Powerhead
Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Recommended operating range r/min 5 000 – 6 000 5 000 – 6 000 5 600 – 6 200
Idle speed r/min 700 ± 50 (in-gear: Approx. 700)
kPa
**Cylinder compression pressure 1 000 – 1 600 (10 – 16, 142 – 228)
(kgf/cm2, psi.)
**Cylinder compression pressure max. kPa
100 (1.0, 14)
difference between cylinders (kgf/cm2, psi.)
kPa 410 – 490 (4.1 – 4.9, 63 – 70) at 3 000 r/min
**Engine oil pressure
(kgf/cm2, psi.) (at normal operating temp.)
• API classification: SG, SH, SJ, SL, SM
Engine oil or NMMA FC-W classification: SG, SH, SJ, SL, SM
• Viscosity rating: SAE 10W-40 or NMMA FC-W 10W-40
5.5 (5.8/4.8): Oil change only
Engine oil amounts L (US/lpm. qt)
5.7 (6.0/5.0): Oil filter change
Thermostat operating temperature °C (°F) 48 – 52 (118 – 125)

**Figures shown are guidelines only, not absolute service limits.

Cylinder Head / Camshaft

Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Cylinder head distortion Limit mm (in.) 0.05 (0.002)
Manifold seating faces distortion Limit mm (in.) 0.10 (0.004)
std. mm (in.) 39.520 – 39.680 (1.5559 – 1.5622)
IN
Limit mm (in.) 39.420 (1.5520)
Cam height
std. mm (in.) 39.320 – 39.480 (1.5480 – 1.5543)
EX
Limit mm (in.) 39.220 (1.5441)
Top, std. mm (in.) 0.020 – 0.062 (0.0008 – 0.0024)
2nd,
Camshaft journal oil 3rd, Limit mm (in.) 0.120 (0.0047)
clearance 4th
std. mm (in.) 0.045 – 0.087 (0.0018 – 0.0034)
5th
Limit mm (in.) 0.120 (0.0047)
Top, std. mm (in.) 23.000 – 23.021 (0.9055 – 0.9063)
2nd,
Camshaft journal (housing) 3rd, Limit mm (in.) —
inside diameter 4th
std. mm (in.) 26.000 – 26.021 (1.0236 – 1.0244)
5th
Limit mm (in.) —
Top, std. mm (in.) 22.959 – 22.980 (0.9039 – 0.9047)
2nd,
Camshaft journal outside 3rd, Limit mm (in.) —
diameter 4th
std. mm (in.) 25.934 – 25.955 (1.0210 – 1.0219)
5th
Limit mm (in.) —
std. mm (in.) —
Camshaft runout
Limit mm (in.) 0.10 (0.004)
Cylinder head bore to tappet std. mm (in.) 0.025 – 0.066 (0.0010 – 0.0026)
clearance Limit mm (in.) 0.150 (0.0059)
Tappet outer diameter std. mm (in.) 30.959 – 30.975 (1.2189 – 1.2195)
Cylinder head tappet bore std. mm (in.) 31.000 – 31.025 (1.2205 – 1.2215)
 General Information: 0A-10

Valve / Valve Guide

Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
IN mm (in.) 33 (1.3)
Valve diameter
EX mm (in.) 28 (1.1)
Tappet clearance IN std. mm (in.) 0.23 – 0.27 (0.009 – 0.011)
(Cold engine condition) EX std. mm (in.) 0.23 – 0.27 (0.009 – 0.011)
IN — 15°, 45°, 60°
Valve seat angle
EX — 15°, 45°
std. mm (in.) 0.020 – 0.047 (0.0008 – 0.0019)
IN
Valve guide to valve stem Limit mm (in.) 0.070 (0.0028)
clearance std. mm (in.) 0.045 – 0.072 (0.0018 – 0.0028)
EX
Limit mm (in.) 0.090 (0.0035)
IN,
Valve guide inside diameter std. mm (in.) 6.000 – 6.012 (0.2362 – 0.2367)
EX
IN,
Valve guide protrusion std. mm (in.) 13.3 – 13.7 (0.52 – 0.54)
EX
IN std. mm (in.) 5.965 – 5.980 (0.2348 – 0.2354)
Valve stem outside diameter
EX std. mm (in.) 5.940 – 5.955 (0.2339 – 0.2344)
IN Limit mm (in.) 0.14 (0.0055)
Valve stem deflection
EX Limit mm (in.) 0.18 (0.0071)
IN,
Valve stem runout Limit mm (in.) 0.05 (0.002)
EX
IN,
Valve head radial runout Limit mm (in.) 0.08 (0.003)
EX
std. mm (in.) 1.0 (0.04)
IN
Limit mm (in.) 0.7 (0.03)
Valve head thickness
std. mm (in.) 1.2 (0.05)
EX
Limit mm (in.) 0.7 (0.03)
IN std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
Valve seat contact width
EX std. mm (in.) 1.1 – 1.3 (0.04 – 0.05)
std. mm (in.) 42.73 (1.682)
Valve spring free length
Limit mm (in.) 41.02 (1.615)
std. N (kg, lbs) 164 – 190 (16.7 – 19.4, 36.8 – 42.7) at 32.6 mm (1.28 in.)
Valve spring preload
Limit N (kg, lbs) 151 (15.1, 33.3) at 32.6 mm (1.28 in.)
Valve spring squareness Limit mm (in.) 2.0 (0.08)
0A-11 General Information:

Cylinder / Piston / Piston Ring

Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Cylinder distortion Limit mm (in.) 0.05 (0.002)
std. mm (in.) 0.020 – 0.040 (0.0008 – 0.0016)
Piston to cylinder clearance
Limit mm (in.) 0.100 (0.0039)
Cylinder bore std. mm (in.) 86.000 – 86.020 (3.3858 – 3.3866)
Cylinder measuring position mm (in.) 50 (2.0) from cylinder top surface
Piston skirt diameter std. mm (in.) 85.970 – 85.990 (3.3846 – 3.3854)
Piston measuring position mm (in.) 26.5 (1.04) from piston skirt end
Cylinder bore wear Limit mm (in.) 0.100 (0.0039)
std. mm (in.) 0.20 – 0.35 (0.008 – 0.014)
1st
Limit mm (in.) 0.70 (0.028)
Piston ring end gap
std. mm (in.) 0.35 – 0.50 (0.014 – 0.020)
2nd
Limit mm (in.) 1.00 (0.039)
std. mm (in.) Approx. 11.6 (0.46)
1st
Limit mm (in.) 9.3 (0.37)
Piston ring free end gap
std. mm (in.) Approx. 11.5 (0.45)
2nd
Limit mm (in.) 9.2 (0.36)
std. mm (in.) 0.030 – 0.070 (0.0012 – 0.0028)
1st
Piston ring to groove Limit mm (in.) 0.120 (0.0047)
clearance std. mm (in.) 0.020 – 0.060 (0.0008 – 0.0024)
2nd
Limit mm (in.) 0.100 (0.0039)
1st std. mm (in.) 1.22 – 1.24 (0.048 – 0.049)
Piston ring groove width 2nd std. mm (in.) 1.51 – 1.53 (0.059 – 0.060)
Oil std. mm (in.) 2.51 – 2.53 (0.099 – 0.100)
1st std. mm (in.) 1.17 – 1.19 (0.046 – 0.047)
Piston ring thickness
2nd std. mm (in.) 1.47 – 1.49 (0.058 – 0.059)
std. mm (in.) 0.006 – 0.017 (0.0002 – 0.0007)
Pin clearance in piston pin hole
Limit mm (in.) 0.040 (0.0016)
std. mm (in.) 20.997 – 21.000 (0.8267 – 0.8268)
Piston pin outside diameter
Limit mm (in.) 20.980 (0.8260)
std. mm (in.) 21.006 – 21.014 (0.8270 – 0.8273)
Piston pin hole diameter
Limit mm (in.) 21.040 (0.8283)
std. mm (in.) 0.003 – 0.016 (0.0001 – 0.0006)
Pin clearance in conrod small end
Limit mm (in.) 0.05 (0.002)

Crankshaft / Conrod
Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Conrod small end inside diameter std. mm (in.) 21.003 – 21.013 (0.8269 – 0.8273)
std. mm (in.) 0.032 – 0.050 (0.0013 – 0.0020)
Conrod big end oil clearance
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 47.000 – 47.018 (1.8504 – 1.8511)
Crank pin outside diameter std. mm (in.) 43.982 – 44.000 (1.7316 – 1.7323)
Crank pin outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Conrod bearing thickness std. mm (in.) 1.481 – 1.496 (0.0583 – 0.0589)
std. mm (in.) 0.100 – 0.250 (0.0039 – 0.0098)
Conrod big end side clearance
Limit mm (in.) 0.350 (0.0138)
Conrod big end width std. mm (in.) 21.950 – 22.000 (0.8642 – 0.8661)
Crank pin width std. mm (in.) 22.100 – 22.200 (0.8700 – 0.8740)
Crankshaft center journal runout Limit mm (in.) 0.04 (0.002)
std. mm (in.) 0.020 – 0.040 (0.0008 – 0.0016)
Crankshaft journal oil clearance
Limit mm (in.) 0.065 (0.0026)
Crankcase bearing holder inside
std. mm (in.) 62.000 – 62.018 (2.4409 – 2.4417)
diameter
 General Information: 0A-12

Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Crankshaft journal outside diameter std. mm (in.) 57.994 – 58.012 (2.2832 – 2.2839)
Crankshaft journal outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (Out-of-round and taper)
Crankshaft bearing thickness std. mm (in.) 1.991 – 2.006 (0.0783 – 0.0790)
std. mm (in.) 0.11 – 0.31 (0.004 – 0.012)
Crankshaft thrust play
Limit mm (in.) 0.35 (0.014)
Crankshaft thrust bearing thickness std. mm (in.) 2.425 – 2.475 (0.0955 – 0.0974)

Electrical
Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Degrees at r/
Ignition timing BTDC 10° – 26°
min
Over revolution limiter r/min 6 200 6 500
CKP sensor resistance Ω at 20 °C 168 – 252
CMP sensor resistance Ω at 20 °C —
Primary Ω at 20 °C 1.9 – 2.5
No.2 – No.3: 18 – 34
Ignition coil resistance (Including high-tension cord and spark plug cap)
Secondary kΩ at 20 °C
No.1 – No.4: 19 – 36
(Including high-tension cord and spark plug cap)
High tension code kΩ/m at 20 °C 12.8 – 19.2 (Approx. 16)
Battery charge coil resistance Ω at 20 °C 0.15 – 0.25
Battery charge coil output (12 V) Watt 480
Type NGK BKR6E
Standard spark plug
Gap mm (in.) 0.7 – 0.8 (0.028 – 0.031)
Main fuse: 60
Load fuse: 60
Starter motor: 30
Fuse amp. rating A
PTT switch: 15
Ign. coil/Injector/ECM/IAC: 30
Fuel pump: 15
Recommended battery capacity (12 V) Ah (kC) 100 (360) or larger
Fuel injector resistance Ω at 20 °C 10 – 14
IAC valve resistance Ω at 20 °C 8 – 12
IAT sensor/Cylinder temp. sensor/Ex.
mani. temp. sensor (Thermistor kΩ at 25 °C 1.8 – 2.3
characteristic)
O2 sensor heater Ω at 20 °C 5.5 – 8.5
ECM main relay coil resistance Ω at 20 °C 145 – 190
Starter motor relay coil resistance Ω at 20 °C 145 – 190
PTT motor relay coil resistance Ω at 20 °C 16 – 24

Starter Motor
Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
Max. continuous time of use Sec. 30
Motor output kW 1.4
std. mm (in.) 16.0 (0.63)
Brush length
Limit mm (in.) 12.0 (0.47)
std. mm (in.) 0.5 – 0.8 (0.02 – 0.03)
Commutator undercut
Limit mm (in.) 0.2 (0.01)
std. mm (in.) 29.0 (1.14)
Commutator outside diameter
Limit mm (in.) 28.0 (1.10)
0A-13 General Information:

PTT Motor
Data
Item Unit DF115AT/ DF140AT/
DF100AT
DF115AZ DF140AZ
std. mm (in.) 9.8 (0.39)
Brush length
Limit mm (in.) 5.5 (0.22)
std. mm (in.) 22.0 (0.87)
Commutator outside diameter
Limit mm (in.) 21.0 (0.83)

Self-Diagnostic Code
0: OFF, 1: ON
Fail-safe system
Failed item Code Lamp flashing pattern
activating
1

MAP sensor 1 3–4 0

YES
MCODE00D34-0-01
1

Cylinder temp. sensor 1–4 0

YES
MCODE00D14-0-01
1

IAT sensor 2–3 0

YES
MCODE00D23-0-01
1

CKP sensor 4–2 0

NO
MCODE00D42-0-01
1

CMP sensor 2–4 0

NO
MCODE00D24-0-01
1

Air intake system 2–2 0

YES
MCODE00D22-0-01
1

MAP sensor 2 3–2 0

NO
MCODE00D32-0-01
1

Exhaust manifold temp. sensor 1–5 0

YES
MCODE00D15-0-01
1

Fuel injector 4–3 0

NO
MCODE00D43-0-01
1

Throttle position sensor 2–1 0

YES
MCODE00D21-0-01
1

Rectifier/Regulator (Over-charging) 1–1 0

NO
MCODE00D11-0-01
1

Oil pressure switch 5–3 0

NO
MCODE00D53-0-01
1

Trim sensor 3–7 0

NO
MCODE00D37-0-01
1

Knock sensor 5–4 0

YES
MCODE00D54-0-01
1

O2 sensor 3–6 0
YES
MCODE00D36-0-02
1

O2 sensor heater 6–3 0

YES
MCODE00D63-0-01
 General Information: 0A-14

Tightening Torque Specifications

CENDG2110107003
NOTICE
Failure to use the correct fasteners or to properly use fasteners can cause parts or system damage.
• When fasteners are removed, always reinstall them at the locations from which they were removed.
• All fasteners must be replaced with fasteners having the same part number.
If a fastener of the correct part number is not available, a fastener of the same size having equal or
higher strength may be used.

Important Fasteners
Thread Tightening torque
Item
diameter N⋅m kgf-m lbf-ft
Cylinder head cover bolt 6 mm 11 1.1 8.0
8 mm 25 2.5 18.0
Cylinder head bolt
10 mm 70 7.0 50.5
8 mm 25 2.5 18.0
Crankcase bolt
10 mm 52 5.2 37.5
17 N⋅m (1.7 kgf-m, 12.3 lbf-ft), then plus turn in 60
Conrod cap bolt 9 mm
degrees.
Camshaft housing bolt 6 mm 11 1.1 8.0
Camshaft timing sprocket bolt 10 mm 78 7.8 56.5
Timing chain guide bolt 6 mm 10 1.0 7.0
Intake manifold bolt/nut 8 mm 23 2.3 16.5
Throttle body bolt 8 mm 23 2.3 16.5
Oil pressure switch — 13 1.3 9.5
Fuel delivery pipe bolt/nut 8 mm 23 2.3 16.5
Fuel delivery pipe plug/union Upper 12 mm 35 3.5 25.5
bolt Lower 12 mm 35 3.5 25.5
Low pressure fuel pump bolt 6 mm 10 1.0 7.0
Thermostat cover bolt 6 mm 10 1.0 7.0
Flywheel bolt 16 mm 245 24.5 177.0
8 mm 23 2.3 16.5
Starter motor mounting bolt
10 mm 50 5.0 36.0
Engine oil filter — 14 1.4 10.0
Engine oil drain plug — 13 1.3 9.5
8 mm 23 2.3 16.5
Power unit mounting bolt
10 mm 50 5.0 36.0
Driveshaft housing bolt 10 mm 50 5.0 36.0
Mount case cover bolt 8 mm 23 2.3 16.5
Front 12 mm 80 8.0 58.0
Upper mount nut
Rear 12 mm 80 8.0 58.0
Upper mount cover bolt 10 mm 50 5.0 36.0
Lower mount bolt/nut 12 mm 60 6.0 43.0
Clamp bracket shaft nut — 43 4.3 31.0
Water pump case bolt 8 mm 17 1.7 12.5
Gearcase bolt 10 mm 54 5.5 40.0
Propeller shaft bearing housing bolt 8 mm 23 2.3 16.6
Pinion nut 14 mm 120 12.0 87.0
Propeller nut 18 mm 55 5.5 40.0
0A-15 General Information:

General Bolt

NOTE
These value are only applicable when torque for a general bolt is not listed in the “Important
Fasteners” table.

Thread Tightening torque

Type of bolt
diameter N⋅m kgf-m lbf-ft
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 4–7 0.4 – 0.7 3.5 – 5.0
8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5

I9J011010014-01 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

(Conventional or “4” marked bolt)
5 mm 2–4 0.2 – 0.4 1.5 – 3.0
6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0
8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5

I9J011010015-01 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

(Stainless steel bolt)
5 mm 3–6 0.3 – 0.6 2.0 – 4.5
6 mm 8 – 12 0.8 – 1.2 6.0 – 8.5
8 mm 18 – 28 1.8 – 2.8 13.0 – 20.0

I9J011010016-01 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

(“7” marked bolt)

Special Tools and Equipment

Recommended Service Material
CENDG2110108001

99000–22810 93691–80030 99000–22B22 99000–25350 99000–31140

PTT Fluid SUZUKI Silicone Seal SUZUKI Outboard SUZUKI Water SUZUKI Bond 1207B
(100 g) Motor Gear Oil Resistant Grease EP2 (100 g)
(250 g)

99000–32020 99000–32050
SUZUKI Thread Lock SUZUKI Thread Lock
Super 1333B (50 g) 1342 (50 g)
 General Information: 0A-16

Special Tool
CENDG2110108002

01500–08403 09900–20101 09900–20202 09900–20203 09900–20204

Bolt Vernier calipers (150 Micrometer (25 – 50 Micrometer (50 – 75 Micrometer (75 – 100
mm) mm) mm) mm)

09900–20205 09900–20602 09900–20605 09900–20606 09900–20607

Micrometer (0 – 25 Dial gauge Dial calipers (10 – 34 Dial gauge Dial gauge
mm) mm)

09900–20701 09900–20803 09900–21304 09900–22301 09900–25008

Magnetic stand Thickness gauge Steel “V” block set Plastigauge (0.025 – Multi circuit tester set
0.076 mm)

09900–28403 09912–58432 09912–58442 09912–58490 09913–50121

Hydrometer Fuel pressure hose Fuel pressure gauge 3-way joint & hose Oil seal remover

09915–47341 09915–64512 09915–64530 09915–67010 09915–77311

Oil filter wrench Compression gauge Compression gauge Compression gauge Oil pressure gauge
hose hose attachment
0A-17 General Information:

09915–78211 09916–10911 09916–14910 09916–19030 09916–34542

Oil pressure gauge Valve lapper Valve lifter attachment Valve lifter Valve guide reamer
adapter handle

09916–37810 09916–38210 09916–46020 09916–49040 09916–57350

Valve guide reamer (ø Valve guide reamer (ø Valve guide remover Tappet holder Valve guide installer
6 mm) 11 mm) handle

09916–68010 09916–77310 09916–84511 09917–47011 09917–49610

Tappet holder spacer Piston ring Tweezers Vacuum pump gauge Vacuum pump adapter
compressor

09917–87810 09917–98221 09919–16010 09921–29410 09922–59410

Valve guide installer Valve guide stem seal Deep socket wrench Driveshaft holder Propeller shaft
attachment installer attachment (10 mm) housing installer

09922–59420 09922–89810 09923–73210 09930–30104 09930–30161

Housing installer Shift lock pin remover Bearing remover Sliding hammer Propeller shaft
handle remover
 General Information: 0A-18

09930–39220 09930–49220 09930–76310 09930–89260 09930–89290

Flywheel remover Flywheel holder Timing light Injector test cord (A) 18 pin & 34 pin test
cord

09930–99320 09933–39810 09941–64511 09944–09810 09944–09820

Digital tester O2 sensor socket Bearing remover PTT trim cap tool PTT cylinder cap tool

09945–69010 09945–79310 09950–69512 09951–09020 09951–09030

PTT rod holder PTT cable extension Gearcase oil leakage Gear adjust spring set Driveshaft preloading
tester spring set

09951–09530 09951–19220 09951–38710 09951–59910 09951–99310

Gear adjusting gauge Attachment Plate Shaft (removal and Gear holder
installation)

09952–09310 09952–99320 Stevens peak reading

Backlash indicator tool Hand air pump voltmeter CD-77
0B-1 Maintenance and Tune-Up:

Maintenance and Tune-Up

General Information

Precautions
Precautions for Maintenance
CENDG2110200001
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
CENDG2110201001
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-3).

Scheduled Maintenance
Periodic Maintenance Schedule Chart
CENDG2110205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace

Interval
Item to be serviced Initial 20 hrs. Every 100 hrs. Every 200 hrs. Every 300 hrs.
or 1 month or 12 months or 12 months or 36 months
Spark plug — I — —
Breather & Fuel line I I — —
Engine oil R R — —
Gear oil R R — —
Lubrication I I — —
Anodes (External) I I — —
Anodes (Internal powerhead) — I — —
Bonding wires — I — —
Battery I I — —
Engine oil filter R — R —
I I — —
Low pressure fuel filter
Replace every 400 hours or 2 years.
Ignition timing — — I —
Idle speed I — I —
Tappet clearance — — — I
Water pump — — I —
Water pump impeller — — I R
Propeller nut & pin I I — —
Bolt & Nuts T T — —
 Maintenance and Tune-Up: 0B-2

Lubrication Point
CENDG2110205002
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
Initially after 20 hours (1 month) and every 100 hours (12 months)
: Grease 99000–25350 (SUZUKI Water Resistant Grease EP2 (250 g))

4
5

IDG211020029-02

1. Throttle and shift linkage 3. Trim ram pad (DF140A) 5. Propeller shaft
2. Grease nipple, swivel bracket 4. Grease nipple, steering bracket
0B-3 Maintenance and Tune-Up:

Service Instructions
Engine Oil Level Check Engine Oil Change and Engine Oil Filter
CENDG2110206001
Replacement
Inspect oil level CENDG2110206002

Before every use Change engine oil

Initially after 20 hours (1 month) and every 100 hours
1) Place outboard motor upright on a level surface.
(12 months)
2) Remove motor cover.
3) Remove oil level dipstick (1) and wipe it clean. 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.

1
Engine Oil Change
IDG211020030-01 1) Place outboard motor upright on a level surface.
4) Reinsert dipstick fully into dipstick tube, then remove 2) Remove oil filler cap.
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: IDG211020003-03
SG, SH, SJ, SL, SM. 3) Place a container under engine oil drain plug.
• Viscosity rating: 4) Remove engine oil drain plug (1) and gasket (2) to
NMMA FC-W 10W-40 or SAE 10W-40 drain engine oil.

2
1
“A”

“B”
IDG211020001-04 IDG211020005-03

“A”: Max. mark (Hole) “B”: Min. mark (Hole)

IDG211020002-02
 Maintenance and Tune-Up: 0B-4

5) Install new gasket and oil drain plug. 7) Reset oil change reminder system’s operation time
Tighten engine oil drain plug to specified torque. to zero (cancellation).

NOTICE NOTE
A previously-used gasket may leak, resulting Refer to “Oil Change Reminder System
in engine damage. Description” in Section 1A (Page 1A-14).

To avoid water entry into oil pan or oil 8) Start engine and allow it to run for several minutes at
leakage into the environment do not reuse idle speed.
gasket once removed. Check oil drain plug for oil leakage.
Always use a new one. Turn off engine and wait for approx. two minutes,
then recheck engine oil level.
Tightening torque
Engine oil drain plug (a): 13 N·m (1.3 kgf-m, 9.5 Engine Oil Filter Replacement
lbf-ft) 1) Drain engine oil in the same manner of engine oil
change procedure.
2) Remove STBD lower side cover.
Refer to “Lower Side Cover Removal and
(a) 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)
IDG211020006-02

6) Pour recommended engine oil into oil filler opening,

then install oil filler cap.
Recommended engine oil
• 4 stroke motor oil (A)

• 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 IDG211020038-01

Engine oil amounts NOTE

Oil change only: 5.5 L (5.8/4.8 US/Imp.qt)
Before fitting a new oil filter, be sure to oil the
Oil filter change: 5.7 L (6.0/5.0 US/Imp.qt)
O-ring.

IDG211020004-02

I9J011020004-01
0B-5 Maintenance and Tune-Up:
5) Screw the new filter on by hand until filter O-ring
contacts the mounting surface.
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)
IDG211020039-02
7) Install STBD lower side cover.
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.
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: 5.5 L (5.8/4.8 US/Imp.qt)
Oil filter change: 5.7 L (6.0/5.0 US/Imp.qt)
9) 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).
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.
Gear Oil Change
CENDG2110206003
Change gear oil
Initially after 20 hours (1 month) and every 100 hours
(12 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.
1
IDG211020007-03
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
1050 ml (35.5/37.0 US/Imp. oz)
IDG211020008-02
5) Install oil level plug before removing oil filler tube
from drain hole.
6) Install oil drain plug.
NOTICE
An used gasket may leak and allow water to
enter the gearcase causing severe damage.
Do not reuse gaskets once removed.
Always use a new gasket.
NOTE
To avoid a possible low gear oil level,
recheck gear oil level 10 minutes after doing
procedure in step 6. If oil level is low, add
additional gear oil until level is correct.
 Maintenance and Tune-Up: 0B-6

Spark Plug Removal and Installation Tightening torque

CENDG2110206004 Spark plug (a): 28 N·m (2.8 kgf-m, 20.0 lbf-ft)
Inspect spark plug
Every 100 hours (12 months)
Standard spark plug
NGK BKR6E
(a)
NOTICE
Non-resistor types of spark plugs will
interfere with the function of the electronic
ignition, causing misfiring, or causing
problems with other electronic boat
equipment and accessories.
IDG211020042-02

Only resistor (R) type spark plugs must be

used with this engine. Spark Plug Inspection and Cleaning
CENDG2110206005
NOTICE
Removal
Non-resistor types of spark plugs will
! WARNING interfere with the function of the electronic
ignition, causing misfiring, or causing
The hot engine can burn you.
problems with other electronic boat
equipment and accessories.
Wait until the engine is cool enough to touch.
Only resistor (R) type spark plugs must be
1) Disconnect the spark plug caps (1).
used with this engine.

Inspect spark plug

Every 100 hours (12 months)
Standard spark plug
NGK BKR6E
1
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.

IDG211020040-01

2) Remove the spark plugs (2) with spark plug wrench.

I9J011020005-01

IDG211020041-03

Installation
Installation is reverse order of removal.
Pay attention to the following:
IDG211020060-01
• Tighten the spark plug to specified torque.
0B-7 Maintenance and Tune-Up:

Spark Plug Gap Tappet clearance adjustment should be checked and

Measure spark plug gap with a thickness gauge. Adjust adjusted:
to within specified range if gap is out of specification. • During scheduled periodic inspection.
Special tool • When valve mechanism is serviced.
: 09900–20803 (Thickness gauge) • When camshafts are disturbed by removing them for
Spark plug gap “a” (Standard) inspection.
0.7 – 0.8 mm (0.028 – 0.031 in.) 1) Remove following parts:
• Lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
• Spark plugs.
Refer to “Spark Plug Removal and Installation”
(Page 0B-6).
2) Remove the ring gear cover (1).
“a”

1
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.

NOTICE
IDG211020054-01
Use of improper spark plugs can cause
severe engine damage. 3) Remove the cylinder head cover (2).
If the reach is too short, carbon will be Refer to “Cylinder Head Cover Removal and
deposited on the threaded portion of the plug Installation” in Section 1D (Page 1D-2).
hole resulting in possible engine damage.

Confirm the thread size and reach when

replacing the plug.

Tappet Clearance Inspection and Adjustment

CENDG2110206006

Inspect tappet clearance

Every 300 hours (36 months)
Inspection 2
The tappet clearance specification is the same for both IDG211020013-05
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.
 Maintenance and Tune-Up: 0B-8

NOTE
This is a left hand (LH) rotation powerhead.
4) Rotate crankshaft counterclockwise to bring cam
nose vertical to shim surface.
5) Measure tappet clearances by inserting thickness
gauge between cam and shim surface.
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.

NOTICE
Turning of the engine in clockwise can cause
water pump impeller damage.

Rotate the crankshaft in the normal running

direction only (counterclockwise) to prevent
“B”
water pump impeller damage. 1 “A”
I9J011020009-01

NOTE 1. Shim “B”: Spark plug hole

• 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.: 0.23 – 0.27 mm (0.009 – 0.011 in.)
“A”: Cut section of the tappet
2) Rotate crankshaft to open (lift up) valve and then
remove camshaft housing bolts where shim is to be
replaced.
3) Assemble the special tools “A” and “B”, then install
special tools with camshaft housing bolts as shown
in figure.
Special tool
(A): 09916–49040 (Tappet holder)
(B): 09916–68010 (Tappet holder spacer)
2

“a”
(A)

(B)
(A)

I9J011020008-01

“a”: 90° IDG211020012-02

2. Camshaft housing bolt

6) If out of specification, adjust tappet clearance by
changing shim.

(A)
(B)

IDG211020055-01

2. Camshaft housing bolt

0B-9 Maintenance and Tune-Up:

! WARNING Tappet clearance specifications

Failure to take proper precautions when
installing or removing the tappet shim can
result in severe personal injury.
When installing or removing the tappet shim:
• Never put in the hand between camshaft
and tappet.
• Use a magnet to remove and install shim.
IN. side: A = B + (C – 0.25 mm)
EX. side: A = B + (C – 0.25 mm)
A: Correct thickness of shim for proper tappet
clearance (mm)
B: Thickness of original shim (mm)
C: Original tappet clearance (mm)
“C”

250 “a”
4) Rotate top of cam 90 degree clockwise and remove
shim from cut-away at tappet.
(Two tappets can be adjusted at the same time)
I9J011020013-01

4 “C”: I.D No. “a”: 2.50 mm

Shim size chart

Thickness Thickness
I.D. No. I.D. No.
(mm) (mm)
218 2.18 260 2.60
3 220 2.20 263 2.63
223 2.23 265 2.65
225 2.25 268 2.68
228 2.28 270 2.70
IDG211020043-01 230 2.30 273 2.73
3. Shim 4. Magnet 233 2.33 275 2.75
235 2.35 278 2.78
NOTE 238 2.38 280 2.80
240 2.40 283 2.83
When installing shim, identification mark on
243 2.43 285 2.85
the shim should face down (towards tappet).
245 2.45 288 2.88
248 2.48 290 2.90
5) After removing shim, measure thickness of original
250 2.50 293 2.93
shim and determine correct thickness of shim for
253 2.53 295 2.95
proper tappet clearance as calculated by following
255 2.55 298 2.98
formula.
258 2.58 300 3.00
Special tool
(C): 09900–20205 (Micrometer (0 – 25 mm))

(C)

IDG211020056-01
 Maintenance and Tune-Up: 0B-10

6) Install shim with the identification number facing 10) After checking and adjusting all valves, reinstall parts
down (towards tappet). removed earlier.
7) Rotate crankshaft to open (lift up) valve. Installation is reverse order of removal.
8) Remove special tools and tighten camshaft housing a) Cylinder Head Cover Installation.
bolts (a) to specified torque. • Install the cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Tightening torque
Installation” in Section 1D (Page 1D-2).
Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft) NOTE
Examine cylinder head cover gasket for
5 (A)
damage. Always replace gasket if sealing
(B)
performance is suspect.

Tightening torque
Cylinder head cover bolts (b): 11 N·m (1.1
(a)
kgf-m, 8.0 lbf-ft)

11 12
6
IDG211020044-02 3
5. Tappet 6. Camshaft 5 8

1 2
9) Recheck tappet clearance.
7 6
NOTE 4
9 10
After completing tappet clearance
adjustment and securing camshaft housing
15
bolts, inspect tappet clearance again. 13 14
IDG211020011-03

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.
 TAPPET SHIM SELECTION CHART [IN. and EX. side]
Shim I.D.
No. 218 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

Present shim
size (mm)

Tappet 2.18 2.20 2.23 2.25 2.28 2.30 2.33 2.35 2.38 2.40 2.43 2.45 2.48 2.50 2.53 2.55 2.58 2.60 2.63 2.65 2.68 2.70 2.73 2.75 2.78 2.80 2.83 2.85 2.88 2.90 2.93 2.95 2.98 3.00
clearance
(mm)

0.00 – 0.04 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278

0.05 – 0.09 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283
0B-11 Maintenance and Tune-Up:

0.10 – 0.14 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288

0.15 – 0.19 220 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293

0.20 – 0.22 220 223 225 225 228 230 233 235 240 240 245 245 250 250 255 255 260 260 263 265 270 270 273 278 280 280 283 285 290 290 293 295

0.23 – 0.27 SPECIFIED CLEARANCE / NO ADJUSTMENT REQUIRED

0.28 – 0.32 223 225 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.33 – 0.37 228 230 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.38 – 0.42 233 235 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.43 – 0.47 238 240 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.48 – 0.52 243 245 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.53 – 0.57 248 250 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300

0.58 – 0.62 253 255 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
Tappet shim selection chart (IN. and EX. side)

0.63 – 0.67 258 260 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300 1. Measure tappet clearance “Engine cold”.
2. Measure present shim size.
0.68 – 0.72 263 265 268 270 273 275 278 280 283 285 288 290 293 295 298 300
3. Match clearance in vertical column with
0.73 – 0.77 268 270 273 275 278 280 283 285 288 290 293 295 298 300 present shim size in horizontal column.
0.78 – 0.82 273 275 278 280 283 285 288 290 293 295 298 300
[ EXAMPLE ]
0.83 – 0.87 278 280 283 285 288 290 293 295 298 300
Tappet clearance is — 0.35 mm
0.88 – 0.92 283 285 288 290 293 295 298 300 Present shim size — 2.40 mm
Shim size to be used — 2.50 mm

IDG211020014-01
 Maintenance and Tune-Up: 0B-12

Idle Speed and Idle Air Control (IAC) Duty Check idle speed and IAC duty as follows. To perform
Inspection idle speed and IAC duty inspection, use personal
CENDG2110206007 computer and SDS tool.
Inspect idle speed and IAC duty 1) Connect SDS tool to engine.
Initially after 20 hours (1 month) and every 200 hours Refer to SDS operation manual for the step 1
(12 months) procedure.
NOTE 2) Start engine and allow to warm up.
3) Check engine speed and IAC duty by using “Service
Before checking idle speed/IAC duty, make
data/Engine data” mode on SDS.
sure of the following.
4) If IAC duty and/or idle speed is out of specification,
• Engine must be warmed up.
inspect idle speed control system referring to “Idle air
• Check idle speed after engine speed has control system check”.
stabilized.
Idle speed in neutral gear (IAC duty)
• Check throttle link mechanism and throttle
650 – 750 r/min (Duty: Approx. 40 – 50%)
valve for smooth operation.
• Lead wires and hoses of electronic fuel 5) Shift into forward, check in-gear idle speed.
injection and engine control systems are If not, check idle air control system.
connected securely.
NOTE
• Ignition timing is within specification.
• Tappet clearance is checked according to • Trolling speed (in-gear idle speed) is same
maintenance schedule. as idle speed.
• No abnormal air drawn in from air intake • Idling/trolling speed of 650 – 750 r/min. is
system. controlled by IAC system.
After all items are confirmed, check idle
Idle speed in gear (IAC duty)
speed and IAC duty.
650 – 750 r/min (Duty: Approx. 40 – 50%)

Ignition Timing Inspection

CENDG2110206008

Inspect ignition timing

1
Every 200 hours (12 months)

NOTE
2 Before checking the ignition timing, make
sure idle speed is adjusted within
specification.

1) Start the engine and allow to warm up.

IDG211020045-02
2) Attach the timing light cord to the No.1 ignition high-
1. IAC valve 2. Throttle body
tension cord (1).
Special tool
(A): 09930–76310 (Timing light)

(A)
IDG211020046-02

3. SDS service connector

IDG211020049-01
0B-13 Maintenance and Tune-Up:

3) Check the ignition timing while operating the engine

in neutral gear at 1 000 r/min.
Ignition timing
Approx. BTDC 10° at 1 000 r/min

(A)

IDG211020050-01

Breather Line and Fuel Line Inspection

CENDG2110206009

Inspect breather line and fuel line

Initially after 20 hours (1 month) and every 100 hours (12 months)
If leakage, cracks, swelling or other damage is found, replace the breather hose and/or fuel line.

Fuel line check point

IDG211020047-02
 Maintenance and Tune-Up: 0B-14

Low Pressure Fuel Filter Inspection 3) Remove the nut (1) securing the low pressure fuel
CENDG2110206010 filter to filter bracket.
Inspect low pressure fuel filter
Initially after 20 hours (1 month) and every 100 hours
(12 months) 1

Replace low pressure fuel filter

Every 400 hours or 2 years
If water accumulation, sediment, leakage, cracks or
other damage is found, replace the low pressure fuel
filter.

IDG211020057-01

NOTICE
Improperly loosening the filter cup can cause
switch lead wires damage.
• Be careful not to twist the switch lead wire
when removing the filter cup.
1
• Disconnect the lead wire connector before
removing the filter cup.
IDG211020051-01

1. Low pressure fuel filter 4) Push the connector lock tab “A”, then disconnect the
switch lead wire connector (2).
! WARNING
Gasoline is extremely flammable and toxic.
It can cause a fire and can be hazardous to
people and pets.
2

Always take the following precautions when

servicing the fuel filter
• Stop the motor before cleaning the low
pressure fuel filter. “A”
• Be careful not to spill fuel. If you do, wipe it
up immediately. IDG211020058-02

• Do not smoke, and keep away from open 5) Place a rag under the filter before removal to catch
flames and sparks. any spilled fuel.
6) Separate the fuel filter cup (3) from the fuel filter
1) Turn the engine off and allow it to cool. body (4) by turning the fuel filter cup
Make sure that the ignition key is in the OFF counterclockwise.
position.
2) Remove STBD lower side cover.
Refer to “Lower Side Cover Removal and 4
Installation” in Section 2A (Page 2A-3).

IDG211020059-01

7) Drain fuel and water in the fuel filter cup (3) into a
suitable container.
0B-15 Maintenance and Tune-Up:

8) Pull out the filter element (5). 1) Remove the lower unit and water pump case.
9) Inspect the filter element (5), O-ring (6) and seal ring Refer to “Water Pump Removal and Installation” in
(7) for damage. Section 3A (Page 3A-6).
If they are damaged, replace them. 2) Inspect water pump case, inner sleeve and under
panel. Replace if wear, cracks, distortion or corrosion
4 is found.
3) Inspect water pump impeller.
Replace if vanes are cut, torn or worn.
7 SUZUKI recommends that replacing the water pump
6
5 impeller every 300 hours (36 months).
4) Assemble the water pump related items.
3 Refer to “Water Pump Removal and Installation” in
Section 3A (Page 3A-6).
IDG211020031-03
5) Install the lower unit assembly.
Refer to “Lower Unit Removal and Installation” in
10) Wash the filter element (5) with clean solvent and dry
Section 3A (Page 3A-5).
it.
11) Assemble the seal ring (7) and filter element (5) in
Propeller / Propeller Nut and Cotter Pin
their original positions.
Inspection
12) Verify that the O-ring (6) is in place in the top of the CENDG2110206013
filter cup (3) and screw the filter cup back into place. Inspect propeller/propeller nut and cotter pin
13) Connect the switch lead wire connector (2). Initially after 20 hours (1 month) and every 100 hours
14) Reinstall the fuel filter. (12 months).
15) Restart the engine and check that there are no leaks 1) Inspect propeller for bent, chipped or broken blades.
around the fuel filter. Replace propeller if damage noticeably affects
operation.
Water Pump and Water Pump Impeller 2) Remove the propeller.
Inspection Refer to “Propeller Removal and Installation” in
CENDG2110206012
Section 3A (Page 3A-4).
Inspect water pump/pump impeller 3) Inspect propeller splines. Replace propeller if splines
Every 200 hours (12 months) are worn, damaged or twisted.
Replace water pump impeller 4) Inspect propeller bush for slippage.
Every 300 hours (36 months) Replace if necessary.

IDG211020016-01

IDG211020032-01

IDG211020017-01

IDG211020033-01
 Maintenance and Tune-Up: 0B-16

5) Install the propeller and related parts. NOTE

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)
The anode cover (1) may be separated from
the power unit body by inserting and turning
a 10 mm bolt (2) to function as a screw jack.
2

Anode Inspection 1 1
CENDG2110206014

Inspect anodes (External)

Initially after 20 hours (1 month) and every 100 hours
(12 months)
Inspect anodes (Internal powerhead)
Every 100 hours (12 months)
IDG211020036-02
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.

NOTICE
If anodes are not properly maintained,
underwater aluminum surfaces (such as the
lower unit) will suffer galvanic corrosion
damage.
• Periodically inspect anodes to make sure
they have not become detached.
IDG211020037-01
• Do not paint anodes, as this will render
them ineffective. NOTE
• Periodically clean anodes with a wire The anode (3) securing bolt should be
brush to remove any coating which might covered with suzuki silicone seal.
decrease their protective ability.
: Sealant 93691–80030 (SUZUKI Silicone Seal
(100 g))

IDG211020034-01

I9J011020023-01

IDG211020035-01
0B-17 Maintenance and Tune-Up:

Bonding Wire Inspection • Batteries should always be kept out of

CENDG2110206015 reach of children.
Inspect bonding wires • When checking or servicing battery,
Every 100 hours (12 months) disconnect the negative (black) cable.
If breakage or other damage is found on bonding wire, Be careful not to cause a short circuit by
replace the wire. allowing metal objects to contact the
If rust, corrosion or other damage is found on terminal, battery posts and motor at the same time.
clean with cleaning solvent or replace the wire. • Wear approved eye protection.

Recommended battery
12 V 100 AH (360 kC) or larger
Refer to “Battery Requirement” in Section 0A (Page 0A-
5).

Connecting Battery

! WARNING
IDG211020021-01 Battery posts, terminals, and related
accessories contain lead and lead
compounds that may be hazardous.

Wash hands after handling.

NOTICE
The electrical system or its components may
be damaged if proper battery precautions are
not followed.
IDG211020022-01
• Be sure to attach battery leads correctly.
Wing nuts must not be used and hexagon
nuts must be used to secure battery cable
Battery Inspection
CENDG2110206016 to the battery terminals to avoid loss of
electrical power.
Inspect battery
Initially after 20 hours (1 month) and every 100 hours • Do not disconnect battery leads from the
(12 months) battery while the engine is running.

! WARNING
Failure to take proper precautions when
handling the battery may cause severe injury.

Be sure to take the following precautions

when handling the battery:
• Never expose the battery to open flames or
electric sparks as batteries generate gas
which is flammable and explosive.
• Do not place the battery near the fuel tank.
• Battery acid is poisonous and corrosive.
Avoid contact with eyes, skin, clothing,
and painted surfaces.
If you come in contact with battery acid,
flush immediately with large amounts of
water and seek immediate medical
attention.
 Maintenance and Tune-Up: 0B-18

How to connect Battery solution level should be between UPPER level

1) Connect positive (+) terminal first. and LOWER level.
If level is low, add distilled water only.
2) Connect negative (–) terminal second.
3) Upon completion of connection, lightly apply grease
to battery terminals.

I9J011020031-01

Battery Solution Specific Gravity Check

Measure the specific gravity of battery solution using a
IAJ311020003-01 hydrometer.
1. Red lead 2. Black lead Battery solution specific gravity (Temperature)
1.28 (20 °C)
How to disconnect
Special tool
1) Disconnect negative (–) terminal first. : 09900–28403 (Hydrometer)
2) Disconnect positive (+) terminal second.

I9J011020032-01

IAJ311020004-01 Bolts and Nuts Inspection

CENDG2110206017
1. Red lead 2. Black lead
Inspect bolts and nuts
Battery Solution Level Check Initially after 20 hours (1 month) and every 100 hours
(12 months)
NOTICE
Check that all bolts and nuts listed below are tightened
If you add diluted sulphuric acid to the to their specified torque.
battery after it has been initially serviced, you Refer to “Tightening Torque Specifications” in Section 0A
will damage the battery. (Page 0A-14).
• Cylinder head cover bolts
Never add diluted sulphuric acid to the
battery after it has been initially serviced. • Intake manifold bolts and nuts
Follow the battery manufacturer’s • Flywheel bolt
instructions for specific maintenance • Power unit mounting bolts
procedures.
• Clamp bracket shaft nut
• Lower mount bolts and nuts
• Gearcase bolts
• Propeller nut
0B-19 Maintenance and Tune-Up:

Oil Pressure Check 5) Connect the oil pressure switch lead wire to engine
CENDG2110206018 body ground by using an appropriate jumper wire.
! CAUTION
Engine oil can be hot enough to burn you.

Do not remove the oil pressure gauge

adapter when the engine is hot. Wait until
engine cools.

Check the engine oil pressure periodically. IDG211150018-01

1) Check the engine oil level. NOTE

2) Remove the bolts and air duct (1).
You should remove oil pressure switch after
disconnecting its lead when perform the oil
1 pressure test.
Then diagnostic code of oil pressure switch
will be displayed while performing the test.
Connect the oil pressure switch lead wire to
engine body ground by using an appropriate
jumper wire before the test (turning on the
ignition switch).
So that the diagnostic code won’t be
displayed.
After the engine starts, disconnect the
IDG211020023-04 jumper wire from switch lead wire.
3) Loosen screw and disconnect blue lead wire (3) from
oil pressure switch (2). NOTE
Remove the oil pressure switch. For cancellation of the self-diagnostic
indication”, refer to “Self-Diagnostic System
Description” in Section 1A (Page 1A-9).

6) Start engine and allow to warm up.

2 7) After the engine starts, disconnect the jumper wire
from switch lead wire.
8) After warming up, shift into forward gear and
increase engine speed to 3 000 r/min, then compare
3 pressure indicated on gauge to specifications.

IDG211020048-01

4) Install oil pressure gauge adaptor into oil pressure

switch hole in place of oil pressure switch.
Special tool
(A): 09915–77311 (Oil pressure gauge)
(B): 09915–78211 (Oil pressure gauge
adapter)
I9J011020033-01

NOTE
(B)
The figure shown below is a guideline only,
not an absolute service limit.

Oil pressure
410 – 490 kPa (4.1 – 4.9 kg/cm2, 63 – 70 psi.)
(A)

IDG211020052-01
 Maintenance and Tune-Up: 0B-20

If oil pressure is lower or higher than specification, 5) Disconnect remote control throttle cable from throttle
the following causes may be considered. lever.
Low oil pressure 6) Move and hold throttle lever (1) in full-open position.
• Clogged oil filter
• Leakage from oil passages
• Defective oil pump
• Defective oil pressure regulator
1
• Damaged O-ring
• Combination of above items
High oil pressure
• Using an engine oil of too high viscosity
• Clogged oil passage
• Clogged oil pressure regulator
IDG211020024-04
• Combination of above items
1. Throttle lever
9) After testing, reinstall oil pressure switch.
Refer to “Oil Pressure Switch Removal and 7) While cranking engine with starter motor, note
Installation” in Section 1E (Page 1E-4). maximum compression pressure reading on gauge
10) Reinstall air duct. for each cylinder.

NOTE
Cylinder Compression Pressure Check
CENDG2110206019 Figures shown are guidelines only, not
The compression pressure reading of cylinder is good absolute service limits.
indicator of its internal condition.
The decision to overhaul the power unit is often based Cylinder compression pressure
on the results of a compression test. Standard: 1 000 – 1 600 kPa (10 – 16 kgf/cm2, 142
Periodic maintenance records kept at your dealership – 228 psi.)
should include compression readings for each
maintenance service. Cylinder compression pressure max. difference
between cylinders
1) Start engine and allow to warm up, then shut engine
100 kPa (1.0 kgf/cm2, 14 psi.)
off.
2) Disconnect all fuel injector connectors at fuel Low compression pressure can indicate one or more
injector. of following:
3) Remove all spark plugs. • Excessively worn cylinder wall
4) Install compression gauge hose attachment into plug • Worn piston or piston rings
hole, then connect compression gauge hose to • Stuck piston rings
gauge hose attachment and compression gauge. • Poor seating of valves
Special tool • Ruptured or otherwise damaged cylinder head
(A): 09915–64512 (Compression gauge) gasket
(B): 09915–64530 (Compression gauge 8) Reinstall parts removed earlier (Spark plugs, etc.).
hose)
(C): 09915–67010 (Compression gauge
hose attachment)

(A)

(C)

(B)

IDG211020053-01
0B-21 Maintenance and Tune-Up:

Section 1
Power Head
CONTENTS
Precautions .................................................1-1
Precautions............................................................. 1-1
Precautions for Powerhead................................... 1-1
Engine Control......................................... 1A-1
Precautions...........................................................1A-1
Precautions on Engine Control 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-9
Fail-Safe System Description............................ 1A-12
Operating Hour Indication System
Engine Electrical Devices ....................... 1C-1
Description ...................................................... 1A-13
Oil Change Reminder System Description........ 1A-14
Water in Fuel Alert System Description ............ 1A-15
Troll Mode System Description ......................... 1A-15
Component Location .........................................1A-16
Engine Control System Components / Engine
Electrical Device Location ............................... 1A-16
Diagnostic Information and Procedures..........1A-16
ECM Power and Ground Circuit Check............. 1A-16
Troubleshooting with Self-Diagnostic Code ...... 1A-17
Self-Diagnostic Code “3 – 4” MAP Sensor........ 1A-18
Self-Diagnostic Code “1 – 4” Cylinder Temp.
Sensor............................................................. 1A-19
Self-Diagnostic Code “2 – 3” IAT Sensor .......... 1A-20
Self-Diagnostic Code “4 – 2” CKP Sensor ........ 1A-21
Self-Diagnostic Code “2 – 4” CMP Sensor........ 1A-22
Self-Diagnostic Code “2 – 2” Air Intake
System ............................................................ 1A-23
Self-Diagnostic Code “3 – 2” MAP Sensor 2..... 1A-24
Self-Diagnostic Code “1 – 5” Ex. Manifold
Temp. Sensor ................................................. 1A-26
Self-Diagnostic Code “4 – 3” Fuel Injector ........ 1A-27
Self-Diagnostic Code “2 – 1” TPS (Throttle
Position Sensor).............................................. 1A-28
Self-Diagnostic Code “1 – 1” Rectifier /
Regulator (Over Charging).............................. 1A-29
Self-Diagnostic Code “5 – 3” Oil Pressure
Switch ............................................................. 1A-30
Self-Diagnostic Code “3 – 7” Trim Sensor ........ 1A-31
Self-Diagnostic Code “5 – 4” Knock Sensor
(DF115A/140A) ............................................... 1A-32
Table of Contents 1- i
Self-Diagnostic Code “3 – 6” O2 Sensor...........1A-33
Self-Diagnostic Code “6 – 3” O2 Sensor
Heater .............................................................1A-34
Troubleshooting Without Self-Diagnostic
Code................................................................1A-35
IAC System Troubleshooting ............................1A-35
Service Instructions ...........................................1A-36
How to Use The 18-Pin and 34-Pin Test Cord
Set...................................................................1A-36
Inspection of The ECM and Its Circuit...............1A-37
ECM Main Relay Inspection..............................1A-40
ECM Removal and Installation..........................1A-40
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-11
IAT Sensor Inspection.......................................1C-11
CMP Sensor Removal and Installation .............1C-12
CMP Sensor Inspection ....................................1C-12
MAP Sensor Removal and Installation..............1C-13
MAP Sensor Output Voltage Inspection............1C-13
O2 Sensor Removal and Installation.................1C-14
O2 Sensor Output Voltage Inspection...............1C-14
O2 Sensor Heater Inspection............................1C-15
Knock Sensor Removal and Installation
(DF115A/140A) ...............................................1C-16
Knock Sensor Inspection (DF115A/140A) ........1C-16
IAC Valve Removal and Installation..................1C-17
IAC Valve Inspection.........................................1C-17
1-ii Table of Contents
TPS Inspection..................................................1C-18
Trim Sensor Removal and Installation ..............1C-19
Trim Sensor Inspection .....................................1C-19
Emergency Stop Switch Inspection...................1C-20
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
Service Instructions.............................................1D-2
Tappet Clearance Inspection ..............................1D-2
Cylinder Head Cover Removal and
Installation .........................................................1D-2
Air Intake Silencer Case Removal and
Installation .........................................................1D-3
Electric Parts Holder Removal and Installation ....1D-4
Intake Manifold and Throttle Body
Components......................................................1D-5
Intake Manifold Removal and Installation ...........1D-6
Throttle Body Removal and Installation ..............1D-8
Throttle Body Inspection .....................................1D-9
Power Unit Removal and Installation ................1D-10
Timing Chain, Chain Tensioner and Camshaft
Sprockets Components...................................1D-15
Timing Chain, Chain Tensioner and Camshaft
Sprockets Removal and Installation................1D-16
Timing Chain, Chain Tensioner and Camshaft
Sprockets Inspection.......................................1D-19
Camshaft, Tappet and Shim Removal and
Installation .......................................................1D-20
Camshaft, Tappet and Shim Inspection ............1D-22
Cylinder Head Assembly Components .............1D-24
Cylinder Head Removal and Installation ...........1D-25
Cylinder Head Disassembly and Assembly ......1D-26
Cylinder Head Components Inspection and
Servicing .........................................................1D-29
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Components ............1D-35
Pistons, Piston Rings, Connecting Rods,
Cylinder and Crankshaft Disassembly and
Assembly ........................................................1D-36
Cylinder, Piston and Piston Ring Inspection
and Servicing ..................................................1D-43
Piston Pin and Conrod Inspection.....................1D-47
Crank Pin and Conrod Bearing Inspection........1D-48
Crankshaft Inspection .......................................1D-50
Crankshaft Main Bearing Inspection .................1D-51
Crankshaft Drive Gear Inspection .....................1D-53
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
Inspection Oil Pump Component Parts ...............1E-4
Oil Pressure Switch Removal and Installation ....1E-4
Oil Pressure Switch Inspection ...........................1E-5
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-1
Electronic Fuel Injection System Description ..... 1G-1
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
Water in Fuel Alert System Description ........... 1G-10
Diagnostic Information and Procedures ......... 1G-10
Fuel Pressure Inspection ................................. 1G-10
Fuel System Diagnosis .................................... 1G-12
Fuel Injection System Troubleshooting ............ 1G-13
Service Instructions .......................................... 1G-14
Fuel Pressure Relief Procedure ....................... 1G-14
Fuel Line Removal and Installation .................. 1G-14
Fuel Line Inspection ......................................... 1G-14
Fuel Leakage Check Procedure....................... 1G-14
Inspection of Fuel Hose Connections .............. 1G-15
High Pressure Fuel Pump Operating Sound
Inspection....................................................... 1G-15
Fuel Vapor Separator Removal and
Installation ...................................................... 1G-16
Fuel Vapor Separator Disassembly and
Assembly........................................................ 1G-16

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-21
Fuel Injector Operating Signal Inspection .........1G-22
Fuel Injector Removal and Installation ..............1G-23
Low Pressure Fuel Pump Removal and
Installation .......................................................1G-25
Low Pressure Fuel Pump Inspection ................1G-26
Water Detection Switch Inspection ...................1G-26
Ignition System........................................ 1H-1
General Description .............................................1H-1
Ignition System Description ................................1H-1
Ignition Control Description .................................1H-2
Component Location ...........................................1H-4
Ignition System Components Location ...............1H-4
Diagnostic Information and Procedures............1H-4
Ignition System Symptom Diagnosis...................1H-4
Ignition System Troubleshooting.........................1H-5
Service Instructions.............................................1H-6
Spark Plug Removal and Installation ..................1H-6
Spark Plug Inspection .........................................1H-6
Ignition Coil Removal and Installation .................1H-6
Ignition Coil Inspection ........................................1H-6
Ignition Coil Operating Signal Inspection ............1H-7
CKP Sensor Inspection .......................................1H-8
CMP Sensor Inspection ......................................1H-8
Ignition Switch Inspection ...................................1H-8
ECM Main Relay Inspection................................1H-8
Starting System .........................................1I-1
General Description .............................................. 1I-1
Electric Starter System Description...................... 1I-1
Table of Contents 1-iii
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-7
Starter Motor Disassembly and Assembly ........... 1I-7
Starter Motor Components Inspection and
Servicing .......................................................... 1I-10
Ignition Switch Inspection................................... 1I-14
Starter Motor Relay Inspection........................... 1I-14
Neutral Switch (Engine Side) Removal and
Installation ........................................................ 1I-15
Neutral Switch Inspection................................... 1I-16
Charging System ..................................... 1K-1
General Description .............................................1K-1
Charging System Description..............................1K-1
Battery Requirement Description ........................1K-1
Component Location ...........................................1K-2
Charging System Components Location.............1K-2
Diagnostic Information and Procedures ............1K-2
Charging System Diagnosis................................1K-2
Service Instructions .............................................1K-3
Charging System Construction ...........................1K-3
Flywheel Removal and Installation......................1K-4
Battery Charge Coil Removal and Installation ....1K-5
Battery Charge Coil Inspection ...........................1K-6
Rectifier / Regulator Removal and Installation ....1K-6
Rectifier / Regulator Inspection ...........................1K-7
Main Fuse Inspection ..........................................1K-7
1-1 Precautions:

Precautions
Power Head

Precautions
Precautions for Powerhead
CENDG2111000001
Refer to “General Precautions” in Section 00 (Page 00-1).

NOTICE
If the electrical circuits is shorted while servicing the power head, the powerhead electrical circuit
could be damage seriously.

When the intended service operation does not require electric power supply from the battery, be sure
to disconnect the negative cable at the battery before starting the service work.
 Engine Control: 1A-1

Engine Control
Power Head

Precautions
Precautions on Engine Control Diagnosis
CENDG2111100001
! WARNING
Service operation of any type performed on engine control system involves a risk of fire and personal
injury if proper precaution are not taken.
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-14).
– Disconnect the high pressure fuel pump wire connector located on the fuel vapor separator.

! CAUTION
If you do not disconnect the battery before disconnecting or connecting the wiring harness, you could
get an electrical shock.
Always turn the ignition switch “OFF” and disconnect the battery cables when wires are being
disconnected or connected.

NOTICE
Failure to take proper precaution when disconnecting the harness connector can cause damage to the
wiring harness.

Hold and pull the connectors when disconnecting.

Do not pull the wires.

NOTE
• To troubleshoot the ECM, and the engine control system, consisting of sensors and actuators, use
the Suzuki Diagnostic System.
• The self-diagnostic codes memory in the ECM will remain even if the battery is disconnected.
• Each electrical circuit is affected by battery voltage, always use a full-charged battery.
• Make sure all ground points have good electrical contact.
• Make sure all wires/cables are securely connected.
1A-2 Engine Control:

General Description
Engine Control System Description
CENDG2111101001
The DF100A/115A/140A models employ an integrated system which performs the control functions for fuel injection,
ignition, idle/trolling speed (idle air), etc. through the ECM (Engine Control Module).

System Structure

INPUT CONTROL OUTPUT

(sensor/switch) (ECM) (actuator etc.)

CKP sensor Fuel injection system Fuel injector

CMP sensor Ignition system Ignition coil

Idle air control system IAC valve

MAP sensor Fuel pump system High pressure fuel pump

IAT sensor

Cylinder temp. sensor

Exhaust manifold temp. sensor Caution system Caution Buzzer

Water detection switch Water in fuel alert system

TPS Self diagnostic system

Monitor-tachometer
Neutral switch Fail safe system

Knock sensor (DF115A/140A)

Operating hour indication system
Oil changing reminder system
Oil pressure switch

Emergency stop switch Starer motor relay,

Start-in-gear protection system (Starter motor)
Ignition switch
Starter motor relay control system

PTT switch Power trim and tilt relay PTT motor relay
control system
Trim/Tilt sensor
Trim gauge
O2 sensor

Troll mode switch

IDG211110001-04
 Engine Control: 1A-3

Engine Control System Flow Diagram

32

33 34
3
36
27 M 2

26 39
25 37

24 1
35 9
40 38
41
42
23
10
21 31
22
17
14 5
28
20 16
18 30
15 29

19 4
8
13 12 7 6
11

IDG211110002-10

1. ECM 12. TPS 23. Neutral switch 34. Low pressure fuel filter/water detection switch
2. Flywheel 13. IAT sensor 24. Trim/Tilt sensor 35. Low pressure fuel pump
3. CKP sensor 14. IAC valve 25. PTT relay 36. Fuel vapor separator
4. EX. manifold temp. sensor 15. PTT switch 26. PTT motor 37. Float
5. O2 sensor 16. ECM main relay 27. Battery 38. High pressure fuel pump
6. Knock sensor (DF115A/140A) 17. Ignition switch 28. Fuel injector 39. Fuel pressure regulator
7. Cylinder temp. sensor 18. Fuse (30 A) 29. Air intake silencer 40. Evaporation hose
8. Spark plug 19. Fuse (15 A) 30. Throttle body 41. Fuel cooler
9. Ignition coil 20. Fuse (60 A) 31. Intake manifold 42. Fuel delivery pipe
10. CMP sensor 21. Fuse (60 A) 32. Fuel tank
11. MAP sensor 22. Starter relay 33. Fuel primer valve
1A-4 Engine Control:

Engine Control Module (ECM)

CENDG2111101002
The ECM sends signals to control the actuators based on the information inputs from each sensor/switch. Major
controls are as follows:
Name of control Description
Fuel injection control • Controls fuel injection amount and timing.
Ignition control • Controls ignition timing.
Idle air control • Controls idling/trolling speed by adjusting the intake air volume
through the IAC valve.
Fuel pump control • Controls the high pressure fuel pump drive.
Caution system control • Informs the operator of abnormal engine conditions.
• Controls engine speed, if activated.
Self-diagnostic system control • Informs the operator of sensor/switch malfunction.
Fail-safe system control • Allows engine operation with a back-up system during sensor/
switch malfunction.
Total operating hour indication system control • Informs the operator of the total operating time.
Oil changing reminder system control • Informs the operator that it is time to replace the engine oil,
based on the maintenance schedule.
Start-in-gear protection system control • Prevents engine starting when the shift lever is positioned in
forward or reverse.
Starter motor relay control system • Prevents starter motor operation when the engine is already
operating.
Power trim and tilt relay control system • Controls On/Off for the PTT relay’s up and down circuits.
Water in fuel alert system • Informs operator of water accumulates in the low pressure fuel
filter.

NOTE
Information related to the Caution System, Self-Diagnostic System, and Total Operating Hours System
is retained in the ECM memory.

IDG211110021-01

1. ECM
 Engine Control: 1A-5

ECM Input / Output Circuit Diagram

MAIN
IG SW RELAY ECM PWR 2 INJECTOR #1
34 42

ECM PWR 1 INJECTOR #2

17 ECM POWER 51
BATTERY
VB MONITOR INJECTOR #3
40
MAIN RELAY CONTROL
14 IPS INJECTOR #4
39

HIGH PRESSURE
FUEL PUMP
NEUTRAL SW 41 M
7
NEUTRAL STARTER RELAY
SW
CONTROL
32
START STARTER
SW RELAY O2 SENSOR
START SW
27 HEATER
RESET BUZZER IPS 46
PTT SW SW RESET SW
25

PTT SW IAC VALVE

PTT SW (UP) 37
18
#1
PTT SW (DN) IGNITION COIL #1 #4
19 43
PTT
RELAY UP IGNITION COIL #2 #2
M 35 IPS 52
PTT PTT #3
RELAY RELAY DN
44 IPS
CKP
SENSOR PWR GND
5 48
PWR GND
CMP 50
22
SENSOR
C
P IPS
BUZZER
28 Bz
SENSOR
PWR (5 V) U OVER HEAT LED
12
4
MAP
SENSOR DIAG LED
20 29

OIL PRESSURE LED

30

TPS TRIM GAUGE

21 IPS 11

TRIM & TILT

SENSOR OVER REV LED
3 13

TACHOMETER
31
O2 SENSOR
36

COMMUNICATION LINE A 16
IAT SENSOR SDS TOOL
10
CYL TEMP COMMUNICATION LINE B 33
23
SENSOR
EX-MANI TEMP
ECM GND
9
SENSOR 15

SENSOR GND
8

580k KNOCK SENSOR

(DF115A/140A)
1

WATER IN
FUEL SW
49
OIL
PRESSURE SW
26
EMERGENCY
24
STOP SW

TROLL SW
2

IDG211110029-07
1A-6 Engine Control:

ECM Connector / Terminals Layout

43 42 41 40 39 38 37 36 35 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18

“A” “B”
IDG211110003-02

“A”: 18-pin connector “B”: 34-pin connector

Terminal Wire color Circuit Terminal Wire color Circuit

1 P/Bl Knock sensor (DF115A/140A) 27 Br Start switch
2 V Troll mode switch 28 Bl/W Buzzer
3 W/Y Trim/Tilt sensor 29 G/W CHECK ENGINE lamp
4 R Power source for sensor 30 Bl/B Oil lamp
5 R/W CKP sensor 31 Y/B Tachometer
6 — — 32 G Starter relay control
7 Y/G Neutral switch 33 Y PC communication line (B)
8 B/W Ground for sensors 34 B/Bl Power source No.2 for ECM
9 V/W Ex. manifold temp. sensor 35 Lg PTT relay “UP”
10 Lg/B IAT sensor 36 Gr/R O2 sensor
11 W/Y Trim gauge 37 R/G IAC valve
12 G/Y TEMP lamp 38 — —
13 P/W REV–LIMIT lamp 39 Lg/W No.4 fuel injector (–)
14 R/B Ground for ECM main relay 40 R/W No.3 fuel injector (–)
15 B Ground for ECM 41 B/R High pressure fuel pump (–)
16 O/Y PC communication line (A) 42 O/B No.1 fuel injector (–)
17 Gr Power source No.1 for ECM 43 O No.1 ignition coil
18 Lbl PTT switch “UP” 44 P PTT relay “DOWN”
19 P PTT switch “DOWN” 45 — —
20 W MAP sensor 46 Lg/B O2 sensor heater
21 Br/Y Throttle position sensor 47 — —
22 Y/Bl CMP sensor 48 B Ground for power
23 Lg/W Cylinder temp. sensor 49 R/Bl Water detection switch
24 Bl/R Emergency stop switch 50 B Ground for power
25 O/W Buzzer cancel 51 B/Br No.2 fuel injector (–)
26 Bl Oil pressure switch 52 Bl No.2 ignition coil
 Engine Control: 1A-7

Caution System Description

CENDG2111101003
The following four caution systems alert the operator when an abnormality occurs on the engine.
• OVER-REVOLUTION CAUTION
• LOW OIL PRESSURE CAUTION
• OVERHEAT CAUTION
• LOW BATTERY VOLTAGE CAUTION
Monitor-Tachometer

“A”
“D”

“C” “B”
I9J011110004-02

“A”: “REV LIMIT” lamp “C”: “TEMP” lamp

“B”: “OIL” lamp “D”: “CHECK ENGINE” lamp

Caution type Caution lamp Caution buzzer Engine RPM limited

Over-revolution Yes “A” No Yes
Low oil pressure Yes “B” (“A”) Yes Yes
Overheat Yes “C” (“A”) Yes Yes
Low battery voltage Yes “D” 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
DF100A/115A: 6 200 r/min.
DF140A: 6 500 r/min.

Action:
Engine speed • 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.
Caution lamp “REV-LIMIT” lamp lights continuously.
Caution buzzer No buzzer sounds.

Reset:
Close the throttle to reduce the engine speed below approx. 3 000 r/min for one second.
1A-8 Engine Control:

Low Oil Pressure Caution System

Condition:
Immediate activation of the system when the oil pressure switch is turned “ON” due to an engine oil pressure drop
below 100 kPa (1.0 kg/cm2, 14 psi.) while the engine is running.

Action:
Engine speed • Automatically reduced to approx. 1 000 r/min. maximum by an intermittent fuel
injection signal.
• The engine automatically stops 3 minutes after the caution system is activated.
Caution lamp • “OIL” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter
activation (1 000 r/min, or higher).
Caution buzzer • Sounds in a series of long (1.5 sec.) beeps.

NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
However, the caution system will repeatedly activate until the cause is eliminated.

Reset:
Stop the engine and check the engine oil level. Refill the engine oil to the correct level if it is below the low oil level
mark.
If the engine oil level is correct, the following causes may be considered:
• Improper oil viscosity.
• Malfunctioning oil pressure switch.
• Clogged oil strainer or oil filter.
• Worn oil pump relief valve.
• Oil leakage from the oil passage.
• Excessive wear/damage of oil pump.

NOTE
The low oil pressure caution system will reset when the oil pressure is restored to over 100 kPa (1.0
kg/cm2, 14 psi.) at approx. 1 000 r/min. or less engine speed operation.
The engine must be stopped and checked immediately once the system is activated.

Overheat Caution System

Condition 1 (Maximum temperature)
Immediate activation of the system when:
• Cylinder temperature reaches 100 °C (212 °F)
• Exhaust manifold temperature reaches 90 °C (194 °F)
Condition 2 (Gradient temperature – Temp. rise vs. Time)
Immediate activation of the system when:
• The average temperature difference between three consecutive 10 second measurement periods of the cylinder
temperature sensor, at engine speeds of 500 r/min or higher, exceeds the limits as shown below.
Temperature range Temperature difference
– 90 °C (– 194 °F) Approx. 3 °C (5.4 °F)
90 °C – (194 °F –) Approx. 1 °C (1.8 °F)

• The average temperature difference between three consecutive 10 second measurement periods of the exhaust
manifold temperature sensor, at engine speeds of 500 r/min. or higher, exceeds the limits as shown below.
Temperature range Temperature difference
– 80 °C (– 176 °F) Approx. 11 °C (19.8 °F)
80 °C – (176 °F –) Approx. 2.5 °C (4.5 °F)
 Engine Control: 1A-9

Action:
Engine speed • Automatically reduced to approx. 3 000 r/min. maximum by intermittent fuel
injection and ignition signals.
• The engine automatically stops 3 minutes after the caution system is
activated.
Caution lamp • “TEMP” lamp lights continuously.
• “REV-LIMIT” lamp lights continuously during engine speed rev-limiter
activation (3 000 r/min. or higher).
Caution buzzer • Sounds in a series of long (1.5 sec.) beeps.

NOTE
If the engine is automatically stopped due to the caution system, the engine can be started again.
The caution system will repeatedly activate until the cause is eliminated.

Reset:
Close the throttle completely and then shift into neutral.
System reset will occur when the cylinder temperature drops below the limits shown below. However, the system may
be activated again unless the cause for overheat (such as insufficient water) is removed.
Caution cause Reset temperature
Condition 1 (Maximum temperature) Approx. 68 – 78 °C (154 – 172 °F)
Condition 2 (Gradient temp. – Temp. rise vs. Time) Approx. 66 – 76 °C (150 – 169 °F)

Low Battery Voltage Caution System

The system is activated when the battery voltage decreases to less than 9 V for 30 seconds.

Action:
Engine speed • No engine speed limiter is activated.
Caution lamp • “CHECK ENGINE” lamp lights continuously.
Caution buzzer • Sounds in a series of long (1.5 sec.) beeps.

Reset:
The caution system is automatically reset when battery voltage increases to more than 9 V.
Refrain from using electrical equipment requiring high amperage, such as hydraulic trim tabs, hydraulic jack plate, etc.,
after this caution is activated.

Self-Diagnostic System Description

CENDG2111101004
The self-diagnostic system alerts the operator when an abnormality occurs in a signal from a sensor, or switch, etc.
When the system is activated, the “CHECK ENGINE” lamp flashes (lights intermittently) according to each code
pattern, along with a buzzer sound.
When the engine is running, the buzzer sounds a series of short (0.2 sec.) beeps. When the engine is not running, the
buzzer sounds according to each code pattern, but not simultaneously with the flashing lamp. The buzzer sound can
be temporally canceled by pushing the ignition key in.
Monitor-Tachometer

“A”
I9J011110005-01

“A”: “CHECK ENGINE” lamp

1A-10 Engine Control:

Priority / Code / Pattern for Self-Diagnostic System Operation

0: OFF, 1: ON
Priority Failed item Code Lamp flashing pattern Fail-Safe system active
1

1 MAP sensor 1 3–4 0

Yes
MCODE00D34-0-01
1

2 Cylinder temp. sensor 1–4 0

Yes
MCODE00D14-0-01
1

3 IAT sensor 2–3 0

Yes
MCODE00D23-0-01
1

4 CKP sensor 4–2 0

No
MCODE00D42-0-01
1

5 CMP sensor 2–4 0

No
MCODE00D24-0-01
1

6 Air intake system 2–2 0

Yes
MCODE00D22-0-01
1

7 MAP sensor 2 3–2 0

No
MCODE00D32-0-01
1

8 Exhaust manifold temp. sensor 1–5 0

Yes
MCODE00D15-0-01
1

9 Fuel injector 4–3 0

No
MCODE00D43-0-01
1

10 Throttle position sensor 2–1 0

Yes
MCODE00D21-0-01
1

11 Rectifier/Regulator (Over-charging) 1–1 0

No
MCODE00D11-0-01
1

12 Oil pressure switch 5–3 0

No
MCODE00D53-0-01
1

13 Trim sensor 3–7 0

No
MCODE00D37-0-01
1

14 Knock sensor (DF115A/140A) 5–4 0

Yes
MCODE00D54-0-01
1

15 O2 sensor 3–6 0
Yes
MCODE00D36-0-02
1

16 O2 sensor heater 6–3 0

Yes
MCODE00D63-0-01
 Engine Control: 1A-11

NOTE
• If two or more items fail at once, the self-diagnostic indication appears according to the priority
order. The indication repeats three times.
• If the failed item remains, the self-diagnostic indication appears again after turning the ignition
switch “ON”.
• After correcting the failed item, the self-diagnostic indication appears until the ECM receives the
proper signal with the engine running.
• Cancellation of the self-diagnostic indication is automatically performed when the failure is
corrected and a normal signal is received by the ECM for a period of 20 – 30 seconds.
• The Rectifier/Regulator self-diagnostic indication may not be displayed when the ignition switch is
turned “ON” because the ECM cannot detect rectifier/regulator charging output if the engine is not
running.
Under this condition, the buzzer will not sound a 1 – 1 code.
However, if the rectifier/regulator has failed, the self diagnostic indication will appear again after
starting the engine.

NOTE
To cancel the diagnostic display for oil pressure switch failure, perform the following procedure after it
is corrected:
1. Turn the ignition key to ON. The diagnostic code for oil pressure switch failure will continue to be
displayed until a normal signal sequence is received by the ECM.
2. Turn the ignition key to OFF once and turn ON again.
At the second turning ON, cancel of the oil pressure switch failure code is completed.

Condition for Self-Diagnostic System Operation

Failed item Condition
• No signal (With engine running).
MAP sensor 1 • Receiving an out of range “4.9 – 114.6 kPa (0.2 – 4.5 V)” signal (With the
engine running.).
• No signal.
Cylinder temp. sensor • Receiving an out of range “– 46 to + 170 °C (– 50.8 – +338 °F) (0.10 – 4.6
V)” signal.
• No signal.
IAT sensor • Receiving an out of range “– 46 to + 169 °C (– 50.8 – +336.2 °F) (0.10 –
4.6 V)” signal.
• During the rotation of the predetermined crankshaft angle, the normal CKP
sensor signal pattern is not received by the ECM.
CKP sensor
• During cranking, CMP sensor signal is received by the ECM, but not CKP
sensor signal.
• During four crankshaft rotations, the normal CMP sensor signal pattern is
CMP sensor
not received by the ECM.
• The engine operates at an abnormally high speed when the ECM is
Air intake system receiving a completely closed signal from the throttle position sensor.
(Criterion: 2 100 r/min minimum)
• From TPS sensor, the full close signal is inputted, but from the MAP
MAP sensor 2
sensor, the signal voltage exceeds 2.0 V.
• No signal.
Exhaust manifold temp. sensor • Receiving an out of range “– 46 to + 170 °C (– 50.8 – +338 °F) (0.10 – 4.6
V)” signal.
Fuel injector • No operation signal from the ECM.
• No signal.
Throttle position sensor
• Receiving an out of range “0.2 – 4.8 V” signal.
Rectifier/Regulator (Over-charging) • Receiving 16 V or higher signal.
• While the engine is stopped and the ignition switch is on, the ECM receives
Oil pressure switch
an “OFF” signal from the oil pressure switch.
1A-12 Engine Control:

Failed item Condition

Trim sensor • Receiving an out of range “0.2 – 4.8 V” signal.
Knock sensor (DF115A/140A) • No signal
• Receiving an out of range “0.55 – 4.39 V” signal.
O2 sensor • The compensation value of fuel injection amount is more than the
predetermined value while the O2 feedback is executed.
• The compensation value of fuel injection amount is below the
predetermined value while the O2 feedback is executed.
O2 sensor heater • No operation signal comes from the ECM. (Open or short in O2 sensor
heater circuit)

Fail-Safe System Description

CENDG2111101005
The fail-safe system is closely related to the self-diagnostic system.
When an abnormality occurs in a sensor signal, the ECM ignores the out-of-range signal and assumes a pre-
programmed value for the failed sensors.
This allows the engine to continue running under the fail-safe condition.

Pre-Programmed Value for Fail-Safe System

Failed item Pre-Programmed value
MAP sensor 1 • 30 – 101.3 kPa
(The value will change according to the current engine speed.)
Air intake system • The control is executed with the maximum engine speed of 2 000 r/min.
Cylinder temp. sensor 60 °C (140 °F)
IAT sensor 45 °C (113 °F)
Exhaust manifold temp. sensor 60 °C (140 °F)
Throttle position sensor • The control is executed with the throttle opening at 30 degrees.
Trim sensor • The control is continued with fixed sensor output as 3.3 V.
Knock sensor (DF115A/140A) • The ignition timing delays with the predetermined amount.
O2 sensor • The fuel injection amount is controlled with the base map.
(The O2 feedback can not be executed.)
O2 sensor heater • The fuel injection amount is controlled with the base map.
(The O2 feedback can not be executed.)

NOTE
There is no back-up system for the ECM itself. The engine will stop if it has failed.
 Engine Control: 1A-13

Operating Hour Indication System Description

CENDG2111101006
When the ignition switch is initially turned “ON” (from “OFF”), the ECM tests the caution system by turning on all four
lamps in the monitor-tachometer and sounding the caution buzzer for an initial two seconds.
For the next three seconds, the ECM indicates the total operating hours, using a combination of the tachometer needle
and “REV-LIMIT” lamp flash.

NOTE
The total operating hours displayed are those of the actual engine operation, not the ignition switch
“ON” time.

Monitor-Tachometer

“B”

“A”
I9J011110006-01

“A”: Needle “B”: “REV-LIMIT” lamp

Chart of Total Operating Hours Indication

Monitor-Tachometer
Total operating hours
Needle “A” indication REV-LIMIT lamp “B” flashing*
0 h – (49 h) No
50 h 500 r/min.
60 h 600 r/min. No
↓ ↓
540 h 5 400 r/min.
550 h 500 r/min.
560 h 600 r/min.
1 time
↓ ↓
1 040 h 5 400 r/min.
1 050 h 500 r/min.
↓ ↓ 2 times
1 540 h 5 400 r/min.
1 550 h 500 r/min.
↓ ↓ 3 times
2 030 h 5 300 r/min.
2 040 h or over 5 400 r/min. 3 times

*: One lamp flash corresponds to 500 hours.

1A-14 Engine Control:

Oil Change Reminder System Description Cancellation Procedure

CENDG2111101007
This system informs the operator that it is time to change
the ENGINE OIL based on the recommended
maintenance schedule.
When the total motor operating hours has reached the
pre-programmed hours, the “OIL” lamp will flash, and the
buzzer will begin a series of double beeps if the engine
is not running (but ignition switch is “ON”).
The above mentioned indication will repeat until the
activated system is manually canceled.
NOTE
This system will activate up to 2 100 hour’s
operation.
1) Turn the ignition key to the “ON” position.
2) Remove the emergency stop switch plate (1).
3) Pull out the emergency stop switch knob (2) three
times in ten seconds.
A short beep will be heard if the cancellation is
successful.
4) Turn the ignition key to the “OFF” position.
5) Set the emergency stop switch plate (1) into the
original position.

Indication of System Activation

1

Buzzer
2

I9J011110007-02

NOTE
I9J011110008-01
• Cancellation of the system is possible
whether or not the engine oil has been
Oil lamp
replaced.
Once the system has been activated,
SUZUKI strongly recommends that the
engine oil be replaced before canceling the
system.
• If the engine oil has been replaced with the
system not activated, it is still necessary to
I9J011110009-01 perform the cancellation procedure to
reset the Oil Change Reminder System.
Action
Starting operation
(*1) (*4)

Indication Cancellation
(*2) (*4)

Indication Cancellation
(*3) (*4)

Indication Cancellation
(*3) (*4)

Indication Cancellation

Repeat
I9J011110010-03

*1: Lapse of initial 20 hour’s operation

*2: Lapse of 80 hour’s operation
*3: Lapse of 100 hour’s operation
*4: When performing cancellation before system activation

Water in Fuel Alert System Description
CENDG2111101009
This engine is equipped with an integral fuel filter/water
separator and associated alert system.
The alert system will activate if water separated from the
fuel exceeds a specific volume.
If this system activates, the red REV-LIMIT lamp will
flash and a buzzer will begin a series of triple beeps
when the engine is in neutral only.
If this system activates, stop the engine, and check the
fuel filter/water separator for water.
For inspection and cleaning of the fuel filter, refer to the
“Low Pressure Fuel Filter Inspection” in Section 0B
(Page 0B-14) and “Water Detection Switch Inspection” in
Section 1G (Page 1G-26).
Monitor-Tachometer
1 • When pressing the “UP” switch, one short beep
IDG211110030-02
1. “REV-LIMIT” lamp
Troll Mode System Description
CENDG2111101008
The troll mode system consists of the optional troll mode
switch, ECM, tachometer/monitor gauge and related
electrical wiring.
The “Troll Mode System” is activated by pressing the troll
mode switch, when the motor is running at in-gear idle
speed. By using this system, you can set and maintain a
desired engine speed with the control switch in a range
from in-gear idle speed (Approx. 700 r/min) to 1 200 r/
min.
5V
1
2 engine speed to 3 000 r/min or more. In both cases, two
TROLL SW
2
IDG211110031-01
1. ECM 2. Troll mode switch
Engine Control: 1A-15
During Troll mode, ECM will control the engine speed as
follows:
ECM calculates the target engine speed with the input
signal from the switch, then controls the IAC valve and
the trolling speed is made to become to the target speed.
Setting The Troll Mode:
1) Shift into forward or reverse gear and make sure that
the throttle is fully closed (in-gear idle speed).
2) Press the “UP” or “DN” position of the troll mode
switch, until you hear one beep.
The REV/TRL (or REV) lamp on the monitor gauge
will flash indicating that the motor has been set to the
troll mode. The REV/TRL (or REV) lamp will
continue to flash while the motor is in the troll mode.
NOTE
The troll mode system will not operate if the
switch is depressed when the remote control
lever is in the neutral position.
Adjusting Trolling Speed:
sounds and the engine speed increases by 50 r/min.
• When pressing the “DN” switch, one short beep
sounds and the engine speed decreases by 50 r/min.
NOTE
• When pressing the “DN” switch at the
lower limit of trolling speed, the engine
speed will not change and three long (0.8
sec.) beeps will sound.
• When pressing the “UP” switch at the
upper limit of trolling speed, the engine
speed will not change and three long (0.8
sec.) beeps will sound.
• Shift operation and throttle control remain
operational, even in troll mode.
Cancelling The Troll Mode:
The troll mode can be cancelled by shifting the remote
control lever to the neutral position, or by increasing the
short (0.1 sec.) beeps sound when cancelling the troll
mode.
1A-16 Engine Control:

Component Location
Engine Control System Components / Engine Electrical Device Location
CENDG2111103001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).

Diagnostic Information and Procedures

ECM Power and Ground Circuit Check
CENDG2111104001
Wiring Diagram

2
7

R
4 3
5
6
W

W
Gr 17
W
B/Bl 34
ECM

R/B 14

1
BATT W

IG Gr Gr

GND B B

IDG211110009-03

1. Battery 3. 60 A fuse 5. 30 A fuse 7. Starter motor

2. Battery cable 4. 60 A fuse 6. ECM main relay

Circuit Description
When the ignition switch is turned “ON”, the main relay turns “ON” (the contact point closes) and the main power is
supplied to the ECM.

Troubleshooting

Step 1
Is operation of the main relay heard when the ignition switch is turned “ON”?

Yes Go to step 4.

No Go to step 2.

Step 2
Are the main fuses (60 A and 60 A), and (for Ignition and ECM) in good condition?

Yes Go to step 3.

No Replace.
 Engine Control: 1A-17

Step 3
1) Disconnect the ECM connector at the ECM with the ignition switch “OFF”.
2) Measure the voltage between the No.14 terminal of the ECM connector and body ground.
Is the voltage 12 V (Battery Voltage)?

Yes Go to step 4.

No • Check the ECM main relay.

Refer to “ECM Main Relay Inspection” (Page 1A-40).
• Poor ECM main relay connection.
• R/B wire open, shorted or poor connection.

Step 4
1) Turn the ignition switch “OFF”.
2) Connect the 18 pin and 34 pin test cord set between the ECM and the main wire harness.
3) Turn the ignition switch “ON”.
4) Measure the voltage between the No.34 terminal and body ground.
Is the voltage 12 V (Battery Voltage)?

Yes Go to step 5.

No • Check the ignition switch.

Refer to “Ignition Switch Inspection” in Section 1I (Page 1I-14).
• Gr, B/Bl wire open circuit or poor connection.

Step 5
1) Turn the ignition switch “OFF”.
2) Connect the 18 pin and 34 pin test cord set between the ECM and the main wire harness.
3) Turn the ignition switch “ON”.
4) Measure the voltage between the No.14 terminal and body ground.
Is the voltage approx. 0.5 V?

Yes Go to step 6.

No • R/B wire open, shorted or poor connection.

• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.

Step 6
1) Turn the ignition switch “ON”.
2) Measure the voltage between the No.17 terminal and body ground.
Is the voltage 12 V (Battery Voltage)?

Yes ECM power and ground circuit are in good condition.

No • Gr wire open, shorted or poor connection.

• Faulty ECM main relay.

Troubleshooting with Self-Diagnostic Code

CENDG2111104002
! WARNING
Before troubleshooting, read and follow the “Precautions on Engine Control Diagnosis” (Page 1A-1).

In this section, troubleshooting procedures are based on the assumption that the “low pressure fuel system” and
“mechanical components (power unit, lower unit, etc.)” are normal.
1A-18 Engine Control:

Self-Diagnostic Code “3 – 4” MAP Sensor

CENDG2111104003
Wiring Diagram

ECM

5V
1

C
W
P
B/W U
5V
R

I9J011110019-02

1. MAP sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the MAP sensor connector.
2) With the ignition switch “ON”, Check the voltage at the “R” wire terminal of the MAP sensor connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground or a poor wire connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in Section 1C (Page 1C-13).
Is it in good condition?

Yes • Substitute a good ECM and recheck.

No • Faulty MAP sensor.

• “R” wire shorted to “W” wire, “B/W” wire open, poor “B/W” wire connection, poor “W” wire connection,
“W” wire open or poor MAP sensor connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.

For step 1

B/W
R
IDG211110010-02
 Engine Control: 1A-19

Self-Diagnostic Code “1 – 4” Cylinder Temp. Sensor

CENDG2111104004
Wiring Diagram

ECM

5V

C
B Lg/W
1 P
B B/W
U

I9J011110021-03

1. Cylinder temp. sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the cylinder temp. sensor connector.
2) With the ignition switch “ON”, check the voltage at the “Lg/W” wire terminal of the cylinder temp. sensor
connector.
Is the voltage 4 V or more?

Yes Go to step 2.

No • “Lg/W” wire shorted to the “B/W” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the Cylinder Temp. Sensor.
Refer to “Cylinder Temp. Sensor Inspection” in Section 1C (Page 1C-8).
Is it in good condition?

Yes Poor cylinder temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty cylinder temp. sensor.

For step 1

I9J011110045-02
1A-20 Engine Control:

Self-Diagnostic Code “2 – 3” IAT Sensor

CENDG2111104005
Wiring Diagram

ECM

5V

C
Lg/B
1 P
B/W
U

I9J011110024-03

1. IAT sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the IAT sensor connector.
2) With the ignition switch “ON”, check the voltage at the “Lg/B” wire terminal of the IAT sensor connector.
Is the voltage 4 V more?

Yes Go to step 2.

No • “Lg/B” wire shorted to “B/W” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C (Page 1C-11).
Is it in good condition?

Yes Poor IAT sensor connection, intermittent trouble or a faulty ECM may be cause.

No Faulty IAT sensor.

For step 1

I9J011110046-01
 Engine Control: 1A-21

Self-Diagnostic Code “4 – 2” CKP Sensor

CENDG2111104006
Wiring Diagram

ECM

C
R/B R/W
P
B/G B/W U

IDG211110012-01

1. CKP sensor

Troubleshooting

Step 1
1) Check the CKP sensor air gap.
Refer to “CKP Sensor Removal and Installation” in Section 1C (Page 1C-10).
Is it in good condition?

Yes Go to step 2.

No Incorrectly adjusted air gap.

Step 2
1) Check the CKP sensor resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-7).
Is it in good condition?

Yes Open wire between the CKP sensor and the ECM, poor lead wire connection or sensor lead wires are
shorted to each other. If lead wire and connection are OK, intermittent trouble or a faulty ECM may be
the cause.

No Faulty CKP sensor.

1A-22 Engine Control:

Self-Diagnostic Code “2 – 4” CMP Sensor

CENDG2111104007
Wiring Diagram

ECM
1 2
B/Bl
Y/Bl
C
P
B/W U

I9J011110055-01

1. CMP sensor 2. + 12 V (From ignition switch)

Troubleshooting Step 4
Step 1 Was terminal “B/Bl” voltage in step 2 within
specification?
Is the CMP sensor installed properly and the wire
harness connected securely? Yes Go to step 5.
Yes Go to step 2. No “B/Bl” wire open circuit. If the wiring and
connection is OK, substitute a known-
No Correct.
good ECM and recheck.
Step 2
Step 5
1) Disconnect the connector from the CMP sensor. Check the CMP sensor and sensor trigger vane.
2) Check for proper connection to the CMP sensor at Refer to “CMP Sensor Inspection” in Section 1C (Page
“B/Bl”, “Y/Bl” and “B/W” wire terminals. 1C-12).
3) If OK, turn the ignition switch “ON” and check the Is check result satisfactory?
voltage at the “B/Bl”, “Y/Bl” and “B/W” wire
terminals of the CMP sensor connector. Yes Substitute a known-good ECM and
recheck.
CMP sensor voltage
Terminal “B/Bl”: 10 – 14 V No Replace CMP sensor.
Terminal “Y/Bl”: 4 – 5 V
Terminal “B/W”: 0 V
Is the voltage satisfactory? For step 2

Yes Go to step 5.

No Go to step 3. B/W

Step 3 Y/Bl

Was terminal “Y/Bl” voltage in step 2 within B/Bl

I9J011110056-01
specification?

Yes Go to step 4.

No “Y/Bl” wire open or shorted to ground/

power supply circuit. If the wiring and
connection is OK, substitute a known-
good ECM and recheck.
 Engine Control: 1A-23

Self-Diagnostic Code “2 – 2” Air Intake System

CENDG2111104008
Wiring Diagram

1 ECM
5V

Br/Y
C
P
B/W U

I9J011110057-01

1. TPS

Troubleshooting Step 3
Step 1 1) Check the MAP sensor, IAC system and intake
manifold (system) for air leakage.
1) With the ignition switch “OFF”, disconnect the
TPS connector. Is the result OK?
2) With the ignition switch “ON”, check the voltage at
Yes Intermittent trouble or faulty ECM.
the “R” wire terminal of TPS connector.
Substitute a known-good ECM and
Is the voltage approx. 4 – 5 V? recheck.

Yes Go to step 2. No Faulty air intake system.

No • “R” wire open, “R” wire shorted to

ground circuit or poor wire connection. For step 1
• If the wiring and connection is OK,
substitute a known-good ECM and
recheck.
R
Step 2
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-
18). B/W
Br/Y
Is it in good condition? IDG211110013-01

Yes Go to step 3.

No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W”
wire open, poor “B/W” wire connection,
poor “Br/Y” wire connection, “Br/Y” wire
open or poor TPS connection.
• If the wiring and connection is OK,
intermittent trouble or a faulty ECM may
be the cause.
1A-24 Engine Control:

Self-Diagnostic Code “3 – 2” MAP Sensor 2

CENDG2111104009
Wiring Diagram

ECM
1 +5 V
R 5V

Br/Y

B/W
C
P
2 U

W
B/W 5V
R

IDG211110032-01

1. TPS 2. MAP sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the MAP sensor connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the MAP sensor connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection” in Section 1C (Page 1C-13).
Is it in good condition?

Yes Go to step 3.

No Faulty MAP sensor.

 Engine Control: 1A-25

Step 3
1) With the ignition switch “OFF”, disconnect the TPS connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 4.

No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 4
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-18).
Is it in good condition?

Yes Intermittent trouble, substitute a known-good ECM and recheck.

No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “Br/Y” wire
connection, “Br/Y” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.

For step 1

B/W
R
IDG211110010-02

For step 3

B/W
Br/Y
IDG211110013-01
1A-26 Engine Control:

Self-Diagnostic Code “1 – 5” Ex. Manifold Temp. Sensor

CENDG2111104010
Wiring Diagram

ECM

5V

C
1 B V/W
P
B B/W
U

I9J011110030-02

1. Ex. manifold temp. sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the Ex. manifold temp sensor connector.
2) With the ignition switch “ON”, check the voltage at the “V/W” wire terminal of the Ex. manifold temp. sensor
connector.
Is the voltage 4 V or more?

Yes Go to step 2.

No • “V/W” wire shorted to “B/W” wire or ground circuit.

• If the wiring is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the Ex. manifold temp. sensor.
Refer to “Ex. Manifold Temp. Sensor Inspection” in Section 1C (Page 1C-9).
Is it in good condition?

Yes Poor Ex. manifold temp. sensor connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty Ex. manifold temp. sensor.

For step 1

I9J011110049-01
 Engine Control: 1A-27

Self-Diagnostic Code “4 – 3” Fuel Injector

CENDG2111104011
Wiring Diagram

12 V (From main relay)

1 ECM
#1
O/B
#2
B/Br
#3
C
R/W
#4
P
Lg/W
U

IDG211110014-01

1. Fuel injector

Troubleshooting Step 4
Step 1 1) Disconnect the ECM connector with the ignition
switch “OFF”, and check all of the injectors for
1) Using a sound scope, check that each injector has
resistance.
an operating sound when the engine is cranking.
Refer to “Resistance Check” in Section 1C (Page
Do all injectors make an operating sound? 1C-7).

Yes Fuel injector and its circuit are in good Is the resistance 10 – 14 Ω for each injector?
condition.
Yes Substitute a known-good ECM and
No Go to step 2. recheck.

Step 2 No Faulty injector or its circuit.

1) Check the fuel injector, the wiring connection and
the wire harness of the fuel injector not making the For step 3
operating sound.
Are all of the above OK?

Yes Substitute a known-good ECM and

recheck.

No Faulty injector or its circuit. Gr

Step 3
1) With the ignition switch “OFF”, disconnect the I9J011110023-02

connector from the fuel injector.

2) Check the voltage at “Gr” wire terminal with the
ignition switch “ON”.
Is the voltage 12 V (battery voltage)?

Yes Go to step 4.

No Power circuit open.

1A-28 Engine Control:

Self-Diagnostic Code “2 – 1” TPS (Throttle Position Sensor)

CENDG2111104012
Wiring Diagram

1 ECM
5V

Br/Y
C
P
B/W U

I9J011110059-01

1. TPS

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the TPS connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of the TPS connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground circuit or poor connection.
• If the wiring and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-18).
Is it in good condition?

Yes Substitute a known-good ECM and recheck.

No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “Br/Y” wire
connection, “Br/Y” wire open or poor TPS connection.
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may be the cause.

For step 1

B/W
Br/Y
IDG211110013-01
 Engine Control: 1A-29

Self-Diagnostic Code “1 – 1” Rectifier / Regulator (Over Charging)

CENDG2111104015
NOTE
• This self-diagnostic code indication may be canceled when turning the ignition switch “ON” (engine
not running), because ECM detects battery voltage.
• It is difficult to thoroughly check the rectifier/regulator. Before replacing it with new one, check that
the ground point has good electrical contact.

Troubleshooting

Step 1
1) Check the Rectifier/Regulator.
Refer to “Rectifier / Regulator Inspection” in Section 1K (Page 1K-7).
Is the result OK?

Yes Go to step 2.

No Faulty Rectifier/Regulator.

Step 2
1) With the engine running, check charging voltage at idle speed.
Is the result 16 V or higher?

Yes Faulty Rectifier/Regulator.

No Faulty ECM or wire continuity/connection failure.

1A-30 Engine Control:

Self-Diagnostic Code “5 – 3” Oil Pressure Switch

CENDG2111104016
Wiring Diagram

ECM
1

Bl
C
P
U

I9J011110063-01

1. Oil pressure switch

Troubleshooting

Step 1
1) With the ignition switch “OFF”, remove the oil pressure switch wire.
2) With the ignition switch “ON”, check the voltage between the oil pressure switch wire terminal and body ground.
Is the voltage approx. 5 V?

Yes Go to step 2.

No • Oil pressure switch wire open or poor connection.

• If wire and connection are OK, substitute a known-good ECM and recheck.

Step 2
1) Check the oil pressure switch operation.
Refer to “Oil Pressure Switch Inspection” in Section 1E (Page 1E-5).
Is it in good condition?

Yes Poor oil pressure switch wire connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty oil pressure switch.

For step 1

I9J011110064-01
 Engine Control: 1A-31

Self-Diagnostic Code “3 – 7” Trim Sensor

CENDG2111104017
Wiring Diagram

ECM
1
5V

B R
C
Y W/Y P
U
Bl B/W

IDG211110035-01

1. Trim sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect trim sensor connector.
2) With the ignition switch “ON”, check the voltage at the “R” wire terminal of trim sensor connector.
Is the voltage approx. 4 – 5 V?

Yes Go to step 2.

No • “R” wire open, “R” wire shorted to ground circuit or poor wire connection.
• If the wire and connection is OK, substitute a known-good ECM and recheck.

Step 2
1) Check the trim sensor output voltage change.
Refer to “Trim Sensor Inspection” in Section 1C (Page 1C-19).
Is it in good condition?

Yes Poor trim sensor connection, intermittent trouble or a faulty ECM.

No • “R” wire shorted to “W/Y” wire, “B/W” wire open, poor “B/W” wire connection, poor “W/Y” wire
connection, “W/Y” wire open or poor trim sensor connection.
• If the wire and connection is OK, intermittent trouble or a faulty ECM may be the cause.
• Faulty trim sensor.

For step 1
W/Y

B/W
R

IDG211110015-04
1A-32 Engine Control:

Self-Diagnostic Code “5 – 4” Knock Sensor (DF115A/140A)

CENDG2111104022
Wiring Diagram

ECM
1

C
R P/Bl P
U

IDG211110026-03

1. Knock sensor

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the knock sensor connector.
2) With the ignition switch “ON”, check the voltage between P/Bl wire terminal of the knock sensor connector and
body ground.
Is the voltage 4 – 5 V?

Yes Go to Step 2.

No • P/Bl wire open, P/Bl wire shorted to ground circuit or poor sensor connection.
• If the wire and connection are OK, substitute a known-good ECM and recheck.

Step 2
1) Inspect knock sensor.
Refer to “Knock Sensor Inspection (DF115A/140A)” in Section 1C (Page 1C-16).
Is it in good condition?

Yes Poor knock sensor connection, intermittent trouble or a faulty ECM may be the cause.

No Faulty knock sensor.

For step 1

P/Bl

IDG211110027-01
 Engine Control: 1A-33

Self-Diagnostic Code “3 – 6” O2 Sensor

CENDG2111104020
Wiring Diagram

OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/R P
W
U
Lg/B

+B
OXH
IDG211110022-03

1. O2 sensor

Troubleshooting
For step 1
Step 1
1) With the ignition switch “OFF”, disconnect the O2
Gr/R
sensor connector.
2) Check continuity between Gr/R terminal of O2
sensor connector and ground, also between Gr/R
and B/W terminals of O2 sensor connector. B/W
Make sure there are not continuity.
3) Disconnect ECM connectors.
Refer to “ECM Removal and Installation” (Page IDG211110023-01

1A-40).
4) Check continuity between Gr/R terminal of O2
sensor connector (harness side) and No.36 B/W
terminal of ECM connector (harness side), also Gr/R
between B/W terminal and No.8 terminal.
Make sure there are continuity.
Are they in good condition?

Yes Go to step 2.

No Gr/R wire shorted, or Gr/R or B/W wire 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 35 36 37 38 39 40 41 42 43

open. 18
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 44 45 46 47 48 49 50 51 52
52

IDG211110024-01
Step 2
1) Check the O2 sensor output voltage.
Refer to “O2 Sensor Output Voltage Inspection” in
Section 1C (Page 1C-14).
Is each voltage OK?

Yes Poor O2 sensor connection, intermittent

trouble or a faulty ECM may be the cause.

No Faulty O2 sensor.
1A-34 Engine Control:

Self-Diagnostic Code “6 – 3” O2 Sensor Heater

CENDG2111104021
Wiring Diagram

OX 12 V
GND
1 ECM
Gr
W
Gr B/W
C
B Gr/R P
W
U
Lg/B

+B
OXH
IDG211110022-03

1. O2 sensor

NOTE
Temperature of the sensor affects resistance value largely.

Make sure that the sensor heater is in atmospheric temperature.

Troubleshooting

Step 1
1) With the ignition switch “OFF”, disconnect the O2 sensor connector.
2) Measure the resistance between W terminals of O2 sensor.
Is the resistance 5.5 – 8.5 Ω at 20 °C (68 °F)?

Yes Go to Step 2.

No Faulty O2 sensor.

Step 2
1) Check the O2 sensor heater voltage.
Refer to “O2 Sensor Heater Inspection” in Section 1C (Page 1C-15).
Is the voltage OK?

Yes • Gr or Lg/B wire open or shorted to ground, or poor No.46 terminal connection.
• If wires and their connection are OK, intermittent trouble or a faulty ECM may be the cause.

No • Gr or Lg/B wire shorted or open.

• Poor connection on O2 sensor or ECM connector.

For step 1

(A) W W

IDG211110025-02
 Engine Control: 1A-35

Troubleshooting Without Self-Diagnostic Code

CENDG2111104018
Before troubleshooting, make sure that there is not a self-diagnostic code indication.

Condition Possible cause Correction / Reference Item

Unstable idling/trolling (or Clogged MAP sensor vacuum passage. Check the vacuum passage.
engine tends to stall) Malfunctioning TPS. Check the TPS sensor.
Faulty IAC system. Check the IAC system.
Fuel pressure out of specification. Check the fuel pressure.
Faulty injector or its circuit. Check the injector and its circuit.
Poor performance of the IAT sensor, Check each sensor.
TPS or MAP sensor.
Faulty ECM. Replace.
Faulty spark plug. Replace.
Faulty ignition coil or its circuit. Check the ignition coil and its circuit.

IAC System Troubleshooting

CENDG2111104019
Wiring Diagram

+12 V (From main relay) ECM

Gr
R/G

IDG211110028-01

1. IAC valve

Troubleshooting Is the resistance 8 – 12 Ω?

Step 1 Yes Proceed to “Unstable Idling/Trolling” in

“Troubleshooting Without Self-Diagnostic
1) Warm up the engine to normal operating
Code” (Page 1A-35) and check items
temperature and keep it idling.
except for “Faulty IAC System”.
2) Using the SDS tool, check the IAC duty cycle and
idle speed. No • Faulty IAC valve.
Idle speed (IAC duty cycle): • Poor connection.
650 – 750 r/min (Approx. 40 – 50%) • Open wire harness.
Is result OK?

Yes IAC system is in good condition. For step 2

No Go to step 2.

Step 2
1) Disconnect the IAC connector at the IAC valve
with ignition switch “OFF”.
2) Check resistance between both terminals of IAC IDG211110020-03
valve.
1A-36 Engine Control:

Service Instructions
How to Use The 18-Pin and 34-Pin Test Cord Set
CENDG2111106001
This test cord is used when checking a circuit for voltage, etc. and is connected between the ECM and the wiring
harness.
To take a measurement, connect the tester probe to the relevant terminal of the test cord.
Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)

ECM

2 1
(A) (A)

(White connector)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

(Black connector) (Black connector)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

(White connector)

3
IDG211110017-02

1. 34-pin test cord side 2. 18-pin test cord side 3. Wire harness
 Engine Control: 1A-37

Inspection of The ECM and Its Circuit

CENDG2111106002
NOTICE
If you connect a voltmeter or ohmmeter directly to ECM terminals by removing ECM connector, you
can damage the control module.

Never connect a voltmeter or an ohmmeter directly to any terminal of ECM by disconnecting control
module connector.

Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)
: 09930–99320 (Digital tester)
Tester knob indication
Voltage ( )
1) Turn the ignition switch “OFF”.
2) Connect the 18-pin and 34-pin test cord set between the ECM and wire harness as shown in figure.
3) Turn the ignition switch “ON”.
4) Connect the tester probe (“–”, Black) to body ground, and measure the voltage according to the “Circuit Voltage
Table” (Page 1A-38).

ECM

2 1
(A) (A)

(White connector)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

(Black connector) (Black connector)

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

(White connector)

3
IDG211110017-02

1. 34-pin test cord side 2. 18-pin test cord side 3. Wire harness
1A-38 Engine Control:

Circuit Voltage Table

43 42 41 40 39 38 37 36 35 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
52 51 50 49 48 47 46 45 44 34 33 32 31 30 29 28 27 26 25 24 23 22 21 20 19 18

“B” “A”
IDG211110018-03

“A”: 34-pin connector “B”: 18-pin connector

Wire
Terminal Circuit Standard voltage Condition/Remarks
color
Approx. 2.5 V Ignition switch ON.
1 P/Bl Knock sensor
Approx. 2.5 V Engine running at idle speed.
Ignition switch ON, troll mode switch UP side
Approx.12 V
push.
2 V Troll mode switch Approx. 2.6 V Ignition switch ON, troll mode switch free.
Ignition switch ON, troll mode switch DOWN side
Approx. 0 V
push.
3 W/Y Trim and Tilt sensor Approx. 2 – 4.2 V Ignition switch ON.
4 R Power source for sensors Approx. 5 V Ignition switch ON.
5 R/W CKP sensor — —
6 — — — —
Approx. 12 V Ignition switch ON, shift into NEUTRAL.
7 Y/G Neutral switch Ignition switch ON, shift into FORWARD or
Approx. 0 V
REVERSE.
8 B/W Ground for sensors — —
9 V/W Ex. manifold temp. sensor 0.14 – 4.75 V Ignition switch ON.
10 Lg/B IAT sensor 0.04 – 4.46 V Ignition switch ON.
11 W/Y Trim gauge — —
12 G/Y TEMP lamp — —
13 P/W REV-LIMIT lamp — —
Approx. 12 V Ignition switch OFF.
14 R/B Ground for ECM main relay
Approx. 0.8 V Ignition switch ON. Engine cranking (running).
15 B Ground for ECM — —
16 O/Y PC communication line (A) — —
Power source No.1 for
17 Gr Approx. 12 V Ignition switch ON.
ECM
Approx. 12 V Ignition switch ON. PTT UP switch ON.
18 Lbl PTT switch “UP”
Approx. 0 V Ignition switch ON. PTT UP switch OFF.
Approx. 12 V Ignition switch ON. PTT DN switch ON.
19 P PTT switch “DOWN”
Approx. 0 V Ignition switch ON. PTT DN switch OFF.
20 W MAP sensor 0.79 – 4.2 V Ignition switch ON.
Approx. 3.8 V Ignition switch ON. Throttle WOT.
21 Br/Y Throttle position sensor
Approx. 0.7 V Ignition switch ON. Throttle FCT.
22 Y/Bl CMP sensor Approx. 0.3 V or 5 V Ignition switch ON.
23 Lg/W Cylinder temp. sensor 0.14 – 4.75 V Ignition switch ON.
Approx. 5 V Ignition switch ON. Stop switch plate IN.
24 Bl/R Emergency stop switch
Approx. 0 V Ignition switch ON. Stop switch plate OUT.
Approx. 12 V Ignition switch ON. Key pushed in.
25 O/W Buzzer cancel
Approx. 0 V Ignition switch ON. Key not pushed in.
Approx. 5 V While engine running.
26 Bl Oil pressure switch
Approx. 0 V Engine stopped (Ignition switch ON).
Approx. 2.6 V Ignition switch ON.
27 Br Start switch
Approx. 12 V Ignition switch START position.
28 Bl/W Buzzer — —
 Engine Control: 1A-39

Wire
Terminal Circuit Standard voltage Condition/Remarks
color
29 G/W CHECK ENGINE lamp — —
30 Bl/B OIL lamp — —
31 Y/B Tachometer — —
Approx. 0.8 V Ignition switch ON, Cranking.
32 G Starter relay control
Approx. 12 V Ignition switch ON, Normal.
33 Y PC communication line (B) — —
Power source No.2 for
34 B/Bl Approx. 12 V Ignition switch ON.
ECM
Approx. 0 V PTT switch UP free.
35 Lg PTT relay “UP”
Approx. 12 V PTT switch UP push.
0.7 V or more While engine idling after warming up.
36 Gr/R O2 sensor
0.2 V or less Engine stopped (Ignition switch ON).
37 R/G IAC valve Approx. 0 V Ignition switch ON.
38 — — — —
39 Lg/W No.4 fuel injector (–) Approx. 12 V Ignition switch ON.
40 R/W No.3 fuel injector (–) Approx. 12 V Ignition switch ON.
• Stop switch plate IN, shift into NEUTRAL.
Approx. 0 V For 3 sec. after ignition switch ON.
41 B/R High pressure fuel pump (–) • While engine running.
Engine stopped. Ignition switch ON.
Approx. 12 V
Stop switch plate IN, shift into NEUTRAL.
42 O/B No.1 fuel injector (–) Approx. 12 V Ignition switch ON.
43 O No.1 ignition coil Approx. 12 V Ignition switch ON.
Approx. 0 V PTT switch DN free.
44 P PTT relay “DOWN”
Approx. 12 V PTT switch DN push.
45 — — — —
Approx. 12 V Ignition switch ON, Engine stopped.
46 Lg/B O2 sensor heater
Approx. 0 V While engine running, after engine warmed up.
47 — — — —
48 B Ground for power — —
Approx. 12 V Ignition switch ON. Water detection switch OFF.
49 R/Bl Water detection switch
Approx. 0 V Ignition switch ON. Water detection switch ON.
50 B Ground for power — —
51 B/Br No.2 fuel injector (–) Approx. 12 V Ignition switch ON.
52 Bl No.2 ignition coil Approx. 12 V Ignition switch ON.
1A-40 Engine Control:

ECM Main Relay Inspection 3) Measure the resistance between relay terminals (4)
CENDG2111106003 and (5).
Inspect the ECM main relay using the following
If out of specification, replace ECM main relay.
procedures:
1) Disconnect the ECM main relay from the fuse box. Tester knob indication
Resistance (Ω)
ECM main relay solenoid coil resistance
1
Standard: 145 – 190 Ω

(A)

IDG211110019-01
I9J011110039-01
1. ECM main relay

ECM Removal and Installation

2) Check continuity between terminal (2) and (3) each
time 12 V power supply is applied to terminal (4) and
(5).
Connect the positive (+) lead to terminal (5), and
negative (–) lead to terminal (4).
NOTICE
If the 12 V power supply wire is connected to
wrong terminal or touched to each other, the
power supply wire, tester may be damaged.
CENDG2111106004
Removal
1) Turn the ignition switch “OFF”.
2) Remove the PORT lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
3) Pull and remove the fuse box (1) from electric part
holder.

Be careful not to touch 12 V power supply

wires to each other or with other terminals.

Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication 1
Continuity ( )
ECM main relay function
Continuity IDG211110033-01

12 V power applied Yes 4) Disconnect lead wire connectors from the ECM (2),
12 V power not applied No then remove ECM.

2 3
5

12 V
CONT
4
2
(A)
I9J011110038-02 IDG211110034-01

Installation
Installation is reverse order of removal.
 Engine Electrical Devices: 1C-1

Engine Electrical Devices

Power Head

Precautions
Precaution for Engine Electrical Device
CENDG2111300001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Engine Control Diagnosis” in Section
1A (Page 1A-1).

General Description
Sensor and Switch Description CMP Sensor
CENDG2111301001
CKP Sensor • The CMP sensor is mounted on the cylinder head and
the trigger vanes are pressed onto the end of the
• There is one CKP sensor installed below the flywheel
exhaust camshaft.
rotor.
This sensor is used to detect piston position.
When the reluctor bars on the flywheel pass the
sensor, a signal (voltage pulse) is generated and sent • Signals received from this sensor are also used by the
to the ECM. This is the fundamental signal used to ECM to determine sequential fuel injection.
judge engine speed and crankshaft angle. • The 12 V power to the CMP sensor is supplied
• There are 32 reluctor bars. They are located 10 through the Ign. (Gr) line of the ignition switch.
degrees apart, except at two positions where they are
30 degrees apart.
During one crankshaft rotation, 32 signals are input to
1
the ECM.
• Failure symptom:
Without the CKP sensor signal input, the ECM does
not output the ignition and fuel injection signals.

IDG211130002-04

1. CMP sensor

1
2

IDG211130001-01

1. CKP sensor 2. Reluctor bar

1C-2 Engine Electrical Devices:

• The CMP sensor is a GMR (Giant Magnet Resistive) • Failure symptom:

semiconductor type sensor.
The GMR semiconductor has the property of varying
the electrical resistance depending on the intensity of
the magnetic force applied.
When the line of magnetic force from the magnet to
the GMR semiconductor is increased or decreased,
the electrical resistance of the GMR semiconductor
will change. The changes in resistance as the
magnets pass create the sensors waveform.
When a trigger vane on the camshaft reluctor aligns
with the sensors internal magnet, the electrical
resistance of the GMR will decrease.
When a trigger vane moves away from the sensor, the
electrical resistance of the GMR will increase.
When the GMR semiconductor voltage becomes
higher than the standard value, the sensors signal will
be lower. And when the voltage becomes lower than
the standard value, the sensors signal will be higher.
The six camshaft trigger vanes provide six high
voltage signals from the CMP sensor to the ECM
during one camshaft rotation (two rotations of
crankshaft).
1 is established by the CMP sensor input timing
2
3
Without the CMP sensor signal input, the ECM does
not output the ignition and fuel injection signals.
• ECM cylinder identification:
The cylinders are identified by a calculation of two
signals; one from the CKP sensor and one from the
CMP sensor.
The ECM measures the time interval of the signals
inputted from the CKP sensor.
When the ECM detects a signal interval that is longer
than normal, it determines that the wide space
between the reluctor bars (30 degree spaced apart
section) has passed through the CKP sensor.
The ECM identifies the cylinder by the number of
CMP sensor signal inputs and the input timing
(pattern) within the gap of the widely spaced reluctors
that have passed the CKP sensor. There are 2 CMP
sensor signal inputs to the ECM when the No.1 or
No.4 cylinders are on the compression stroke, but the
input timing (pattern) is different.
Thus the cylinder identification is established.
When a compression stroke takes place either in the
No.2 or the No.3 cylinder, the number of CMP sensor
signal inputs is 1. Likewise, the cylinder identification
(pattern).

4
Signal
High
Low
5
I9J011130001-01

1. Camshaft 4. Magnet
2. Trigger vane 5. CMP sensor
3. Magnet resistive semiconductor

32 signals / crankshaft 1 rotation

CKP sensor
signal
10° 30°

140° 220° 40° 40°

180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC TDC
No.1 cylinder Cm. Ep. Ex. In. Cm. Ep.
TDC TDC
No.3 cylinder In. Cm. Ep. Ex. In. Cm.
TDC TDC
No.4 cylinder Ex. In. Cm. Ep. Ex. In.
TDC TDC
No.2 cylinder Ep. Ex. In. Cm. Ep. Ex.

Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake

I9J011130002-04
 Engine Electrical Devices: 1C-3

Cylinder Temperature Sensor Exhaust Manifold Temperature Sensor

The cylinder temperature sensor is installed on the
cylinder (top side) and is used to detect the cylinder
temperature.
This is a thermistor type sensor (resistance of which
changes depending on temperature) and inputs a signal
to the ECM as a voltage value. This signal is used to
compensate the fuel injection duration, ignition timing,
etc.
This sensor is also used to detect engine over-heat as
the ECM detects both the temperature and temperature
change rate (gradient temp.-temperature rise vs. time).
The exhaust manifold temperature sensor is installed on
the exhaust manifold and used to detect exhaust
manifold temperature.
This sensor is the same type as the cylinder temperature
sensor, and inputs a signal to the ECM as a voltage
value.
This signal is also used to detect engine over-heat.
1

IDG211130004-04

1. Exhaust manifold temp. sensor

IAT Sensor
IDG211130003-04 The IAT sensor is installed on the bottom of the air
1. Cylinder temp. sensor silencer and is used to detect the intake air temperature.
This sensor is the same type as the cylinder temperature
sensor, and inputs a signal to the ECM as a voltage
(k ) value.
This signal is used to compensate the fuel injection
duration.
Resistance

Temperature (C°)
I9J011130003-02 1

IDG211130005-01

1. IAT sensor
1C-4 Engine Electrical Devices:
MAP Sensor
The MAP sensor is installed on the intake manifold and
used to detect the intake manifold pressure.
This sensor inputs the intake manifold pressure to the
ECM as a voltage value.
This input signal is used as the fundamental signal to
determine fuel injection duration, ignition timing, etc.
1 3000 r/min.
IDG211130006-02
1. MAP sensor
Throttle Position Sensor (TPS)
The TPS is installed on the throttle body and detects the
degree of throttle opening. The throttle shaft is
interlocked with the TPS shaft.
This sensor is a variable resistor, changing resistance
(Ohms) in accordance with the throttle opening.
The varying resistance value is converted to voltage and
input to the ECM.
Based on the TPS voltage, the ECM calculates the idle
and throttle opening positions to determine the control
modes of the various controls systems (Idle air control,
fuel injection control system, etc.).
1 1. Neutral switch
IDG211130007-01
1. TPS
Neutral Switch
The neutral switch is installed on the cylinder block
(STBD side) and is used to detect the shift position.
This switch is “ON” in neutral and “OFF” in forward or
reverse.
The ECM performs the following control based on the
neutral switch signal:
• When the shift is in forward or reverse at the time of
engine start, the fuel injection function is cancelled.
• When the shift lever is in neutral, fuel injection is
controlled to prevent engine speed from exceeding
• After shifting into forward or reverse from neutral, the
IAC valve is controlled to increase intake air to
prevent unstable engine idle or stalling.
• When the shift lever is in forward or reverse at the
time of engine start, the ECM will not supply power to
the starter motor relay, thus preventing starter motor
engagement.
(Start-in-gear protection.
Refer to “Start-In-Gear Protection System Description”
in Section 1I (Page 1I-2).)
1
IDG211130008-01
Knock Sensor (DF115A/140A)
Knock sensor uses a piezoelectric ceramics element
which converts engine vibration into voltage signals and
detects knocking from them.
Receiving signals from the knock sensor, ECM controls
the ignition timing to prevent knocking.
IDG211130057-03
1. Knock sensor

O2 Sensor with Heater
The O2 sensor is install on the top of the cylinder.
O2 sensor detects the oxygen concentration in the
exhaust gas and feed it back to the ECM, compensating
the fuel injection duration.
The fuel injection amount is compensated based on the
oxygen density in the exhaust gas detected with the O2
sensor by the value programmed based on this data,
engine speed, etc.
To make the O2 sensor function properly, a built-in
heater is equipped in O2 sensor.
The built-in heater is turned on or off by ECM.
1 With the ignition switch in the “OFF” position, and the UP
IDG211130058-03
1. O2 sensor
Trim Sensor
The trim sensor is variable resistor type.
With the sensor signal received, the ECM performs the
learning of the trim/tilt position and it controls the position
of both the trim down limit and the tilt up limit.
The trim sensor signal also operates the trim meter
through the ECM.
IDG211130009-01
1. Trim sensor
Engine Electrical Devices: 1C-5
• Failure symptom:
In the event of sensor failure:
– The ECM performs the control on the assumption
that the sensor output is 3.3 V.
– The control of the trim down limit and the tilt up limit
becomes inoperative.
– The trim gauge indicates a full trim position.
NOTE
When the ECM has been replaced, the trim
sensor removed/reinstalled, or the mid unit
overhauled, resetting of both the tilt up limit
and trim down limit must be performed.
ECM Main Relay
The ECM main relay is installed in the fuse box.
When energized by turning the ignition switch “ON”,
battery voltage is supplied to the ECM, fuel injector,
ignition coil, IAC valve and high pressure fuel pump.
or DOWN button of the PTT switch pressed, the main
relay turns “ON” to supply 12 V power to the ECM, which
then performs the on/off control of the PTT motor relay.
1
IDG211130010-01
1. ECM main relay
1C-6 Engine Electrical Devices:

Cranking Switch Signal ECM Power Source Line

The ECM detects if the engine is being started by the CENDG2111301002
The ECM is battery dependent and must be provided
position of ignition switch. When the ignition key is
with its own dedicated 12 V power supply. The electrical
turned to ST position, a voltage (12 V) signal is input to
circuits which provide this supply are:
the ECM.
The ECM in turn sets the ignition, fuel injection, IAC, etc. 1. When the ignition switch is turned “ON”, battery
to the starting mode. power passes from the white lead wire, through the
When the key is turned to the IG position, after the ignition switch contacts to the Gr output lead wire to
engine has been started, the input voltage becomes the No.34 terminal of the ECM.
approx. 2.5 V.
NOTE
2 3 Ensure that the battery cable connections are
+12V 1 clean and secure.
A failure at the battery connection will cause
incorrect operation of the ECM and starter
OFF
motor cranking system.
IG
ST 2. When the ECM main relay is energized, by turning
the ignition switch “ON”, battery voltage is supplied
ECM to the No.17 terminal of the ECM.

I9J011130004-03
7

1. Ignition switch 3. Starter motor relay R

2. Neutral switch 4 3
5
Emergency Stop Switch 6
W

When the cord from the plate of the switch is secured to

the operator, the plate will be pulled off if the operator is
suddenly thrown overboard.

W
The circuit of emergency stop switch will be closed when W
Gr 17

the plate is removed. B/Bl 34

ECM
Then the ECM does not provide fuel injector operating
signal, ignition signal, fuel pump operating signal and R/B 14
starter motor relay operating signal. 1
W
Failure symptoms: BATT

A switch short circuit will not allow the motor to start. IG Gr Gr

GND B B

IDG211130012-03

1. Battery 5. 30 A fuse
2. Battery cable 6. ECM main relay
3. 60 A fuse 7. Starter motor
1 4. 60 A fuse
1

IAJ611130015-01

1. Emergency stop switch

 Engine Electrical Devices: 1C-7

Component Location
Location of Sensor and Switch
CENDG2111303001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).

Service Instructions
Resistance Check
CENDG2111306001

Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (Ω)

NOTE
Make sure ignition switch is always OFF when measuring resistance.

1) Turn ignition switch OFF.

2) Disconnect battery cables from battery.
3) Disconnect wire harness connectors from ECM.
4) Connect the tester probes to terminal (wire harness side) and measure resistance according to the “Resistance
Table” (Page 1C-7).

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 35 36 37 38 39 40 41 42 43

18
18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 44 45 46 47 48 49 50 51 52
52

3 1 2

IDG211130048-02

1. Engine main wire harness 2. 18-pin connector 3. 34-pin connector

Resistance Table
Terminal for tester probe
Circuit Standard resistance at 20 °C (68 °F)
connection
CKP sensor 5 (R/W) to 8 (B/W) 168 – 252 Ω
Fuel injector No.1 42 (O/B) to 17 (Gr)
Fuel injector No.2 51 (B/Br) to 17 (Gr)
10 – 14 Ω
Fuel injector No.3 40 (R/W) to 17 (Gr)
Fuel injector No.4 39 (Lg/W) to 17 (Gr)
IAC Valve 37 (R/G) to 17 (Gr) 8 – 12 Ω
O2 sensor heater 46 (Lg/B) to 17 (Gr) 5.5 – 8.5 Ω
IAT sensor 10 (Lg/B) to 8 (B/W) 0 °C (32 °F): 5.3 – 6.6 kΩ
Cylinder temperature sensor 23 (Lg/W) to 8 (B/W) 25 °C (77 °F): 1.8 – 2.3 kΩ
50 °C (122 °F): 0.73 – 0.96 kΩ
Ex. manifold temperature sensor 9 (V/W) to 8 (B/W) 75 °C (135 °F): 0.33 – 0.45 kΩ
(Thermistor characteristic)
1C-8 Engine Electrical Devices:

Cylinder Temp. Sensor Removal and Cylinder Temp. Sensor Inspection

CENDG2111306003
Installation
CENDG2111306002 1) Remove the cylinder temperature sensor.
Removal Refer to “Cylinder Temp. Sensor Removal and
1) Loosen the cable tie (1), then disconnect the cylinder Installation” (Page 1C-8).
temp. sensor lead wire connector (2). 2) Immerse temperature sensing part of cylinder temp.
2) Loosen and remove the cylinder temp. sensor (3). sensor in water.
3) Measure resistance between sensor terminals while
1 heating water gradually.
4) If measured resistance does not change in the
proportion indicated, replace sensor.
Cylinder temp. sensor specification
3 Water
2 temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45
IDG211130011-05

Installation 1
Installation is reverse order of removal.
• Clean mating surface of sensor and cylinder.
• Tighten sensor to specified torque.
Tightening torque
Cylinder temp. sensor (a): 8 N·m (0.8 kgf-m, 5.8
lbf-ft)

2
I9J011130051-01

(a) 1. Thermometer 2. Heater

Resistance

IDG211130013-02

• Check wire routing.

Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).

Temperature
I9J011130008-02

5) Reinstall the cylinder temp. sensor.

Refer to “Cylinder Temp. Sensor Removal and
Installation” (Page 1C-8).
 Engine Electrical Devices: 1C-9

Ex. Manifold Temp. Sensor Removal and Ex. Manifold Temp. Sensor Inspection
CENDG2111306005
Installation
CENDG2111306004 1) Remove the Ex. manifold temp. sensor.
Removal Refer to “Ex. Manifold Temp. Sensor Removal and
1) Disconnect the Ex. manifold temp. sensor lead wire Installation” (Page 1C-9).
connector (1). 2) Immerse temperature sensing part of Ex. manifold
2) Loosen and remove the Ex. manifold temp. sensor temp. sensor in water.
(2). 3) Measure resistance between sensor terminals while
heating water gradually.
4) If measured resistance does not change in the
proportion indicated, replace sensor.

2
Ex. manifold temp. sensor specification
Water
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
1 °C (°F)
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45

IDG211130014-03
1
Installation
Installation is reverse order of removal.
• Clean mating surface of sensor and exhaust cover.
• Tighten sensor to specified torque.
Tightening torque
Ex. manifold temp. sensor (a): 8 N·m (0.8 kgf-m,
5.8 lbf-ft)
2
I9J011130051-01

1. Thermometer 2. Heater

(a)
Resistance

IDG211130015-03

• Check wiring harness routing.

Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
Temperature
I9J011130008-02

5) Reinstall the Ex. manifold temp. sensor.

Refer to “Ex. Manifold Temp. Sensor Removal and
Installation” (Page 1C-9).
1C-10 Engine Electrical Devices:

CKP Sensor Removal and Installation Installation

CENDG2111306006 Installation is reverse order of removal with special
Removal
attention to the following steps.
1) Remove lower side covers.
• Apply thread lock to sensor securing screws.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3). : Thread lock cement 99000–32050 (SUZUKI
2) Remove ring gear cover (1). Thread Lock 1342 (50 g))
• Install CKP sensor with air gap of 0.75 mm between
1
sensor and reluctor bar on flywheel, then tighten
sensor mounting screws securely.
CKP sensor air gap “a”
0.75 mm (0.030 in.)

IDG211190003-02
2
3) Remove air intake silencer case.
Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-3).
“a”
4) Disconnect CKP sensor lead wire connector (2). 1
5) Remove two screws and CKP sensor (3). IDG211130019-01

1. CKP sensor 3. Thickness gauge

2. Reluctor bar

• Check to ensure that all removed parts are back in

3 original position.
• Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
2
CKP Sensor Inspection
CENDG2111306007
IDG211130016-04 Inspect the CKP sensor.
Refer to “Resistance Check” (Page 1C-7).
 Engine Electrical Devices: 1C-11

IAT Sensor Removal and Installation IAT Sensor Inspection

CENDG2111306008 CENDG2111306009
Removal 1) Remove the IAT sensor.
1) Remove lower side covers. Refer to “IAT Sensor Removal and Installation”
Refer to “Lower Side Cover Removal and (Page 1C-11).
Installation” in Section 2A (Page 2A-3). 2) Immerse temperature sensing part of IAT sensor in
2) Remove three bolts and air intake silencer case (1). water.
Disconnect breather hose (2) from air intake silencer 3) Measure resistance between sensor terminals while
case. heating water gradually.
4) If measured resistance does not change in the
proportion indicated, replace sensor.
1
IAT sensor specification
Water
temperature: 0 (32) 25 (77) 50 (122) 75 (135)
°C (°F)
2
Resistance 0.73 – 0.33 –
5.3 – 6.6 1.8 – 2.3
(kΩ) 0.96 0.45

IDG211130021-04
1

2
I9J011130007-03

1. Thermometer 2. Heater

IDG211130022-03

3) Disconnect the sensor lead wire connector (3) and

remove IAT sensor.
Resistance

Temperature
I9J011130008-02

IDG211130020-04 5) Reinstall the IAT sensor.

Refer to “IAT Sensor Removal and Installation”
Installation (Page 1C-11).
Installation is reverse order of removal with special
attention to the following steps.
• Check to ensure that all removed parts are back in
original position.
• Check wiring harness routing.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
1C-12 Engine Electrical Devices:

CMP Sensor Removal and Installation Special tool

CENDG2111306010 : 09930–99320 (Digital tester)
Removal
1) Disconnect the CMP sensor lead wire connector (1) Tester knob indication
at sensor. DC voltage ( )
2) Remove the bolt and CMP sensor (2).
34-pin test cord (Black connector)
3

2
22

IDG211130025-01

IDG211130023-03
34-pin test cord (White connector)
Installation
Installation is reverse order of removal. 2

• Install CMP sensor, then tighten bolt securely.

8
• Connect sensor lead wire connector to CMP sensor.

CMP Sensor Inspection

CENDG2111306011
1) Turn ignition switch OFF.
2) Remove the bolt and CMP sensor.
IDG211130026-01
3) Connect the 18-pin and 34-pin test cord set between
ECM and wire harness as shown in figure. 6) Turn Ignition switch ON.
7) Measure the voltage when the tip of a steel
Special tool screwdriver is brought near and then pulled away
(A): 09930–89290 (18 pin & 34 pin test from the sensor tip.
cord)
When screwdriver is brought near
ECM Approx. 5.0 V

(A)
When screwdriver is pulled away
(A)
Approx. 0.3 V

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
3
2
5
1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

1
IDG211130066-01
4
1. Wire harness 3. Black connector
2. White connector
IDG211130027-01
4) Connect the tester probe (“+”, Red) to No.22 4. Screw driver 5. CMP sensor
terminal.
5) Connect the tester probe (“–”, Black) to No.8 8) If the voltage does not change in the above test,
terminal (or to body ground). check wire harnesses for open and short.
If wire harnesses are in good condition, replace CMP
sensor and recheck.
9) Reinstall CMP sensor.
 Engine Electrical Devices: 1C-13

MAP Sensor Removal and Installation 3) Remove the screws and MAP sensor (1) from intake
CENDG2111306012 manifold.
Removal
Refer to “MAP Sensor Removal and Installation”
1) Remove the air intake silencer case. (Page 1C-13).
Refer to “Air Intake Silencer Case Removal and
4) Install MAP sensor into special tool.
Installation” in Section 1D (Page 1D-3).
5) Connect vacuum pump gauge (with hose) to MAP
2) Disconnect lead wire connector (1) at MAP sensor.
sensor (special tool) as shown in figure.
3) Remove the bolts and MAP sensor (2).
Special tool
(B): 09917–49610 (Vacuum pump adapter)
(C): 09917–47011 (Vacuum pump gauge)

2 (C)
1

(B)

I9J011130015-01
IDG211130028-04
6) Turn ignition switch ON.
Installation 7) While applying negative pressure (vacuum) to MAP
Installation is reverse order of removal. sensor, measure “20” terminal voltage.
• Install MAP sensor, then tighten mounting screw
MAP sensor output voltage change
securely.
Negative pressure: 0 40 80
• Connect sensor lead wire connector to MAP sensor. kPa (kg/cm2, mmHg) (0, 0) (0.4, 300) (0.8, 600)
• Install air intake silencer case. “20” terminal
Refer to “Air Intake Silencer Case Removal and 4.00 2.42 0.84
voltage (V)
Installation” in Section 1D (Page 1D-3).
(At 759.8 mmHg, 101.3 kPa, 29.91 inHg
MAP Sensor Output Voltage Inspection barometric pressure.)
CENDG2111306013
1) Turn ignition switch OFF. 34-pin test cord (Black connector)
2) Connect the 18-pin and 34-pin test cord set between
3
ECM and wire harness as shown in figure.
(A)
Special tool
(A): 09930–89290 (18 pin & 34 pin test 20
cord)

ECM

(A)
(A)

IDG211130031-02
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52
3
2 Special tool
1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30 : 09930–99320 (Digital tester)
14 15 16 17 31 32 33 34

Tester knob indication

DC voltage ( )
1 8) If out of specification, Check wire harnesses for open
IDG211130029-01 and short. If wire harnesses are in good condition,
1. Wire harness 3. Black connector replace MAP sensor and recheck.
2. White connector
9) Reinstall MAP sensor.
Refer to “MAP Sensor Removal and Installation”
(Page 1C-13).
1C-14 Engine Electrical Devices:

O2 Sensor Removal and Installation

CENDG2111306019
Removal
1) Remove the cable tie (3) and disconnect the O2
sensor lead wire connector (2).
2) Using special tool, remove the O2 sensor (1).
Special tool
(A): 09933–39810 (O2 sensor socket)
1 (a)

3 IDG211130041-02

O2 Sensor Output Voltage Inspection

2 CENDG2111306020

1 1) Turn the ignition switch “OFF”.

2) Connect the 18-pin and 34-pin test cord set between
ECM and wiring harness as shown in figure.
Special tool
IDG211130040-01 (A): 09930–89290 (18 pin & 34 pin test
cord)
(A)

IDG211130059-04 IDG211130049-01

1. O2 sensor
Installation
Installation is reverse order of removal with special
attention to the following steps. ECM
• Tighten the O2 sensor (1) to the specified torque.
(A)
Tightening torque (A)
2
O2 Sensor (a): 10 N·m (1.0 kgf-m, 7.0 lbf-ft)

NOTE 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

3
• Always keep the O2 sensor away from any 1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30

grease and oil. 14 15 16 17 31 32 33 34

• Examine O2 sensor gasket for damage.

Always replace O2 sensor assembly if
sealing performance is suspect. 1
IDG211130050-01

1. Wire harness 3. White connector (34-pin)

2. White connector (18-pin)
 Engine Electrical Devices: 1C-15

3) Connect the tester probe (“+”, Red) to No.36

terminal. 1 2
4) Connect the tester probe (“–”, Black) to No.8
terminal (or to body ground).
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DC voltage ( )
IDG211130060-01

18-pin test cord (White connector) 1. Heater (+) 2. Heater (–)

2 4) If measurement exceeds specification, replace O2

sensor.
36 5) Connect O2 sensor lead wire connector to wire
harness.
6) Connect the 18-pin and 34-pin test cord set between
ECM and wiring harness as shown in figure.
Special tool
(A): 09930–89290 (18 pin & 34 pin test
IDG211130051-01 cord)

34-pin test cord (White connector) ECM

3 (A)
(A)
2

8
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

IDG211130052-01
1
5) Turn ignition switch ON. IDG211130053-02

6) Measure the O2 sensor output voltage. 1. Wire harness 2. White connector

O2 sensor output voltage

7) Connect the tester probe (“+”, Red) to No.46
0.2 V or less
terminal.
7) Start engine and allow to warm up. 8) Connect the tester probe (“–”, Black) to body ground.
8) After warming up, measure the O2 sensor output
Special tool
voltage while holding the engine speed at idling.
: 09930–99320 (Digital tester)
O2 sensor output voltage at idling
Tester knob indication
0.7 V and more
DC voltage ( )
9) If the voltage does not change in the above test,
check wiring harness for open and short. 18-pin test cord (White connector)
If wiring harness is in good condition, replace O2
sensor and recheck. 2

O2 Sensor Heater Inspection 46

CENDG2111306024
1) Turn the ignition switch OFF.
2) Disconnect O2 sensor lead wire connector.
3) Measure resistance between sensor terminals (1)
and (2).
IDG211130054-01
O2 Sensor heater resistance at 20 °C (68 °F)
5.5 – 8.5 Ω
1C-16 Engine Electrical Devices:

9) Turn the ignition switch “ON” and measure the O2 • Install the intake manifold.
sensor heater voltage. Refer to “Intake Manifold Removal and Installation” in
Section 1D (Page 1D-6).
O2 sensor heater voltage
Approx. 12 V (Battery voltage)
Knock Sensor Inspection (DF115A/140A)
10) Start engine and allow to warm up. CENDG2111306022

11) After warming up, measure the O2 sensor heater 1) Turn ignition switch OFF.
voltage while holding the engine speed at idling. Disconnect the knock sensor lead wire connector
(1).
O2 sensor heater voltage at idling
Approx. 0 – 0.3 V
12) If inspection in step 9 and/or step 11 out of
specification, check wiring harness for open and
short.
1
If wire harnesses are in good condition, replace O2
sensor and recheck.

Knock Sensor Removal and Installation

(DF115A/140A)
CENDG2111306021
Removal IDG211130055-01
1) Remove the intake manifold. 2) Turn ignition switch ON.
Refer to “Intake Manifold Removal and Installation”
3) Measure the voltage between sensor connector
in Section 1D (Page 1D-6).
terminal (wire harness side) and body ground.
2) Remove the knock sensor (1).
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DC voltage ( )
1
Knock sensor connector terminal voltage
Approx. 5 V

DC V
IDG211130045-01

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Tighten the knock sensor to the specified torque.
Tightening torque IDG211130056-02
Knock Sensor (a): 22 N·m (2.2 kgf-m, 16.0 lbf-ft)

(a)

IDG211130043-01
 Engine Electrical Devices: 1C-17

4) Turn ignition switch OFF. IAC Valve Removal and Installation

Connect sensor connector to wire harness. CENDG2111306014
Removal
5) Connect the 18-pin and 34-pin test cord set between
1) Remove the air intake silencer case.
ECM and wire harness as shown in figure.
Refer to “Air Intake Silencer Case Removal and
Special tool Installation” in Section 1D (Page 1D-3).
(A): 09930–89290 (18 pin & 34 pin test 2) Disconnect IAC valve lead wire connector at IAC
cord) valve (1).
ECM
3) Remove bolts (2) and IAC valve.

(A) (A)

35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

2
1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30 1
14 15 16 17 31 32 33 34

2
1
IDG211130061-03
IDG211130032-01
1. Wire harness 2. White connector
Installation
6) Connect the tester probe (“+”, Red) to No.1 terminal. Installation is reverse order of removal.
7) Connect the tester probe (“–”, Black) to No.15 • Install IAC valve, then tighten mounting bolts securely.
terminal (or to body ground). • Connect IAC valve lead wire connector to IAC valve.
34-pin test cord (White connector)
• Install the air intake silencer case.
2 Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-3).
1
15
IAC Valve Inspection
CENDG2111306015
1) Remove the air intake silencer case.
Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-3).
2) Disconnect connector from IAC valve.
IDG211130062-01
3) Check IAC resistance.
8) Check for sensor output voltage.
IAC valve resistance
Sensor output voltage
IAC valve resistance 8 – 12 Ω
Ignition switch ON Approx. 2.5 V
Engine running at idle speed Approx. 2.5 V
If out of specification, replace IAC valve.
9) If out of specification, Check wire harnesses for open
and short. If wire harnesses are in good condition,
replace knock sensor and recheck.

IDG211130033-02

4) Reinstall the air intake silencer case.

Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-3).
1C-18 Engine Electrical Devices:

TPS Inspection 3) Connect tester probe (“+”, Red) to No.21 terminal.

CENDG2111306016
4) Connect tester probe (“–”, Black) to No.8 terminal (or
1) Turn ignition switch OFF.
to body ground).
2) Connect the 18-pin and 34-pin test cord set between 34-pin test cord (Black connector)
ECM and wire harness as shown in figure.
3
Special tool
(A): 09930–89290 (18 pin & 34 pin test
cord) 21

IDG211130036-01

34-pin test cord (White connector)

2

IDG211130034-03 8

1. TPS

ECM

(A)
(A) IDG211130037-01

5) Turn the ignition switch ON.

35 36 37 38 39 40 41 42 43 44 45 46 47
6) Check for sensor output voltage.
48 49 50 51 52
3
2 Slowly move the throttle lever to open, and check if
1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
voltage changes linearly within specification,
14 15 16 17 31 32 33 34 according to throttle valve opening angle.
Sensor output voltage
FCT position: Approx. 0.7 V
1 WOT position: Approx. 3.8 V
IDG211130035-01

1. Wire harness 3. Black connector Special tool

2. White connector : 09930–99320 (Digital tester)
Tester knob indication
DC voltage ( )

NOTICE
The throttle body will lose its original
performance if it has been disassembled and
reassembled.

Do not try to adjust or remove any of the

throttle body component parts (Throttle
position sensor, throttle valve, throttle stop
screw, etc.).
These components have been factory
adjusted to precise specifications.

7) If out of specification, check wire harnesses for open

and short. If wire harnesses are in good condition,
replace the throttle body and recheck.
 Engine Electrical Devices: 1C-19

Trim Sensor Removal and Installation Trim Sensor Inspection

CENDG2111306023 CENDG2111306018
Removal 1) Turn ignition switch OFF.
1) Remove lower side covers. 2) Connect the 18-pin and 34-pin test cord set between
Refer to “Lower Side Cover Removal and ECM and wire harness as shown in figure.
Installation” in Section 2A (Page 2A-3).
Special tool
2) Disconnect the trim sensor lead wire connector (1).
(A): 09930–89290 (18 pin & 34 pin test
Cut the cable ties (2) binding trim sensor lead wire.
cord)
3) Remove the bolt (3) and trim sensor (4).
ECM

(A) (A)
1
4

2 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

2
1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

IDG211130046-01
1
IDG211130024-05

Installation 1. Wire harness 2. White connector

Installation is reverse order of removal with special

attention to the following steps.
• Bind the white taping point “A” on the trim sensor lead
wire to swivel bracket with cable tie.
3) Connect tester probe (“+”, Red) to No.3 terminal.
4) Connect tester probe (“–”, Black) to No.8 terminal (or
to body ground).
34-pin test cord (White connector)
2

3 8

“A”
IDG211130063-01

IDG211130047-01 Special tool

• Install lower side covers. : 09930–99320 (Digital tester)
Refer to “Lower Side Cover Removal and Installation” Tester knob indication
in Section 2A (Page 2A-3). DC voltage ( )
5) Turn the ignition switch ON.
6) Check for sensor output voltage.
Operate the PTT switch, and check if voltage
changes linearly within specification, according to
trim/tilt position.
Sensor output voltage
Trim/Tilt position Output voltage
Full trim down Approx. 2 V
Full tilt up Approx. 4.2 V

7) If out of specification, check wire harnesses for open

and short. If wire harnesses are in good condition,
replace trim sensor and recheck.
1C-20 Engine Electrical Devices:

Emergency Stop Switch Inspection

CENDG2111306025
1) Disconnect the emergency stop switch lead wire.
2) Check the continuity/infinity between the wiring leads (A)
under the condition shown below.
Special tool B
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Tester probe connection Tester B
Red (+) Black (–) indicates
Lock plate
Infinity IDG211130064-01
installed
Black Black
Lock plate
Continuity
removed

(A)

B
IDG211130065-01

3) If out of specification, replace the switch.

 Power Unit Mechanical: 1D-1

Power Unit Mechanical

Power Head

General Description
Power Unit Construction Description
CENDG2111401001
The power unit is direct water cooled, in line 4 cylinder, 4 stroke gasoline unit with its DOHC (Double overhead
camshaft) valve mechanism for “V” type valve configuration and 16 valves (4 valves/one cylinder).
The double overhead camshaft is mounted over the cylinder head, it is driven from crankshaft through driven gear and
timing chain, and no pushed rods are provided in the valve train system.

Powerhead Direction of Rotation

NOTE
This is a left hand (LH) rotation powerhead.

Cylinder Number
Cylinder number is as mentioned in figure.

No.1

No.2

No.3

No.4

IDG211140002-01

Diagnostic Information and Procedures

Cylinder Compression Check
CENDG2111404001
Refer to “Cylinder Compression Pressure Check” in Section 0B (Page 0B-20).

Oil Pressure Check

CENDG2111404002
Refer to “Oil Pressure Check” in Section 0B (Page 0B-19).
1D-2 Power Unit Mechanical:

Service Instructions
Tappet Clearance Inspection 5) Loosen the fifteen bolts securing cylinder head cover
CENDG2111406001 in ascending order of numbers, then remove the
Refer to “Tappet Clearance Inspection and Adjustment”
cylinder head cover.
in Section 0B (Page 0B-7).
5 4
Cylinder Head Cover Removal and Installation 13
CENDG2111406003
Removal 11 8
14
1) Remove both lower side covers. 15
Refer to “Lower Side Cover Removal and
9 10
Installation” in Section 2A (Page 2A-3). 12
6
2) Loosen the clamp securing breather hose (1), then 7
disconnect the breather hose from cylinder head
cover. 1
3 2
IDG211140007-03

6) Remove the gaskets (6) from cylinder head cover.

1

IDG211140003-02

3) Disconnect all spark plug caps (2).

IDG211140006-02

Installation
Installation is reverse order of removal with special
attention to the following steps.
• Clean sealing surface on cylinder head and cover.
2
• Remove oil, old sealant, and dust from sealing
surfaces.
• After cleaning, apply sealant to cylinder head sealing
surface area as shown in figure.
IDG211140004-02 : Sealant 99000–31140 (SUZUKI Bond
4) Disconnect fuel inlet hose (4) and outlet hose (5) 1207B (100 g))
from low pressure fuel pump (3).
Remove bolts and low pressure fuel pump.

3
4
IDG211140008-01

IDG211140005-01
 Power Unit Mechanical: 1D-3

• Install new gaskets (1) to cylinder head cover. Air Intake Silencer Case Removal and
Installation
NOTICE CENDG2111406004

A previously used gasket may leak, resulting Removal

in engine damage. 1) Remove the ring gear cover (1).

Do not reuse gasket once removed. Always

use a new one.
1

IDG211140011-02

2) Remove the three bolts securing air intake silencer

case (2).
3) Disconnect the breather hose (3) and remove the air
IDG211140009-01
intake silencer case.
• Install cylinder head cover to cylinder head, then
tighten cylinder head cover bolts in ascending order of
numbers.
2
NOTE
Use care when installing cylinder head cover.
Be certain cylinder head cover gaskets
remain in their correct position.

Tightening torque
Cylinder head cover bolt (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
IDG211140012-01

11 12
3
5 8 3
2
1
2

7 6
4
10
9

15
13 14
IDG211140010-03

• Install the low pressure fuel pump. IDG211140013-02

Refer to “Low Pressure Fuel Pump Removal and 4) Disconnect the IAT sensor connector (4).
Installation” in Section 1G (Page 1G-25).
• Perform the following final assembly checks to ensure
proper and safe operation.
– All parts removed have been returned to their
original positions.
– Wire and hose routing matches service manual 4
illustration.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-1) and “Water Hose Routing” in Section 4B
(Page 4B-5).
– No oil leakage is evident during final test running.
IDG211140014-02
1D-4 Power Unit Mechanical:

Installation 4) Remove the bolt (3) securing main harness GND

Installation is reverse order of removal.
Electric Parts Holder Removal and Installation
CENDG2111406005
Removal
! CAUTION
Failure to take proper precaution when
removing electrical parts may result in
personal injury and/or damage to electronic
components.
lead wire and negative (–) battery cable.
Remove the nut (4) securing positive (+) battery
cable and main harness (R) lead wire.
Disconnect the red lead wire connector (5) from
terminal “S” on starter magnetic switch.
5

Prior to removing electrical parts, disconnect 4

battery cables from battery.
3
1) Remove the lower side covers.
Refer to “Lower Side Cover Removal and
IDG211140017-01
Installation” in Section 2A (Page 2A-3).
5) Pull off EX. temp. sensor lead wire connector (6),
2) Pull and remove the fuse box (1) from electric parts rectifier/regulator lead wire connectors (7), SDS
holder. service connector (8), gauge connector (9) from
electric parts holder.

7
9 8

6
IDG211140015-02

3) Disconnect the connectors (2) from ECM. IDG211140018-02

6) Disconnect the connectors (10) from PTT motor

relay.
Remove the bolt (11) securing harness GND lead
wire and electric parts holder.
7) Remove the electric parts holder from cylinder block.

NOTE
To remove the electric parts holder from
2
cylinder block, slide it downward first.

IDG211140016-02

11
10

IDG211140019-02
 Power Unit Mechanical: 1D-5

8) Remove the harness clamps (12) and connector (13) 9) Remove the PTT motor relay (14) and ECM (15)
from electric parts holder. from electric parts holder.

12
15
13

14

IDG211140020-02 IDG211140021-01

Installation
Installation is reverse order.
Perform the following final assembly checks to ensure
proper and safe operation.
• All parts removed have been returned to their original
positions.
• Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).

Intake Manifold and Throttle Body Components

CENDG2111406006

(a)

2
D
FW

IDG211140022-02

1. Intake manifold assembly 3. Filter 5. IAC valve

2. Throttle body assembly 4. IAC valve hose : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
1D-6 Power Unit Mechanical:

Intake Manifold Removal and Installation
CENDG2111406007
Removal
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section
1G (Page 1G-14).
2) Disconnect the battery cables from battery.
3) Remove the lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
4) Remove the ring gear cover (1).
1 container or absorbed by the cloth.
7) Loosen clamp and place a large cloth over end of
fuel feed hose (4).
Slowly pull fuel feed hose from fuel delivery pipe.
Drain any excess fuel in hose into a small container.
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
A small amount of fuel may be released when
the fuel feed hose is disconnected.
Place container under the fuel feed hose or
fuel delivery pipe upper union with a shop
cloth so that the released fuel is caught in the
Place the fuel soaked cloth in an approved
container.

IDG211140023-02

5) Remove the two bolts and air duct (2).

4

IDG211140026-02

8) Disconnect the high pressure fuel pump connector

(5).
Disconnect the knock sensor lead wire connector
(6). (DF115A/140A)
Remove the fuel delivery pipe assembly (7).
Refer to “Fuel Injector Removal and Installation” in
IDG211140024-02
Section 1G (Page 1G-23).
6) Disconnect fuel outlet hose (3) from the low pressure
fuel pump.

7
5

3
6

IDG211140027-01

IDG211140025-02
 Power Unit Mechanical: 1D-7

9) Remove the air intake silencer case (8). 12) Disconnect the water hose (13) from engine holder.
Refer to “Air Intake Silencer Case Removal and
Installation” (Page 1D-3).

8 13

IDG211140031-02

13) Loosen the nine bolts and two nuts in ascending

IDG211140028-02 order of numbers.
10) Disconnect MAP sensor connector (9) at MAP Remove the intake manifold assembly.
sensor.
Remove the throttle body (10).
Refer to “Throttle Body Removal and Installation” 3
6
(Page 1D-8).
1
10 7

11

8 9
9
2
4 5

IDG211140032-02

10 14) Remove the dowel pins (14) and gasket (15).

IDG211140029-02

11) Disconnect the water inlet hose (11) and outlet hose
(12) from fuel vapor separator.
14

15

IDG211140033-03

11 15) Remove the fuel vapor separator (16) from intake

manifold.
12
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-16).
IDG211140030-01

16

IDG211140034-02
1D-8 Power Unit Mechanical:

Installation – Wire and hose routing matches service manual

Installation is reverse order of removal with special
attention to the following steps.
NOTICE
Air leakage will induce a lean air/fuel mix
which will result in severe engine damage.
Do not reuse gasket once removed.
Always use a new gasket.
• Install the fuel vapor separator to intake manifold.
Refer to “Fuel Vapor Separator Removal and
Installation” in Section 1G (Page 1G-16).
• Install the dowel pins (1) and gasket (2).
illustration.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-3) and “Fuel Hose Routing” in
Section 4B (Page 4B-1).
– No fuel leakage is evident during final test running.
Throttle Body Removal and Installation
CENDG2111406008
Removal
1) Remove the air intake silencer case.
Refer to “Air Intake Silencer Case Removal and
Installation” (Page 1D-3).
2) Remove the flame arrester (1).

1
1

IDG211140035-03
IDG211140071-03
3) Disconnect IAC valve connector (2).
• Install the intake manifold assembly, then tighten bolts Disconnect TPS connector (3).
and nuts in ascending order of numbers. Remove the throttle link rod (4) from throttle body.
Tightening torque 4) Remove the four bolts securing throttle body to
Intake manifold bolt/nut (a): 23 N·m (2.3 kgf-m, intake manifold, then detach throttle body.
16.5 lbf-ft)
2

6 9 3

11
2 5 (a)

1
4
4 3
10
8 7
IDG211140036-02
IDG211140072-03 5) Remove the gasket (5).
• Install fuel delivery pipe assembly.
Refer to “Fuel Injector Removal and Installation” in
Section 1G (Page 1G-23).
• Install the throttle body.
Refer to “Throttle Body Removal and Installation”
(Page 1D-8).
• Perform the following final assembly checks to ensure
proper and safe operation.
5
– All parts removed have been returned to their
original positions.

IDG211140037-01
 Power Unit Mechanical: 1D-9

Installation Throttle Body Inspection

Installation is reverse order of removal with special
attention to the following steps.
NOTICE
Air leakage will induce a lean air/fuel mix
which will result in severe engine damage.
Do not reuse gasket once removed.
Always use a new gasket.
• Install the gasket (1).
CENDG2111406009
NOTICE
The throttle body will lose its original
performance if it has been disassembled and
reassembled.
• Do not try to disassemble the throttle body.
• Do not try to adjust or remove any of the
throttle body component parts (Throttle
position sensor, throttle valve, throttle
stop screw, etc.).
These components have been factory
adjusted to precise specifications.

• Clean throttle body bore by compressed air.

• Check that throttle lever and throttle valve moves
smoothly.
• Replace throttle body if necessary.
1

IDG211140038-01

• Install the throttle body to intake manifold, then

securely tighten the four bolts to specified torque.
Tightening torque
Throttle body bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf-
ft)

IDG211140040-01

(a)

IDG211140039-02

• Install the air intake silencer case.

Refer to “Air Intake Silencer Case Removal and IDG211140041-01
Installation” (Page 1D-3).
1D-10 Power Unit Mechanical:

Power Unit Removal and Installation 8) Remove the flywheel (6).

CENDG2111406010 Refer to “Flywheel Removal and Installation” in
Removal
Section 1K (Page 1K-4).
1) Relieve fuel pressure.
Refer to “Fuel Pressure Relief Procedure” in Section Special tool
1G (Page 1G-14). (A): 09930–49220 (Flywheel holder)
(B): 09930–39220 (Flywheel remover)
2) Drain engine oil.
3) Disconnect battery cables from battery.
4) Remove the intake manifold assembly (1). (A) (B)
Refer to “Intake Manifold Removal and Installation”
(Page 1D-6).
5) Remove the cylinder head cover (2) and spark plugs.
6
Refer to “Cylinder Head Cover Removal and
Installation” (Page 1D-2).

6
IDG211140044-03
2
9) Remove the battery charge coil (7).
1 Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-5).

IDG211140042-02 7
6) Disconnect the rectifier/regulator lead wire “Gr” (3)
from the fuse box.
Remove the electric parts holder (4).
Refer to “Electric Parts Holder Removal and
Installation” (Page 1D-4).
7) Remove the starter motor (5).
Refer to “Starter Motor Removal and Installation” in IDG211140045-01

Section 1I (Page 1I-4). 10) Disconnect water return hose (8) from thermostat
cover.
Remove bolt and water return hose pipe (9).

5
4

3 9

IDG211140043-01

IDG211140046-01
 Power Unit Mechanical: 1D-11

11) Disconnect cylinder temp. sensor lead wire 14) Loosen screw and disconnect blue lead wire from oil
connector (10), O2 sensor lead wire connector (11) pressure switch (17).
and CMP sensor connector (12).

17

10
12

11 IDG211140050-01

IDG211140047-01 15) Remove CKP sensor (18).

12) Disconnect two ignition coil connectors, then remove Disconnect water hose (19).
four bolts and ignition coils (13).

18

19

13

IDG211140051-01

IDG211140048-01 16) Remove the two bolts and front panel (20).
13) Disconnect EX. manifold temp. sensor lead wire
connector (14).
Remove nine bolts and rectifier/regulator (15). 20
Refer to “Rectifier / Regulator Removal and
Installation” in Section 1K (Page 1K-6).
Remove oil level gauge guide (16).

15

IDG211140052-01

17) Remove the screws securing the connector holder

14 (21).
Disconnect the water hose (22).
16

IDG211140049-01
21

22

IDG211140053-01
1D-12 Power Unit Mechanical:

18) Remove the cotter pin (23) and washer (24). 22) Remove the sixteen bolts securing power unit.
Remove the clutch lever link (25) from the clutch
shaft arm.

25

24
23 IDG211140058-01

IDG211140054-01

19) Remove E-ring (26), clutch control lever (27) and

clutch shaft arm (28).

26
28

IDG211140059-01
27

IDG211140055-01

20) Disconnect the lead wire connector of neutral switch

(29).
Remove two bolts (30), then clutch lever holder (31)
with fuel hose.

31 IDG211140060-01

23) Lift up and remove power unit from engine holder.

24) Remove the dowel pins (34) and gasket (35).
30

34 34
29

IDG211140056-01

21) Remove the pins (32) and side cover seal (33).

35
34

32 IDG211140061-01

33

IDG211140057-01
 Power Unit Mechanical: 1D-13

Installation • Lower the power unit onto engine holder.

Installation is reverse order of removal with special
attention to the following step.
NOTICE
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.
Do not reuse gasket. Always replace with
new part.
Power unit
• Install dowel pins (1) and gasket (2).
Apply water resistant grease to driveshaft splines.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
NOTE
Rotate crankshaft to aid alignment of
driveshaft and counter shaft splines.
• Apply suzuki silicone seal to power unit mounting
bolts and tighten bolts to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone Seal
(100 g))
Tightening torque
Power unit mounting bolt (10 mm): 50 N·m (5.0
kgf-m, 36.0 lbf-ft)
Power unit mounting bolt (8 mm): 23 N·m (2.3
kgf-m, 16.5 lbf-ft)

1 1

2
1

IDG211140064-04
IDG211140062-01

NOTE
Before installing power unit, apply sealant to
the two hatched areas shown in the
illustration at below.

: Sealant 99000–31140 (SUZUKI Bond

1207B (100 g))

IDG211140065-04

IDG211140063-01

IDG211140066-03
1D-14 Power Unit Mechanical:

Flywheel Cylinder head cover

• Install CKP sensor (1). • Install cylinder head cover.
Refer to “CKP Sensor Removal and Installation” in Refer to “Cylinder Head Cover Removal and
Section 1C (Page 1C-10). Installation” (Page 1D-2).
• Install battery charge coil (2).
NOTICE
Refer to “Battery Charge Coil Removal and
Installation” in Section 1K (Page 1K-5). A previously used gasket may leak, resulting
in engine damage.

Do not reuse gasket once removed. Always

use a new one.
2

1
IDG211140067-01

• Install flywheel (3) and tighten flywheel bolts to

specified torque.
Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-4).
IDG211140069-02
Tightening torque
Flywheel bolt (a): 245 N·m (24.5 kgf-m, 177 lbf-ft) Intake manifold
Special tool • Install intake manifold (1).
(A): 09930–49220 (Flywheel holder) Refer to “Intake Manifold Removal and Installation”
(Page 1D-6).

(a)
1

(A)

IDG211140068-01
IDG211140073-02

Fuel injectors
• Install fuel injectors and fuel delivery pipe (1).
Refer to “Fuel Injector Removal and Installation” in
Section 1G (Page 1G-23).

IDG211140070-02
 Power Unit Mechanical: 1D-15

Perform the following final assembly checks to
ensure proper and safe operation.
• All parts removed have been returned to their original
positions.
• Fuel and water hose routing matches service manual
illustration.
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
5).
• Wire routing matches service manual illustration.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
• No fuel leakage is evident when fuel system is
pressurized.
Refer to “Fuel Leakage Check Procedure” in Section
1G (Page 1G-14).
• No water leakage is evident during final test running.

Timing Chain, Chain Tensioner and Camshaft Sprockets Components

CENDG2111406011

8
9
7

5
4

3
6

1
IDG211140074-01

1. Crankshaft/Drive gear 4. Timing chain guide 7. Oil pump drive sprocket

2. Driven gear/Timing sprocket 5. Timing chain tensioner 8. Exhaust camshaft and timing sprocket
3. Timing chain 6. Timing chain tensioner adjuster 9. Intake camshaft and timing sprocket
1D-16 Power Unit Mechanical:

Timing Chain, Chain Tensioner and Camshaft 4) Remove bolts (3) and timing chain guide (4).
Sprockets Removal and Installation
CENDG2111406012
Removal
3
1) Remove the power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-10).
2) Turn the crankshaft in its normal running direction
4
“A” until the matching mark “B” (key) on the
crankshaft drive gear points to 12 o’clock position
(toward cylinder head). 3

NOTICE
IDG211140077-01
After the timing chain has been removed, 5) Remove bolt, nut and chain tensioner adjuster (5).
independently turning camshaft or Remove bolt (6) and chain tensioner (7).
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts.

Do not rotate the camshaft and/or crankshaft 6

with timing chain removed. 7

IDG211140078-01

6) Remove timing chain (8), exhaust camshaft timing

“B”
sprocket (9) and pin (10).
Remove bolt (11), intake camshaft timing sprocket
(12) and pin.

NOTE
“A”
Hold camshaft by placing a wrench on the
IDG211140075-01 hexagon area of camshaft.
“A”: Crankshaft normal running direction
“B”: Matching mark (key)

8
3) Remove bolt (1) and oil pump drive sprocket (2).

NOTE
Hold camshaft by placing a wrench on the
hexagon area of camshaft.
11
9 10 12

1 IDG211140079-01

IDG211140076-01
 Power Unit Mechanical: 1D-17

7) Remove driven gear (13). 4) Tighten the bolt (6) to the specified torque.

NOTE
Hold camshaft by placing a wrench on the
hexagon area of camshaft.
13 Tightening torque
IN. timing sprocket bolt (a): 78 N·m (7.8 kgf-m,
56.5 lbf-ft)
5) Check that engraved lines “C” and “F” on sprockets
are opposite each other and aligned with mating face
“G” of cylinder head cover when matching marks
IDG211140080-01 (dot) “H” and “I” on sprockets are located as shown
in figure.
Installation
Installation is reverse order of removal with special “H” “I”
attention to the following steps.
“C” “F” “G”
1) Check that matching mark (key way) “A” on the “G”
crankshaft drive gear points to 12 o’clock position
(towards cylinder head).
2) Install the driven gear (1) on the cylinder block so
that matching mark “A” aligns with matching mark
“B” on the driven gear as shown in illustration.

6 (a)
IDG211140083-02

6) As shown in figure, position timing chain on driven

gear sprocket with GOLD plate (7) of chain aligned
“B” with matching mark “B” on driven gear, then engage
1
“A” timing chain with exhaust sprocket with one BLUE
plate (8) of chain aligned with matching mark “H” of
exhaust sprocket.
7) As shown in figure, engage timing chain with intake
sprocket with another BLUE plate (8) of chain
IDG211140081-01 aligned with matching mark “I” of intake sprocket.
3) Install pin (2) and sprocket (3) on exhaust camshaft.
Install pin (4) and sprocket (5) on intake camshaft. 8 8

NOTE “H” “I”

When installing camshaft timing sprocket,
position side of sprocket with two engraved
lines “C”, “D”, “E” and “F” facing down
toward engine holder as shown in figure.

“D” “E”
“C” “F”

7
3
5
2 4
“B”
IDG211140082-01

IDG211140084-01
1D-18 Power Unit Mechanical:

8) Apply engine oil to the timing chain guide (9). Install 12) Apply engine oil to timing chain.
the timing chain guide, then tighten bolts securely. Remove stopper (15) from tensioner adjuster to
release plunger.

15

9
(b)

IDG211140085-01

9) Apply engine oil to chain tensioner (10). IDG211140088-05

Insert spacer (11) into chain tensioner.
Install chain tensioner as shown in figure.
13) Turn crankshaft in normal running direction two
complete turns and check that crankshaft matching
mark (key way) “A” points toward the top and at the
same time, engraved lines “C” and “F” on sprockets
aligns with cylinder head cover mating face “G”.

11

“C” “F”
10 “G” “G”

10

IDG211140086-01

10) With latch of tensioner adjuster pushed in and

plunger pushed back into body, insert stopper
between latch and body.
After inserting stopper, check to make sure that
plunger will not come out.

13 15
12 14
13

IDG211140087-01

12. Plunger 14. Body

“A”
13. Latch 15. Stopper

11) Install timing chain tensioner adjuster.

Tighten bolt and nut to specified torque.
IDG211140089-01
Tightening torque
Timing chain tensioner adjuster bolt/nut (b): 11 14) Install oil pump drive sprocket (16) and tighten bolt to
N·m (1.1 kgf-m, 8.0 lbf-ft) specified torque.

NOTE
Hold camshaft by placing a wrench on the
hexagon area of camshaft.
 Power Unit Mechanical: 1D-19

Tightening torque Timing Chain Tensioner / Chain Guide

Oil pump drive sprocket bolt (c): 78 N·m (7.8 • Check chain tensioner shoe for wear or damage.
kgf-m, 56.5 lbf-ft) If excessive wear or other damage is found, replace it.
• Check chain guide shoe for wear or damage.
If excessive wear or other damage is found, replace it.

16
(c)

IDG211140090-02

Timing Chain, Chain Tensioner and Camshaft IDG211140093-01

Sprockets Inspection
CENDG2111406013
NOTE Camshaft Timing Sprocket
Check teeth of sprocket for wear or damage.
If any component is worn excessively, If excessive wear or other damage is found, replace it.
cracked, defective or damaged in any way, it
must be replaced.

Timing Chain
Inspect timing chain for wear or damage.
If excessive wear or other damage is found, replace it.

IDG211140094-01

Driven Gear and Drive Gear Bearing

• Inspect drive gear and driven gear for wear or other
damage.
Replace if necessary.
IDG211140092-01
• Inspect driven gear bearing for pitting, rough or other
Tensioner Adjuster damage.
Inspect tensioner adjuster for smooth operation. Replace if necessary.
Replace if fault is noted.
Check oil delivery passage to tensioner.

I9J011140182-01 IDG211140091-01

1. Latch 3. Oil passage

2. Tooth surface
1D-20 Power Unit Mechanical:

Camshaft, Tappet and Shim Removal and 5) Remove tappets and tappet shims.
Installation
CENDG2111406014 NOTE
Removal All tappets and tappet shims must be
1) Remove the power unit. installed in their original positions.
Refer to “Power Unit Removal and Installation” For ease of assembly, lay out tappets and
(Page 1D-10). record shim thickness for each individual
2) Remove the timing chain and chain tensioner. cylinder/valve position.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
(Page 1D-16).
3) Remove the bolts securing camshaft housing to
cylinder head, then remove each camshaft housing.

NOTE
For ease of assembly, note position of each
individual camshaft housing.

IDG211140097-01

Installation
Installation is reverse order of removal with special
attention to the following steps.
1) Apply engine oil around tappets.
2) Install tappets and tappet shims.

IDG211140095-01

4) Remove intake camshaft (1) and exhaust camshaft

(2).

IDG211140098-01

3) Apply engine oil to surface of each camshaft lobe

1 and journal, then place them onto cylinder head.

NOTE
IDG211140096-02 Before installing camshafts, turn crankshaft
until the matching mark (key way) “A” on the
crankshaft drive gear points to 12 o’clock
(toward cylinder head).
 Power Unit Mechanical: 1D-21

6) Check position of camshaft housing. Install housings

as indicated by these marks.

NOTE
Embossed marks are provided on each
camshaft housing indicating position and
direction of installation.

“E”

IDG211140099-01
“F”

“G”

“A” IDG211140103-01

“E”: I: Intake side, E: Exhaust side

“F”: Position from flywheel magneto side
“G”: Pointing to flywheel magneto side

7) Lightly seat all housing bolts.

IDG211140100-01
4) Adjust relative position between sprockets and chain
so that matching marks (dot) “B” on timing sprockets
are as shown in figure and engraved lines “C” on
sprockets align with cylinder head cover mating face
“D”.
According to numerical order in figure, tighten bolts
to 1/3 of specified torque, then 2/3 of specified
torque and finally to full specified torque.
NOTE
Apply engine oil lightly to housing bolt.

“B” “B” Tightening torque

“C” Camshaft housing bolt (a): 11 N·m (1.1 kgf-m,
“C”
“D” 8.0 lbf-ft)
“D”

17 20 10 9 2 1 6 5 14 13

IDG211140101-01

“B”: Matching mark

“C”: Engraved line 19
“D”: Cylinder head cover mating face

5) Install camshaft housing pins as shown in figure.

18 21 12 11 4 3 8 7 16 15
IDG211140104-01
1
8) Install timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
(Page 1D-16).
9) Adjust tappet clearance.
Refer to “Tappet Clearance Inspection and
Adjustment” in Section 0B (Page 0B-7).
IDG211140185-01

1. Pin
1D-22 Power Unit Mechanical:

Camshaft, Tappet and Shim Inspection Camshaft Journal Wear

CENDG2111406015 Check camshaft journals and camshaft housings for
NOTE pitting, scratches, wear or damage.
If any component is worn excessively, If any of the above conditions are found, replace
cracked, defective or damaged in any way, it camshaft or cylinder head with housing.
must be replaced.
NOTE
Cam Face Camshaft housing and cylinder head must be
Inspect cam face for scratches and wear. replaced as a set.
If any of the above conditions are found, replace
camshaft.

Cam Wear
Using micrometer, measure cam height.
If measurement exceeds service limit, replace camshaft.
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm))

Cam height “a” (For DF100A/115A/140A) I9J011140030-01

Standard Service limit
39.520 – 39.680 mm 39.420 mm Camshaft Journal Oil Clearance
IN
(1.5559 – 1.5622 in) (1.5520 in) Check journal oil clearance using Plastigauge as follows.
39.320 – 39.480 mm 39.220 mm
EX 1) Clean housing and camshaft journals.
(1.5480 – 1.5543 in) (1.5441 in)
2) Install camshaft to cylinder head.
3) Place Plastigauge across the full width of camshaft
journal (parallel to camshaft).
(A)
Special tool
(A): 09900–22301 (Plastigauge (0.025 –
0.076 mm))

(A)

“a”

IDG211140105-01

Camshaft Runout
Support camshaft on a surface plate using a set of V-
blocks.
Measure runout using a dial gauge.
IDG211140107-01
If measurement exceeds service limit, replace camshaft.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–20701 (Magnetic stand)
Camshaft runout
Service limit: 0.10 mm (0.004 in.)

(B) (A)

IDG211140106-02
 Power Unit Mechanical: 1D-23

4) Install camshaft housing. Tighten housing bolts in 3 If journal oil clearance exceeds the service limit,
steps (1/3 of specification, 2/3 of specification, full measure camshaft journal (outside dia.) and
torque specification) in the indicated order. camshaft housing (inner dia.). Based on
measurements, replace camshaft and/or cylinder
Tightening torque
head with camshaft housing.
Camshaft housing bolt: 11 N·m (1.1 kgf-m, 8.0
lbf-ft) Camshaft journal outside diameter No.1 – No.4
Standard: 22.959 – 22.980 mm (0.9039 – 0.9047
NOTE in.)
Do not rotate camshaft while Plastigauge is
Camshaft journal outside diameter No.5
installed.
Standard: 25.934 – 25.955 mm (1.0210 – 1.0219
in.)
Camshaft journal (housing) inside diameter No.1
17 20 10 9 2 1 6 5 14 13 – No.4
Standard: 23.000 – 23.021 mm (0.9055 – 0.9063
in.)

19 Camshaft journal (housing) inside diameter No.5

Standard: 26.000 – 26.021 mm (1.0236 – 1.0244
in.)
Special tool
18 21 12 11 4 3 8 7 16 15
(B): 09900–20202 (Micrometer (25 – 50
IDG211140108-01
mm))
(B): 09900–20205 (Micrometer (0 – 25 mm))
5) Remove camshaft housing.
6) Using scale (1) on Plastigauge envelope, measure
Plastigauge (2) at its widest point.
(B)
Camshaft journal oil clearance No.1 – No.4
Standard: 0.020 – 0.062 mm (0.0008 – 0.0024 in.)
Service limit: 0.120 mm (0.0047 in.)
Camshaft journal oil clearance No.5
Standard: 0.045 – 0.087 mm (0.0018 – 0.0034 in.)
Service limit: 0.120 mm (0.0047 in.)

IDG211140109-01
2 1

IDG211140184-02

1. Scale 2. Plastigauge

I9J011140200-02
1D-24 Power Unit Mechanical:

Wear of Tappet and Shim Cylinder head tappet bore

Check tappet and shim for pitting, scratches, or damage. Standard: 31.000 – 31.025 mm (1.2205 – 1.2215 in.)
If any above conditions are found, replace component.

I9J011140076-01
I9J011140031-01
Measure cylinder head bore and tappet outside diameter
to determine cylinder head to tappet clearance.
If clearance exceeds service limit, replace tappet or
cylinder head.
Special tool
: 09900–20202 (Micrometer (25 – 50 mm))
Cylinder head bore to tappet clearance
Standard: 0.025 – 0.066 mm (0.0010 – 0.0026 in.)
Service limit: 0.150 mm (0.0059 in.)
Tappet outer diameter
Standard: 30.959 – 30.975 mm (1.2189 – 1.2195 in.) I9J011140032-01

Cylinder Head Assembly Components

CENDG2111406016

11 (a) 10

6
12 (b)

1
IDG211140110-01

1. Intake valve 5. Valve stem seal 9. Tappet : 70 N⋅m (7.0 kgf-m, 50.5 lbf-ft)
2. Exhaust valve 6. Valve spring 10. Tappet shim : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft)
3. Valve guide 7. Valve spring retainer 11. Cylinder head bolt (10 mm) : Apply engine oil.

4. Valve spring seat 8. Valve cotter 12. Cylinder head bolt (8 mm)
 Power Unit Mechanical: 1D-25

Cylinder Head Removal and Installation

CENDG2111406017
Removal
1) Prior to removing cylinder head assembly;
• Remove the power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-10).
• Remove the timing chain. (A)

Refer to “Timing Chain, Chain Tensioner and

Camshaft Sprockets Removal and Installation”
(Page 1D-16).
• Remove the IN. and EX. camshafts. IDG211140112-01

Refer to “Camshaft, Tappet and Shim Removal

and Installation” (Page 1D-20). Installation
Installation is in reverse order of removal paying special
• Remove bolts and oil pump (1).
attention to the following steps.
Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-3). NOTICE
• Remove oil relief valve (2). A previously used gasket may leak
combustion gas and/or cooling water,
resulting in engine damage.

Do not reuse gasket once removed.

Always use a new gasket.
1
1) Insert the dowel pins (1) and place a new cylinder
head gasket (2) into position on the cylinder.

2
2
IDG211140186-01

2) Loosen and remove eighteen cylinder head bolts in

the order indicated in figure.
Remove cylinder head assembly and head gasket.

NOTE
Use special tool (10 mm deep socket wrench) 1
when loosening cylinder head bolts.
IDG211140113-01
Special tool
(A): 09919–16010 (Deep socket wrench (10 NOTE
mm)) Before installing cylinder head gasket, apply
sealant to both surfaces of the hatched areas
2 6 4 15 7 8 3
5
shown in illustration.
9 1
13
11 : Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))

12
14 18 17 16 10
IDG211140111-01

IDG211140187-02
1D-26 Power Unit Mechanical:

2) Position cylinder head on cylinder. d) Finally tighten all cylinder head bolts to specified
torque according to sequence in figure.
NOTE
Tightening torque
Use special tool (10 mm deep socket wrench)
Cylinder head bolt (Final step) [10 mm]: 70
when tightening cylinder head bolts.
N·m (7.0 kgf-m, 50.5 lbf-ft)
Special tool Cylinder head bolt (Final step) [8 mm]: 25
(A): 09919–16010 (Deep socket wrench (10 N·m (2.5 kgf-m, 18.0 lbf-ft)
mm))
3) Apply engine oil to cylinder head bolts and tighten
them gradually as follows.
a) Tighten all cylinder head bolts to 50 percent (%)
of specified torque according to sequence in
figure.
(A)
Tightening torque
Cylinder head bolt (1st step) [10 mm]: 35
N·m (3.5 kgf-m, 25.5 lbf-ft)
Cylinder head bolt (1st step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft) IDG211140115-01

4) Install the IN. and EX. camshafts.

17 13 15 4 12 11 16 Refer to “Camshaft, Tappet and Shim Removal and
10 14 Installation” (Page 1D-20).
18
6 5) Install the oil pump and oil relief valve.
8 Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-3).
6) Install the timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
(Page 1D-16).
7
5 1 2 3 9 Cylinder Head Disassembly and Assembly
CENDG2111406018
IDG211140114-01
Disassembly
b) Loosen all cylinder head bolts to 0 N⋅m (0 kgf-m,
0 lbf-ft.) according to reverse sequence in figure. 1) Using valve lifter and attachment, remove valve
cotters (1) while compressing valve spring.
c) Again tighten all cylinder head bolts to 50
percent (%) of specified torque according to Special tool
sequence in figure. (A): 09916–19030 (Valve lifter)
(B): 09916–14910 (Valve lifter attachment)
Tightening torque
(C): 09916–84511 (Tweezers)
Cylinder head bolt (3rd step) [10 mm]: 35
N·m (3.5 kgf-m, 25.5 lbf-ft)
Cylinder head bolt (3rd step) [8 mm]: 12 N·m
(1.2 kgf-m, 8.5 lbf-ft)
(A)

(B)

IDG211140116-02
 Power Unit Mechanical: 1D-27

Assembly
(C) Reassemble in reverse order of disassembly paying
special attention to the following steps.
(A)

(B) 6
5

2
4

1
I9J011140209-01 3
2) Remove valve spring retainer (2), valve spring (3) I9J011140212-03

and valve (4). 1) Install valve spring seat (1) to cylinder head.
2) After applying engine oil to stem seal (2) and spindle
1 2 3 5 6 4 of special tool (A), fit stem seal to spindle.
Then, pushing special tool by hand, install stem seal
to valve guide.
Check to be sure that seal is properly fixed to valve
1
guide.
I9J011140210-01
NOTICE
3) Remove valve stem seal (5) and valve spring seat
(6). Removing the stem seal can be damaged,
causing oil to get down past the seal.
NOTE
Reassemble each valve and valve spring in Do not reuse stem seal once removed.
their original positions. Always install new seal.

Special tool
(A): 09917–98221 (Valve guide stem seal
installer attachment)
5 (B): 09916–57350 (Valve guide installer
handle)
6

(B)

(A)
I9J011140211-02
2

I9J011140033-03
1D-28 Power Unit Mechanical:

3) Apply engine oil to stem seal, valve guide bore and 6) Hold valve spring compressed with special tool and
valve stem. install valve cotters (6).
4) Install valve (3) to valve guide. Make sure valve cotters are properly seated in
groove “A”.
NOTE
NOTE
Reassemble each valve and valve spring to
their original position. When compressing the valve spring, be
careful not to damage the tappet hole.

Special tool
(C): 09916–19030 (Valve lifter)
(D): 09916–14910 (Valve lifter attachment)
(E): 09916–84511 (Tweezers)

(C)

I9J011140034-01

5) Install valve spring (4), and valve retainer (5).

(D)
NOTE
Set valve spring in place with narrow spiral
IDG211140117-03
area facing valve seat.

(E)

“C” (C)

“A” (D)
6

6
“A”
I9J011140036-02
“B”

“D”
I9J011140035-01

“A”: Large-pitch “C”: Valve spring retainer side

“B”: Small-pitch “D”: Valve spring seat side
 Power Unit Mechanical: 1D-29

Cylinder Head Components Inspection and • Check water jackets. If clogged or obstructed, clean
Servicing water jackets.
CENDG2111406019
NOTE
If cracks, excessive wear or other damage is
found on any component, replace
component.

Cylinder Head
• Remove all carbon from combustion chambers.

NOTE
• Do not use any sharp edged tool to scrape
carbon off cylinder head or its IDG211140119-01
components.
• Be careful not to scuff or nick metal Cylinder head distortion
surfaces when decarbonizing. • Using a straightedge and thickness gauge, measure
cylinder head distortion (gasket surface) at a total of
six locations as shown.
If measurement exceeds service limit, resurface or
replace cylinder head.
Special tool
(A): 09900–20803 (Thickness gauge)
Cylinder head distortion
Service limit: 0.05 mm (0.002 in.)

I9J011140037-01

• Check cylinder head for cracks in intake and exhaust

ports, combustion chambers, and head surface.
• Check valve seat, if cracks or other damage is found,
replace cylinder head.

IDG211140120-01

(A)

IDG211140118-01

IDG211140121-01
1D-30 Power Unit Mechanical:

Manifold seating faces distortion Valve guide inside diameter

Using a straightedge and thickness gauge, check Using a small bore gauge, measure valve guide inside
cylinder head to manifold seating faces. diameter.
If measurement exceeds service limit, resurface or
Valve guide inside diameter
replace cylinder head.
Standard (IN., EX.): 6.000 – 6.012 mm (0.2362 –
Special tool 0.2367 in.)
(A): 09900–20803 (Thickness gauge)
Manifold seating faces distortion
Service limit: 0.10 mm (0.004 in.)

(A) I9J011140040-01

IDG211140122-01 Valve guide to valve stem clearance

Valve and Valve Guide
Valve guide to valve stem clearance
Using a micrometer and bore gauge, take diameter
readings on valve stems and guides to check guide to
stem clearance.
Be sure to take readings at more than one place along
the length of each stem and guide.
If measurement exceeds service limit, replace valve and/
or valve guide.
Refer to “Valve guide replacement” (Page 1D-33).
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
Valve stem outside diameter
Using micrometer, measure valve stem outside
diameter.
Valve stem outside diameter
Standard (IN.): 5.965 – 5.980 mm (0.2348 – 0.2354 in.)
Standard (EX.): 5.940 – 5.955 mm (0.2339 – 0.2344
in.)
Standard (IN.): 0.020 – 0.047 mm (0.0008 – 0.0019 in.)
Standard (EX.): 0.045 – 0.072 mm (0.0018 – 0.0028
in.)
Service limit (IN.): 0.070 mm (0.0028 in.)
Service limit (EX.): 0.090 mm (0.0035 in.)
Valve stem deflection
If unable to measure valve guide inside diameter, check
“Valve stem deflection”.
If measurement exceeds service limit, replace valve.
If measurement still exceeds service limit with new
valve, replace valve guide.
Measure valve stem deflection as follows;
1) Install valve into valve guide.
2) Position valve head at approx. 5 mm away from
valve seat.
3) Move valve stem end in the direction “a” – “b”, and
measure deflection.
Special tool
(A): 09900–20606 (Dial gauge)
: 09900–20701 (Magnetic stand)
Valve stem deflection
Service limit (IN.): 0.14 mm (0.0055 in.)
Service limit (EX.): 0.18 mm (0.0071 in.)

“a”
“b”

(A)
(A)
I9J011140039-02

IDG211140123-02
 Power Unit Mechanical: 1D-31

Valve stem end Valve head radial runout

Inspect valve stem end face for pitting and wear.
If pitting or wear is found, valve stem end may be
resurfaced.
Use caution when resurfacing, do not grind away stem
end chamfer.
When chamfer has been worn away, replace valve.
Measure valve head radial runout.
To measure runout, rotate valve slowly.
If measurement exceeds service limit, replace valve.
Special tool
(A): 09900–20606 (Dial gauge)
(B): 09900–21304 (Steel “V” block set)
: 09900–20701 (Magnetic stand)
Valve head radial runout
Service limit: 0.08 mm (0.003 in.)

(A)

I9J011140041-01

Valve stem runout

(B)
Measure valve stem runout.
I9J011140043-03
If measurement exceeds service limit, replace valve.
Special tool Valve head thickness
(A): 09900–20606 (Dial gauge) Measure thickness “a” of valve head.
(B): 09900–20701 (Magnetic stand) If measurement exceeds service limit, replace valve.
(C): 09900–21304 (Steel “V” block set)
Special tool
Valve stem runout : 09900–20101 (Vernier calipers (150 mm))
Service limit: 0.05 mm (0.0020 in.)
Valve head thickness
Standard (IN.): 1.0 mm (0.04 in.)
Standard (EX.): 1.2 mm (0.05 in.)
(A) Service limit (IN.): 0.7 mm (0.03 in.)
Service limit (EX.): 0.7 mm (0.03 in.)

(B)
(C)

I9J011140042-02

“a”
45°
I9J011140044-01
1D-32 Power Unit Mechanical:

Valve seat contact width Valve seat servicing

Measure valve seat contact width as follows: If valve seat contact width is out of specification, reface
1) Remove all carbon from valve and seat. valve seat as follows:
2) Coat valve seat evenly with prussian blue (or Valve seat angle
equivalent). Intake side: 15°/45°/60°
3) Install valve into valve guide. Exhaust side: 15°/45°
4) Put valve lapper on valve.
Special tool
(A): 09916–10911 (Valve lapper)
˚
˚ ˚
˚ ˚
IDG211140125-01

To reface a valve seat, use the following valve seat

(A) cutting tool.
• Valve seat cutter 45° (Neway 122)
• Valve seat cutter 15° (Neway 121)
• Valve seat cutter 60° (Neway 114)
• Solid pilot (Neway, N-120-6.0)
IDG211140124-01

5) Rotate valve while gently tapping valve contact area • Handle (Neway, N-505) (09916-54910)
against seat. NOTE
6) Continue until a pattern is on valve seat face with
Turn cutter clockwise, never
prussian blue.
counterclockwise.
7) Measure valve seat contact width “b”.
1) Remove all carbon from valve and valve seat.
Special tool
: 09900–20101 (Vernier calipers (150 mm)) 2) Using 45° angle cutter, reface valve seat.
3) Check valve seat contact width “a”.
Valve seat contact width “b”
Refer to “Valve seat contact width” (Page 1D-32).
Standard (IN., EX.): 1.1 – 1.3 mm (0.04 – 0.05 in.)
Too high (wide)
If measurement exceeds specification, repair valve
seat.
Refer to “Valve seat servicing” (Page 1D-32).

“a”

I9J011140047-01
“b”

Too low (narrow)

I9J011140045-01

“a”

I9J011140048-01
 Power Unit Mechanical: 1D-33

• If width “a” is too high (or wide), reface valve seat Valve guide replacement
using 15° angle cutter.
• If width “a” is too low (or narrow), reface valve seat
using 60° angle cutter (Intake side).
• If width “a” is too low (or narrow), reface valve seat
using 45° angle cutter (Exhaust side).
NOTE
Be careful not to damage cylinder head when
replacing valve guide.
1) Using valve guide remover, drive valve guide out
from combustion chamber side towards valve spring
side.

NOTE
Do not reuse valve guide once it has been
removed.
Always use a new valve guide (oversize)
when assembling.

Special tool
IDG211140126-01
(A): 09916–46020 (Valve guide remover)
4) Clean up any burrs using 45° angle cutter very
lightly.

NOTE
Cut seat areas minimally only.
Do not cut more than necessary. (A)

5) Lap valve on seat in two steps, first with coarse grit

lapping compound applied to face and the second
with fine grit compound.
6) Recheck valve seat contact width “a”.

NOTE I9J011140050-01

2) Ream valve guide hole with ø 11 mm reamer to true

Clean and assemble cylinder head and valve
hole and remove burrs.
components.
Fill intake and exhaust ports with solvent to NOTICE
check for leaks between valve seat and valve.
If any leaks occur, inspect valve seat and Improper handling of the reamer will cause
face for burrs or other things that could damage to the valve guide hole.
prevent valve from sealing.
When refinishing or removing the reamer
from the valve guide hole, always turn it
clockwise.

Special tool
(B): 09916–38210 (Valve guide reamer (ø 11
mm))
(C): 09916–34542 (Valve guide reamer
handle)

(C)

IDG211140127-01

(B)

IDG211140128-01
1D-34 Power Unit Mechanical:

3) Install valve guide to cylinder head. Valve spring free length

• Heat cylinder head to a temperature of 80 – 100 Standard (IN., EX.): 42.73 mm (1.682 in.)
°C (176 – 212 °F). Service limit (IN., EX.) 41.02 mm (1.615 in.)
Apply heat uniformly so that head will not be
distorted.
• Use special tools to drive new valve guide into
hole.
Drive in new valve guide until special tool (valve
guide installer attachment) contacts cylinder head.
• After installing, check valve guide protrusion “a”.
(A)
Special tool I9J011140054-02

(D): 09916–57350 (Valve guide installer

handle) Valve spring preload
(E): 09917–87810 (Valve guide installer Measure valve spring preload.
attachment) If lower than service limit, replace valve spring.

Valve guide protrusion “a” Special tool

Standard (IN., EX.): 13.3 – 13.7 mm (0.52 – 0.54 : 09900–20101 (Vernier calipers (150 mm))
in.) Valve spring preload
Standard (IN., EX.): 164 – 190 N (16.7 – 19.4 kg, 36.8 –
42.7 lbs.) at 32.6 mm (1.28 in.)
Service limit (IN., EX.): 151 N (15.1 kg, 33.3 lbs.) at
32.6 mm (1.28 in.)
(D)

“a” (E)

I9J011140052-01

4) Ream valve guide bore with ø 6 mm reamer.

NOTE
I9J011140055-01
Clean and oil valve guide bore after reaming.
Valve spring squareness
Special tool
Use a square and surface plate to check each spring for
(F): 09916–37810 (Valve guide reamer (ø 6
squareness (clearance between end of valve spring and
mm))
square).
(C): 09916–34542 (Valve guide reamer
If measurement exceeds service limit, replace valve
handle)
spring.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Valve spring squareness “a”
(C)
(F)
Service limit (IN., EX.): 2.0 mm (0.08 in.)

“a”

IDG211140129-02

Valve spring free length

Check spring strength by measuring free length.
If lower than service limit, replace valve spring.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm)) I9J011140056-02
 Power Unit Mechanical: 1D-35

Pistons, Piston Rings, Connecting Rods, Cylinder and Crankshaft Components

CENDG2111406020

10 11
14 9 (a)

5
4
FW 3
D
8 2

16 (b)

15 (c) 6

7
13
12 17

IDG211140130-03

1. Cylinder block 7. Conrod bearing 13. Dowel pin : 25 N⋅m (2.5 kgf-m, 18.0 lbf-ft)
2. Piston ring set 8. Conrod cap 14. Crankcase : 52 N⋅m (5.2 kgf-m, 37.5 lbf-ft)
3. Piston 9. Conrod cap bolt 15. Crankcase (inside) bolt : Apply engine oil.

4. Piston pin 10. Oil seal 16. Crankcase (outside) bolt : Apply Molybdenum oil solution.

5. Circlip 11. Crankshaft 17. Thrust bearing

6. Conrod 12. Crankshaft main bearing : 17 N⋅m (1.7 kgf-m, 12.3 lbf-ft),
then plus turn in 60 degrees.
1D-36 Power Unit Mechanical:

Pistons, Piston Rings, Connecting Rods, 4) Remove ten crankcase (outside) bolts (4).
Cylinder and Crankshaft Disassembly and Remove ten crankcase (inside) bolts (5).
Assembly Remove crankcase (6) from cylinder block.
CENDG2111406021
Disassembly
1) Before performing service work in this section: 4

• Remove power unit.

Refer to “Power Unit Removal and Installation”
(Page 1D-10).
• Remove timing chain.
Refer to “Timing Chain, Chain Tensioner and
Camshaft Sprockets Removal and Installation”
(Page 1D-16). 5
• Remove cylinder head. 6
Refer to “Cylinder Head Removal and Installation” IDG211140133-01

(Page 1D-25). 5) Remove all conrod cap bolts and conrod caps (7).
2) Remove driven gear (1). NOTE
For proper assembly, mark cylinder number
on all pistons, conrods, and conrod caps,
1 using quick drying paint.

4 3 2 1
IDG211140131-01

3) Remove oil filter (2).

Remove oil pressure switch (3).
Special tool
: 09915–47341 (Oil filter wrench) IDG211140134-02

2
3

IDG211140132-01 IDG211140135-01
 Power Unit Mechanical: 1D-37

6) Remove crankshaft (8). 8) Remove two compression rings (top and 2nd) and oil
Remove oil seal (9) from crankshaft. ring from piston. Mark cylinder number on conrod
using quick dry paint.

1
9

IDG211140136-01

7) Mark cylinder number on pistons using quick dry IDG211140138-01

paint. 9) Remove piston pin circlips (10) as shown.

Push piston (with conrod) out through the top of
cylinder bore.
10
NOTE
• To prevent damage to piston rings,
decarbon top of cylinder bore wall before
removing piston.
• Reassemble each conrod cap to its
original position after removing piston
from bore. IDG211140139-01

10) Remove piston pin (11) from conrod.

NOTE
Reassemble each piston, piston pin and
conrod in their original combination and
position.
4 3 2 1

IDG211140137-01

11

IDG211140140-01
1D-38 Power Unit Mechanical:

Assembly
Assembly is reverse order of disassembly paying special
1
attention to the following steps.

NOTICE
4
If any of the parts is reinstalled into a position
3
different from the original position, engine 4
problems could occur.
2
If original components are not replaced, each
piston, piston pin and conrod is to be
assembled and installed in its original order
and position.
I9J011140010-01

Piston to conrod
Piston ring to piston
• Apply engine oil to piston pin (1), piston pin bore and
conrod (2). 1) Install the oil ring.
• Assemble conrod (2) to piston (3) as shown in figure • Apply engine oil to piston rings.
and insert piston pin (1) through piston and conrod. • Install spacer (1) first, then side rails (2) to piston.
• Install piston pin circlips (4).
2
NOTE
• “92J” mark on conrod and up mark “A” on
piston dome must face toward flywheel 1
side.
• Always use new piston pin circlip.
• Install so that circlip end gap comes within
such range as indicated by arrow. 2
End gap of the circlip should not be
aligned with the cutaway in the piston pin I9J011140011-01

bore. NOTE
When installing spacer, do not allow spacer
“C” ends to overlap in groove.

“A”
“A”
92J

“B”

“B”
IDG211140141-02

“A”: Up mark “C”: Flywheel side

“B”: Circlip end gap direction
I9J011140012-01

“A”: Incorrect “B”: Correct

 Power Unit Mechanical: 1D-39

2) Install the piston rings. Piston to cylinder

• Apply engine oil to piston rings. 1) Install conrod bearing (1) to conrod (2) and cap (3).
• Install 2nd ring (3) and 1st ring (4) to piston.
NOTICE
If the bearing is reinstalled into a position
different from the original position, engine
“RN” problems could occur.
“R” 4
If original bearings are not replaced,
3
“D”
assemble each bearing to its original
position.

NOTICE
IDG211140142-01
If oil is present between the bearing’s outside
NOTE surface and conrod surface, the bearing
• 1st ring (4) and 2nd ring (3) differ in shape could heat up to very high temperature,
as shown in figure. resulting in seizure.
• Also indicated in figure, the 1st and 2nd
Be sure to thoroughly wipe off any trace of oil
ring are marked “D” with the letter “R” or
that is present between the bearing’s outside
“RN” which must face towards top of
surface and conrod surface.
piston.

4
4
3 2

1
3 3
IDG211140188-01

3) Position piston rings so gaps are staggered at IDG211140143-01

approximately 90 degree angles as shown.

“D”

“G” “H”

“F” “E”
I9J011140016-01

“D”: Up mark “G”: 2nd ring and oil ring spacer

“E”: 1st ring “H”: Oil ring upper side rail
“F”: Oil ring lower side rail
1D-40 Power Unit Mechanical:

2) Apply engine oil to piston and cylinder walls. NOTICE

3) Insert piston and conrod assembly (4) into cylinder If oil is present between the bearing’s outside
bore from cylinder head side using special tool. surface and crank bearing holder surface, the
bearing could heat up to very high
NOTE
temperature, resulting in seizure.
Position the up mark “A” on piston head to
flywheel side “B”. Be sure to thoroughly wipe off any trace of oil
that is present between the bearing’s outside
Special tool surface and crank bearing holder surface.
(A): 09916–77310 (Piston ring compressor)
NOTE
Assemble main bearing half containing oil
groove/hole to cylinder block.
(A) Assemble the main bearing half without oil
groove to crankcase.

NOTE
Align bearing tab “A” with notch in cylinder
and crankcase.

IDG211140144-01

B
4 1 1

A
IDG211140146-02

IDG211140145-02

“A”: Up mark “B”: Flywheel side

“A”
Crankshaft to cylinder
Install crankshaft main bearings (1) in cylinder and
crankcase.
Apply engine oil to bearings.

NOTICE “C” “B”

If the bearing is reinstalled into a position

different from the original position, engine
problems could occur. IDG211140147-01

“A”: Bearing tab “B”: Oil hole “C”: Oil groove

If original bearings are not replaced,
assemble each bearing to its original
position.
 Power Unit Mechanical: 1D-41

Thrust bearing
Apply engine oil to the thrust bearings and install them in
cylinder block overlapping both sides of the No.4 main
journal.
Oil grooves “A” on the thrust bearing must face towards
crank webs.

IDG211140150-01

3) Install conrod cap.

a) Apply molybdenum oil solution to crank pin and
“A” conrod bearing.
IDG211140148-02
b) Install dowel pins (2) and conrod cap (3) (with
1. Thrust bearing “A”: Oil groove bearing) to conrod with embossed mark on the
cap toward flywheel side.
Crankshaft
NOTE
NOTE
Reassemble each conrod cap to its original
Replace the oil seal with new one. position.
Do not mix them in position.
NOTE
Install upper oil seal with its spring/lipped
side facing inward. 3 2

1) Apply engine oil to upper oil seal lip.

Install upper oil seal (1) to crankshaft.
2) Apply engine oil to crank pin and crankshaft main
journal and install crankshaft in cylinder.

NOTE 2
When installing crankshaft to cylinder, be
sure to fit tab of upper oil seal in groove of
cylinder. IDG211140151-03

A
B

1
IDG211140152-02
IDG211140149-01
3. Conrod cap “B”: Embossed mark (>)
“A”: Flywheel side
1D-42 Power Unit Mechanical:

4) Apply engine oil to conrod bolts. Crankcase to cylinder

Tighten conrod cap bolts in three steps as follows. 1) Clean mating surface of cylinder and crankcase.
a) Lightly seat all conrod bolts at first, then tighten Apply suzuki bond to mating surface of crankcase as
bolts 12 N⋅m (1.2 kgf-m, 8.7 lbf-ft) of specified shown.
torque.
NOTE
Tightening torque
Apply bond to mating surface only.
Conrod cap bolt (1st step): 12 N·m (1.2 kgf-
Do not allow bond to contact surface of
m, 8.7 lbf-ft)
bearing.
b) Tighten bolts 17 N⋅m (1.7 kgf-m, 12.3 lbf-ft) of
specified torque. : Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
Tightening torque
Conrod cap bolt (2nd step): 17 N·m (1.7 kgf-
m, 12.3 lbf-ft)

IDG211140153-01

c) Finally tighten bolts 60 degrees turn from the

point of step (b) using an angular torque gauge.
Tightening torque IDG211140155-01
Conrod cap bolt (Final step): 60 degrees “A”: Apply bond “–” marked line.

NOTE
2) Install five dowel pins (1).
Purchase a commercially available angular
torque gauge for this step of tightening bolts.

60°

IDG211140156-02

IDG211140154-01

d) Pour approx. 2 ml of engine oil to each side

surface of the conrod big end for initial
lubrication.
 Power Unit Mechanical: 1D-43

3) Install crankcase to cylinder. Cylinder head

Apply engine oil to crankcase bolts. Refer to “Cylinder Head Removal and Installation” (Page
Tighten crankcase bolts in three steps following the 1D-25).
order indicated below.
Timing chain
NOTE Refer to “Timing Chain, Chain Tensioner and Camshaft
Tighten 10 mm (0.394 in.) thread diameter Sprockets Removal and Installation” (Page 1D-16).
bolts first (following the order shown in
figure), then tighten 8 mm (0.315 in.) thread Oil pump
diameter bolts. Refer to “Oil Pump Removal and Installation” in Section
1E (Page 1E-3).
Tightening torque
Crankcase (inside) bolt (10 mm thread diameter) Power unit
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft) Refer to “Power Unit Removal and Installation” (Page
Crankcase (inside) bolt (10 mm thread diameter) 1D-10).
[2nd step]: 21 N·m (2.1 kgf-m, 15.0 lbf-ft)
Crankcase (inside) bolt (10 mm thread diameter) Cylinder, Piston and Piston Ring Inspection and
[Final step]: 52 N·m (5.2 kgf-m, 37.5 lbf-ft)
Servicing
CENDG2111406022
Tightening torque
NOTE
Crankcase (outside) bolt (8 mm thread
diameter): 25 N·m (2.5 kgf-m, 18.1 lbf-ft) If cracks, excessive wear or other damage is
found on any component, replace
8 component.
7

17 18 Cylinder Distortion
Using a straightedge and thickness gauge, measure
cylinder distortion (gasket surface) at a total of six
4 locations as shown.
13 If measurement exceeds service limit, resurface or
3 14 replace cylinder.
Special tool
11 12 (A): 09900–20803 (Thickness gauge)
1 2 Cylinder distortion
15 Service limit: 0.05 mm (0.002 in.)
16

5
6

19
20
9 10
IDG211140157-01

NOTE
After tightening crankcase bolts, check to be
sure that crankshaft rotates smoothly when
turned by hand.
IDG211140158-01

(A)

IDG211140159-01
1D-44 Power Unit Mechanical:

Water Jackets Cylinder Bore Wear (Difference)

Check water jackets. Using telescoping gauge (1), measure cylinder bore in
If clogged or obstruction is found, clean water jacket. both axial (vertical line, following crankshaft) and
transverse (horizontal line across crankshaft) directions
at two positions as shown in figure.

NOTE
Purchase a commercially available
telescoping gauge for this measurement.

Check the following:

• Difference between measurements at the two
positions (Taper).
• Difference between axial and transverse
IDG211140160-01 measurement (Out-of-round).
If measurement exceeds service limit, bore or replace
Driven Gear / Bearing cylinder.
• Inspect driven gear for wear or other damage. Cylinder bore wear (difference)
Replace if necessary. Service limit: 0.10 mm (0.0039 in.)
• Inspect driven gear bearing for pitting, rough or other
damage.
Replace if necessary.

4
3 1
2
1

IDG211140162-01

IDG211140161-01
“a”
1. Driven gear 3. O-ring
2. Plug 4. Circlip
“b”
Cylinder Bore
Inspect cylinder walls for scratches, roughness, or ridges
which indicate excessive wear.
If cylinder bore is very rough, deeply scratched or ridged, I9J011140060-01
bore cylinder and use oversize piston.
“a”: 50 mm (1.97 in.) “b”: 90 mm (3.54 in.)
 Power Unit Mechanical: 1D-45

Piston to Cylinder Clearance Identification of Oversize Piston / Piston Ring

1) Measure the piston diameter at a point 26.5 mm One oversize piston/piston ring components, 0.50 mm is
(1.04 in.) above the piston skirt at a right angle to the available. Oversize piston/piston ring are marked as
piston pin bore. shown, below.

Special tool Piston

(A): 09900–20204 (Micrometer (75 – 100 Oversize I.D. mark
mm)) 0.50 mm 50
Piston skirt diameter
Standard: 85.970 – 85.990 mm (3.3846 – 3.3854
in.)

“a” “A”

(A)
I9J011140061-02

“a”: 26.5 mm (1.04 in.) I9J011140062-02

“A”: I.D. mark

2) Measure the cylinder bore at 50 mm (1.97 in.) below
the cylinder head gasket surface at a right angle to 1st and 2nd Piston ring
the crankshaft pin. Oversize I.D. mark
NOTE 0.50 mm 50

Purchase a commercially available

1st, 2nd ring
telescoping gauge (1) for this measurement.
“B”
Cylinder bore diameter
Standard: 86.000 – 86.020 mm (3.3858 – 3.3866
in.)

I9J011140063-03

“B”: I.D. mark

50 mm
1 (1.97 in.)
Oil ring
Oversize I.D. mark
0.50 mm One white paint

Oil ring spacer

IDG211140163-02

3) Calculate the piston/cylinder clearance (Clearance

equals difference between piston diameter and
cylinder bore measurements).
If clearance exceeds service limit, replace piston
and/or cylinder or bore cylinder.
“C”
Piston to cylinder clearance I9J011140064-02

Standard: 0.020 – 0.040 mm (0.0008 – 0.0016 in.) “C”: I.D. mark

Service limit: 0.100 mm (0.0039 in.)
1D-46 Power Unit Mechanical:

Piston Piston Ring

Visual inspection
Inspect piston for faults, cracks or other damage.
Damaged or faulty piston(s) should be replaced.
Piston ring to groove clearance
Before checking, piston grooves must be clean, dry and
free of carbon.
Fit piston ring into piston groove, and measure clearance
between ring and ring groove using thickness gauge.
If measurement exceeds service limit, replace piston
and/or piston ring.
Special tool
(A): 09900–20803 (Thickness gauge)
Piston ring to groove clearance
Standard (1st): 0.030 – 0.070 mm (0.0012 – 0.0028 in.)
Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024
in.)
Service limit (1st): 0.12 mm (0.0047 in.)
Service limit (2nd): 0.10 mm (0.0039 in.)
Piston ring end gap
Measure piston ring end gap with piston ring in the
lowest position of cylinder bore.
If measurement exceeds service limit, replace piston
ring.
Special tool
(A): 09900–20803 (Thickness gauge)
Piston ring end gap
Standard (1st): 0.20 – 0.35 mm (0.008 – 0.014 in.)
Standard (2nd): 0.35 – 0.50 mm (0.014 – 0.020 in.)
Service limit (1st): 0.70 mm (0.028 in.)
Service limit (2nd): 1.00 mm (0.039 in.)
(A)
1

1
I9J011140066-02

1. Cylinder 2. Piston ring

(A) Piston ring free end gap

Measure piston ring free end gap using vernier calipers.
If measurement exceeds service limit, replace piston
ring.

I9J011140065-03 Special tool

1. Piston ring
Piston ring groove width
Standard (1st): 1.22 – 1.24 mm (0.048 – 0.049 in.)
Standard (2nd): 1.51 – 1.53 mm (0.059 – 0.060 in.)
Standard (Oil): 2.51 – 2.53 mm (0.099 – 0.100 in.)
Piston ring thickness
Standard (1st): 1.17 – 1.19 mm (0.046 – 0.047 in.)
Standard (2nd): 1.47 – 1.49 mm (0.058 – 0.059 in.)
(A): 09900–20101 (Vernier calipers (150 mm))
Piston ring free end gap
Standard (1st): Approx. 11.6 mm (0.46 in.)
Standard (2nd): Approx. 11.5 mm (0.45 in.)
Service limit (1st): 9.3 mm (0.37 in.)
Service limit (2nd): 9.2 mm (0.36 in.)

(A)

I9J011140067-02
 Power Unit Mechanical: 1D-47

Piston Pin and Conrod Inspection

CENDG2111406023
Piston Pin
Visual inspection
• Check piston pin, conrod small end bore and piston
pin hole for wear or damage.
If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin
can move smoothly in the piston pin hole.
(B)
If improper condition is found, replace the piston pin
and/or piston. I9J011140069-02

Piston pin clearance

Check the piston pin clearance in the conrod small end.
(B)
Replace the conrod if its small end is badly worn or
damaged or if clearance exceeds service limit.
Measure the following item:
Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
(B): 09900–20605 (Dial calipers (10 – 34 mm))
I9J011140070-02

Piston pin outside diameter

Standard: 20.997 – 21.000 mm (0.8267 – 0.8268 in.)
Service limit: 20.980 (0.8260 in.)
Piston pin hole diameter
Standard: 21.006 – 21.014 mm (0.8270 – 0.8273 in.)
Service limit: 21.040 (0.8283 in.)
Conrod small end bore
Standard: 21.003 – 21.013 mm (0.8269 – 0.8273 in.)
Pin clearance in piston pin hole
Standard: 0.006 – 0.017 mm (0.0002 – 0.0007 in.)
Service limit: 0.040 (0.0016 in.)
Pin clearance in conrod small end
Standard: 0.003 – 0.016 mm (0.0001 – 0.0006 in.)
Service limit: 0.050 (0.0020 in.)
Conrod big end side clearance
Measure conrod big end side clearance with conrod
installed on crank pin as shown.
If measurement exceeds service limit, replace conrod
and/or crankshaft.
Special tool
(A): 09900–20803 (Thickness gauge)
Conrod big end side clearance
Standard: 0.100 – 0.250 mm (0.0039 – 0.0098 in.)
Service limit: 0.35 mm (0.0138 in.)
Conrod big end width
Standard: 21.950 – 22.000 mm (0.8642 – 0.8661 in.)
Crank pin width
Standard: 22.100 – 22.200 mm (0.870 – 0.8740 in.)

(A)

(A)
I9J011140068-02

IDG211140164-01
1D-48 Power Unit Mechanical:

Crank Pin and Conrod Bearing Inspection Conrod Big End Oil Clearance
CENDG2111406024 Check conrod big end oil clearance as follows:
Crank Pin Diameter
Inspect crank pin for uneven wear or damage. 1) Clean surface of conrod (1), conrod cap (2), conrod
Measure crank pin for out-of-round “a” – “b” or taper “c” – bearings and crank pin.
“d” with micrometer. 2) Install conrod bearing (3) onto conrod and conrod
If crank pin is damaged, out-of-round “a” – “b” or taper cap.
“c” – “d” is out of service limit, replace crankshaft.
NOTE
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm)) • Reassemble each bearing and conrod cap
to their original position.
Crank pin diameter • Do not apply oil to bearing.
Standard: 43.982 – 44.000 mm (1.7316 – 1.7323 in.)
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.)
1
2

(A)

A ab
3
B IDG211140166-02

3) Place a piece of Plastigauge on crank pin parallel to

IDG211140165-01 crankshaft. Avoid placing Plastigauge over oil hole.

Conrod Bearing Visual Inspection Special tool

Inspect bearing shell for proper contact pattern and (A): 09900–22301 (Plastigauge (0.025 –
signs of fusion, pitting, burning or flaking. 0.076 mm))
Bearing shells found in defective condition must be
replaced.

(A)

I9J011140071-01

IDG211140167-01
 Power Unit Mechanical: 1D-49

4) Install conrod cap (with bearing) to conrod with the c) Finally tighten bolts 60 degrees turn from the
embossed mark (4) on cap toward flywheel side. point of step b) using an angular torque gauge.
Tightening torque
“A” Conrod cap bolt (Final step): 60 degrees

NOTE
Purchase a commercially available angular
torque gauge for this step of tightening bolts.

IDG211140168-02
60°
4. Embossed mark (>) “A”: Flywheel side

5) Apply engine oil to conrod bolts.

Tighten conrod cap bolts in three steps as follows.
a) Lightly seat all conrod bolts at first, then tighten
bolts 12 N⋅m (1.2 kgf-m, 8.7 lbf-ft) of specified
torque. IDG211140170-02

Tightening torque NOTE

Conrod cap bolt (1st step): 12 N·m (1.2 kgf- Do not rotate conrod with Plastigauge in
m, 8.7 lbf-ft) place.
b) Tighten bolts 17 N⋅m (1.7 kgf-m, 12.3 lbf-ft) of
specified torque. 6) Remove conrod and conrod cap from crank pin.
7) Using scale (5) on Plastigauge envelope, measure
Tightening torque
Plastigauge width at its widest point.
Conrod cap bolt (2nd step) (a): 17 N·m (1.7
If measurement exceeds service limit, replace
kgf-m, 12.3 lbf-ft)
conrod bearing.
Conrod big end oil clearance
Standard: 0.032 – 0.050 mm (0.0013 – 0.0020 in.)
Service limit: 0.080 mm (0.0031 in.)
(a)

IDG211140169-01

IDG211140171-02

5. Scale
1D-50 Power Unit Mechanical:

Crankshaft Inspection Out-of-Round and Taper (Uneven Wear) of Journals

CENDG2111406026 An unevenly worn crankshaft journal shows up as a
Crankshaft Runout
difference in diameter at a cross section or along its
Using a dial gauge, measure runout at center journal.
length (or both).
If measurement exceeds service limit, replace
This difference, if any, is determined by taking
crankshaft.
micrometer readings.
Special tool If any journal is badly damaged or if measurements
(A): 09900–20607 (Dial gauge) exceed service limit, replace crankshaft.
(B): 09900–20701 (Magnetic stand)
Special tool
Crankshaft runout (A): 09900–20203 (Micrometer (50 – 75 mm))
Service limit: 0.04 mm (0.002 in.)
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.)
(A) Out-of-round: A – B
Taper: a – b
Crankshaft journal outside diameter
Standard: 57.994 – 58.012 mm (2.2832 – 2.2839 in.)

IDG211140173-02

Crankshaft Thrust Play

1) Measure thrust play with crankshaft, thrust bearing, ab
A
journal bearing and crankcase/cylinder block
assembled in a normal manner. B
Tighten crankcase bolts to specified torque.
IDG211140175-01
Tightening torque
Crankcase (inside) bolt (10 mm): 52 N·m (5.2
kgf-m, 37.5 lbf-ft)
Crankcase (outside) bolt (8 mm): 25 N·m (2.5
kgf-m, 18.1 lbf-ft)
2) Use a dial gauge to read displacement in axial
(thrust) direction of crankshaft.
If measurement exceeds service limit, replace
crankshaft thrust bearing.
Crankshaft thrust play
Standard: 0.11 – 0.31 mm (0.004 – 0.012 in.)
Service limit: 0.35 mm (0.014 in.)
Crankshaft thrust bearing thickness
Standard: 2.425 – 2.475 mm (0.0955 – 0.0974 in.)

IDG211140174-01
 Power Unit Mechanical: 1D-51

Crankshaft Main Bearing Inspection

CENDG2111406027
Crankshaft Main Bearing Visual Inspection
Check bearings for pitting, scratches, wear or damage.
If any improper condition is found, replace both upper
and lower halves. 1 1
Always replace both bearing halves, never replace only
one half of a bearing set.

IDG211140176-01

“A”

I9J011140073-01

Crankshaft Journal Oil Clearance “C” “B”

Check clearance using Plastigauge according to the
following procedure.

NOTE IDG211140177-01

“A”: Bearing tab “B”: Oil hole “C”: Oil groove

Assemble each bearing in its original
position before checking clearance.
3) Install crankshaft to cylinder.
1) Clean surface of bearing holder (crankcase, and 4) Place a piece of Plastigauge across full width of
cylinder), bearing, and main bearing journal. bearing (parallel to crankshaft) on journal.
2) Install main bearing (1) to cylinder and crankcase. Do not place Plastigauge over oil hole.
Special tool
NOTE
(A): 09900–22301 (Plastigauge (0.025 –
• Align tab “A” of bearing with notch in 0.076 mm))
cylinder and crankcase.
NOTE
• Do not apply engine oil to bearing.
Do not rotate crankshaft while Plastigauge is
• Install main bearing half with oil hole/
installed.
groove towards cylinder side.

(A)
IDG211140178-01
1D-52 Power Unit Mechanical:

5) Assemble crankcase to cylinder. 7) Remove crankcase from cylinder.

6) Apply engine oil to crankcase bolts.
Tighten crankcase bolts in three steps following the
order indicated below.
NOTE
Tighten 10 mm (0.394 in.) thread diameter
bolts first (following the order shown in
figure), then tighten 8 mm (0.315 in.) thread
diameter bolts.
8) Using scale (2) on Plastigauge envelope, measure
Plastigauge width at its widest point.
Crankshaft journal oil clearance
Standard: 0.020 – 0.040 mm (0.0008 – 0.0016 in.)
Service limit: 0.065 mm (0.0026 in.)
2

Tightening torque
Crankcase (inside) bolt (10 mm thread diameter)
[1st step]: 11 N·m (1.1 kgf-m, 8.0 lbf-ft)
Crankcase (inside) bolt (10 mm thread diameter)
[2nd step]: 21 N·m (2.1 kgf-m, 15.0 lbf-ft)
Crankcase (inside) bolt (10 mm thread diameter)
[Final step]: 52 N·m (5.2 kgf-m, 37.5 lbf-ft)
IDG211140180-01
Tightening torque
Crankcase (outside) bolt (8 mm thread 2. Scale

diameter): 25 N·m (2.5 kgf-m, 18.1 lbf-ft)

9) If measurement exceeds service limit, replace
NOTE crankshaft main bearing.
Crankcase must be torqued to specification
NOTE
in order to assure proper compression of
Plastigauge and accurate reading of For bearing replacement, see the “Selection
clearance. of Main Bearings” (Page 1D-52).

Selection of Main Bearings

19 5 15 1 11 3 13 17 Whenever a bearing requires replacement, select a new
bearing according to following procedure.
7
9
1) First, check journal diameter.
As shown in figure, upper (flywheel side) crank web
of No.1 cylinder has five stamped code numerals.
The numerals (1, 2 and 3) represent the journal
10 diameters shown below.
Numeral stamped Journal diameter
8
58.0061 – 58.0120 mm
1
(2.28370 – 2.28393 in.)
18
20 4 58.0001 – 58.0060 mm
6 16 2 12 14 2
IDG211140179-01
(2.28346 – 2.28370 in.)
57.9940 – 58.0000 mm
3
(2.28322 – 2.28346 in.)

“A”
“B”
“C”
“D”
“E”

IDG211140181-01

“A”: No.1 journal code “D”: No.4 journal code

“B”: No.2 journal code “E”: No.5 journal code
“C”: No.3 journal code
 Power Unit Mechanical: 1D-53

2) Next, check bearing holder inside diameter without

bearing.
As shown in figure, the cylinder block PORT side has
five stamped code letters.
The letters (A, B and C) represent the bearing holder
inside diameters shown below.
Crank bearing holder inside
Code
diameter (w/o bearing)
62.0000 – 62.0060 mm “L”
A
(2.44094 – 2.44118 in.) IDG211140189-01

62.0061 – 62.0120 mm “L”: Color mark

B
(2.44118 – 2.44141 in.)
62.0121 – 62.0180 mm 4) Select crankshaft main bearing referring to the below
C
(2.44142 – 2.44165 in.) table.
For example, If number stamped on crank web is “1”
and alphabet stamped on cylinder block is “B”, install
“J” a new bearing painted in “Black” to it’s journal.
“I”
“H” Numeral stamped on crank
“G” web (journal outside diameter)
“F”
1 2 3
Code A Green Black No color
stamped B Black No color Yellow
on
cylinder
block
(Bearing C No color Yellow Blue
holder
“K” inside
IDG211140182-01
diameter)
“F”: No.1 holder code “I”: No.4 holder code
“G”: No.2 holder code “J”: No.5 holder code NOTE
“H”: No.3 holder code “K”: Flywheel side
Measure crankshaft journal oil clearance
3) There are five main bearings available, each of again after installing new bearing selected.
differing thickness. Refer to “Crankshaft Journal Oil Clearance”
To distinguish them, a color mark is painted at the (Page 1D-51).
position indicated in figure.
Each color represents the following thickness Crankshaft Drive Gear Inspection
measured at the center of the bearing. CENDG2111406028
Inspect drive gear. Replace crankshaft if the drive gear is
Color mark Bearing thickness
damaged or worn.
1.990 – 1.994 mm
Green
(0.0783 – 0.0785 in.)
1.993 – 1.997 mm
Black
(0.0785 – 0.0786 in.)
1.996 – 2.000 mm
No color mark
(0.0786 – 0.0787 in.)
1.999 – 2.003 mm
Yellow
(0.0787 – 0.0789 in.)
2.002 – 2.006 mm
Blue
(0.0788 – 0.0790 in.)

IDG211140183-01
1E-1 Power Unit Lubrication:

Power Unit Lubrication

Power Head

General Description
Engine Lubrication Description
CENDG2111501001
A camshaft driven trochoid type pump provides engine oil to all power unit components requiring lubrication.
Oil from the oil pan is drawn through the oil strainer and passed through a spin-on type oil filter before entering the
main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and oil filter to maintain oil pressure at a constant
level.
From the main gallery, oil flow is directed through either drilled internal passages or by splash method to those
surfaces requiring lubrication.

Schematic and Routing Diagram

Engine Oil Lubrication Chart
CENDG2111502001

OIL PRESSURE
No.1 No.1
No.1 JOURNAL No.1 JOURNAL SWITCH
CAM FACE CAM FACE

No.1
No.2 No.2 CRANK JOURNAL
No.2 JOURNAL No.2 JOURNAL
CAM FACE CAM FACE

No.1 CRANK PIN No.1 PISTON

No.3 No.3
No.3 JOURNAL No.3 JOURNAL
CAM FACE CAM FACE
No.2
CRANK JOURNAL
No.4 No.4
No.4 JOURNAL No.4 JOURNAL
CAM FACE CAM FACE
No.2 CRANK PIN No.2 PISTON

No.5 JOURNAL No.5 JOURNAL No.3

CRANK JOURNAL

CHAIN TENSIONER
No.3 CRANK PIN No.3 PISTON

CAMSHAFT LOWER HOUSING No.4

CRANK JOURNAL

CYLINDER HEAD No.4 CRANK PIN No.4 PISTON

No.5
OIL FILTER
CRANK JOURNAL

OIL RELIEF
OIL PUMP
VALVE

OIL STRAINER

OIL PAN
IDG211150001-04
 Power Unit Lubrication: 1E-2

Diagnostic Information and Procedures

Oil Pressure Check
CENDG2111504001
Refer to “Oil Pressure Check” in Section 0B (Page 0B-19).

Oil Change Reminder System

CENDG2111504002
Refer to “Oil Change Reminder System Description” in Section 1A (Page 1A-14).

Low Oil Pressure Caution System

CENDG2111504003
Refer to “Caution System Description” in Section 1A (Page 1A-7).

Powerhead Lubrication System Diagnosis

CENDG2111504004

Condition Possible cause Correction / Reference Item

Low oil pressure Clogged oil filter. Replace.
Leakage from oil passages. Repair or replace.
Defective oil pump. Replace.
Defective oil pressure regulator. Replace.
Damaged O-ring. Replace.
Combination of above items. Repair or replace.
High oil pressure Using an engine oil of too high viscosity. Replace.
Clogged oil passage. Clean or replace.
Clogged oil pressure regulator. Replace.
Combination of above items. Repair or replace
1E-3 Power Unit Lubrication:

Service Instructions
Oil Pump Removal and Installation Installation
CENDG2111506001 Installation is reverse order of removal with special
Removal
attention to the following steps.
1) Remove the power unit.
• Assemble washer (1), pin (2), driven sprocket (3) and
Refer to “Power Unit Removal and Installation” in
circlip (4) to oil pump shaft.
Section 1D (Page 1D-10).

NOTE
Hold camshaft by placing a wrench on
hexagon area of camshaft. 1

3
1

4
IDG211150004-01

• Apply engine oil to seal ring (5), then install seal ring
to oil pump body.

NOTICE
A previously-used seal ring may leak,
IDG211150002-01
resulting in engine damage.
1. Oil pump drive sprocket
Do not re-use the seal ring once removed.
2) Remove bolt securing oil pump drive sprocket to Always use a new seal ring.
camshaft, then remove oil pump drive sprocket.
3) Remove three bolts and oil pump assembly (1).

1
5

IDG211150005-01

IDG211150003-01 • Install oil pump (6) to cylinder head block, then tighten
4) Remove circlip (2), driven sprocket (3), pin (4) and three bolts securely.
washer. Tightening torque
Oil pump bolt (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft)

3
(a)

4
2 6

IDG211150014-01

IDG211150006-01
 Power Unit Lubrication: 1E-4

• Install oil pump drive sprocket (7) and tighten bolt Oil Pressure Switch Removal and Installation
securely. CENDG2111506004
Removal
Tightening torque 1) Remove the bolts and air duct (1).
Oil pump drive sprocket bolt (b): 78 N·m (7.8 kgf-
m, 56.5 lbf-ft)
1

(b)
IDG211150016-02

2) Loosen screw (2) and disconnect blue lead wire (3)

IDG211150015-01
from oil pressure switch (4).
Inspection Oil Pump Component Parts
CENDG2111506003
Oil Pump

NOTICE 4

Disassembling the oil pump can lead to 3

troubles.
2
The oil pump is a nonrepairable component.
Do not attempt to disassemble the oil pump.
It must be replaced as a complete unit if it is
defective. IDG211150009-02

3) Remove oil pressure switch from cylinder block.

Inspect outer/inner rotors and oil pump body for wear or
other damage. Replace if necessary.
Installation
Installation is reverse order of removal with special
Seal Ring
attention to the following steps.
Inspect of seal ring for nick, cut or wear.
• Before installing oil pressure switch, wrap screw
Drive / Driven Sprocket threads with sealing tape (1), then tighten switch to
Inspect teeth of sprocket for wear or other damage. specified torque.
Replace if necessary. NOTE
Cut off any excess sealing tape from switch
threads before installation.

Tightening torque
Oil pressure switch (a): 13 N·m (1.3 kgf-m, 9.5 lbf-
ft)

IDG211150007-01

1
I9J011150002-01
1E-5 Power Unit Lubrication:

2) Remove the blue lead wire (2) from oil pressure

switch (3).

(a)

IDG211150010-03

• Start engine and check oil pressure switch for oil

leakage. IDG211150012-02

Reseal switch if oil leakage is found. 3) Connect the oil pressure switch lead wire to engine
• Cover the oil pressure switch with the cap. body ground by using an appropriate jumper wire.

Oil Pressure Switch Inspection

CENDG2111506005
NOTE
Before checking the oil pressure switch,
make sure the engine oil pressure is within
specification.
IDG211150018-01
1) Remove the bolts and air duct (1).
NOTE
You should remove oil pressure switch lead
1 when perform the oil pressure switch
inspection.
Then diagnostic code of oil pressure switch
will be displayed while performing the
inspection.
Connect the oil pressure switch lead wire to
engine body ground by using an appropriate
jumper wire before the engine starts (turning
on the ignition switch).
IDG211150016-02
So that the diagnostic code won’t be
displayed.
After the engine starts, disconnect the
jumper wire from switch lead wire.

NOTE
For cancellation of the “self-diagnostic
indication”, refer to “Self-Diagnostic System
Description” in Section 1A (Page 1A-9).
 Power Unit Lubrication: 1E-6

4) After the engine starts, disconnect the jumper wire Oil Strainer Removal and Installation
from switch lead wire. CENDG2111506006
Removal
5) Check the continuity between the switch terminal Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
and engine body ground. Mounts Disassembly” in Section 2A (Page 2A-6).
Special tool
: 09930–99320 (Digital tester) Installation
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Tester knob indication Mounts Assembly” in Section 2A (Page 2A-8).
Continuity ( )
Oil pressure switch continuity Oil Strainer Related Parts Inspection
Engine running: Infinity CENDG2111506007

Engine stopped: Continuity • Inspect oil strainer. Replace strainer if cracked,

damaged or other abnormal conditions.
If clog or obstruction, clean oil strainer.
• Check condition of O-rings. Replace O-ring if nicked,
cut, worn or other abnormal condition.

I9J011150003-01

6) If measurement exceeds specification, replace oil

pressure switch.
7) After testing oil pressure switch, reinstall parts
removed earlier.
IDG211150013-02
1F-1 Power Unit Cooling System:

Power Unit Cooling System

Power Head

General Description
Water Cooling System Description
CENDG2111601001
The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead
assembly.
To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine
operation, there is a thermostat in the cylinder head.
Motor temperature and cooling system efficiency are monitored by cylinder temp. sensor and exhaust manifold temp.
sensor in the cylinder. If temperature higher than normal is detected by a sensor, an advance caution of overheat
condition is provided.

Displacement Type Water Pump Description

CENDG2111601002
In this displacement type water pump, the water pressure is increased by the change in volume between the impeller
and the pump case. As a result, the increased water pressure enables the water pump to circulate the cooling water.

5
6
7
I9J011160003-01

1. Water inlet 3. Key 5. Water pump impeller 7. Driveshaft

2. Water outlet 4. Water pump case 6. Under panel

Water Pressure Valve Description

CENDG2111601003
If cylinder water pressure is high when thermostat is closed, the valve will open to relieve the pressure.

1 2

IDG211160008-01

1. Water pressure valve cover 2. Water pressure valve

 Power Unit Cooling System: 1F-2

Schematic and Routing Diagram

Cooling Water Circulation Chart
CENDG2111602001
The water cooling system includes the lower unit water pump, lower unit to power unit water supply tube, oil pan water
pressure valve, power unit water passages and thermostat.
This system cools both the power unit and exhaust and is shown in schematic form below.
If overheating occurs, the components of the cooling system must be inspected for blockage, corrosion build-up or
component damage.

RETURN HOSE

When open

THERMOSTAT

CYLINDER HEAD CYLINDER

FUEL
VAPOR
SEPARATOR EXHAUST
CRANKCASE
WATER JACKET

ENGINE HOLDER

PILOT
WATER HOLE
ENGINE HOLDER

OIL PAN OIL PAN

WATER
PRESSURE
DRIVESHAFT VALVE
WATER TUBE
HOUSING

WATER PUMP

PROPELLER WATER INTAKE

EXHAUST OUTLET

WATER

IDG211160001-03
1F-3 Power Unit Cooling System:

Diagnostic Information and Procedures

Powerhead Cooling System Diagnosis
CENDG2111604001

Condition Possible cause Correction / Reference Item

Overheating powerhead Water inlet screen obstructed. Clean.
Water passage obstructed. Clean or replace.
Pump plate not sealing. Check and repair.
Water pump impeller damage. Replace.
Water pump housing and/or plate worn. Replace.
Water pump housing seal worn. Replace.
Water tube grommet damaged. Replace.
Thermostat damaged/defective. Replace.
Water tube obstructed. Clean.
Water tube defective. Replace.
Water pressure valve damaged/ Replace.
defective.
Overcooling powerhead Thermostat damaged/defective. Replace.

Service Instructions
Thermostat Removal and Installation Installation
CENDG2111606001 Installation is reverse order of removal with special
Removal
attention to the following steps.
1) Disconnect water hose (1) from thermostat cover.
• Assemble thermostat (1) and thermostat cover (2) to
2) Remove the three bolts (2) securing the thermostat cylinder head block and secure with bolts (3).
cover (3), then remove the cover.
Tightening torque
3) Remove the thermostat (4).
Thermostat cover bolt (a): 10 N·m (1.0 kgf-m, 7.2
lbf-ft)

2
3 (a)
3
4
2
1

IDG211160002-03

IDG211160003-02

• Check to ensure that all removed parts are back in

place.
 Power Unit Cooling System: 1F-4

Thermostat Inspection Water Pressure Valve Removal and Installation

CENDG2111606002 CENDG2111606003
Inspect the thermostat in the following procedures: Removal
1) Remove the thermostat. 1) Remove lower side cover.
Refer to “Thermostat Removal and Installation” Refer to “Lower Side Cover Removal and
(Page 1F-3). Installation” in Section 2A (Page 2A-3).
2) Inspect the thermostat. 2) Remove two bolts (1), water pressure valve cover (2)
If salt deposits, corrosion, wear or other damage is and water pressure valve (3).
found, clean or replace.

IDG211160005-01

IDG211160004-01

3) Check thermostat opening temperature as follows:

a) Insert a length of thread between thermostat
valve/body and suspend thermostat in a
container filled with water. 3
b) Place thermometer in container and heat water.
Observe water temperature when thermostat
valve opens and releases thread.
Thermostat operating temperature
Standard: 48 – 52 °C (118 – 125 °F)
IDG211160006-01

2
3

I9J011160002-01

1. Thermometer 3. Thermostat
2. Heater

If thermostat valve does not open as specified

above, or sticks in any position, replace it.
4) Install the thermostat.
Refer to “Thermostat Removal and Installation”
(Page 1F-3).
1F-5 Power Unit Cooling System:

Installation Water Pressure Valve Related Item Inspection

CENDG2111606004
1) Install O-ring (1) to water pressure valve cover (2). Inspect the water pressure valve in the following
procedures:
1) Remove the water pressure valve.
Refer to “Water Pressure Valve Removal and
2
Installation” (Page 1F-4).
1 2) Inspect the water pressure valve.
If salt deposits, corrosion, wear or other damage is
found, clean or replace.
Inspect O-ring. Replace if nicked, cut or torn.

IDG211160009-01

NOTE
Align projections “A” on valve’s seal rubber
with cutaway parts “B” on valve cover when
installing.

IDG211160007-01
“A”
“B” 3) Install the water pressure valve.
Refer to “Water Pressure Valve Removal and
Installation” (Page 1F-4).

Water Pump Removal and Installation

CENDG2111606005
Refer to “Water Pump Removal and Installation” in
Section 3A (Page 3A-6).
IDG211160011-01

2) Install water pressure valve (3) and water pressure Water Pump Related Item Inspection
CENDG2111606006
valve cover (2) to oil pan and secure with bolts (4). Refer to “Water Pump and Related Item Inspection” in
Section 3A (Page 3A-8).

4
Water Tube Removal and Installation
CENDG2111606007
3 2 Removal
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Disassembly” in Section 2A (Page 2A-6).

Installation
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly” in Section 2A (Page 2A-8).
IDG211160010-01

3) Install lower side cover.

Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
Water Tube Related Item Inspection
CENDG2111606008
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Related Component Inspection” in Section 2A
(Page 2A-13).
 Fuel System: 1G-1

Fuel System
Power Head

Precautions
Precautions on Fuel System Service
CENDG2111700001
! WARNING
Service operation of any type performed on the fuel system involves a risk of fire and injury if proper
precautions are not taken.

Be sure to take the following precautions when working around gasoline or servicing the fuel system.
• Disconnect battery cables except when battery power is required for servicing/inspection.
• Keep the working area well ventilated and away from open flame (such as gas heater) or sparks.
• Do not smoke or allow anyone else to smoke near the working areas.
Post a “NO SMOKING” sign.
• Keep a fully charged CO2 fire extinguisher readily available for use.
• Always use appropriate safety equipment and wear safety glasses when working around a
pressurized fuel system.
• To avoid potential fire hazards, do not allow fuel to spill on hot engine parts or on operating
electrical components.
• Wipe up fuel spills immediately.
• Before loosening or disconnecting the fuel feed line, be sure to relieve the fuel system of fuel
pressure by following the fuel pressure relief procedure.
• When disconnecting a fitting on the fuel line, cover the fitting with a shop cloth to soak up the small
amount of fuel that may flow out from the disconnected fuel line. Put the used cloth in an approved
container.
• Since fuel hose connections vary with the pipe type, connect and clamp each hose using the correct
method for each specific connection.
After connecting a hose, check that there is no twist or kink in the hose.
• When installing hose clamps, position tabs to avoid contact with other parts.
• Be sure hoses do not contact rods, levers or other components with engine either operating or at
rest.

General Description
Electronic Fuel Injection System Description
CENDG2111701001
The fuel injection system used by the DF100A/115A/140A is a speed-density, multi-point, sequential, electronic fuel
injection type.
The fuel injection system is composed of the fuel line components, air intake components, and components for system
control (ECM, sensors, switches, etc.).

Fuel Injection Control System Outline

Sensors are mounted at precise locations on the motor to monitor the current conditions of engine operation and send
signals to the ECM.
Based on these signals, the ECM determines the optimum fuel injection time duration (fuel amount), fuel injection
timing (multi-point sequential timing) and controls the injector operating signals accordingly.
In regards to fuel injection timing, the fuel injection end timing is set depending on engine rpm. The ECM calculates
the amount of fuel injection based on the engines operating conditions, and determines the fuel injection start timing.
In the injection timing chart below, the injection end timing is set at 30° BTDC on the exhaust stroke.
1G-2 Fuel System:

Basic sensors
ECM
MAP sensor:
Informs ECM of intake manifold pressure. Fuel injection time duration
CKP sensor: (amount) is determined by
Informs ECM of engine speed and crankshaft angle. a digital map designed in
relation to intake manifold
Compensating sensors pressure and engine
Cylinder temperature sensor: speed.
Informs ECM of cylinder temperature.
Exhaust manifold temperature sensor:
Informs ECM of exhaust manifold temperature.
Fuel amount compensation
IAT sensor:
Informs ECM of intake air temperature.
TPS (Throttle position sensor):
Multi-point sequential timing
Informs ECM of throttle opening angle.
Battery voltage:
Constantly monitored by the ECM.
O2 sensor:
Informs ECM of oxygen concentration in exhaust gas. Signal Signal Signal Signal

Others
CMP sensor:
Informs ECM of camshaft angle. Fuel injector
Neutral switch:
Informs ECM of shift position (neutral or in-gear).
9

1 CPU “A”

2 7 A A A A
4

5 8
IDG211170001-07

1. Battery charge coil 6. Ignition switch

2. Rectifier/regulator 7. ECM main relay
3. 60 A fuse 8. Fuel injector
4. 30 A fuse 9. ECM
5. Battery “A”: Sensor/switch signal input
 Fuel System: 1G-3

Fuel Injection Timing Chart

32 signals / crankshaft 1 rotation

CKP sensor
signal

140° 220° 40° 40°

180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
TDC TDC
No.1 cylinder Cm. Ep. Ex. In. Cm. Ep.
TDC TDC
No.3 cylinder In. Cm. Ep. Ex. In. Cm.
TDC TDC
No.4 cylinder Ex. In. Cm. Ep. Ex. In.
TDC TDC
No.2 cylinder Ep. Ex. In. Cm. Ep. Ex.

Injection time duration Injection end timing: 30° BTDC on Ex.stroke

No.1 Injection
signal
No.3 Injection
signal
No.4 Injection
signal
No.2 Injection
signal
Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake,
IDG211170019-03

Fuel Injection Control Mode

When cranking:
Fuel is injected in each cylinders according to the “Start up mode” map which is based on the cylinder temperature and
intake air temperature (Sequential injection).

After start (Fast-idle function):

The fuel injection amount is controlled so that the engine rpm stays within the fast idle speed map until the cylinder
temperature reaches normal operating temperature.

When idling / trolling:

The fuel injection amount is controlled to maintain a stable engine speed at the specified idle/trolling rpm.

When running (normal operation):

ECM calculates the target air/fuel ratio on basis of signals from O2 sensor, CKP sensor, MAP sensor, etc.
ECM compensates the basic fuel injection amount so as to obtain the calculated air/fuel ratio. (The operation is called
“lean burn control”.)

When accelerating:
The fuel injection amount is controlled to increase.

When decelerating:
The fuel injection amount is controlled to decrease.
The fuel injection is also cut off on very rapid engine deceleration.
1G-4 Fuel System:

Fuel Delivery System Components Description

CENDG2111701002
The fuel delivery system is composed of the low pressure fuel line components (Fuel tank, filter, pump etc.), fuel vapor
separator, high pressure fuel pump, fuel pressure regulator (located in the fuel vapor separator), delivery pipe, fuel
injectors and hoses.
Fuel is supplied through the primer bulb, low pressure fuel filter, and low pressure fuel pump to the fuel vapor
separator.
Fuel flow from the fuel vapor separator is pressurized by the high pressure fuel pump and supplied through the fuel
filter and fuel delivery pipe to the fuel injectors.
The pressure regulator maintains fuel pressure in the feed line between the high pressure fuel pump and fuel injector.
This pressure, maintained at a constant level, is higher than the pressure in the vapor separator chamber.
When fuel feed line pressure exceeds vapor separator chamber pressure by more than approx. 295 kPa (2.95 kg/cm2,
42 psi.), the valve in the fuel pressure regulator will open and return the excess fuel to the vapor separator chamber.
Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals supplied from the
ECM.

3 2

5
1
4

8
9 6

7
“A”

15 11

10

12

14
13
IDG211170002-04

1. Fuel tank 5. Fuel vapor separator 9. Evaporation hose 13. Throttle body
2. Primer bulb 6. Float 10. Fuel delivery pipe 14. Intake manifold
3. Low pressure fuel filter 7. High pressure fuel pump 11. Fuel injector 15. Fuel cooler
4. Low pressure fuel pump 8. Fuel pressure regulator 12. Intake silencer “A”: To atmosphere
 Fuel System: 1G-5

Fuel Vapor Separator

The fuel vapor separator incorporates a float system that maintains a constant fuel level inside the separator chamber.
As the fuel level decreases, fuel flows into the vapor separator from the low pressure fuel pump.
The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from
the fuel pressure regulator.
This vapor is routed through the evaporation hose to the atmosphere.

High Pressure Fuel Pump

The high pressure fuel pump is an “integral” type in which the pump mechanism is located within the fuel vapor
separator.
To supply the optimum fuel amount, the pump is driven by the duty cycle signal from the ECM.

“B”

“A”
“C”
7

1
4

“D”
“E”

“F”
IDG211170003-04

1. High pressure fuel pump 5. Float chamber “B”: Fuel outlet “F”: Fuel drain
2. Suction filter 6. Fuel pressure regulator “C”: Vapor
3. Needle valve 7. Fuel outlet filter “D”: Water inlet
4. Float “A”: Fuel inlet “E”: Water outlet
1G-6 Fuel System:

Fuel Pressure Regulator

The fuel pressure regulator is located in the fuel vapor separator.
The regulator's function in the system is to maintain constant fuel pressure to the injectors while the engine is
operating.
The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure balanced.
Fuel pressure, adjusted by the regulator, is constantly maintained higher than the pressure in the fuel vapor separator
chamber by approx. 295 kPa (2.95 kg/cm2, 42 psi.).
By-pass fuel is returned to the fuel vapor separator chamber.

VALVE CLOSED VALVE OPENED

(below 295 kPa) (over 295 kPa)

1 1
2 2

“A” “A”

3 “C”

“B”
IDG211170020-02

1. Fuel pressure regulator 3. Float chamber “B”: To float chamber

2. Air passage “A”: From high pressure fuel pump “C”: By-pass fuel

Fuel Injector
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the solenoid coil is energized pulling up the plunger.
This opens the injector valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel injected is determined by the amount of time (duration)
the electromagnetic valve is open.

IDG211170074-01

1. Fuel injector
 Fuel System: 1G-7

High Pressure Fuel Pump Control System Description

CENDG2111701003
To supply the optimum fuel amount, the ECM controls the fuel pump drive duty cycle, a repeated “ON”/“OFF” signal, at
a specified rate (1 000 times a second).
Based on engine speed and battery voltage, the ECM determines the optimum duty cycle (repeating “ON” time rate
within a cycle) and sends this signal to the fuel pump.

CKP sensor:
Informs ECM of engine speed.

Battery voltage
ECM Signal FP
Ignition switch:
Informs ECM of “START” signal. Fuel pump

Cylinder temp. sensor:

Informs ECM of cylinder temperature.
IDG211170021-01

6 ECM

CPU
3
7
4

5
1

FP
BATT
8

2
IDG211170022-03

1. Sensor/Switch signal input 5. 60 A fuse

2. Fuel pump 6. Battery charge coil
3. ECM main relay 7. Rectifier/Regulator
4. 30 A fuse 8. Ignition switch

Duty cycle signal for fuel pump (example: 80% duty)

“ON” time × 100 = duty (%)

1 cycle time

0.8 ms

OFF

ON Time
1 ms (1cycle)

I9J011170008-01

Control Modes
Before start:
For 3 seconds after the ignition switch is turned “ON”, the fuel pump is controlled to operate at a 100% duty cycle to
initially pressurize the high pressure fuel line.

When cranking:
The fuel pump is controlled to operate at a 50 – 100% duty cycle.
The duty cycle changes depending on cylinder temperature.
1G-8 Fuel System:

When running (normal operation):

The fuel pump is controlled to operate at a 50 – 100% duty cycle based on the current engine speed and battery
voltage.

Air Intake Components Description

CENDG2111701004
Air, after entering through the silencer case, passes through the throttle body and flows into the surge tank where it is
then distributed to the intake manifold.
Intake manifold pressure, monitored by the MAP sensor, is an indirect measurement of the intake air amount.
When the throttle is fully closed, the main supply of intake manifold air necessary to sustain engine idle passes
through the by-pass air passage.
To maintain engine idle speed at specification, the ECM controlled IAC valve supplies a regulated amount of additional
air through the IAC (Idle Air Control) passage.

“A”
1

“A”
6 4

5
IDG211170004-02

1. Throttle body 3. Intake manifold 5. MAP sensor 7. Air intake silencer

2. IAC valve 4. Throttle position sensor 6. IAT sensor “A”: Air-flow

Throttle Body
• The throttle body assembly consists of the main bore,
throttle valve and TPS (Throttle Position Sensor).
• The throttle body adjusts the intake air amount with
the throttle valve which is connected to the throttle
lever linkage.
• The TPS installed on the throttle body informs the 2
ECM of the throttle valve opening angle.

NOTE 1

Do not try to adjust or remove any of the

IDG211170023-01
throttle body component parts (Throttle
Position Sensor, throttle valve, throttle stop 1. Throttle body assembly 2. TPS
screw, etc.).
These components have been factory
adjusted to precise specifications.
 Fuel System: 1G-9

Idle Air Control System Description

CENDG2111701005
IAC Valve / Passage
The IAC valve is a linear solenoid plunger type mounted on the intake manifold.
Its purpose is to control the amount of intake air flowing from the IAC passage.
The IAC valve is driven by the duty cycle signal from the ECM.

“A” 2

“A”

IDG211170005-02

1. IAC valve 2. Intake manifold “A”: Air flow

Idle Air Control System Description

The ECM controls the duty cycle signal of the IAC valve to regulate a portion of the intake air flow to the intake
manifold.
This system is used for the following purposes:
• To keep idling/trolling at the specified speed.
• To improve driveability when decelerating. (Dash-pot effect)
• To improve engine starting and warm-up performance. (Fast-idle function)
The sensors shown below monitor current engine condition and send signals to the ECM.
Based on these signals, the ECM determines the optimum duty cycle (repeating “ON” time rate within a cycle).
A repeating ON/OFF signal at a specified rate (250 times a second) is then sent to the IAC valve.

CKP sensor:
Informs ECM of engine speed.

MAP sensor: Signal

Informs ECM of intake manifold pressure.

TPS:
ECM
Informs ECM of throttle opening angle.

Cylinder temp. sensor:

Informs ECM of cylinder temperature.

IAT sensor:
Informs ECM of intake air temperature. IAC valve
IDG211170018-03
1G-10 Fuel System:

IAC Valve Control Mode

Before started:
The IAC valve is always closed (0% duty) when engine is not running. (Ignition switch “OFF”).

When cranking:
The IAC valve is controlled to operate at 100% duty.

After start (fast-idle function):

The IAC valve is controlled to operate at approx. 40 – 100% duty until the timer, (set according to cylinder temperature
at cranking) expires.
Then the duty gradually decreases until the engine rpm slows to the preset idle speed.

When idling / trolling:

The IAC valve is controlled so that the engine speed is stable at the idling/trolling speed specified.
During this period, the IAC valve has a duty cycle of approx. 40 – 50%, but will vary slightly as idling/trolling conditions
change.

When running (normal operation):

The IAC valve is controlled to operate at a 40 – 100% duty, dependent on current engine operating conditions.

When decelerating (dash-pot effect):

When the throttle valve is suddenly returned to fully closed, and the throttle position sensor signal changes to “fully
closed”, the IAC valve is controlled to gradually return to an idle/troll operating position to prevent engine stalling or
unstable running.

NOTE
Due to the limited intake air flow from the IAC passage, and in order to effectively use both the “Dash-
pot effect” and “Fast-idle function”, an IAC valve operating position of 40 – 50% at idling/trolling speed
is required.

Water in Fuel Alert System Description

CENDG2111701006
Refer to “Water in Fuel Alert System Description” in Section 1A (Page 1A-15).

Diagnostic Information and Procedures

Fuel Pressure Inspection
CENDG2111704001
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
risk or fire and personal injury.
1) Relieve fuel pressure in fuel feed line.
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
14).
2) Loosen the clamp and place a large cloth over the
end of fuel feed hose (1).
Disconnect the high pressure fuel feed hose (1) from
the fuel delivery pipe upper union (2).

2 1

IDG211170026-02

3) Connect special tools (pressure gauge, pressure
hose and pressure joint) between fuel feed hose (1)
and fuel delivery pipe upper union as shown in
figure.
Clamp the hose securely to ensure that no leaks
occur during checking.
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
A small amount of fuel may be released when
the fuel feed hose is disconnected.
Place container under the fuel feed hose or
fuel delivery pipe with a shop cloth so that
the released fuel is caught in the container or
absorbed by the cloth. Place the fuel soaked
cloth in an approved container.
Special tool
(A): 09912–58442 (Fuel pressure gauge)
(B): 09912–58432 (Fuel pressure hose)
(C): 09912–58490 (3-way joint & hose)
(A)
(B)
(C)
2 gauge.
IDG211170027-03
2. Delivery pipe upper union 3. Fuel delivery pipe
4) Ensure the emergency stop switch lock plate is in
place.
Shift into “Neutral” position.
5) Squeeze fuel primer bulb until you feel resistance.
6) Turn ignition switch “ON” for 3 seconds (to operate
the fuel pump), then turn it “OFF”.
7) Repeat this (“ON” and “OFF”) procedure 3 or 4 times
to pressurize the fuel system and then check the fuel
pressure.
OFF
ON
I9J011170018-01
Fuel System: 1G-11
8) Check for any signs of fuel leakage.
9) Measure fuel pressure at cranking or idle speed
operation.
Fuel pressure
Standard: Approx. 295 kPa (2.95 kg/cm2, 42 psi.)
10) Stop engine and wait 5 minutes.
Check the residual fuel pressure in line.
Residual fuel pressure
Standard: 200 kPa (2.0 kg/cm2, 28.4 psi.) or more
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
The fuel feed line is under high fuel pressure,
make sure to release fuel pressure according
to the fuel pressure relief procedures
mentioned earlier.
Use the following procedures to remove the
fuel pressure gauge.
• Place a container under the joint to catch
the fuel.
• Cover the joint with rag and loosen joint
nut slowly to gradually release any
residual fuel pressure.
11) After checking fuel pressure, remove fuel pressure
4
IDG211170067-02
4. Joint nut
12) Reconnect fuel line.
13) With the engine not running and ignition switch “ON”,
check the fuel system for leaks.
1G-12 Fuel System:

Fuel System Diagnosis

CENDG2111704002

Condition Possible cause Correction / Reference Item

Engine will not start or Clogging, bending or improper routing of Clean, repair or replace.
hard to start (Fuel does fuel hose.
not reach the fuel delivery Fuel pump failure. Replace.
pipe). Fuel pressure regulator failure. Replace.
Fuel injector(s) failure. Replace.
Wiring connection failure. Repair or replace.
Engine will not start or Neutral switch failure Replace.
hard to start. Throttle position sensor failure. Replace.
MAP sensor failure. Replace.
ECM failure. Replace.
Cylinder temp. sensor failure. Replace.
IAT sensor failure. Replace.
High pressure fuel pump failure. Replace.
Fuel hose improperly routed. Reroute properly.
IAC system failure Check idle air control system.
Unstable idling/trolling or Neutral switch failure Replace.
engine tends to stall. Throttle position sensor failure. Replace.
IAC system failure. Check idle air control system.
IAC passage clogged. Clean.
ECM failure. Replace.
Wire continuity/connection failure. Repair or replace.
Fuel injector(s) clogged. Replace.
Fuel pressure regulator failure. Check fuel pressure. Replace if necessary.
High pressure fuel pump failure. Check fuel pump and its circuit. Replace.
Fuel filter clogged. Clean or replace.
Clogging, bending or improper routing of Clean, reroute, repair or replace.
fuel hose.
Insufficient engine power Air leakage from air intake system. Repair or replace.
in high speed range (Air
intake system failure).
Insufficient engine power Fuel pressure too low. Check fuel pressure. Repair or replace.
in high speed range Throttle position sensor failure. Replace.
(Control circuit or sensor ECM failure. Replace.
failure).
Insufficient engine power Fuel injector(s) clogged. Replace.
in high speed range Throttle position sensor failure. Replace.
(Engine internal parts or ECM failure. Replace.
electrical equipment
failure).
 Fuel System: 1G-13

Fuel Injection System Troubleshooting Step 4

CENDG2111704003
Before starting the troubleshooting, make sure that: Check Wire circuit.
• There is no self-diagnostic code indication. • Turn “OFF” ignition switch.
• Emergency stop switch plate is set in place. • Disconnect connector from ECM.
• Measure resistance between each “O/B”, “B/Br”, “R/
Step 1 W”, “Lg/W” wire terminal of the fuel injector
Check fuel injector operating sound. connector and body ground.
• Check each injector for operating sound at engine
Is resistance infinity?
cranking. ( (Page 1G-21))
Do all four injectors make operating sound? Yes Go to step 5.

Yes Fuel injector circuit is in good condition. No “O/B”, “B/Br”, “R/W”, and/or “Lg/W” wire(s)
are shorted to ground.
No Go to step 2.
Step 5
Step 2 Check Wire circuit.
Check fuel injector resistance. • Connect connector to ECM.
• Turn ignition switch off, disconnect connectors from • Measure voltage between each “O/B”, “B/Br”, “R/
fuel injectors. W”, “Lg/W” wire terminal of fuel injector connector
• Check for proper connection to fuel injector at each and body ground with ignition switch turned “ON”.
terminal.
Is voltage 0 V?
• If good condition, check all fuel injector for
resistance. ( (Page 1G-21)) Yes Go to step 6.
Are all injectors in good condition? No “O/B”, “B/Br”, “R/W”, and/or “Lg/W” wire(s)
are shorted to power supply circuit.
Yes Go to step 3.

No Faulty fuel injector. Step 6

Check fuel injector operating signal.
Step 3 • Connect connectors to each fuel injector and ECM
Check fuel injector power supply. with ignition switch turned “OFF”.
• Measure voltage between each “Gr” wire terminal of • Measure fuel injector operating signal between each
fuel injector connector and engine body ground with “42”, “51”, “40”, “39” terminal of ECM and body
ignition switch turned “ON”. ground. ( (Page 1G-22))
Is voltage 10 – 14 V? Is voltage 6 – 10 V or over?

Yes Go to step 4. Yes If check result is satisfactory, substitute a

known-good ECM and recheck.
No • “Gr” wire open or shorted.
• If it is in good condition, check ECM No “O/B”, “B/Br”, “R/W”, and/or “Lg/W” wire(s)
power source and ground circuit. are open circuit.
1G-14 Fuel System:
Service Instructions
Fuel Pressure Relief Procedure
CENDG2111706001
After making sure that engine is cold, relieve fuel
pressure as follows:
1) Turn “OFF” ignition switch.
2) Disconnect the high pressure fuel pump lead wire
connector (1) at high pressure fuel pump.
1 risk or fire and personal injury.
IDG211170028-02
3) Disconnect the ignition coil primary lead wire
connectors (2) from all of the ignition coils.
2
IDG211170029-02
4) Crank the engine 5 – 10 times (3 seconds each time)
to dissipate the fuel pressure in lines.
5) Make sure fuel pressure has been relieved by
pinching the high pressure fuel hose (3) between
finger tips (the line should feel soft, without
pressure).
3
IDG211170030-02
6) Upon completion of servicing, connect the ignition
coil primary lead wires and high pressure fuel pump
lead wire.
Fuel Line Removal and Installation
CENDG2111706002
Pay special attention to the following points when
removing or installing fuel hoses.
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service” (Page 1G-1) in order to reduce the
• The fuel feed line is under high pressure, use special
care when servicing it.
• Spilled gasoline should be wiped off immediately.
• Perform the following checks to ensure proper and
safe operation of the repaired unit.
– Check fuel hose routing.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-1).
– Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page
1G-14).
Fuel Line Inspection
CENDG2111706003
Visually inspect fuel lines for evidence of fuel leakage,
cracking, deterioration, or damage. Make sure all clamps
are secure. Replace parts as needed.
Fuel Leakage Check Procedure
CENDG2111706004
After performing any fuel system service, always be sure
there is no fuel leakage by checking as follows.
1) Squeeze fuel primer bulb until you feel resistance.
2) Shift into “Neutral” position.
3) Ensure emergency stop switch lock plate is in place.
4) Turn ignition switch “ON” for 3 seconds (to operate
fuel pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times
to pressurize the fuel system.
5) Once pressurized, check all connections and
components for any signs of leakage.
OFF
ON
I9J011170020-01
 Fuel System: 1G-15

Inspection of Fuel Hose Connections High Pressure Fuel Pump Operating Sound
CENDG2111706005
Note that the fuel hose connection varies with each type
Inspection
CENDG2111706006
of pipe. Be sure to connect and clamp each hose 1) Install the emergency stop switch lock plate into
correctly by referring to the figure. position.
• For type “A” (short barbed end) pipe, the hose must 2) Shift into “Neutral”.
completely cover pipe.
3) Turn ignition switch “ON” and check for fuel pump
Type “A”
operating sound.
1
2 NOTE
Fuel pump operating sound is low because
the pump is inside the fuel vapor separator. If
you cannot hear the pump sound clearly, use
a sound scope or long blade screw driver.
“a” 3
Fuel pump operating sound
I9J011170012-01 Sounds for approx. 3 seconds only
1. Clamp (Clip) 3. Joint pipe (each time the ignition switch is turned to the
2. Hose “a”: 3 – 7 mm (0.1 – 0.3 in) “ON” position)

• For type “B” (bent end) pipe, hose must cover the
straight part of pipe by 20 – 30 mm (0.8 – 1.2 in.).
Type “B”

“b”
“a”

I9J011170013-01
IDG211170031-02
“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in) 4) If no pump operating sound is heard:
a) Turn ignition key to the “OFF” position, check for
• For type “C” pipe, hose must fit up against the flanged contact failure in the lead wire connector.
part of pipe.
Type “C” b) Check that the drive voltage is outputting from
the ECM and no abnormal conditions exist in the
engine main wiring harness.
c) If inspection in steps “a” and “b” are OK, replace
the high pressure fuel pump.
“a”
I9J011170014-01

“a”: 3 – 7 mm (0.1 – 0.3 in)

• For type “D” pipe, the hose must cover the pipe by 20
– 30 mm (0.8 – 1.2 in.).
Type “D”

“b”
“a”
I9J011170015-01

“a”: 3 – 7 mm (0.1 – 0.3 in) “b”: 20 – 30 mm (0.8 – 1.2 in)

1G-16 Fuel System:

Fuel Vapor Separator Removal and Installation Fuel Vapor Separator Disassembly and
CENDG2111706007
Removal
Assembly
CENDG2111706008
1) Remove the intake manifold assembly. Disassembly
Refer to “Intake Manifold Removal and Installation” 1) Remove five screws (1).
in Section 1D (Page 1D-6). Remove the separator cover (2) with the high
2) Remove the bolts and fuel vapor separator. pressure fuel pump from separator case (3).
Disconnect the fuel inlet hose (1), outlet hose (2),
drain hose (3) and evaporation hose (4) from fuel
vapor separator.
1 2

2
1 4

IDG211170033-02

2) Remove the spacer (4) and suction filter (5).

3
IDG211170032-03
4

Installation
5
Installation is in the reverse order of removal with special
attention to the following steps.
• Install the fuel vapor separator, then tighten the bolts
securely.
• Install the intake manifold assembly.
Refer to “Intake Manifold Removal and Installation” in
Section 1D (Page 1D-6).
• Check to ensure that all removed parts are back in IDG211170034-02

place. 3) Remove the screw (6) and float pin (7).

• Check hose and wire routing. Remove the float (8) and needle valve (9).
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
1) and “Water Hose Routing” in Section 4B (Page 4B-
5).
• Check for fuel leakage.
Refer to “Fuel Leakage Check Procedure” (Page 1G-
14).

IDG211170035-02

9 8

7
IDG211170036-02
 Fuel System: 1G-17

4) Disconnect the high pressure fuel pump lead wire 8) Remove the fuel pressure regulator assembly (17)
connector. from separator cover.
Remove in sequence the large O-ring (18), holder
(19), O-ring (20) and washer (21).

IDG211170037-01
17
5) Remove the high pressure fuel pump (10), bush (11),
joint (12) and bush (13) from the separator cover. IDG211170040-02

6) Remove the fuel outlet filter (14) from separator

cover.

20
21
13

14 12
19
18
11 IDG211170041-02

10
IDG211170038-02
Assembly
Assembly is in the reverse order of disassembly with
7) Remove the screw (15) and valve seat (16).
special attention to the following steps.

Fuel pressure regulator

1) Assemble the fuel pressure regulator in the following
sequence:
holder (1), O-ring (2), fuel pressure regulator (3),
washer (4) and O-ring (5).
15
NOTE
Apply fuel to the O-rings before installing.
16
IDG211170039-02

5
4
3

1
IDG211170042-01
1G-18 Fuel System:

2) Install the fuel pressure regulator assembly (6) to Float / Float pin
separator cover. • Install the valve seat (1), then tighten screw (2)
securely.
• Install the needle valve (3), float (4) and float pin (5),
then tighten screw (6) securely.

2
3
6 6

IDG211170043-01
1 5

High pressure fuel pump

Connect the pump lead wire connector, then install the
IDG211170046-01
filter (1), bush (2), joint (3), bush (4) and high pressure
fuel pump (5). NOTE
NOTE After assembling, check for smooth and free
float movement.
Apply fuel to the joint and bush before
installing.

1
2

4
5 IDG211170047-02

IDG211170044-01
Checking float height
Measure the float height.
Special tool
: 09900–20101 (Vernier calipers (150 mm))
Float height “a”
Standard: 47 ± 3.0 mm (1.85 ± 0.12 in)

NOTE
Make sure that the float weight is not applied
to the needle valve.

IDG211170045-01

“a”

IAJ611170037-01
 Fuel System: 1G-19

Setting float height 2) Install the suction filter (2), spacer (3) and separator
To correct specification, bend only adjustment tab (1). case (4) and then tighten the screws securely.
NOTE
3
When adjusting the tab, do not bend to the
point that it applies pressure to the needle 2
and seat.

IDG211170050-02

IDG211170048-02

Separator cover / Separator case

1) Install the seal ring (1) and then apply Suzuki Bond
evenly to only the outside mating surface of the
separator case as shown in figure. 4
: Sealant 99000–31140 (SUZUKI Bond IDG211170051-02
1207B (100 g))
Final assembly check
NOTE
• Check to ensure that all removed parts are back in
• Clean mating surfaces before applying place.
bond.
• Do not apply bond to seal ring, groove or
inside mating surface.

1
“A”

IDG211170049-02

1. Seal ring “A”: Outside

1G-20 Fuel System:

Inspection of Fuel Vapor Separator Component Separator Cover and Case

Parts Inspect the separator cover and case.
CENDG2111706009 Replace if cracked, damaged or other abnormal
NOTE conditions.
If cracks, excessive wear or other damage is
found on any component, replace the NOTE
component. Separator cover and case are a set.
If any repair is required on the cover or case,
Needle Valve / Valve Seat replace them as a fuel vapor separator
Inspect the needle valve and valve seat for grooves, assembly.
other damage or dirt.
Replace or clean if necessary.

IDG211170054-01

IAJ611170044-01
Fuel Pressure Regulator
Float Inspect the fuel pressure regulator for damage or
Inspect the float for cracks or other damage. corrosion.
Replace if necessary. Replace if cracked, damaged or other abnormal
conditions.

IDG211170052-01
IAJ611170048-01
Filter
Check fuel suction filter and fuel outlet filter for evidence
of dirt and contamination.
If present, replace or clean and check for presence of
dirt in fuel tank.

IDG211170053-01
 Fuel System: 1G-21

Fuel Injector Inspection with Injector in Place Individual Fuel Injector Operating Sound
CENDG2111706010
Inspection
1) Using a sound scope or equivalent, check the CENDG2111706011
operating sound of the fuel injector when the engine 1) Disconnect the ignition coil lead wire connectors
is running or cranking. from all of the ignition coils.
Injector operating sound cycle should vary according 2) Disconnect the fuel injector lead wire connector and
to engine speed. connect the test cord.
If no sound or an unusual sound is heard, check
injector circuit (wire or connector) or injector. Special tool
(A): 09930–89260 (Injector test cord (A))

“Click” “Cli c k ”

(A)

IDG211170068-02
1. Injector body
2) Disconnect the lead wire connector from the fuel
injector.
3) Connect a digital tester between the terminals of the
injector and measure resistance.
If out of specification, replace the fuel injector.
IDG211170072-02
3) Connect the Gr wire to body ground.
4) Momentarily touch the B/Y wire to the starter motor
magnetic switch terminal “B” (connected to battery
positive (+) terminal) and check for injector operating
sound.
If out of specification, replace fuel injector.

Special tool NOTICE

: 09930–99320 (Digital tester) If battery power is applied too long in any of
Tester knob indication the following tests, the coil of the fuel injector
Resistance (Ω) may burn.

Fuel injector resistance Fuel injector test must be completed within

Standard: 10 – 14 Ω at 20 °C few seconds to avoid burning of the coil.

Fuel injector operating sound

“Click”

Gr

IDG211170070-01

4) Connect the lead wire connector to the fuel injector

B/Y
securely.
IDG211170073-01

1. Starter motor magnetic switch “B” terminal

1G-22 Fuel System:

Fuel Injector Operating Signal Inspection

CENDG2111706012

ECM

(A) (A)

2
3
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

2 3

39 40 42 51

(A)
IDG211170071-03

1. Wire harness 3. Black connector (18-pin) 5. Starter motor magnetic switch “B” terminal
2. White connector (18-pin) 4. Peak voltmeter stevens CD-77

Special tool
: 09930–89290 (18 pin & 34 pin test cord)
: Stevens peak reading voltmeter CD-77
Tester knob indication
NEG 50
1) Disconnect both ignition coil connectors from the ignition coils.
2) Connect the test cord between the ECM and wire harness as shown in figure, then turn ignition switch “ON”.
3) Connect the tester probe (“–”, Black) to the starter motor magnetic switch terminal “B” (connected to battery
positive (+) terminal) as shown in figure.
4) Connect the tester probe (“+”, Red) to each terminal.
Injector Terminal Wire color (Engine harness)
No.1 42 O/B
No.2 51 B/Br
No.3 40 R/W
No.4 39 Lg/W

5) Crank the engine and measure the voltage.

If out of specification, inspect the related parts as described in “Fuel System Diagnostic Information/Fuel Injection
System Troubleshooting”.
Refer to “Fuel System Diagnosis” (Page 1G-12) and “Fuel Injection System Troubleshooting” (Page 1G-13).
Fuel injector operating signal
Standard: Approx. 6 – 10 V or over
 Fuel System: 1G-23

Fuel Injector Removal and Installation
CENDG2111706013
Removal
1) Remove the STBD lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Relieve the fuel pressure in the fuel feed line
according to “Fuel Pressure Relief Procedure”.
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
14).
3) Loosen the clamp and place a large cloth over the
end of the fuel feed hose (1).
Slowly pull the fuel feed hose from the fuel delivery
pipe.
Drain any excess fuel in the hose into a small
container.
5) Remove the bolt and nut securing the low pressure
fuel filter bracket (3).
6) Remove the nut and the fuel delivery pipe (4) (with
fuel injectors).
! WARNING
Gasoline is a flammable material that can
cause fire hazard or burns.
A small amount of fuel may be released when
the fuel injector is removed from delivery
pipe.
Place a shop cloth under fuel injector before
removal to absorb any fuel released.
Dispose of fuel soaked cloth in appropriate
container.

1
3

IDG211170055-01

4) Disconnect the four fuel injector connectors (2). IDG211170057-01

7) Remove each fuel injector from the delivery pipe.

IDG211170056-01

IDG211170058-01
1G-24 Fuel System:

Installation • Tighten the delivery pipe nuts (6) to the specified

Installation is in the reverse order of removal with special torque and make sure that the injectors rotate
attention to the following steps. smoothly.

! WARNING Tightening torque

Fuel delivery pipe nut (a): 23 N·m (2.3 kgf-m, 16.5
Failure to take proper precaution when lbf-ft)
reinstalling fuel injector can result in fuel
leakage or damage.

Do not re-use O-ring and cushion once

removed.
Always use new parts.
6 (a)

• Replace the O-ring (1) with a new one using care to

avoid nicks or cuts during installation.

IDG211170061-01

• Reconnect the fuel feed hose and fuel line securely.

• Connect the lead wire connector to the injectors
securely.
1 “A” 3
IDG211170013-01

2. Grommet “A”: Apply fuel to O-ring.

• Replace the cushion (3) with a new one and install to

the cylinder head.
• Install the collars (4).

IDG211170069-01

• Make sure the emergency stop switch lock plate is in

3 place.
4 Shift into “Neutral” position.
• Squeeze the fuel primer bulb until you feel resistance.
Turn ignition switch “ON” for 3 seconds (to operate
fuel pump), then turn it “OFF”.
Repeat this (“ON” and “OFF”) procedure 3 or 4 times
IDG211170059-02 to pressurize the fuel system.
• Apply a thin coat of fuel to injector O-rings, then install Check for fuel leaks around the fuel injectors.
the injectors into the delivery pipe (5) and cylinder
head.
Make sure that the injectors rotate smoothly.

IDG211170060-02
 Fuel System: 1G-25

Low Pressure Fuel Pump Removal and Installation

Installation Installation is in the reverse order of removal with special
CENDG2111706014 attention to the following steps.
NOTICE
Disassembling the low pressure fuel pump NOTE
can lead to troubles. • Before installing the fuel pump, rotate the
crankshaft to bring the No.1 (top cylinder)
The low pressure fuel pump is a piston to Top Dead Center on the
nonrepairable component. compression stroke.
Do not attempt to disassemble the low
• Do not reuse O-ring once removed.
pressure fuel pump.
Always use a new O-ring.
It must be replaced as a complete unit if it is
defective. • Install the low pressure fuel pump.
Removal Tightening torque
1) Disconnect the fuel inlet hose (1) and outlet hose (2) Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-
from low pressure fuel pump (3). m, 7.0 lbf-ft)
2) Remove two bolts (4).

2
4
(a)

1
4 IDG211170064-01

IDG211170062-03
• Connect the fuel inlet and outlet hoses.
3) Remove fuel pump.
Note the position before removing the O-ring (5).

IDG211170063-02
1G-26 Fuel System:

Low Pressure Fuel Pump Inspection Water Detection Switch Inspection

CENDG2111706015 CENDG2111706016
NOTICE Inspect the water detection switch using the following
Disassembling the low pressure fuel pump procedures.
can lead to troubles. 1) Remove the low pressure fuel filter.
Remove filter cup.
The low pressure fuel pump is a Refer to “Low Pressure Fuel Filter Inspection” in
nonrepairable component. Section 0B (Page 0B-14).
Do not attempt to disassemble the low 2) Connect the tester probes to the lead wire terminals
pressure fuel pump. as shown.
It must be replaced as a complete unit if it is 3) Check if continuity/infinity can be measured by
defective. moving float, checking each position.
If out of specification, replace the switch (fuel filter
Low Pressure Fuel Pump
case) with a new one.
Inspect the low pressure fuel pump.
If leakage, cracks, damage or other abnormal condition Special tool
is found, replace fuel pump assembly. (A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Float position Tester indication
Raise the float fully up Continuity
Lower the float completely. Infinity

IDG211170065-01

(A)

I9J011170072-01

IDG211170066-02

1. Float 2. Stopper

4) Assemble and re-install the fuel filter.

Refer to “Low Pressure Fuel Filter Inspection” in
Section 0B (Page 0B-14).
 Ignition System: 1H-1

Ignition System
Power Head

General Description
Ignition System Description
CENDG2111801001
The ignition system used by the DF100A/115A/140A is a fully transistorized, electronic microcomputer timing
advanced type.
This system is battery powered, with the ECM controlling all of the ignition timing functions.
The ignition system is composed of the ignition coil, spark plug and components for system control (ECM, sensor,
switch etc.).
When the ignition switch is “ON”, battery voltage (12 V) is applied to the circuit as shown in the illustration.
The ECM determines the optimum ignition timing and duration of current flowing through the ignition coil primary
winding based on the signals received from various sensors. At the calculated time of ignition, the transistor in the
ECM turns “OFF”, breaking the ground circuit.
In this way, a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated.

ECM

6 1
17

4 OFF
IG

14

3 2 7
No.1
IGT1 43 No.4
IGT2 52
No.2
No.3

34

32

Sensor/Switch signal

IDG211180004-04

1. Main relay 3. Battery 5. Fuse 30 A 7. Neutral switch

2. Ignition switch 4. Fuse 60 A 6. Fuse 30 A 8. Starter relay
1H-2 Ignition System:

Ignition Control Description

CENDG2111801002
Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM.
Based on these signals, the ECM determines the optimum ignition timing and releases voltage to the ignition coils.

Basic sensors ECM

MAP sensor: Ignition timing is determined by a
Informs ECM of intake manifold pressure. digital map designed in relation to
CKP sensor: intake manifold pressure and
engine speed.
Informs ECM of engine speed and crankshaft angle.

Compensating sensors
Cylinder temperature sensor:
Informs ECM of cylinder temperature. Ignition timing compensation
Throttle position sensor:
Informs ECM of throttle opening angle.
IAT sensor:
Informs ECM of intake air temperature.
Knock sensor (DF115A/140A):
Informs ECM of knocking level.

Others
CMP sensor: Signal Signal
Informs ECM of camshaft angle.
Ignition switch: Ign.coil Ign.coil
Informs ECM of “START” signal.
Neutral switch:
Informs ECM of shift position.
Battery voltage: Spark plug
Constantly monitored by the ECM.
IDG211180001-04

Ignition Specification
Ignition system Full-transistorized ignition
Advance Electronic microcomputer control
Ignition timing 10° BTDC – 26° BTDC
Firing order 1—3—4—2
 Ignition System: 1H-3

Ignition Timing Chart

The following chart is an example for ignition at 10° BTDC.

32 signals / crankshaft 1 rotation

CKP sensor
signal

40° 40°
140° 220° 180° 100° 140°
CMP sensor
signal
CMP sensor - 6 signals / 720°(crankshaft 2 rotation)

TDC TDC
No.1 cylinder Cm. Ep. Ex. In. Cm. Ep.
TDC TDC
No.3 cylinder In. Cm. Ep. Ex. In. Cm.
TDC TDC
No.4 cylinder Ex. In. Cm. Ep. Ex. In.
TDC TDC
No.2 cylinder Ep. Ex. In. Cm. Ep. Ex.

Spark timing
No.1 Ignition
signal
No.3 Ignition
signal
No.4 Ignition
signal
No.2 Ignition
signal

Cm.: Compression, Ep.: Explosion, Ex.: Exhaust, In.: Intake, TDC: Top Dead Center
IDG211180005-02

Ignition Timing Control Mode

• When cranking
The ignition timing is fixed at 5° BTDC until the engine starts.
• When operating (Normal operation)
The ignition timing ranges between 10° – 26° BTDC, depending on current engine operating conditions.
• Knock control compensation (DF115A/140A)
This compensation is added when knocking is detected so as to recover from knocking state immediately.
1H-4 Ignition System:

Component Location
Ignition System Components Location
CENDG2111803001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).

Diagnostic Information and Procedures

Ignition System Symptom Diagnosis
CENDG2111804001

Condition Possible cause Correction / Reference Item

Engine cranks, but will Blown fuse for ignition system. Replace.
not start or weak spark. Loose connection or disconnection of Connect securely.
(No spark) lead wire.
Faulty spark plug(s). Replace.
Faulty ignition coil. Replace.
Faulty CKP sensor. Replace.
Faulty CMP sensor or sensor trigger Replace.
vane of camshaft.
Faulty ECM. Replace.
Spark plug is wet or Incorrect gasoline. Change.
quickly becomes fouled Incorrect spark plug. Replace.
with carbon.
Spark plug quickly Worn piston ring. Replace.
become fouled with oil or Worn piston. Replace.
carbon. Worn cylinder. Replace.
Excessive valve stem to valve guide Replace.
clearance.
Worn valve stem seal. Replace.
Spark plug electrodes Incorrect spark plug. Change.
overheat or burn. Overheated engine. Tune-up.
Loose spark plug. Tighten.
 Ignition System: 1H-5

Ignition System Troubleshooting Step 6

CENDG2111804002
Before starting the troubleshooting, make sure that: Measure the battery voltage between input lead
• There is not self-diagnostic code indication. wire at ECM with the ignition switch in “ON”
• Emergency stop switch plate is set in place. position. Is result OK?
Perform the following ignition system tests when the
Yes Go to step 7.
engine is hard to start in order to determine if the cause
is in the ignition or another system. No • Faulty ignition switch.

Step 1 • Faulty ECM main relay.

• Broken wire harness or poor connection
Check the ignition system connector for poor
of related circuit connector.
connections. Is there connection in the ignition
system connectors? Step 7
Yes Go to step 2. Check CKP sensor. Refer to “CKP Sensor
Inspection” in Section 1C (Page 1C-10). Is result
No Poor connection of connectors.
OK?
Step 2 Yes Go to step 8.
Check spark condition.
No • Check air gap between CKP sensor
Yes Go to step 3. and flywheel reluctor bars.
• Adjust CKP sensor air gap.
No No or weak sparks.
• Replace CKP sensor or flywheel.
Step 3
Step 8
Check if the spark plugs are in good condition.
Check CMP sensor. Refer to “CMP Sensor
Yes Go to step 4. Inspection” in Section 1C (Page 1C-12). Is result
OK?
No Replace spark plug with a new one.
Yes Go to step 9.
Step 4
No • Check CMP sensor.
Check ignition coil assembly power supply and
ground circuits for open and short. Are circuits in • Check CMP sensor trigger vane.
good condition? • Replace CMP sensor or Ex. camshaft.
Yes Go to step 5. Step 9
No Repair or replace. Substitute a known-good ignition coil assembly
then repeat step 2. Is check result of step 2
Step 5 satisfactory?
Check ignition coil operating signal. Is result OK? Yes Go to step 10.
Yes Go to step 6. No Substitute a known good ECM, then
No Check ignition coil operating signal wire repeat step 2.
for open, short and poor connection.
Step 10
Check the ignition timing by using timing light
(Approx. 10° BTDC at 1 000 r/min). Is result OK?

Yes System is in good condition.

No Check input signals related to this system.

1H-6 Ignition System:

Service Instructions
Spark Plug Removal and Installation
CENDG2111806001
Refer to “Spark Plug Removal and Installation” in
Section 0B (Page 0B-6).

Spark Plug Inspection 1

CENDG2111806002
Refer to “Spark Plug Inspection and Cleaning” in Section
0B (Page 0B-6).

Ignition Coil Removal and Installation

CENDG2111806003
Removal IDG211180007-01
1) Disconnect the battery cables at the battery. 2) Connect the tester probes to each ignition coil as
2) Disconnect all the spark plug caps (1). shown.
3) Disconnect the ignition coil connectors (2). Primary coil resistance
4) Remove the bolts and ignition coils (3). Standard: 1.9 – 2.5 Ω at 20 °C

(A)

“B” “A”
1
2

IDG211180006-01

IDG211180002-02
Installation
A: Positive (+) terminal (O or Bl) B: Negative (–) terminal (Gr)
1) Install the ignition coil, then secure the ignition coil
with its mounting bolts. If measurement is out of specification, replace the
2) Connect the ignition coil connectors. ignition coil.
3) Connect the battery cables to battery.
Secondary Coil Side
Ignition Coil Inspection 1) Disconnect the spark plug caps from the spark plugs.
CENDG2111806004
2) Connect the tester probes to the plug caps as
Special tool shown.
(A): 09930–99320 (Digital tester)
Secondary coil resistance
Tester knob indication No.2 & 3 standard: 18 – 34 kΩ at 20 °C
Resistance (Ω) No.1 & 4 standard: 19 – 36 kΩ at 20 °C
Primary Coil Side
(A)
1) Disconnect the ignition coil connectors (1).

IDG211180003-02

If measurement is out of specification, replace the

ignition coil.
 Ignition System: 1H-7

Ignition Coil Operating Signal Inspection

CENDG2111806005

Special tool
(A): 09930–89290 (18 pin & 34 pin test cord)
: Stevens peak reading voltmeter CD-77
Tester knob indication
NEG 50
1) Disconnect all injector connectors from the fuel injectors.
2) Connect the test cord between the ECM and the wire harness as shown in figure then turn ignition switch ON.

ECM

(A) (A)

2
3
35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52

1 2 3 4 5 6 7 8 9 10 11 12 13 18 19 20 21 22 23 24 25 26 27 28 29 30
14 15 16 17 31 32 33 34

1
4

2 3

43 52

(A)
IDG211180009-02

1. Wire harness 3. Black connector (18-pin) 5. Starter motor magnetic switch terminal “B”
2. White connector (18-pin) 4. Peak voltmeter stevens CD-77

3) Connect tester probe (–) (Black) to starter motor magnetic switch terminal “B” (connected to battery positive (+)
terminal) as shown in figure.
4) Connect the tester probe Red (+) to each terminal, one at a time to test each circuit.
Terminal Wire color (Harness side)
No.2 & 3 ignition coil 52 Bl
No.1 & 4 ignition coil 43 O

5) Crank the engine and measure the voltage.

If out of specification, inspect the related parts.
Refer to “Ignition System Symptom Diagnosis” (Page 1H-4) and “Ignition System Troubleshooting” (Page 1H-5).
Ignition coil operating signal
Standard: 6 – 10 V
1H-8 Ignition System:

CKP Sensor Inspection

CENDG2111806006
Refer to “CKP Sensor Inspection” in Section 1C (Page 1C-10).

CMP Sensor Inspection

CENDG2111806007
Refer to “CMP Sensor Inspection” in Section 1C (Page 1C-12).

Ignition Switch Inspection

CENDG2111806008
Refer to “Ignition Switch Inspection” in Section 1I (Page 1I-14).

ECM Main Relay Inspection

CENDG2111806009
Refer to “ECM Main Relay Inspection” in Section 1A (Page 1A-40).
 Starting System: 1I-1

Starting System
Power Head

General Description
Electric Starter System Description
CENDG2111901001
The starting circuit consists of the battery, starting motor, ignition switch, neutral switch, starter relay, ECM and related
electrical wiring.
These components are connected electrically as shown in the figure below.
In the circuit shown in the figure below, the magnetic switch coils and starter relay coil are magnetized when the
ignition switch is closed (turned to “START”).
The resulting plunger and pinion shift lever movement causes the pinion to engage the engine flywheel gear, the
magnetic switch main contacts to close, and engine cranking to take place.
When the engine starts, the pinion over-running clutch protects the armature from excessive speed until the switch is
opened, at which time the torsion spring causes the pinion to disengage.

1
5 4 3
R
6
R
G
8 7
R

Y/G

10 2 W
15

12 13 14

PUSH FREE ST IG OFF

W
GND B 19
STOP G 11
BATT W
IG Gr
START Br
20
17 B.Z
RESET O 16
PUSH TURN Br
Br
Br
Br Br
Bl/R
B G
B B

18
IDG211190001-04

1. Starter relay 6. Plunger 11. 30 A Fuse (Starter) 16. Neutral switch

2. Battery 7. Shift lever 12. 30 A Fuse (ECM) 17. Ignition switch
3. Magnetic switch 8. Ring gear 13. 60 A Fuse (Load) 18. Emergency stop switch
4. Pull-in coil 9. Starter motor 14. 60 A Fuse (Main) 19. ECM
5. Hold-in coil 10. Pinion and over-running clutch 15. Main relay 20. Neutral switch
1I-2 Starting System:

Starter Motor Operation Condition Description Start-In-Gear Protection System Description

CENDG2111901002
The starter motor relay is controlled by the ECM.
• The starter motor relay will only engage when the
ignition switch is turned to the “START” position if the
all of the following conditions are satisfied.
– Lock plate is attached to emergency stop switch.
– Neutral switch is in the “ON” position.
– Engine is not already operating.
• After returning the ignition key to the “ON” position
from “START”, the starter motor continues to run for 4
seconds until engine starts.
NOTE
The continuous operating time of the starter
motor is set at five seconds.
When this time is exceeded, the starter motor
will automatically stop.
If the motor stops, wait about ten seconds for
the motor to cool down and try again.
CENDG2111901003
To avoid accidental movement of the boat at the time of
engine starting, the system prohibits starter motor
operation when the shift lever is “IN” gear.
Control by Neutral Switch
A switch to detect “Neutral” gear position is located on
the clutch lever holder and operated by the clutch control
lever.
This ON/OFF type switch is ON in “Neutral” and OFF in
“Forward” or “Reverse”.
When attempting to start the engine, the ECM detects
the shift position using the neutral switch.
When the neutral switch is OFF, the ECM does not
provide a starter motor relay operating signal and fuel
injector operating signal.
“Neutral”
“Reverse” “Forward” 1

IDG211190002-03

1. Clutch lever 2. Neutral switch

Operation by neutral switch on engine starting

Operation
Shift High
Fuel Starter
position Ignition pressure
injection motor
fuel pump
Neutral Yes Yes Yes Yes
Forward/
No No Yes No
Reverse
 Starting System: 1I-3

Component Location
Starting System Components Location
CENDG2111903001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).

Diagnostic Information and Procedures

Starter System Troubleshooting
CENDG2111904001
! CAUTION
Failure to take proper precaution when starter system troubleshooting may result in personal injury
and/or damage to electronic components.

If any abnormality is found, immediately disconnect the battery cables from the battery.

NOTE
Before troubleshooting the electric starter system, make sure of the following:
• Battery is fully charged.
• All cables/wires are securely connected.
• Shift is in “Neutral” position.
• Emergency stop switch lock plate is set in place.
• Fuse is not blown.

Condition Possible cause Correction / Reference Item

Motor not running. (No Poor or broken battery connection.
operating sound of Loose or corroded battery connection.
magnetic switch.) Weak or shorted battery.
Defective neutral switch.
Fuse blown.
Defective ignition switch.
Open circuit between ignition switch and
magnetic switch.
Defective emergency stop switch.
Lead wire disconnected or loose.
Poor contacting action of ignition switch
and magnetic switch.
Defective starter motor control relay.
Defective ECM and its circuit.
Open circuit in pull-in coil.
Brushes are seating poorly or worn.
Motor not running. Weak or shorted battery.
(Operating sound of Battery voltage too low due to battery
magnetic switch heard.) deterioration.
Loose or corroded battery connection.
Burnt main contact point, or poor
contacting action of magnetic switch.
Brushes are seating poorly or worn.
Weakened brush spring.
Burnt commutator.
Shorted or open winding in armature.
Excessive friction in engine.
Replace.
Repair or retighten.
Replace or recharge battery.
Neutral switch inspection. Replace.
Replace.
Ignition switch inspection. Replace.
Repair.
Replace. Emergency stop switch inspection.
Retighten.
Replace. Ignition switch inspection. Magnetic
switch inspection.
Main relay and starter motor relay inspection.
Inspection of ECM and its circuit.
Replace magnetic switch. Magnetic switch
inspection.
Repair or replace. Brushes inspection.
Replace or recharge battery.
Replace battery.
Repair or retighten.
Replace magnetic switch. Magnetic switch
inspection.
Replace or repair. Brushes inspection.
Replace.
Replace armature. Commutator inspection.
Replace. Armature inspection.
Repair.
1I-4 Starting System:

Condition Possible cause Correction / Reference Item

Starter motor running but Insufficient contact of magnetic switchReplace magnetic switch. Magnetic switch
too slow. (Low torque) main contacts. inspection.
(If battery and wiring are Shorted armature. Replace. Armature inspection.
satisfactory, inspect Dirty or corroded commutator. Repair commutator or replace armature.
starting motor.) Armature inspection.
Worn brushes. Replace brushes.
Weakened brush spring. Replace.
Starter motor running, but Worn pinion tip. Replace over-running clutch.
not cranking engine. Poor sliding of over-running clutch. Repair.
Over-running clutch slipping. Replace over-running clutch.
Worn teeth of ring gear. Replace flywheel.
Starter motor does not Broken contact point of magnetic switch. Replace magnetic switch.
stop running. Short-circuit magnetic switch coil. Replace magnetic switch.

Service Instructions
Starter Motor Removal and Installation 2) Remove bolt (2) securing main harness GND lead
CENDG2111906001 wire and negative (–) battery cable.
Removal
Remove nut (3) securing positive (+) battery cable
NOTICE and main harness (R) lead wire.
If the 12 V electrical system is shorted while
servicing the starter motor, the engine
electrical circuits could be damaged
seriously. 3

Prior to removing starter motor, disconnect

the battery cable at the battery.
2
1) Remove bolt and ring gear cover (1).

1
IDG211190004-02

3) Disconnect Red lead wire connector (4) from

terminal “S” of starter magnetic switch.

IDG211190003-02
4

IDG211190005-02
 Starting System: 1I-5

4) Remove two bolts and starter motor (5). Starter Motor Test
CENDG2111906002
! CAUTION
Sparks resulting from short circuit between
the positive (+) and negative (–) terminals
during connections to the battery could
cause a burn.

5 Be careful not to short-circuit the positive (+)

and negative (–) cables and connect them
only to the correct terminals.

IDG211190006-02 ! CAUTION
5) Remove the dowel pins (6).
If the cable used for the test is not adequately
thick, the cable may become extremely hot
due to large current flowing through it and
you could get burned.

Be sure to connect the battery and the

starting motor with a lead wire of the same
size as original equipment.
6
NOTICE
If battery power is applied too long in any of
the following tests, the coil of the magnetic
IDG211190032-01
switch may burn.
Installation
Installation is in the reverse order of removal with special Each test must be completed within 3 – 5
attention to the following steps. seconds to avoid burning of the coil.
• Install the starter motor and tighten starter motor
mounting bolts securely.
Tightening torque
Starter motor mounting bolt (a): 50 N·m (5.0 kgf-
m, 36.0 lbf-ft)
Starter motor mounting bolt (b): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft)

(a)

(b)

IDG211190007-03

• Check to ensure that all removed parts are back in

place.
1I-6 Starting System:

Pull-In / Hold-In Test Plunger and Pinion Return Test

Disconnect the negative lead from the switch/motor
NOTE body.
Before testing, disconnect the brush lead Check that the plunger and pinion return inward.
from terminal “M”. If the plunger and pinion don't return inward, replace the
magnetic switch.
Connect the battery to the magnetic switch as shown in
the figure.
• Check that the plunger and pinion (over-running
clutch) move outward.
If the plunger and pinion don’t move, replace the
magnetic switch.

1
3
4

I9J011190004-01

No-Load Performance Test

NOTE
2 Before performing the following test, secure
the starter motor to the test bench.
I9J011190002-02

1. Terminal “S” 3. Terminal “B” 1) Connect a battery and ammeter to the starter motor
2. Terminal “M” 4. Brush lead as shown.
2) Check that the starter rotates smoothly and steadily
• While connected as above with the plunger out, with the pinion moving out. Check that the ammeter
disconnect the negative lead from terminal “M”. indicates the specified current.
Check that the plunger and pinion remain out. If the
plunger and pinion return inward, replace the Specified current (No-load performance test)
magnetic switch. Within 90 A at 11 V

I9J011190005-01

I9J011190003-01
 Starting System: 1I-7

Starter Motor Components

CENDG2111906003

1 3 4 5 6 7 8 9 2 (a)
10

20

21 26 24 24 23 22
19 25

12 (b)

11
14 17
13 15 16 18
IDG211190008-02

1. Nut 9. Shift lever 17. Armature 25. Center bracket

2. Bolt 10. Front housing 18. Center cover plate 26. Rubber ring
3. Magnetic switch 11. Screw 19. Internal gear : 7 N⋅m (0.7 kgf-m, 5.1 lbf-ft)
4. Gasket 12. Through bolt 20. Planetary gear : 5.5 N⋅m (0.55 kgf-m, 4.0 lbf-ft)
5. Spring 13. Rear cover 21. Pinion shaft : Apply grease.
6. Plunger 14. Thrust washer 22. Pinion
7. Torsion spring 15. Brush holder 23. E-ring
8. Rubber packing 16. Yoke 24. Washer

Starter Motor Disassembly and Assembly

CENDG2111906004
Disassembly
When overhauling the starting motor, it is recommended “A”
that the component parts be cleaned thoroughly.
However, the yoke assembly, armature coil, over-
running clutch assembly, magnetic switch assembly and
rubber or plastic parts should not be washed in a “C” “B”
degreasing tank or with a grease dissolving solvent.
These parts should be cleaned with compressed air or
wiped with clean cloth.

NOTE IDG211190009-01

Before disassembling the starting motor, be

sure to put match marks at three locations
(“A”, “B” and “C”) as shown in the figure at
right to avoid any possible component
alignment mistakes.
1I-8 Starting System:

1) Remove nut (1) from the magnetic switch, then 5) Remove thrust washer (9) with a screwdriver.
disconnect the connecting wire (2).
2) Remove two bolts (3) securing the magnetic switch.

9
2 3
1

IDG211190013-01

6) Pull the brush spring (10) up to separate the brush

IDG211190010-01 from the surface of the commutator, then remove the
3) Remove the magnetic switch (4) and rubber packing brush holder (11).
(5).

4 10

11

IDG211190014-01

IDG211190011-01 7) Remove the yoke (12) and armature (13).

4) Remove screws (6), long through bolts (7) and the
rear cover (8).
12
7
6

6
13

IDG211190015-01

7
IDG211190012-01
 Starting System: 1I-9

8) Remove the center cover plate (14). 12) Remove the pinion (20).
9) Remove the planetary gears (15) and internal gear
NOTE
(16).
To remove the pinion, hold the pinion shaft
and pull the pinion up while turning it.
Repeat this process several times then the
14
15 pinion will be removed.

16
IDG211190016-02

10) Remove the center bracket (17) (with shift lever (19),
pinion (20) and pinion shaft (21)) from front housing 20
(18).
IDG211190019-01

13) Remove the pinion shaft (21), washers (23) and

19 rubber ring (24) from the center bracket.

24
21
23 23

20 18
17

IDG211190017-01

11) Remove the shift lever (19) and E-ring (22).

IDG211190020-01

19
22 Assembly
Assembly is in the reverse order of disassembly with
special attention to the following steps.
Reassemble the starter motor, refer to “Starter Motor
Components” (Page 1I-7).
• When installing the armature, use care to avoid
breaking the brushes.

IDG211190018-01

IDG211190021-01
1I-10 Starting System:

Starter Motor Components Inspection and Commutator undercut “a”

Servicing Standard: 0.5 – 0.8 mm (0.02 – 0.03 in.)
CENDG2111906005 Service limit: 0.2 mm (0.01 in.)
Armature and Commutator
• Inspect the commutator surface. If surface is gummy 3
or dirty, clean with # 500 grit emery paper (1).

1 “a”

2
I9J011190024-01

2. Mica 3. Segment

• Check for continuity between the commutator (4) and

the armature core (5)/shaft (6).
I9J011190022-01
Replace the armature if continuity is indicated.
• Measure the commutator outside diameter. If the
measurement exceeds the service limit, replace the Special tool
armature. (B): 09930–99320 (Digital tester)
Special tool Tester knob indication
(A): 09900–20101 (Vernier calipers (150 Continuity ( )
mm))
4
Commutator outside diameter 6
Standard: 29.0 mm (1.14 in.)
Service limit: 28.0 mm (1.10 in.)

(A)

(B)
(B)
I9J011190025-01

4. Commutator 5. Armature core 6. Shaft

I9J011190023-01
• Check for continuity between adjacent commutator
• Check that the mica (insulator) (2) between the
segments. Replace armature if no continuity is
segments (3) is undercut to specified depth “a”.
indicated.
If the measurement exceeds the service limit, cut to
the specified depth. Tester knob indication
Continuity ( )
! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.

Wear safety glasses when using compressed

air.

NOTE
I9J011190026-01
Remove all particles of mica and metal using
compressed air.
 Starting System: 1I-11

Brushes Shift Lever

Check the length of each brush (1). Inspect the shift lever for wear. Replace if necessary.
If brushes are worn down to the service limit, they must
be replaced.
Special tool
(A): 09900–20101 (Vernier calipers (150 mm))
Brush length
Standard: 16.0 mm (0.63 in.)
Service limit: 12.0 mm (0.47 in.)

IDG211190022-01

Pinion and Over-Running Clutch

• Inspect the pinion for wear, damage or other abnormal
conditions.
Check that the clutch locks up when turned in the
1
direction of drive and rotates smoothly in reverse
direction. Replace if necessary.
IDG211190033-01

Brush Holder
Check brush holder continuity.
Replace the brush holder if the tester doesn't show the
below.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Brush holder continuity IDG211190023-01
Continuity • Inspect spline teeth for wear or other damage.
Brush holder positive (+) to brush Inspect the pinion for smooth movement. Replace if
No
holder negative (–) necessary.
Brush holder positive (+) to base
No
plate (ground)

(‫)ޓ‬
(–)

IDG211190024-01

1
I9J011190028-01

1. Base plate
1I-12 Starting System:

Gear Front Housing

Inspect planetary gears and internal gear for wear,
damage or other abnormal conditions.
Replace if necessary.
• Inspect the front housing for wear, damage or other
abnormal conditions. Replace if necessary.
• Inspect the bearing for wear or other damage.
Replace if necessary.

IDG211190025-01

IDG211190027-01
Pinion Shaft / Pinion Shaft Bushing
• Inspect the pinion shaft for wear, damage or other Armature Shaft Bush
abnormal conditions. Replace if necessary. Inspect the bushing for wear or other damage.
• Inspect the pinion shaft bushing for wear or other Replace if necessary.
damage.
Replace if necessary.

IDG211190028-01

IDG211190026-01 Plunger
Inspect the plunger for wear or other damage.
Replace if necessary.

IDG211190029-01
 Starting System: 1I-13

Magnetic Switch Hold-in coil open circuit test

Push in the plunger and release. The plunger should Check for continuity across the magnetic switch “S”
return quickly to its original position. terminal (1) and coil case (4).
Replace if necessary. If no continuity exists, the coil is open and should be
replaced.
Special tool
(A): 09930–99320 (Digital tester)
1
Tester knob indication
Continuity ( )

(A)
3
IDG211190030-01
2
1. Plunger
1
Pull-in coil open circuit test
Check for continuity across the magnetic switch “S”
terminal (1) and “M” terminal (2). I9J011190039-01
If no continuity exists, the coil is open and should be 1. Terminal “S” 3. Terminal “B”
replaced. 2. Terminal “M” 4. Coil case

Special tool
(A): 09930–99320 (Digital tester) Contact points test
Put the plunger on the under side and then push the
Tester knob indication magnetic switch down.
Continuity ( ) At this time, check for continuity between terminal “B”
and terminal “M”.
3
Continuity indicates proper condition. If no continuity
exists, replace the magnetic switch and/or plunger.
Special tool
2 (A) (A): 09930–99320 (Digital tester)
1
Tester knob indication
Continuity ( )

I9J011190038-02 (A)
1. Terminal “S” 3. Terminal “B”
2. Terminal “M”

I9J011190040-01
1I-14 Starting System:

Ignition Switch Inspection Starter Motor Relay Inspection

CENDG2111906006 CENDG2111906007
Inspect the ignition switch using the following Inspect the starter motor relay using the following
procedures: procedures:
1) Disconnect the ignition switch from remo-con box 1) Disconnect the starter motor relay from the fuse box.
wiring harness.
2) Check continuity between wiring leads at the key
positions shown in the chart.
1
3) If out of specification, replace the ignition switch.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )

Switch lead wires

Key position IDG211190034-01

B G W Gr Br O 1. Starter motor relay

OFF
2) Check continuity between terminal (2) and (3) each
ON time 12 V power supply is applied to terminal (4) and
(5).
START Connect the positive (+) lead to terminal (5), and
FREE negative (–) lead to terminal (4).

PUSH NOTICE
: Continuity If the 12 V power supply wire is connected to
IDG211190040-01
wrong terminal or touched to each other, the
power supply wire, tester may be damaged.

(OFF) (ON) Be careful not to touch 12 V power supply

FREE wires to each other or with other terminals.
(START)
Special tool
(A): 09930–99320 (Digital tester)
PUSH
Tester knob indication
Continuity ( )
Starter motor relay function
Continuity
12 V power applied Yes
12 V power not applied No
O
Br
B 3
W 2
5

12 V
W/R Bl
Gr CONT
G
B G
Bl 4
Br Br Gr
I9J011190042-02 (A)
IDG211190039-01
 Starting System: 1I-15

3) Measure the resistance between relay terminals (4) 4) Remove two screws (3) and neutral switch (4) from
and (5). clutch lever holder.
If out of specification, replace starter motor relay.
Tester knob indication
Resistance (Ω)
3
Starter motor relay solenoid coil resistance
Standard: 145 – 190 Ω

(A)
4

IDG211190037-01

Installation
I9J011190044-02
Installation is reverse order of removal with special
attention to the following steps.
Neutral Switch (Engine Side) Removal and • Check wiring harness routing.
Installation Refer to “Wiring Harness Routing Diagram” in Section
CENDG2111906010 4A (Page 4A-3).
Removal
• Apply water resistant grease to the switch lever.
1) Remove the lower side covers.
Refer to “Lower Side Cover Removal and : Grease 99000–25350 (SUZUKI Water
Installation” in Section 2A (Page 2A-3). Resistant Grease EP2 (250 g))
2) Disconnect the neutral switch lead wire connector
(1).

IDG211190038-01

• Install lower side covers.

Refer to “Lower Side Cover Removal and Installation”
IDG211190035-01
in Section 2A (Page 2A-3).
3) Remove two bolts (2) securing clutch lever holder.

IDG211190036-01
1I-16 Starting System:

Neutral Switch Inspection Neutral Switch on Engine Side

CENDG2111906008
Check for continuity/infinity of the neutral switch. 1) Disconnect the neutral switch lead wire connector.
2) Check continuity/infinity between the Yellow/Green
Special tool and Brown lead wires while operating the remo-con
(A): 09930–99320 (Digital tester) handle.
Tester knob indication Special tool
Continuity ( ) (A): 09930–99320 (Digital tester)
Neutral Switch in Remo-Con Box Neutral switch function
1) Disconnect the neutral switch lead wire connector Shift position Tester indicates
from the ignition switch. Neutral Continuity
2) Check continuity/infinity between the switch brown Forward Infinity
wire leads while operating the remo-con handle. Reverse Infinity
If out of specification, replace the neutral switch.
Neutral switch function
Shift position Tester indicates
Neutral Continuity “Neutral”
Forward Infinity “Reverse” “Forward” 1
Reverse Infinity

(A)

“Reverse” “Forward”
2

IDG211190002-03

1. Clutch lever 2. Neutral switch

Br

(A)

Br
I9J011190045-03
Y/G

Br

I9J011190047-03

3) If out of specification:
• 1st:
Check the remo-con cable adjustment, readjust if
necessary.
• 2nd:
Check the wire harnesses for open and short
circuits.
If the wire harnesses are in good condition,
replace the neutral switch and recheck.
Refer to “Neutral Switch (Engine Side) Removal
and Installation” (Page 1I-15).

NOTE
After installing the neutral switch, check for
correct function by operating the remo-con
handle.
 Charging System: 1K-1

Charging System
Power Head

General Description
Charging System Description
CENDG2111B01001
The battery charging system circuit is illustrated below.
It is composed of the battery charge coil, rectifier/regulator and battery. The three phase AC current generated from
the battery charge coil is converted by the rectifier/regulator into regulated DC current which is used to charge the
battery.
Battery charge coil output
Standard: 12 V 27 A (480 W) at 3 000 r/min
Regulated voltage
Standard: 14.2 – 15.2 V

2
9
W
W W
W W
W

To ECM
To ECM
R/B To fuel injector W
W
To ignition coil W
B
To high pressure fuel pump Gr
Others
4

M
To ignition switch 8 7 6

To starter relay

– +

5
IDG2111B0001-07

1. Flywheel (Magneto) 4. Starter motor 7. Load fuse 60 A

2. Battery charge coil 5. Battery 8. ECM fuse 30 A
3. Rectifier/Regulator 6. Main fuse 60 A 9. Main relay

Battery Requirement Description

CENDG2111B01002
Refer to “Battery Requirement” in Section 0A (Page 0A-5).
1K-2 Charging System:

Component Location
Charging System Components Location
CENDG2111B03001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).

Diagnostic Information and Procedures

Charging System Diagnosis
CENDG2111B04001

Condition Possible cause Correction / Reference Item

Alternator (Battery charge Open or short circuit lead wires. Repair or replace.
coil) does not charge. Open or short circuit battery charge coil. Replace.
Rectifier/Regulator failure. Replace.
Main fuse blown out. Replace.
Poor or broken battery connection. Repair or Replace.
Alternator (Battery charge Rectifier/Regulator failure. Replace.
coil) overcharge. Poorly grounded rectifier/regulator. Repair or Retighten.
Unstable charging Short circuit battery charge coil. Replace.
Loose lead wire connection. Repair or replace.
Rectifier/Regulator failure. Replace.
Poor or broken battery connection. Repair or replace.
 Charging System: 1K-3

Service Instructions
Charging System Construction
CENDG2111B06001
NOTE
Flywheel bolt (1) is a left hand thread.

1 (a)

2
4

12

13 14
6

15
16
5

11
8
10 9

IDG2111B0013-01

1. Bolt 6. Bolt 11. Wiring harness assembly 16. Fuse (30 A, 15 A)

2. Washer 7. Electric parts holder 12. Fuse case upper cover : 245 N⋅m (24.5 kgf-m, 177.0 lbf-ft)
3. Flywheel 8. Rectifier/Regulator 13. O-ring : Apply engine oil.

4. Key 9. Bolt 14. Fuse (60 A) : Apply SUZUKI Bond 1207B.

5. Battery charge coil 10. Gasket 15. Relay
1K-4 Charging System:

Flywheel Removal and Installation 3) Using special tool, loosen flywheel from crankshaft.
CENDG2111B06002
Removal Special tool
(B): 09930–39220 (Flywheel remover)
! CAUTION
Failure to take proper precaution when
removing flywheel may result in personal
injury and/or damage to electronic
components.

Prior to removing flywheel, disconnect

battery cables from battery.
(B)
1) Remove the ring gear cover (1).

IDG2111B0015-01

4) Remove the flywheel bolt (1), washer (2), flywheel

1
(3) and key (4).

1
2

IDG211140023-02
3
2) Loosen flywheel bolt 2 – 3 turns in clockwise
direction.

NOTE 4
IDG2111B0016-01
Flywheel bolt is left hand thread.

NOTE
Do not remove flywheel bolt at this time.
This bolt prevents damage to the crankshaft
when using flywheel remover tools.

Special tool
(A): 09930–49220 (Flywheel holder)

(A)

IDG2111B0014-01
 Charging System: 1K-5

Installation 1) Remove flywheel.

Installation is reverse order of removal with special
attention to the following steps.
• Clean flywheel and crankshaft mating surfaces with
cleaning solvent.
• Apply engine oil lightly to flywheel bolt before
installing.
Refer to “Flywheel Removal and Installation” (Page
1K-4).
2) Disconnect battery charge coil lead wire connectors
(1).
3) Remove the bolt (2) securing air intake silencer
case.
4) Remove four bolts and battery charge coil (3).

1
2
IDG2111B0017-01

• Tighten flywheel bolt to specified torque.

Special tool IDG2111B0004-03
(A): 09930–49220 (Flywheel holder)
Installation
Tightening torque
Installation is reverse order of removal with special
Flywheel bolt (a): 245 N·m (24.5 kgf-m, 177.0 lbf-
attention to the following steps.
ft)
• Apply suzuki bond 1207B to the coil securing bolts.
: Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
• Install battery charge coil, then tighten bolts securely.

(A)

IDG2111B0018-01

• After installing flywheel and torquing bolt to

specification, check air gap between CKP sensor and
flywheel reluctor bars.
Refer to “CKP Sensor Removal and Installation” in
IDG2111B0006-02
Section 1C (Page 1C-10).
• Check that coil lead wires are routed properly and
away from hot or rotating parts.
Battery Charge Coil Removal and Installation
CENDG2111B06003 For wire routing, refer to “Wiring Harness Routing
Removal Diagram” in Section 4A (Page 4A-3).
• Install flywheel and tighten flywheel bolt to specified
! CAUTION
torque.
Failure to take proper precaution when Refer to “Flywheel Removal and Installation” (Page
removing electrical parts may result in 1K-4).
personal injury and/or damage to electronic
components.

Prior to removing electrical parts, disconnect

battery cables from battery.
1K-6 Charging System:

Battery Charge Coil Inspection 2) Disconnect battery charge coil lead wire connectors
CENDG2111B06004 (1) and EX. manifold temp. sensor lead wire
Measure battery charge coil resistance in the following connector (2).
procedure.
1) Disconnect battery charge coil leads from rectifier/
regulator.
2) Measure resistance between leads in the
combinations shown. 1
If measurement exceeds specification, replace
battery charge coil.
2
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (Ω) IDG2111B0020-01

Battery charge coil resistance 3) Remove bolt securing starter motor band, then
Terminal for tester probe connection Resistance remove ground lead wire (3) of rectifier/regulator.
White 1 to White 2
White 2 to White 3 0.15 – 0.25 Ω
White 3 to White 1

IDG2111B0021-01

4) Remove the nut and positive “Gr” lead wire (4) from
fuse box.

W
W
W

IDG2111B0008-01

Rectifier / Regulator Removal and Installation 4

CENDG2111B06005
Removal IDG2111B0022-01

! CAUTION 5) Remove nine bolts and rectifier/regulator (5).

Failure to take proper precaution when

removing electrical parts may result in
personal injury and/or damage to electronic 5
components.

Prior to removing electrical parts, disconnect

battery cables from battery.

1) Remove the lower side covers.

Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
IDG2111B0010-04

6) Remove the gasket.

 Charging System: 1K-7

Installation
Installation is reverse order of removal with special AC 2 AC 3
attention to the following steps. AC 1
• Replace the gasket with a new one. (+)

NOTICE
A previously-used gasket may leak, resulting (–) AC AC AC
in engine damage. Gr

Do not re-use gasket once removed. Always

use a new gasket.

• Connect lead wire connectors. Check that lead wire B

routed properly.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).

Rectifier / Regulator Inspection

CENDG2111B06006
Inspect the rectifier/regulator in the following procedures:
1) Disconnect all lead wires of rectifier/regulator.
2) Measure voltage between leads in the combinations
shown.
If measurement exceeds specification, replace
rectifier/regulator.
Special tool
: 09900–25008 (Multi circuit tester set) IDG2111B0019-04

Tester knob indication 3) Connect all lead wires of rectifier/regulator.

Diode test ( )
Unit: V Main Fuse Inspection
CENDG2111B06007
Tester probe (+) Inspect the main fuse in the following procedures.
+ – AC 1 AC 2 AC 3
1) Remove the main fuse from fuse box.
+ — 0.6 – 0.9 0.3 – 0.6 0.3 – 0.6 0.3 – 0.6
Tester – * — * * * 2) Inspect continuity between both terminal of fuse.
probe AC 1 * 0.3 – 0.6 — * * If no continuity is indicated, replace fuse.
(–) AC 2 * 0.3 – 0.6 * — * Special tool
AC 3 * 0.3 – 0.6 * * — : 09930–99320 (Digital tester)

*: 1.4 V or more (tester’s battery voltage) Tester knob indication

Continuity ( )
NOTE
If the tester reads 1.4 V or below when the
tester probes are not connected, replace its
battery.

CONT

I9J0111B0023-01
1K-8 Charging System:

Section 2
Mid Unit
CONTENTS
Precautions .................................................2-1
Precautions............................................................. 2-1
Precaution for Mid Unit ......................................... 2-1
Housing and Bracket............................... 2A-1
Precautions...........................................................2A-1
Precaution for Housing and Bracket ................... 2A-1
Service Instructions.............................................2A-2
Lower Side Cover Components .......................... 2A-2
Lower Side Cover Removal and Installation ....... 2A-3
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Components ....................................... 2A-4
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Disassembly ....................................... 2A-6
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Assembly............................................ 2A-8
Engine Holder / Oil Pan / Driveshaft Housing
/ Mounts Related Component Inspection ........ 2A-13
Clutch Shaft Bearing and Oil Seal
Replacement ................................................... 2A-14
Driven Gear Bearing and Oil Seal
Replacement ................................................... 2A-16
Clamp / Swivel / Steering Bracket
Components.................................................... 2A-17
Clamp / Swivel / Steering Brackets
Disassembly.................................................... 2A-19
Clamp / Swivel / Steering Brackets Assembly .. 2A-21
Clamp / Swivel / Steering Brackets Related
Components Inspection .................................. 2A-24
Power Trim and Tilt ................................. 2B-1
Precautions...........................................................2B-1
Precaution for Power Trim and Tilt...................... 2B-1
General Description .............................................2B-1
Power Trim and Tilt Description .......................... 2B-1
Principles of Power Trim and Tilt Operation
Description (One-Cylinder Type) ...................... 2B-4
Principles of Power Trim and Tilt Operation
Description (Three-Cylinder Type) .................... 2B-9
Schematic and Routing Diagram......................2B-15
Power Trim and Tilt System Diagram ............... 2B-15
Table of Contents 2- i
Diagnostic Information and Procedures ..........2B-16
2
Diagnose PTT System Malfunction...................2B-16
Service Instructions ...........................................2B-17
Checking PTT Fluid Level (One-Cylinder
Type) ...............................................................2B-17
Checking PTT Fluid Level (Three-Cylinder
Type) ...............................................................2B-17
Air Bleeding from PTT Unit ...............................2B-18
Setting of Trim Down Position Limit ..................2B-18
Setting Tilt Up Limit Position .............................2B-19
Power Trim and Tilt Unit Removal and
Installation (One-Cylinder Type) .....................2B-20
Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)...................2B-23
Power Trim and Tilt Unit Components (One-
Cylinder Type).................................................2B-27
Power Trim and Tilt Unit Components (Three-
Cylinder Type).................................................2B-28
Power Trim and Tilt Unit Disassembly (One-
Cylinder Type).................................................2B-29
Power Trim and Tilt Unit Reassembly (One-
Cylinder Type).................................................2B-30
Power Trim and Tilt Unit Components
Cleaning and Inspecting (One-Cylinder
Type) ...............................................................2B-32
Power Trim and Tilt Motor Removal and
Installation (One-Cylinder Type) .....................2B-33
Power Trim and Tilt Unit Disassembly (Three-
Cylinder Type).................................................2B-34
Power Trim and Tilt Unit Reassembly (Three-
Cylinder Type).................................................2B-36
Power Trim and Tilt Unit Components
Cleaning and Inspecting (Three-Cylinder
Type) ...............................................................2B-39
Power Trim and Tilt Motor Removal and
Installation (Three-Cylinder Type)...................2B-41
Power Trim and Tilt Motor Disassembly and
Assembly.........................................................2B-42
PTT Motor Related Items Inspection.................2B-43
PTT Motor Relay Inspection..............................2B-44
PTT Switch Inspection ......................................2B-45
2-1 Precautions:

Precautions
Mid Unit

Precautions
Precaution for Mid Unit
CENDG2112000001
Refer to “General Precautions” in Section 00 (Page 00-1).
 Housing and Bracket: 2A-1

Housing and Bracket

Mid Unit

Precautions
Precaution for Housing and Bracket
CENDG2112100001
NOTICE
Do not break or cut bonding wires, as they perform an important function in the prevention of galvanic
corrosion or build up of static charges.
Replace any damaged wire.

NOTE
• When dismantling housing and bracket, inspect mountings and bolts for damage and wear. Replace
if necessary.
• Check the condition of the zinc anodes on lower section of mid unit. Replace if necessary.
2A-2 Housing and Bracket:

Service Instructions
Lower Side Cover Components
CENDG2112106001

15

12
17 16
14
8
10 11 10
1
11
12 18

14 20

3
13 19
5
13
14
2

12
11
10

IDG211210001-02

1. PORT lower side cover 7. Pin 13. Engine cover hook 19. Cushion
2. STBD lower side cover 8. PORT hook lever 14. Bolt 20. Washer
3. Screw 9. STBD hook lever 15. Front hook lever : Apply water resistance grease.
4. Screw 10. Bushing 16. Front panel
5. Plug 11. Washer 17. Engine cover front hook
6. Side cover seal 12. Wave washer 18. Bolt
 Housing and Bracket: 2A-3

Lower Side Cover Removal and Installation

CENDG2112106002
Removal
1) Remove seven screws (1) and STBD lower side cover (2).

IDG211210002-02

2) Remove two screws (3) and PORT lower side cover (4).

IDG211210003-02

3) Disconnect PTT switch lead wire connector.

IDG211210004-02

Installation
Installation is reverse order of removal with special attention to the following step.
• Tighten lower side cover screws to specified torque.
Tightening torque
Lower side cover screw: 3 N·m (0.3 kgf-m, 2.0 lbf-ft)
2A-4 Housing and Bracket:

Engine Holder / Oil Pan / Driveshaft Housing / Mounts Components

CENDG2112106003

2 (a)
1

6
5
11
7
8 (b) 9
12

10 13

15

14

16 17
18 20 33

19

21
23 32
22 (e)
28 (c)

31
24

25

26

29 27

30 (d)
IDG211210005-07

1. Mount case cover 12. Bolt 23. Upper mount plate : 23 N⋅m (2.3 kgf-m, 16.5 lbf-ft)
2. Bolt 13. O-ring 24. Upper mount bolt : 22 N⋅m (2.2 kgf-m, 16.0 lbf-ft)
3. Gasket 14. Bolt 25. Washer : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft)
4. Engine holder gasket 15. Dowel pin 26. Upper mount : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft)
5. Oil seal 16. Bolt 27. Upper mount cover : 80 N⋅m (8.0 kgf-m, 58.0 lbf-ft)
6. Bolt 17. Circlip 28. Bolt : Apply engine oil.

7. Oil seal 18. Bearing 29. Washer : Apply SUZUKI water resistant grease.
8. Plug 19. Oil seal 30. Nut : Apply SUZUKI thread lock 1342.
9. Washer 20. Dowel pin 31. Oil strainer
10. Engine holder 21. Upper thrust mount 32. Bolt
11. Water return union 22. Nut 33. O-ring
 Housing and Bracket: 2A-5

6
3 (a)
7

8 9
2

5
4

10 12
11

15 13

16
17
21
20
22

28
14
27

23
24
19 18 (c)
29
25
31 30
32

26 (b)
IDG211210006-03

1. Gasket 11. Water plug 21. Washer 31. Bonding wire

2. Gasket 12. Bushing 22. Stopper 32. Screw
3. Oil drain plug 13. Water tube 23. Lower mount : 13 N⋅m (1.3 kgf-m, 9.5 lbf-ft)
4. Oil pan 14. Bushing 24. Washer : 60 N⋅m (6.0 kgf-m, 43.0 lbf-ft)
5. Bolt 15. Bolt 25. Washer : 50 N⋅m (5.0 kgf-m, 36.0 lbf-ft)
6. Indicator tube cover 16. Driveshaft housing 26. Bolt : Apply SUZUKI thread lock 1342.
7. O-ring 17. Pin 27. Lower mount bracket : Apply SUZUKI silicon seal.
8. Indicator tube 18. Bolt 28. Lower thrust mount
9. Exhaust pipe 19. Lower mount cover 29. Bush (w/transomX)
10. O-ring 20. Nut 30. Circlip
2A-6 Housing and Bracket:

Engine Holder / Oil Pan / Driveshaft Housing / 6) Remove STBD/PORT lower mount nuts (6) and
Mounts Disassembly lower mount bolts (7).
CENDG2112106004 Remove lower mounts (8).
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-10).
2) Remove the lower unit.
Refer to “Lower Unit Removal and Installation” in
Section 3A (Page 3A-5).
3) Disconnect water hoses (1) and (2).

7 8 6

IDG211210010-01

7 6
IDG211210007-02
8
4) Remove the screw and bonding wire (3). IDG211210011-01

7) Remove two upper mount nuts (9) and washers.

IDG211210008-01

5) Remove the bolt (4) securing the STBD/PORT lower IDG211210012-01

mount covers, then detach the lower mount covers
8) Remove driveshaft housing with oil pan.
(5).

IDG211210013-02
IDG211210009-01
 Housing and Bracket: 2A-7

9) Remove four bolts and mount case cover (10). 13) Remove four bolts (17) and the engine holder (18).

18

17
10

IDG211210014-02 IDG211210018-01

10) Remove the gasket (11) and upper thrust mount

(12).
18

11 12

17

IDG211210019-03

14) Remove the dowel pins (19) and gasket (20).

IDG211210015-02

11) Remove two nuts (14) securing upper mount plate

(13), then remove upper mount plate (13).

19

13

20

IDG211210087-01

14 15) Remove oil strainer bolts (21) and oil strainer (22).

IDG211210016-01

12) Remove four bolts (16) securing upper mount cover

(15), then remove upper mount assemblies.

22
16
21

15 15 IDG211210020-03

IDG211210017-02
2A-8 Housing and Bracket:

16) Loosen and remove the clutch shaft plug (23). 19) Remove two bolts, water pressure valve cover (27)
and water pressure valve (28).

23

28

27

IDG211210025-04

17) Push the clutch shaft (24) down to free it from the IDG211210023-03

engine holder. 20) Remove the pins (29) and water tube (30).

29
24
30

29

IDG211210064-03 IDG211210022-02

18) Remove eight bolts (25) and oil pan (26).

Engine Holder / Oil Pan / Driveshaft Housing /
Mounts Assembly
CENDG2112106005
Assembly is in reverse order of disassembly with special
26
attention to the following steps.

Driveshaft Housing
• Install water tube (1).
25

IDG211210021-03

IDG211210026-01
 Housing and Bracket: 2A-9

Water Pressure Valve Clutch Shaft

• Install O-ring (2) to pressure valve cover (4). • Slide the clutch shaft (9) into place.
• Install pressure valve (3) and pressure valve cover (4)
to oil pan and secure with bolts.
Refer to “Water Pressure Valve Removal and 9
Installation” in Section 1F (Page 1F-4).

2
IDG211210043-03

4 • Tighten the clutch shaft plug (10), pre-coated with

4
thread lock, to specified torque.
Tightening torque
IDG211210045-03
Clutch shaft plug (a): 22 N·m (2.2 kgf-m, 16.0 lbf-
ft)
Oil Pan / Driveshaft Housing
• Install two dowel pins (5) to driveshaft housing (6). : Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
• Install the oil pan (7) to driveshaft housing (6) by
aligning the water tube with the oil pan water passage.
Tighten the eight bolts (8) securely. 10 (a)

NOTE
Apply sealant to mating surfaces of
driveshaft housing and oil pan.

: Sealant 93691–80030 (SUZUKI Silicone Seal

(100 g))

7
IDG211210044-03

Engine Holder
• Apply engine oil to O-rings (11), then install the O-
rings to oil strainer (12).
• Install oil strainer to engine holder, then tighten bolts
securely.
5 6
12
IDG211210027-03

12

7 11

8 6
IDG211210029-03

IDG211210028-04
2A-10 Housing and Bracket:

• Install two dowel pins (13) and gasket (14) to oil pan. Upper Mount
• Place washer (18) and upper mount (19) on upper
NOTICE
mount bolts (17).
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage. NOTE
Install the washer (18) to the mount bolt as its
Do not reuse gasket. Always assemble with a chamfered side faces to the bolt head as
new gasket. shown in the figure.

13 14

18

13
19

17
IDG211210030-03
IDG211210033-04
• Install engine holder (15) to oil pan, then securely • Install the upper mount plate (20) into the upper
tighten it with bolts (16). mount bolts.
• Apply Thread Lock 1342 to threads of upper mount
plate nuts (21), then install the upper mount plate nuts
(21).
16 Do not tighten plate nuts at this time.

NOTE
Set the upper mount plate (20) in place with
the “UP” mark upward.

15

IDG211210031-05

UP
20

15

IDG211210035-03
16

IDG211210032-05

17

20 21
21

IDG211210034-05
 Housing and Bracket: 2A-11

• Install upper mount covers (22), then tighten upper • Install upper thrust mount (24).
mount cover bolts (23), pre-coated with thread lock, to
specified torque.

NOTE 24
Rib of upper mount cover (22) must be
placed outside.

: Thread lock cement 99000–32050 (SUZUKI

Thread Lock 1342 (50 g))
Tightening torque
Upper mount cover bolts (b): 50 N·m (5.0 kgf-m,
36.0 lbf-ft) IDG211210039-03

• Install gasket (25) and mount case cover (26), then

tighten four bolts (27) to specified torque.
Tightening torque
Mount case cover bolt (d): 23 N·m (2.3 kgf-m, 16.5
lbf-ft)

22

25

IDG211210037-03

23 (b)

IDG211210040-04

22 22 27 (d) 26

IDG211210036-03

• Tighten upper mount plate nuts (21), pre-coated with

thread lock, to specified torque.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
IDG211210041-04
Tightening torque
Upper mount plate nut (c): 80 N·m (8.0 kgf-m,
58.0 lbf-ft)

21 (c)
IDG211210038-03
2A-12 Housing and Bracket:

Oil Pan / Driveshaft Housing
• Install engine holder/oil pan to steering bracket.
• Install washer (28) and upper mount nut (29), then
tighten two nuts, pre-coated with thread lock, to
specified torque.
Tightening torque
Upper mount nut (e): 80 N·m (8.0 kgf-m, 58 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
• Install lower mount covers (37) to driveshaft housing,
then tighten mount cover bolts (38), pre-coated with
thread lock, to specified torque.
Tightening torque
Lower mount cover bolt (g): 50 N·m (5.0 kgf-m,
36.0 lbf-ft)
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))

37
28

29 (e)

38 (g)
IDG211210048-04

IDG211210042-04
Bonding Wire
Lower Mount / Bolt / Nut • Reattach the bonding wire (39), then tighten screw
securely.
• Place washer (30), damper (31), lower mount (32)
and washer (33) into driveshaft housing.
• Install lower mount bolt (34) and washer (35), then
tighten mount bolt with nut (36), pre-coated with
thread lock, to specified torque.
Tightening torque
Lower mount bolt (f): 60 N·m (6.0 kgf-m, 43.0 lbf-
ft)
: Thread lock cement 99000–32050 (SUZUKI 39
Thread Lock 1342 (50 g))

IDG211210049-04
36
• Install the lower unit.
Refer to “Lower Unit Removal and Installation” in
Section 3A (Page 3A-5).
• Install the power unit.
Refer to “Power Unit Removal and Installation” in
35 33 Section 1D (Page 1D-10).
31 30
34 (f) 32
IDG211210046-04

34 (f)

IDG211210047-03
 Housing and Bracket: 2A-13

Engine Holder / Oil Pan / Driveshaft Housing / Oil Strainer

Mounts Related Component Inspection • Inspect the oil strainer. Replace the strainer if
CENDG2112106006
cracked, damaged or other abnormal conditions are
Refer to “Engine Holder / Oil Pan / Driveshaft Housing /
found.
Mounts Disassembly” (Page 2A-6) and “Engine Holder /
If clogged or obstructed, clean the oil strainer.
Oil Pan / Driveshaft Housing / Mounts Assembly” (Page
2A-8). • Check condition of O-ring. Replace O-ring if nicked,
cut, worn or other abnormal condition are found.
NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.

Engine Holder
• Inspect the engine holder. Replace if cracked,
damaged, or other abnormal conditions are noted.
• Check water passage. If clogged or obstructed, clean
water passage.
• Visually check the clutch shaft bearing. Replace if
IDG211150013-02
pitted, noisy, rough or other abnormal conditions are
found.
Oil Pan / Driveshaft Housing
• Check the clutch shaft oil seal. Replace the oil seal if
• Check oil pan, driveshaft housing.
nicked, cut, worn or other abnormal conditions are
If cracks, defects or other damage is found, replace it.
found.

IDG211210053-01
IDG211210050-01

Mount Case Cover

• Inspect the mount case cover. Replace the mount
case cover if cracked, damaged or other abnormal
conditions are found.

IDG211210051-01
2A-14 Housing and Bracket:

Mounts Clutch Shaft Bearing and Oil Seal Replacement

CENDG2112106007
• Check upper, lower and thrust mounts.
1) Remove the engine holder.
If excessive wear, corrosion or other damage is found,
Refer to “Engine Holder / Oil Pan / Driveshaft
replace mount.
Housing / Mounts Disassembly” (Page 2A-6).
• Inspect mount cover. Replace mount cover if cracked,
2) Extract oil seal (1) with oil seal remover.
damaged or other abnormal conditions are found.
NOTICE
Removing the oil seal can cause damage to
the seal lips, causing oil to leak.

Do not reuse oil seal once removed.

Always use a new oil seal.

Special tool
(A): 09913–50121 (Oil seal remover)

IDG211210054-01
(A)
Water Tube / Water Tube Grommet
• Check water tube.
If a clog or obstruction is found, clean water tube.
If cracks, corrosion or other damage is found, replace
water tube.
1
• Check water tube grommet.
If excessive wear or other damage is found, replace
grommet. IDG211210056-01

3) Remove circlip (2).

IDG211210055-01

IDG211210057-01
 Housing and Bracket: 2A-15

4) Remove bearing (3) with special tool and sliding 6) Apply water resistant grease to outer circumference
hammer. of oil seal (5).
Drive oil seal into engine holder.
NOTICE Apply water resistant grease to the seal lip.
Removing the bearing can cause damage to
the ball retainer. NOTE
If the removed bearing is re-used, problem Install oil seal as shown in the figure.
will occur in shift system.
: Grease 99000–25350 (SUZUKI Water
Do not reuse the bearing once removed. Resistant Grease EP2 (250 g))
Always use a new bearing.

Special tool
(B): 09923–73210 (Bearing remover)
(C): 09930–30104 (Sliding hammer) 5

IDG211210060-02

7) Install circlip (6).

(B) Install clutch shaft (7).
Tighten the clutch shaft plug (8), pre-coated with
(C)
thread lock, to specified torque.
IDG211210058-01
Tightening torque
5) Apply engine oil to outer circumference of bearing
Clutch shaft plug (a): 22 N·m (2.2 kgf-m, 16.0 lbf-
(4).
ft)
Install bearing (4) into engine holder.
: Thread lock cement 99000–32050
(SUZUKI Thread Lock 1342 (50 g))

7 8 (a)

6
IDG211210059-02

IDG211210065-01

8) Reassemble the engine holder.

Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Assembly” (Page 2A-8).
2A-16 Housing and Bracket:

Driven Gear Bearing and Oil Seal Replacement
CENDG2112106009
1) Remove the engine holder.
Refer to “Engine Holder / Oil Pan / Driveshaft
Housing / Mounts Disassembly” (Page 2A-6).
2) Remove bearing (1) with special tool and sliding
hammer.
NOTICE
Removing the bearing can cause damage to
the ball retainer.
If the removed bearing is re-used, problem
will occur in the reduction system.
4) Apply water resistant grease to outer circumference
of oil seal.
5) Drive the oil seal into the engine holder.
NOTE
Install driveshaft upper and driven gear oil
seals with lip (spring side) facing as shown in
figure.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

Do not re-use the bearing once removed.

Always use a new bearing.

Special tool
(A): 09941–64511 (Bearing remover)
(B): 09930–30104 (Sliding hammer)

IDG211210061-01

1 6) Apply engine oil to outer circumference of bearing

(1). Install bearing into engine holder.
(A)

(B)

IDG211210088-01

3) Extract oil seal (2) with oil seal remover.

Special tool
(C): 09913–50121 (Oil seal remover)
1
IDG211210062-01

7) Reassemble the engine holder.

(C)
Refer to “Engine Holder / Oil Pan / Driveshaft
2
Housing / Mounts Assembly” (Page 2A-8).

IDG211210089-02
 Housing and Bracket: 2A-17

Clamp / Swivel / Steering Bracket Components

CENDG2112106010
DF100A / 115A

4 (a)
5
15 14
13
12 16

27
28

1
30 34
23 28
29 35
37
22 12
24 31 36 13
33 38
25 2
32
26

40
16 39

17
18 22 3
19 23

20
6
10
21
7

11

10
9
8
IDG211210090-04

1. STBD clamp bracket 12. Bolt 23. Washer 34. Washer

2. PORT clamp bracket 13. Washer 24. Grease nipple 35. Pin
3. Clamp bracket shaft 14. Steering bracket 25. Screw 36. Nut
4. Nut 15. Washer 26. Clamp 37. Tilt lock lever PORT
5. Washer 16. Bushing 27. Tilt lock lever 38. Rubber
6. Anode 17. Oil seal 28. Bushing 39. Bonding wire
7. Bolt 18. Washer 29. Spring 40. Screw
8. Bolt 19. Shim 30. Link : 43 N⋅m (4.3 kgf-m, 31.0 lbf-ft)
9. Washer 20. Lower mount bracket 31. Spring : Apply SUZUKI water resistance grease.
10. Bushing 21. Circlip 32. Bracket
11. Lower shaft 22. Bushing 33. Screw
2A-18 Housing and Bracket:

DF140A

15
4 (a) 13
5
12 16

14
27

28

1 28 30 34 25
23
29
37 35
22 24 31 36 26
12
25 13
33 38

26 32 2

40
16 3
39
17
18
22
19 23

20

9
21 6 41
10
8 7 42

11

10
9
IDG211210091-04

1. STBD clamp bracket 12. Bolt 23. Washer 34. Washer

2. PORT clamp bracket 13. Washer 24. Grease nipple 35. Pin
3. Clamp bracket shaft 14. Steering bracket 25. Screw 36. Nut
4. Nut 15. Washer 26. Clamp 37. Tilt lock lever PORT
5. Washer 16. Bushing 27. Tilt lock lever 38. Rubber
6. Anode 17. Oil seal 28. Bushing 39. Bonding wire
7. Bolt 18. Washer 29. Spring 40. Screw
8. PTT unit 19. Shim 30. Link 41. Tilt pin
9. Bolt 20. Lower mount bracket 31. Spring 42. Nut
10. Bushing 21. Circlip 32. Bracket : 43 N⋅m (4.3 kgf-m, 31.0 lbf-ft)
11. Lower shaft 22. Bushing 33. Screw : Apply SUZUKI water resistance grease.
 Housing and Bracket: 2A-19

Clamp / Swivel / Steering Brackets Disassembly 7) Remove bolt (11) and trim sensor (12).
CENDG2112106011 Cut the cable tie (13) securing sensor lead wire.
1) Remove engine holder/oil pan and driveshaft
housing.
Refer to “Engine Holder / Oil Pan / Driveshaft 12
Housing / Mounts Disassembly” (Page 2A-6).
2) Remove screw and bonding wire (1) from lower
mount bracket.
3) Remove circlip (2). 13 11

2 IDG211210093-01

8) Slide the lower trim sensor cam plate (14) off.

9) Remove the upper trim sensor cam (15) from clamp
bracket shaft.
1

15
IDG211210066-02

4) Remove lower mount bracket (3), shims (4), and

washer (5) from the steering bracket.

14

5 IDG211210069-02

4 10) Connect the special tool to PTT motor and raise the
swivel bracket.
3 Special tool
: 09945–79310 (PTT cable extension)
IDG211210067-02 Remove circlip (16) and push out tilt cylinder upper
5) Lift steering bracket (6) upward to remove from rod (17).
swivel bracket.
Remove washer (7) and upper bushing (8).
6) Remove swivel bracket seal (9) and lower bushing
(10).

17
6 10
9

16
7
8
IDG211210092-01

IDG211210068-02
2A-20 Housing and Bracket:

11) Remove nut and tilt pin (18). 13) Remove screw and bonding wire (25) from swivel
Remove PTT cylinder lower shaft bolts (19). bracket.
Remove bolts and anode (20). Slide STBD clamp bracket (26) off clamp bracket
Remove screw and bonding wire (21). shaft.
Remove PTT unit.
Refer to “Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)” in Section 2B
(Page 2B-23).
18

19

25

20 21 26
IDG211210070-03

12) Using flat blade screw driver, drive locking edge of

lock washer (22) to clamp bracket side.
Remove the two STBD motor mounting bolts (23).
Remove the clamp bracket shaft nut (24) and IDG211210073-04

washer. 14) Remove the bolt (27) securing clamp bracket shaft to
PORT clamp bracket.
Remove PORT motor mounting bolt.

22

27
24

23
IDG211210072-03

IDG211210074-03

15) Pull PORT clamp bracket (30) outward to remove

clamp bracket and bracket shaft (28) from swivel
bracket (29).
Remove washer (31) and bushing (32) from each
side of swivel bracket.

29 30

28
32 31
31 32
IDG211210075-02
 Housing and Bracket: 2A-21

Clamp / Swivel / Steering Brackets Assembly • Apply Thread Lock 1342 to threads of shaft bolt (6)
CENDG2112106012 before threading it to PORT clamp bracket.
Assembly is reverse order of disassembly with special
Install the shaft bolt (6), then tighten it securely.
attention to the following steps.
• Tighten PORT motor mounting bolt (7).
Clamp Bracket / Swivel Bracket : Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
NOTE
Before installing clamp bracket to swivel
bracket, apply grease to clamp bracket shaft
and bushings. 6

: Grease 99000–25350 (SUZUKI Water Resistant

Grease EP2 (250 g))
• Insert PORT and STBD bushings (2) into the swivel
bracket (1).
7

IDG211210094-02

1 • Install PTT unit assembly.

Refer to “Power Trim and Tilt Unit Removal and
Installation (One-Cylinder Type)” in Section 2B (Page
2B-20) or “Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)” in Section 2B
(Page 2B-23).
• Install washer (8), STBD clamp bracket (9), lock
2 2 washer (10) and clamp bracket shaft nut (11).
IDG211210076-02
• Tighten clamp bracket shaft nut (11) to specified
• Assemble PORT clamp bracket (4), washer (5), clamp torque.
bracket shaft (3) and swivel bracket (1).
Tightening torque
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
31.0 lbf-ft)

9
3
4
5
1
IDG211210077-02

IDG211210095-01

10

11 (a)

IDG211210078-03
2A-22 Housing and Bracket:

• After tightening clamp bracket shaft nut to specified

torque, bend lock washer (10) edge toward nut to
secure nut. 3

4
5

10

IDG211210097-03

Steering Bracket
IDG211210079-04 • Apply water resistant grease to steering bracket shaft.

Trim Sensor and Trim Sensor Cam : Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
• Install the upper trim sensor cam (1) engaging its
locating pin “A” with the clamp bracket shaft hole “B”. NOTE
Apply grease to bushings, oil seal lip and
pilot shaft portion of steering bracket.
1
• Install upper bushing (1) and washer (2) to swivel
“A”
bracket.
• Install lower bushing (3) and swivel bracket seal (4) to
swivel bracket.
“B” NOTE
Install bracket seal (4) with oil seal lip (spring
side) facing downward.
IDG211210099-02

• Install the lower trim sensor cam plate (2). • Install steering bracket (5) to swivel bracket.

5
2

IDG211210096-03

• Install the trim sensor assembly (3), then secure it 2

with bolts (4). 1
• Secure white taping point of sensor lead wire with
3
cable tie (5).
4

“A”
IDG211210098-02

1. Upper bushing 4. Swivel bracket seal

2. Washer 5. Steering bracket
3. Lower bushing “A”: Seal lip
 Housing and Bracket: 2A-23

Lower Mount Bracket Lubrication

• Install washer (1) and shim (2), and then slide the After completing reassembly of the mid unit, apply
lower mount bracket (3) upward on the splines until it grease through each grease nipple.
contacts the shim. : Grease 99000–25350 (SUZUKI Water Resistant
Grease EP2 (250 g))

IDG211210080-02

• Install circlip (4) to retain lower mount bracket. IDG211210083-01

• Install lower thrust mount (5) to lower mount bracket.

IDG211210084-02
IDG211210081-02

Bonding Wire
Reattach bonding wires to swivel bracket and tighten
screws securely.

IDG211210082-02
2A-24 Housing and Bracket:

Clamp / Swivel / Steering Brackets Related Clamp Bracket Shaft

Components Inspection Check clamp bracket shaft.
CENDG2112106013 If clamp bracket shaft is bent or twisted, replace shaft.
Refer to “Clamp / Swivel / Steering Brackets
Disassembly” (Page 2A-19) and “Clamp / Swivel /
Steering Brackets Assembly” (Page 2A-21).

NOTE
If any component is found to be excessively
worn, cracked, defective or damaged in any
way, it must be replaced.

Bushings
Check all bushings. If excessive wear or other damage
is found, replace bushing. If bushing fit is loose when
installing, replace bushing. I9J011210120-01

Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).

IDG211210085-02

Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal.
IDG211210086-02

I9J011210118-01
 Power Trim and Tilt: 2B-1

Power Trim and Tilt

Mid Unit

Precautions
Precaution for Power Trim and Tilt
CENDG2112200001
! WARNING
Failure to take proper precaution when servicing a PTT unit can cause severe personal injury.

Be sure to take the following precautions when servicing the PTT system:
• During removal or installation of PTT unit, the engine must be firmly secured and its weight fully
supported by the hoist.
• Before checking PTT fluid level, tilt the motor to the full-up position and engage the tilt lock lever.

NOTE
• To prevent system malfunctions, ensure that all components are kept free from dirt or
contamination.
• Reinstall all O-rings, seals, springs etc. with the component(s) to which they belong. This will
prevent possible confusion and will ensure correct reassembly.

General Description
Power Trim and Tilt Description
CENDG2112201001
• There are two kinds of PTT system on these models.
One is three-cylinder type (DF140A) and the other is one-cylinder type (DF100A/115A).
• The power trim and tilt system components are an electric motor, a pump unit, a fluid reservoir and trim/tilt
cylinder(s).
The outboard can be trimmed “UP” or “DOWN” while under way, and can be tilted for beaching, operating in shallow
water or trailering.
Trim and tilt “UP” or “DOWN” is obtained by supplying power to a permanent magnet type motor. This motor will
rotate clockwise for “UP” or counterclockwise for “DOWN”, according to power delivered via the PTT relay, which is
mounted on the electric part holder.
• The PTT relay is controlled by the ECM.
The ON/OFF signal for the PTT UP or DOWN is inputted to the ECM PTT relay drive circuit from ECM terminals
No.18 or 19 and the output signal from terminals No.35 or 44.

NOTE
With the ignition switch in the OFF position, and the PTT switch operated, the tilt/trim will operate.
With the ignition switch in the OFF position, operating the PTT switch will supply a 12 V power signal
to the ECM.
When this signal is received, the ECM operates the main relay (ON), allowing the ECM drive signal to
feedback to the ECM and the PTT relay circuit.
Thus the PTT system functions only if the PTT switch is operated.
When the PTT switch signal turns from ON to OFF and a predetermined time has elapsed, the ECM
drive voltage will be interrupted automatically.
2B-2 Power Trim and Tilt:

Power Trim and Tilt Hydraulic Diagram

One-cylinder type

1
2

3
20 19
18 17 4
21
5

22

14 6

7
15 16
11 8

13
12 9

10

I9J011220001-02

1. PTT motor 9. Free piston 17. “DOWN” relief valve

2. Tilt rod 10. Lower cylinder chamber 18. Spool valve No.1
3. Oil reservoir 11. Manual release valve 19. Check valve No.1
4. Tilt cylinder upper chamber 12. Thermal valve 20. Check valve No.2
5. Floating tube 13. 2-way valve 21. Spool valve No.2
6. Trim cylinder upper chamber 14. Gear pump 22. “DOWN” pressure main check valve
7. Tilt piston 15. “UP” pressure main check valve
8. Trim piston 16. “UP” relief valve
 Power Trim and Tilt: 2B-3

Three-cylinder type

10
1

15

3
17
13
4 18

5
8

2 14

12
7 16

6
19

11

20
IDG211220029-01

1. PTT motor 8. Up relief valve 15. Gear pump

2. Up check valve 9. Free piston 16. Down relief orifice
3. Up shuttle valve 10. Oil reservoir 17. Filter
4. Down shuttle valve 11. Trim rod 18. Tank room orifice
5. Down check valve 12. Manual release valve 19. Impact relief valve
6. Tilt cylinder Upper chamber 13. Pump room orifice 20. Cylinder body
7. Down relief check valve 14. Tilt rod
2B-4 Power Trim and Tilt:

Principles of Power Trim and Tilt Operation Description (One-Cylinder Type)

CENDG2112201002
By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will
change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder.

Trim / Tilt Up Circuit

• When the PTT switch is operated “UP” position, the electric motor and gear pump (1) will rotate on clockwise
direction.
• Pressurized oil will open check valve (2), oil will flow from the reservoir to spool valve (3) via the pump and spool
valve (4).
• Operation of spool valve (3) in the “DOWN” direction will cause the main check valve (5) to open.
• Oil in the upper chamber of the cylinder will return to the pump via a 2-way valve.
Then the oil pressure will rise and open the “UP” pressure main check valve (6), then allowing oil to flow to the lower
chamber of cylinder.
This makes the piston rod push up and the engine tilt up.
• Oil flows from the reservoir to the pump through check valve (2).
Oil flows through the “DOWN” pressure main check valve (5) and returns to the pump.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check
valve (6) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full tilt up position is attained, sustained operation of the “UP” relay will cause oil flow to be returned to the
reservoir through the “UP” relief valve (7).

2
4

3 7

5 1 6

I9J011220002-01
 Power Trim and Tilt: 2B-5

Trim / Tilt Down Circuit

• When the PTT switch is operated in the “DOWN” position, the electric motor will rotate in a counterclockwise
direction and turn the gear pump.
• Check valve (1) will open; oil will flow from the reservoir to the spool valve (2).
This makes spool valve (3) move to downward, and causes the “UP” pressure main check valve (4) to open.
• Oil in the lower chamber will return to pump, and then oil pressure increase will open the “DOWN” pressure main
check valve (5), allowing oil flow to the upper chamber of cylinder.
This makes the piston rod push down and the engine will tilt down.
• Oil flows from the reservoir to the pump through check valve (1).
Surplus oil in the pump flows through the “DOWN” relief valve (6) and returns to the reservoir.
• When the trim motor stops, both the “DOWN” pressure main check valve (5) and the “UP” pressure main check
valve (4) will close to retain tilt/trim position.
• In the trim area, the trim piston and floating tube are moving with the piston rod.
• When full trim/tilt down position is attained, sustained operation of the “DOWN” relay will cause oil to be returned to
the reservoir through the “DOWN” relief valve (6).

6
2

I9J011220003-02
2B-6 Power Trim and Tilt:

Shock Absorber Circuit

Shock valve
Should the lower unit strike an underwater object while in motion, the piston will rise abruptly, creating a sudden high
impact pressure in the upper cylinder chamber (1). The shock valve (2) will then open, allowing oil to flow into the area
between the tilt ram piston (3) and the free piston (4), thereby dampening (absorbing) the impact.
Return valve
When the point of impact has passed, propeller thrust and motor weight will force the tilt ram piston back downward.
The oil from between the ram piston (3) and the free piston (4) is then expelled through the return valve (5) before
flowing into the upper cylinder chamber (1).

1
5

I9J011220004-01
 Power Trim and Tilt: 2B-7

Manual Release Circuit (Manual Valve)

Turn the manual valve a maximum of three full turns counterclockwise.
When the manual release valve (1) is loosened, oil will flow unimpeded (without resistance) through the internal pump
tubes, thereby facilitating manual tilting or lowering of the outboard. To hold the engine in a selected position, the
manual valve must be closed again.

: Tilt “DOWN”

: Tilt “UP”

I9J011220005-02
2B-8 Power Trim and Tilt:

Thermal Valve
As temperature goes up, oil pressure will increase and the oil in PTT unit will expand.
High oil pressure in the upper cylinder chamber (1) caused by rising temperature will release the thermal valve (2) and
make the oil flow to the reservoir to prevent damage to the PTT unit.

I9J011220006-01
 Power Trim and Tilt: 2B-9

Principles of Power Trim and Tilt Operation Description (Three-Cylinder Type)

CENDG2112201004
By motor operation, the geared pump will be driven, and by turning the motor to the right or to the left, oil flow will
change its direction. This causes “UP” and “DOWN” movements of the piston rod of the tilt cylinder and the trim rod of
the trim cylinder.

Trim / Tilt Up Circuit

• When the PTT switch is operated “UP” position, the electric motor and gear pump (1) will operation on clockwise
direction.
• Pressurized oil will open “Up” check valve (2) and the oil will flow through “Up” shuttle valve (3) to the “Down” shuttle
valve (4). Following operation of valve (4), “Down” check valve (5) will open mechanically.
• Pressurized oil flows through the “Up” check valve (2) to the bottom of the trim and tilt cylinders, thereby pushing the
trim and tilt pistons upward.
• Residual oil in the upper area of the tilt cylinder (6) is returned to the pump through “Down” check valve (5).
• Any oil in the area above both trim cylinder pistons will be returned to the reservoir.
• Oil will then flow from the reservoir to the pump to stabilize the balance of the oil volumes.
• When the engine is fully tilted up, oil pressure will correspondingly increase in the lower chamber of the tilt and trim
cylinders. But, to protect the PTT unit from excessively high pump pressure, the “Up” relief valve (8) begins to open.

4 8

5
2

7
6

IDG211220030-01
2B-10 Power Trim and Tilt:

Trim / Tilt Down Circuit

• When the PTT switch is operated in the “DOWN” position, the electric motor will rotate in a counterclockwise
direction and turn the gear pump.
• The oil pressure will open the “Down” check valve (1) and oil will be forced through the “Down” shuttle valve (2).
When the oil reaches “Up” shuttle valve (3), the “Up check valve (4) will begin to open mechanically.
• The pressurized oil flows through “Down” check valve (1) and then enters the upper area of the tilt cylinder.
This thereby forces the tilt rod piston downward.
• When the swivel bracket contacts the trim rams, this pressure forces the trim pistons downward and oil from the
reservoir is then able to enter the area above both trim rod pistons.
• Oil from the lower area of the trim and tilt cylinders now returns to the pump through “Up” check valve (4).
• Throughout the tilt action operation range, there is a difference in oil volume between the upper and lower
chambers of the tilt cylinder, and any surplus oil is therefore directed to the reservoir by means of the “Down” relief
orifice (5).
• Throughout trim operation range, oil will be discharged from the bottom of all three cylinders and the pump will only
supply oil to the tilt cylinder. Excess oil is then vented to the reservoir through the “Down” relief orifice (5).
• To prevent damage from excessive oil pressure when all three rods are fully retraced, this pressure is relieved
through the “Down” relief orifice (5).

3
2
4

IDG211220031-01
 Power Trim and Tilt: 2B-11

Shock Absorber Circuit

This incorporated safety feature is for protection of the gearcase and prevention of internal PTT pressure build-up in
the event of an impact.
• The pressure from a sudden impact will make impact relief valve (1) open, allowing oil from the upper area of the tilt
cylinder to flow into the area between the tilt rod piston and the free piston. The tilt rod will then extend.
• When the moment of impact has passed, the PTT DOWN switch must be activated to return the engine to within the
normal trim range. When the switch is pressed, the oil between the piston and free piston will be directed to the
cylinder upper chamber via the return valve below the tilt piston.

IDG211220032-01
2B-12 Power Trim and Tilt:

Manual Release Circuit (Down Mode)

• By opening the manual release valve (1), the engine can be lowered manually to a running position. Oil underneath
the trim and tilt pistons will be directed through this valve into the area above the tilt rod piston.
• The volume of oil flowing from under the trim rod pistons will be larger than the area above the tilt rod piston can
accommodate. Excess oil therefore returns through the manual release valve (1) to the reservoir.

IDG211220033-01
 Power Trim and Tilt: 2B-13

Manual Release Circuit (Up Mode)

• With the manual release valve (1) open, the engine can also be raised manually to the fully tilted position.
• Oil from the upper chamber of the tilt cylinder will flow through valve (1) into the lower chamber of the cylinder.
• The upward movement of the piston rod will increase the cylinder area beneath it, thereby allowing oil from the
reservoir to flow into this area.

IDG211220034-01
2B-14 Power Trim and Tilt:

Tilt System Pressure Relief

• If engine speed exceeds approx. 1500 r/min when operating in shallow water drive mode, oil pressure will increase
underneath the tilt piston. The relief valve (2) (incorporated in the manual release valve (1)) will then open.
• The oil below the tilt piston will then flow to the reservoir through the relief valve (2).
• As the power of the engine continues to exert downward force on the tilt piston, this will open “Down” check valve
(3), thereby allowing oil from the reservoir to flow into the chamber above the tilt piston.
• In this way, high internal pressure is relieved and the engine will slowly tilt downward until it reaches the highest
position in the Trim range.

Thermal Expansion Relief

• High ambient temperature will, through thermal expansion, induce a build-up of oil pressure inside the PTT unit.
• Expansion of the oil and the resulting high pressure will open the relief valve (2), thereby providing unit protection by
directing oil back to the reservoir.
Expanded oil in the tilt cylinder upper chamber will return to reservoir passing through impact relief valve (4) → free
piston check valve (5) → thermal relief valve (2).

IDG211220035-02
 Power Trim and Tilt: 2B-15

Schematic and Routing Diagram

Power Trim and Tilt System Diagram
CENDG2112202001

8 9 11 12 7
R M

R
2

W B BATT
6
W/R
10
Lbl
P
R/B
W

B B/W

3 1
4
Lg

W-tube

Lbl
Lg
R
Lbl
Gr

W/R
P
Lbl
P

19 18

START
14 35 OFF
ON
5
B GND
ECM
W BATT
17 44 Gr IGN
Br START

34
B/Bl

IDG211220001-05

1. PTT switch (Remote control box) 5. Ignition switch 9. ECM fuse 30 A

2. PTT switch (Side cover) 6. Battery 10. PTT switch fuse 15 A
3. PTT motor relay 7. Starter motor 11. Load fuse 60 A
4. PTT motor 8. ECM main relay 12. Main fuse 60 A
2B-16 Power Trim and Tilt:

Diagnostic Information and Procedures

Diagnose PTT System Malfunction
CENDG2112204001

Condition Possible cause Correction / Reference Item

Motor will not trim/tilt at Blown fuse for PTT system. Inspection and replace.
all (No up, no down). (Main: 60 A, Load: 60 A, PTT switch: 15
A, ECM: 30 A).
Defective PTT switch. Replace.
Open circuit between main fuse 60 A Repair.
and PTT relay.
Defective main relay. Replace.
Defective PTT relay. Replace.
Defective ECM and/or PTT system Inspection of ECM and its circuit in section 1A.
circuit.
Open circuit between main fuse and Repair.
starter motor magnetic switch.
Defective PTT motor armature. Replace.
Defective PTT motor armature brushes. Replace.
Defective PTT pump. Replace.
Manual release valve leaking. • Ensure that valve is fully closed.
• Inspect manual release valve.
Motor will not trim/tilt up. Defective PTT switch. Replace.
Defective PTT relay. Replace.
Open light blue lead wire circuit. Repair or replace.
Defective ECM. Replace.
Motor will not trim/tilt Defective PTT switch. Replace.
down. Defective PTT relay. Replace.
Open pink lead wire circuit. Repair or replace.
Defective ECM. Replace.
PTT motor operates, but Low PTT fluid level. Added PTT fluid.
no motor trim/tilt Manual release valve leaking. • Ensure that valve is fully closed.
movement. • Inspect manual release valve.
Debris in system. Inspect for debris.
Broken drive joint in PTT pump. Replace.
Broken PTT pump. Replace.
Tilt piston leaking. • Replace PTT unit assembly.
• Inspect tilt/trim rod seal(s).
Motor will not retain Manual release valve leaking. • Ensure that valve is fully closed.
selected trim and tilt • Inspect manual release valve.
setting, creeps Tilt piston leaking. • Replace PTT unit assembly.
downward.
• Inspect tilt/trim rod seal(s).
Debris in system. Inspect for debris.
PTT motor operates at Low PTT fluid level. Added PTT fluid.
higher than normal speed, Manual release valve leaking. • Ensure that valve is fully closed.
or with high pitched • Inspect manual release valve.
“squealing” sound. No Broken drive joint in PTT pump. Replace.
trim/tilt action.
 Power Trim and Tilt: 2B-17

Service Instructions
Checking PTT Fluid Level (One-Cylinder Type) 5) Reinstall oil filler plug.
CENDG2112206001
1) Raise the engine to the full-tilt up position. Checking PTT Fluid Level (Three-Cylinder Type)
2) Lower the manual tilt lock lever (1). CENDG2112206015
1) Raise the engine to a full-tilt up position.
2) Lower the manual tilt lock lever (1).

IDG211220002-02

3) Remove the oil filler plug (2).

IDG211220037-02

3) Remove the oil filler plug (2).

IDG211220003-01

4) If oil can be seen at filler plug level, the reservoir is

full. IDG211220038-01
If fluid level is low, refill with the recommended PTT 4) If oil can be seen at filler plug level, the reservoir is
fluid. full.
If fluid level is low, refill with the recommended PTT
NOTICE
fluid.
Mixing of different fluids may cause chemical
reaction and deterioration. NOTICE
Mixing of different fluids may cause chemical
To ensure consistent pump operation, never reaction and deterioration.
mix different types of PTT fluid.
To ensure consistent pump operation, never
Recommended PTT fluid mix different types of PTT fluid.
• 99000-22810 (PTT Fluid (1 Liter))
• Dexron III automatic transmission fluid or Recommended PTT fluid
equivalent • 99000-22810 (PTT Fluid (1 Liter))
• Dexron III automatic transmission fluid or
equivalent

I9J011220008-01
2B-18 Power Trim and Tilt:

Setting of Trim Down Position Limit

CENDG2112206003
“A” Once the ECM has been replaced or the trim sensor
removed and reinstalled, the resetting of the trim lower
position limit should be performed.
Perform this set-up after the current position setting has
been cancelled, as explained in the following
procedures.

Canceling Trim Down Position Limit Setting

2
1) Turn the ignition key to the “ON” position.
Lower the motor until trim position.
IDG211220039-02
2) Pull out the emergency stop switch lock plate.
“A”: Oil level (when full tilted)
3) Make sure that remote control handle is in “Neutral”.
5) Reinstall oil filler plug (2). (Check that the neutral switch is in the “ON”
position.)
Air Bleeding from PTT Unit
CENDG2112206002
1) Check that the manual release valve (1) is tightened
to the specified torque.

NOTE
Do not over tighten manual release valve.

Tightening torque
Manual release valve (a): 3.5 N·m (0.35 kgf-m,
2.5 lbf-ft)
Direction of rotation I9J011220054-01

Counterclockwise: Open 4) Top mount type:

Clockwise: Close Using the throttle only function of the remote control
box, move the control handle forward until the
caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control
box, move the warm-up lever upward until the
1 (a)
caution buzzer sounds one time.

“NEUTRAL” “NEUTRAL”
IDG211220004-01

2) Operate the PTT switch, raising and lowering the

motor up and down (full tilt position to full trim down
position) 4 to 5 times.

I9J011220055-01

IDG211220005-02

3) Check PTT fluid level, topping off if necessary.

4) Reinstall oil filler plug.
 Power Trim and Tilt: 2B-19

5) Press the “DOWN” side of the PTT switch for three
seconds and the buzzer will sound two times briefly
indicating the setting has been canceled.
1
Setting Tilt Up Limit Position
CENDG2112206004
If the outboard motor contacts the motor well of the boat
during full tilt up operation, the upper limit setting should
be reset. Perform this set-up after the current position
setting has been canceled, as explained in the following
procedure.

Canceling Tilt Up Position Limit Setting

DOWN
1) Turn the ignition key to the “ON” position.
Raise the motor until tilt position.
I9J011220056-03
NOTE
1. PTT switch
Before canceling the upper limit setting, raise
6) Return the throttle to the fully closed position. the motor at any position of the tilt range.

Setting Trim Down Position Limit 2) Pull out the emergency stop switch lock plate.
1) Press the “DOWN” side of the PTT switch so that the 3) Make sure that remote control handle is in “Neutral”.
full trim down position is obtained. (Check that the neutral switch is in “ON” position.)
2) Turn the ignition key to the “ON” position.
3) Pull out the emergency stop switch lock plate.
4) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in the “ON”
position.)
5) Top mount type:
Using the throttle only function of the remote control
box, move the control handle forward until the
caution buzzer sounds one time verifying the set
mode is active.
Side mount type: I9J011220057-01
Using the throttle only function of the remote control 4) Top mount type:
box, move the warm-up lever upward until the Using the throttle only function of the remote control
caution buzzer sounds one time verifying the set box, move the control handle forward until the
mode is active. caution buzzer sounds one time.
6) Press the “DOWN” side of the PTT switch three Side mount type:
times within three seconds. The buzzer will sound Using the throttle only function of the remote control
one time briefly indicating the setting has been box, move the warm-up lever upward until the
accepted. caution buzzer sounds one time.
7) With the throttle fully closed, install the lock plate on
the emergency switch.
Press the “UP” side of the PTT switch to obtain the
“NEUTRAL” “NEUTRAL”
full tilt up position and then press the “DOWN” switch
to obtain the full trim down position. Check that the
positions are set.

I9J011220058-01
2B-20 Power Trim and Tilt:

5) Press the “UP” side of the PTT switch for three Power Trim and Tilt Unit Removal and
seconds and the buzzer will sound twice briefly Installation (One-Cylinder Type)
indicating the setting has been canceled. CENDG2112206005
Removal
1) Remove the lower side covers.
UP Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Raise the engine to the full tilt up position and lower
the manual tilt lock lever (1).
1
! WARNING
I9J011220059-02 Failure to take proper precaution when
1. PTT switch servicing a PTT unit can cause severe
personal injury.
6) Return the throttle to the fully closed position.
During the removal or installation of PTT unit,
Setting Tilt Up Position Limit the engine must be firmly secured and its
1) Press the UP side of the PTT switch so that the weight fully supported by the hoist. (See
optimum full tilt up position for the boat can be below)
obtained.
2) Turn the ignition key to the “ON” position.
3) Pull out the emergency stop switch lock plate.
4) Make sure that remote control handle is in “Neutral”.
(Check that the neutral switch is in “ON” position.)
5) Top mount type: 1
Using the throttle only function of the remote control
box, move the control handle forward until the
caution buzzer sounds one time.
Side mount type:
Using the throttle only function of the remote control
box, move the warm-up lever upward until the IDG211220006-01
caution buzzer sounds one time.
6) Press the “UP” side of PTT switch three times within
three seconds.
The buzzer will sound one time briefly indicating the
setting has been accepted.
7) Return the throttle to the fully closed position and
install the lock plate on the emergency switch.
Operate the full tilt up and full trim down operations
several times by pressing the PTT switch and check
that the settings of both the trim down limit and tilt up
limit is properly set.
I9J011220061-02
 Power Trim and Tilt: 2B-21

3) Remove the tilt rod snap ring (2) and push the tilt 7) Remove PTT cylinder lower shaft bolts (6).
cylinder upper shaft pin (3) out.

6 6

IDG211220011-02
IDG211220007-01 8) Remove two STBD motor mounting bolts (7).
4) Lower the tilt rod to the full down position and Using flat screw driver, drive locking edge of lock
disconnect the battery cable. washer (8) to clamp bracket side.
Loosen and remove the clamp bracket shaft nut (9).
Remove the screw and bonding wire (10) from
swivel bracket.

10

8
9

IDG211220008-01

5) Disconnect the PTT motor cable wire connector from

the PTT sub wiring harness. Cut the cable tie binding 7
PTT motor cable and trim sensor lead. Remove the IDG211220093-02

PTT motor cable from engine lower cover. 9) Slide the STBD clamp bracket (11) off clamp bracket
shaft, then remove PTT unit with lower shaft.

11
IDG211220009-01

6) Remove two bolts and anode (4). Remove the screw IDG211220012-03

securing bonding wire (5).

4
IDG211220010-04
2B-22 Power Trim and Tilt:

Installation • Tighten lower shaft bolts (4), pre-coated with thread

Installation is reverse order of removal with special lock, to specified torque.
attention to the following steps.
: Thread lock cement 99000–32050 (SUZUKI
• Lower tilt rod to full down position. Thread Lock 1342 (50 g))
• Apply water resistant grease to the tilt cylinder lower
Tightening torque
shaft (2) and lower shaft bushings (1).
PTT cylinder lower shaft bolt (b): 50 N·m (5.0 kgf-
Install the lower shaft (2) and bushings (1) to PTT unit.
m, 36.0 lbf-ft)
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

1 4 (b)

2
IDG211220015-03

• Install anode (5) and bonding wire, then tighten bolts

IDG211220013-01 securely. Install bonding wire (6), then tighten screw
• Place the PTT unit (with lower shaft) in position, then securely.
install the clamp bracket.

5
IDG211220016-03
IDG211220014-01 • Apply water resistant grease to tilt rod upper bushings
• Tighten clamp bracket shaft nut (3) to specified (7), then install bushings in tilt rod.
torque. Operate the PTT motor to extend the PTT rod upward.
Align the tilt rod with the hole in the swivel bracket as
Tightening torque
the tilt rod extends.
Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
31.0 lbf-ft) : Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
• After tightening clamp bracket shaft nut to specified
torque, bend lock washer edge toward nut to secure
nut.
7
7

3 (a)

IDG211220017-02

IDG211220094-02

• Apply water resistant grease to the PTT rod upper
shaft (8), then insert the shaft through the swivel
bracket and tilt rod.
Secure the upper shaft with the snap ring (9).
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
9 !
8
IDG211220018-02
• Route the PTT motor cable in through the lower cover
and connect the PTT cable connector to the PTT sub-
wiring harness.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
IDG211220019-01
• Final assembly check
Perform the following checks to ensure proper and
safe operation of repaired unit:
– All parts removed have been returned to their
original positions.
– Wire routing matches service manual illustration.
Power Trim and Tilt: 2B-23
Power Trim and Tilt Unit Removal and
Installation (Three-Cylinder Type)
CENDG2112206016
Removal
1) Remove the lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-3).
2) Raise the engine to the full tilt up position and lower
the manual tilt lock lever (1).
WARNING
Failure to take proper precaution when
servicing a PTT unit can cause severe
personal injury.
During the removal or installation of PTT unit,
the engine must be firmly secured and its
weight fully supported by the hoist. (See
below)
IDG211220040-02
I9J011220061-02
3) Remove the tilt rod snap ring (2) and push the tilt
cylinder upper shaft pin (3) out.
IDG211220041-02
2B-24 Power Trim and Tilt:

4) Lower the tilt rod to the full down position and 7) Remove the tilt pin. Remove PTT cylinder lower
disconnect the battery cable. shaft bolts (6).

6 6

IDG211220042-01 IDG211220046-03

5) Disconnect the PTT motor cable wire connector from
the PTT sub-wiring harness. Cut the cable tie
binding PTT motor cable and trim sensor lead.
Remove the PTT motor cable from engine lower
cover.
8) Remove two STBD motor mounting bolts (7).
Using flat screw driver, drive locking edge of lock
washer (8) to clamp bracket side.
Loosen and remove the clamp bracket shaft nut (9).
Remove the screw and bonding wire from swivel
bracket.

IDG211220043-01 7
6) Remove two bolts and anode (4). Remove the screw IDG211220045-03

securing bonding wire (5). 9) Slide the STBD clamp bracket (10) off the clamp
bracket shaft, then remove the PTT unit with lower
shaft.

10
4
IDG211220044-03

IDG211220047-03
 Power Trim and Tilt: 2B-25

Installation • Tighten the clamp bracket shaft nut (4) to specified

Installation is reverse order of removal with special torque.
attention to the following steps.
Tightening torque
• Lower tilt rod to full down position. Clamp bracket shaft nut (a): 43 N·m (4.3 kgf-m,
• Apply water resistant grease to the tilt cylinder lower 31.0 lbf-ft)
shaft (1) and lower shaft bushings (2).
• After tightening clamp bracket shaft nut (4) to
Install the lower shaft (1) and bushings (2) to PTT unit.
specified torque, bend lock washer (3) edge toward
: Grease 99000–25350 (SUZUKI Water nut to secure nut.
Resistant Grease EP2 (250 g))

2
4 (a)

1
2
IDG211220051-01
IDG211220048-02 • Tighten two lower shaft bolts (5), pre-coated with
• Place the PTT unit (with lower shaft) in position, then thread lock, to specified torque.
install the clamp bracket.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
Tightening torque
PTT cylinder lower shaft bolt (b): 50 N·m (5.0 kgf-
m, 36.0 lbf-ft)

IDG211220049-01

5 (b)

IDG211220050-02
2B-26 Power Trim and Tilt:

• Install anode (6) and bonding wire, then tighten bolts
securely. Install bonding wire (7), then tighten screw
securely.
7
• Apply water resistant grease to the PTT rod upper
shaft (9), then insert the shaft through the swivel
bracket and tilt rod.
Secure the upper shaft with the snap ring (10).
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

10

9
6
IDG211220052-03

• Apply water resistant grease to tilt rod upper bushings

(8), then install bushings in tilt rod.
Operate the PTT motor to extend the PTT rod upward. IDG211220054-01
Align the tilt rod with the hole in the swivel bracket as
• Route the PTT motor cable in through the lower cover
the tilt rod extends.
and connect the PTT cable connector to the PTT sub-
: Grease 99000–25350 (SUZUKI Water wiring harness.
Resistant Grease EP2 (250 g)) Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).

IDG211220053-01

IDG211220055-01

• Final assembly check

Perform the following checks to ensure proper and
safe operation of repaired unit:
– All parts removed have been returned to their
original positions.
– Wire routing matches service manual illustration.
 Power Trim and Tilt: 2B-27

Power Trim and Tilt Unit Components (One-Cylinder Type)

CENDG2112206006

1 (a)

9
2

10
5 3
4

6
11
7 18

19 13

12

20
14 14
8
21

15
22

16
17
23
D
FW 25

24 26
IDG211220095-02

1. Joint 8. Manifold assembly 15. Brush holder 22. Pump assembly

2. Reservoir 9. Field case 16. Screw 23. Bolt
3. Plug 10. O-ring 17. Oil seal 24. Bolt
4. O-ring 11. Armature 18. Drive joint 25. Bolt
5. Bolt 12. Brush set 19. Filter 26. Manual valve
6. Clamp 13. Breaker assembly 20. O-ring : 108 N⋅m (10.8 kgf-m, 78.0 lbf-ft)
7. O-ring 14. Spring 21. O-ring : Apply thread lock to the thread area.
2B-28 Power Trim and Tilt:

Power Trim and Tilt Unit Components (Three-Cylinder Type)

CENDG2112206017

14

9
2 (a)
8
15
5 (b)

13 4
3 16
23

24 18
7
4
17
10
25
12 19 19
11
26

20
27

21
22
28
D
FW 30

29 31
IDG211220056-04

1. Manifold assembly 10. Free piston 19. Spring 28. Bolt

2. Piston assembly 11. O-ring 20. Brush holder 29. Bolt
3. Trim ram 12. Ring 21. Screw 30. Bolt
4. O-ring 13. Reservoir bolt 22. Oil seal 31. Manual valve
5. Trim cylinder head 14. Field case 23. Drive joint : 210 N⋅m (21.0 kgf-m, 152.0 lbf-ft)
6. O-ring 15. O-ring 24. Filter : 170 N⋅m (17.0 kgf-m, 123.0 lbf-ft)
7. PTT manifold 16. Armature 25. O-ring
8. Reservoir 17. Brush set 26. O-ring
9. Cap 18. Breaker assembly 27. Pump assembly
 Power Trim and Tilt: 2B-29

Power Trim and Tilt Unit Disassembly (One- 4) Remove the manual release valve snap ring (1),
Cylinder Type) then unscrew the manual release valve (2).
CENDG2112206007
NOTE
Before disassembly, wash the PTT body with
a stiff bristle brush and hot, soapy water to
remove sand or dirt. Dry the PTT body with
compressed air. 2

1) Place the lower section of the PTT unit in a vise.

Tighten the vise only enough to secure the PTT unit,
DO NOT OVER TIGHTEN. 1 2

NOTE
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
I9J011220012-01
5) Remove the PTT motor assembly (3).
Refer to “Power Trim and Tilt Motor Removal and
Installation (One-Cylinder Type)” (Page 2B-33).
Note the position of drive joint (4) and O-ring (5),
before removing them.

4
IDG211220020-02
I9J011220013-01
2) Connect the PTT cable extension to PTT motor
cable connector. 6) Remove the three bolts securing the PTT pump
assembly (6), then detach the PTT pump assembly
Special tool from PTT cylinder body.
(A): 09945–79310 (PTT cable extension) Note the position of O-rings (7), before removing
3) Connect the PTT cable extension leads (G, Bl) to them.
battery and operate PTT motor until tilt rod is at
maximum stroke (full-tilt up position). Unscrew the
filler plug and drain PTT oil into a suitable container.
7

(A)
6

I9J011220014-01

I9J011220011-01
2B-30 Power Trim and Tilt:

7) Using special tool, unscrew the upper eye (8). Power Trim and Tilt Unit Reassembly (One-
Special tool Cylinder Type)
CENDG2112206008
(B): 09945–69010 (PTT rod holder) Assembly is reverse order of disassembly with special
attention to following steps.

8 NOTE
• Do not reuse O-rings and seals once
removed.
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
(B)
• Do not reuse PTT fluid, always refill with
new fluid.
I9J011220016-01
Reservoir
8) Remove the four bolts securing the reservoir (9),
• Apply PTT fluid to reservoir seal, then install reservoir.
then detach the reservoir from the PTT body.
• Tighten four bolts securely.
9) Remove the O-ring (10).
Tightening torque
Reservoir bolt (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft)
9

I9J011220015-01

(a)
I9J011220018-01

Upper Eye
• Apply thread lock super 1333B to threads of upper
eye before threading it onto tilt rod.
10
: Thread lock cement 99000–32020 (SUZUKI
Thread Lock Super 1333B (50 g))
• Tighten upper eye to specified torque.
Tightening torque
I9J011220017-01 Upper eye (a): 108 N·m (10.8 kgf-m, 78.0 lbf-ft)
Special tool
(A): 09945–69010 (PTT rod holder)

(a)

(A)

I9J011220019-01
 Power Trim and Tilt: 2B-31

PTT Pump Assembly PTT Motor

• Install four O-rings (1) to PTT body assembly. • Install the PTT motor.
Refer to “Power Trim and Tilt Motor Removal and
NOTE Installation (One-Cylinder Type)” (Page 2B-33).
Lubricate O-rings with PTT fluid before
installing. PTT Fluid
• Pour recommended PTT fluid into reservoir to
• Install PTT pump assembly, then tighten three bolts specified level.
(a) (b) to specified torque. Refer to “Checking PTT Fluid Level (One-Cylinder
Tightening torque Type)” (Page 2B-17).
PTT pump assembly bolt (a): 8 N·m (0.8 kgf-m,
5.8 lbf-ft) Air Bleeding
PTT pump assembly bolt (b): 5.5 N·m (0.55 kgf- Before installing the PTT unit on the outboard motor, use
m, 4.0 lbf-ft) the following procedure to bleed air from the system.
1) Support the PTT unit in an upright position in a vise.
2) Fill the reservoir with PTT fluid to the specified level,
then install oil filler plug.
1

(a) (a)

(b)

I9J011220020-01

Manual Release Valve I9J011220022-01

• Oil and install the manual release valve (1). 3) Tighten the manual release valve to the specified
Tighten the valve to specified torque. torque.
• Install snap ring (2). Tightening torque
Tightening torque Manual release valve: 3.5 N·m (0.35 kgf-m, 2.5
Manual release valve (a): 3.5 N·m (0.35 kgf-m, 2.5 lbf-ft)
lbf-ft) 4) Connect the PTT cable extension to the PTT motor
cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
1 1 (a)
5) Connect the two extension cable lead wires (Bl to
positive/G to negative) to the battery as shown in the
illustration.
Operate the PTT motor until the PTT rod is in the
fully trimmed down position (completely retracted).
2 If the rod does not come down completely, push it in
by hand while operating the motor.
I9J011220021-01

(A)

I9J011220023-01
2B-32 Power Trim and Tilt:

6) Reverse the two extension cable lead wires (G to • Inspect reservoir for cracks, nicks or damage.
positive/Bl to negative). Replace if necessary.
Operate the PTT motor until the PTT rod is in the full • Inspect reservoir seal for cuts, nicks or wear.
tilt up position (fully extended).
If the rod does not come up completely, pull it up by
hand while operating the motor.

(A)

I9J011220026-01

I9J011220024-01
• Inspect all O-rings for cuts, nicks or tears.
7) Remove the reservoir oil filler plug and fill with PTT
fluid to the specified level.
8) Repeat procedures 5 – 7 until the fluid level in the
PTT unit stabilizes at the specified level.

NOTE
Repeat the air bleeding procedure after the
PTT unit has been installed on the outboard
motor.
Refer to “Air Bleeding from PTT Unit” (Page
2B-18).
IDG211220021-01

• Inspect manual release valve for damage. Replace if

Power Trim and Tilt Unit Components Cleaning necessary.
and Inspecting (One-Cylinder Type) • Inspect O-rings for cuts, nicks or tears.
CENDG2112206009
Arrange all components on a clean sheet of paper.

NOTE
• Do not lay PTT components out on a rag,
as dirt or lint may be transferred to these
items which may cause possible system
operating problems.
• If excessive wear, cracks, defective or
other damage is found on any component,
replace component.

• Inspect PTT pump assembly for cracks, nicks, IDG211220022-01

stripped threads and any other imperfections.

Replace if necessary.

I9J011220025-01
 Power Trim and Tilt: 2B-33

• Inspect lower shaft and upper shaft for bends, twists 3) Remove the four screws securing the PTT motor (1)
or other damage. Replace if necessary. to the PTT pump assembly.
• Inspect all bushings for excessive wear or other
damage. Replace if necessary.
If bushing fit is loose when installing, replace bushing.
• Inspect upper and lower shaft for bent, twist or other
damage. Replace if necessary.

IDG211220025-01

4) Detach the PTT motor from PTT pump assembly.

Note the position of drive joint (2) and O-ring (3) and
remove them.

IDG211220023-01

Power Trim and Tilt Motor Removal and

Installation (One-Cylinder Type)
CENDG2112206010
Removal
1) Remove Power Trim and Tilt unit. 3
Refer to “Power Trim and Tilt Unit Removal and 2
Installation (One-Cylinder Type)” (Page 2B-20).

NOTE
I9J011220031-01
Before removing PTT motor, wash the PTT
body with a stiff bristle brush and hot, soapy Installation
water to remove sand or dirt. Dry the PTT Installation is reverse of removal with special attention to
body with compressed air. following steps.
• Ensure that the drive joint (1) is aligned and firmly
2) Place the lower section of the PTT unit in a vise. inserted into the gear pump assembly.
Tighten the vise only enough to secure the PTT unit,
• Fit O-ring (2) to PTT motor.
DO NOT OVER TIGHTEN.

NOTE
2
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
4

1
3
I9J011220032-02

• Check the level of PTT fluid contained in the PTT

pump assembly. If level is low, add recommended
PTT fluid until level with mating surface of PTT motor.

IDG211220024-02
2B-34 Power Trim and Tilt:

• Ensure that the faces of the PTT motor and pump unit
are free of dirt or debris.
When attaching the PTT motor to the PTT pump
assembly (3), ensure that the tip of armature shaft (4)
fits firmly into the drive joint (1).
• Tighten the four screws (a) to specified torque.
Tightening torque
PTT motor screws (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft)
2) Connect the PTT cable extension to PTT motor
cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
3) Connect the PTT cable extension leads (G, Bl) to
battery and operate PTT motor until tilt rod is at
maximum stroke (full-tilt up position). Unscrew the
filler plug and drain PTT oil into a suitable container.

(a)
(A)
(a)

IDG211220026-01
• Pour recommended PTT fluid into reservoir until
specified level.
• Perform the air bleeding procedure.
Refer to “Power Trim and Tilt Unit Reassembly (One-
Cylinder Type)” (Page 2B-30).
IDG211220058-01
4) Remove the three screws securing reservoir (1),
then detach the reservoir (1) from cylinder body.
Note the position of O-ring (2) and remove it.
1

Power Trim and Tilt Unit Disassembly (Three-

Cylinder Type)
CENDG2112206018
NOTE
Before disassembly, wash the PTT body with
a stiff bristle brush and hot, soapy water to
remove sand or dirt. Dry the PTT body with
compressed air.
IDG211220059-01
1) Place the lower section of the PTT unit in a vise.
Tighten the vise only enough to secure the PTT unit,
DO NOT OVER TIGHTEN.

NOTE
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
1

IDG211220062-01

IDG211220057-02
 Power Trim and Tilt: 2B-35

5) Remove the PTT motor assembly (3).

Refer to “Power Trim and Tilt Motor Removal and 10
Installation (Three-Cylinder Type)” (Page 2B-41). 12
9
Note the position of drive joint (4) and O-ring (5),
before removing them.

5
3

9 11
IDG211220064-04

8) Using special tool, unscrew the PTT cylinder head

(13).
4 Special tool
(B): 09944–09820 (PTT cylinder cap tool)

IDG211220060-01

6) Remove the manual release valve snap ring (6),

then unscrew the manual release valve (7).

(B)

13

IDG211220065-02

7 9) Pull the tilt rod/piston assembly (14) out of the tilt

6
cylinder.
Remove the free piston (15) from the tilt cylinder.
IDG211220061-01

7) Remove the three bolts securing the PTT pump

assembly (8), then detach the PTT pump assembly 14
from PTT cylinder body.
Note the position of O-rings (9), orifice collar (with
ball valve) (10), orifice collar (with filter and ball
valve) (12) and orifice collar (11), before removing
them. 15

IDG211220066-01

10) Unscrew the piston retaining nut from the bottom of

8 the tilt rod and remove the washer.
Carefully retain and account for four shock valves,
each composed of spring, rod and ball.

IDG211220063-01

IDG211220067-01
2B-36 Power Trim and Tilt:

11) Remove the piston assembly and PTT cylinder head Power Trim and Tilt Unit Reassembly (Three-
from the tilt rod by sliding them down and off the rod Cylinder Type)
end. CENDG2112206019
Assembly is reverse order of disassembly with special
attention to following steps.

NOTE
• Do not reuse O-rings and seals once
removed.
Always use new parts.
• Lubricate all components and O-rings with
PTT fluid before assembly.
• Do not reuse PTT fluid, always refill with
new fluid.
IDG211220068-01

12) Using special tool, unscrew the trim cylinder head.
Special tool
(C): 09944–09810 (PTT trim cap tool)
Tilt Rod
• When tightening the piston retaining nut on the tilt rod
piston, apply Thread lock 1342 to the threads.
Tighten the nut to specified torque.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
Tightening torque
Piston retaining nut (a): 100 N·m (10.0 kgf-m, 72.5
lbf-ft)

(C)

IDG211220069-02
(a)
13) Pull the trim rod/piston assembly out of the trim
cylinder.

IDG211220071-01

IDG211220070-01
 Power Trim and Tilt: 2B-37

Installing Tilt Rod / Piston Trim Rod

• Pour 100 ml (3.4 oz) of PTT fluid into cylinder. • Pour PTT fluid into the trim cylinder until it is topped
• Insert the free piston into cylinder and push it down to off.
the bottom of the cylinder. • Insert the trim rod/piston assembly into cylinder and
• Pour PTT fluid into the cylinder until it is topped off. thread the trim cylinder head by hand until fully
seated.
• Insert the tilt rod/piston into cylinder and thread the tilt
cylinder head by hand until fully seated. • Tighten the trim cylinder head to specified torque
using special tool.
• Tighten the cylinder head to specified torque using
special tool. Tightening torque
Trim cylinder head (a): 170 N·m (17.0 kgf-m, 123.0
Free piston
lbf-ft)
Special tool
Top OFF (B): 09944–09810 (PTT trim cap tool)
Cylinder

(a) Upper edge

(B)

IDG211220072-01

Tightening torque
Tilt cylinder head (a): 210 N·m (21.0 kgf-m, 152.0
lbf-ft)
IDG211220074-03
Special tool
(A): 09944–09820 (PTT cylinder cap tool)
PTT Pump Assembly
• Install five O-rings and orifice collars to PTT cylinder
body.
(A)
NOTE
Lubricate O-rings with PTT fluid before
installing.

(a) • Install PTT pump assembly, then tighten three screws

to specified torque.
Tightening torque
IDG211220073-02
PTT pump case screw (a): 8.5 N·m (0.85 kgf-m,
6.0 lbf-ft)

O-ring /
Orifice collar

O-ring

O-ring

(a)

Orifice collar

IDG211220075-03
2B-38 Power Trim and Tilt:

Manual Release Valve PTT Fluid

• Oil and install the manual release valve (1). • Pour recommended PTT fluid into reservoir to
Tighten the valve to specified torque. specified level.
• Install snap ring (2). Refer to “Checking PTT Fluid Level (Three-Cylinder
Type)” (Page 2B-17).
Tightening torque
Manual release valve (a): 3.5 N·m (0.35 kgf-m, 2.5 Air Bleeding
lbf-ft) Before installing the PTT unit on the outboard motor, use
the following procedure to bleed air from the system.
1) Support the PTT unit in an upright position in a vise.
2) Fill the reservoir with PTT fluid to the specified level,
1 (a) then install oil filler plug.

Oil level (When full-tilted)

1 2

IDG211220076-01

PTT Motor
• Install the PTT motor.
Refer to “Power Trim and Tilt Motor Removal and
IDG211220078-01
Installation (Three-Cylinder Type)” (Page 2B-41).
3) Tighten the manual release valve to the specified
Reservoir torque.
• Install O-ring (1) and reservoir, then tighten bolts to Tightening torque
specified torque. Manual release valve: 3.5 N·m (0.35 kgf-m, 2.5
lbf-ft)
Tightening torque
Reservoir bolt (a): 5 N·m (0.5 kgf-m, 3.5 lbf-ft) 4) Connect the PTT cable extension to the PTT motor
cable connector.
Special tool
(A): 09945–79310 (PTT cable extension)
1
5) Connect the two extension cable lead wires (G to
positive/Bl to negative) to the battery as shown in the
illustration.
Operate the PTT motor until the PTT rod is in the
fully trimmed down position (completely retracted).
(a) If the rod does not come down completely, push it in
by hand while operating the motor.
IDG211220077-01

(A)

IDG211220079-01
 Power Trim and Tilt: 2B-39

6) Reverse the two extension cable lead wires (Bl to Power Trim and Tilt Unit Components Cleaning
positive/G to negative). Operate the PTT motor until and Inspecting (Three-Cylinder Type)
the PTT rod is in the full tilt up position (fully CENDG2112206020

extended). If the rod does not come up completely, Thoroughly wash all metal components with cleaning
pull it up by hand while operating the motor. solvent and dry them with compressed air.
Arrange all components on a clean sheet of paper.

NOTE
• Do not lay PTT components out on a rag,
as dirt or lint may be transferred to these
(A) items which may cause possible system
operating problems.
• If excessive wear, cracks, defective or
other damage is found on any component,
replace component.

IDG211220080-01 • Inspect tilt rod and trim rod, replace if damaged or

7) Remove the reservoir oil filler plug and fill with PTT bent.
fluid to the specified level. • Inspect the surface of tilt rod and trim rod for scores,
8) Repeat procedures 5 – 7 until the fluid level in the grooves or roughness.
PTT unit stabilizes at the specified level. Slight roughness may be removed with fine emery
paper.
NOTE A badly scored or grooved rod must be replaced.
Repeat the air bleeding procedure after the
PTT unit has been installed on the outboard
motor.
Refer to “Air Bleeding from PTT Unit” (Page
2B-18).

IDG211220082-01

IDG211220096-01
2B-40 Power Trim and Tilt:

• Inspect the PTT cap seal and O-ring. • Inspect manual release valve for damage.
Replace if cuts, nicks, or excessive wear is found. Inspect manual release valve O-ring.
Replace if nicked or cut.
NOTE
It is recommended that the O-ring always be
replaced once the tilt/trim cylinder has been
disassembled.

• Inspect the shock valves (spring, rod and ball).

Replace if there are any signs of rust or pitting.

IDG211220085-02

• Inspect lower rod.

If bending, cracks, corrosion or other damage is
found, replace lower rod.
• Inspect upper shaft for bent, twist or other damage.
Replace if necessary.
IDG211220083-01

• Inspect the cylinder bore for evidence of a rough or

grooved surface.
Light honing may rectify slight surface roughness or
scarring, but a deeply scarred surface will require
replacement of the tilt cylinder.

IDG211220097-01

• Inspect all bushings for excessive wear or other

damage. Replace if necessary.
If bushing fit is loose when installing, replace bushing.

IDG211220084-01

IDG211220086-01
 Power Trim and Tilt: 2B-41

Power Trim and Tilt Motor Removal and 4) Detach the PTT motor from PTT pump assembly.
Installation (Three-Cylinder Type) Note the position of drive joint (2) and O-ring (3) and
CENDG2112206021 remove them.
Removal
1) Remove Power Trim and Tilt unit.
Refer to “Power Trim and Tilt Unit Removal and 3
Installation (Three-Cylinder Type)” (Page 2B-23).

NOTE
Before removing PTT motor, wash the PTT 2
body with a stiff bristle brush and hot, soapy
water to remove sand or dirt. Dry the PTT
body with compressed air.

2) Place the lower section of the PTT unit in a vise.

Tighten the vise only enough to secure the PTT unit,
DO NOT OVER TIGHTEN.
NOTE
To prevent damage to the PTT cylinder use
wood blocks, vise jaw protectors, etc.,
between the vise jaws and PTT components
before tightening vise.
IDG211220089-01
Installation
Installation is reverse of removal with special attention to
following steps.
• Ensure that the drive joint (1) is aligned and firmly
inserted into the gear pump assembly.
• Fit O-ring (2) to PTT motor.

IDG211220090-01
IDG211220087-02

3) Remove the four screws securing the PTT motor (1)

to the PTT pump assembly. 2

3
IDG211220091-01

IDG211220088-01
2B-42 Power Trim and Tilt:

• Check the level of PTT fluid contained in the PTT 4) Remove the two screws (3) securing the field case to
pump assembly. If level is low, add recommended the brush holder.
PTT fluid until level with mating surface of PTT motor.
• Ensure that the faces of the PTT motor and pump unit
are free of dirt or debris.
When attaching the PTT motor to the PTT pump
assembly (3), ensure that the tip of armature shaft (4) 3
fits firmly into the drive joint (1).
• Tighten the four screws (a) to specified torque.
Tightening torque
PTT motor screws (a): 5 N·m (0.5 kgf-m, 3.6 lbf-ft) I9J011220035-01

5) Slide the field case upward and away from the brush
holder.

NOTE
When separating field case from brush
holder, push the PTT motor cables into brush
holder as the field case is removed.
(a)

IDG211220092-02

• Pour recommended PTT fluid into reservoir until

specified level.
• Perform the air bleeding procedure.
Refer to “Power Trim and Tilt Unit Reassembly
(Three-Cylinder Type)” (Page 2B-36).

Power Trim and Tilt Motor Disassembly and

I9J011220036-01
Assembly
CENDG2112206011 6) Disconnect PTT motor cables from brush holder.
Disassembly Remove armature from field case. Note the position
1) For correct assembly, scribe an alignment mark on of the O-ring encircling the brush holder.
the field case and brush holder.
2) Slide cable protector tube upward.
3) Remove the screw securing the motor cable holder
(1), then slide motor cable holder and grommets (2)
out as shown in figure.

2
1

I9J011220037-01

I9J011220034-01
 Power Trim and Tilt: 2B-43

Assembly
Assembly is reverse of disassembly with special
attention to following steps. (A)

• Install O-ring (1).

• Install armature (2) to brush holder first. When
installing the armature, use care to avoid breaking the
brushes.

2
I9J011220040-01
1
• Check continuity between adjacent commutator
segments.
Replace armature if no continuity is indicated.

(A)

I9J011220038-01

• Match up previously scribed alignment marks.

• When assembling field case to brush holder, pull out
on the PTT motor cables as the field case is
assembled into position.
• Apply silicone seal to PTT motor cable holder and
grommets and install cable holder screw.
I9J011220041-01
: Sealant 93691–80030 (SUZUKI Silicone • Inspect the commutator surface.
Seal (100 g)) If surface is gummy or dirty, clean with 400 grit emery
paper (1).
• Measure commutator outside diameter.
If measurement exceeds service limit, replace
armature.
Special tool
(B): 09900–20101 (Vernier calipers (150
mm))
Commutator outside diameter
Standard: 22.0 mm (0.87 in)
I9J011220039-01 Service limit: 21.0 mm (0.83 in)

PTT Motor Related Items Inspection

CENDG2112206012
Armature and Commutator
• Check for continuity between the commutator and the
armature core/shaft. Replace armature if continuity is
indicated.
1
Special tool
(A): 09930–99320 (Digital tester) (B)

Tester knob indication

Continuity ( ) I9J011220042-01
2B-44 Power Trim and Tilt:

• Ensure that the mica (insulator) between commutator O-ring

segments are undercut “a” to specified depth. • Inspect the O-ring between the PTT motor and PTT
If undercut is less than service limit, cut to specified pump assembly. Replace if cuts, nicks or tears are
depth. found.
! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.

Wear safety glasses when using compressed

air.

NOTE
Remove all particles of mica and metal using
I9J011220045-01
compressed air.

Commutator undercut PTT Motor Relay Inspection

CENDG2112206013
Standard: 1.6 – 1.9 mm (0.06 – 0.07 in.)
Service limit: 1.0 mm (0.04 in.) 1) Remove the PTT motor relay from the electric parts
holder.
“A”
Refer to “Electric Parts Holder Removal and
Installation” in Section 1D (Page 1D-4).
2) Check the resistance between each two terminals.
“a” Special tool
(A): 09930–99320 (Digital tester)
“B” Tester knob indication
I9J011220043-01 Resistance (Ω)
“A”: Segment “B”: Mica
PTT relay coil resistance
Between “terminal (1)” and “terminal (4)”: 16 – 24
Brushes Ω
• Check the length of each brush. Between “terminal (2)” and “terminal (4)”: 16 – 24
If brushes are worn down to the service limit, they Ω
must be replaced.
Special tool
(B): 09900–20101 (Vernier calipers (150
mm))
Brush length
Standard: 9.8 mm (0.39 in.)
Service limit: 5.5 mm (0.22 in.)

1 2

4
3
(B)
IDG211220099-01

(A)

IDG211220027-03
 Power Trim and Tilt: 2B-45

NOTICE PTT Switch Inspection

CENDG2112206014
If the 12 V power supply wire is connected to Test continuity between the switch lead wires at each of
wrong terminal or touched to each other, the the three switch positions.
power supply wire, tester may be damaged. If out of specification, replace PTT switch.

Be careful not to touch 12 V power supply Special tool

wires to each other or with other terminals. : 09930–99320 (Digital tester)
Tester knob indication
3) Check continuity between terminal (3) and (5) each Continuity ( )
time 12 V power supply is applied to terminal (1) and
Tester probe connection Tester
(4).
Red (+) Black (–) indicates
Connect the positive (+) lead to terminal (1), and
DN side
negative (–) lead to terminal (4). Terminal (2) Terminal (1) Continuity
depressed
4) Check continuity between terminal (3) and (6) each UP side
time 12 V power supply is applied to terminal (2) and Terminal (3) Terminal (1) Continuity
depressed
(4). Not Terminal (2)
Connect the positive (+) lead to terminal (2), and Terminal (1) Infinity
depressed Terminal (3)
negative (–) lead to terminal (4).

2 5 6
1 1
(W/R)
2
(P) 3
(Lbl)

3 4

I9J011220048-02

(A)
IDG211220098-03
1 (Lg)
1. Terminal 1 (UP coil) 4. Terminal 4 (GND) 3 (Lbl)
2. Terminal 2 (DN coil) 5. Terminal 5 (For UP)
3. Terminal 3 (Power) 6. Terminal 6 (For DN)
2 (R)
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )

PTT relay function

Continuity
12 V power applied Yes
12 V power not applied No

5) If inspection in step 2 and/or step 3, 4 fails, replace I9J011220049-03

PTT motor relay.
6) Install the PTT motor relay to the electric parts
holder.
Refer to “Electric Parts Holder Removal and
Installation” in Section 1D (Page 1D-4).
2B-46 Power Trim and Tilt:

Section 3
Lower Unit
CONTENTS
Precautions .................................................3-1
Precautions............................................................. 3-1
General Precautions ............................................. 3-1
Precaution for Lower Unit ..................................... 3-1
Left Hand Rotation Unit .......................... 3B-1
Right Hand Rotation Unit........................ 3A-1
Diagnostic Information and Procedures............3A-1
Diagnose Lower Unit Malfunction ....................... 3A-1
Service Instructions.............................................3A-2
Lower Unit Components ..................................... 3A-2
Propeller Removal and Installation ..................... 3A-4
Propeller / Propeller Nut / Cotter Pin
Inspection.......................................................... 3A-4
Lower Unit Removal and Installation................... 3A-5
Water Pump Removal and Installation................ 3A-6
Water Pump and Related Item Inspection .......... 3A-8
Lower Unit Disassembly...................................... 3A-8
Pinion Bearing Removal and Installation .......... 3A-11
Lower Unit Related Item Inspection .................. 3A-12
Propeller Shaft Oil Seal Replacement............... 3A-15
Driveshaft Oil Seal Replacement ...................... 3A-16
Lower Unit Assembly ........................................ 3A-16
Table of Contents 3- i
Trim Tab Adjustment.........................................3A-22
Lower Unit Gears - Shimming and Adjustment ..3A-23
Diagnostic Information and Procedures ............3B-1
Diagnose Lower Unit Malfunction .......................3B-1 3
Service Instructions .............................................3B-2
Lower Unit Components......................................3B-2
Propeller Removal and Installation .....................3B-4
Propeller / Propeller Nut / Cotter Pin
Inspection..........................................................3B-4
Lower Unit Removal and Installation...................3B-5
Water Pump Removal and Installation................3B-6
Water Pump and Related Item Inspection ..........3B-8
Lower Unit Disassembly......................................3B-8
Pinion Bearing Removal and Installation ..........3B-12
Lower Unit Related Items Inspection ................3B-13
Propeller Shaft Oil Seal Replacement...............3B-16
Driveshaft Oil Seal Replacement ......................3B-16
Lower Unit Assembly ........................................3B-17
Trim Tab Adjustment.........................................3B-23
Lower Unit Gears - Shimming and Adjustment ..3B-24
3-1 Precautions:

Precautions
Lower Unit

Precautions
General Precautions
CENDG2113000001
Refer to “General Precautions” in Section 00 (Page 00-1).

Precaution for Lower Unit

CENDG2113000002
! WARNING
Failure to take proper precautions when installing or removing the propeller can result in severe
personal injury.

When installing or removing the propeller:

• Shift into Neutral and remove the emergency stop switch lock plate so that the motor cannot be
started accidentally.
• Wear gloves to protect hands, and lock the propeller by placing a block of wood between the
propeller blade tips and the anti-cavitation plate before attempting to remove or install propeller nut.

! WARNING
Failure to take proper precautions when removing or installing the lower unit can result in severe
personal injury.

When installing or removing the lower unit:

• Always disconnect the battery cable, before removing lower unit.
• Remove the emergency stop switch lock plate from the emergency stop switch.

NOTE
• When draining lower unit gear oil, check the following points.
– Water ingress (white, milky appearance)
– Overheating or burning (black appearance, charred smell)
– Metal filings or deposits
• If reassembling with original components and gears, do not omit or add any shims or thrust
washers.
• To simplify reassembly and to prevent confusion, note the positions and quantities of all shims and
thrust washers. Retain these items next to the gears or bearings to which they belong.
 Right Hand Rotation Unit: 3A-1

Right Hand Rotation Unit

Lower Unit

Diagnostic Information and Procedures

Diagnose Lower Unit Malfunction
CENDG2113104001
Trouble Check Chart

Condition Possible cause Correction / Reference Item

Engine stalls when Idling speed set too low. Adjustment.
engaging gear Propeller shaft bearings damaged, Replace.
lacking lubrication or seized.
Engaging gear(s) has no Clutch out of adjustment. Adjustment.
effect on propulsion Driveshaft broken or splines damaged. Replace.
Chipped or worn dog clutches. Replace.
Propeller not secured correctly (fallen Inspection or retighten.
off).
Loss of power. (Assuming Propeller bush slipping. Replace.
engine is OK) Bent or worn propeller. Repair or replace.
Engine shakes the boat Failed propeller bush. Replace.
Bent driveshaft or propeller shaft. Replace.
Damaged propeller. Replace.
Clutch will not engage or Seized shift rod. Inspection.
disengage Clutch shaft and clutch rod have Inspection.
become detached.
Seized/broken remote control cable. Replace.
Problem at control box end. Inspection or replace.
3A-2 Right Hand Rotation Unit:

Service Instructions
Lower Unit Components
CENDG2113106001

13 (c) 11
1

3 6

2 12
14
16 15
4 9
7
5 17

9 8 18
19
32
31 30
10
20
22 29
21
23

24

25

26
33

35
28 (b)

27 (a)
34
35
37

36

IDG211310100-06

1. Oil seal cover 12. Water pump case 23. Union 34. Bolt
2. Oil seal 13. Bolt 24. Hose 35. Screw
3. Bolt 14. Dowel pin 25. Nipple 36. Water filter PORT
4. Shift rod guide housing 15. Key 26. Gearcase 37. Water filter STBD
5. O-ring 16. Water pump case sealing 27. Bolt : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
6. Shift rod 17. Inner sleeve 28. Bolt : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
7. Magnet 18. Water pump impeller 29. Dowel pin : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft)
8. Shifter yoke 19. Under panel 30. Anode : Apply SUZUKI Water Resistant Grease.
9. Pin 20. Gasket 31. Washer : Apply SUZUKI Silicon seal.
10. Horizontal slider 21. Exhaust seal rubber 32. Bolt
11. Bush 22. Exhaust seal plate 33. Trim tab
 Right Hand Rotation Unit: 3A-3

47
4 50
49
5 48
1 52
2
46
3 51 (c)
6
7

9
23
10 21 (b)
24 17
12 22
13 (d) 11
27 18
25
20 19

28 (a)
45
26
33 43
41 44
40
14

31 42
32 38
34
35 30 36 37
38
39
29

15

16 (d)
IDG211310101-05

1. Driveshaft 16. Plug 31. Thrust washer 46. Stopper

2. Bolt 17. Ring 32. Shim 47. Propeller
3. Driveshaft oil seal housing 18. Oil seal protector 33. Bearing 48. Propeller bush
4. Oil seal 19. Oil seal 34. Forward gear bearing housing 49. Spacer
5. Oil seal 20. Bearing 35. Pin 50. Washer
6. O-ring 21. Bolt 36. Clutch dog forward spacer 51. Propeller nut
7. Shim 22. Propeller shaft bearing housing 37. Spring 52. Cotter pin
8. Bearing 23. Bearing 38. Large detent ball : 120 N⋅m (12 kgf-m, 87.0 lbf-ft)
9. Driveshaft collar 24. O-ring 39. Small detent ball : 23 N⋅m (2.3 kgf-m, 16.6 lbf-ft)
10. Dowel pin 25. Shim 40. Connector pin : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
11. Pinion bearing 26. Reverse gear 41. Clutch dog shifter : 10 N⋅m (1.0 kgf-m, 7.2 lbf-ft)
12. Gasket 27. Pinion gear 42. Dog pin : Apply SUZUKI Water Resistant Grease.
13. Plug 28. Pinion nut 43. Dog spring : Apply SUZUKI Outboard Motor Gear Oil.
14. Gearcase 29. Forward gear 44. Propeller shaft : Apply SUZUKI Thread Lock 1342.
15. Gasket 30. Bearing 45. Thrust washer
3A-4 Right Hand Rotation Unit:

Propeller Removal and Installation Installation

CENDG2113106002
1) Coat the propeller shaft splines liberally with Suzuki
! WARNING water resistant grease.
Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water
installing or removing the propeller can Resistant Grease EP2 (250 g))
result in severe personal injury.
2) Install propeller stopper (1) onto propeller shaft, then
When installing or removing the propeller: slide on the propeller (2).
• Shift into “Neutral” and remove the 3) Fit spacer (3), washer (4) and nut (5), then tighten
emergency stop switch lock plate so that nut to specified torque.
the motor cannot be started accidentally. 4) Push cotter pin (6) through nut and shaft, then bend
• Wear gloves to protect hands, and lock the to secure.
propeller by placing a block of wood Tightening torque
between the propeller blade tips and the Propeller nut (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
anti-cavitation plate before attempting to
remove or install propeller nut. 3
2
Removal
1) Shift to “Neutral” position. 6
5
2) Remove cotter pin (1) from propeller nut and remove 1 4
propeller nut (2).
3) Remove washer (3), spacer (4), propeller (5) and
stopper (6) from the propeller shaft.

I9J011310017-01

(a)

I9J011310001-01

4 I9J011310003-04
5

Propeller / Propeller Nut / Cotter Pin Inspection

1 CENDG2113106003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-15).

I9J011310002-02
 Right Hand Rotation Unit: 3A-5

Lower Unit Removal and Installation Installation

CENDG2113106004
Removal 1) Apply clutch rod splines with Water Resistant
Grease, then install clutch rod (1) by aligning clutch
! WARNING rod splines with splines in clutch shaft.

Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water

removing or installing the lower unit can Resistant Grease EP2 (250 g))
result in severe personal injury.

Always disconnect the battery cable, before

removing lower unit.

1) Shift to “Neutral” position. Remove bolt and trim tab

(1). 1

IDG211310105-01

2) Ensure that shift rod (2) is at “Neutral” position.

NOTE
1 Before installing lower unit, bring shift to
Neutral position by turning shift rod right or
left.
IDG211310001-01

2) Remove seven bolts (2) and separate gearcase (3)

from driveshaft housing.

NOTE
Before gearcase is removed completely,
disconnect speedometer pick up tube (4)
Front
from gearcase. direction
2

2 IDG211310004-03

3) Insert two dowel pins (3).

4) Apply water resistant grease to driveshaft and shift
rod splines.
3 5) Apply a light coating of suzuki silicone seal to mating
surfaces of gearcase and driveshaft housing.
: Sealant 93691–80030 (SUZUKI Silicone
IDG211310002-01 Seal (100 g))

IDG211310005-02
IDG211310003-01
3A-6 Right Hand Rotation Unit:

6) Set the clutch control lever (4) at “Neutral” position, Water Pump Removal and Installation
then slide the lower unit (5) into place, ensuring that CENDG2113106005

the top of driveshaft engages properly with driven Removal

gear shaft and that water tube locates in water pump 1) Remove the lower unit.
case outlet. Refer to “Lower Unit Removal and Installation” (Page
3A-5).
NOTE 2) Loosen four bolts (1), then remove water pump case
In order for shift rod and clutch rod splines to (2).
be aligned correctly, clutch rod may need to
be turned slightly right or left.

IDG211310008-01
“N” 4 3) Remove impeller (3), impeller key (4), under panel
(5) and dowel pins (6).
IDG211310006-02
Keep impeller key (4) for reuse and discard the plate
7) Apply suzuki silicone seal to seven gearcase bolts gasket.
and tighten them to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
3
Tightening torque
Gearcase bolt (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
6

5 6

IDG211310009-01

(a)
4) Remove inner sleeve (7), sealing (8).

NOTE
5 To facilitate the removal of inner sleeve from
pump case, warm up the entire case using a
IDG211310007-02
heater like hair dryer.
8) Shift the clutch control lever to “Forward” and
“Reverse” position from “Neutral” position to check
proper gear engagement.

IDG211310011-02
 Right Hand Rotation Unit: 3A-7

Installation
1) Place the dowel pins (1), gasket (2) and under panel
(3) into position.
2) Insert the key (4) in the driveshaft and slide the
impeller (5) onto driveshaft, ensuring that key and
keyway is aligned.

8
1 5
IDG211310014-01

3 4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
1
case inner sleeve and under panel for initial
2 lubrication.
IDG211310012-01

3) Place the sealing (7) into groove of the pump case

(6).

NOTE
Do not reuse sealing once removed.
Always use new sealing.

IDG211310015-01

5) Install the pump case assembly (9) while rotating

driveshaft clockwise to flex the impeller vanes in the
6
correct direction.
Securely tighten the four pump case bolts (10) to the
specified torque.
IDG211310013-01 Tightening torque
4) Install inner sleeve (8) into the pump case, ensuring Water pump case bolt (a): 17 N·m (1.7 kgf-m,
that projection of inner sleeve and groove of pump 12.5 lbf-ft)
case are aligned.

NOTE
Before installing pump inner sleeve, apply
water resistant grease lightly between inner
9
sleeve and pump case mating surfaces.

: Grease 99000–25350 (SUZUKI Water

Resistant Grease EP2 (250 g))
10 (a)

IDG211310016-01

6) Install the Lower Unit.

Refer to “Lower Unit Removal and Installation” (Page
3A-5).
3A-8 Right Hand Rotation Unit:

Water Pump and Related Item Inspection Lower Unit Disassembly

CENDG2113106006
Inspect the following parts.
• Inspect impeller. Replace if vanes are cut, torn, worn
or other abnormal conditions.
• Inspect pump case. Replace if cracked, distorted or
other abnormal conditions are noted.
• Inspect pump inner sleeve. Replace if worn, cracked,
distorted, corroded or other abnormal conditions are
noted.
• Inspect under panel. Replace if cracked, distorted,
corroded or other abnormal conditions are noted.
NOTE
Do not reuse sealing once removed.
Always use new sealing.
CENDG2113106007
1) Remove the lower unit.
Refer to “Lower Unit Removal and Installation” (Page
3A-5).
2) Remove the propeller.
Refer to “Propeller Removal and Installation” (Page
3A-4).
3) Remove the water pump and related parts.
Refer to “Lower Unit Removal and Installation” (Page
3A-5) and “Water Pump Removal and Installation”
(Page 3A-6).
4) Place a drain pan under oil drain plug. Remove oil
drain plug (1) first then oil level plug (2) and allow
gear oil to drain.
Inspect oil for water, contaminates or metal.

1
IDG211310019-01
IDG211310017-01 5) Remove the bolts (3) and shift rod guide housing
assembly (4).

IDG211310018-01

IDG211310020-01

6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.

IDG211310021-01
 Right Hand Rotation Unit: 3A-9

7) Using special tools, pull out the propeller shaft 10) Lift out driveshaft assembly (9).
bearing housing.
Remove the propeller shaft and bearing housing
assembly (6).
Special tool
9
(A): 09930–30104 (Sliding hammer)
(B): 09930–30161 (Propeller shaft remover)

IDG211310025-01
(A)
11) Remove the driveshaft collar (10) from driveshaft (If
necessary).
6
(B)

IDG211310022-02

8) Hold the pinion nut securely, then fit special tool to

the driveshaft and loosen the pinion nut. Remove
pinion nut (7).
Special tool
(C): 09921–29410 (Driveshaft holder) 10

IDG211310026-01

12) Remove the pinion gear (11).

7
(C)

IDG211310023-01

9) Remove the four bolts securing driveshaft oil seal 11

housing (8), then remove oil seal housing and pinion
gear shim.
IDG211310027-01

13) Remove the forward gear (12) and thrust bearing

(13).

13

IDG211310024-01

12
IDG211310028-01
3A-10 Right Hand Rotation Unit:

14) Remove the bearing thrust washer (14) and back-up

shim (15).

26

27

28
15
25

14 IDG211310030-02

e) Use special tool to push the dog pin (29) out of

IDG211310102-01 the clutch dog shifter (28).
15) Remove the forward gear bearing housing (16).
Special tool
Account for dowel pin (17).
(D): 09922–89810 (Shift lock pin
remover)
16 17
(D)

29

IDG211310103-01
28
16) To disassemble propeller shaft components, refer to IDG211310031-02

following. f) Remove clutch dog shifter (28) and connector

a) Slide propeller shaft away from reverse gear (21) pin (30) from propeller shaft.
and bearing housing assembly (22).
Account for the reverse gear back-up shim (23)
and reverse gear thrust washer (24).
30

22
21

28
29

IDG211310032-02

24 23 g) Remove large detent ball (31), detent spring

(32), large detent ball (33) and two small detent
IDG211310029-01 balls (34) from connector pin (30).
b) Remove horizontal slider (25).
c) Remove forward gear thrust washer (26).
d) Remove the spring (27) from the clutch dog
shifter (28).
30

34

33 32 31
IDG211310033-01
 Right Hand Rotation Unit: 3A-11

17) To disassemble shift rod components, refer to Special tool

following. (A): 09951–59910 (Shaft (removal and
a) Remove oil seal cover (35). installation))
(B): 09951–38710 (Plate)
b) Slide shift rod (36) out of shift rod guide housing
(C): 01500–08403 (Bolt)
(37).
(D): 09951–19220 (Attachment)
c) Remove oil seal (38) from shift rod guide (E): 09930–30104 (Sliding hammer)
housing.

37

35
38

36

IDG211310034-01

d) Remove the shifter yoke (40) from the shift rod

(36) by driving out the pin (39).
I9J011310018-03

Removal
1) Disassemble the lower unit.
39
Refer to “Lower Unit Disassembly” (Page 3A-8).
40
2) Place the attachment (D) inside the pinion bearing.
36 3) Insert the removal shaft (A) into attachment (D).
4) Thread sliding hammer (E) into top of removal shaft
(A).
5) Put wood block under pinion bearing.
6) Drive the pinion bearing out downwards by striking
IDG211310035-02
top of shaft (A) with sliding hammer (E).

Pinion Bearing Removal and Installation

CENDG2113106008
NOTICE
(E)
Removing the bearing can cause damage to
needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the
lower unit.

Do not reuse pinion bearings once removed.

(A)
Always use new ones.

Removal and Installation Tools

To remove the pinion bearing from the gearcase, use the
following special tools.
(D)

1
2

IDG211310037-03

1. Pinion bearing 2. Wood block

3A-12 Right Hand Rotation Unit:

Installation Lower Unit Related Item Inspection

NOTE
• Before installing bearing, ensure that
inside of gearcase is clean and free of
debris.
• Ensure that the bearing stamped mark
faces upward.
1) Set the installer shaft (A), plate (B), attachment (D),
and pinion bearing as shown in the figure.
2) Place the installer shaft (A) (with pinion bearing on
end of installer shaft) into the gearcase.
3) Secure the plate (B) by tightening the bolt (C).
4) Thread the sliding hammer (E) into the top of the
installer shaft (A).
5) Drive the pinion bearing down into position by gently
striking the installer shaft (A) until the coupler
touches plate.
6) Assemble the lower unit.
Refer to “Lower Unit Assembly” (Page 3A-16).
(E)
(B)
(A)
CENDG2113106009
! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.
Wear safety glasses when using compressed
air.
NOTE
• If any component is worn excessively,
cracked, defective or damaged in any way,
it must be replaced.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.
Gearcase
• Inspect the gearcase. Replace if cracked, damaged or
other abnormal conditions are noted.
• Visually check the pinion bearing. Replace bearing if
pitted, rough or other abnormal conditions are noted.
NOTE
If removal and replacement are required,
refer to “Pinion Bearing Removal and
Installation” (Page 3A-11).
(C)

IDG211310038-02

(E)

IDG211310041-01

(C)
(A)
(B)

(D)

IDG211310039-04

1. Pinion bearing

Gears / Bearing
• Inspect forward, reverse and pinion gear teeth and
engaging dogs.
Replace gears if damaged, worn or other abnormal
conditions are noted.
• Inspect forward gear thrust bearing.
Replace bearing if pitted, noisy, rough or other
abnormal conditions are noted.
• Inspect forward gear bearing housing.
Replace if cracked, damaged or other abnormal
conditions are noted.
• Inspect forward gear bearing.
Replace bearing if pitted, noisy, rough or other
abnormal conditions are noted.
IDG211310042-01
IDG211310043-01
Right Hand Rotation Unit: 3A-13
Propeller Shaft Components
• Inspect horizontal slider and connector pin.
Replace if wear, damage or other abnormal condition.
• Inspect detent balls. Replace if wear, damage or other
abnormal conditions are noted.
• Inspect clutch dog shifter. Replace if chipped, worn,
damaged or other abnormal conditions are noted.
• Inspect dog pin. Replace if bent, worn or other
abnormal conditions are noted.
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.
IDG211310044-01
• Check detent spring by measuring its free length. If
free length is not within specifications, replace detent
spring.
Detent spring free length “a”
Standard: 27.8 mm (1.09 in.)
Service limit: 25.0 mm (0.98 in.)
“a”
I9J011310062-01
3A-14 Right Hand Rotation Unit:
Propeller Shaft Bearing Housing
• Inspect housing. Replace if cracked, damaged or
other abnormal conditions are noted.
• Inspect reverse gear bearing and propeller shaft
bearing. Replace bearing if pitted, noisy, rough or
other abnormal conditions are noted.
• Check condition of oil seal and O-ring. Replace oil
seal and O-ring if nicked, cut, worn or other abnormal
conditions are noted.
IDG211310045-01
IDG211310046-01
Shift Rod Guide Housing Components
• Inspect shift rod guide housing.
Replace if cracked, damaged or other abnormal
conditions are noted.
• Inspect shifter yoke. Replace if worn, damaged or
other abnormal conditions are noted.
• Inspect shift rod/splines. Replace if worn, twisted,
damaged or other abnormal conditions are noted.
• Inspect O-ring. Replace if nicked, cut, torn, swollen or
other abnormal conditions are noted.
• Inspect oil seal and oil seal cover. Replace if nicked,
cut, worn or other abnormal conditions are noted.
IDG211310047-01
IDG211310048-01
Driveshaft Oil Seal Housing
• Inspect housing. Replace if cracked, damaged or
other abnormal conditions are noted.
• Check condition of oil seals. Replace if nicked, cut,
worn or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other
abnormal conditions are noted.
IDG211310049-01
 Right Hand Rotation Unit: 3A-15

Driveshaft 3) Extract seals (3) with oil seal remover.

• Inspect driveshaft/splines. Replace if worn, twisted,
NOTICE
damaged or other abnormal conditions are noted.
Removing the oil seal can cause damage to
• Inspect driveshaft bearing, replace if pitted, noisy,
the seal lips, causing oil to leak.
rough or other abnormal conditions are noted.
Do not reuse the oil seal once removed.
Always use new one.

Special tool
(A): 09913–50121 (Oil seal remover)

(A)

IDG211310050-01

IDG211310053-01

4) Apply water resistant grease to the inner

circumference of the housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
5) Using an oil seal installer, drive the two oil seals (one
at a time) into the propeller shaft bearing housing.
IDG211310051-01 The lipped portion of the seals must face towards the
propeller. Apply water resistant grease to the seal
Propeller Shaft Oil Seal Replacement lips.
CENDG2113106010
1) Remove the propeller shaft bearing housing.
Refer to “Lower Unit Disassembly” (Page 3A-8). “A”
2) Remove the retaining ring (1) and washer (2).

IDG211310054-02
2
“A”: Direction of propeller

6) Install the washer and retaining ring.

IDG211310052-01
7) Assemble the propeller shaft bearing housing.
Refer to “Lower Unit Assembly” (Page 3A-16).
3A-16 Right Hand Rotation Unit:

Driveshaft Oil Seal Replacement Lower Unit Assembly

CENDG2113106011
1) Remove the driveshaft oil seal housing.
Refer to “Lower Unit Disassembly” (Page 3A-8).
2) Using special tool, remove two oil seals out of the
driveshaft oil seal housing.
Special tool
(A): 09913–50121 (Oil seal remover)
NOTICE
Removing the oil seal can cause damage to
the seal lips, causing oil to leak.
Do not reuse the oil seal once removed.
Always use new one.
(A)
CENDG2113106012
Assembly is in reverse order of disassembly with special
attention to the following steps.
NOTICE
Failure to correctly adjust the gear position
will result in lower unit damage.
Before final assembly of lower unit, be
absolutely certain that all gear contact, shim
adjustments and tolerances are correct.
Refer to “Lower Unit Gears - Shimming and
Adjustment” (Page 3A-23).
NOTE
• Make sure that all parts used in assembly
are clean and lubricated.
• It is recommended that all seals, gaskets
and O-rings be replaced with new on
assembly.
• After assembly, check parts for tightness
and smoothness of operation.

Forward Gear Bearing Housing

Install dowel pin (1) and forward gear bearing housing
(2).
IDG211310055-01

3) Apply water resistant grease to inner circumference 2 1

of driveshaft oil seal housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
4) Grease the inner lips of oil seal.
With the lips facing away from driveshaft bearing,
place seal in position and drive it into the oil seal
housing.

IDG211310057-01

“A”

IDG211310056-02

“A”: Direction of water pump case

5) Assemble the driveshaft oil seal housing.

Refer to “Lower Unit Assembly” (Page 3A-16).
 Right Hand Rotation Unit: 3A-17

Forward Gear Driveshaft

Place the forward gear back-up shim (1), thrust washer • Assemble the driveshaft collar (1) to driveshaft.
(2), forward gear thrust bearing (3) in position, then After installing driveshaft collar, fit the convex part of
install forward gear (4). collar in the concave part of driveshaft by turning
collar.

1
IDG211310058-01

IDG211310061-01

• Lower the driveshaft assembly (2) down into the

gearcase until the bottom of shaft protrudes through
center of pinion gear.

3
2
4

IDG211310059-01

Pinion Gear
Place pinion gear (1) in gearcase.
IDG211310062-01

• Install the bearing outer race (3) and pinion gear shim
(4) to driveshaft.

1
4
IDG211310060-01
3

IDG211310063-01
3A-18 Right Hand Rotation Unit:

Driveshaft Oil Seal Housing

• Apply water resistant grease to the driveshaft oil seal.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
• Apply water resistant grease to O-ring (1), then install
O-ring into groove on the driveshaft oil seal housing
(2). (A)

1 (a)

2
IDG211310066-01

1 Propeller Shaft
• Slide the clutch dog shifter (2) onto the propeller shaft
(1).

NOTE
The side of the clutch dog shifter marked
IDG211310064-01 with the letter “R” must face towards reverse
• Install the driveshaft oil seal housing on the gearcase, gear.
then tighten four bolts (3) securely.

“R”
3

IDG211310065-01
• Insert two small detent balls (3), large detent ball (4),
Pinion Nut
• Apply thread lock 1342 to the threads of pinion nut (1)
before threading it onto driveshaft.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
• Tighten pinion nut to specified torque.
2
IDG211310067-01
detent spring (5) and large detent ball (6) into
connector pin (7). Then depress detent ball (6) and
temporarily insert stopper pin “A” into dog pin hole of
connector pin, as shown in figure.
7

NOTE
It is recommended the original pinion nut be
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly. 6
3
5
Special tool 4
(A): 09921–29410 (Driveshaft holder) IDG211310068-01

Tightening torque NOTE

Pinion nut (a): 120 N·m (12.0 kgf-m, 87.0 lbf-ft)
Temporarily insert a water pump case dowel
pin “A” into the connector pin to prevent the
detent ball from falling out.
 Right Hand Rotation Unit: 3A-19

• Assemble horizontal slider (6) to connector pin.

“A” • Apply water resistant grease to the bearing housing
O-ring (7).

IDG211310069-03 7
• Insert the connector pin (7) (with detent balls) into
propeller shaft (1).
• Align the holes in the shifter dog and connector pin
6
and then slide the dog pin (8) through both dog and
connector pin. (save the temporarily installed dowel
pin “A” pushed out as the dog pin is inserted.)
• Install the dog pin retaining spring (9), ensuring that it
fits snugly into the groove on the dog shifter.
IDG211310072-02

NOTE
Before installing the propeller shaft/bearing
housing assembly, move the shifter dog to
bring the horizontal slider to the “Neutral”
8 position.
1
• Using special tools, install the propeller shaft and
housing assembly in the gearcase.

7 Special tool
9
(A): 09922–59410 (Propeller shaft housing
IDG211310070-01
installer)
Propeller Shaft / Bearing Housing (B): 09922–59420 (Housing installer handle)
• Place the forward thrust washer (1) and reverse thrust
washer (2) on the propeller shaft.
(A)
• Install back-up shim (3) and reverse gear (4) to
propeller shaft bearing housing (5).
• Slide propeller shaft into reverse gear and propeller
shaft bearing housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
: Gear Oil 99000–22B22 (SUZUKI Outboard
Motor Gear Oil) (B)
IDG211310073-01

• When the housing is fully seated, tighten both

4 retaining bolts to the specified torque.
Tightening torque
2 Bearing housing bolt (a): 23 N·m (2.3 kgf-m, 16.6
lbf-ft)
1 5

3
(a)

IDG211310071-02

IDG211310074-01
3A-20 Right Hand Rotation Unit:

Checking Propeller Shaft Thrust Play
Check propeller shaft thrust play.
Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3A-23).
Special tool
(A): 09951–09530 (Gear adjusting gauge)
• Attach shifter yoke (4) to sift rod (3), then insert pin
(5).
• Install pin (6) to shift rod, then slide shift rod guide
housing onto shift rod.

4
(A)
3

IDG211310077-01

IDG211310075-01 NOTE
Before install the shift unit (shift rod guide
Shift Rod Guide Housing housing assembly), be sure to put the
• Apply water resistant grease to the oil seal. horizontal slider (7) in the neutral position.
• Using an oil seal installer, drive the oil seal (1) into the
shift rod guide housing (2).
The lipped portion of oil seal must face towards the “A”
driveshaft housing.
8
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g)) 7

IDG211310078-04

7. Horizontal slider
8. Forward gear bearing housing
“A”: Shift rod center

2
1 3 • Apply water resistant grease to the shift rod guide
6 housing O-ring.
IDG211310076-03 : Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

Front
direction

4
IDG211310079-02

NOTE
Before installing the shift rod guide housing
assembly, bring the shifter yoke to the
“Neutral” position by turning the shift rod
right or left.
 Right Hand Rotation Unit: 3A-21

• Install the shift rod guide housing assembly (9) by Leakage Check
aligning the shifter yoke with the groove in horizontal Check for leakage of oil seal and O-ring when applying
slider, then tighten two housing bolts (10) securely. specified pressure inside of the gearcase.
1) Install the test tool into the oil level hole.
2) Connect the air pump to the tester.
9 3) Rotate driveshaft and propeller shaft clockwise
several times and then apply specified pressure for
the test.

NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
10

Do not exceed pressure of 110 kPa (1.1 kg/

IDG211310080-03
cm2, 15.6 psi.).

7 NOTE
Apply low initial pressure of 20 – 40 kPa (0.2
– 0.4 kg/cm2, 2.8 – 5.7 psi.) first, then apply
specified pressure.

Special tool
(A): 09950–69512 (Gearcase oil leakage
tester)
4
IDG211310081-03 (B): 09952–99320 (Hand air pump)
• Turn the shift rod from the “Neutral” position to the Leakage pressure test
“Forward” and “Reverse” position to check proper 100 kPa (1.0 kg/cm2, 14.2 psi.)
gear engagement.
• Apply enough water resistant grease on oil seal
before putting oil seal cover (11) so that there is no
space between them.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

(A)
11
(B)

IDG211310083-01

4) Once stabilized, pressure should remain steady for

at least 5 min.
If pressure does not fall, sealing performance is
correct.

IDG211310082-04
3A-22 Right Hand Rotation Unit:

Water Pump Lower Unit

Install the water pump and related parts. Install the Lower Unit.
Refer to “Lower Unit Removal and Installation” (Page Refer to “Lower Unit Removal and Installation” (Page
3A-5) and “Water Pump Removal and Installation” (Page 3A-5).
3A-6).

Propeller
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3A-
4).

Trim Tab Adjustment

CENDG2113106013
The trim tab counteracts or minimizes propeller torque pull felt through the steering system.
If the steering is pulls to the starboard or port side, adjust the trim tab with the following procedure.
1) Loosen the trim tab bolt (1).

IDG211310084-01

2) Changing the trim tab setting.

• To compensate for a veer to starboard, set the trailing edge of tab (2) to the right (as viewed from behind).
• To compensate for a veer to port, set the trailing edge of tab to the left.

I9J011310010-03

3) Tighten the bolt of trim tab.

4) Test drive the boat and repeat the procedure 1) – 3) to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be neutral and there should be no tendency for the steering to be
pulled to either port or starboard.
 Right Hand Rotation Unit: 3A-23

Lower Unit Gears - Shimming and Adjustment

CENDG2113106014
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash
will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim/Washer and mounting position
Item Available thickness (mm) Design specification thickness (mm)
0.50, 0.55, 0.60, 0.65, 0.70, 0.75, 0.80,
Pinion gaer back-up shim 1.0
0.85, 0.90, 0.95, 1.00, 1.05, 1.10, 1.15
0.60, 0.65, 0.70, 0.75, 0.80, 0.85, 0.90,
Forward gear back-up shim 1.1
0.95, 1.00
Forward gear thrust washer 9.0 9.0
Propeller shaft reverse thrust
1.5, 1.7, 1.9, 2.1, 2.3, 2.4, 2.6, 2.7, 2.8 1.5
washer
Reverse gear back-up shim 1.0, 1.1, 1.2, 1.3, 1.4, 1.5, 1.6 1.5

3
5
2

IDG211310085-01

1. Pinion gear back-up shim 3. Forward gear thrust washer 5. Reverse gear back-up shim
2. Forward gear back-up shim 4. Propeller shaft reverse thrust washer
3A-24 Right Hand Rotation Unit:

Driveshaft Preloading Spring Set
Install the special tool (A) on the driveshaft as shown in
figure when adjusting the gear shim and tooth contact
pattern.
Apply preload to the driveshaft then an appropriate
adjustment can be obtained.
Forward Gear / Pinion Gear Back-Up Shim
Adjustment
Prior to adjustment
1) Install standard pinion gear back-up shim thickness
according to ± design specification mark on the gear.

NOTE
After adjusting the forward/reverse gear
shim, remove the special tool from
driveshaft.

Special tool
(A): 09951–09030 (Driveshaft preloading spring “A”
IDG211310104-01
set)
“A”: ± design spec. mark

2) Assemble the special tool (A) on the driveshaft as

shown.

1
2
(A)

(A)

IDG211310086-01

(A)

1 IDG211310087-02
2
1. Spring 2. Washer

3) Correctly assemble driveshaft oil seal housing,

driveshaft, forward gear, pinion gear and related
components.
Refer to “Lower Unit Assembly” (Page 3A-16).
(A) Do not install reverse gear at this time.

IDG211310087-02

1. Spring 2. Washer

IDG211310088-01

4) Tighten pinion nut to specified torque.

Tightening torque
Pinion nut: 120 N·m (12.0 kgf-m, 87.0 lbf-ft)
 Right Hand Rotation Unit: 3A-25

Adjusting gear backlash Checking and adjusting tooth contact pattern

1) Assemble special tools to driveshaft as shown in (Pinion gear and forward gear)
figure. Check tooth contact pattern using the following
procedure.
Special tool
1) To assess tooth contact, apply a light coat of
(A): 09900–20602 (Dial gauge)
prussian blue on the convex surface of the forward
(B): 09900–20701 (Magnetic stand)
gear.
(C): 09952–09310 (Backlash indicator tool)
2) Install the propeller shaft and housing assembly
(minus reverse gear and internal components).
(B)
(C)
3) Push the propeller shaft inward and hold it in
position.

Push
(A)

IDG211310089-01

(C)
IDG211310091-01

4) Using the driveshaft holder tool, rotate the driveshaft

5 – 6 times.
Special tool
(A)
(A): 09921–29410 (Driveshaft holder)

IDG211310090-01

2) Push forward gear inward and hold it by hand, align

dial gauge pointer at 90° to the mark on the backlash
indicator tool and read backlash on dial gauge by (A)
lightly moving driveshaft clockwise and
counterclockwise by hand.
Gear backlash
0.3 – 0.5 mm (0.012 – 0.020 in.)
• If the backlash measured is larger than the
specification, add the amount over the IDG211310092-01
specification to the temporary use forward gear
5) Carefully remove the propeller shaft and housing to
back-up shim and install this shim.
check the tooth contact pattern.
• If the backlash measured is smaller than the
specification, subtract the amount less than the “A”
specification from the temporary use forward gear “a”
back-up shim and install this shim. “B”
“C”

“F”

“G”
“D”

“E”
I9J011310013-02

“A”: Concave side “E”: Tooth bottom

“B”: Convex side “F”: Toe
“C”: Heel “G”: Tooth contact pattern
“D”: Tooth top “a”: Tooth width
3A-26 Right Hand Rotation Unit:

Optimum tooth contact Example [B]

The optimum tooth contact is shown in the figure. A shim Incorrect bottom side toe contact.
adjustment may be necessary to obtain this contact Correction measures.
pattern. • Increase thickness of forward gear shim.
NOTE • Slightly decrease pinion gear shim thickness.
Gear backlash should be checked when NOTICE
increasing or decreasing shim thickness to
Setting the tooth contact in the bottom side
adjust tooth contact.
toe contact may cause chipping on pinion
gear.
Optimum tooth contact Do not set the tooth contact as such bottom
side toe contact.
“a”
“b”
“A” Example of incorrect

“C” “C”
“B” “A”
I9J011310014-02
I9J011310016-01
“A”: Heel “a”: Approx. 1/3 of tooth width
“B”: Convex side “b”: Approx. 1 mm (0.04 in) Rechecking Gear Backlash
“C”: Toe After obtaining optimum tooth contact, gear backlash
should be measured.
Example [A] 1) Assemble special tools to driveshaft as shown in
Incorrect topside toe contact. figure.
Correction measures.
• Decrease thickness of forward gear shim. Special tool
(A): 09900–20602 (Dial gauge)
• Slightly increase pinion gear shim thickness.
(B): 09900–20701 (Magnetic stand)
NOTICE (C): 09952–09310 (Backlash indicator tool)
Setting the tooth contact in the top side toe
(B)
contact may cause damage and chipping on (C)
forward and pinion gears.
Do not set the tooth contact as such top side
toe contact.

Example of incorrect
(A)

“C”
IDG211310093-02
“A” 2) Push the forward gear inward and fix it by hand, then
I9J011310015-01
read backlash on dial graduation by lightly moving
driveshaft clockwise and counterclockwise by hand.
Designate this amount of gear backlash as (A).

NOTE
Gear backlash (A) must be known to adjust
reverse gear shim.

Gear backlash (A)

0.3 – 0.5 mm (0.012 – 0.020 in.)
 Right Hand Rotation Unit: 3A-27

Reverse Gear Back-Up Shim Adjustment 4) Install the gear holder to the propeller shaft bearing
After adjusting the forward gear tooth contact pattern, housing and then attach it to the propeller shaft as
follow the procedure below to adjust the reverse gear. shown.
1) Correctly assemble and install reverse gear, 5) Turning bolt (2) counterclockwise to pull reverse
propeller shaft, propeller shaft bearing housing and gear outward, tighten lightly the bolt after having
related components. stopped. Do not over tighten.
2) Screw a slide hammer assembly onto the propeller
shaft and strike it a few gentle outward taps.
Special tool
(A): 09930–30161 (Propeller shaft remover)
(B): 09930–30104 (Sliding hammer)
(C)

(C)

IDG211310097-05

(C)
(A)

(B)
IDG211310095-03

3) Remove the adapters (1) from special tool.

Special tool
(C): 09951–99310 (Gear holder)

IDG211310106-03

1 6) Assemble backlash indicator tool and dial gauge as

(C) shown in figure.
1 7) Read backlash on dial gauge by lightly moving
driveshaft clockwise and counterclockwise by hand.
Designate this measurement as backlash (B).
Gear backlash (B)
Approx. 0.5 – 0.8 mm (0.019 – 0.020 in.)
IDG211310096-03
8) Compare backlash (B) to backlash (A).
Refer to “Rechecking Gear Backlash” (Page 3A-26).
Reverse gear back-up shim adjustment is correct if
(B) is equal to (A).
• If (B) is less than (A), reduce reverse gear back-
up shim thickness.

IDG211310098-01

1. Backlash indicator tool 2. Dial gauge

3A-28 Right Hand Rotation Unit:

Checking propeller shaft thrust play 1) Assemble the gear adjusting gauge to the propeller
After adjusting all gear positions, measure the propeller shaft.
shaft thrust play. If not within the following specification,
Special tool
a shim adjustment is required.
(A): 09951–09530 (Gear adjusting gauge)
NOTE
Maintain the forward gear thrust washer at
standard thickness (9.0 mm) and use only the
propelle shaft reverse thrust washer to adjust (A)
thrust play.

Propeller shaft thrust play

Approx. 0.2 – 0.4 mm (0.01 – 0.02 in.)

IDG211310099-01

2) Push propeller shaft inward.

3) Hold the shaft in and set the dial gauge pointer to
zero.
4) Slowly pull the shaft outward and read the maximum
thrust play on the dial gauge.
• If the measurement is more than the specification,
increase the propeller shaft reverse thrust washer
thickness.
• If the measurement is less than the specification,
reduce the propeller shaft reverse thrust washer
thickness.
 Left Hand Rotation Unit: 3B-1

Left Hand Rotation Unit

Lower Unit

Diagnostic Information and Procedures

Diagnose Lower Unit Malfunction
CENDG2113204001
Trouble Check Chart

Condition Possible cause Correction / Reference Item

Engine stalls when Idling speed set too low. Adjustment.
engaging gear Propeller shaft bearings damaged, Replace.
lacking lubrication or seized.
Engaging gear(s) has no Clutch out of adjustment. Adjustment.
effect on propulsion Driveshaft broken or splines damaged. Replace.
Chipped or worn dog clutches. Replace.
Propeller not secured correctly (fallen Inspection or retighten.
off).
Loss of power. (Assuming Propeller bush slipping. Replace.
engine is OK) Bent or worn propeller. Repair or replace.
Engine shakes the boat Failed propeller bush. Replace.
Bent driveshaft or propeller shaft. Replace.
Damaged propeller. Replace.
Clutch will not engage or Seized shift rod. Inspection.
disengage Clutch shaft and clutch rod have Inspection.
become detached.
Seized/broken remote control cable. Replace.
Problem at control box end. Inspection or replace.
3B-2 Left Hand Rotation Unit:

Service Instructions
Lower Unit Components
CENDG2113206001

13 (c) 11
1

3 6

2 12
14
16 15
4 9
7
5 17

9 18
8
19
32
31 30
10
20
22 29
21
23

24

25

26
33

35
28 (b)

27 (a)
34
35
37

36

IDG211320110-03

1. Oil seal cover 12. Water pump case 23. Union 34. Bolt
2. Oil seal 13. Bolt 24. Hose 35. Screw
3. Bolt 14. Dowel pin 25. Nipple 36. Water filter PORT
4. Shift rod guide housing 15. Key 26. Gearcase 37. Water filter STBD
5. O-ring 16. Water pump case sealing 27. Bolt : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
6. Shift rod 17. Inner sleeve 28. Bolt : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
7. Magnet 18. Water pump impeller 29. Dowel pin : 17 N⋅m (1.7 kgf-m, 12.5 lbf-ft)
8. Shifter yoke 19. Under panel 30. Anode : Apply SUZUKI Water Resistant Grease.
9. Pin 20. Gasket 31. Washer : Apply SUZUKI Silicon seal.
10. Horizontal slider 21. Exhaust seal rubber 32. Bolt
11. Bush 22. Exhaust seal plate 33. Trim tab
 Left Hand Rotation Unit: 3B-3

4
1
52 56 (c)
5
55
54
2
53 57
3
8
51 19 (b)
6

7 15

16
9 17
18
20
13 21
23
11 31 22
10 (d) 12 24
25
26
27
32 (a) 28

29
30
33
14 34
35
50
36
37
38 47 49
40 39 48
41
46
44
11

10 (d)
42 43
45
IDG211320106-04

1. Driveshaft 17. Oil seal 33. Reverse gear 49. Dog spring
2. Bolt 18. Bearing 34. Bearing 50. Propeller shaft
3. Driveshaft oil seal housing 19. Bolt 35. Reverse gear retainer 51. Stopper
4. Oil seal 20. Propeller shaft bearing housing 36. Thrust bearing 52. Propeller
5. Oil seal 21. Bearing 37. Thrust washer 53. Propeller bush
6. Shim 22. O-ring 38. Backup shim 54. Spacer
7. Bearing 23. Shim 39. Bearing 55. Washer
8. O-ring 24. Washer 40. Reverse gear bearing 56. Propeller nut
housing
9. Driveshaft collar 25. Bearing 41. Pin 57. Cotter pin
10. Plug 26. Thrust washer 42. Spacer : 120 N⋅m (12 kgf-m, 87.0 lbf-ft)
11. Gasket 27. Backup shim 43. Small detent ball : 23 N⋅m (2.3 kgf-m, 16.6 lbf-ft)
12. Pinion bearing 28. Thrust washer 44. Spring : 55 N⋅m (5.5 kgf-m, 40 lbf-ft)
13. Dowel pin 29. Forward gear thrust bearing 45. Large detent bell : 10 N⋅m (1.0 kgf-m, 7.2 lbf-ft)
14. Gearcase 30. Forward gear 46. Dog pin : Apply SUZUKI Water Resistant Grease.
15. Ring 31. Pinion gear 47. Connector pin : Apply SUZUKI Outboard Motor Gear Oil.
16. Oil seal protector 32. Pinion nut 48. Clutch dog shifter : Apply SUZUKI Thread Lock 1342.
3B-4 Left Hand Rotation Unit:

Propeller Removal and Installation Installation

CENDG2113206002
1) Coat the propeller shaft splines liberally with Suzuki
! WARNING water resistant grease.
Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water
installing or removing the propeller can Resistant Grease EP2 (250 g))
result in severe personal injury.
2) Install propeller stopper (1) onto propeller shaft, then
When installing or removing the propeller: slide on the propeller (2).
• Shift into “Neutral” and remove the 3) Fit spacer (3), washer (4) and nut (5), then tighten
emergency stop switch lock plate so that nut to specified torque.
the motor cannot be started accidentally. 4) Push cotter pin (6) through nut and shaft, then bend
• Wear gloves to protect hands, and lock the to secure.
propeller by placing a block of wood Tightening torque
between the propeller blade tips and the Propeller nut (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
anti-cavitation plate before attempting to
remove or install propeller nut. 3
2
Removal
1) Shift to “Neutral” position. 6
5
2) Remove cotter pin (1) from propeller nut and remove 1 4
propeller nut (2).
3) Remove washer (3), spacer (4), propeller (5) and
stopper (6) from the propeller shaft.

I9J011310017-01

(a)

I9J011310001-01

4 I9J011310003-04
5

Propeller / Propeller Nut / Cotter Pin Inspection

1 CENDG2113206003
2 Refer to “Propeller / Propeller Nut and Cotter Pin
6 3 Inspection” in Section 0B (Page 0B-15).

I9J011310002-02
 Left Hand Rotation Unit: 3B-5

Lower Unit Removal and Installation Installation

CENDG2113206004
Removal 1) Apply clutch rod splines with Water Resistant
Grease, then install clutch rod (1) by aligning clutch
! WARNING rod splines with splines in clutch shaft.

Failure to take proper precautions when : Grease 99000–25350 (SUZUKI Water

removing or installing the lower unit can Resistant Grease EP2 (250 g))
result in severe personal injury.

Always disconnect the battery cable, before

removing lower unit.

1) Shift to “Neutral” position. Remove bolt and trim tab

(1).
1

IDG211320111-02

2) Ensure that shift rod (2) is at “Neutral” position.

NOTE
1 Before installing lower unit, bring shift to
Neutral position by turning shift rod right or
left.
IDG211320001-01

2) Remove seven bolts (2) and separate gearcase (3)

from driveshaft housing.

NOTE
Before gearcase is removed completely,
disconnect speedometer pick up tube (4)
Front
from gearcase. direction
2

2 IDG211320004-02

3) Insert two dowel pins (3).

4) Apply water resistant grease to driveshaft and shift
rod splines.
3 5) Apply a light coating of Suzuki silicone seal to mating
surfaces of gearcase and driveshaft housing.
: Sealant 93691–80030 (SUZUKI Silicone
IDG211320002-01 Seal (100 g))

IDG211320005-02
IDG211320003-01
3B-6 Left Hand Rotation Unit:

6) Set the clutch control lever (4) at “Neutral” position, Water Pump Removal and Installation
then slide the lower unit (5) into place, ensuring that CENDG2113206005

the top of driveshaft engages properly with driven Removal

gear shaft and that water tube locates in water pump 1) Remove the lower unit.
case outlet. Refer to “Lower Unit Removal and Installation” (Page
3B-5).
NOTE 2) Loosen four bolts (1), then remove water pump case
In order for shift rod and clutch rod splines to (2).
be aligned correctly, clutch rod may need to
be turned slightly right or left.

IDG211320008-01
N
4 3) Remove impeller (3), impeller key (4), under panel
(5) and dowel pins (6).
IDG211320006-03
Keep impeller key (4) for reuse and discard the
7) Apply Suzuki silicone seal to seven gearcase bolts gasket.
and tighten them to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
3
Tightening torque
Gearcase bolt (a): 55 N·m (5.5 kgf-m, 40.0 lbf-ft)
6

5 6

IDG211320009-01

(a)
4) Remove inner sleeve (7), sealing (8).

NOTE
5 To facilitate the removal of inner sleeve from
pump case, warm up the entire case using a
IDG211320007-02
heater like hair dryer.
8) Shift the clutch control lever to “Forward” and
“Reverse” position from “Neutral” position to check
proper gear engagement.

IDG211320107-02
 Left Hand Rotation Unit: 3B-7

Installation
1) Place the dowel pins (1), gasket (2) and under panel
(3) into position.
2) Insert the key (4) in the driveshaft and slide the
impeller (5) onto driveshaft, ensuring that key and
keyway is aligned.

8
1 5
IDG211320013-03

3 4 NOTE
Before installing water pump case assembly,
apply water resistant grease lightly on pump
1
case inner sleeve and under panel for initial
2 lubrication.
IDG211320011-01

3) Place the sealing (7) into groove of the pump case

(6).

NOTE
Do not reuse sealing once removed.
Always use new sealing.

IDG211320014-01

5) Install the pump case assembly (9) while rotating

driveshaft clockwise to flex the impeller vanes in the
6
correct direction.
Securely tighten the four pump case bolts (10) to the
specified torque.
IDG211320012-01 Tightening torque
4) Install inner sleeve (8) into the pump case, ensuring Water pump case bolt (a): 17 N·m (1.7 kgf-m,
that projection of inner sleeve and groove of pump 12.5 lbf-ft)
case are aligned.

NOTE
Before installing pump inner sleeve, apply
water resistant grease lightly between inner
9
sleeve and pump case mating surfaces.

: Grease 99000–25350 (SUZUKI Water

Resistant Grease EP2 (250 g))
10 (a)

IDG211320015-01

6) Install the Lower Unit.

Refer to “Lower Unit Removal and Installation” (Page
3B-5).
3B-8 Left Hand Rotation Unit:

Water Pump and Related Item Inspection Lower Unit Disassembly

CENDG2113206006
Inspect the following parts.
• Inspect impeller. Replace if vanes are cut, torn, worn
or other abnormal conditions.
• Inspect pump case. Replace if cracked, distorted or
other abnormal conditions are noted.
• Inspect pump inner sleeve. Replace if worn, cracked,
distorted, corroded or other abnormal conditions are
noted.
• Inspect under panel. Replace if cracked, distorted,
corroded or other abnormal conditions are noted.
NOTE
Do not reuse sealing once removed.
Always use new sealing.
CENDG2113206007
1) Remove the lower unit.
Refer to “Lower Unit Removal and Installation” (Page
3B-5).
2) Remove the propeller.
Refer to “Propeller Removal and Installation” (Page
3B-4).
3) Remove the water pump and related parts.
Refer to “Lower Unit Removal and Installation” (Page
3B-5) and “Water Pump Removal and Installation”
(Page 3B-6).
4) Place a drain pan under oil drain plug. Remove oil
drain plug (1) first then oil level plug (2) and allow
gear oil to drain.
Inspect oil for water, contaminates or metal.

1
IDG211320018-01
IDG211320016-01 5) Remove the bolts (3) and shift rod guide housing
assembly (4).

IDG211320017-01

IDG211320019-01

6) Remove two bolts (5) securing the propeller shaft

bearing housing to the gearcase.

IDG211320020-01
 Left Hand Rotation Unit: 3B-9

7) Using special tools, pull out the propeller shaft 10) Lift out driveshaft assembly (9).
bearing housing. Remove the propeller shaft and
bearing housing assembly (6).
Special tool
(A): 09930–30104 (Sliding hammer)
9
(B): 09930–30161 (Propeller shaft remover)

(A)
IDG211320024-01

11) Remove driveshaft collar (10) from driveshaft (If

6 necessary).
(B)

IDG211320021-02

8) Hold the pinion nut securely, then fit special tool to

the driveshaft and loosen the pinion nut. Remove
pinion nut (7).
Special tool
(C): 09921–29410 (Driveshaft holder)
10

IDG211320025-01

12) Remove the pinion gear (11).

7
(C)

IDG211320022-01

9) Remove the four bolts securing driveshaft oil seal

housing (8), then remove oil seal housing and pinion
gear shim. 11

IDG211320026-01

13) Remove reverse gear (12) (with reverse gear

retainer (13)) and thrust bearing (14).

14

IDG211320023-01
13

12

IDG211320027-01
3B-10 Left Hand Rotation Unit:

14) Remove the reverse gear (12) from reverse gear 17) To disassemble propeller shaft components, refer to
retainer (13). following.
a) Slide propeller shaft away from forward gear (19)
12
and bearing housing assembly (20).

13
20
IDG211320028-01

15) Remove the bearing thrust washer (15) and back-up 19

shim (16). IDG211320031-01

b) Remove the forward gear (21), forward gear

thrust bearing (22), forward gear thrust washer
(23), forward gear back-up shim (24).

22
21

16

15

IDG211320029-01
24
16) Remove the reverse gear bearing housing (17) and 23
IDG211320032-01
dowel pin (18).
c) Remove the propeller shaft thrust washer (25),
propeller shaft thrust bearing (26), bearing
washer (27) and shim (28) from propeller shaft
bearing housing.

28
27
26
25

17 18
IDG211320030-01

IDG211320033-01
 Left Hand Rotation Unit: 3B-11

d) To disassemble propeller shaft components,
refer to following.
Remove horizontal slider (29) and spacer (30).
Remove the spring (31) from the clutch dog
shifter (32).
g) Remove large detent ball (35), detent spring
(36), large detent ball (37) and two small detent
balls (38) from connector pin (34).
34

30
38

32
37 36 35
31
IDG211320037-02
29
18) To disassemble shift rod components, refer to
IDG211320034-02 following.
e) Use special tool to push the dog pin (33) out of a) Remove oil seal cover (39).
the clutch dog shifter (32).
b) Slide shift rod (40) out of shift rod guide housing
Special tool (41).
(D): 09922–89810 (Shift lock pin c) Draw the oil seal (42) out of shift rod guide
remover) housing.

(D)
41

33 20
39

42

40

32
IDG211320035-02 IDG211320038-02

f) Remove the clutch dog shifter (32) and d) Separate the shifter yoke (44) from shift rod (40)
connector pin (34) from propeller shaft. by driving out the pin (43).

34 43
44

40

33 32

IDG211320036-02 IDG211320039-02
3B-12 Left Hand Rotation Unit:

Pinion Bearing Removal and Installation Removal

CENDG2113206008
NOTICE 1) Disassemble the lower unit.
Refer to “Lower Unit Disassembly” (Page 3B-8).
Removing the bearing can cause damage to
2) Place the attachment (D) inside the pinion bearing.
needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the 3) Insert the removal shaft (A) into attachment (D).
lower unit. 4) Thread sliding hammer (E) into top of removal shaft
(A).
Do not reuse pinion bearings once removed. 5) Put wood block under pinion bearing.
Always use new ones.
6) Drive the pinion bearing out downwards by striking
Removal and Installation Tools top of shaft (A) with sliding hammer (E).
To remove the pinion bearing from the gearcase, use the
following special tools.
Special tool (E)
(A): 09951–59910 (Shaft (removal and
installation))
(B): 09951–38710 (Plate)
(C): 01500–08403 (Bolt)
(D): 09951–19220 (Attachment)
(E): 09930–30104 (Sliding hammer) (A)

(D)

1 2

IDG211320041-03

1. Pinion bearing 2. Wood block

I9J011310018-03
 Left Hand Rotation Unit: 3B-13

Installation Lower Unit Related Items Inspection

NOTE
• Before installing bearing, ensure that
inside of gearcase is clean and free of
debris.
• Ensure that the bearing stamped mark
faces upward.
1) Set the installer shaft (A), plate (B), attachment (D),
and pinion bearing as shown in the figure.
2) Place the installer shaft (A) (with pinion bearing on
end of installer shaft) into the gearcase.
3) Secure the plate (B) by tightening the bolt (C).
4) Thread the sliding hammer (E) into the top of the
installer shaft (A).
5) Drive the pinion bearing down into position by gently
striking the installer shaft (A) until the coupler
touches plate.
6) Assemble the lower unit.
Refer to “Lower Unit Assembly” (Page 3B-17).
(E)
(B)
(A)
CENDG2113206009
! WARNING
Failure to following proper precautions
during use of the compressed air may cause
severe personal injury.
Wear safety glasses when using compressed
air.
NOTE
• If any component is worn excessively,
cracked, defective or damaged in any way,
it must be replaced.
• Thoroughly wash all metal components
with cleaning solvent and dry with
compressed air.
Gearcase
• Inspect the gearcase. Replace if cracked, damaged or
other abnormal conditions are noted.
• Visually check the pinion bearing. Replace bearing if
pitted, rough or other abnormal conditions are noted.
NOTE
If removal and replacement are required,
refer to “Pinion Bearing Removal and
Installation” (Page 3B-12).
(C)

IDG211310038-02

(E)

IDG211320045-01

(C)
(A)
(B)

(D)

IDG211310039-04

1. Pinion bearing
3B-14 Left Hand Rotation Unit:

Gears / Bearing
• Inspect forward, reverse and pinion gear teeth and
engaging dogs.
Replace gears if damaged, worn or other abnormal
conditions are noted.
• Inspect forward gear thrust bearing.
Replace bearing if pitted, noisy, rough or other
abnormal conditions are noted.

IDG211320048-03

• Check detent spring by measuring its free length. If

free length is not within specifications, replace detent
spring.
Detent spring free length “a”
Standard: 27.8 mm (1.09 in.)
Service limit: 25.0 mm (0.98 in.)

IDG211320046-01 “a”

Reverse Gear Bearing Housing / Retainer

• Inspect the reverse gear retainer and reverse gear
bearing housing.
Replace if cracked or damaged. I9J011310062-01

• Visually check each bearings. Replace if pitted, noisy
or rough.
Propeller Shaft Bearing Housing
• Inspect housing. Replace if cracked, damaged or
other abnormal conditions are noted.
• Inspect forward gear bearing and propeller shaft
bearing. Replace bearing if pitted, noisy, rough or
other abnormal conditions are noted.
• Check condition of oil seal and O-ring. Replace oil
seal and O-ring if nicked, cut, worn or other abnormal
conditions are noted.

IDG211320047-01

Propeller Shaft Components

• Inspect horizontal slider and connector pin.
Replace if wear, damage or other abnormal condition.
• Inspect detent balls. Replace if wear, damage or other
abnormal conditions are noted.
• Inspect clutch dog shifter. Replace if chipped, worn,
IDG211320049-01
damaged or other abnormal conditions are noted.
• Inspect dog pin. Replace if bent, worn or other
abnormal conditions are noted.
• Inspect propeller shaft/splines. Replace if worn,
twisted, damaged or other abnormal conditions are
noted.
 Left Hand Rotation Unit: 3B-15

Driveshaft Oil Seal Housing

• Inspect housing. Replace if cracked, damaged or
other abnormal conditions are noted.
• Check condition of oil seals. Replace if nicked, cut,
worn or other abnormal conditions are noted.
• Inspect O-ring. Replace if worn, nicked, cut or other
abnormal conditions are noted.

IDG211320050-01

Shift Rod Guide Housing Components

• Inspect shift rod guide housing.
Replace if cracked, damaged or other abnormal
conditions are noted.
• Inspect shifter yoke. Replace if worn, damaged or
other abnormal conditions are noted. IDG211320053-01
• Inspect shift rod/splines. Replace if worn, twisted,
damaged or other abnormal conditions are noted. Driveshaft
• Inspect O-ring. Replace if nicked, cut, torn, swollen or • Inspect driveshaft/splines. Replace if worn, twisted,
other abnormal conditions are noted. damaged or other abnormal conditions are noted.
• Inspect oil seal and oil seal cover. Replace if nicked, • Inspect driveshaft bearing, replace if pitted, noisy,
cut, worn or other abnormal conditions are noted. rough or other abnormal conditions are noted.

IDG211320051-01 IDG211320054-01

IDG211320052-01 IDG211320055-01
3B-16 Left Hand Rotation Unit:

Propeller Shaft Oil Seal Replacement
CENDG2113206010
1) Remove the propeller shaft bearing housing.
Refer to “Lower Unit Disassembly” (Page 3B-8).
2) Remove the retaining ring (1) and washer (2).
1
4) Apply water resistant grease to the inner
circumference of the housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
5) Using an oil seal installer, drive the two oil seals (one
at a time) into the propeller shaft bearing housing.
The lipped portion of the seal must face towards the
propeller. Apply water resistant grease to the seal
lips.

“A”
2

IDG211320056-01

3) Extract the seals (3) with oil seal remover.

NOTICE
Removing the oil seal can cause damage to
the seal lips, causing oil to leak. IDG211320058-02

“A”: Direction of propeller

Do not reuse the oil seal once removed.
Always use new one. 6) Install the washer and retaining ring.
7) Assemble the propeller shaft bearing housing.
Special tool
Refer to “Lower Unit Assembly” (Page 3B-17).
(A): 09913–50121 (Oil seal remover)
Driveshaft Oil Seal Replacement
CENDG2113206011
1) Remove the driveshaft oil seal housing.
Refer to “Lower Unit Disassembly” (Page 3B-8).
(A)
2) Using special tool, remove two oil seals out of the
driveshaft oil seal housing.
Special tool
3 (A): 09913–50121 (Oil seal remover)

NOTICE
IDG211320057-01 Removing the oil seal can cause damage to
the seal lips, causing oil to leak.

Do not reuse the oil seal once removed.

Always use new one.

(A)

IDG211320059-01
 Left Hand Rotation Unit: 3B-17

3) Apply water resistant grease to inner circumference Reverse Gear Bearing Housing
of driveshaft oil seal housing. • Install dowel pin (1) and reverse gear bearing housing
: Grease 99000–25350 (SUZUKI Water (2) in position.
Resistant Grease EP2 (250 g))
4) Grease the inner lips of oil seal.
With the lips facing away from driveshaft bearing,
place seal in position and drive it into the oil seal
housing.

“A”
2 1
IDG211320061-01

Reverse Gear
• Place reverse gear back-up shim (1) and bearing
thrust washer (2) in position.
• Assemble the reverse gear thrust bearing (3), reverse
IDG211320060-02
gear retainer (4) and reverse gear (5), then install
reverse gear/retainer assembly.
“A”: Direction of water pump case

5) Assemble the driveshaft oil seal housing.

Refer to “Lower Unit Assembly” (Page 3B-17).
1

Lower Unit Assembly

CENDG2113206012
Assembly is in reverse order of disassembly with special
attention to the following steps.

NOTICE
Failure to correctly adjust the gear position 2
will result in lower unit damage. IDG211320062-01
Before final assembly of lower unit, be
absolutely certain that all gear contact, shim
adjustments and tolerances are correct. 3
(Refer to “Lower Unit Gears - Shimming and 4
Adjustment” (Page 3B-24).)

NOTE
• Make sure that all parts used in assembly
are clean and lubricated.
• It is recommended that all seals, gaskets
and O-rings be replaced with new on 5
assembly. IDG211320063-01

• After assembly, check parts for tightness

and smoothness of operation.
3B-18 Left Hand Rotation Unit:

Pinion Gear • Install the bearing outer race (3) and pinion gear shim
Place pinion gear (1) in gearcase. (4) to driveshaft.

4
3
1

IDG211320064-01 IDG211320067-01

Driveshaft Driveshaft Oil Seal Housing

• Assemble the driveshaft collar (1) to driveshaft.
After installing driveshaft collar, fit the convex part of
collar in the concave part of driveshaft by turning
collar.
• Apply water resistant grease to the driveshaft oil seal.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
• Apply water resistant grease to O-ring (1), then install
O-ring into groove on the driveshaft oil seal housing
(2).

1
1

IDG211320065-01

• Lower the driveshaft assembly (2) down into the

gearcase until the bottom of shaft protrudes through
center of pinion gear. IDG211320068-01

• Install the driveshaft oil seal housing on the gearcase,

then tighten four bolts (3) securely.

IDG211320066-01

IDG211320069-01
 Left Hand Rotation Unit: 3B-19

Pinion Nut Propeller Shaft

• Apply thread lock 1342 to the threads of pinion nut (1) • Slide the clutch dog shifter (2) onto the propeller shaft
before threading it onto driveshaft. (1).
: Thread lock cement 99000–32050 (SUZUKI NOTE
Thread Lock 1342 (50 g))
The side of the clutch dog shifter marked
• Tighten pinion nut to specified torque. with the letter “R” must face towards reverse
gear.
NOTE
It is recommended the original pinion nut is
used for the purposes of shimming during
repair. A new pinion nut should be used on
final assembly.

Special tool 1
(A): 09921–29410 (Driveshaft holder) “R”

Tightening torque
Pinion nut (a): 120 N·m (12.0 kgf-m, 87.0 lbf-ft) 2

IDG211320071-01

• Insert two small detent balls (3), large detent ball (4),
detent spring (5) and large detent ball (6) into
connector pin (7). Then depress detent ball (6) and
temporarily insert stopper pin “A” into dog pin hole of
(A) connector pin, as shown in figure.
1 (a)
7

IDG211320070-01

6
3
5
4
IDG211320072-01

NOTE
Temporarily insert a water pump case dowel
pin “A” into the connector pin to prevent the
detent ball from falling out.

“A”

IDG211310069-03
3B-20 Left Hand Rotation Unit:

• Insert the connector pin (7) (with detent balls) into • Install shim (2), bearing washer (3), propeller shaft
propeller shaft (1). thrust bearing (4), propeller shaft thrust washer (5)
• Align the holes in the clutch dog shifter and connector into propeller shaft bearing housing (6).
pin and then slide the dog pin (8) through both clutch
dog shifter and connector pin. (save the temporarily 2
3
installed dowel pin “A” pushed out as the dog pin is 4
inserted.) 5

• Install the dog pin retaining spring (9), ensuring that it

fits snugly into the groove on the dog shifter.

IDG211320077-02

• Install forward gear back-up shim (7), forward gear

thrust washer (8), forward gear thrust bearing (9) and
1 8 forward gear (10) to propeller shaft bearing housing.

9
7 10
9
IDG211320074-01

• Install the spacer (10) to propeller shaft.

7
8
IDG211320078-02

• Slide propeller shaft (11) into forward gear and

propeller shaft bearing housing.
• Assemble horizontal slider (12) to connector pin.

10
IDG211320075-01 11

Forward Gear / Propeller Shaft / Bearing Housing

Assemble the propeller shaft in the following sequence.
• Apply Water Resistant Grease to O-ring (1), then
install the O-ring into the groove on the propeller shaft
bearing housing.
12
IDG211320079-01

NOTE
Before installing propeller shaft/bearing
housing assembly, move shifter dog to bring
horizontal slider to the neutral position.

IDG211320076-01

: Grease 99000–25350 (SUZUKI Water

Resistant Grease EP2 (250 g))
: Gear Oil 99000–22B22 (SUZUKI Outboard
Motor Gear Oil)
 Left Hand Rotation Unit: 3B-21

• To hold the correct bearing position, pull propeller
shaft backward and then install propeller shaft and
housing assembly in the gearcase.
NOTE
To make the bearing housing fully seated in
the gearcase, tap the housing gently with
plastic mallet.
Shift Rod Guide Housing
• Apply water resistant grease to oil seal. Using an oil
seal installer, drive the oil seal (1) into the shift rod
guide housing (2). The lipped portion of oil seal must
face towards the driveshaft housing.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

2
1 3
6
IDG211320083-03

IDG211320080-02 • Attach shifter yoke (4) to shift rod (3), then insert pin
• When the housing is fully seated, tighten both (5). Install the pin (6) to shift rod.
retaining bolts to the specified torque. • Slide shift rod guide housing (2) onto shift rod.
Tightening torque
Bearing housing bolt (a): 23 N·m (2.3 kgf-m, 16.6
lbf-ft) 3

(a)

5
4

IDG211320084-02

IDG211320081-01
Checking Propeller Shaft Thrust Play
Check propeller shaft thrust play.
Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3B-24).
NOTE
Before install the shift unit (shift rod guide
housing assembly), be sure to put the
horizontal slider (7) in the neutral position.
7

Special tool 8
(A): 09951–09530 (Gear adjusting gauge)
“A”

(A)

IDG211320085-03

7. Horizontal slider
8. Reverse gear bearing housing
“A”: Shift rod center

IDG211320082-01
3B-22 Left Hand Rotation Unit:

• Apply water resistant grease to the shift rod guide • Turn the shift rod from the “Neutral” position to the
housing O-ring. “Forward” and “Reverse” position to check proper
gear engagement.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g)) • Apply enough Water Resistant Grease on oil seal
before putting oil seal cover (11) so that there is no
space between them.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))

Front
direction 11

4
IDG211320086-02

NOTE
Before installing the shift rod guide housing
assembly, bring the shifter yoke to the
“Neutral” position by turning the shift rod
IDG211310082-04
right or left.

• Install the shift rod guide housing assembly (9) by

aligning the shifter yoke with the groove in the
horizontal slider (7), then tighten the housing bolt (10)
securely.

10

IDG211320087-03

7
IDG211320088-03

Leakage Check
Check for leakage of oil seal and O-ring when applying
specified pressure inside of the gearcase.
1) Install the test tool into the oil level hole.
2) Connect the air pump to the tester.
3) Rotate driveshaft and propeller shaft clockwise
several times and then apply specified pressure for
the test.
NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
Do not exceed pressure of 110 kPa (1.1 kg/
cm2, 15.6 psi.).
NOTE
Apply low initial pressure of 20 – 40 kPa (0.2
– 0.4 kg/cm2, 2.8 – 5.7 psi.) first, then apply
specified pressure.
Special tool
(A): 09950–69512 (Gearcase oil leakage
tester)
(B): 09952–99320 (Hand air pump)
Leakage pressure test
100 kPa (1.0 kg/cm2, 14.2 psi.)
(A)
(B)
IDG211320090-01
4) Once stabilized, pressure should remain steady for
at least 5 min.
If pressure does not fall, sealing performance is
correct.
Water Pump
Install the water pump and related parts.
Refer to “Lower Unit Removal and Installation” (Page
3B-5) and “Water Pump Removal and Installation” (Page
3B-6).
Left Hand Rotation Unit: 3B-23
Propeller
Install the propeller.
Refer to “Propeller Removal and Installation” (Page 3B-
4).
Lower Unit
Install the Lower Unit.
Refer to “Lower Unit Removal and Installation” (Page
3B-5).
Trim Tab Adjustment
CENDG2113206013
The trim tab counteracts or minimizes propeller torque
pull felt through the steering system.
If the steering is pulls to the starboard or port side, adjust
the trim tab with the following procedure.
1) Loosen the trim tab bolt (1).
1
IDG211320091-01
2) Changing the trim tab setting.
• To compensate for a veer to starboard, set the
trailing edge of tab (2) to the right (as viewed from
behind).
• To compensate for a veer to port, set the trailing
edge of tab to the left.
2
I9J011310010-03
3) Tighten the bolt of trim tab.
4) Test drive the boat and repeat the procedure 1) – 3)
to set the trim tab in the best position.
With a properly adjusted trim tab, steering should be
neutral and there should be no tendency for the
steering to be pulled to either port or starboard.
3B-24 Left Hand Rotation Unit:

Lower Unit Gears - Shimming and Adjustment

CENDG2113206014
If the lower unit has been rebuilt or has had components replaced, shimming for the correct gear contact and backlash
will have to be checked and/or adjusted to ensure smooth, reliable operation.
Shim/Washer and mounting position
Item Available thickness (mm) Design specification thickness (mm)
0.50, 0.55, 0.60, 0.65, 0.70, 0.75,
Pinion gear back-up shim 0.80, 0.85, 0.90, 0.95, 1.00, 1.05, 1.0
1.10, 1.15
0.60, 0.65, 0.70, 0.75, 0.80, 0.85,
Forward gear back-up shim 0.8
0.90, 0.95, 1.00
0.60, 0.70, 0.80, 0.90, 0.95, 1.00,
Propeller shaft thrust shim 1.0
1.05, 1.10, 1.15
Reverse gear back-up shim 0.8, 0.9, 1.0, 1.1, 1.2, 1.3, 1.4 1.0

2
3

IDG211320092-01

1. Pinion gear back-up shim 3. Propeller shaft thrust shim

2. Forward gear back-up shim 4. Reverse gear back-up shim
 Left Hand Rotation Unit: 3B-25

Driveshaft Preloading Spring Set
Install the special tool (A) on the driveshaft as shown in
figure when adjusting the gear shim and tooth contact
pattern.
Apply preload to the driveshaft then an appropriate
adjustment can be obtained.
Reverse Gear / Pinion Gear Back-Up Shim
Adjustment
Prior to adjustment
1) Install standard pinion gear back-up shim thickness
according to ± design specification mark on the gear.

NOTE
After adjusting the forward/reverse gear
shim, remove the special tool from
driveshaft.

Special tool
(A): 09951–09030 (Driveshaft preloading spring “A”
IDG211320108-01
set)
“A”: ± design spec. mark

2) Place the special tool to driveshaft as shown in the

illustration.
Special tool
: 09951–09030 (Driveshaft preloading
spring set)
(A)

(A) 1
2
IDG211320093-01

1
2

IDG211320094-02

1. Spring 2. Washer

3) Correctly assemble driveshaft oil seal housing,

driveshaft, reverse gear, pinion gear and related
IDG211320094-02
components.
Refer to “Lower Unit Assembly” (Page 3B-17).
1. Spring 2. Washer
Do not install forward gear at this time.

IDG211320095-01

4) Tighten pinion nut to specified torque.

Tightening torque
Pinion nut: 120 N·m (12.0 kgf-m, 87.0 lbf-ft)
3B-26 Left Hand Rotation Unit:

Adjusting gear backlash Forward Gear Shim

1) Assemble special tools to driveshaft as shown in After adjusting reverse gear backlash, follow the
figure. procedure below to adjust forward gear.

Special tool Adjusting gear backlash

(A): 09900–20602 (Dial gauge)
1) Place the special tool to driveshaft as shown in the
(B): 09900–20701 (Magnetic stand)
illustration.
(C): 09952–09310 (Backlash indicator tool)
Special tool
(B) : 09951–09030 (Driveshaft preloading
(C)
spring set)

1
2

(A)

IDG211320096-01

2) Push reverse gear inward and hold it by hand, align

dial gauge pointer at 90° to the mark on the backlash
indicator tool and read backlash on dial gauge by IDG211320094-02

lightly moving driveshaft clockwise and 1. Spring 2. Washer

counterclockwise by hand.
2) Correctly assemble driveshaft oil seal housing,
Gear backlash driveshaft, reverse gear, pinion gear and related
Approx. 0.5 – 0.8 mm (0.020 – 0.031 in.) components.
(C)
3) Tighten pinion nut to specified torque.
Tightening torque
Pinion nut: 120 N·m (12.5 kgf-m, 87.0 lbf-ft)
4) Correctly assemble forward gear, forward gear
bearing, propeller shaft, propeller shaft thrust
(A)
bearing, propeller shaft bearing housing and related
components.
IDG211320097-03 When assemble the forward gear and propeller shaft
• If the backlash measured is larger than the housing assembly, place the special tool between
specification, add the amount over the clutch dog shifter and forward gear as shown in the
specification to the temporary use reverse gear illustration.
back-up shim and install this shim. NOTE
• If the backlash measured is smaller than the
specification, subtract the amount less than the • Before installing special tool, move shifter
specification from the temporary use reverse gear dog to reverse position.
back-up shim and install this shim. • Set the special tool in place with thin
washer facing the clutch dog.

Special tool
(A): 09951–09020 (Gear adjust spring set)

(A)

IDG211320098-03
 Left Hand Rotation Unit: 3B-27

• If the backlash measured is larger than the

specification, add the amount over the
(A) specification to the temporary use forward gear
back-up shim and install this shim.
• If the backlash measured is smaller than the
specification, subtract the amount less than the
specification from the temporary use forward gear
back-up shim and install this shim.

(D)

IDG211320099-01

5) Install forward gear and propeller shaft housing

assembly into gearcase, then tighten both bearing
housing retaining bolts to specified torque.
(B)

IDG211320112-02

Checking and adjusting tooth contact pattern

(Pinion gear and forward gear)
Check tooth contact pattern using the following
procedure.
1) To assess tooth contact, apply a light coat of
prussian blue on the convex surface of the forward
gear.
2) Install the special tool as shown in the figures.
IDG211320100-01
Install forward gear and propeller shaft housing
6) Assemble special tools to driveshaft as shown in assembly into gearcase, then tighten both bearing
figure. housing retaining bolts to specified torque.
Special tool Tightening torque
(B): 09900–20602 (Dial gauge) Bearing housing: 23 N·m (2.3 kgf-m, 16.6 lbf-ft)
(C): 09900–20701 (Magnetic stand)
(D): 09952–09310 (Backlash indicator tool) Special tool
(A): 09951–09020 (Gear adjust spring set)

(C) (A)
(D)

(B)

IDG211320102-04

IDG211320101-01

7) Align dial gauge pointer at 90° to the mark on the (A)

backlash indicator tool and read backlash on dial
gauge by lightly moving driveshaft clockwise and
counterclockwise by hand.
Gear backlash
Approx. 0.3 – 0.5 mm (0.012 – 0.020 in)

IDG211320103-02
3B-28 Left Hand Rotation Unit:

3) Using the driveshaft holder tool, rotate the driveshaft Example [A]
5 – 6 times. Incorrect topside toe contact.
Correction measures.
Special tool
(B): 09921–29410 (Driveshaft holder) • Decrease thickness of forward gear shim.
• Slightly increase pinion gear shim thickness.

NOTICE
Setting the tooth contact in the top side toe
(B) contact may cause damage and chipping on
forward and pinion gears.
Do not set the tooth contact as such top side
toe contact.

Example of incorrect

IDG211320104-04

4) Carefully remove the propeller shaft and housing to “C”

check the tooth contact pattern.
“A”
“A” I9J011310015-01
“a”
“B”
Example [B]
“C”
Incorrect bottom side toe contact.
“F” Correction measures.
• Increase thickness of forward gear shim.
“G”
“D” • Slightly decrease pinion gear shim thickness.
“E” NOTICE
I9J011310013-02
Setting the tooth contact in the bottom side
“A”: Concave side “E”: Tooth bottom toe contact may cause chipping on pinion
“B”: Convex side “F”: Toe gear.
“C”: Heel “G”: Tooth contact pattern
Do not set the tooth contact as such bottom
“D”: Tooth top “a”: Tooth width
side toe contact.
Optimum tooth contact
The optimum tooth contact is shown in the figure. A shim Example of incorrect
adjustment may be necessary to obtain this contact
pattern.

NOTE “C”
Gear backlash should be checked when “A”
increasing or decreasing shim thickness to I9J011310016-01
adjust tooth contact.

Optimum tooth contact

“a”
“b”
“A”

“C”

“B”
I9J011310014-02

“A”: Heel “a”: Approx. 1/3 of tooth width

“B”: Convex side “b”: Approx. 1 mm (0.04 in)
“C”: Toe
 Left Hand Rotation Unit: 3B-29

Checking propeller shaft thrust play 2) Push propeller shaft inward.

After adjusting all gear positions, measure the propeller 3) Hold the shaft in and set the dial gauge pointer to
shaft thrust play. If not within the following specification, zero.
a shim adjustment is required.
4) Slowly pull the shaft outward and read the maximum
NOTE thrust play on the dial gauge.
Use only the propeller shaft thrust shim to • If the measurement is more than the specification,
adjust thrust play. increase the propeller shaft thrust shim thickness.
• If the measurement is less than the specification,
Propeller shaft thrust play reduce the propeller shaft thrust shim thickness.
Approx. 0.2 – 0.4 mm (0.01 – 0.02 in.)
1) Assemble the gear adjusting gauge to the propeller
shaft.
Special tool
(A): 09951–09530 (Gear adjusting gauge)

(A)

IDG211320105-01
3B-30 Left Hand Rotation Unit:
 Table of Contents 4- i

Section 4

Wire / Hose Routing

CONTENTS

Precautions .................................................4-1 Wiring Harness Routing Diagram........................4A-3

Precautions............................................................. 4-1
Precautions for Wire / Hose Routing..................... 4-1
Fuel / Water Hose Routing ...................... 4B-1
Component Location ............................................. 4-1
Electrical Component Location ............................. 4-1
Wire Routing ............................................ 4A-1
Schematic and Routing Diagram........................4A-1
Wiring Diagram ................................................... 4A-1
Precautions...........................................................4B-1
Precautions for Fuel / Water Hose Routing.........4B-1
Schematic and Routing Diagram ........................4B-1
Fuel Hose Routing ..............................................4B-1
Water Hose Routing............................................4B-5
4
4-1 Precautions:

Precautions
Wire / Hose Routing

Precautions
Precautions for Wire / Hose Routing
CENDG2114000001
Refer to “General Precautions” in Section 00 (Page 00-1).

Component Location
Electrical Component Location
CENDG2114003001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
 Wire / Hose Routing

WIRE COLOR
B : Black Bl/B : Blue / Black
Bl : Blue Bl/R : Blue / Red DIGITAL GAUGE DIAGRAM
(OPTION)
Br : Brown Bl/W : Blue / White
Dg : Dark green Bl/Y : Blue / Yellow CAP
G : Green Lg/B : Light green / Black
Wiring Diagram

Gr : Gray Lg/R : Light green / Red GAUGE

Lbl : Light blue Lg/W : Light green / White CONNECTOR

P/W
G/W
Bl/B

P/W
G/W
Bl/B
Lg : Light green O/B : Orange / Black
O : Orange O/G : Orange / Green GAUGE COMMUNICATION

P/W
P : Pink

G/W
Bl/B
O/W : Orange / White CONNECTOR CONNECTOR

Y
B
O/Y
R : Red

B/Bl
O/Y : Orange / Yellow
V : Violet P/B : Pink / Black CAP
W : White P/W : Pink / White

P/W
G/W
Bl/B
Y : Yellow R/B : Red / Black
B/G : Black / Green R/G : Red / Green COMMUNICATION
CONNECTOR
Wire Routing

B/R : Black / Red R/W : Red / White

Y
B
O/Y
B/Bl
B/W : Black / White V/W : Violet / White HIGH PRESSURE
B/Y : Black / Yellow W/R : White / Red FUEL PUMP
Bl
G/W : Green / White W/Y : White / Yellow OIL PRESSURE SWITCH
B B/R
G/Y : Green / Yellow Y/B : Yellow / Black Bl W
CKP
Y/G : Yellow / Green SENSOR BATTERY
CHARGE COIL
FUEL INJECTOR
IAC VALVE Gr
R/G Gr
No.1 O/B
STARTER Gr
MOTOR No.2 B/Br
Gr
MAP B/W No.3 R/W
R
SENSOR W
Gr
R No.4 Lg/W
Lg
R
R
R
CYLINDER TEMP
SENSOR

B
B

R/B
IAT SENSOR

B/G
B
B/W
Lg/B
B
V Lg/W
W W B B/W
W W
W W

B/W
R/W
Br/Y B/W
R Y/Bl
TPS B/W B/Bl

CMP SENSOR
MAIN STARTER FUSE BOX
NEUTRAL SWITCH RELAY RELAY
R/G
B
Gr
N ON
Y/G
B F.R OFF Br FUSE
METER ECM
ILLUMINATION 15A 30A 30A 15A 60A 60A
SWITCH B
Gr
R/G
B

Y/G
B/Bl

B
TROLL MODE

R
R
R
R

G
W
W
W
W
W
W

W
W
W
Refer to “Wire Color Symbols” in Section 0A (Page 0A-2).

Y/G
Y/G
W/R

R/B
SWITCH

R/G
Gr Gr B
EX. TEMP

R/G
B B METER Gr
DN UP SENSOR IGNITION COIL
B/W B

G
W
Br

Gr
V/W B

P
B
Lbl
Y/B

Y/G
O/Y
G/Y
R/B

Bl
W/Y
V/W

P/Bl

Lg
B/Bl
G/W
No.1

Br/Y

B/R

R/G
B/Br

Lg/B
R/G Gr

P
Y
R
B

Bl
B O

R/B
P/W
W/Y
B/W
Y/Bl

Bl/R
Bl/B
O/W

Lg/B
Bl/W

B
Lg/W

Lg
O/B

R/Bl

B
Gr/R
R/W

R/G
Gr
TRIM
DF100A

Gr Gr

R/G
W/Y W/Y W/Y
No.4
B B METER B V B

R/G R/G
B B
MONITOR/
TACHOMETER RECTIFIER & No.2
Gr Gr REGULATOR Gr
TACHOMETER Bl/B Bl/B
B B G/Y G/Y Bl
Y Y WITH LED P P
G/W G/W

No.3

PTT SWITCH NEUTRAL SWITCH

REMOTE CONTROL BOX N ON
(SIDE) F.R OFF
W-TUBE

Lbl Lbl
Lg W/R
IGNITION R P
SWITCH

Br Br W/Y W/Y
Br Br B Y
Bl/B Bl/B
G/Y G/Y
Lbl Lbl P P/W
W/R
Schematic and Routing Diagram

W/R G/W G/W

P P Lbl Lbl
P P
O O O O/W
Gr Gr W W W W
Bl Bl Br Br Br Br
W/R W/R Y Y/B
G G G Bl/R
B G CAUTION BUZZER Gr Gr Gr B/Bl
B B Bl Bl/W Bl/W Bl/W
B B B B
Gr
B/W
Gr/R
Lg/B
B
R/Bl

REMOCON W
EMERGENCY CABLE
STOP SWITCH
LOCK PLATE IN RUN
B
W
W

Gr

LOCK PLATE OFF STOP

B/W Gr, W

R
R
B
Lbl
+B
GND
OX
OXH

W/R

W/Y
B/W
BONDER BONDER
WATER
R
O2 SENSOR DETECTION
P
B SWITCH

Y
Lg

R
B
P

Bl
Lbl

W/R
B

DN UP

BATTERY
12V 100AH PTT SWITCH
B/W B/W
B B

TRIM
SENSOR PTT
RELAY B
B/Bl R Lbl P W
PTT MOTOR
JOINT CONNECTOR BONDER
Wire Routing:

IDG211410010-05
4A-1

CENDG2114102001
 WIRE COLOR
B : Black Bl/B : Blue / Black
Bl : Blue Bl/R : Blue / Red DIGITAL GAUGE DIAGRAM
(OPTION)
Br : Brown Bl/W : Blue / White
Dg : Dark green Bl/Y : Blue / Yellow CAP
G : Green Lg/B : Light green / Black
Gr : Gray Lg/R : Light green / Red GAUGE
Lbl : Light blue Lg/W : Light green / White CONNECTOR

P/W
G/W
Bl/B

P/W
G/W
Bl/B
Lg : Light green O/B : Orange / Black
O : Orange O/G : Orange / Green GAUGE COMMUNICATION

P/W
P : Pink

G/W
Bl/B
O/W : Orange / White CONNECTOR CONNECTOR
4A-2 Wire Routing:

Y
B
O/Y
R : Red

B/Bl
O/Y : Orange / Yellow
V : Violet P/B : Pink / Black CAP
W : White P/W : Pink / White

P/W
G/W
Bl/B
Y : Yellow R/B : Red / Black
B/G : Black / Green R/G : Red / Green COMMUNICATION
CONNECTOR
B/R : Black / Red R/W : Red / White

Y
B
O/Y
B/Bl
B/W : Black / White V/W : Violet / White HIGH PRESSURE
B/Y : Black / Yellow W/R : White / Red FUEL PUMP
Bl
G/W : Green / White W/Y : White / Yellow OIL PRESSURE SWITCH
B B/R
G/Y : Green / Yellow Y/B : Yellow / Black Bl W
CKP
Y/G : Yellow / Green SENSOR BATTERY
CHARGE COIL
FUEL INJECTOR
IAC VALVE Gr
R/G Gr
No.1 O/B
STARTER Gr
MOTOR No.2 B/Br
Gr
MAP B/W No.3 R/W
R
SENSOR W
Gr
R No.4 Lg/W
Lg
R
R
R
CYLINDER TEMP
SENSOR
B

B
B

R/B
IAT SENSOR

B/G
B

B/W
Lg/B
B
V Lg/W
W W B B/W
W W
W W

B/W
Br/Y R/W B/W
R Y/Bl
TPS B/W B/Bl

CMP SENSOR
MAIN STARTER FUSE BOX
NEUTRAL SWITCH RELAY RELAY
R/G
B
Gr
N ON
Y/G
B F.R OFF Br FUSE
METER ECM
ILLUMINATION 15A 30A 30A 15A 60A 60A
SWITCH B
Gr
R/G
B

Y/G
B/Bl

B
TROLL MODE

R
R
R
R

G
W
W
W
W
W
W

W
W
W
Y/G
Y/G
W/R

R/B
SWITCH

R/G
Gr Gr B
EX. TEMP

R/G
B B METER Gr
DN UP SENSOR IGNITION COIL
B/W B
V

G
W
Br

Gr

V/W B

P
B
Lbl
Y/B

Y/G
O/Y
G/Y
R/B

Bl
W/Y
V/W

P/Bl

Lg
B/Bl
G/W

No.1
Br/Y

B/R

R/G
B/Br

Lg/B
R/G Gr
P
Y
R
B

Bl

B O
R/B
P/W
W/Y
B/W
Y/Bl

Bl/R
Bl/B
O/W

Lg/B
Bl/W

B
Lg/W

Lg
O/B

R/Bl

B
Gr/R
R/W

R/G
Gr
Gr Gr TRIM

R/G
W/Y W/Y W/Y
No.4
B B METER B V B

R/G R/G
B B
DF115A/140A

MONITOR/
TACHOMETER RECTIFIER & No.2
Gr Gr REGULATOR Gr
TACHOMETER Bl/B Bl/B
B B G/Y G/Y Bl
Y Y WITH LED P P
G/W G/W

No.3

PTT SWITCH NEUTRAL SWITCH

REMOTE CONTROL BOX N ON
(SIDE) F.R OFF
W-TUBE

Lbl Lbl
Lg W/R
R P
IGNITION
SWITCH

Br Br W/Y W/Y
Br Br B Y
Bl/B Bl/B
G/Y G/Y
Lbl Lbl P P/W
W/R W/R G/W G/W
P P Lbl Lbl
P P
O O O O/W
Gr Gr W W W W
Bl Bl Br Br Br Br
W/R W/R Y Y/B
G G G Bl/R
B G CAUTION BUZZER Gr Gr Gr B/Bl
B B Bl Bl/W Bl/W Bl/W
B B B B
Gr
B/W
Gr/R
Lg/B
B
R/Bl

REMOCON W
P/Bl

EMERGENCY CABLE
STOP SWITCH
LOCK PLATE IN RUN
B
W
W

Gr

LOCK PLATE OFF STOP

R

B/W Gr, W
P

R
R
B
Lbl
+B
GND
OX
OXH

W/R

W/Y
B/W
BONDER BONDER
WATER
O2 SENSOR DETECTION
KNOCK
R
P

SENSOR SWITCH
B

Y
Lg

R
B
P

Bl
Lbl

W/R
B

DN UP

BATTERY
12V 100AH PTT SWITCH
B/W B/W
B B

TRIM
SENSOR PTT
RELAY B
B/Bl R Lbl P W
PTT MOTOR
JOINT CONNECTOR BONDER

IDG211410001-07
 Wire Routing: 4A-3

Wiring Harness Routing Diagram

CENDG2114102002

3
IDG211410002-01

1. PTT motor relay holder 2. PTT motor relay 3. Sub-wiring harness

IDG211410003-01

4. Electric parts holder 6. Cushion

5. ECM 7. Fuse box
4A-4 Wire Routing:

3
(b)
4
(a)

4
2 18 (e)
1
“C”
H

3 View “C” 17

16
A

7 13

6
5 B 15 (d)

14
8 “A”

(c)

10
C

D
9 3 G 12
View “A” E
11
F

IDG211410004-02

1. Stater motor
2. Flywheel
3. Main harness (R)
4. Battery cable (positive (+))
5. Battery cable (negative (–))
6. Main harness (Ground)
: Set the back of each terminal together.
7. Battery charge coil lead wire
: Pass battery charge coil lead wire between
battery positive and negative lead wires.
8. Electric parts holder
9. Regulator lead wire (Gr)
10. Cap
: Insert main harness (R) to cap hole and
cover the terminals with cap.
11. Bolt
: Tighten with harness (Ground) lead wire.
12. Clamp “E”: Route rectifier/regulator lead wire (Gr)
between ECM and fuse box lead wires.
13. Ignition coil No.1 “F”: Route rectifier/regulator lead wire (Gr)
front side of Ex. Manifold temp. sensor.
14. Ignition coil No.2 “G”: Route rectifier/regulator lead wire (Gr)
behind Ex. Manifold temp. sensor
connector.
15. EX. manifold temp. sensor “H”: Route O2 sensor lead wire behind
water return hose.
16. Bolt : 245 N⋅m (24.5 kgf-m, 177.0 lbf-ft)
: Tighten with rectifier/regulator ground
lead wire.
17. CMP sensor : 8.6 N⋅m (0.86 kgf-m, 6.0 lbf-ft)
18. O2 sensor : 4.5 N⋅m (0.45 kgf-m, 3.5 lbf-ft)
“A”: Route terminal “S” lead wire behind battery : 8 N⋅m (0.8 kgf-m, 5.8 lbf-ft)
cable.
“B”: Route main harness (R) between battery : 10 N⋅m (1.0 kgf-m, 7.0 lbf-ft)
positive and negative cables.
“C”: Route trim sensor lead wire above CKP
sensor and neutral switch lead wires.
“D”: Route PTT sub-harness front side of main
harness.
 Wire Routing: 4A-5

1 4

2
IDG211410005-01

1. Battery charge coil 3. MAP sensor

2. Battery charge coil lead wire 4. Band
: Bind the cylinder temp. sensor lead wire, O2 sensor lead wire and water return
hose with band.
4A-6 Wire Routing:

“A” “B”
1

IDG211410006-01

1. Oil pressure switch 4. Clamp “B”: Outside

: Tighten the lead wire in 45° as shown. Cover the oil : Fix harness and evaporation hose with clamp.
pressure switch with cap.
2. Knock sensor (DF115A/140A) 5. Neutral switch
3. Clamp (DF115A/140A) “A”: Cylinder block side
: Bind the knock sensor connector on the white taping point
of the harness with clamp.

1. CMP sensor
2. Rectifier/Regulator
Wire Routing: 4A-7
5
IDG211410007-03
3. Ignition coil No.1 5. High tension code clamp
: Make sure number printed on cord matches : Fix high-tension cord as shown.
to cylinder number.
4. Ignition coil No.2 6. Water detection switch
: Make sure number printed on cord matches
to cylinder number.
4A-8 Wire Routing:

(a)
1

8 A

7
5 6
IDG211410008-02

1. CKP sensor 5. PTT sub harness “A”: Route PTT cable and trim sensor lead wire (7)
under front panel boss.
2. Air intake silencer case 6. Main harness : 5 N⋅m (0.5 kgf-m, 3.5 lb-ft)
3. IAT sensor 7. Trim sensor lead wire
: Install IAT sensor to the air intake silencer case.
4. Clamp 8. Connector holder
: Clamp PTT sub harness (5), main harness (6) and
trim sensor lead wire (7) as shown.

“A”

1 2 3
View “A”
IDG211410009-02

1. Trim sensor 3. Clamp

: Bind the trim sensor lead wire to swivel bracket at white taping position.
2. Trim sensor cam 4. PTT switch
 Fuel / Water Hose Routing: 4B-1

Fuel / Water Hose Routing

Wire / Hose Routing

Precautions
Precautions for Fuel / Water Hose Routing
CENDG2114200001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Fuel System Service” in Section 1G
(Page 1G-1).

Schematic and Routing Diagram

Fuel Hose Routing
CENDG2114202001

6 5

11

9
10
8
IDG211420001-03

1. Intake manifold 7. Throttle body

2. Fuel vapor separator 8. Water hose (Fuel vapor separator to engine holder)
3. Fuel hose (Low pressure fuel pump to fuel vapor separator) 9. Water hose (3-way joint to fuel vapor separator)
4. Fuel hose (Fuel vapor separator to fuel delivery pipe) 10. Water hose (3-way joint to crankcase lower)
5. Hose clamp 11. Fuel drain hose
6. IAC valve
4B-2 Fuel / Water Hose Routing:

1
6
3

5
2
8 7

10
9 14

15
16
11

10
9
15
12
8

14

13

IDG211420002-03

1. Intake manifold 9. Clamp

: Clamp evaporation hose (8) as shown.
2. Fuel vapor separator 10. Bolt
3. Fuel hose (Low pressure fuel pump to fuel vapor separator) 11. Water hose (Fuel vapor separator to engine holder)
4. Fuel hose (Fuel vapor separator to fuel delivery pipe) 12. 3-way joint
5. Hose clamp 13. Water hose (Engine holder to 3-way joint)
6. IAC valve 14. Water hose (3-way joint to fuel vapor separator)
7. Throttle body 15. Water hose (3-way joint to crankcase lower)
8. Evaporation hose 16. Fuel drain hose
 Fuel / Water Hose Routing: 4B-3

2 3 4
15
26 (a)
13
5

16
16 14

8 7
9
28 (b) 2 1

6
17 “B”
10
18
11
12 19

A
27 (c)

20 20

23 24
View “B”
25

21

22
IDG211420003-03

1. Fuel vapor separator 17. Low pressure fuel pump

2. Evaporation hose 18. Fuel hose (Low pressure fuel filter to low pressure fuel pump)
3. Fuel hose (Fuel vapor separator to fuel delivery pipe) 19. Low pressure fuel filter
4. Breather hose 20. Fuel hose (Joint to low pressure fuel filter)
5. Fuel main joint (E40)/Fuel hose union (Others) 21. Clamp
: Clamp evaporation hose (2) as shown.
6. Intake manifold 22. Bolt
7. Insulator 23. Cushion
: Set the evaporation hose end 50 – 70 mm (2.0 – 2.7 in) out from cushion.
8. Nut 24. Paint mark (White)
9. Stud bolt 25. Clamp
10. Fuel delivery pipe 26. Union bolt
11. Fuel injector 27. Fuel delivery pipe plug
12. Cushion 28. Fuel filter nut
13. High pressure fuel pump lead wire A: Route the fuel hose (Joint to low pressure fuel filter) above the starter motor cable.
14. Knock sensor lead wire (DF115A/140A) : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
15. Fuel hose (Low pressure fuel pump to fuel vapor : 10 N⋅m (1.0 kgf-m, 7.0 lb-ft)
separator)
16. Clamp : 35 N⋅m (3.5 kgf-m, 25.5 lb-ft)
: Clamp the hose (2), lead wires (13) and (14) (DF115A/
140A) to keep them off from intake manifold.
4B-4 Fuel / Water Hose Routing:

3
4 1

IDG211420004-02

1. Fuel injector 4. O-ring

2. Fuel hose (low pressure fuel pump to fuel vapor separator) 5. Low pressure fuel filter
3. Low pressure fuel pump

“a”

1
4 2

5
6 5

“A”
8
View “A”
IDG211420005-02

1. Fuel main joint (E40)/Fuel hose union (Others) 6. MAP sensor

2. Fuel hose (Fuel vapor separator to fuel delivery pipe) 7. Air intake silencer case
3. Fuel hose (Low pressure fuel pump to fuel vapor separator) 8. Intake manifold
4. Hose clamp “a”: 57°
: Set the hose clamp between the paint mark points of fuel hoses (2) and (3).
5. Breather hose
: Pass the breather hose so as not to be caught between air intake silencer case and MAP sensor connector.
 Fuel / Water Hose Routing: 4B-5

Water Hose Routing

CENDG2114202002

4
10

5
8
7 11
5 “A”
2

10 7

View “A”
1
2

IDG211420006-06

1. Crankcase
2. Water hose (Crankcase to engine holder)
3. Crankcase water jacket cover
4. Speedometer hose
5. Water hose (3-way joint to crankcase) 9. Water hose (Engine holder to 3-way joint)
6. Side cover seal 10. Water hose (Fuel vapor separator to engine holder)
7. Water hose (3-way joint to fuel vapor separator) 11. Clamp
: Clamp the fuel hose and water hose (5) together.
8. 3-way joint
4B-6 Fuel / Water Hose Routing:

“A”

2
A

View “A”

“B”

6 3 3
View “B”

IDG211420007-02

1. Water return hose 5. Water return hose union

2. Thermostat 6. O-ring
3. Water hose (Fuel vapor separator to engine holder) A: Assemble the water return hose with the paint marking facing upward.
4. Engine holder B: Securely insert the water return hose until the stopper.
 Prepared by

Outboard Motor Engineering Department

September, 2012
Manual No. 99500-92J00-01E
Printed in Japan

388
 TOP

99500-92J00-01E

99500-92J00-01E
2013

DIC502 Pantone 303C Pantone 485 Pantone 294 Black

No. 667 99500-92J00-01E DF100A/115A/140A Service Manual Cover for PS printing (14mm) 5/0 2013/01/23 BOTTOM