13303129-2012-2013 Suzuki Lean Burn Df15a Df20a 4-Stroke Outboard Repair Manual Download
13303129-2012-2013 Suzuki Lean Burn Df15a Df20a 4-Stroke Outboard Repair Manual Download
13303129-2012-2013 Suzuki Lean Burn Df15a Df20a 4-Stroke Outboard Repair Manual Download
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
Manual Starting System ..........................................1J-1
Charging System.................................................... 1K-1
Mid Unit ....................................................................... 2-i
Precautions .............................................................. 2-1 5
Housing and Bracket.............................................. 2A-1
Lower Unit................................................................... 3-i
Precautions .............................................................. 3-1
Right Hand Rotation Unit ....................................... 3A-1 6
Wire / Hose Routing ................................................... 4-i
Precautions .............................................................. 4-1
Wire Routing .......................................................... 4A-1
Fuel / Water Hose Routing..................................... 4B-1 7
10
11
12
Table of Contents 00- i
Section 00
00
Precautions
CONTENTS
Precautions
Precautions
Precautions
General Precautions
CENDK1110000001
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 moisture-
proof 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:
Table of Contents 0- i
Section 0
General Information
0
CONTENTS
General Information
General Information
General Description
Symbols
CENDK1110101001
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:
CENDK1110101002 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
B (Base Color)
IAJ311010009-01
8 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 entièrement le carburant du
séparateur de vapeurs ou du
carburateur avant de procéder.
• Pour plus de détail, voir le manuel
du propriétaire.
IDK111010005-01
IDK111010006-01
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
combination)
DF 20A 5% Methanol, 10% Ethanol, 15% MTBE
02002F
Engine Oil
THAI SUZUKI MOTOR CO.,LTD.
MADE IN THAILAND FABRIQUE AU THAILANDE NOTICE
Use of a poor quality engine oil can adversely
2 3
IDK111010001-01 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
Oil quality is a major contributor to your engine’s
A second engine serial number plate is pressed into a
performance and life. Always select good quality engine
boss on the cylinder block.
oil.
Suzuki recommends the use of SAE 10W-40 SUZUKI
MARINE 4-CYCLE ENGINE OIL.
If SUZUKI MARINE 4-CYCLE ENGINE OIL is not
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.
XXXXXX
API Classification SAE Viscosity Grade
1 SG
SH 10W–40
SJ
IDK111010004-01 SL
10W–30
1. Serial number plate 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.
0A-5 General Information:
Battery Requirement
CENDK1110101010
Suzuki recommends a 12 volt cranking type lead acid battery for the DF15A/20A.
Minimum battery requirement for starting the engine is provided below.
The battery must satisfy one of the specifications described below.
NOTE
• The specifications listed below are the minimum battery rating requirements for starting the engine.
• Additional electrical loads from the boat will require larger capacity batteries.
• Dual-purpose (Cranking / Deep Cycle) batteries can be used if they meet the minimum specifications
listed below (MCA, CCA, or RC).
• Do not use a Deep Cycle battery for the main cranking battery.
• The use of Maintenance-Free, sealed, or Gel-Cell batteries is not recommended because they may
not be compatible with Suzuki’s charging system.
• When connecting batteries in parallel, they must be of the same type, capacity, manufacturer, and of
similar age. When replacement is necessary, they should be replaced as a set.
• It is recommended that the battery be installed in an enclosed case.
• When connecting batteries, hexagon nuts must be used to secure battery leads to battery terminals.
Battery specification
450 Marine Cranking Amps (MCA)/ABYC, or 330 Cold Cranking Amps (CCA)/SAE or 70 Reserve Capacity (RC)
Minutes/SAE or 12 V 35 AH
0A-7 General Information:
Specifications
Specifications
CENDK1110107001
NOTE
These specifications are subject to change without notice.
Model Pre-fix
Data
Item Unit
DF15A DF15AE DF20A DF20AE
PRE-FIX 01504F 02002F
Performance
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Maximum output kW (PS) 11.0 (15) 14.7 (20)
Recommended operating range r/min 5 000 – 6 000 5 300 – 6 300
Idle speed r/min 850 ± 50 (in-gear: Approx. 800 – 900)
Powerhead
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Engine type 4-stroke SOHC
Number of cylinders 2
Bore mm (in.) 60.4 (2.38)
Stroke mm (in.) 57.0 (2.24)
Total displacement cm3 (cu. in) 327 (19.9)
Compression ratio :1 10.5
Spark plug NGK CPR6EA-9
Ignition system Digital CDI
Fuel supply system Electronic fuel injection
Exhaust system Through prop exhaust
Cooling system Water cooled
Lubrication system Wet sump by trochoid pump
Starting system Manual Electric Manual Electric
Throttle control Twist grip Twist grip
Choke system —
General Information: 0A-8
Bracket
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Trim angle degree 0 – 16 (–8 to 8)
Number of tilt pin position 5
Maximum tilt angle degree 73 (–8 to 65)
Lower Unit
Data
Item Unit
DF15A DF15AE DF20A DF20AE
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 forward) Clockwise
Blade x Dia. (in.) x Pitch (in.)
3 x 9 and 1/4 x 7
3 x 9 and 1/4 x 8
Propeller
3 x 9 and 1/4 x 9
3 x 9 and 1/4 x 10
3 x 9 and 1/4 x 11
0A-9 General Information:
Service Data
CENDK1110107002
NOTE
These service data are subject to change without notice.
Powerhead
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Recommended operating range r/min 5 000 – 6 000 5 300 – 6 300
Idle speed r/min 850 ± 50 (in-gear: Approx. 800 – 900)
DF15A/AE, DF20A/AE (With decompression system):
kPa
**Cylinder compression pressure 350 – 900 (3.5 – 9, 50 – 128)
(kgf/cm2, psi.)
{Crank with recoil starter}
**Cylinder compression pressure max. kPa
100 (1.0, 14)
difference between cylinders (kgf/cm2, psi.)
kPa 200 – 500 (2.0 – 5.0, 29 – 71) 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
1.0 (1.1 / 0.9): Oil change only
Engine oil amounts L (US/lpm. qt)
1.1 (1.2 / 1.0): Oil filter change
Thermostat operating temperature °C (°F) 48 – 52 (118 – 126)
Crankshaft / Conrod
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Conrod small end inside diameter std. mm (in.) 16.006 – 16.014 (0.6302 – 0.6304)
std. mm (in.) 0.025 – 0.045 (0.0010 – 0.0018)
Conrod big end oil clearance
Limit mm (in.) 0.080 (0.0031)
Conrod big end inside diameter std. mm (in.) 29.025 – 29.034 (1.1427 – 1.1431)
Crank pin outside diameter std. mm (in.) 28.989 – 29.000 (1.1413 – 1.1417)
Crank pin outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (out-of-round and taper)
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.) 19.950 – 20.000 (0.7854 – 0.7874)
Crank pin width std. mm (in.) 20.10 – 20.20 (0.7913 – 0.7953)
Crankshaft journal runout Limit mm (in.) 0.04 (0.0016)
std. mm (in.) 0.020 – 0.047 (0.0008 – 0.0019)
Crankshaft journal oil clearance
Limit mm (in.) 0.080 (0.0031)
Crankcase bearing holder inside
std. mm (in.) 35.000 – 35.008 (1.3780 – 1.3783)
diameter
Crankshaft journal outside diameter std. mm (in.) 31.989 – 32.000 (1.2594 – 1.2598)
Crankshaft journal outside diameter
Limit mm (in.) 0.010 (0.0004)
difference (out-of-round and taper)
General Information: 0A-12
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Crankshaft bearing thickness std. mm (in.) 1.486 – 1.490 (0.0585 – 0.0587)
std. mm (in.) 0.10 – 0.30 (0.004 – 0.012)
Crankshaft thrust play
Limit mm (in.) 0.60 (0.024)
Crankshaft length std. mm (in.) 126.8 – 126.9 (4.992 – 4.996)
Crankcase length std. mm (in.) 127.0 – 127.1 (5.000 – 5.004)
Electrical
Data
Item Unit
DF15A DF15AE DF20A DF20AE
Degrees at r/
Ignition timing 5° BTDC – 10° BTDC 5° BTDC – 20° BTDC
min
Over revolution limiter r/min 6 200 6 300
CKP sensor resistance Ω at 20 °C 148 – 222 (R/B – B)
Power source coil resistance Ω at 20 °C 2.1 – 3.2 (W – B): Manual start model
Primary Ω at 20 °C 0.08 – 0.11 (O – B)
Ignition coil resistance
Secondary kΩ at 20 °C 3.5 – 4.7 (HT cord – HT cord)
Spark plug cap resistance kΩ at 20 °C 4–6
0.5 – 0.8: Manual start model
Battery charge coil resistance Ω at 20 °C
0.7 – 1.1: Electric start model
72: Manual start model
Battery charge coil output (12 V) Watt
144: Electric start model
Type NGK CPR6EA-9
Standard spark plug
Gap mm (in.) 0.8 – 0.9 (0.031 – 0.035)
Electric starter model
Fuse amp. rating A 30A: Main
10A: ECM
Recommended battery capacity (12 V) Ah (kC) 35 (126) or larger
Fuel injector resistance Ω at 20 °C 10 – 14
IAC valve resistance Ω at 20 °C 31 – 42
IAT sensor / Cylinder temp. sensor
kΩ at 25 °C 1.8 – 2.3
(Thermistor characteristic)
Starter motor relay coil resistance Ω at 20 °C 145 – 190: Electric start model
Peak Voltage
NOTE
Requirement for peak voltage measurement:
• Remove all spark plugs to eliminate the variables at cranking speed.
• Use a STEVENS peak voltage tester, model CD-77.
• Use the 26-pin test cord.
• Crank with recoil starter or starter motor.
Test 1
Test 2
1 O
CKP sensor
R/B 26
B
B 7
Test 5 Test 3, 4
ECM power Fuel injector
W 13 2 O/B
15 B/Br
IDK111010002-01
General Information: 0A-14
Test 1
Test 2
1 O
CKP sensor
R/B 26
B
B 7
Test 3 Test 4, 5
Power source coil Fuel injector
Br/R 13 2 O/B
15 B/Br
Br/W 11
IDK111010003-01
0A-15 General Information:
Self-Diagnostic code
0: OFF, 1: ON
Priority Failed item Code Lamp flashing pattern Fail-Safe system active
1
Important Fasteners
Thread Tightening torque
Item
diameter Nm kgf-m lbf-ft
Cylinder head cover bolt 6 mm 10 1.0 7.2
Cylinder head bolt 8 mm 30 3.0 21.7
6 mm 10 1.0 7.2
Crankcase bolt
8 mm 25 2.5 18.0
Conrod cap bolt 6 mm 10 1.0 7.2
Oil pump screw 6 mm 8.5 0.9 6.5
Intake manifold bolt 8 mm 23 2.3 16.5
Throttle body mounting bolt 6 mm 11 1.1 8.0
Fuel pump bolt 6 mm 10 1.0 7.2
Oil pressure switch — 13 1.3 9.5
Valve adjusting lock nut 5 mm 11 1.1 8.0
Timing pulley nut 27 mm 50 5.0 36.0
Oil regulator 14 mm 27 2.7 19.5
Camshaft pulley bolt 6 mm 10 1.0 7.2
Thermostat cover bolt 6 mm 10 1.0 7.2
Flywheel nut 14 mm 90 9.0 65
Starter motor mounting bolt 8 mm 23 2.3 16.5
Engine oil drain plug 12 mm 13 1.3 9.5
Power unit mounting bolt 8 mm 23 2.3 16.5
Driveshaft housing bolt 8 mm 23 2.3 16.5
Upper mount nut 10 mm 35 3.5 25.0
Lower mount cover bolt 8 mm 23 2.3 16.5
Shallow drive arm bolt 10 mm 25 2.5 18.0
Tiller handle cover bolt 8 mm 23 2.3 16.5
Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0
Water pump case nut 6 mm 6 0.6 4.3
Gearcase bolt 8 mm 17 1.7 12.3
Propeller shaft bearing housing bolt 6 mm 8 0.8 5.8
Propeller nut 12 mm 18 1.8 13.0
0A-17 General Information:
General Bolt
NOTE
These value are only applicable when torque for a general bolt is not listed in the “Important
Fasteners” table.
Special Tool
CENDK1110108002
Precautions
Precautions for Maintenance
CENDK1110200001
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
CENDK1110201001
Refer to “Fuel and Oil Recommendations” in Section 0A (Page 0A-4).
Scheduled Maintenance
Periodic Maintenance Schedule Chart
CENDK1110205001
NOTE
I = Inspect and clean, adjust, lubricate or replace, if necessary
T = Tighten
R = Replace
Interval
Item to be serviced Initial 20 hrs. or 1 Every 100 hrs. or Every 200 hrs. or Every 300 hrs. or
month 12 months 12 months 36 months
Spark plug — I — —
Breather hose and fuel line I I — —
Engine oil R R — —
Gear oil R R — —
Lubrication I I — —
Anodes (external) I I — —
Anodes (internal powerhead) — I — —
Battery I I — —
Engine oil filter R — R —
I I — —
Low pressure fuel filter
Replace every 400 hours or 2 years.
— — I —
Timing belt
Replace every 4 years.
Ignition timing — — I —
Idle speed I — I —
Valve clearance I — I —
Water pump — — I —
Water pump impeller — — I R
Propeller nut and pin I I — —
Bolt and Nuts T T — —
Maintenance and Tune-Up: 0B-2
Lubrication Point
CENDK1110205002
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))
3
1
4
IDK111020008-01
1. Throttle cable 3. Grease nipple, swivel bracket 5. Grease nipple, steering bracket
2. NSI cable 4. Clamp screw 6. Propeller shaft
0B-3 Maintenance and Tune-Up:
Service Instructions
Engine Oil Level Check
CENDK1110206001
IDK111020013-01
“A”
IDK111020003-01
“B”
IDK111020009-02
3) Place a container under engine oil drain plug. 6) Pour the recommended engine oil into oil filler
4) Remove engine oil drain plug (2) and gasket (3) to opening, then install oil filler cap.
drain engine oil. Recommended engine oil
• 4 stroke motor oil
• NMMA FC-W classification:
SG, SH, SJ, SL, SM. or API classification:
SG, SH, SJ, SL, SM.
2 • Viscosity rating:
NMMA FC-W 10W-40 or SAE 10W-40
Engine oil amounts
Oil change only: 1.0 L (1.1/0.9 US/Imp.qt)
3 Oil filter change: 1.1 L (1.2/1.0 US/Imp.qt)
IDK111020014-01
NOTICE
A previously-used gasket may leak, resulting
in engine damage.
NOTE
Refer to “Oil Change Reminder System
Description” in Section 1A (Page 1A-14).
(a)
IDK111020016-01
0B-5 Maintenance and Tune-Up:
4) Place a shop cloth under the oil filter cap before 7) Install the spring (5) to the oil filter cap.
removal to absorb any oil released. 8) Replace the O-ring (6) with a new one and oil it.
5) Remove the three bolts securing the oil filter cap (2), 9) Install the new oil filter (7).
then remove filter cap and oil filter (3).
7
5
IDK111020020-01
IDK111020017-01
10) Install the oil filter cap, then tighten three bolts
securely.
IDK111020018-01
IDK111020021-01
NOTICE
11) Install the fuel filter to original position.
If the filter is installed improperly, serious
engine damage may result.
NOTICE
A previously-used O-ring may leak, resulting
in engine damage.
IDK111020019-01
Maintenance and Tune-Up: 0B-6
12) Install PORT side cover. 4) Fill with recommended gear oil through oil drain hole
Refer to “Lower Side Cover Removal and until oil just starts to flow out from oil level hole.
Installation” in Section 2A (Page 2A-2).
Recommended gear oil
13) Pour the recommended engine oil into the oil filler
• Suzuki Outboard Motor Gear Oil or API
opening, then install oil filler cap.
classification GL5, Viscosity rating SAE # 90
Check the oil level in the same manner of engine oil
Hypoid gear oil.
change procedure.
Gear oil amount
Recommended engine oil
250 ml (8.4/8.8 US/Imp. oz)
• 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: 1.0 L (1.1/0.9 US/Imp.qt)
Oil filter change: 1.1 L (1.2/1.0 US/Imp.qt) IAJ311020022-01
14) Start engine and allow it to run for several minutes at 5) Install oil level plug before removing oil filler tube
idle speed. from drain hole.
Check that there are no leaks around oil filter cap. 6) Install oil drain plug.
Turn off engine and wait for approx. two minutes,
NOTICE
then recheck engine oil level.
15) Reset oil change reminder system’s operation time An used gasket may leak and allow water to
to zero (cancellation). enter the gearcase causing severe damage.
IAJ311020012-01
0B-7 Maintenance and Tune-Up:
Removal
IDK111020025-01
! WARNING
Spark Plug Inspection and Cleaning
The hot engine can burn you. CENDK1110206005
NOTICE
Wait until the engine is cool enough to touch. Non-resistor types of spark plugs will
interfere with the function of the electronic
1) Disconnect the spark plug caps (1). ignition, causing misfiring, or causing
problems with other electronic boat
equipment and accessories.
IDK111020023-01
Carbon Deposits
Inspect for carbon deposits on spark plug base.
2) Remove the spark plug with spark plug wrench.
If carbon is present, remove it with a spark plug cleaning
machine or by carefully using a pointed tool.
IDK111020024-01 I9J011020005-01
Maintenance and Tune-Up: 0B-8
“a”
1
I9J011020007-01
Condition of Electrodes
Inspect electrode for a worn or burnt condition.
IDK111020026-01
If it is extremely worn or burnt, replace spark plug.
Also, be sure to replace spark plug if it has a broken NOTICE
insulator, damaged thread, etc.
Turning of the engine in counterclockwise
NOTICE can cause water pump impeller damage.
Use of improper spark plugs can cause
Rotate the crankshaft in the normal running
severe engine damage.
direction only (clockwise) to prevent water
If the reach is too short, carbon will be
pump impeller damage.
deposited on the threaded portion of the plug
hole resulting in possible engine damage.
IAJ311020030-02
“B” 1. Lock nut 3. Valve stem
“A” 2. Valve adjusting screw 4. Valve clearance
“A” Adjustment
1) Loosen valve adjusting lock nut (1).
IDK111020028-03
2) Turn valve adjusting screw (2) using the valve
“A”: Punch mark (○) “B”: INDEX mark adjustment driver to bring valve clearance to within
specification.
NOTE
Special tool
• The piston must be at its TDC position on a (A): 09900–20803 (Thickness gauge)
compression stroke to check or adjust (B): 09917–14910 (Valve adjustment driver)
valve clearance.
• The valve clearance specification is for
COLD engine condition.
(B)
(A)
4) Measure valve clearances by inserting the thickness
gauge between valve stem end and valve adjusting
screw on rocker arm.
1 2
Special tool
(A): 09900–20803 (Thickness gauge)
Valve clearance (cold engine condition):
IN.: 0.18 – 0.22 mm (0.007 – 0.009 in.) IDK111020030-01
EX.: 0.18 – 0.22 mm (0.007 – 0.009 in.) 3) Tighten valve adjusting lock nut while holding valve
adjusting screw.
Tightening torque
Valve adjusting lock nut (a): 11 N·m (1.1 kgf-m,
8.0 lbf-ft)
(a)
(A)
IDK111020029-01
IDK111020031-01
Maintenance and Tune-Up: 0B-10
NOTICE
A previously-used gasket may leak, resulting
in engine damage.
Tightening torque 1
Cylinder head cover bolts (b): 10 N·m (1.0 IDK111020033-01
kgf-m, 7.2 lbf-ft)
1. Timing belt
(A)
IDK111020037-01
6) Remove the bolt (3) and air intake silencer case (4).
IDK111020034-01
4
(C)
IDK111020038-01
7 6
8 5
IDK111020039-01
IDK111020036-01
IDK111020040-01
Maintenance and Tune-Up: 0B-12
9) Disconnect the lead wire connectors at the following 12) Lift stator base from cylinder block and lay it as
sensors and actuator. (Throttle position sensor, IAC shown figure.
valve, MAP sensor, CMP sensor, Fuel injector)
IDK111020045-01
IDK111020041-01
NOTICE
10) Disconnect wire harness connector from ECM, then
remove ECM. Turning of the engine in counterclockwise
Remove the two bolts (10) securing electric parts can cause water pump impeller damage.
holder.
Rotate the crankshaft in the normal running
direction only (clockwise) to prevent water
pump impeller damage.
IDK111020042-01
(D)
13
10
2
IDK111020046-04
IDK111020043-01 NOTICE
11) Remove the four bolts securing stator base (11). After the timing belt has been removed,
Remove the two bolts securing starter motor (12). independently turning cam pulley or
crankshaft will cause interference between
piston and valve, which cause damage to
these related parts.
12
Do not rotate the cam pulley and/or
crankshaft with timing belt removed.
11
IDK111020044-02
0B-13 Maintenance and Tune-Up:
14) Remove the timing belt (14) from the cam pulley first,
then from the timing pulley.
14 IDK111020048-01
15) Install the timing belt on the timing pulley first, then
4
the cam pulley.
NOTICE
Grease, oil or any similar material will IDK111020050-03
damage the timing belt.
1. Punch mark on cam pulley
2. INDEX mark on cylinder head
Always keep the timing belt away from any 3. Punch mark on timing pulley nut lock washer
grease and oil. 4. INDEX mark on cylinder block
NOTE
The timing belt must be installed with the
arrow mark on the timing belt toward the
direction of rotation.
Maintenance and Tune-Up: 0B-14
17) Install the stator base, then tighten bolts securely. Idle Speed and Idle Air Control (IAC) Duty
Tighten the starter motor mounting bolts securely. Inspection
CENDK1110206009
NOTE
Before checking idle speed/IAC duty, make
sure of the following.
• Engine must be warmed up.
• Check idle speed after engine speed has
stabilized.
IDK111020051-01
• Check throttle link mechanism and throttle
18) Install the following parts. valve for smooth operation.
a) Flywheel. • Lead wire and hoses of electronic fuel
Refer to “Flywheel Removal and Installation” in injection and engine control systems are
Section 1K (Page 1K-4). connected securely.
Special tool • Ignition timing is within specification.
(A): 09930–39520 (Flywheel holder) • Valve clearance is checked according to
Tightening torque maintenance schedule.
Flywheel nut (a): 90 N·m (9.0 kgf-m, 65 lbf-ft) • No abnormal air drawn in from air intake
system.
After all items are confirmed, check idle
speed.
(A)
Inspection
1) Start engine and allow to warm up.
2) Attach engine tachometer cord to the ignition coil
high-tension cord.
(a) Special tool
: 09900–26006 (Engine tachometer)
IDK111020052-01 NOTE
b) Recoil starter. Check and/or adjust the idle speed after the
Refer to “Recoil Starter Removal and Installation” engine speed has stabilized.
in Section 1J (Page 1J-3).
c) Spark plugs.
Refer to “Spark Plug Removal and Installation”
(Page 0B-7).
d) Lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-2).
19) Final assembly check.
• All parts removed have been returned their
original positions.
• Check wire and hose routing.
Refer to “Wiring Harness Routing Diagram” in
IDK111020053-01
Section 4A (Page 4A-3) and “Fuel Hose Routing”
in Section 4B (Page 4B-2) and “Water Hose 3) Check engine idle speed.
Routing” in Section 4B (Page 4B-5). Idle speed in neutral gear (IAC duty)
800 – 900 r/min. (Duty: Approx. 10%)
0B-15 Maintenance and Tune-Up:
NOTE
• While IAC valve duty is at a fixed 10% duty,
the caution lamp will flash.
• The fixed mode will continue for 5 minutes.
IDK111020054-01
IDK111020055-01
Maintenance and Tune-Up: 0B-16
NOTE
Before checking the ignition timing, make
sure idle speed is adjusted within
specification.
IDK111020056-01
(A)
IDK111020057-01
IDK111020010-01
IDK111020058-01
Always take the following precautions when Replace water pump impeller
servicing the fuel filter: Every 300 hours (36 months)
• Stop the motor before cleaning the fuel
filter.
• Be careful not to spill fuel. If you do, wipe it
up immediately.
• Do not smoke, and keep away from open
flames and sparks.
1 2
IDK111020007-01
IAJ311020002-01
1
2
IAJ311020056-01
Anodes Inspection
CENDK1110206016
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.
• Do not paint anodes, as this will render IDK111020062-01
them ineffective.
• Periodically clean anodes with a wire
brush to remove any coating which might
decrease their protective ability.
Maintenance and Tune-Up: 0B-20
Connecting Battery
! WARNING
Battery posts, terminals, and related
accessories contain lead and lead IAJ311020004-01
I9J011020032-01
IDK111020063-01
Maintenance and Tune-Up: 0B-22
4) Loosen screw and disconnect blue / yellow lead wire 8) Start engine and allow to warm up.
(2) from oil pressure switch (3). 9) After warming up, shift into forward gear and
Remove the oil pressure switch. increase engine speed to 3 000 r/min., then compare
pressure indicated on gauge to specifications.
NOTE
The figure shown below is a guideline only,
not an absolute service limit.
3
Oil pressure
200 – 500 kPa (2.0 – 5.0 kg/cm2, 29 – 71 psi.)
2 at 3 000 r/min., oil temp. at normal operating
temp.
10) If oil pressure is lower or higher than specification,
IDK111020064-01 the following causes may be considered.
5) Install oil pressure gauge adaptor into oil pressure Low oil pressure
switch hole in place of oil pressure switch. • Clogged oil filter
Special tool • Leakage from oil passages
(A): 09915–77311 (Oil pressure gauge) • Defective oil pump
(B): 09915–78211 (Oil pressure gauge
• Defective oil pressure regulator
adapter)
• Damage O-ring
• Combination of above items
High oil pressure
(A) • Using an engine oil of too high viscosity
• Clogged oil passage
• Clogged oil pressure regulator
(B) • Combination of above items
11) After testing, reinstall oil pressure switch.
Refer to “Oil Pressure Switch Removal and
Installation” in Section 1E (Page 1E-5).
IDK111020065-01 12) Check the engine oil level.
6) Install the fuel filter to filter bracket.
7) Attach the engine tachometer to ignition coil high- Cylinder Compression Pressure Check
CENDK1110206020
tension cord. The compression pressure reading of cylinder is good
Special tool indicator of its internal condition.
(C): 09900–26006 (Engine tachometer) The decision to overhaul the power unit is often based
on the results of a compression test.
Periodic maintenance records kept at your dealership
should include compression readings for each
maintenance service.
1) Start engine and allow to warm up, then shut engine
(C) off.
2) Remove the STBD / PORT lower side cover.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-2).
3) Remove all spark plugs.
IDK111020066-01
0B-23 Maintenance and Tune-Up:
IDK111020069-01
IDK111020070-02
NOTE
(B) Figures shown are guidelines only, not
absolute service limits.
Section 1
Power Head
CONTENTS
Intake Manifold Removal and Installation ...........1D-5 Fuel System ............................................. 1G-1
Throttle Body Removal and Installation ..............1D-7 Precautions.......................................................... 1G-1
Throttle Body Inspection .....................................1D-7 Precautions on Fuel System Service ................. 1G-1
Camshaft Pulley Removal and Installation..........1D-7
General Description ............................................ 1G-2
Power Unit Removal and Installation ..................1D-8
Electronic Fuel Injection System Description ..... 1G-2
Camshaft, Rocker Arm and Rocker Arm Shaft
Fuel Delivery System Components
Removal and Installation.................................1D-16
Description ....................................................... 1G-4
Camshaft, Rocker Arm and Rocker Arm Shaft
High Pressure Fuel Pump Control System
Inspection........................................................1D-17
Description ....................................................... 1G-6
Cylinder Head Assembly Components .............1D-19
Air Intake Components Description.................... 1G-7
Cylinder Head Removal and Installation ...........1D-20
Idle Air Control System Description ................... 1G-9
Cylinder Head Disassembly and Assembly ......1D-21
Diagnostic Information and Procedures ......... 1G-10
Cylinder Head Components Inspection and
Fuel Pressure Inspection ................................. 1G-10
Servicing .........................................................1D-23
Fuel System Diagnosis .................................... 1G-12
Pistons, Piston Rings, Connecting Rods,
Fuel Injection System Troubleshooting ............ 1G-13
Cylinder and Crankshaft Components ............1D-30
Pistons, Piston Rings, Connecting Rods, Service Instructions .......................................... 1G-14
Cylinder and Crankshaft Disassembly and Fuel Pressure Relief Procedure ....................... 1G-14
Assembly ........................................................1D-31 Fuel Line Removal and Installation .................. 1G-14
Cylinder, Piston and Piston Ring Inspection Fuel Line Inspection ......................................... 1G-14
and Servicing ..................................................1D-39 Fuel Leakage Check Procedure....................... 1G-14
Piston Pin and Conrod Inspection.....................1D-42 Inspection of Fuel Hose Connections .............. 1G-15
Crank Pin and Conrod Inspection .....................1D-43 Fuel Vapor Separator Removal and
Crankshaft Inspection .......................................1D-45 Installation ...................................................... 1G-15
Crankshaft Main Bearing Inspection .................1D-46 Inspection of Fuel Vapor Separator ................. 1G-16
Crankshaft Oil Seal Inspection..........................1D-48 High Pressure Fuel Pump Removal and
Installation ...................................................... 1G-16
Power Unit Lubrication ............................1E-1 High Pressure Fuel Pump Inspection............... 1G-17
General Description ............................................. 1E-1 Fuel Injector Inspection with Injector in Place .. 1G-17
Engine Lubrication Description ........................... 1E-1 Individual Fuel Injector Operating Sound
Inspection....................................................... 1G-18
Schematic and Routing Diagram........................ 1E-1
Fuel Injector Operating Signal Inspection ........ 1G-19
Engine Oil Lubrication Chart ............................... 1E-1
Fuel Injector Removal and Installation ............. 1G-20
Diagnostic Information and Procedures............ 1E-2 Low Pressure Fuel Pump Removal and
Oil Pressure Check ............................................. 1E-2 Installation ...................................................... 1G-22
Low Oil Pressure Caution System ...................... 1E-2 Low Pressure Fuel Pump Inspection ............... 1G-23
Powerhead Lubrication System Diagnosis.......... 1E-2 Fuel Tank Construction .................................... 1G-24
Service Instructions............................................. 1E-2 Fuel Tank Disassembly and Reassembly ........ 1G-24
Oil Pump Removal and Installation ..................... 1E-2 Fuel Tank Components Inspection .................. 1G-24
Oil Pump Disassembly and Assembly ................ 1E-3
Inspection Oil Pump Component Parts ............... 1E-4 Ignition System........................................ 1H-1
Oil Pressure Switch Removal and Installation .... 1E-5 General Description .............................................1H-1
Oil Pressure Switch Inspection ........................... 1E-5 Ignition System Description.................................1H-1
Ignition Control Description .................................1H-2
Power Unit Cooling System ....................1F-1
Component Location ...........................................1H-3
General Description ............................................. 1F-1 Ignition System Components Location................1H-3
Water Cooling System Description ..................... 1F-1
Diagnostic Information and Procedures ............1H-3
Displacement Type Water Pump Description ..... 1F-1
Ignition System Symptom Diagnosis...................1H-3
Schematic and Routing Diagram........................ 1F-2 Ignition System Troubleshooting .........................1H-3
Cooling Water Circulation Chart.......................... 1F-2
Service Instructions .............................................1H-5
Diagnostic Information and Procedures............ 1F-3 Spark Plug Removal and Installation ..................1H-5
Powerhead Cooling System Diagnosis ............... 1F-3 Spark Plug Inspection .........................................1H-5
Service Instructions............................................. 1F-3 Ignition Coil Removal and Installation .................1H-5
Thermostat Removal and Installation.................. 1F-3 Ignition Coil Inspection ........................................1H-6
Thermostat and Related Items Inspection .......... 1F-4 Spark Plug Cap Inspection..................................1H-7
Water Pump Removal and Installation................ 1F-5 Ignition Coil Primary Peak Voltage Inspection ....1H-7
Water Pump Related Item Inspection ................. 1F-5 CKP Sensor Inspection .......................................1H-7
Water Tube Removal and Installation ................. 1F-5 ECM Power Source Coil Inspection ....................1H-7
Water Tube Related Item Inspection................... 1F-5 Emergency and Engine Stop Switch
Inspection..........................................................1H-7
Table of Contents 1-iii
Starting System .........................................1I-1 Recoil Starter Removal and Installation .............. 1J-3
General Description .............................................. 1I-1 Recoil Starter Disassembly and Assembly ......... 1J-4
Electric Starter System Description...................... 1I-1 Recoil Starter Components Cleaning and
Start-In-Gear Protection System Description ....... 1I-1 Inspection.......................................................... 1J-7
NSI Cable Installation and Adjustment................ 1J-8
Component Location ............................................ 1I-2
Starting System Components Location................ 1I-2
Charging System ..................................... 1K-1
Diagnostic Information and Procedures............. 1I-2
General Description .............................................1K-1
Starter System Symptom Diagnosis .................... 1I-2
Charging System Description..............................1K-1
Starter System Troubleshooting .......................... 1I-3
Battery Requirement Description ........................1K-2
Service Instructions.............................................. 1I-5
Component Location ...........................................1K-2
Starter Motor Removal and Installation................ 1I-5
Charging System Components Location.............1K-2
Starter Motor Test ................................................ 1I-6
Starter Motor Components................................... 1I-8 Diagnostic Information and Procedures ............1K-2
Starter Motor Disassembly and Assembly ........... 1I-8 Charging System Diagnosis................................1K-2
Starter Motor Components Inspection and Service Instructions .............................................1K-3
Servicing .......................................................... 1I-10 Charging System Construction ...........................1K-3
Starter Motor Relay Inspection .......................... 1I-14 Flywheel Removal and Installation......................1K-4
Neutral Switch Inspection .................................. 1I-15 Battery Charge Coil / CKP Sensor / Stator
Starter Button Inspection ................................... 1I-16 Base Removal and Installation..........................1K-5
ECM Power Source Coil / Battery Charge Coil
Manual Starting System...........................1J-1 / CKP Sensor / Stator Base Removal and
Precautions........................................................... 1J-1 Installation .......................................................1K-10
Precaution for Manual Starting System................1J-1 Battery Charge Coil Inspection .........................1K-15
General Description ............................................. 1J-1 Rectifier / Regulator Removal and Installation ..1K-15
Manual Starting System .......................................1J-1 Rectifier / Regulator Inspection .........................1K-16
Battery Relay Inspection ...................................1K-17
Service Instructions............................................. 1J-2
Fuse Inspection.................................................1K-18
Recoil Starter Components ..................................1J-2
1-1 Precautions:
Precautions
Power Head
Precautions
Precautions for Powerhead
CENDK1111000001
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
CENDK1111100001
! 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 high pressure fuel pump.
! 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.
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
CENDK1111101001
The DF15A/20A 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
NOTE
The engine operating time can be checked by SDS Ver.7.
Engine Control: 1A-3
23
24 25
32
18
27
2
28 1
14
30
E.C.M.
29 5
4
13
31
3 6 26
12 10
21 33
11
20
16
19
15
17
22
9 8 7
IDK111110002-05
19
20 21
27
23
2
24 1
26
E.C.M. 5
25
4
11
12 3 22
6
14
17 28 10
16
15
13
9 8 7 18
IDK111110003-05
1. Flywheel 8. Throttle position sensor 15. Fuel injector 22. Low pressure fuel pump
2. CKP sensor 9. IAT sensor 16. Air intake silencer 23. Fuel vapor separator
3. Cylinder temp. sensor 10. IAC valve 17. Throttle body 24. Float
4. Spark plug 11. Oil pressure switch 18. Intake manifold 25. High pressure fuel pump
5. Ignition coil 12. Neutral switch 19. Fuel tank 26. Fuel cooler
6. CMP sensor 13. Emergency stop switch 20. Fuel primer bulb 27. Evaporation chamber
7. MAP sensor 14. ECM power source coil 21. Low pressure fuel filter 28. By-pass screw
Engine Control: 1A-5
NOTE
• Information related to the Caution system, Self-Diagnostic System, and Total Operating Hours
System is retained in the ECM memory.
• The SDS Ver.7 is necessary for checking the total operating time.
• ECM is different for the manual starter model and electric starter model.
IDK111110032-01
1. ECM
1A-6 Engine Control:
RECTIFIER
& REGULATOR
10A
13 DC POWER POWER OUTPUT 9
BATTER
RELAY
FUEL INJECTOR #2 15
26 CKP SENSOR
IAC 17
25 CMP SENSOR
FUSE DIAG LED 16
30A 12 SENSOR POWER
TACHOMETER 18
BATTERY
10 TPS
OIL PRESSURE SW 6
START SW
23 MAP SENSOR OIL PRESSURE SW
22 IAT SENSOR
3
STARTER FUEL
RELAY 24 CYL TEMP SENSOR F/P 4 PUMP
(HP)
5
7 ECM GND
NEUTRAL SW
IGNITION COIL 1
POWER GND 14
8 NEUTRAL SW
COMMUNICATION 20
LINE A SDS
21 EMERGENCY SW COMMUNICATION
19
LINE B
IDK111110005-03
Engine Control: 1A-7
13 AC POWER 1
POWER OUTPUT 9
11 AC POWER 2
FUEL INJECTOR #1 2
FUEL INJECTOR #2 15
26 CKP SENSOR
IAC 17 12V
25 CMP SENSOR
DIAG LED 16
12 SENSOR POWER
TACHOMETER 18
10 TPS
23 MAP SENSOR
3
22 IAT SENSOR FUEL
F/P 4 PUMP
(HP)
24 CYL TEMP SENSOR 5
7 ECM GND
IGNITION COIL 1
6 OIL PRESSURE SW
POWER GND 14
8 NEUTRAL SW COMMUNICATION
20
LINE A
SDS
21 EMERGENCY SW COMMUNICATION 19
LINE B
IDK111110006-03
1A-8 Engine Control:
“A”
IDK111110007-01
“A”: ECM
IDK111110023-02
1. Caution lamp
Lamp Check
For two seconds after inputting electric power to the ECM:
• The caution lamp turns ON.
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 cancelled.
Caution lamp Caution lamp lights continuously.
Reset:
Close the throttle to reduce the engine speed below approx. 3 000 r/min. for one second.
NOTE
In neutral gear, the preset maximum engine speed value before the over-revolution caution system
activates is 3 000 r/min.
In the operation of Neutral gear over-revolution caution system, the caution lamp does not light.
To cancel the Neutral gear over-revolution caution control, close throttle completely.
1A-10 Engine Control:
Action:
Engine speed • Automatically reduced to approx. 2 000 r/min. maximum by an intermittent fuel injection signal.
• The engine automatically stops 3 minutes after the caution system is activated.
Caution lamp Caution lamp lights continuously.
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 15 kPa (0.15
kg/cm2, 2 psi.) at approx. 2 000 r/min. or less engine speed operation.
The engine must be stopped and checked immediately once the system is activated.
Engine Control: 1A-11
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 Caution lamp lights continuously.
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:
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.
Reset temperature Approx. 70 °C (158 °F)
NOTE
• Charging current will not flow from the rectifier / regulator to the battery while this system is
activated.
• When the system is activated the starter motor will not operate because the battery voltage is too
low.
“A”
IDK111110024-01
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 starting the engine.
• 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.
Engine Control: 1A-13
NOTE
There is no back-up system for the ECM itself. The engine will stop if it has failed.
1A-14 Engine Control:
IDK111110025-01
IDK111110026-01
1. Caution lamp
NOTE
Indication of System Activation
• Cancellation of the system is possible
whether or not the engine oil has been
Caution lamp flashing pattern replaced.
1.0 sec 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
1.2 sec
system not activated, it is still necessary to
IDK111110004-01 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
Component Location
Engine Control System Components / Engine Electrical Device Location
CENDK1111103001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
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.
ECM
1
5V
4
W
C 3
P
B U
5V 2
R
B
IDK111110011-01
Step 2
1) Check the MAP sensor output voltage change.
Refer to “MAP Sensor Output Voltage Inspection”
in Section 1C (Page 1C-11).
IDK111110033-01
Is it in good condition?
1A-16 Engine Control:
ECM
1 B Lg/W
C 4
P 2
B B U
3
IDK111110012-02
Troubleshooting
Step 1
1) Stop the engine.
2) Disconnect the cylinder temp. sensor connector.
3) Connect the ECM power source cable to the SDS communication connector and battery.
4) 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.
Step 2
1) Disconnect the ECM power source cable.
2) 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.
For step 1
I9J011110045-02
Engine Control: 1A-17
ECM
5V
1 B Lg/W
C 4
P 2
B B U
3
IDK111110013-02
Troubleshooting
Step 1
1) Stop the engine.
2) Disconnect IAT sensor connector.
3) Connect the ECM power source cable to the SDS communication connector and battery.
4) Check the voltage at the “Lg/B” wire terminal of the IAT sensor connector.
Is the voltage 4 V or more?
Yes Go to step 2.
Step 2
1) Disconnect the ECM power source cable.
2) Check the IAT sensor.
Refer to “IAT Sensor Inspection” in Section 1C (Page 1C-8).
Is it in good condition?
Yes Poor IAT sensor connection, intermittent trouble or a faulty ECM may be cause.
For step 1
I9J011110046-01
1A-18 Engine Control:
ECM
R/B R/B
C
P
B/W B U
IDK111110014-02
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-6).
Is it in good condition?
Yes Go to step 2.
Step 2
1) Check the CKP sensor resistance.
Refer to “Resistance Check” in Section 1C (Page 1C-5).
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.
1 ECM
Gr/R
C 4
Y/Bl 2
P
B U
3
IDK111110015-01
Troubleshooting Step 4
Step 1 Was terminal “Gr/R” voltage in step 2 within
specification?
Is CMP sensor installed properly and the wire
harness connected securely? Yes Go to step 5.
Yes Go to step 2. No “Gr/R” wire open circuit. If the wiring and
connection is OK, substitute a known-
No Correct.
good ECM and recheck.
Step 2
Step 5
1) Stop the engine.
1) Disconnect the ECM power source cable.
2) Disconnect the connector from the CMP sensor.
2) Check the CMP sensor and sensor trigger vane.
3) Connect the ECM power source cable to the SDS Refer to “CMP Sensor Inspection” in Section 1C
communication connector and battery. (Page 1C-9).
4) Check for proper connection to the CMP sensor at
Is check result satisfactory?
“Gr/R”, “Y/Bl” and “B” wire terminals.
5) If OK, check the voltage at the “Gr/R”, “Y/B” and Yes Substitute a known-good ECM and
“B” wire terminals of the CMP sensor connector. recheck.
CMP sensor voltage No Replace CMP sensor.
Terminal “Gr/R”: 10 – 14 V
Terminal “Y/Bl”: 4 – 5 V
Terminal “B”: 0 V For step 2
Is the voltage satisfactory?
Yes Go to step 5.
B
No Go to step 3.
Y/Bl
Step 3 Gr/R
IDK111110008-01
Was terminal “Y/Bl” voltage in step 2 within
specification?
Yes Go to step 4.
1 ECM
5V
4
R
3
Br/Y
C
P 2
B U
IDK111110016-01
Troubleshooting Step 3
Step 1 1) Check the MAP sensor, IAC system and intake
manifold (system) for air leakage.
1) Stop the engine.
2) Disconnect the TPS connector. Is the result OK?
3) Connect the ECM power source cable to the SDS Yes Intermittent trouble or faulty ECM.
communication connector and battery. Substitute a known-good ECM and
4) Check the voltage at the “R” wire terminal of TPS recheck.
connector.
No Faulty air intake system.
Is the voltage approx. 4 – 5 V?
Yes Go to step 2.
For step 1
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 R
recheck.
Step 2
1) Check the TPS output voltage change. B
Br/Y
Refer to “TPS Inspection” in Section 1C (Page 1C-
12).
Is it in good condition? IDK111110009-02
Yes Go to step 3.
No • Faulty TPS.
• “R” wire shorted to “Br/Y” wire, “B” wire
open, poor “B” 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.
Engine Control: 1A-21
ECM
1 + 5V
R 5V
Br/Y
B
C 5
4
P
U 3
2 W
B
5V
R
IDK111110017-01
Is it in good condition?
Step 3
R
1) Disconnect the TPS connector.
2) Check the voltage at the “R” wire terminal of the
TPS connector.
Is the voltage approx. 4 – 5 V? B
W
Yes Go to step 4.
IDK111110027-03
1A-22 Engine Control:
1 ECM
#1
O/B
#2 4
C 3
B/Br
P 2
IDK111110018-02
Troubleshooting Step 4
Step 1 1) Disconnect the ECM power source cable.
1) Using a sound scope, check that each injector has 2) Disconnect the ECM connector, and check all of
an operating sound when the engine is cranking. the injectors for resistance.
Refer to “Resistance Check” in Section 1C (Page
Do all injectors make an operating sound? 1C-5).
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 3
1) Stop the engine. IDK111110010-01
Yes Go to step 4.
1 ECM
5V
R 4
C 3
Br/Y
P
B U 2
IDK111110019-01
Troubleshooting Step 2
Step 1 1) Check the TPS output voltage change.
Refer to “TPS Inspection” in Section 1C (Page 1C-
1) Stop the engine.
12).
2) Disconnect TPS connector.
Is it in good condition?
3) Connect the ECM power source cable to the SDS
communication connector and battery. Yes Substitute a known-good ECM and
4) Check the voltage at the “R” wire terminal of the recheck.
TPS connector.
No • Faulty TPS.
Is the voltage approx. 4 – 5 V? • “R” wire shorted to “Br/Y” wire, “B” wire
Yes Go to step 2. open, poor “B” wire connection, poor
“Br/Y” wire connection, “Br/Y” wire open
No • “R” wire open, “R” wire shorted to or poor TPS connection.
ground circuit or poor connection.
• If the wiring and connection is OK,
• If the wiring and connection is OK, intermittent trouble or a faulty ECM may
substitute a known-good ECM and be the cause.
recheck.
Troubleshooting Step 2
Step 1 1) With the engine running, check charging voltage
at idle speed.
1) Check the rectifier / regulator resistance.
Refer to “Rectifier / Regulator Inspection” in Is the result 16 V or higher?
Section 1K (Page 1K-16).
Yes Faulty rectifier / regulator.
Is the result OK?
No Faulty ECM or wire continuity / connection
Yes Go to step 2. failure.
No Faulty rectifier / regulator.
1A-24 Engine Control:
ECM
1
4
3
C
Bl/Y
P 2
U
IDK111110020-01
Troubleshooting Step 2
Step 1 1) Disconnect the ECM power source cable.
1) Stop the engine. 2) Check the oil pressure switch operation.
Refer to “Oil Pressure Switch Inspection” in
2) Remove the oil pressure switch wire at switch.
Section 1E (Page 1E-5).
3) Connect the ECM power source cable to the SDS
communication connector and battery. Is it in good condition?
4) Check the voltage between the oil pressure switch Yes Poor oil pressure switch wire connection,
wire terminal and body ground. intermittent trouble or a faulty ECM may
Is the voltage approx. 5 V? be the cause.
I9J011110064-01
ECM
1
IDK111110021-01
1. IAC valve
Troubleshooting
Step 1
1) Warm up the engine to normal operating temperature and keep it idling.
2) Using the SDS tool, check the IAC duty cycle and idle speed. Adjust if necessary.
Idle speed (IAC duty cycle)
800 – 900 r/min (approx. 10%)
Is result OK?
No Go to step 2.
Step 2
1) Disconnect the IAC connector at IAC valve.
2) Check the resistance between terminals.
Is the resistance 31 – 42 Ω?
Yes Proceed to “Unstable Idling / Trolling” in “Troubleshooting Without Self-Diagnostic Code” (Page 1A-24)
and check items except for “Faulty IAC system”.
Service Instructions
How to Use The 26 Pin Test Cord
CENDK1111106003
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): 09930–88940 (26-pin test cord)
(A)
3 4
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
2
IDK111110028-01
Never connect a voltmeter or an ohmmeter directly to any terminal of ECM by disconnecting control
module connector.
Special tool
(A): 09930–88940 (26-pin test cord)
(B): 09933–08910 (ECM power source cable)
(C): 09930–99320 (Digital tester)
Tester knob indication
DCV
1) Stop the engine.
2) Connect the 26-pin test cord between the ECM and wire harness as shown in figure.
(A)
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
(C)
IDK111110029-01
3) Connect the ECM power source cable to the SDS communication connector (1) and battery as shown figure.
(B)
IDK111110030-03
4) Connect the tester probe (“–”, Black) to body ground, and measure the voltage according to the “Circuit Voltage
Table” (Page 1A-28).
1A-28 Engine Control:
“A”
IDK111110007-01
Wire
Terminal Circuit Standard voltage Condition / Remarks
color
1 O Ignition coil — —
2 O/B No.1 Fuel injector Approx. 12 V • 12 V electric power is supplied to ECM.
3 B/Y High pressure fuel pump (V) Approx. 0.6 V • 12 V electric power is supplied to ECM.
4 B/R High pressure fuel pump (W) Approx. 0.6 V • 12 V electric power is supplied to ECM.
5 B/W High pressure fuel pump (U) Approx. 0.6 V • 12 V electric power is supplied to ECM.
6 Bl/Y Oil pressure switch — —
7 B Ground for ECM — —
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Shift into Neutral
8 Y/G Neutral switch
• 12 V electric power is supplied to ECM.
Approx. 4.7 V
• Shift into Forward or Reverse
• 12 V electric power is supplied to ECM.
Approx. 8 V • While cranking engine with starter
9 Gr/R Power output
motor.
Approx. 12 V • 12 V electric power is supplied to ECM.
• 12 V electric power is supplied to ECM.
Approx. 0.7 V
• Throttle FCT
10 Br/Y Throttle position sensor
• 12 V electric power is supplied to ECM.
Approx. 4 V
• Throttle WOT
11 P/B Battery relay — —
12 R Power for sensor (5V) Approx. 5 V • 12 V electric power is supplied to ECM.
• While cranking engine with starter
13 W DC power for ECM Approx. 8 V
motor.
14 B Ground for ECM power — —
15 B/Br No.2 Fuel injector Approx. 12 V • 12 V electric power is supplied to ECM.
16 P Diag LED — —
17 W/B IAC valve Approx. 0 V • 12 V electric power is supplied to ECM.
18 Y/B Tachometer — —
19 Y Communication line (B) — —
20 O/Y Communication line (A) — —
• 12 V electric power is supplied to ECM.
Approx. 5 V
• Stop switch plate IN.
21 Bl/R Emergency stop switch
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Stop switch plate OUT.
22 Lg/B IAT sensor 0.04 – 4.6 V • 12 V electric power is supplied to ECM.
23 W MAP sensor 0.79 – 4.2 V • 12 V electric power is supplied to ECM.
24 Lg/W Cylinder temp. sensor 0.14 – 4.75 V • 12 V electric power is supplied to ECM.
25 Y/Bl CMP sensor Approx. 0.3 V or 5 V • 12 V electric power is supplied to ECM.
26 R/B CKP sensor — —
Engine Control: 1A-29
“A”
IDK111110007-01
Wire
Terminal Circuit Standard voltage Condition / Remarks
color
1 O Ignition coil — —
2 O/B No.1 Fuel injector Approx. 12 V • 12 V electric power is supplied to ECM.
3 B/Y High pressure fuel pump (V) Approx. 0.6 V • 12 V electric power is supplied to ECM.
4 B/R High pressure fuel pump (W) Approx. 0.6 V • 12 V electric power is supplied to ECM.
5 B/W High pressure fuel pump (U) Approx. 0.6 V • 12 V electric power is supplied to ECM.
6 Bl/Y Oil pressure switch — —
7 B Ground for ECM — —
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Shift into Neutral
8 Y/G Neutral switch
• 12 V electric power is supplied to ECM.
Approx. 4.7 V
• Shift into Forward or Reverse
9 Gr/R Power output Approx. 12 V • 12 V electric power is supplied to ECM.
• 12 V electric power is supplied to ECM.
Approx. 0.7 V
• Throttle FCT
10 Br/Y Throttle position sensor
• 12 V electric power is supplied to ECM.
Approx. 4 V
• Throttle WOT
• Disconnect ECM power source cable.
11 Br/W AC power No.2 for ECM Approx. 0.5 – 1.0 V
• Crank the engine.
12 R Power for sensor (5V) Approx. 5 V • 12 V electric power is supplied to ECM.
• Disconnect ECM power source cable.
13 Br/R AC power No.1 for ECM Approx. 0.5 – 1.0 V
• Crank the engine.
14 B Ground for ECM power — —
15 B/Br No.2 Fuel injector Approx. 12 V • 12 V electric power is supplied to ECM.
16 P Diag LED — —
17 W/B IAC valve Approx. 0 V • 12 V electric power is supplied to ECM.
18 Y/B Tachometer — —
19 Y Communication line (B) — —
20 O/Y Communication line (A) — —
• 12 V electric power is supplied to ECM.
Approx. 5 V
• Stop switch plate IN.
21 Bl/R Emergency stop switch
• 12 V electric power is supplied to ECM.
Approx. 0 V
• Stop switch plate OUT.
22 Lg/B IAT sensor 0.04 – 4.6 V • 12 V electric power is supplied to ECM.
23 W MAP sensor 0.79 – 4.2 V • 12 V electric power is supplied to ECM.
24 Lg/W Cylinder temp. sensor 0.14 – 4.75 V • 12 V electric power is supplied to ECM.
25 Y/Bl CMP sensor Approx. 0.3 V or 5 V • 12 V electric power is supplied to ECM.
26 R/B CKP sensor — —
1A-30 Engine Control:
ECM Removal and Installation 2) For tests using 1.5 V power source (or battery),
CENDK1111106001 connect the lamp lead wire to the 1.5 V power
Removal
source (or battery) as shown below.
1) Disconnect lead wire connector from ECM (1).
• Pink lead wire to Battery (+)
2) Remove the ECM.
• Black lead wire to Battery (–)
When 1.5 V applied
Lamp ON
If out of specification, replace the caution lamp.
IDK111110031-02
B P
Installation
Installation is reverse order of removal.
NOTICE
Failure to correctly supply the voltage will B
result in lamp damage. “A”
IDK111110022-02
Precautions
Precaution for Engine Electrical Device
CENDK1111300001
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
CENDK1111301001
CKP Sensor
• There is one CKP sensor installed on the stator base. 1
When the reluctor bars on the flywheel pass the
sensor, a signal (voltage pulse) is generated and sent
to the ECM. This is the fundamental signal used to
judge engine speed and crankshaft angle.
• There are 34 reluctor bars. They are located 10
degrees apart, except at one position where it is 30
degrees apart.
During one crankshaft rotation, 34 signals are input to IDK111130021-02
the ECM.
1. CMP sensor
• Failure Symptom:
Without the CKP sensor signal input, the ECM does
not output the ignition and fuel injection signals. 1
2
3
4
Signal
High
1 Low
5
IDK111130008-01
2
1. Camshaft (Cam pulley) 4. Magnet
IDK111130020-02 2. Trigger vane 5. CMP sensor
3. Magnet resistive semiconductor
1. CKP sensor 2. Reluctor bar
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
No.1 cylinder Cm Ep Ex In Cm Ep
No.2 cylinder Ex In Cm Ep Ex In
IDK111130023-02
1
1. IAT sensor
IDK111130022-02
(k )
Resistance
Temperature (C°)
I9J011130003-02
Engine Electrical Devices: 1C-3
1. MAP sensor
1
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
IDK111130025-02
and throttle opening position to determine the control
1. Neutral switch
modes of the various controls systems (Idle air control,
fuel injection control system, etc.).
Emergency Stop Switch
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.
The circuit of emergency stop switch will be closed when
the plate is removed.
Then the ECM does not provide fuel injector operating
signal, ignition signal and fuel pump operating signal.
Failure Symptoms
A switch short circuit will not allow the motor to start.
IDK111130009-01
1. TPS
IDK111130026-02
IDK111130027-02
13
1. Battery relay
4
ECM Power Source
CENDK1111301002
Manual Starter Model 11
The AC output to which electricity is generated by the
ECM power source coil is input through No.13 and
No.14 terminal to the ECM.
The AC output is rectified to the DC power in ECM, and it 5
is supplied to the engine control system.
2 6
IDK111130004-01
1. Flywheel 4. ECM
2. Battery charge coil 5. Battery relay
3. Rectifier / Regulator 6. Battery
13 11
3
IDK111130003-01
1. Flywheel 3. ECM
2. ECM power source coil
Engine Electrical Devices: 1C-5
Component Location
Location of Sensor and Switch
CENDK1111303001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
Service Instructions
Resistance Check
CENDK1111306001
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Resistance (Ω)
1) Stop the engine.
2) Disconnect battery cables from battery.
3) Disconnect wire harness connector from ECM.
4) Connect the tester probes to terminal (wire harness side) and measure resistance according to the “Resistance
Table” (Page 1C-5).
1 2 3 4 5 6 7 8 9 10 11 12 13
14 15 16 17 18 19 20 21 22 23 24 25 26
2
1
IDK111130005-01
Resistance Table
Terminal for tester probe
Circuit Standard resistance (at 20 °C)
connection
ECM Power source coil (Manual
13 (Br/R) to 11 (Br/W) 2.1 – 3.2 Ω
starter model)
CKP sensor 26 (R/B) to 7 (B) 148 – 222 Ω
Fuel injector No.1 2 (O/B) to 9 (Gr/R)
10 – 14 Ω
Fuel injector No.2 15 (B/Br) to 9 (Gr/R)
IAC Valve 17 (W/B) to 9 (Gr/R) 31 – 42 Ω
IAT sensor 22 (Lg/B) to 7 (B) 0 ° C (32 °F): 5.3 – 6.6 kΩ
25 ° C (77 °F): 1.8 – 2.3 kΩ
50 ° C (122 °F): 0.73 – 0.96 kΩ
Cylinder temperature sensor 24 (Lg/W) to 7 (B)
75 ° C (135 °F): 0.33 – 0.45 kΩ
(Thermistor characteristic)
1C-6 Engine Electrical Devices:
ECM Power Source Coil Peak Voltage CKP Sensor Peak Voltage Inspection
CENDK1111306004
Inspection
CENDK1111306002 Special tool
Applicable model: Manual starter model
: Stevens peak reading voltmeter CD-77
Special tool
Tester knob indication
: Stevens peak reading voltmeter CD-77
SEN 5
Tester knob indication
1) Disconnect the wire harness connector from ECM.
POS 50
2) Connect the tester probe (“–”, Black) to No.7
1) Disconnect the wire harness connector from ECM. terminal (or to body ground) as shown in figure.
2) Connect the tester probe (“–”, Black) to No.11 3) Connect the tester probe (“+”, Red) to No.26
terminal as shown in figure. terminal.
3) Connect the tester probe (“+”, Red) to No.13 Tester probe connection
terminal. Red (+) Black (–)
Tester probe connection No.26 (R/B) No.7 (B)
Red (+) Black (–)
No.13 (Br/R) No.11 (Br/W)
26
11 13
IDK111130007-01
Cylinder Temp. Sensor Removal and 5) Cut the cable tie securing sensor lead wire.
Installation Loosen and remove the cylinder temp. sensor (4).
CENDK1111306006
Removal
1) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
2) Disconnect lead wire connector from ECM (1), then
remove ECM. 4
IDK111130031-02
1
Installation
Installation is reverse order of removal.
• Clean mating surface of sensor and cylinder.
• Tighten sensor to specified torque.
IDK111130028-02
Tightening torque
Cylinder temp. sensor (a): 9 N·m (0.9 kgf-m, 6.5
3) Disconnect the cylinder temp. sensor lead wire
lbf-ft)
connector (2).
(a)
IDK111130032-02
IDK111130029-02
• Connect connector to sensor securely.
4) Remove the bolt (3) securing lead wire clamp.
• Secure the sensor lead wire with the cable tie.
• Check to ensure that all removed parts are back in
original position.
3 • Check wire routing.
Refer to “Wiring Harness Routing Diagram” in Section
4A (Page 4A-3).
IDK111130030-02
1C-8 Engine Electrical Devices:
Installation
Installation is reverse order of removal.
1
• Install CMP sensor, then tighten mounting bolt
securely.
• Connect sensor lead wire connector to CMP sensor.
1. Thermometer 2. Heater
1
Resistance
IDK111130034-01
IDK111130035-02
IDK111130034-01
1C-10 Engine Electrical Devices:
4) Connect the 26-pin test cord between ECM and wire 8) Measure the voltage when the tip of a steel
harness as shown in figure. screwdriver is brought near and then pulled away
from the sensor tip.
Special tool
(B): 09930–88940 (26-pin test cord) When screwdriver is brought near
Approx. 5 V
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
4
IDK111130018-02
1
IDK111130010-01 4. Screw driver 5. CMP sensor
1. Wire harness 2. Black connector 3. ECM
9) If the voltage does not change in the above test,
5) Connect the ECM power source cable to battery. check wire harnesses for open and short.
6) Connect the tester probe (“+”, Red) to No.25 If wire harnesses are in good condition, replace CMP
terminal. sensor and recheck.
7) Connect the tester probe (“–”, Black) to No.7 10) Reinstall CMP sensor.
terminal (or to body ground).
MAP Sensor Removal and Installation
Special tool CENDK1111306013
: 09930–99320 (Digital tester) Removal
Tester knob indication 1) Disconnect lead wire connector (1) at MAP sensor.
DC Voltage 2) Remove the bolt (2) and MAP sensor (3).
25
3
2
1
IDK111130011-02 IDK111130036-02
Installation
Installation is reverse order of removal.
• Install MAP sensor, then tighten mounting bolt
securely.
• Connect sensor lead wire connector to MAP sensor.
Engine Electrical Devices: 1C-11
MAP Sensor Output Voltage Inspection 4) Connect vacuum pump gauge (with hose) to MAP
CENDK1111306014 sensor as shown in figure.
1) Connect the 26-pin test cord between ECM and wire
harness as shown in figure. Special tool
(C): 09917–47011 (Vacuum pump gauge)
Special tool
(A): 09930–88940 (26-pin test cord) (C)
(A)
2
IDK111130002-03
2) Connect the ECM power source cable to SDS (at 759.8 mmHg, 101.3 kPa, 29.91 inHg
communication connector and battery. barometric pressure.)
Special tool
(B): 09933–08910 (ECM power source 26-pin test cord (White connector)
cable)
23
(B)
IDK111130013-01
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
IDK111130037-02
DC Voltage ( )
3) Remove the bolt and MAP sensor (1) from intake
manifold. 6) If out of specification, Check wire harnesses for open
and short. If wire harnesses are in good condition,
replace MAP sensor and recheck.
7) Reinstall MAP sensor.
1 Refer to “MAP Sensor Removal and Installation”
(Page 1C-10).
IDK111130038-01
1C-12 Engine Electrical Devices:
screw, etc.).
These components have been factory
adjusted to precise specifications.
If out of specification, replace IAC valve. 3) Connect the 26-pin test cord between ECM and wire
harness as shown in figure.
IAC valve resistance
Standard: 31 – 42 Ω Special tool
(B): 09930–88940 (26-pin test cord)
(B)
1
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
IDK111130039-01
2
IDK111130014-01
IDK111130019-01
Engine Electrical Devices: 1C-13
6) Connect tester probe (“–”, Black) to No.7 terminal (or Emergency and Engine Stop Switch Inspection
to body ground) CENDK1111306008
26-pin test cord (White connector) 1) Disconnect the emergency stop switch lead wire.
2) Check the continuity / infinity between the wiring
3
leads under the condition shown below.
Special tool
7 10
(A): 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
Tester probe connection Tester
Red (+) Black (–) indicates
Lock plate
IDK111130015-01
Infinity
installed
7) Check for sensor output voltage.
Lock plate
Slowly move the throttle control grip to open, and Continuity
removed
check if voltage changes linearly within specification,
Lock plate Blue / Red Black
according to throttle valve opening angle.
installed
Sensor output voltage and stop Continuity
FCT position: Approx. 0.7 V button
WOT position: Approx. 3.8 V depressed
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
DC Voltage ( ) (A)
NOTICE
2
The throttle body will lose its original
performance if it has been disassembled and
reassembled.
1
Do not try to adjust or remove any of the
throttle body component parts (Throttle
position sensor, throttle valve, throttle stop
IDK111130016-01
screw, etc.).
These components have been factory 1. Bl/R 2. B
(A)
1
IDK111130017-02
1. Bl/R 2. B
General Description
Power Unit Construction Description
CENDK1111401001
The engine is direct water-cooled, in-line 2 cylinders, 4 stroke cycle gasoline unit with SOHC (single overhead
camshaft) valve mechanism.
The SOHC is mounted over the cylinder head; it is driven by crankshaft through timing belt (cogged belt).
Unlike conventional overhead valve (OHV) engines, this engine has no push rods. Thus, valve movement is more
direct and enables them to follow crankshaft rotation without any delay.
Cylinder Number
Cylinder number is as mentioned in figure.
“A”
“B”
IDK111140023-01
Service Instructions
Valve Clearance Inspection 2) Remove the recoil starter (1).
CENDK1111406001 Refer to “Recoil Starter Removal and Installation” in
Refer to “Valve Clearance Inspection and Adjustment” in
Section 1J (Page 1J-3).
Section 0B (Page 0B-8).
3) Remove the breather hose (2) from cylinder head 6) Pull off the fuel return hose (8) from hose clamp.
cover. 7) Remove the harness clamp (9) from cylinder head
cover by releasing clamps’ lock.
2
8 9
IDK111140034-01
4) Remove the bolts (3) and fuel pump guard (4). IDK111140037-01
10
4
IDK111140035-01
6 11
IDK111140036-02
IDK111140039-01
1D-3 Power Unit Mechanical:
2
2
IDK111140042-01
“6” “3” 5
“4” “5”
IDK111140041-01
Installation
Installation is reverse order of removal.
• Install air intake silencer case (1), then tighten bolt
1
securely.
IDK111140045-03
2 3
5 7
4
IDK111140046-02
Intake Manifold Removal and Installation 5) Remove the two bolts (7) and then remove the
CENDK1111406005 intake manifold and throttle body assembly (8).
Removal
1) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
2) Remove the air intake silencer case (1).
Refer to “Air Intake Silencer Case Removal and 7
Installation” (Page 1D-3).
8
1 7
IDK111140050-01
9
IDK111140047-02
IDK111140051-01
IDK111140049-01
IDK111140048-01
Power Unit Mechanical: 1D-6
• Install the O-ring (1) to throttle body. • Install the intake manifold and throttle body assembly
(6), then tighten bolts securely.
Tightening torque
Intake manifold (b): 23 N·m (2.3 kgf-m, 16.5 lbf-ft)
(b)
1
IDK111140053-01 6
(b)
• Assemble the throttle body (2) and intake manifold
(3), then secure with bolts.
Tightening torque IDK111140057-01
Throttle body (a): 11 N·m (1.1 kgf-m, 8.0 lbf-ft) • Connect the lead wire connectors to each sensor and
actuator.
3 • Install the frame arrester (7).
(a)
IDK111140054-01
7
IDK111140058-01
2 • Install the throttle cable (8).
Refer to “Throttle Control Cable Installation and
Adjustment” in Section 2A (Page 2A-5).
3
(a)
8
IDK111140055-01
4 IDK111140059-01
IDK111140056-01
1D-7 Power Unit Mechanical:
• Install the air intake silencer case. • Check that throttle drum and throttle valve moves
Refer to “Air Intake Silencer Case Removal and smoothly.
Installation” (Page 1D-3). • Replace throttle body if necessary.
• Install the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3).
• 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
illustration.
Refer to “Wiring Harness Routing Diagram” in
Section 4A (Page 4A-3) and “Fuel Hose Routing” in
Section 4B (Page 4B-2). IDK111140061-01
Throttle Body Removal and Installation Camshaft Pulley Removal and Installation
CENDK1111406006
CENDK1111406023
Removal
Refer to “Intake Manifold Removal and Installation”
(Page 1D-5). 1) Remove the cylinder head cover.
Refer to “Cylinder Head Cover Removal and
Throttle Body Inspection Installation” (Page 1D-1).
CENDK1111406024
NOTICE NOTICE
The throttle body will lose its original After the timing belt has been removed,
performance if it has been disassembled and independently turning cam pulley or
reassembled. crankshaft will cause interference between
piston and valve, which cause damage to
• Do not try to disassemble the throttle body.
these related parts.
• Do not try to adjust or remove any of the
throttle body component parts (Throttle Do not rotate the cam pulley and/or
position sensor, throttle valve, throttle crankshaft with timing belt removed.
stop screw, etc.).
These components have been factory NOTE
adjusted to precise specifications.
To prevent valve damage, loosen valve
• Clean throttle body bore by compressed air. adjusting screws fully before removing
timing belt.
• Remove all carbon from the throttle valve and its
circumference. 2) Loosen all valve adjusting lock nut (1).
Loosen the four valve adjusting screws (2) fully.
Leave the screws in place.
1 2
1
IDK111140060-01
2
IDK111140001-02
Power Unit Mechanical: 1D-8
IDK111140064-01
5
6 Power Unit Removal and Installation
CENDK1111406007
6 Removal
IDK111140002-02 Before removing power unit:
• Disconnect battery cables from battery.
Installation
Installation is reverse order of removal with special • Drain engine oil.
attention to the following steps. 1) Remove both lower side covers.
• Install the key (1), camshaft pulley (2), washer (3) and Refer to “Lower Side Cover Removal and
bolt (4), then tighten camshaft pulley bolt to specified Installation” in Section 2A (Page 2A-2).
torque. 2) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Tightening torque
Section 1J (Page 1J-3).
Camshaft pulley bolt (a): 10 N·m (1.0 kgf-m, 7.2
lbf-ft) 3) Remove the air intake silencer case, throttle body
and intake manifold (1).
Refer to “Intake Manifold Removal and Installation”
2 (Page 1D-5).
IDK111140063-01
1
IDK111140065-01
1D-9 Power Unit Mechanical:
4) Remove the fuel line according to the following d) Remove the bolts and high pressure fuel pump
procedure. guard (8).
a) Remove the fuel inlet hose (2) from fuel filter. Disconnect the lead wire connector (9) at high
Remove the fuel filter (3) from filter bracket. pressure fuel pump.
8
3
2
IDK111140024-01 IDK111140027-01
b) Remove the bolt (4) securing fuel vapor e) Disconnect the fuel outlet hose (10) from fuel
separator (5). delivery pipe.
Remove the fuel vapor separator (5) from Remove the high pressure fuel pump (11) from
separator bracket. cylinder head cover.
4
5 11
10
IDK111140025-01 IDK111140028-01
c) Remove the two bolts (6) securing fuel cooler f) Remove the two bolts securing low pressure fuel
(7). pump (12), then detach the low pressure fuel
pump from cylinder head cover.
6 12
6
7
IDK111140026-01
IDK111140029-01
Power Unit Mechanical: 1D-10
g) Disconnect the water discharge hose (13) from 5) Remove the flywheel (15).
driveshaft housing. Refer to “Flywheel Removal and Installation” in
Section 1K (Page 1K-4).
Special tool
(A): 09930–39520 (Flywheel holder)
(B): 09930–39210 (Flywheel remover bolt)
(C): 09930–39411 (Flywheel remover)
15
(A)
13
IDK111140030-02
(B)
IDK111140066-01
IDK111140031-02
17
IDK111140067-01
IDK111140032-01
18
19
IDK111140068-01
1D-11 Power Unit Mechanical:
8) Remove the bolt and neutral switch (20). 12) Remove the clutch rod arm (28) from clutch rod (29).
29
20
28
IDK111140069-01 IDK111140073-01
9) Remove the cotter pin (21) and washer (22), then 13) Remove the clutch notch lever (30), then account for
remove the clutch lever link (23). clutch notch ball (31) and spring (32).
22
21
23 32
31
30
IDK111140070-01 IDK111140074-01
10) Loosen the clutch rod lock nut (24). 14) Remove the two bolts and ignition coil (33). Remove
To separate the clutch rod from the shift rod, all spark plugs.
unscrew the connector (25).
25
33
24
IDK111140075-01
IDK111140071-01 15) Remove the two bolts and fuel filter bracket (34).
11) Remove the two bolts (26) and clutch control lever /
shaft (27).
27
34
26
IDK111140076-01
26
IDK111140072-01
Power Unit Mechanical: 1D-12
16) Remove the bolt and oil level dipstick tube (35). 20) Remove the cylinder head cover (42).
Note the position before removing O-ring (36). Refer to “Cylinder Head Cover Removal and
Installation” (Page 1D-1).
35
36
42
IDK111140077-01
17) Remove the bolt and PORT side cover holder (37). IDK111140081-01
37 43
44
IDK111140078-01 43
18) Remove the bolts (38), fuel delivery pipe (39) and
fuel injectors (40). 44
Refer to “Fuel Injector Removal and Installation” in IDK111140082-01
41
IDK111140083-01
IDK111140080-01
1D-13 Power Unit Mechanical:
23) Remove the ten bolts. • Install dowel pins (1), gasket (2).
Lift up and remove power unit from engine holder. Apply water resistant grease to driveshaft splines.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
2
1
IDK111140084-01
1
IDK111140087-01
NOTE
Rotate crankshaft to aid alignment of
driveshaft and crankshaft splines.
NOTE
Before installing power unit, apply sealant to
IDK111140088-01
the two hatched areas shown in the
illustration.
(a)
IDK111140089-01
IDK111140086-01
Power Unit Mechanical: 1D-14
IDK111140093-02
IDK111140090-01 • Install the clutch rod arm (4) to clutch rod (5).
NOTE
Before installing cylinder head cover, check
5
valve clearance.
Refer to “Valve Clearance Inspection and
Adjustment” in Section 0B (Page 0B-8).
6
IDK111140091-01
Fuel injector
• Install the fuel delivery pipe and fuel injectors. 7 7
Refer to “Fuel Injector Removal and Installation” in
Section 1G (Page 1G-20).
IDK111140095-01
IDK111140092-01
1D-15 Power Unit Mechanical:
IDK111140096-01
IDK111140099-01
Flywheel
• Install the stator base / coil assembly (1). Final assembly check
Refer to “Battery Charge Coil / CKP Sensor / Stator • Perform the following final assembly checks to ensure
Base Removal and Installation” in Section 1K (Page proper and safe operation of the repaired unit.
1K-5). – All parts removed have been returned to their
original positions.
– Lower unit gear engagement is properly adjusted.
1 – Fuel and water hose routing matches service
manual illustration.
Refer to “Fuel Hose Routing” in Section 4B (Page
4B-2) 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).
IDK111140097-01 – No fuel leakage is evident when fuel system is
• Install flywheel (2) and tighten flywheel nut to pressurized.
specified torque. Refer to “Fuel Leakage Check Procedure” in
Refer to “Flywheel Removal and Installation” in Section 1G (Page 1G-14).
Section 1K (Page 1K-4). – No water leakage is evident during final test
running.
Tightening torque
Flywheel nut (a): 90 N·m (9.0 kgf-m, 65 lbf-ft)
Special tool
(A): 09930–39520 (Flywheel holder)
(B): 09930–39210 (Flywheel remover bolt)
(a)
(A) 2
(B)
IDK111140098-02
Power Unit Mechanical: 1D-16
Camshaft, Rocker Arm and Rocker Arm Shaft 5) Remove the spring (4), rocker arms (5).
Removal and Installation
CENDK1111406008
Removal
5 5
1) Remove the power unit. 4
Refer to “Power Unit Removal and Installation”
(Page 1D-8).
2) Remove the camshaft pulley (1).
Refer to “Camshaft Pulley Removal and Installation”
(Page 1D-7).
IDK111140103-01
NOTE
Pull out camshaft toward oil pan side.
IDK111140100-01 6
3) Remove the oil pump (2).
Refer to “Oil Pump Removal and Installation” in
Section 1E (Page 1E-2).
IDK111140104-01
IDK111140101-01
IDK111140105-01
IDK111140102-01
NOTE
Reassemble each rocker arm to original
position.
1D-17 Power Unit Mechanical:
Installation 5) Install the rocker arms (3), rocker arm spring (5) and
1) Install the oil seal (1) with the spring / lipped side rocker arm shaft (4).
facing inward. Apply engine oil to oil seal lip.
NOTICE 3
3 5
Removing the oil seal can cause damage to
the seal lips, causing oil to leak.
IDK111140107-01
IDK111140003-02
IDK111140004-02
Decompression Parts
Inspect the decompression parts on the camshaft.
(B)
If abnormal movement is found, replace the camshaft.
(A)
IDK111140109-01
(B)
IAJ311140093-01
IAJ311140096-01
1D-19 Power Unit Mechanical:
IAJ311140018-01
7 8 10 (b)
9 (a)
2
1
3
IDK111140013-01
1. Intake valve 5. Valve stem seal 9. Cylinder head bolt (Inside) : Apply engine oil.
“7”
“5” “3”
1
IDK111140113-01
NOTE
Use special tool (8 mm deep socket wrench)
“6” when tightening cylinder head bolts.
“4”
“8”
“1” “2”
Special tool
IDK111140111-01
(A): 09919–19910 (Deep socket wrench
(8mm))
3) Apply engine oil to cylinder head inside bolts only.
NOTE
(A) Do not apply oil to cylinder head outside
bolts.
IDK111140112-01
1D-21 Power Unit Mechanical:
“2”
IDK111140116-01
“4” “6”
(C)
(A)
(B)
“3”
“5”
“8” “1”
“7”
IDK111140114-02
1
I9J011140209-01
(A)
2) Remove valve spring retainer (2), valve spring (3)
and valve (4).
1 2 3 5 6 4
IDK111140115-01
6
IDK111140117-01
Power Unit Mechanical: 1D-22
Assembly 3) Apply engine oil to stem seal, valve guide bore and
Reassemble in reverse order of disassembly paying valve stem.
special attention to the following steps. 4) Install valve (3) to valve guide.
NOTE
6
5 Reassemble each valve and valve spring to
their original position.
2
4
3
I9J011140212-03
“A”
2
“B”
1
IDK111140118-01 “D”
I9J011140035-01
6) Hold valve spring compressed with special tool and Cylinder Head
install valve cotters (6). • Remove all carbon from combustion chambers.
Make sure valve cotters are properly seated in
groove “A”. NOTE
Special tool • Do not use any sharp edged tool to scrape
(C): 09916–14510 (Valve lifter) carbon off cylinder head or its
(D): 09916–14521 (Valve lifter attachment) components.
(E): 09916–84511 (Tweezers) • Be careful not to scuff or nick metal
surfaces when decarbonizing.
(D)
(C)
IDK111140119-01
(E) IDK111140120-01
6
“A”
I9J011140036-02
IDK111140122-01
Power Unit Mechanical: 1D-24
NOTE
Distorted mating surface of cylinder head
and cylinder head gasket causes combustion
gas and/or cooling water to leak, which may
result in overheating and reduced power
output.
(A)
IDK111140124-01
(A)
NOTE
I9J011140039-02
Cylinder head can be resurfaced, using a
surface plate and #400 grit wet sandpaper.
Move the cylinder head in a figure eight
pattern when sanding.
1D-25 Power Unit Mechanical:
I9J011140041-01
(B)
“a” “b”
(A)
IDK111140126-01
Power Unit Mechanical: 1D-26
(A)
(A)
(B)
I9J011140043-03
“a”
45°
I9J011140044-01
“b”
I9J011140045-01
1D-27 Power Unit Mechanical:
Valve seat servicing • If width “a” is too high (or wide), reface valve seat
If valve seat contact width is out of specification, reface using small angle cutter.
valve seat as follows: • If width “a” is too low (or narrow), reface valve seat
Valve seat angle using 45° angle cutter.
Intake side: 15° / 45°
Exhaust side: 15° / 45°
IN. EX
.
45° 45°
15° 15°
IAJ311140015-01
“a”
I9J011140047-01
“a”
I9J011140048-01
Power Unit Mechanical: 1D-28
Valve guide replacement 3) Drive valve guide in from valve spring side to the
specified height.
NOTE Measure valve guide protrusion “a”.
Be careful not to damage cylinder head when
Special tool
replacing valve guide.
(A): 09916–44910 (Valve guide remover)
1) Using valve guide remover, drive valve guide out : 09900–20101 (Vernier calipers (150 mm))
from combustion chamber side towards valve spring Valve guide protrusion “a”
side. Standard (IN., EX.): 9.8 – 10.2 mm (0.39 – 0.40 in.)
NOTE
Do not reuse valve guide once it has been “a”
removed.
Always use a new valve guide (oversize) (A)
when assembling.
Special tool
(A): 09916–44910 (Valve guide remover)
(A)
IDK111140017-01
NOTE
Clean and oil valve guide bore after reaming.
Special tool
(D): 09916–34550 (Valve guide reamer (ø 5.5
IDK111140015-01
mm))
2) Ream valve guide hole with ø 11 mm reamer to true (C): 09916–34542 (Valve guide reamer
hole and remove burrs. handle)
NOTICE
(C)
Improper handling of the reamer will cause
damage to the valve guide hole. (D)
Special tool
(B): 09916–38210 (Valve guide reamer (ø 11 IDK111140018-01
mm))
(C): 09916–34542 (Valve guide reamer
handle)
(C)
(B)
IDK111140016-01
1D-29 Power Unit Mechanical:
“a”
(A)
I9J011140054-02
I9J011140055-01
Power Unit Mechanical: 1D-30
15 (b)
16 (c)
14
13
13
11 7
12
8 (a)
10
12
9
5 4
3 5
IDK111140019-03
Pistons, Piston Rings, Connecting Rods, 5) Remove the thermostat cover (6) and thermostat.
Cylinder and Crankshaft Disassembly and Refer to “Thermostat Removal and Installation” in
Assembly Section 1F (Page 1F-3).
CENDK1111406015
Disassembly
1) Before performing service work in this section:
• Remove power unit.
Refer to “Power Unit Removal and Installation”
(Page 1D-8).
• Remove cylinder head.
Refer to “Cylinder Head Removal and Installation”
(Page 1D-20). 6
IDK111140133-01
IDK111140130-01
7
3) Remove screws (2), oil filter cap (3) and oil filter (4).
IDK111140134-01
NOTE
The pulley nut has been applied the thread
lock cement.
Slightly tap the pulley nut to
4
counterclockwise using a flat screw driver
and a hammer before loosening the nut.
IDK111140131-01
9
8
IDK111140132-01 (A)
IDK111140135-01
Power Unit Mechanical: 1D-32
8) Remove the lock washer (9), upper guide (10), 10) Remove all conrod cap bolts (16) and conrod caps
timing pulley (11), key (12) and lower guide (13). (17).
9
9
10 17
16
12
11
10 13
11
IDK111140006-03 IDK111140138-01
19
14
19 18
15
IDK111140136-01 IDK111140139-01
IDK111140137-01
1
2
IDK111140140-01
1D-33 Power Unit Mechanical:
13) Remove two compression rings (top and 2nd) and oil Assembly
ring from piston. Mark cylinder number on conrod Assembly is reverse order of disassembly paying special
using quick dry paint. attention to the following steps.
NOTICE
If any of the parts is reinstalled into a position
different from the original position, engine
problems could occur.
Piston to conrod
IDK111140141-01
• Apply engine oil to piston pin (1), piston pin bore and
14) Remove piston pin circlips (20) as shown.
conrod (2).
• Assemble conrod (2) to piston (3) as shown in figure
20 and insert piston pin (1) through piston and conrod.
• Install piston pin circlips (4).
NOTE
• Make sure conrod is installed in direction
as shown in figure.
• Always use new piston pin circlip.
IDK111140020-01
• Install so that circlip end gap comes within
15) Remove piston pin from conrod. such range as indicated by arrow.
End gap of the circlip should not be
NOTE
aligned with the cutaway in the piston pin
Reassemble each piston, piston pin and bore.
conrod in their original combination and
position.
“A”
“B”
“B”
“C”
IDK111140007-02
1
4 “2R” 4
3
“C”
2
IAJ311140004-01
IDK111140008-01
4
4
I9J011140011-01
NOTE
When installing spacer, do not allow spacer 3 3
ends to overlap in groove. IDK111140009-01
“D”
“G” “H”
“B”
“F” “E”
I9J011140012-01
I9J011140016-01
“A”: Incorrect “B”: Correct
“D”: Up mark “G”: 2nd ring
“E”: 1st ring “H”: Oil ring upper side rail
“F”: Oil ring lower side rail
1D-35 Power Unit Mechanical:
NOTICE
If oil is present between the bearing’s outside
surface and crank bearing holder surface, the
(A)
bearing could heat up to very high
1 temperature, resulting in seizure.
IDK111140142-02 NOTE
Align bearing tab “A” with notch in cylinder
and crankcase.
“B”
“A”
IDK111140143-02
1
IDK111140144-01
1
“A”
IDK111140145-01
Power Unit Mechanical: 1D-36
NOTE 4
When installing crankshaft to cylinder, be
sure to fit tab of seal in groove of cylinder. “A”
IDK111140148-01
2
IDK111140146-01
(a)
IDK111140149-01
IDK111140147-01
1D-37 Power Unit Mechanical:
“3” “1”
“4” “2”
“10”
“6” “8”
IDK111140151-01
“A” NOTE
“B” After tightening crankcase bolts, check to be
sure that crankshaft rotates smoothly when
“A” : Apply bond “ ” marked area. turned by hand.
“B” : Do not apply bond “ ” marked area.
IDK111140021-02
1 IDK111140152-01
IDK111140150-01
Power Unit Mechanical: 1D-38
5
IDK111140154-01
3 4
2 (A)
3
1
1
IDK111140010-02
5
IDK111140155-01
5
IDK111140153-01
IDK111140156-01
1D-39 Power Unit Mechanical:
Cylinder Distortion
Using a straightedge and thickness gauge, measure
IDK111140157-01 cylinder distortion (gasket surface) at a total of six
locations as shown.
Engine oil filter If measurement exceeds service limit, resurface or
Install the engine oil filter (1) and oil filter cap (2). replace cylinder.
Refer to “Engine Oil Change and Engine Oil Filter
Replacement” in Section 0B (Page 0B-3). Special tool
(A): 09900–20803 (Thickness gauge)
Cylinder distortion
1
Service limit: 0.06 mm (0.002 in.)
2
IDK111140158-01
Thermostat
Install the thermostat (1) and thermostat cover (2). IDK111140160-01
Refer to “Thermostat Removal and Installation” in
Section 1F (Page 1F-3).
(A)
1
IDK111140161-01
IDK111140159-01
Power Unit Mechanical: 1D-40
IDK111140162-01
Water Jackets
Check water jackets.
If clogged or obstruction is found, clean water jacket. IDK111140163-02
“a”
“b”
I9J011140060-01
NOTE
Purchase a commercially available “a”
telescoping gauge for this measurement.
(A)
I9J011140061-02
“a”: 9 mm
1D-41 Power Unit Mechanical:
I9J011140063-03
50 mm
1 Oil ring
Oversize I.D. mark
0.50 mm One red paint
IDK111140164-01
in.)
Service limit: 0.100 mm (0.0039 in.) Piston
Visual inspection
Identification of Oversize Piston / Piston Ring Inspect piston for faults, cracks or other damage.
One oversize piston / piston ring components, 0.50 mm Damaged or faulty piston(s) should be replaced.
is available. Oversize piston / piston ring are marked as
shown, below. Piston ring to groove clearance
Before checking, piston grooves must be clean, dry and
Piston free of carbon.
Oversize I.D. mark Fit piston ring into piston groove, and measure clearance
0.50 mm 50 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.)
“A” Standard (2nd): 0.020 – 0.060 mm (0.0008 – 0.0024
in.)
Service limit (1st): 0.12 mm (0.005 in.)
IDK111140012-01 Service limit (2nd): 0.10 mm (0.004 in.)
“A”: I.D. mark: 50
Power Unit Mechanical: 1D-42
1. Piston ring
I9J011140067-02
Piston Ring
Piston ring end gap
Piston Pin and Conrod Inspection
Measure piston ring end gap with piston ring in the CENDK1111406017
lowest position of cylinder bore. Piston Pin
If measurement exceeds service limit, replace piston Visual inspection
ring. • Check piston pin, conrod small end bore and piston
Special tool pin hole for wear or damage.
(A): 09900–20803 (Thickness gauge) If badly worn or damaged, replace component.
• Apply engine oil on piston pin so that the piston pin
Piston ring end gap
can move smoothly in the piston pin hole.
Standard (1st): 0.12 – 0.25 mm (0.0047 – 0.0098 in.)
If improper condition is found, replace the piston pin
Standard (2nd): 0.26 – 0.39 mm (0.0102 – 0.0154 in.)
and/or piston.
Service limit (1st): 0.70 mm (0.028 in.)
Service limit (2nd): 0.70 mm (0.028 in.)
Piston pin clearance
Check the piston pin clearance in the conrod small end.
Replace the conrod if its small end is badly worn or
damaged or if clearance exceeds service limit.
(A)
Measure the following item:
1 Special tool
(A): 09900–20205 (Micrometer (0 – 25 mm))
2 (B): 09900–20605 (Dial calipers (10 – 34 mm))
Piston pin outside diameter
Standard: 15.995 – 16.000 mm (0.6297 – 0.6299 in.)
Service limit: 15.980 (0.6291 in.)
IDK111140165-01
(A)
(A)
I9J011140068-02
IDK111140166-01
(B)
Special tool
(A): 09900–20202 (Micrometer (25 – 50 mm))
Crank pin diameter
Standard: 28.989 – 29.000 mm (1.1413 – 1.1417 in.)
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.)
I9J011140070-02
IAJ311140009-03
Power Unit Mechanical: 1D-44
Conrod Big End Inside Diameter Crank Pin / Conrod Big End Oil Clearance
Measure the conrod big end inside diameter as follows. Check conrod big end oil clearance as follows:
1) Clean the surface of the conrod and the conrod cap. 1) Clean surface of conrod, conrod cap and crank pin.
2) Install the conrod cap to the conrod. 2) Place a piece of Plastigauge on crank pin parallel to
3) Apply the engine oil to the conrod bolts and tighten crankshaft. Avoid placing Plastigauge over oil hole.
the bolts to the specified torque. Special tool
Tightening torque (A): 09900–22301 (Plastigauge (0.025 –
Conrod cap bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft) 0.076 mm))
(A)
(a)
IAJ311140010-01 IAJ311140157-01
4) Measure the conrod big end inside diameter. 3) Install conrod and conrod cap to crank pin.
4) Apply engine oil to conrod cap bolts, then tighten
Special tool
conrod cap bolts in two steps.
: 09900–20605 (Dial calipers (10 – 34 mm))
Tightening torque
Conrod big end inside diameter
Conrod cap bolt [1st step] (a): 5 N·m (0.5 kgf-m,
Standard: 29.025 – 29.034 mm (1.1427 – 1.1431
3.5 lbf-ft)
in)
Conrod cap bolt [Final step] (a): 10 N·m (1.0 kgf-
m, 7.2 lbf-ft)
(A) (a)
IAJ311140011-01
IAJ311140158-01
NOTE
Do not rotate conrod with Plastigauge in
place.
1D-45 Power Unit Mechanical:
5) Remove conrod and conrod cap from crank pin. Crankshaft Thrust Play
6) Using scale on plastigauge envelope, measure Measure the crankshaft thrust play.
plastigauge width at its widest point. Special tool
If measurement exceeds service limit, replace the (A): 09900–20803 (Thickness gauge)
conrod assembly and/or crankshaft.
Crankshaft thrust play
Conrod big end oil clearance Service limit: 0.6 mm (0.024 in.)
Standard: 0.025 – 0.045 mm (0.0010 – 0.0018 in.)
Service limit: 0.080 mm (0.0031 in.)
(A)
1
IDK111140167-01
“b”
IAJ311140176-01
IDK111140168-01
Power Unit Mechanical: 1D-46
Out-of-Round and Taper (Uneven Wear) of Journals Crankshaft Journal Oil Clearance
An unevenly worn crankshaft journal shows up as a Check clearance using Plastigauge according to the
difference in diameter at a cross section or along its following procedure.
length (or both).
This difference, if any, is determined by taking NOTE
micrometer readings. Assemble each bearing in its original
If any journal is badly damaged or if measurements position before checking clearance.
exceed service limit, replace crankshaft.
1) Clean surface of bearing holder (crankcase, and
Special tool cylinder), bearing, and main bearing journal.
(A): 09900–20202 (Micrometer (25 – 50 mm))
2) Install main bearing (1) to cylinder and crankcase.
Out-of-round and taper
Service limit: 0.01 mm (0.0004 in.) NOTE
1
1
1 1
IDK111140169-01
IAJ311140012-03
IAJ311140163-01
I9J011140073-01
1D-47 Power Unit Mechanical:
“4” “2”
(A)
“10”
“6” “8”
IDK111140170-01
IAJ311140164-01
NOTE
Do not apply oil to 6 mm (0.23 in.) crankcase IDK111140171-01
IAJ311140167-02
2. Plastigauge 3. Scale
IAJ311140168-01
1E-1 Power Unit Lubrication:
General Description
Engine Lubrication Description
CENDK1111501001
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 hose and passed through a oil filter before entering the main oil gallery.
A pressure regulator (relief valve) is positioned between the oil pump and main gallery 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.
M
Crankshaft main journal #1 A Camshaft upper journal
I
N
Crank pin #1
G Rocker arm and
A Cam face
Piston L
L
Crankshaft main E Oil pressure switch
journal #2 R
Y
Oil regulator
Crank pin #2
Cylinder block
Cylinder head
Oil pump
Cylinder head
Cylinder block
Engine holder
Oil hose
Oil pan
IDK111150018-05
Power Unit Lubrication: 1E-2
Service Instructions
Oil Pump Removal and Installation 3) Turn the oil pump shaft (4) until the pin (3) comes out
CENDK1111506001 through hole of oil gallery block (2).
Removal
Remove the oil gallery block.
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
Section 1D (Page 1D-8).
4
2) Remove the three screws (1) securing oil pump, then 2 2
remove the oil pump and oil gallery block (2).
3 3
2 IDK111150001-02
1
IDK111150016-02
1E-3 Power Unit Lubrication:
2 1
IDK111150005-02
IDK111150002-02
4
3
“A”
IDK111150007-02
IDK111150003-02
IDK111150006-02
1 (a)
IDK111150004-01
Power Unit Lubrication: 1E-4
IDK111150009-03
IDK111150019-02
5) Install the rotor plate (5), and then tighten screw (6)
securely.
After mounting the rotor plate, make sure that each
rotor turns smoothly by hand.
IDK111150023-01
5 6
IDK111150010-02
1E-5 Power Unit Lubrication:
1 IDK111150014-02
IDK111150020-02
5
3
IDK111150021-01
4
• Check to ensure that all removed parts are back in
place.
IDK111150017-02
Oil Pressure Switch Inspection
4) Remove oil pressure switch from cylinder block. CENDK1111506005
NOTE
Installation Before checking the oil pressure switch,
Installation is reverse order of removal with special make sure the engine oil pressure is within
attention to the following steps. specification.
• Before installing oil pressure switch, wrap screw
threads with sealing tape (1), then tighten switch to 1) Temporarily remove the SDS service connector (1)
specified torque. from electric part holder.
2) Temporarily remove the fuel filter (2) from filter
NOTE
bracket.
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)
1
2
IDK111150022-02
1
I9J011150002-01
Power Unit Lubrication: 1E-6
IDK111150015-01
I9J011150003-01
General Description
Water Cooling System Description
CENDK1111601001
The cooling system uses a displacement type flexible vane impeller to supply cooling water to the powerhead
assembly.
To prevent incomplete combustion due to an overcooled engine, and to ensure proper water flow during cold engine
operation, there is a thermostat in the cylinder block.
Motor temperature and cooling system efficiency are monitored by cylinder temp. sensor in the cylinder. If temperature
higher than normal is detected by a sensor, an advance caution of overheat condition is provided.
5
1
5
2
6
1 7 3
IAJ311160002-01
When OPEN
WATER TUBE
WATER PUMP
PROPELLER
WATER INLET
EXHAUST OUTLET
WATER
IAJ311160001-02
1F-3 Power Unit Cooling System:
Service Instructions
Thermostat Removal and Installation 4) Remove the three bolts (7) securing the thermostat
CENDK1111606001 cover (8), then remove the cover and thermostat (9).
Removal
1) Remove the recoil starter.
Refer to “Recoil Starter Removal and Installation” in
Section 1J (Page 1J-3). 7
IDK111160001-02
3
2
9
IDK111160006-02
6 5 4
IDK111160007-02
Power Unit Cooling System: 1F-4
2
IDK111160008-02
4 (a)
2
IAJ311160008-01
IDK111160005-02
1F-5 Power Unit Cooling System:
3) Check thermostat opening temperature as follows: Water Pump Removal and Installation
CENDK1111606003
a) Insert a length of thread between thermostat Refer to “Water Pump Removal and Installation” in
valve / body and suspend thermostat in a Section 3A (Page 3A-6).
container filled with water.
b) Place thermometer in container and heat water. Water Pump Related Item Inspection
Observe water temperature when thermostat CENDK1111606004
valve opens and releases thread. Refer to “Water Pump and Related Items Inspection” in
Section 3A (Page 3A-8).
Thermostat operating temperature
Standard: 48 – 52 °C (118 – 126 °F)
Water Tube Removal and Installation
CENDK1111606005
Removal
Refer to “Engine Holder / Driveshaft Housing / Mounts
1 Disassembly” in Section 2A (Page 2A-14).
Installation
Refer to “Engine Holder / Driveshaft Housing / Mounts
2
3 Assembly” in Section 2A (Page 2A-15).
IDK111160009-02
Fuel System
Power Head
Precautions
Precautions on Fuel System Service
CENDK1111700001
! 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.
1G-2 Fuel System:
General Description
Electronic Fuel Injection System Description
CENDK1111701001
The fuel injection system used by the DF15A/20A 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.).
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
speed.
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
IAT sensor:
Informs ECM of intake air temperature. Fuel amount compensation
TPS (Throttle position sensor):
Informs ECM of throttle opening angle.
Multi-point sequential timing
Others
CMP sensor:
Informs ECM of camshaft angle. Signal Signal
Neutral switch:
Informs ECM of shift position (neutral or in-gear).
Injector
IDK111170001-01
5
1
CPU “A”
3
A A
2
4
IDK111170002-03
CMP sensor
signal
CMP sensor - 6 signals / 720° (crankshaft 2 rotation)
No.1 cylinder Cm Ep Ex In Cm Ep
No.2 cylinder Ex In Cm Ep Ex In
Injection time duration Injection end timing: 210° BTDC on intake stroke
No.1 Injection
signal
No.2 Injection
signal
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:
“A” 14 11 12
“B”
4 13 12
3 5
10
2
9
1
6 8
7
IDK111170004-04
3
2
5
IDK111170005-02
1. Fuel inlet (from low pressure fuel pump) 3. Cap 5. Fuel outlet (to fuel cooler)
2. Air vent 4. Return fuel inlet (from high pressure fuel 6. Float
pump / fuel pressure regulator)
4
5
2
IDK111170006-02
Fuel Injector
The fuel injector is an electromagnetic valve operated by a signal from the ECM.
When the injection signal is supplied to the fuel injector, the solenoid coil is energized pulling up the plunger.
This opens the injector valve and injects fuel.
Because the fuel pressure is kept constant, the amount of fuel injected is determined by the amount of time (duration)
the valve is open.
IDK111170060-03
1. Fuel injector
ECM Signal FP
Fuel pump
IDK111170007-02
ECM
4 3
CPU
5 6
2 FP
IDK111170009-02
0.8 ms
OFF
ON Time
1 ms (1cycle)
IDK111170011-01
Control Modes
When cranking:
The fuel pump is controlled to operate at “start-up” mode.
Air flow
2
7
8
1
6 4 3
5
IDK111170012-02
Throttle Body
• The throttle body assembly consists of the main bore, throttle valve, by-pass air passage, IAC passage, by-pass air
screw 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 of throttle valve opening angle.
NOTE
Do not try to adjust or remove any of the throttle body component parts (Throttle position sensor,
throttle valve, throttle stop screw, etc.).
These components have been factory adjusted to precise specifications.
IDK111170015-01
NOTE
For the by-pass air screw adjustment procedure, refer to “Idle Speed and Idle Air Control (IAC) Duty
Inspection” in Section 0B (Page 0B-14).
IDK111170020-01
3
1
IDK111170016-01
CKP sensor:
Informs ECM of engine speed.
When cranking:
The IAC valve is controlled to operate at 100% duty.
NOTE
Due to the limited intake air flow from the IAC passage and in order to effectively use both the “Dash-
pot effect” and “Fast-idle function”, the by-pass air screw must be adjusted to provide IAC valve
operation at 10 ± 5% duty at the engine idling / trolling specification.
For the by-pass air screw adjustment procedure, refer to “Idle Speed and Idle Air Control (IAC) Duty
Inspection” in Section 0B (Page 0B-14).
2
1
IDK111170021-01
Fuel System: 1G-11
4) Connect special tools (pressure gauge, pressure 6) Check for any signs of fuel leakage.
hose and pressure joint) between fuel feed hose (3) 7) Measure fuel pressure at cranking or idle speed
and fuel delivery pipe as shown in figure. operation.
Clamp the hose securely to ensure that no leaks If out of specification, check each possibly defective
occur during checking. parts (high pressure fuel pump, fuel pressure
regulator, fuel injector, etc.).
! WARNING Replace if found defective.
Gasoline is a flammable material that can Fuel pressure
cause fire hazard or burns. Standard: Approx. 300 kPa (3.0 kg/cm2, 43 psi)
(C)
(B)
IDK111170023-01
(A)
1 4
(B)
(C)
I9J011170019-01
4. Joint nut
IAJ311170008-01
1G-12 Fuel System:
No Go to step 2. Step 5
Check wire circuit.
Step 2 • Connect the connector to ECM.
Check fuel injector resistance. • Measure voltage between each “O/B”, “B/Br” wire
• Stop the engine, disconnect connectors from fuel terminal of fuel injector connector and body ground
injectors. with engine cranking.
• Check for proper connection to fuel injector at each Special tool
terminal. : Stevens peak reading voltmeter CD-77
• If good condition, check all fuel injector for
Tester knob indication
resistance. (Refer to page 1G-18.)
POS50
Are all injectors in good condition?
Is voltage 0 V?
Yes Go to step 3.
Yes Go to step 6.
No Faulty fuel injector.
No “O/B” and/or “B/Br” wire(s) are shorted to
power supply circuit.
Step 3
Check fuel injector power supply.
Step 6
• Measure voltage between each “Gray/Red” wire Check fuel injector operating signal.
terminal of fuel injector connector and engine body
• Connect connectors to each fuel injector and ECM.
ground with engine cranking.
• Measure fuel injector operating signal between each
Special tool “2”, “15”, terminal of ECM and body ground.
: Stevens peak reading voltmeter CD-77 (Refer to page 1G-19.)
Tester knob indication Is voltage approx. 20 V or over?
POS50
Yes If check result is satisfactory, substitute a
Is voltage 5 V or over? known-good ECM and recheck.
Yes Go to step 4. No “O/B” and/or “B/Br” wire(s) are open
No • “Gray/Red” wire open or shorted. circuit.
• If it is in good condition, check ECM
power source and ground circuit.
1G-14 Fuel System:
Service Instructions
Fuel Pressure Relief Procedure Fuel Line Removal and Installation
CENDK1111706016 CENDK1111706001
After making sure that engine is cold, relieve fuel Pay special attention to the following points when
pressure as follows. removing or installing fuel hoses.
1) Stop the engine.
! WARNING
2) Loosen the bolts securing high pressure fuel pump
guard (1). Gasoline is a flammable material that can
Disconnect high pressure fuel pump lead wire cause fire hazard or burns.
connector (2) at high pressure fuel pump.
Before starting the following procedure, be
sure to observe “Precautions on Fuel System
Service:” in order to reduce the risk or fire
2 and personal injury.
IDK111170054-01
IAJ311170008-01
6) Upon completion of servicing, connect ignition coil
primary lead wire and high pressure fuel pump lead
wire. Tighten the fuel pump guard bolts.
Fuel System: 1G-15
Inspection of Fuel Hose Connections Fuel Vapor Separator Removal and Installation
CENDK1111706004 CENDK1111706017
Note that the fuel hose connection varies with each type NOTICE
of pipe. Be sure to connect and clamp each hose Disassembling the fuel vapor separator can
correctly by referring to the figure. lead to troubles.
• For type “A” (short barbed end) pipe, the hose must
completely cover pipe. The fuel vapor separator is a non-repairable
Type “A” component.
Do not attempt to disassemble the fuel vapor
1
2 separator.
It must be replaced as a complete unit if it is
defective.
Removal
1) Loosen the fuel drain screw (1) and drain the
“a” 3
gasoline into a suitable container.
I9J011170012-01
• 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” IDK111170027-01
“a” 2) Remove the low pressure fuel filter (2) from filter
bracket.
I9J011170013-01
• For type “C” pipe, hose must fit up against the flanged
part of pipe.
Type “C”
“a”
I9J011170014-01 IDK111170028-02
“a”: 3 – 7 mm (0.1 – 0.3 in) 3) Disconnect the fuel inlet hose (3), fuel return hose
(4) and evaporation hose (5) from fuel vapor
• For type “D” pipe, the hose must cover the pipe by 20 separator.
– 30 mm (0.8 – 1.2 in.).
Type “D” 5
3
“b”
“a”
I9J011170015-01
IDK111170029-01
1G-16 Fuel System:
4) Remove the bolt (6) and fuel vapor separator (7). Fuel Vapor Separator Assembly
Disconnect the fuel outlet hose (8) from fuel vapor Inspect the fuel vapor separator.
separator. If leakage, cracks, damage or other abnormal condition
is found, replace fuel vapor separator assembly.
8
IDK111170030-01
IDK111170055-01
Installation
Installation is in the reverse order of removal with special High Pressure Fuel Pump Removal and
attention to the following steps. Installation
• Install the fuel vapor separator, then tighten the bolt CENDK1111706019
securely. NOTICE
• Check to ensure that all removed parts are back in Disassembling the high pressure fuel pump
place. can lead to troubles.
• Check hose and wire routing.
The high pressure fuel pump is a non-
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
repairable component.
2).
Do not attempt to disassemble the high
• Check for fuel leakage. pressure fuel pump.
Refer to “Fuel Leakage Check Procedure” (Page 1G- It must be replaced as a complete unit if it is
14). defective.
IDK111170031-01
Fuel System: 1G-17
4) Disconnect the pump lead wire connector (3) at high High Pressure Fuel Pump Inspection
pressure fuel pump. CENDK1111706026
1) Disconnect pump lead wire connector from high
pressure fuel pump.
2) Check each coil of fuel pump for resistance.
Fuel pump resistance
Terminals Resistance
Between “1” and “2”
Between “2” and “3” 2.0 – 2.6 Ω
3 Between “3” and “1”
IDK111170032-01 1
5) Disconnect the fuel inlet hose (4) / outlet hose (5). 2
Disconnect the fuel vapor hose (6) and fuel return
3
hose (7).
6) Remove the high pressure fuel pump from cylinder
head cover.
6 7
IDK111170056-01
5
1) Using a sound scope or equivalent, check the
4 operating sound of the fuel injector when the engine
IDK111170033-01 is running or cranking.
Injector operating sound cycle should vary according
Installation to engine speed.
Installation is in the reverse order of removal with special If no sound or an unusual sound is heard, check
attention to the following steps. injector circuit (wire or connector) or injector.
• Install the high pressure fuel pump, pump guard, then
tighten bolt securely.
• Check to ensure that all removed parts are back in
place.
• Check hose and wire routing.
Refer to “Fuel Hose Routing” in Section 4B (Page 4B-
2).
• Check for fuel leakage. “click”
Refer to “Fuel Leakage Check Procedure” (Page 1G- 1
14).
IDK111170034-02
1. Injector body
1G-18 Fuel System:
2) Disconnect the lead wire connector from the fuel 3) Connect the Gray wire to battery negative terminal.
injector. 4) Momentarily touch the Black/ Yellow wire to battery
3) Connect a digital tester between the terminals of the positive (+) terminal and check for injector operating
injector and measure resistance. sound.
If out of specification, replace the fuel injector. 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 – 14.0 Ω
few seconds to avoid burning of the coil.
“click”
IDK111170035-01
(A)
IDK111170036-03
Fuel System: 1G-19
(A)
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
2
2 7
15
IDK111170017-04
Special tool
(A): 09930–88940 (26-pin test cord)
: Stevens peak reading voltmeter CD-77
Tester knob indication
POS 50
1) Disconnect ignition coil lead wire connector from the ignition coil.
2) Connect the test cord between the ECM and wire harness as shown in figure.
3) Connect the tester probe (“–”, Black) to No.7 terminal (or to body ground) as shown in figure.
4) Connect the tester probe (“+”, Red) to each terminal.
Injector Terminal Wire color (Engine harness)
No.1 2 O/B
No.2 15 B/Br
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. 20 V or over
1G-20 Fuel System:
Fuel Injector Removal and Installation 4) Remove two bolts and fuel delivery pipe (4) (with fuel
CENDK1111706023 injectors).
Removal
1) Relieve the fuel pressure in the fuel feed line
according to “Fuel Pressure Relief Procedure.”
Refer to “Fuel Pressure Relief Procedure” (Page 1G-
14).
2) Disconnect the two fuel injector connectors (1).
IDK111170039-01
! WARNING
1
Gasoline is a flammable material that can
cause fire hazard or burns.
IDK111170058-01
A small amount of fuel may be released when
3) Loosen the clamp (2) and place a large cloth over the fuel injector is removed from delivery
the end of fuel feed hose (3). pipe.
Slowly pull the fuel feed hose from the fuel delivery Place a shop cloth under fuel injector before
pipe. removal to absorb any fuel released.
Drain any excess fuel in the hose into a small Dispose of fuel soaked cloth in appropriate
container. container.
3
2 5
IDK111170038-01
IDK111170040-01
Fuel System: 1G-21
2 1
IDK111170043-01
3
“A”
IDK111170018-01
4 (a)
2) Replace the injector cushion (3) with a new one and
install to the cylinder head.
IDK111170044-01
IDK111170041-01
4
IDK111170045-02
5 6
8) Make sure the emergency stop switch lock plate is in
place.
Shift into “NEUTRAL” position.
9) Squeeze the fuel primer bulb until you feel
resistance.
7
10) Pull the starter grip sharply several times.
IDK111170042-01
11) Repeat step 9 and 10 to fill the high pressure fuel
feed line with fuel.
Check for fuel leaks around the fuel injector.
1G-22 Fuel System:
Low Pressure Fuel Pump Removal and 5) Pull off the fuel return hose (7) from hose clamp (8).
Installation Remove the hose clamp (8) from cylinder head
CENDK1111706024 cover by releasing clamps’ lock.
NOTICE
Disassembling the low pressure fuel pump
can lead to troubles.
8
The low pressure fuel pump is a non-
repairable component.
Do not attempt to disassemble the low 7
pressure fuel pump.
It must be replaced as a complete unit if it is
defective.
Removal
IDK111170048-01
1) Remove both lower side covers.
6) Remove two bolts (10).
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-2). 7) Remove fuel pump (11).
2) Remove the bolts (1) and high pressure fuel pump
guard (2).
3) Disconnect the lead wire connector (3) at high 10
pressure fuel pump.
1
3
10
11
IDK111170049-01
1
2
IDK111170046-02 12
4) Disconnect inlet hose (4) and outlet hose (5) from
low pressure fuel pump (6).
IDK111170050-01
4 6
IDK111170059-01
Fuel System: 1G-23
Tightening torque
Low pressure fuel pump bolt (a): 10 N·m (1.0 kgf-m,
7.2 lbf-ft)
IDK111170052-01
(a)
(a)
IDK111170051-01
IDK111170053-01
Low Pressure Fuel Pump Inspection
CENDK1111706025
NOTICE
Disassembling the low pressure fuel pump
can lead to troubles.
2 4
5
5
6
5
1 5
3
9
8 10 7
12
13 11
IAJ311170014-02
1
2
2
1
IAJ311170015-01
Fuel Hose
Inspect the fuel hoses. If cut, crack, leakage, abrasion,
tear or deterioration is found, replace the hoses.
IAJ311170017-01
IAJ311170018-01
1H-1 Ignition System:
Ignition System
ower Head
General Description
Ignition System Description
CENDK1111801001
A digital CDI (condenser discharged ignition) system is employed on the DF15A/20A.
A condenser built in the ECM stores an electrical energy supplied from the ECM power source.
The electrical energy stored in the condenser is released to the ignition coil primary windings by the ignition timing
signal calculated by the ECM, then a high surge voltage is generated in the ignition coil secondary windings and
wakes ignition spark.
4
6
1 3
“A”
SCR
CPU
2
IDK111180002-04
1. ECM 4. Power circuit-1 “A”: ECM power source (from power source coil)
2. Sensor/switch signal input 5. Power circuit-2
3. Condenser 6. Ignition coil
Ignition System: 1H-2
Compensating sensors
Cylinder temperature sensor:
Informs ECM of cylinder temperature.
Ignition timing compensation
Throttle position sensor:
Informs ECM of throttle opening angle.
Neutral switch:
Informs ECM of shift position and change. Signal
IAT sensor:
Informs ECM of intake air temperature. Ign.coil
Spark plug
IDK111180003-01
Ignition Specification
Ignition type Digital CDI
Advance Electronic microcomputer control
5° BTDC – 10° BTDC (DF15A)
Ignition timing
5° BTDC – 20° BTDC (DF20A)
Firing order Simultaneous ignition
NOTE
The ignition timing remains at BTDC 5° when the shift lever is in neutral.
1H-3 Ignition System:
Component Location
Ignition System Components Location
CENDK1111803001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
Step 5 Step 10
Check neutral switch condition. Check CMP sensor.
Refer to “Neutral Switch Inspection” in Section 1I Refer to “CMP Sensor Inspection” in Section 1C (Page
(Page 1I-15). 1C-9).
Is result OK? Is result OK?
No Faulty ECM.
1H-5 Ignition System:
Service Instructions
Spark Plug Removal and Installation 6) Remove the bolts (7) and ignition coil (8).
CENDK1111806001
Refer to “Spark Plug Removal and Installation” in
Section 0B (Page 0B-7).
7
1 IDK111180007-02
Installation
IDK111180004-01 1) Install the ignition coil (1), then secure the ignition
3) Remove the bolts (3) securing fuel cooler (2). coil with its mounting bolts.
2) Connect ignition coil lead wire connector.
2
1
3
IDK111180005-01
2
IDK111180006-01
4) Install the fuel cooler (3), then secure fuel cooler with 3) Connect the tester probe to the coil lead wires as
its mounting bolts. shown.
Primary coil resistance
Standard: 0.08 – 0.11 Ω
O B
IDK111180011-01
Special tool
(A): 09930–99320 (Digital tester)
Tester knob indication
Resistance (Ω)
Primary Coil Side
1) Remove PORT lower side cover.
Refer to “Lower Side Cover Removal and
(A)
Installation” in Section 2A (Page 2A-2). IAJ311180004-02
2) Disconnect the ignition coil lead wire connector. If measurement is out of specification, replace the
ignition coil.
1H-7 Ignition System:
Spark Plug Cap Inspection 3) Connect the tester probe to the test cord lead wires
CENDK1111806005 as shown.
Measure the spark plug cap resistance in the following
Tester probe connection
procedure.
Red (+) Black (–)
Special tool No.14 terminal
No.1 terminal
(A): 09930–99320 (Digital tester) (or engine body ground)
Tester knob indication
Resistance (Ω) 26-pin test cord (White connector)
1 2 3 4 5 6 7 8 9 10 11 12 13 25 26
14 15 16 17 18 19 20 21 22 23 24
IDK111180013-03
Starting System
Power Head
General Description
Electric Starter System Description
CENDK1111901001
The starting circuit consists of the battery, starting motor, starter button, neutral switch, starter relay 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 starter
button is closed (Starter button depressed).
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 starter
button is opened, at which time the torsion spring causes the pinion to disengage.
4 3
5
6
8 R
7
13 16 1
R
R
11
12
R
10
9
P/B R R W Y/G Br R R
15
W/R R
Br Br
14
Br B
Y/G Y/G
IDK111190002-03
3
2
IDK111190009-01
Component Location
Starting System Components Location
CENDK1111903001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
If any abnormality is found, immediately disconnect 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.
• Fuse is not blown.
“A” 1
5 4 3
“C”
“D” 7
Y/G
2
“B”
R
Br
Br
“E”
R W/R
6
IDK111190003-03
Yes Go to step 4.
Step 4
1) Measure voltage between “R” lead wire terminal
“C” and body ground with starter button
depressed.
Is voltage 12 V (battery voltage)?
Yes Go to step 5.
Service Instructions
Starter Motor Removal and Installation 5) Remove the two bolts securing rectifier and regulator
CENDK1111906001 (7).
Removal
NOTICE
If the 12 V electrical system is shorted while
servicing the starter motor, the engine
electrical circuits could be damaged
seriously.
Installation” in Section 2A (Page 2A-2). 6) Remove the bolt (8) securing rectifier bracket.
2) Remove the recoil starter. Loosen the bolt (9) securing starter motor band (10).
Refer to “Recoil Starter Removal and Installation” in
NOTE
Section 1J (Page 1J-3).
3) Remove the flywheel (1). Complete removal of the starter motor band
Refer to “Flywheel Removal and Installation” in bolts is not required.
Section 1K (Page 1K-4).
Special tool
(A): 09930–39520 (Flywheel holder) 8
(B): 09930–39210 (Flywheel remover bolt)
(C): 09930–39411 (Flywheel remover)
(B)
(A)
10
IDK111190013-01
5 IDK111190014-01
4
3
6 2
IDK111190011-02
1I-6 Starting System:
9) Lift up the stator base, then remove the starter motor Starter Motor Test
(13). CENDK1111906002
! CAUTION
Sparks resulting from short circuit between
the positive (+) and negative (–) terminals
during connections to the battery could
cause a burn.
13
Be careful not to short-circuit the positive (+)
and negative (–) cables and connect them
only to the correct terminals.
! CAUTION
IDK111190015-01
If the cable used for the test is not adequately
Installation thick, the cable may become extremely hot
Installation is in the reverse order of removal with special due to large current flowing through it and
attention to the following steps. you could get burned.
• Install the starter motor and tighten starter motor
Be sure to connect the battery and the
mounting bolts securely.
starting motor with a lead wire of the same
Tightening torque size as original equipment.
Starter motor mounting bolt (a): 23 N·m (2.3 kgf-
m, 16.5 lbf-ft) NOTICE
If battery power is applied too long in any of
the following tests, the coil of the magnetic
switch may burn.
(a) (a)
IDK111190016-01
1
3
4
I9J011190004-01
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
1I-8 Starting System:
1 3 4 5 6 7 8 9 2 (a)
10
20
19 21 26 24 25 24 23 22 28 27
12 (b) 11 13 14 15 16 17 18
I9J011190006-02
“C” “B”
I9J011190007-01
Starting System: 1I-9
1) Remove nut (1) from the magnetic switch, then 6) Pull the brush spring (9) up to separate the brush
disconnect the connecting wire (2). from the surface of the commutator, then remove the
2) Remove two bolts (3) securing the magnetic switch. brush holder (10).
3
1
2
9
10
I9J011190008-01 I9J011190012-01
3) Remove the magnetic switch (4). 7) Remove the yoke (11) and armature (12).
11
4
12
I9J011190009-01 I9J011190013-01
4) Remove screws (5), long through bolts (6) and the 8) Remove the center cover plate (13).
rear cover (7). 9) Remove the planetary gears (14) and internal gear
(15).
6
7 14
5
5
6
15
13
I9J011190010-01
10) Remove the center bracket (16) (with shift lever (18),
pinion (19) and pinion shaft (20)) from front housing
(17).
8
18
17
19
I9J011190011-01
20
16
I9J011190015-02
1I-10 Starting System:
11) Remove the shift lever (18). 14) Remove the pinion shaft (20), washers (24) and
rubber ring (25) from the center bracket.
25
20 24
18 24
I9J011190016-01
I9J011190020-01
! WARNING
Failure to take proper precautions when Assembly
removing stopper ring can cause personal Assembly is in the reverse order of disassembly with
injury. special attention to the following steps.
Reassemble the starter motor, refer to “Starter Motor
Wear safety glasses when disassembling and Components” (Page 1I-8).
assembling the stopper ring. • When installing the armature, use care to avoid
breaking the brushes.
NOTE
Using a screw-driver, pry off the stopper ring.
12) Push the pinion stopper (21) down, then remove the
stopper ring (22). Remove the pinion stopper and
pinion (19).
22
21
21
I9J011190021-01
19
Starter Motor Components Inspection and
Servicing
CENDK1111906005
Armature and Commutator
• Inspect the commutator surface. If surface is gummy
I9J011190017-01
or dirty, clean with # 500 grit emery paper (1).
13) Remove the E-ring (23).
1
23
I9J011190022-01
I9J011190019-01
Starting System: 1I-11
• Measure the commutator outside diameter. If the • Check for continuity between the commutator (4) and
measurement exceeds the service limit, replace the the armature core (5) / shaft (6).
armature. Replace the armature if continuity is indicated.
Special tool Special tool
(A): 09900–20101 (Vernier calipers (150 (B): 09930–99320 (Digital tester)
mm))
Tester knob indication
Commutator outside diameter Continuity ( )
Standard: 29.0 mm (1.14 in.)
Service limit: 28.0 mm (1.10 in.) 4
6
(A)
(B)
(B)
I9J011190023-01 IDK111190004-01
• Check that the mica (insulator) between the segments • Check for continuity between adjacent commutator
is undercut to specified depth. segments. Replace armature if no continuity is
If the measurement exceeds the service limit, cut to indicated.
the specified depth.
Tester knob indication
! WARNING Continuity ( )
NOTE
Remove all particles of mica and metal using I9J011190026-01
compressed air.
Brushes
Commutator undercut “a” Check the length of each brush (1).
Standard: 0.5 – 0.8 mm (0.02 – 0.03 in.) If brushes are worn down to the service limit, they must
Service limit: 0.2 mm (0.01 in.) be replaced.
Special tool
3
(A): 09900–20101 (Vernier calipers (150 mm))
Brush length
“a” Standard: 16.0 mm (0.63 in.)
Service limit: 12.0 mm (0.47 in.)
(A)
2
I9J011190024-01
2. Mica 3. Segment
I9J011190027-01
1I-12 Starting System:
I9J011190030-01
(–)
• Inspect spline teeth for wear or other damage.
Inspect the pinion for smooth movement. Replace if
necessary.
1
IDK111190005-01
1. Base plate
Shift Lever
Inspect the shift lever for wear. Replace if necessary.
I9J011190031-01
Gear
Inspect planetary gears and internal gear for wear,
damage or other abnormal conditions.
Replace if necessary.
I9J011190029-01
I9J011190032-01
Starting System: 1I-13
I9J011190036-01
Magnetic Switch
Push in the plunger and release. The plunger should
I9J011190033-01
return quickly to its original position.
Replace if necessary.
Front Housing
• Inspect the front housing for wear, damage or other
abnormal conditions. Replace if necessary.
• Inspect the bushing for wear or other damage. 1
Replace if necessary.
I9J011190037-01
1. Plunger
2 (A)
1
I9J011190035-01
I9J011190038-02
1
(A)
3
2
IDK111190017-01
1
2) Pull out the starter motor relay and relay cover (2)
from electric parts holder. Remove the relay cover
I9J011190039-01
(3), then disconnect the starter motor relay (4) from
the lead wire connector.
1. Terminal “S” 3. Terminal “B”
2. Terminal “M” 4. Coil case
(A)
IDK111190019-01
I9J011190040-01
Starting System: 1I-15
3) Check continuity between terminal (5) and (6) each Neutral Switch Inspection
time 12 V power supply is applied to terminal (7) and CENDK1111906008
Check for continuity / infinity of the neutral switch.
(8).
Connect the positive (+) lead to terminal (8), and Special tool
negative (–) lead to terminal (7). (A): 09930–99320 (Digital tester)
NOTICE Tester knob indication
Continuity ( )
If the 12 V power supply wire is connected to
wrong terminal or touched to each other, the 1) Disconnect lead wire connector from ECM, then
power supply wire, tester may be damaged. remove ECM.
2) Disconnect the neutral switch lead wire connector.
Be careful not to touch 12 V power supply
3) Check continuity / infinity between the Yellow / Green
wires to each other or with other terminals.
and Brown lead wires while operating the shift lever.
Special tool Special tool
(A): 09930–99320 (Digital tester) (A): 09930–99320 (Digital tester)
Tester knob indication Neutral switch function
Continuity ( ) Shift position Tester indicates
Starter motor relay function Neutral Continuity
Continuity Forward Infinity
12 V power applied Yes Reverse Infinity
12 V power not applied No
1
5 6
8
12 V
CONT 2
(A)
IDK111190001-01 IDK111190020-01
4) Measure the resistance between relay terminals (7) 1. Clutch shaft 2. Neutral switch
and (8).
If out of specification, replace starter motor relay.
Tester knob indication
Resistance (Ω)
Starter motor relay solenoid coil resistance Y/G
Standard: 145 – 190 Ω
Br
(A)
IDK111190006-01
I9J011190044-02
4) If out of specification:
• 1st:
Check switch position adjustment, readjust if
necessary.
• 2nd:
Replace the neutral switch and recheck.
NOTE
After installing the neutral switch, check for
correct function by operating the shift lever.
Br W/R
(A)
IDK111190008-01
Precautions
Precaution for Manual Starting System
CENDK1111A00001
! CAUTION
Failure to take proper precautions when servicing the recoil starter can cause personal injury.
Wear safety glasses and hand protection when winding or unwinding this component.
General Description
Manual Starting System
CENDK1111A01001
The manual starter engages the flywheel ratchet with one pawl when the starter grip is pulled.
A recoil spring is wound as the starter rope pulls and rewinds as the starter grip is returned to the case.
The NSI set linked to the clutch notch lever prevents accidental manual starter engagement while the motor is in gear.
3 4
IDK1111A0028-03
Service Instructions
Recoil Starter Components
CENDK1111A06001
3
4
5
19
7 6
1
11
20
10
12
15 13
14 16
17
18
IDK1111A0033-02
Recoil Starter Removal and Installation 5) Remove the NSI cable from clutch notch lever (7).
CENDK1111A06002
Removal
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” in Section 2A (Page 2A-2).
2) Remove the three screws (1) securing the
evaporation chamber (2), then slide the chamber (2)
with hoses away from the recoil starter case.
IDK1111A0029-01
1
2
IDK1111A0001-02
IDK1111A0030-01
3
7) Pull off the breather hose (9) from hose clamp (10).
Slightly pull the intake silencer case (11) horizontally,
then the grommet “B” on silencer case is away from
recoil starter base “A” as shown below.
9
IDK1111A0002-01 10
4) Loosen the lock nuts (4) and remove NSI cable (5)
from cable bracket (6).
“A”
5 11
“B”
4 IDK1111A0031-02
IDK1111A0003-01
13
12
IDK1111A0032-01
1J-4 Manual Starting System:
Installation 2) Remove the screw (2), then remove the friction plate
Installation is in the reverse order of removal with special (3) with the friction spring (4).
attention to the following. 3) Remove the reel (1).
• Tighten the silencer case bolt securely.
• Install the evaporation chamber, then tighten three
3 4
screws securely. 2
• Check to ensure that all removed parts are back in
place.
• Check the neutral start interlock function.
Refer to “NSI Cable Installation and Adjustment”
(Page 1J-8).
• Wire and hose routing matches service manual 1
illustration.
Refer to “Wiring Harness Routing Diagram” in Section
IDK1111A0005-01
4A (Page 4A-3) and “Fuel Hose Routing” in Section
4) Remove the screw (5) first, and then take off the
4B (Page 4B-2).
ratchet (pawl) (6), ratchet guide (7) and return spring
(8).
IDK1111A0034-01
IDK1111A0006-02
Recoil Starter Disassembly and Assembly
CENDK1111A06003
! CAUTION
Failure to take proper precautions when 6
servicing the recoil starter can cause
personal injury.
Disassembly 8
1) Pull the rope out of recoil case and guide the rope
IDK1111A0008-01
into notch “A” in the reel (1), then turn the reel
clockwise to release the coiled tension in the recoil
spring.
“A”
IDK1111A0004-01
Manual Starting System: 1J-5
5) Remove the recoil rope (9). 8) Remove the reel stopper spring (16) and reel
stopper (17).
17
16
IDK1111A0007-01
IDK1111A0011-01
NOTE
Do not remove the recoil spring unless Assembly
replacement is necessary. Reassembly is in the reverse order of disassembly with
It should be visually inspected in its special attention to the following reassembling step.
assembled position. • Install the reel stopper (1).
6) Remove the recoil spring (10).
10
IDK1111A0025-01
11
12
15
IDK1111A0012-01
13
14
IDK1111A0010-01
1J-6 Manual Starting System:
• Install NSI set and NSI cable (3). • Install the ratchet set (6), then tighten ratchet with
Apply grease to NSI cable. screw (7).
Apply thread lock 1342 to screw (7) before threading.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
IDK1111A0016-01
IDK1111A0013-01
“B” “A”
IDK1111A0026-01
NOTE
“C”
IDK1111A0015-01
“D”
IDK1111A0018-01
Manual Starting System: 1J-7
NOTE
Twist friction plate slightly to align holes “E”
in plate with square lugs “F” on center boss.
IDK1111A0021-01
10
11
9 • Inspect the reel and recoil case.
If any cracks or damage is found on them, replace it.
“E”
“F”
IDK1111A0019-01
IDK1111A0020-01
IDK1111A0024-01
1J-8 Manual Starting System:
1 6
“A”
7
2
“B” 5
IDK1111A0027-01
! WARNING
If the NSI cable is removed or left without correct adjustment, there is a high risk of losing one’s
balance and/or being thrown overboard if the motor starts in gear.
Do not operate the motor when the NSI cable is detached or the adjustment is not correctly done.
Charging System: 1K-1
Charging System
Power Head
General Description
Charging System Description
CENDK1111B01001
The battery charging system circuit is illustrated below.
It is composed of the Battery Charge Coil, Rectifier / regulator and Battery. The 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
On the electric starter models:
Standard: 12 V 12 A (144 W) at 3 000 r/min
On the manual starter models:
Standard: 12 V 6 A (72 W) at 5 000 r/min
Regulated voltage
Standard: 13.5 – 14.4 Volts
Electric Starter Model
3
1
Y Y
Y Y 2
Y Y
W W
B
5 4
R R R 6
W
P/B
W
7
ECM
8
B R
M
9
IDK1111B0001-04
R
Y
5 4
R
Y
7
W W
B
B B
3
W
R
8
W
6 ------: “A”
IAJ3111B0002-01
Component Location
Charging System Components Location
CENDK1111B03001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
Service Instructions
Charging System Construction
CENDK1111B06001
1 (a)
3 2
7
7
8 6
9 5
9
10
10
12
11
13
14
21
17
19
22
16
15
18
20
23
IDK1111B0051-01
Flywheel Removal and Installation 4) Remove the flywheel nut (1), washer (2), flywheel (3)
CENDK1111B06002 and key (4).
Removal
! CAUTION 1
2
Failure to take proper precaution when 4
removing flywheel may result in personal
injury and/or damage to electronic 3
components.
Special tool
(A): 09930–39520 (Flywheel holder)
(A)
IDK1111B0053-01
(a)
(B)
(A)
(B)
(C)
IDK1111B0056-01
IDK1111B0055-01
Charging System: 1K-5
• After installing flywheel and torquing nut to 2) Disconnect the starter switch lead wire connector
specification, check air gap between CKP sensor and (1), the caution lamp lead wire connector (2) and the
flywheel reluctor bars. engine stop switch lead wire connector (3).
CKP sensor air gap “a”
0.75 mm (0.030 in)
3
1
2 2
3
1
IDK1111B0007-01
“a” 3) Remove the air intake silencer case (4).
1
IDK1111B0002-04
Refer to “Air Intake Silencer Case Removal and
Installation” in Section 1D (Page 1D-3).
1. CKP sensor 3. Thickness gauge
2. Flywheel reluctor bar
NOTE
8
Motor depicted is electric starter model.
7
Removal
1) Remove flywheel.
Refer to “Flywheel Removal and Installation” (Page
1K-4). 5 6
9
IDK1111B0009-01
1K-6 Charging System:
5) Disconnect the TPS lead wire connector (10), the 9) Disconnect lead wire connector from ECM (17), then
IAC valve lead wire connector (11) and the MAP remove ECM.
sensor lead wire connector (12).
10
12
17
11
IDK1111B0014-01
19
14
13
18
IDK1111B0011-01
15
15 20
IDK1111B0012-01 IDK1111B0016-01
8) Remove the bolt (16) securing rectifier / regulator 11) Remove the bolts (21) securing electric parts holder.
bracket.
21
16 21
IDK1111B0017-01
IDK1111B0013-01
Charging System: 1K-7
12) Remove the bolt (22) securing harness GND lead 16) Disconnect the lead wire connector (27) at high
wire. pressure fuel pump.
Remove harness clamp (28) from harness clamp
bracket by releasing clamps’ lock.
22
27
28
IDK1111B0018-01
23
IDK1111B0019-01
29
24
IDK1111B0020-02
19) Remove the six bolts (32) securing stator base (33).
33
26
26
IDK1111B0021-01
32
IDK1111B0025-01
1K-8 Charging System:
20) Remove the stator base (with battery charge coil / Installation
CKP sensor, electric parts holder and main harness). Installation is reverse order of removal with special
attention to the following steps.
IDK1111B0026-01
35
IDK1111B0031-01
34 • Install battery charge coil (1), then tighten coil
mounting screws securely.
• Install CKP sensor (2), then tighten sensor mounting
screws securely.
IDK1111B0027-01
36 2
IDK1111B0032-01
Stator base
• Install two dowel pins (1) in position.
37 38
IDK1111B0029-01
1
1
IDK1111B0033-01
IDK1111B0030-01
Charging System: 1K-9
• Install stator base, then tighten stator base mounting • Tighten the anode cover bolt (4) securely.
bolts securely.
Tightening torque
Stator base bolt [8 mm] (a): 23 N·m (2.3 kgf-m,
16.5 lbf-ft)
Stator base bolt [6 mm] (b): 10 N·m (1.0 kgf-m, 7.2
lbf-ft)
(b)
4
IDK1111B0037-01
(a)
IDK1111B0034-01
Wiring
• Install the positive battery cable (1) and positive cable
(2) to starter motor, then tighten nut securely.
Connect the lead wire (3) to “S” terminal of starter 5
magnetic switch.
IDK1111B0038-01
2 • Install the electric parts holder (6), then tighten it with
bolts.
Tighten the harness GND lead wire with bolt.
1
3
IDK1111B0035-01
IDK1111B0039-01
IDK1111B0036-01
IDK1111B0040-01
1K-10 Charging System:
Removal
1) Remove flywheel.
Refer to “Flywheel Removal and Installation” (Page
1K-4).
IDK1111B0041-01 2) Disconnect the caution lamp lead wire connector (1)
and the engine stop switch lead wire connector (2).
Flywheel
• Install flywheel and tighten flywheel nut to specified
torque.
Refer to “Flywheel Removal and Installation” (Page
1K-4).
2
Special tool
(A): 09930–39520 (Flywheel holder)
Tightening torque 1
Flywheel nut (a): 90 N·m (9.0 kgf-m, 65 lbf-ft)
IDK1111B0057-01
(A)
IDK1111B0056-01
6 4
IDK1111B0059-02
Charging System: 1K-11
5) Remove the bolt (7) securing anode cover. 8) Disconnect the neutral switch lead wire connector
Disconnect the CMP sensor lead wire connector (8) (10).
at sensor. Disconnect the cylinder temp. sensor lead wire
connector (11).
Disconnect the power source / CKP sensor lead wire
connector (12).
10 11
8
12
IDK1111B0060-01
IDK1111B0063-01
9
13
IDK1111B0061-01
10
IDK1111B0062-01 14
IDK1111B0065-01
15
IDK1111B0066-01
1K-12 Charging System:
12) Disconnect the ignition coil lead wire connector (16). 16) Remove the stator base (with ECM power source
Loosen screw and disconnect lead wire from oil coil / battery charge coil / CKP sensor and main
pressure switch (17). harness).
17) Remove the three screws (24) securing the ECM
power source coil / battery charge coil (25).
17
25
24
16
IDK1111B0067-01
27
19
18
26
IDK1111B0068-01
IDK1111B0072-01
20
21
IDK1111B0069-01
15) Remove the four bolts (22) securing stator base (23).
IDK1111B0073-01
22
23
IDK1111B0070-01
Charging System: 1K-13
IDK1111B0076-01
(a)
IDK1111B0073-01
IDK1111B0077-01
Wiring
• Connect the lead wire connectors to each sensor and
actuator.
IDK1111B0074-01 • Tighten the anode cover bolt securely.
• Install CKP sensor (2), then tighten sensor mounting
screws securely.
IDK1111B0078-01
IDK1111B0075-01
1K-14 Charging System:
IDK1111B0079-01 IDK1111B0083-01
IDK1111B0080-01 (a)
• Install the electric parts holder (1), then tighten it with
bolts (2).
Tighten the harness GND lead wire with bolt (3). (A)
2 IDK1111B0056-01
IDK1111B0082-01
Charging System: 1K-15
IDK1111B0084-01
Installation
1) Install rectifier / regulator (1), then tighten bolts (2)
securely.
2) Connect lead wire connector to rectifier / regulator. 2
Check that lead wire routed properly.
IDK1111B0046-01
NOTE
The values given below are for a SUZUKI pocket tester.
As thyristors, diodes, etc. are used inside this rectifier / regulator, the resistance values will differ
when an ohmmeter other than SUZUKI pocket tester is used.
IDK1111B0003-02
Special tool
: 09900–25010 (Pocket tester)
Tester knob indication
Resistance (x 1 kΩ)
—
IDK1111B0004-02
Charging System: 1K-17
Battery Relay Inspection 4) Check continuity between terminal (5) and (6) each
CENDK1111B06011 time 12 V power supply is applied to terminal (7) and
Inspect the battery relay using the following procedures:
(8).
1) Disconnect lead wire connector from ECM (1), then Connect the positive (+) lead to terminal (8), and
remove ECM. negative (–) lead to terminal (7).
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.
5 6
8
2 12 V
CONT
7
IDK1111B0048-01
(A)
IDK1111B0005-01
IDK1111B0049-01 (A)
IDK1111B0006-01
Fuse Inspection
CENDK1111B06008
Inspect the fuse in the following procedures.
1) Remove the fuse from fuse case (1).
2) Inspect continuity between both terminal of fuse.
If no continuity is indicated, replace fuse.
Special tool
: 09930–99320 (Digital tester)
Tester knob indication
Continuity ( )
“B”
“A”
IDK1111B0050-01
CONT
IAJ3111B0029-01
Table of Contents 2- i
Section 2
Mid Unit
CONTENTS
Precautions
Mid Unit
Precautions
Precaution for Mid Unit
CENDK1112000001
Refer to “General Precautions” in Section 00 (Page 00-1).
Housing and Bracket: 2A-1
Precautions
Precaution for Housing and Bracket
CENDK1112100001
NOTE
When dismantling housing and bracket, inspect mountings and bolts for damage and wear. Replace if
necessary.
Service Instructions
Lower Side Cover Components
CENDK1112106001
10
21
12
4
11
16
5
14
17
1
15
6 19 18
13
3 (a)
7
8 (b)
20
IDK111210024-06
1. Lower side cover STBD 7. Cushion 13. Cable grommet 19. Cushion
2. Lower side cover PORT 8. Screw 14. Cushion 20. Revet
3. Screw 9. Hook 15. Holder 21. Clip
4. Side cover rubber 10. Fastener 16. Screw : 5 Nm (0.5 kgf-m, 3.6 lbf-ft)
5. Side cover seal 11. Pin 17. Upper mount seal STBD : 5 Nm (0.5 kgf-m, 3.6 lbf-ft)
6. Front panel 12. Washer 18. Upper mount seal PORT : Apply SUZUKI Silicone seal
2A-2 Housing and Bracket:
“A”
IDK111210025-01
2) Remove the snap pin (2), washer (3), pin (4) and
fastener (5).
2 5 IDK111210029-01
6 1
2
IDK111210027-01
IDK111210030-01
8
9
IDK111210028-01
Housing and Bracket: 2A-3
3) Loosen the bolt (3) securing shift lever (4). 5) Loosen the cable clamp (11) and remove the battery
Remove the bolt (3), shift lever (4), washer (5), cable (12) from handle bracket.
washer (6), wave washers (7) and spacer (8).
11
12
3
IDK111210031-02
8
4
13 13
3 5 6 7
IDK111210023-01
9 15
16
10
IDK111210018-02
14 14
IDK111210032-01
2A-4 Housing and Bracket:
1
1
3
IDK111210033-03
NOTE (a)
Before installing tiller handle cover, check IDK111210035-01
that lead wire and cable routing properly.
Throttle cables
• Tighten handle cover bolts to the specified torque. • Install the throttle cables (1) to throttle drum and cable
Tightening torque bracket (2), then tighten nuts (3) securely.
Tiller handle bolt (a): 23 N·m (2.3 kgf-m, 16.5 lbf- • Adjust of throttle control cable.
ft) Refer to “Throttle Control Cable Installation and
Adjustment” (Page 2A-5).
4
5
2
3
1
(a)
IDK111210034-02
3
IDK111210020-02
“A”
1 “B”
5 “C”
2
5
4 6
IDK111210021-03
NOTE
If the throttle valve does not operate smoothly or open/close completely, check for the throttle cable
routing or inner cable tension.
Steering Friction Adjuster Disassembly and 2) Remove the two bolts (1) securing handle bracket.
Assembly
CENDK1112106005
Disassembly 1
Removal
1) Remove both lower side covers.
Refer to “Lower Side Cover Removal and
Installation” (Page 2A-2).
IDK111210036-01
2A-6 Housing and Bracket:
2 2
3 3 1
IDK111210040-01
IDK111210037-01
2
6
4 5
7
IDK111210038-01
6 9
10
IDK111210039-01
11
12
IDK111210003-02
Assembly 4) Install the steering adjuster lever (8), washer (9) and
Assemble the steering friction adjuster set in the washer (10).
following sequence:
NOTE
Reassembly When install the washer (9) and (10), put
1) Thread the shaft (1) to the adjuster base plate (2) as rough face of each washer together.
shown in the figure.
10
IDK111210044-01
IDK111210041-01
2) Install the friction washer (3), spacer (4) and friction 5) Place the steering adjuster plate (11) between the
washer (5). friction washer (3) and (5).
5
11
3
IDK111210045-02
IDK111210042-01
3) Install the upper plate (6) and washer (7). 6) Install the friction adjuster nut (12).
Move the steering adjuster lever to fully left position.
Tighten the friction adjuster nut (12) to specified
torque.
Tightening torque
Steering friction adjuster nut (a): 9 N·m (0.9 kgf-
7 m, 6.5 lbf-ft)
IDK111210043-01
12 (a)
IDK111210046-01
2A-8 Housing and Bracket:
Installation
1) Place the steering friction adjuster assembly into
position.
2) Apply Thread Lock 1342 to the threads of adjuster
mounting bolts before threading it.
3) Temporarily tighten all mounting bolts.
4) Tighten the bolts (1) to specified torque.
Tightening torque
Bolt (a): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)
5) Move the steering adjuster lever to fully left position.
Tighten the bolt (2) and, next, tighten bolt (3) to
specified torque.
Tightening torque
Bolt (b): 10 N·m (1.0 kgf-m, 7.2 lbf-ft)
1 (a)
1 (a)
IDK111210047-01
2 (b) 3 (b)
IDK111210048-01
14
21
13
17 18
16 (b)
19
15
8
9
10
11
12
2
3
4
6
7 (a)
IDK111210049-01
Tiller Handle Disassembly and Assembly 4) Remove the handle rod (8) and throttle cable
CENDK1112106007 assembly.
Disassembly
Remove the throttle cables (9) from throttle rod.
1) Remove the screw (1) and throttle grip (2).
1 9
2
IDK111210053-01
IDK111210050-01
2) Remove the screw (3), throttle adjuster knob (4) and Assembly
lower plate (5). Assembly is in the reverse order of disassembly with
special attention to the following steps.
Reassemble the tiller handle, refer to “Tiller Handle
Components” (Page 2A-9).
1) Install the throttle cables (1) to throttle rod.
3
4
IDK111210051-01
3) Remove the spring (6) and bush (7) from handle rod.
1
IDK111210054-01
IDK111210052-01
IDK111210055-01
Housing and Bracket: 2A-11
3
4
IDK111210056-01
6
IDK111210058-01
8 (a)
IDK111210059-01
2A-12 Housing and Bracket:
4
3
7
8 5 13
7 14
11
9 8
12 (b)
10 (a)
IDK111210060-02
1. Gasket 6. Upper mount bolt 11. Washer : 35 Nm (3.5 kgf-m, 25.0 lbf-ft)
2. Engine holder 7. Upper mount 12. Upper mount nut : Apply SUZUKI thread lock 1342.
3. Dowel pin 8. Mount cover 13. Clip
4. Driveshaft upper oil seal 9. Upper side mount 14. Oil hose
5. Thrust stopper 10. Bolt : 23 Nm (2.3 kgf-m, 16.5 lbf-ft)
Housing and Bracket: 2A-13
8
7
9
6
5 (a)
16
12
11
15 (b)
17
11
14
10 18
14
13
IDK111210061-01
1. Gasket 7. Bolt 13. Lower mount cover PORT : 13 Nm (1.3 kgf-m, 9.5 lbf-ft)
2. Exhaust pipe 8. Water plug 14. Pin : 23 Nm (2.3 kgf-m, 16.5 lbf-ft)
3. Dowel pin 9. Gasket 15. Lower mount cover bolt : Apply SUZUKI thread lock 1342.
4. Driveshaft housing 10. Lower thrust mount 16. Grommet
5. Oil drain plug 11. Lower side mount 17. Water tube
6. Gasket 12. Lower mount cover STBD 18. Water tube guide
2A-14 Housing and Bracket:
Engine Holder / Driveshaft Housing / Mounts 6) Remove the PORT lower mount cover (6), lower side
Disassembly mount (7) and pilot shaft washer (8).
CENDK1112106009
1) Remove the power unit.
Refer to “Power Unit Removal and Installation” in
8
Section 1D (Page 1D-8).
2) Remove the lower unit.
Refer to “Lower Unit Removal and Installation” in
Section 3A (Page 3A-5).
3) Remove the side cover seal (1).
6
7
IDK111210006-01
IDK111210062-01 9
4) Remove the two bolts (2) securing PORT/ STBD
lower mount covers.
10
IDK111210063-01
IDK111210004-01
IDK111210064-01
5 9) Remove STBD/PORT upper mount nuts (11) and
washers (12).
4 3
IDK111210005-01
12
11
IDK111210065-01
Housing and Bracket: 2A-15
10) Remove the upper mount bolts (13), upper mount 14) Remove the water tube guide (19), water tube (20)
cover (10), upper mount (14) and thrust stopper (15). and water tube grommet (21).
21
10
14
13 19
15
IDK111210066-01
20
IDK111210012-01
11) Remove the upper side mount (16).
IDK111210008-02
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
12) Remove the six bolts and the engine holder (17)
from the driveshaft housing. • Install the water tube (2) and water tube guide (3).
17
1
3
2
IDK111210067-01
IAJ311210006-02
13) Loosen the clip securing oil hose (18), then remove
the oil hose from engine holder. • Install the oil hose (4), then secure it with clip (5).
18
IDK111210069-01
IDK111210068-01
2A-16 Housing and Bracket:
• Install two dowel pins (6) and gasket (7) to driveshaft • Assemble these items in the following sequence:
housing. Place the upper mount (2), upper mount cover (3) and
thrust stopper (4) on upper mount bolts (5).
NOTICE
Previously used gasket may leak oil and/or
cooling water, resulting in engine damage.
7
3
6 4 2
IDK111210073-01
IDK111210070-01
IDK111210071-01
Upper Mount
• Install the upper side mount (1).
6 7 (a)
1
IDK111210075-01
IDK111210072-01
Housing and Bracket: 2A-17
Engine Holder and Driveshaft Housing • Install the pilot shaft washer (5), then place PORT
• Install the engine holder and driveshaft housing. lower mount cover (with lower mount) to driveshaft
housing and steering shaft.
• Place the mount cover (1) into position, then tighten
mount cover bolts (2), pre-coated with thread lock, to NOTE
specified torque.
When attaching the lower mount cover to
Tightening torque steering shaft, ensure that the retaining pin
Upper mount cover bolt (a): 23 N·m (2.3 kgf-m, (3) properly fits into the hole “A” of steering
16.5 lbf-ft) shaft.
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
2 (a)
5
“A”
1
IAJ311210091-02
IDK111210076-01
IAJ311210092-01
• Install the lower side mount (6), and pin (7) to STBD
3 lower mount cover (8).
1 4
8
IAJ311210090-03
7
6
IAJ311210093-01
2A-18 Housing and Bracket:
• Install STBD lower mount cover (with lower mount) to Engine Holder / Driveshaft Housing / Mounts
driveshaft housing and steering shaft. Related Component Inspection
CENDK1112106011
NOTE Refer to “Engine Holder / Driveshaft Housing / Mounts
When attaching the lower mount cover to Disassembly” (Page 2A-14) and “Engine Holder /
steering shaft, ensure that the retaining pin Driveshaft Housing / Mounts Assembly” (Page 2A-15).
(7) properly fits into the hole “A” of steering NOTE
shaft.
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.
“A”
• Check water passage. If clogged or obstructed, clean
water passage.
IAJ311210094-02
Mount Cover
• Inspect the mount cover. Replace the mount cover if
cracked, damaged or other abnormal conditions are
found.
(a)
IAJ311210095-01
IDK111210078-01
Housing and Bracket: 2A-19
IDK111210079-01
Mount
• Check upper, lower and thrust mounts. IDK111210081-01
If excessive wear, corrosion or other damage is found, 3) Apply water resistant grease to outer circumference
replace mount. of oil seal.
• Check mount bolts. 4) Drive the oil seal into the engine holder.
If cracks, corrosion or other damage is found, replace
NOTE
bolt.
Install oil seal with lip (spring side) facing
downward (oil pan side).
IDK111210080-01
IAJ311210100-01
2A-20 Housing and Bracket:
11
12
13
4 (a)
1 5
6
2
5
14
15
8
16
17
10
IDK111210013-03
1. Clamp bracket STBD 6. Release lever 11. Tilt pin 16. Washer
2. Clamp bracket PORT 7. Clamp handle 12. Spring 17. Nut
3. Clamp bracket shaft 8. Pin 13. Stopper : 43 Nm (4.3 kgf-m, 31.0 lbf-ft)
4. Nut 9. Clamp screw 14. Bolt : Apply SUZUKI water resistance grease.
5. Bush 10. Clamp plate 15. Spacer : Apply SUZUKI thread lock 1342.
Housing and Bracket: 2A-21
37 (a)
36
36
35
34
33
30
32
2
28
31
30 1
29
28
3
27
5
12
8
17 9
10
14 11
13
26
16 12
18 13
14
20
15
19
4
23
6
22 21
7
25
24
IDK111210014-03
Clamp / Swivel / Steering Brackets Disassembly 5) Lift steering bracket (9) upward to remove from
CENDK1112106014 swivel bracket.
1) Remove engine holder / driveshaft housing. Remove the washer (10), upper bush (11) from
Refer to “Engine Holder / Driveshaft Housing / swivel bracket.
Mounts Disassembly” (Page 2A-14).
2) Remove the two bolts (1) and handle bracket (2).
9
2
10
11
1
IAJ311210106-01
13
3 12
4 IAJ311210107-01
14
IAJ311210108-01
15
IAJ311210110-01
Housing and Bracket: 2A-23
9) Remove the tilt lock pin (16). 13) Remove two springs (28) from reverse lock arm (29)
Remove the nut (17), bolt (18) and spacer (19). and pin (30).
29 28 30
16
19 19
16 18 28
17
IAJ311210111-01 IDK111210087-01
10) Remove the PORT clamp bracket (20). 14) Remove the release arm pin (30) and release link
(31).
20
30
31
IDK111210009-02
clamp bracket and bracket shaft (22) from swivel 15) Remove the cotter pin (32), washer (33), pin (34)
bracket (23). Remove bushings (24) from each side and reverse lock arm link (35).
of swivel bracket. Remove the cotter pin (36), pin (37) and reverse lock
arm (38).
23 24
21
35
22
33
24
34
38
37 32
36
IDK111210086-01
26
27
25
26
IAJ311210007-02
2A-24 Housing and Bracket:
Clamp / Swivel / Steering Brackets Assembly Clamp Bracket and Swivel Bracket
CENDK1112106015
Assembly is reverse order of disassembly with special NOTE
attention to the following steps.
Before installing clamp bracket to swivel
bracket, apply grease to clamp bracket shaft
Shallow Drive Arm
and bushings.
• Install shallow drive arm (1).
• Tighten the shallow drive arm bolts (2), pre-coated : Grease 99000–25350 (SUZUKI Water Resistant
with thread lock, to specified torque. Grease EP2 (250 g))
Tightening torque 1) Connect the release link (1) to release lever (2).
Shallow drive arm bolt (a): 25 N·m (2.5 kgf-m,
18.0 lbf-ft) 2
1
: Thread lock cement 99000–32050 (SUZUKI
Thread Lock 1342 (50 g))
2 (a)
1 IDK111210091-01
IAJ311210116-01
3
• Install the arm spring (3) as shown. 4
3
3
IDK111210092-01
7 4
5
8
2
IDK111210093-01
Housing and Bracket: 2A-25
4) Install PORT clamp bracket (9). 2) Install the upper bushing (2) and washer (3) to swivel
bracket.
NOTE
• The bushing (2), (4) outside face is tapered.
Install the bushing into the swivel bracket
with the smaller diameter side being
9 inserted first.
• Be certain that steering adjuster (1) is
placed between upper bushing (2) and
swivel bracket casing.
IDK111210094-01
IAJ311210127-01
NOTE
10 (a) Install bracket seal (5) with oil seal lip (spring
side) facing downward
IDK111210010-03
Steering Bracket
1) Install the steering adjuster plate (1) to swivel
bracket.
: Grease 99000–25350 (SUZUKI Water
Resistant Grease EP2 (250 g))
NOTE
Apply grease to bushings, seal and pilot 4
shaft portion of steering bracket. 5
IAJ311210128-01
IDK111210095-01
2A-26 Housing and Bracket:
IDK111210096-01
IDK111210099-01
3 (a)
IDK111210097-01
Housing and Bracket: 2A-27
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. IDK111210101-01
Bracket
Check clamp brackets, steering bracket and swivel
bracket.
If cracks or other damage is found, replace bracket (s).
IDK111210100-01
Oil Seal
Check swivel bracket seal. If excessive wear or other
damage is found, replace seal.
IDK111210102-01
IAJ311210134-01
2A-28 Housing and Bracket:
Table of Contents 3- i
Section 3
Lower Unit
CONTENTS
Precautions
Lower Unit
Precautions
General Precautions
CENDK1113000001
Refer to “General Precautions” in Section 00 (Page 00-1).
! WARNING
Failure to take proper precautions when removing or installing the lower unit can result in severe
personal injury.
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
Service Instructions
Lower Unit Components
CENDK1113106001
24 (c)
25
1 29
2
3
26
4
8
4
6
9 27
5
7
30
15
31
10 14
11 32
13
17
16
33
21 (a)
22 12
34
23 (b)
18 35
19
20
23 (b)
28
21 (a)
22
IAJ311310002-05
10
11
1
12
11 37
36 (b)
35
34
33 31 (a)
2 32
3
4 30
5 31 (a)
6 29
27
7
28
26
25
20 24
23
22
19
21
14 18
15 17
16
13
IDK111310001-02
Removal
1) Shift to “Neutral” position. 5
2) Remove cotter pin (1) from propeller nut and remove 4
1
propeller nut (2).
3) Remove washer (3), propeller (4) and stopper (5)
from the propeller shaft.
IDK111310003-01
(a)
I9J011310001-01
I9J011310003-04
4
IDK111310002-01
Right Hand Rotation Unit: 3A-5
2 1
1
IAJ311310013-01
4) Slide the lower unit (2) into place, making sure that
the top of the driveshaft engages properly with the
crankshaft and that water tube locates in the water
IAJ311310011-01 pump case outlet.
3) Remove four bolts (3) and separate gearcase (4) Apply SUZUKI SILICONE SEAL to the retaining
from driveshaft housing. bolts (3) and tighten them to specified torque.
: Sealant 93691–80030 (SUZUKI Silicone
Seal (100 g))
3 Tightening torque
Gearcase bolt (a): 17 N·m (1.7 kgf-m, 12.3 lbf-ft)
3 (a)
4
IAJ311310012-01
IAJ311310014-02
3A-6 Right Hand Rotation Unit:
5) Connect the clutch rod and the shift rod using the e) With the clutch rod connector (4) securely held,
clutch rod connector in the following procedure: tighten the lower nut (6) firmly against the
connector.
NOTE
f) Shift the shift lever from Neutral to Forward and
The clutch rod connector is not a turnbuckle Reverse to check that the gear starts
but just a long nut with right-hand thread. engagement of both gears are at an equal angle
from Neutral.
a) Screw the clutch rod connector (4) onto the
clutch rod (5) all the way to the end of its thread.
Water Pump Removal and Installation
b) Screw the lower nut (6) onto the shift rod (7) all CENDK1113106005
the way to the end of its thread. Removal
c) Locate the shift cam at Neutral position by 1) Remove the lower unit. Refer to “Lower Unit
moving shift rod (7) up or down and then hold it Removal and Installation” (Page 3A-5).
at the position. 2) Loosen four nuts (1), then remove water pump case
d) While holding the clutch lever (8), shift lever (9) (2).
and shift cam at neutral position, screw the
clutch rod connector (4) onto the shift rod (7)
until the connector contacts the lower nut (6).
1
5 5
2
4
4
6 6
IAJ311310017-01
7 7 3) Remove impeller (3), impeller key (4), pump under
plate (5) and dowel pins (6).
IAJ311310008-01
Keep impeller key (4) for reuse and discard the plate
gasket.
3
9
6
4
8
5
IDK111310007-01 6
IAJ311310018-01
Right Hand Rotation Unit: 3A-7
NOTE 4) Install inner sleeve (7) into the pump case, ensuring
To facilitate the removal of inner sleeve from that projection of inner sleeve and groove of pump
pump case, warm up the entire case using a case are aligned.
heater like hair dryer. : Sealant 99000–31140 (SUZUKI Bond
1207B (100 g))
4) Remove inner sleeve (7) from pump case.
IAJ311310021-02
IAJ311310019-01
NOTE
Installation Before installing water pump case assembly,
1) Place the dowel pins (1), under panel gasket (2) and apply water resistant grease lightly on pump
under panel (3) into position. case inner sleeve and under panel for initial
2) Install the pump case gasket (4). lubrication.
3) Insert the key (5) in the driveshaft and slide the
: Grease 99000–25350 (SUZUKI Water
impeller (6) onto driveshaft, ensuring that key and
Resistant Grease EP2 (250 g))
keyway is aligned.
6
1
4
5
2
1
3
IAJ311310022-01
IAJ311310020-01
5) Install the pump case assembly (8) while rotating
NOTE driveshaft clockwise to flex the impeller vanes in the
correct direction.
• Before installing pump inner sleeve, apply
Securely tighten the four pump case nuts (9) to the
SUZUKI Bond 1207B lightly between inner
specified torque.
sleeve and pump case mating surfaces.
• Do not apply bond to inner sleeve top Tightening torque
surfaces. Water pump case nut (a): 6 N·m (0.6 kgf-m, 4.3
lbf-ft)
9 (a)
IAJ311310023-01
3A-8 Right Hand Rotation Unit:
6) Install the Lower Unit. Refer to “Lower Unit Removal 4) Place a drain pan under oil drain plug. Remove oil
and Installation” (Page 3A-5). drain plug (1) first then oil level plug (2) and allow
gear oil to drain.
Water Pump and Related Items Inspection Inspect oil for water, contaminates or metal.
CENDK1113106006
Inspect the following parts.
• Inspect impeller. Replace if vanes are cut, torn, worn 2
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,
1
corroded or other abnormal conditions are noted.
IAJ311310026-01
IAJ311310024-01
IAJ311310027-01
IAJ311310025-01
(A)
Lower Unit Disassembly
CENDK1113106007
1) Remove the lower unit. Refer to “Lower Unit
Removal and Installation” (Page 3A-5).
2) Remove the propeller. Refer to “Propeller Removal (B)
4
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 IAJ311310028-01
3A-6).
Right Hand Rotation Unit: 3A-9
7) Remove the nut (5), two bolts and shift rod guide 11) Push the dust seal (11) and shift rod guide (10) out
stopper (6). from driveshaft oil seal housing.
10
11
IAJ311310029-01 IAJ311310033-01
8) Lift out driveshaft (7), driveshaft oil seal housing (8) 12) Separate the shift cam (12) from the shift rod (13) by
and shift rod assembly (9). driving out the spring pin (14).
7
9
8 13
14 12
IAJ311310030-01 IAJ311310034-01
9) Remove driveshaft (7) from driveshaft oil seal 13) Remove the pinion gear (15), thrust washer (16),
housing (8). thrust bearing (17), thrust washer (18) and pinion
gear back up shim (19).
16
17
18
19
8
7 15
IAJ311310031-01
10) Slide the shift rod (9) out of the shift rod guide (10). IAJ311310035-01
10
9
IAJ311310032-01
3A-10 Right Hand Rotation Unit:
14) Remove the forward gear (20), thrust washer (21) b) Pull the push rod (29) and push pin (30) out of
and forward gear back-up shim (22). the propeller shaft.
c) Remove the spring (31) from clutch dog shifter
(32).
20
30
21
29
22
31
32
IDK111310008-01
15) Remove the exhaust seal core (23) and seal rubber
(24) (if necessary.) IAJ311310039-01
23
IAJ311310037-01
(A)
25
34
27 26
28
32
IDK111310009-01
IAJ311310041-01
Right Hand Rotation Unit: 3A-11
Pinion Bearing Removal and Installation 2) Remove the water pump stud bolts (1).
CENDK1113106008
NOTICE
Removing the bearing can cause damage to 1
needle rollers and outer race. If the removed
bearing is re-used, problem will occur in the
lower unit.
(C) (D)
(H)
(A)
(E) IAJ311310044-01
B B
(F) (G) C
IDK111310004-01 D
E
4
Removal
1) Disassemble the lower unit. 3
Refer to “Lower Unit Disassembly” (Page 3A-8).
F
G
IDK111310005-02
3A-12 Right Hand Rotation Unit:
(D)
IDK111310010-01
F
H
1
A
E IAJ311310048-01
D
IDK111310006-03
Right Hand Rotation Unit: 3A-13
IDK111310011-01
IAJ311310051-01
IAJ311310050-01
IAJ311310052-01
“a”
I9J011310062-01
3A-14 Right Hand Rotation Unit:
Propeller Shaft Bearing Housing Shift Rod and Shift Cam Components
• Inspect housing. Replace if cracked, damaged or • Inspect the “stepped” surfaces of shift cam.
other abnormal conditions are noted. Replace if worn, damaged or other abnormal
• Inspect reverse gear bearing and propeller shaft conditions are noted.
bushing. Replace bushing if pitted, rough or other • Inspect shift rod guide. Replace if cracked, damaged
abnormal conditions are noted. or other abnormal conditions are noted.
• Check condition of oil seal and O-ring. Replace oil • Inspect O-ring. Replace if nicked, cut, torn, swollen or
seal and O-ring if nicked, cut, worn or other abnormal other abnormal conditions are noted.
conditions are noted.
IAJ311310055-01
IAJ311310053-01
IAJ311310056-01
IAJ311310054-01
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.
IAJ311310057-01
Right Hand Rotation Unit: 3A-15
Special tool
(A): 09913–50121 (Oil seal remover)
IAJ311310058-01
(A)
IAJ311310060-02
IAJ311310010-02
Forward Gear
Place the forward gear back-up shim (1) in position, then
install forward gear (2).
IAJ311310061-01
Direction of
water pump case
IDK111310015-01
Pinion Gear • Install the pin (4) and washer (5) to shift rod.
1) Apply gear oil to the thrust bearing (1) and pinion
gear (2).
2) Assemble the back-up shim (3), thrust washer (I.D.
20 mm) (4), thrust bearing (1), thrust washer (I.D. 21 5
mm) (5) to the pinion gear (2), then place the pinion
gear / washer assembly in gearcase. 4
1
IAJ311310066-01
4
• Install the shift rod / cam assembly to gearcase.
3
NOTE
2 Be sure the stepped section “A” of shift cam
faces towards propeller shaft.
IAJ311310063-02
Driveshaft
Lower the driveshaft assembly (1) down into the
gearcase until the bottom of shaft passes to center of “A”
pinion gear.
IAJ311310067-01
2 2
3
1 1
IAJ311310068-01
IAJ311310065-01
3A-18 Right Hand Rotation Unit:
• Apply water resistant grease to the driveshaft oil seal. • Install the dust seal (5).
: Grease 99000–25350 (SUZUKI Water • Install the shift rod guide stopper (6), then secure it
Resistant Grease EP2 (250 g)) with the bolts (7).
7 6
5
IAJ311310072-01
IAJ311310069-01
IAJ311310070-01
2 4
“F”
IAJ311310071-02
2
1
IAJ311310074-01
Right Hand Rotation Unit: 3A-19
• Insert the return spring (3) into propeller shaft. Propeller Shaft / Bearing Housing
Depress the return spring and then slide the dog pin • Place the forward thrust washer (1) and reverse thrust
(4) through both dog and propeller shaft as shown in washer (2) on the propeller shaft.
figure.
• 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)
IAJ311310075-01
2
5
3
3 4
IDK111310013-01
7
8
5
IDK111310014-01
NOTE
IAJ311310077-01
Before installing propeller shaft / bearing
housing assembly, bring shift cam to the
forward position by moving shift rod up or
down.
3A-20 Right Hand Rotation Unit:
• Install the propeller shaft and housing assembly in the Leakage Check
gearcase with the arrow mark “A” of housing toward Check for leakage of oil seal and O-ring when applying
upside. specified pressure inside of the gearcase.
• When the housing is fully seated, tighten both 1) Temporarily fasten the driveshaft oil seal housing to
retaining bolts to the specified torque. gearcase with water pump case and nuts.
Install the water pump case, then tighten the pump
Tightening torque
case nuts securely.
Bearing housing bolt (a): 8 N·m (0.8 kgf-m, 5.8
lbf-ft) 2) Install the test tool into the oil level hole.
3) Connect the air pump to the tester.
(a)
Special tool
(A): 09950–69512 (Gearcase oil leakage
tester)
“A” (B): 09950–69710 (Attachment)
(C): 09952–99320 (Hand air pump)
IAJ311310080-01
(A)
(C)
IAJ311310084-01
IAJ311310081-02
4) Rotate driveshaft and propeller shaft clockwise
Checking Propeller Shaft Thrust Play several times and then apply specified pressure for
Check propeller shaft thrust play. the test.
Refer to “Lower Unit Gears - Shimming and Adjustment”
(Page 3A-21). NOTICE
Failure to correctly apply the test pressure
will result in oil seal damage.
1
5
2 3 4
IAJ311310007-02
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-22 Right Hand Rotation Unit:
Forward Gear / Pinion Gear Back-Up Shim • If backlash is smaller than specified, the forward gear
Adjustment back-up shim thickness must be decreased.
Follow the procedure below to adjust forward gear /
pinion gear.
Prior to adjustment
1) Correctly assemble driveshaft oil seal housing,
driveshaft, forward gear, pinion gear and related
components.
Do not install reverse gear at this time.
Refer to “Lower Unit Assembly” (Page 3A-16).
IAJ311310087-01
Initial checking
1) To assess tooth contact, apply a light coat of
IAJ311310085-01 Prussian Blue on both sides (drive side and coast
2) Temporarily fasten the driveshaft oil seal housing to side) of the forward gear surface.
gearcase with water pump case and nuts.
Install the water pump case, then tighten the pump 1 3
2
case nuts securely.
Do not install water pump impeller at this time.
4
ICJ311310006-01
IAJ311310088-01
Right Hand Rotation Unit: 3A-23
ICJ311310011-01
5) Carefully remove the propeller shaft and the housing to check the tooth contact pattern on forward gear.
The tooth contact pattern will appear similar as one of the following three figures.
B B B
A A A
D D D
E E E
ICJ311310007-02
“d” NOTICE
Setting the tooth contact in the top side toe
“C” “E” contact may cause damage and chipping on
“A”
“G” forward and pinion gears.
ICJ311310004-02 Do not set the tooth contact as such top side
A: Drive side G: Tooth bottom toe contact.
C: Heel “a”: Tooth width
D: Toe “b”: 0.5 – 1.0 mm
E: Tooth contact pattern “d”: Approx. 1/3 of tooth width
Example of incorrect contact
F: Tooth top
“b” “a”
“F”
Example [B]
“D” Incorrect bottom side toe contact.
Correction measures.
“c”
• Increase thickness of forward gear shim.
“d”
• Slightly decrease pinion gear shim thickness.
“E”
“B” “C” NOTICE
“G”
ICJ311310005-04
Setting the tooth contact in the bottom side
toe contact may cause chipping on pinion
B: Coast side G: Tooth bottom
gear.
C: Heel “a”: Tooth width
Do not set the tooth contact as such bottom
D: Toe “b”: 0.5 – 1.0 mm
E: Tooth contact pattern “c”: 0 – 2 mm
side toe contact.
F: Tooth top “d”: Approx. 1/3 of tooth width
“D”
“C”
ICJ311310009-02
Right Hand Rotation Unit: 3A-25
Reverse Gear Back-Up Shim Adjustment Checking propeller shaft thrust play
After adjusting the forward gear tooth contact pattern, After adjusting all gear positions, measure the propeller
follow the procedure below to adjust the reverse gear. shaft thrust play. If not within the following specification,
1) Correctly assemble and install reverse gear, a shim adjustment is required.
propeller shaft, propeller shaft bearing housing and
NOTE
related components.
Maintain the forward gear thrust washer at
standard thickness (2.0 mm) and use only the
propeller shaft reverse thrust washer to
adjust thrust play.
IAJ311310092-02
Section 4
Precautions
Wire / Hose Routing
Precautions
Precautions for Wire / Hose Routing
CENDK1114000001
Refer to “General Precautions” in Section 00 (Page 00-1).
Component Location
Electrical Component Location
CENDK1114003001
Refer to “Wiring Harness Routing Diagram” in Section 4A (Page 4A-3).
Wire / Hose Routing
DF15A/20A
Wiring Diagram
MAP W
R
SENSOR B
IAT SENSOR
B
Lg/B
THROTTLE Br/Y
R
SENSOR B
Gr/R
W/B
IAC VALVE
R
Wire Routing
Gr/R
O/B #1
FUEL INJECTOR
B
Gr/R
B/Br #2
B
Y/Bl
Gr/R CMP SENSOR
Gr/R
EMERGENCY STOP & ENGINE STOP SWITCH
B B
Emergency stop switch: Lock plate IN RUN Bl/R Bl/R
R P
W W COIL
B
Bl/Y
FUSE 20A OIL PRESSURE SWITCH
W Br/W
B Br/R
B/G B 14.7kPa (0.15kgf/cm2) or less
W W R/B R/B
ON
B B
CKP SENSOR
#1
B
B
CYLINDER TEMP
SENSOR B B #2
B Lg/W
IGNITION COIL
BATTERY NEUTRAL SWITCH
Br B
N ON Y/G Y/G
B
F.R OFF Gr/R
O/Y SDS
Y
Optional parts
Y/B TACHOMETER
SIGNAL
Schematic and Routing Diagram
WIRE COLOR
P
Y
B
R
B
O
W
B/Y
Y/B
Y/G
R/B
B/R
O/Y
O/B
W/B
Y/Bl
B/W
Bl/Y
Bl/R
Br/Y
Br/R
B/Br
Gr/R
Lg/B
Br/W
Lg/W
B.......... Black B/Br......Black with Brown tracer Lg/B..... Light green with Black tracer
Br........ Brown B/R.......Black with Red tracer Lg/W.... Light green with White tracer
O......... Orange B/W...... Black with White tracer O/B...... Orange with Black tracer
P.......... Pink B/Y....... Black with Yellow tracer O/Y...... Orange with Yellow tracer
R.......... Red BI/R......Blue with Red tracer R/B.......Red with Black tracer ENGINE CONTROL
W......... White BI/Y...... Blue with Yellow tracer Y/B....... Yellow with Black tracer MODULE
Y.......... Yellow Br/R......Brown with Red tracer Y/Bl.......Yellow with Blue tracer
Br/W......Brown with White tracer Y/G...... Yellow with Green tracer
Br/Y......Brown with Yellow tracer W/B..... White with Black tracer
Gr/R..... Gray with Red tracer
Wire Routing:
IDK111410001-02
CENDK1114102001
4A-1
DF15AE/20AE
MAP W
R
B
4A-2 Wire Routing:
THROTTLE Br/Y
R
SENSOR B
Gr/R
W/B
IAC VALVE
R
Gr/R
O/B #1
R
B
STARTING FUEL INJECTOR
B
MOTOR Gr/R
#2
B
B/Br
R
M B
Y/Bl
Gr/R
Gr/R CMP SENSOR
R
BATTERY
B B
EMERGENCY STOP & ENGINE STOP SWITCH Bl/R Bl/R
Emergency stop switch: Lock plate IN RUN
Lock plate OUT STOP
Engine stop switch: Button pushed STOP B/W
B/Y
B/R FUEL PUMP
START SWITCH W/R R
RECTIFIER & Br Br
PUSH START
REGULATOR
MAGNETO
B Gr/R
Y Y P P
Y Y
CAUTION
Y Y
LAMP
W W
B
CKP SENSOR
Bl/Y
OIL PRESSURE SWITCH
BATTERY STARTER B/W B
14.7kPa (0.15kgf/cm2) or less
R/B R/B
RELAY RELAY ON
CKP SENSOR FUSE 10A
W W #1
B
B
O
FUSE 30A
CYLINDER TEMP R R
SENSOR B B #2
B Lg/W
IGNITION COIL
NEUTRAL SWITCH
R
R
R
R
W
Br
P/B
Y/G
Br B
N ON Y/G Y/G
B
F.R OFF Gr/R
O/Y SDS
Y
Y/B TACHOMETER
SIGNAL
WIRE COLOR
P
Y
B
R
B
O
W
W
P/B
B/Y
Y/B
B.......... Black B/Br......Black with Brown tracer Lg/W.... Light green with White tracer
Y/G
R/B
B/R
O/Y
O/B
W/B
Y/Bl
B/W
Bl/Y
Bl/R
Br/Y
B/Br
Gr/R
Lg/B
Lg/W
Br........ Brown B/R.......Black with Red tracer O/B...... Orange with Black tracer
O......... Orange B/W...... Black with White tracer O/Y...... Orange with Yellow tracer
P.......... Pink B/Y....... Black with Yellow tracer P/B...... Pink with Black tracer
R.......... Red BI/R......Blue with Red tracer R/B.......Red with Black tracer
ENGINE CONTROL
W......... White BI/Y...... Blue with Yellow tracer Y/B....... Yellow with Black tracer MODULE
Y.......... Yellow Br/Y......Brown with Yellow tracer Y/Bl.......Yellow with Blue tracer
Gr/R..... Gray with Red tracer Y/G...... Yellow with Green tracer
Lg/B..... Light green with Black tracer W/B..... White with Black tracer
IDK111410002-01
Wire Routing: 4A-3
2
3
1 4
5
15
10
14
13 12 8
11
10 9
IDK111410003-01
2 2
1
3
6
3
5
5
6
6
IDK111410004-03
1
2 15
14 7
14 9
8
10 3
11
12
13
11 13
17 (a)
16 6 18
18
16
17 (a)
6
15
IDK111410005-03
1. Flywheel 6. Battery cable (+) 11. Fuel injector connector 16. Harness lead wire (+)
: Position the cable in the location illustrated.
2. CKP sensor 7. IAC valve 12. High pressure fuel pump 17. Nut
3. IAT sensor 8. MAP sensor 13. Fuel injector 18. Starter motor magnetic switch
4. Battery cable (–) 9. Joint connector 14. Cable tie : 9 Nm (0.9 kgf-m, 6.5 lbf-ft)
5. Clamp 10. CMP sensor 15. Starter motor
21 20
19 1
4
5
18 4
16 13
12 3
10
9 6
11 8 7
15
17 14
IDK111410006-01
1. Oil pressure switch 7. Clamp 13. Neutral switch 19. Starter motor
: Cover the oil pressure switch with cap
2. Harness clamp 8. Ignition coil 14. Bracket 20. ECM
3. High pressure fuel pump 9. Harness clamp 15. Bolt 21. Fuse case
4. Spark plug cap 10. Clamp 16. Actuator
5. Clamp 11. Harness GND lead wire 17. Nut
: Clamp the high-tension cord seal and wiring harness
6. Clamp 12. Clamp 18. Rectifier / Regulator
Wire Routing: 4A-5
7
6
8
9
2 1
12
4
10 11
IDK111410007-01
1. Starter motor 4. Bolt 7. Caution lamp lead wire 10. Caution lamp lead wire connector
: Tighten rectifier GND lead wire with bolt.
2. CKP sensor 5. Battery cable (–) 8. Starter button lead wire 11. Stop switch lead wire connector
3. Rectifier / 6. IAT sensor 9. Stop switch lead wire 12. Starter button lead wire connector
Regulator
4
1
2 1
3
2
2
3
5
IDK111410008-01
5
2
3
4 (a) 1
IDK111410009-01
2
1
5 3
5 4
IDK111410010-01
3
1 2
8
4
5
12
11 6
10 9 7
IDK111410011-01
1. Cylinder temp. sensor 4. ECM power source coil and battery charge coil 7. MAP sensor 10. Cable tie
2. Clamp 5. CKP sensor 8. Main harness 11. Cable tie
: Fix the cylinder temp. sensor lead wire.
3. ECM 6. IAT sensor 9. Joint connector 12. CMP sensor
2 2
3
3 5
1
4 5
5
IDK111410012-01
1
11 4 2
6 5
7
8
3
9
8 10
IDK111410013-01
4
5
16 13
12 11 3
10 9
6
8 7
15
17 14
IDK111410014-02
2 3
6
5
IDK111410015-01
3 1
4
3
3
4 6
IDK111410016-01
2
3
4 (a)
1
IDK111410017-02
2
3
IDK111410018-01
Precautions
Precautions for Fuel / Water Hose Routing
CENDK1114200001
Refer to “General Precautions” in Section 00 (Page 00-1) and “Precautions on Fuel System Service” in Section 1G
(Page 1G-1).
4B-2 Fuel / Water Hose Routing:
18 3 7
18
18 11
17 8
18
17 9
10
4 17
1 2 13
18
18
6
12
18 5
18
15 18
15 14
16
15
IDK111420001-03
1. Fuel connector 10. Fuel hose (Low pressure fuel pump to fuel vapor separator)
2. Fuel hose (Connector to fuel filter) 11. Evaporation chamber
3. Fuel filter 12. High pressure fuel pump
4. Fuel vapor separator 13. Fuel hose (High pressure fuel pump to evaporation chamber)
5. Fuel hose (Fuel vapor separator to fuel cooler) 14. Fuel hose (Fuel cooler to high pressure fuel pump)
6. Fuel cooler 15. Fuel drain hose
: Insert the drain hose end into the steering adjuster plate as shown figure.
7. Evaporation hose 16. Steering adjuster plate
8. Fuel hose (Fuel vapor separator to evaporation chamber) 17. Clamp
9. Fuel hose (Fuel filter to low pressure fuel pump) 18. Clamp (Clip)
Fuel / Water Hose Routing: 4B-3
1
10
6
“A”
7
9
“B”
10
8
10 “A”
5 “B” 10
2
4
10 10
3 5
“A”
3 10
IDK111420002-02
1. Breather hose 7. Fuel hose (Low pressure fuel pump to fuel vapor separator)
2. Fuel hose (High pressure fuel pump to fuel delivery pipe) 8. Fuel hose (Fuel filter to low pressure fuel pump)
3. Fuel hose (Fuel cooler to high pressure fuel pump) 9. Clamp
4. Fuel cooler 10. Clamp (Clip)
5. High pressure fuel pump “A”: White marking
6. Fuel hose (High pressure fuel pump to evaporation chamber) “B”: Yellow marking
5 “A” “A” 6
IDK111420003-01
9 9
3
2
4
5
IDK111420004-01
1. Breather hose 4. Fuel hose (High pressure fuel pump to fuel delivery pipe) 7. Fuel hose (High pressure fuel pump to evaporation chamber)
2. Fuel injector 5. Fuel hose (Fuel cooler to high pressure fuel pump) 8. Clamp
3. Fuel delivery pipe 6. Fuel hose (High pressure fuel pump to fuel vapor separator) 9. Clamp (Clip)
Fuel / Water Hose Routing: 4B-5
1
2
3
IDK111420005-02
1. Water hose (Fuel cooler to housing) 3. Side cover seal 5. Fuel cooler
2. Clamp 4. Water hose (housing to fuel cooler)
Prepared by
June, 2012
Manual No. 99500-89L00-01E
Printed in Japan
312
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