SUZUKI OUTBOARD MOTOR FH 4/S/é FOUR STROKE For ’04 model Sees ealuraioyo “Ra” (U4) MUDEL DF4/5/6 “K4” (04) MODEL FOREWORD This supplementary service manual describes the outline, technical data and servicing procedures for the “K4” (04) models outboard motor. Please read and thoroughly familiarize yourself with this information before using it for your service activities. NOTE: Use this supplement with the following service manual: DF4/5/6 Service Manual ( P/no. 99500-91J0 * -01E) CONTENTS — SPECIFICATIONS. SERVICE DATA TIGHTENING TORQUE MATERIALS REQUIRED MODIFICATIONS CYLINDER HEAD .. CARBURETOR. INTAKE MANIFOLD... FLAME ARRESTER. FLAME ARRESTER HOLDER. IGNITER UNIT. STEERING ADJUSTER KNOB AND SWIVEL BRACKET COVER .. REVERSE LOCK ARM PROPELLER SHAFT AND BUSH WATER TUBE UPPER GROMMET. DRIVESHAFT HOUSING GASKET .. FUEL HOSE ROUTING*SPECIFICATIONS + These specifications are subject to change without notice. tem Unit ~ — a DF4 DFS DF6 PREFIX 0401F | ~—«OOS01F o0601F DIMENSIONS & WEIGHT ‘Overall Tength (ront to back) mm (in) ‘554 (21.8) with tiler handle raised ‘Overall width (side to side) nm (in) 309 (12.2) | Overall height s mm (in) 1064 (41.9) L rm (in) 1191 (46.9) Weight s ig (bs) 26 65.1) eee L kg (b9) 27 (67.3) - Transom height S_| mm (inch type) 442 (15) - L_| ram Gch typay 569 (20) PERFORMANCE Maximum output wes) | 294 | 376 4416) Recommended operating ange ‘min | 4000 ~ 5000 4500 ~ 5500 4750 ~ 5750 ste good ee smn 1300 250 (gear: approx. 1150) | ingen 1250 KEIHIN _ 1300 = 50 | carb (n-gea appro. 1200) POWERHEAD Engine type “itoKe ORV “Number of eyinders 1 Bore mm (in) 62.0 (2.44) : ‘Stroke mmm (a) 40(8t) Total displacement ‘om? (eu in) 138 64) Compression ratio 7 92 Sparkplug Nok | BPREES Ignition system ‘SUZUKI PEI Digital COI) Fuel supply system Carburetor Exhaust system ‘Above prop exhaust Cooling system ‘Water cooled Lubrication system Wet sump by trochoid pump Starting aysiom Manual Choke system ‘Manual Thrattle control “Twist ipUraire “Ka (U4) MUVEL tem Unit LJ DF4 I DFS DF6 FUEL & OIL Fl ‘Suzuka ighy recommends that you use sloohotree unleaded gasoline with a minimum pump octane rating of 87 (2! method) or $1 (Research method) However, bends of unleaded gasoline and alcoho with ak tcuiaont eta covert may be wed are L(Usiimp. gal) 1.5 (0.40/0.33) Engine ol ~ ‘API classification SE, SF SG, SH, SJ Viscosity rating 10W-40 [Enso otarouns (USino. ab 07 @740e) Gear oi! - ‘SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oll amounts. mi (USfimp. 02) 190 (6.4/6.7) BRACKET "Tim angle Degees | 790 (Shallow drive angie 3,45) ‘Number of it pin positon Adjustable 5 ‘Maximum tangle Degrees 7 (rom lowest tt pin positon) LOWER UNIT C Reversing sysiom Gear \Prransmission Fonvarg- Neutral Reverse Reduction system | Bovel goa Gear ratio Z 12:29 (1.99) Driveline impact protection Spline drive rubber hub Propeller StS~=~CS« Blade_x Diam. (in) x Pah (in _ ax 7% « 6 (C601) 3 x 7% x 6% (CBI) 3x 7% x 7 (C7)wreo1o ne (U4) MUUEL *SERVICE DATA These service data are subject to change without notice. 1 om | Data e = nit | - DF4 DFS DF6 POWERHEAD Recommended ee rfemin 4000 ~ 5000 4500 ~ 5500 4750-5750 6 | - UNI 1350 + 50 Es 120 +50 (e-gear approx 1150) | gn gph 2 5s [rea — 1900 260 ee oo = Gindrcamposson : — ° “Cinder coveenson pa Ges 550 ~650 65-65, 78-22) Eng al API casacaton SE, BF 86, 55,5) Viscosity rang SAE 10040 Enghe of arena Tustin a) 07 (07/062) Thermostat operating . - temperature ene eee ** Figures shown are guidelines only, not absolute service limits. CARBURETOR © Item Unit os | DFa Drs | __OF6 Pilot screw uncovered type Type MIKUNIBV22-14 | WIKUNIBV22-14 | KEIINEO2-15 [1.0 mark 7 91001 91010 9160 Main jet # 775 - 78 Pilot # 35 38 Pilot sorew Tums open 2he% Float height mm 7 1421 1041 © Pilot screw covered type (For U.S. model) Type MIKUNIBV22-14 = MIKUNTBV22-16 LD mark 9130 = 9150 Mainjet 7 ms | — eS Pilot jet ~ # 35. = 5 Pilot screw Turns open PRE-SET = PRE-SET Float height mm 1441 = q 1421DF4/5/6 “KA” ('04) MODEL_5 Data tem unit | | —________™i_ Dra DFS DF6 CYLINDER HEAD/CAMSHAFT Gyjlinder head distortion | Limit | __mm (ny 10.05 (0.002) Cam height w Se] ame ‘82.460 ~ 82.520 (1.2780 ~ 1.2808) 8 Limit [mm (in) 92.160 (1.2661) x LS | em {32.598 — 92.596 (1.2610 ~ 1.2894) Limit | mm ny 32.298 (7.2692) sto | mm(n) 0.016 — 0.062 (0.0006 - 0.0024) u i cal eo Camshaft journal | | Limit | _ mm (ay (0.150 (0.0058) _ ~ oil clearance 7 STO | mm(in) 0.016 — 0.052 (0.0006 — 0.0020) Limit | _mm (in) 0.150 (0.0059) Camshaft [Upper] STD | _ mm (ay 15.000 15.026 (0.5906 — 0.5937) holder insiso : * tometer Lower STO | _mm Gn) 16.000 — 16.018 (0.6299 0.6306) Camshat [Upper] sto | mmiiny 14.966 ~ 14.984 (0.5892 ~ 0.5899) journal outside diamoter Lower] STD | mm (in) 15.966 ~ 15.984 (0.6286 ~ 0.6293) omy re} SFrarory “Ka” (U4) MODEL, Data ttem unit DF4 DFS DF6 VALVE / VALVE GUIDE Valve diameter N | amay 240 (0.94) =x | _mm ny 22.0 (0.87) Wang canes Tin | St [mm (0.03 ~ 0107 (0.00% — 0.008) old engine | condition) ex| S10 | mmény 0.03 - 0.7 (0.001 — 0.008) Valve seat angle IN| Degrees 15,45 ex_| Degrees 15,45 Waive guide to || $1 | my (0.025 0.052 (0.0010 — 0.0020) valvo stom Clearance Limit [ra Gp 1075 (0.0030) ex LS | _mmimy (0.045 ~ 0.072 (0.0078 — 0.0028) Tit [rm 0.090 (0.0035) Valve guide a Coe » Wave guide | lnvex| STD io) 5.500 ~ 5512 (0.2165 ~0.2170) Nae guide Iayex{ STD | meni) 11.0 0.43) Valve stom in| St | mmGny 5.460 ~ 6475 (02160 0.2166) outside diameter Fex|stp | mm (my) 5.ad0 ~ 6.466 (02142 - 0.2148) Valve stom detection }N.4 Lit | mm (in) 0.35 (0.014) Valve stom runout [INE Limit | mm (in) 0.05 (0.002) Valve head Inge) Limit | mm ir) 6.08 (0.009) Valve head sro | _ mm (n) 1.0 (0.04) | thickness Tit | —_ mm Gn) 05 (0.02) Valve seat IN| st | _ amin 08- 1.0 0.08 -0.04) contact width Tex] STD [eam fn) 10-4. (0.04 - 0.05) Valve spring free STD | _mm(iny 285 (1.16) length Limit [mem (a) 283 (1.11) ‘Valve spring tension | ST | _N (Ko, tbe) 189 169 (19.9 — 159, 906 — 95:1) for 19.8 mm (0.76 in) Limit | N(g, tbs) 127 (12.7, 26.) for 18.3 mm (0.76 in)ee >? DF4/5/6 “K4” (04) MODEL_7 Item Unit t——— = DFA DFs DF CYLINDER /PISTON/PISTON RING Cynder distortion | Umi’ | mmimy 005 (0008) Piston to eylinder [-st0 [mm np (0.010 — 0.040 (0.0004 0.0016) | elearanoe Limit | mam (in) 0.100 (0.0038) Cylinder bore STD | mm (in) 62.000 ~ 62.015 (2.4409 - 2.4415) Cyfinder measuring poston mm (a) 25 (1.4) fom eynde op surface Piston skirt diameter ‘sTD mm (in), 61.975 — 61.990 (2.4400 - 2.4406) Piston measuring postion rom (in) 78 (06) fom piston skit end Cylinder bore wear Limit [mm (in) 0.100 (0.0039) Piston ring STD [mm Gn) 0.20 - 0.35 (0.008 — 0.014) fend gap el 0:70 (0.028) Tel S| 0:35 ~0.50 (0014-0000) [init | or fy 1.00 (0.080) Piston ring tat, | ST [mm ony ‘Approx. 85 (0.33) free end gan | and] Limit | mm (a) 68 (027) Patonng | yg, | ST [mm oy 0.03007 (0.401 ~ 0.008) 1 gpooe | and Lit Tm ey 8 (005 Piston rg [SL st [em 1221.24 00489040 al ‘groove width oil | STD mm (in), 2.51 — 2.53 (0.099 - 0.100) atone [88 co | mien ee teat Pin clearance in st | mm) 10,006 — 0.019 (0.0002 - 0.0007) piston pin hole mit [mm (inp (0.040 (0.0016) Wawaipin ouside STD | mem 17,995 — 18.000 (0.7085 ~ 0.7087) mit | mm (ny 17.980 (0.7078) as STD | __mmn) 18.006 ~ 16.014 (0.7089 ~ 0.7080) diameter [timit [mm Gin) 18.080 (0.7098) ee STD | _mmn) (0.006 ~ 0.079 (0.0002 ~ 0.0007) jconrod small end [timit [mm Gin) (0.050 (0.0020)B__Uraro/e “KA” (U4) MODEL Data tem Unit DF4 OFS DF6 QO CRANKSHAFT / CONROD Conrod smal end ST] mma) 18.006 — 18.044 (0.7089 ~ 0.7092) eee timt | mmm) | 18040-7702) —— Conrod big end ol S1D | __mmin) (0.015 — 0.085 (0.0006 - 0.0014) 0 Clearance Limit |“ mm (a) (0.080 (0.0081), ince darter sro | mman 28,015 ~ 26.025 (1.1000 ~ 1.1039) Crank pin outside : z diameter STD mm (in) 27.990 — 28,000 (1.1020 - 1.1024) Crank pin outside diameter difference Limit | mm (in) 0.010 (0.0004) (out-ofround and taper) Conrdbig endede | STD | mmm) 0200.90 (0.008 ~ 0.0088) Clearance | Limit mm (in) 1.20 (0.047) Convoabig ond wah] STO | mm ey 290 2580 (0817-0957) “Crank pin with | ST | mmo 24.00 2420 (0.985 0.959) Crankshaft runout Limit mm (in) 0.05 © 002) Crankshaft lower st | mm(in) (0.020 — 0.062 (0.0008 — 0.0024) jaf wee ate Ti OO) 6 ‘Crankcase lower - Rees mse dameter | STD | mm (in) 25,000 ~ 25.021 (0.9848 ~ 0.9851) Granksat lower | sr | an 24.959 —24 980 (0.9826 0.9835) diameterg coe DF4ISI6 “Ke Data tem Unit ~ Dra DFS DFS ELECTRICAL Ignition timing BTOC 1 - 26 * 7 o (For US. mode earees BTDC 6-265 BTDC 3 35 (Except for US, model) (Over revolution limiter ‘min 000 Ignition coil resistance [Secondary _kQ at 20°C 8.4 — 124 [Righ-tension cord ~ pulser core] =] Spark plug cap resistance KG at 20°C 75-125 Battory charge col resistance eptaiead Qa200 06-1.0(R-¥1 Battery charge col output (12) nae a (Optional part) - Stendardsparkpug [Tipe NGK BPRGES Gap mm (in) 0.7 - 0.8 (0.028 — 0.031) LOWER UNIT Design specification thickness for shim & washer Pinion gear backup shim rm (i) 2.0 (0.08) Forward gear backup shim rm (i) 12 (0.08) Forward gear thrust washer mm (i) 1.0 (008) Reverse gear thrust washer im (i) 1.0 (0.04) Fooverse gear backup shim ‘mm (i) 0.8 (0.03) Initial selection-shim adjustment may be required.w TIGHTENING TORQUE Tightening Torque — Important Fasteners THREAD TIGHTENING TORQUE, = DIAMETER | im kgm ibft Cylinder head cover bolt _ émm 8 08 60 Cylinder head bolt amm 28 28 205 Crankcase bolt 6mm 40 1.0 70 Conrod cap bolt amm at 24 150 Rocker arm pivot bolt émm 10 1.0 70 Valve adjusting lock nut 6mm 1 1 80 Intake manifold bolt émm 10 1.0 70 CDI & coil unit mounting bolt émm 10 1.0 70 Carburetor mounting bolt 6mm 10 1.0 70 Fuel pump mounting bolt - émm 8 08. 60 Fuel tank mounting bolt “6mm 40 1.0 70 Flywheel nut 12mm 50. 50 36.0 Engine olf drain plug 410mm 10 1.0 70 | Power unit mounting bolt émm 10 1.0 70 Tiller handle pivot Bolt amm 12 12 85 Nut amm 7 17 125 Steering bracket cover bolt 6mm 10 1.0 70 ‘Swivel bracket cover bolt émm 10 1.0 70 Gearcase nut/ bolt 8mm 17 17, 125 Water pump case nut 6mm 8 08 60 Shift rod guide plate bolt 6mm a | os 60 Rod connecting plate bolt 6mm i 14 80 Propeller shaft bearing housing bolt émm_ | 8 | 08 6.0 Clamp bracket shaft nut 10mm 25 25 180DF4/5/6 “K4’ MATERIALS REQUIRED ‘SUZUKIOUTBOARD ‘SUZUKISUPER ‘SUZUKI WATER RESISTANT] SUZUKISILICONE 99000-31120 0 + 20000 25020 0000-22640 eoosenne 500025160 (400 mlx 24 pes) Go 2509) 9) “Stoke Motor Of THREAD LOCK™1382" 99000-22080 API : SE, SF, SG, SH, SJ (509) SAE: 100-40 NOTE: * Marked part No. is in U.S. market only.2 Ur a/ayD “Ka MOVEL MODIFICATIONS CYLINDER HEAD The intake port and exhaust port have been changed in shape. Early For DF6 Only (Except for U.S. Model) The intake port has been changed in shape and machining, CARBURETOR For DF6 Only (Except for U.S. Model) ‘The carburetor type has been changed from "MIKUNI" to "KEIHIN" In accordance with this change, the intake manifold, flame arrester and flame arrester holder have been changed. Type KEIHIN BC 21-15 LD. Mark 9160 a Main Jet #78 Pilot Jet #38 Pilot Screw 2-718 + 3/4 turns open Float Height me 101mm 7DF4/5/6 “K4" (04) MODEL _13 INTAKE MANIFOLD For DF6 Only (Except for U.S. Mode!) a ‘The intake manifold has been changed in shape. Added 1.0. mark: ¢3 mm hole O U Bae CO) Jeena Q © Oo © Ee (ae VIEW A FLAME ARRESTER For DF6 Only (Except for U.S. Model) oO The flame arrester has been changed in shape. 2 Eatly FLAME ARRESTER HOLDER The flame arrester holder has been changed in shape. Eatly LateIGNITER UNIT For DF6 Only (Except for U.S. Model) The ignition timing has been changed. eo Ignition Timing: BTDC 3° - BTDC 28° LD. mark: White paint ~» Pink paint STEERING ADJUSTER KNOB AND SWIVEL BRACKET COVER The steering adjuster knob has been changed in thread pitch size. In accordance with this change, the swivel bracket cover has been changed in thread hole pitch size. “Thread pitch: 1.25 mm ~» 0.78 rom ‘Swivel bracket cover im Steering adjuster knob REVERSE LOCK ARM DF4/s ‘The reverse lock arm has been change in shape and added dacrotized coat. 125 mm 9 613.3 mm_ B1.0mm—> 85mm 9.0 mm -»8.5 mmDraisi6 “Ka” (04) MODEL _15 PROPELLER SHAFT AND BUSH Fas The propeller shaft, bush and related items have been changed. Propeller bush Propeller bush oe — & >= imc NOTE The late propeller shaft, bush and bush stopper are the same parts equipped with the DFE. WATER TUBE UPPER GROMMET The water tube upper grommet has been changed in shape. $4.0 mm 42.5 mm ‘Added chamiering °o ry “ ‘Added chamfering DRIVESHAFT HOUSING GASKET ‘The print bead has been added on the driveshaft housing gasket. ‘Added print beadFUEL HOSE ROUTING For DF4 (Prepared by SUZUKI MOTOR CORPORATION Marine & Power Products Division January, 2004 Manual No.99501-91J10-016, Printed in Japan