Suzuki DF9, 9, DF15 Service Manual

Download

Page 1

For 2005 model

99500-94J01-01E

Page 2

FOREWORD

This manual contains an introductory description of the SUZUKI DF9.9/15 Outboard motors and procedures for inspection, service and overhaul of their main components. General knowledge information is not included.

Please read the GENERAL INFORMATION section to familiarize yourself with basic information concerning this motor. Read and refer to the other sections in this manual for information regarding proper inspection and service procedures.

This manual will help you better understand these outboard motors, assisting you in providing your customers with optimum and quick service.

GROUP INDEX

GENERAL INFORMATION

PERIODIC MAINTENANCE

IGNITION AND ELECTRICAL

FUEL SYSTEM

RECOIL STARTER

• This manual has been prepared using the latest information available at the time of publication. Differences may exist between the content of this manual and the actual outboard motor.

• Illustrations in this manual are used to show the basic principles of operation and work procedures and may not represent the actual outboard motor in exact detail.

• This manual is intended for use by technicians who already possess the basic knowledge and skills to service SUZUKI outboard motors. Persons without such knowledge and skills should not attempt to service SUZUKI outboard engines by relying on this manual only and should contact an authorized SUZUKI outboard motor dealer.



Apprentice mechanics or do-it-yourself mechanics that don’t have the proper tools and equipment may not be able to properly perform the services described in this manual. Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers.

POWER UNIT

MID UNIT

LOWER UNIT

WIRE/HOSE ROUTING

DF9.9/15 “K6” (’06) MODEL

DF9.9/15 “K7” (’07) MODEL

DF9.9T/TH “K8” (’08) MODEL

NOTE: This manual is compiled based on 2005 (K5) model.

SERVICE DEPARTMENT

Page 3

HOW TO USE THIS MANUAL

TO LOCATE WHAT YOU ARE LOOKING FOR:

1. The text of this manual is divided into sections.

2. The section titles are listed on the previous page in a GROUP INDEX. Select the section needed for reference.

3. Holding the manual as shown at the right will allow you to find the first page of the section easily.

4. The first page of each section contains a table of contents to easily locate the item and page you need.

COMPONENT PARTS AND IMPORTANT ITEM ILLUSTRATIONS

Under the name of each system or unit, an exploded view is provided with work instructions and other service information such as the tightening torque, lubrication and locking agent points.

Example:

80 N·m (8.0 kg-m, 58.0 lb-ft)

1. Nut

2. Washer

3. Flywheel

4. Key

5. Battery & condenser charge coil

6. Pulser coil

7. Screw

8. Screw

9. Stator base

10. Bolt

11. Bolt

12. Dowel pin

NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent.

Page 4

SYMBOL

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 SYMBOL DEFINITION

Torque control required. Data beside it indicates specified torque.

Apply the THREAD LOCK “1342”.

Apply the oil. Use the engine oil unless otherwise specified.

Apply the SUZUKI OUTBOARD MOTOR GEAR OIL.

Apply the SUZUKI SUPER GREASE “A”. Measure in resistance range.

Apply the SUZUKI WATER RESISTANT GREASE.

Apply the SUZUKI BOND “1207B”. Use peak voltmeter “Stevens CD-77”.

Apply the SUZUKI SILICONE SEAL. Use special tool.

Apply the THREAD LOCK SUPER “1333B”.

Measure in DC voltage range.

Measure in continuity test range.

Page 5

GENERAL INFORMATION 1-1

GENERAL INFORMATION

CONTENTS

WARNING/CAUTION/NOTE .........................................................................1- 2

GENERAL PRECAUTIONS ...........................................................................1- 2

IDENTIFICATION NUMBER LOCATION ......................................................1- 4

FUEL AND OIL ..............................................................................................1- 5

GASOLINE RECOMMENDATION .........................................................1- 5

ENGINE OIL ...........................................................................................1- 5

ENGINE BREAK-IN .......................................................................................1- 6

WARM-UP RECOMMENDATION ..........................................................1- 6

THROTTLE RECOMMENDATION .........................................................1- 6

PROPELLERS ...............................................................................................1- 7

SPECIFICATIONS .........................................................................................1- 8

SERVICE DATA .............................................................................................1-10

TIGHTENING TORQUE .................................................................................1-17

SPECIAL TOOLS ..........................................................................................1-19

MATERIALS REQUIRED ..............................................................................1-22

Page 6

1-2 GENERAL INFORMATION

WARNING/CAUTION/NOTE

Please read this manual and follow its instructions carefully. To emphasize special information, the symbol and the words WARNING, CAUTION and NOTE have special meanings. Pay special attention to the messages highlighted by these signal words.



Indicates a potential hazard that could result in death or injury.



Indicates a potential hazard that could result in motor damage.

NOTE: Indicates special information to make maintenance easier or instructions clearer.

Please note, however, that the warnings and cautions contained in this manual cannot possibly cover all potential hazards relating to the servicing, or lack of servicing, of the outboard motor. In addition to the WARNING and CAUTION stated, you must also use good judgement and observe basic mechanical safety principles.

GENERAL PRECAUTIONS



• Proper service and repair procedures are important for the safety of the service mechanic and the safety and reliability of the outboard motor.

• To avoid eye injury, always wear protective goggles when filing metals, working on a grinder, or doing other work, which could cause flying material particles.

• 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 and on a boat, ensure that the necessary safety equipment is on board. Such equipment includes: flotation aids for each person, fire extinguisher, distress signals, anchor, paddles, bilge pump, first-aid kit, emergency starter rope, etc.

• When working with toxic or flammable materials, make sure that the area you work in is wellventilated and that you follow all of the material manufacturer’s instructions.

• Never use gasoline as a cleaning solvent.

• To avoid getting burned, do not touch the engine, engine oil or exhaust system during or shortly after engine operation.

• Oil can be hazardous. Children and pets may be harmed from contact with oil. Keep new and used oil away from children and pets. To minimize your exposure to oil, wear a long sleeve shirt and moisture-proof gloves (such as dishwashing gloves) when changing oil. If oil contacts your skin, wash thoroughly with soap and water. Launder any clothing or rags if wet with oil. Recycle or properly dispose of used oil.

• After servicing fuel, oil/engine cooling system and 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.

Page 7

GENERAL INFORMATION 1-3



• If parts replacement is necessary, replace the parts with Suzuki Genuine Parts or their equivalent.

• When removing parts that are to be reused, keep them arranged in an orderly manner so that they may be reinstalled in the proper order and orientation.

• Be sure to use special tools when instructed.

• Make sure that all parts used in assembly are clean and also lubricated when specified.

• When use of a certain type of lubricant, bond or sealant is specified, be sure to use the specified type.

• When removing the battery, disconnect the negative cable first and then the positive cable. When reconnecting the battery, connect the positive cable first and then the negative cable.

• When performing service to electrical parts, if the service procedures do not require using battery power, disconnect the negative cable at the battery.

• Tighten cylinder head and case bolts and nuts, beginning with larger diameter and ending with smaller diameter. Always tighten from inside to outside diagonally to the specified tightening torque.

• Whenever you remove oil seals, gaskets, packing, O-rings, locking washers, locking nuts, cotter pins, circlips and certain other parts as specified, always replace them with new. Also, before installing these new parts, be sure to remove any left over material from the mating surfaces.

• Never reuse a circlip. When installing a new circlip, take care not to expand the end gap larger than required to slip the circlip over the shaft. After installing a circlip, always ensure that it is completely seated in its groove and securely fitted.

• Use a torque wrench to tighten fasteners to the torque values when specified. Remove grease or oil from screw/bolt threads unless a lubricant is specified.

• After assembly, check parts for tightness and operation.

• To protect the environment, do not unlawfully dispose of used motor oil, other fluids and batteries.

• To protect the Earth’s natural resources, properly dispose of used motor parts.

Page 8

1-4 GENERAL INFORMATION

1. Serial number plate

IDENTIFICATION NUMBER LOCATION

MODEL, PRE-FIX, SERIAL NUMBER

The MODEL, PRE-FIX and SERIAL NUMBER of motor are stamped on a plate attached to the clamp bracket.

Example

Model

THAI SUZUKI MOTOR CO.,LTD.

MADE IN THAILAND FABRIQUE AU THAILANDE

Pre-fix

ENGINE SERIAL NUMBER

A second engine serial number plate is pressed into a boss on the cylinder block.

Serial number

111

XXXXXX

1. Serial number plate

Page 9

FUEL AND OIL

GASOLINE RECOMMENDATION

Suzuki highly recommends that you use alcohol-free unleaded gasoline with a minimum pump octane rating of 87 (R/2+M/2 method) or 91 (Research method). However, blends of unleaded gasoline and alcohol with equivalent octane content may be used. Allowable maximum blend of a single additive (not combination):

5% Methanol, 10% Ethanol, 15% MTBE



If leaded gasoline is used, engine damage may result. Use only unleaded gasoline.

GENERAL INFORMATION 1-5

ENGINE OIL

Use only oils that are rated SE, SF, SG, SH or SJ under the API (American Petroleum Institute) classification system. The viscosity rating should be SAE 10W-40. If SAE 10W-40 motor oil is not available, select an alternative according to the chart at right.

Page 10

1-6 GENERAL INFORMATION

ENGINE BREAK-IN

The first 10 hours are critically important to ensure correct running of either a brand new motor or a motor that has been reconditioned or rebuilt. How the motor is operated during this time will have direct bearing on its life span and long-term durability.

Break-in period: 10 hours

WARM-UP RECOMMENDATION

Allow sufficient idling time (more than 5 minutes) for the engine to warm up after cold engine starting.

THROTTLE RECOMMENDATION

NOTE: Avoid maintaining a constant engine speed for an extended period at any time during the engine break-in by varying the throttle position occasionally.

1. FIRST 2 HOURS For first 15 minutes, operate the engine in-gear at idling speed. During the remaining 1 hour and 45 minutes, operate the engine in-gear at less than 1/2 (half) throttle (3 000 r/min).

NOTE: The throttle may be briefly opened beyond the recommended setting to plane the boat, but must be reduced to the recommended setting immediately after planing.

2. NEXT 1 HOUR Operate the engine in-gear at less than 3/4 (three-quarter) throttle (4 000 r/min).

3. LAST 7 HOURS Operate the engine in-gear at desired engine speed. However, do not operate continuously at full throttle for more than 5 minutes.

Page 11

PROPELLERS

An outboard motor is designed to develop its rated power within a specified engine speed range. The maximum rated power delivered by the DF9.9/15 models are shown below.

GENERAL INFORMATION 1-7

Recommended full throttle speed range

If the standard propeller fails to meet the above requirement, use another pitch propeller to hold the engine speed within the range specified above.

Propeller selection chart

Blade × Diam. (in) × Pitch (in)

3 × 9-1/4 × 7 (M701) 3 × 9-1/4 × 8 (M821) 3 × 9-1/4 × 9 (M901, M911) 3 × 9-1/4 × 10 (M1001, M1011) 3 × 9-1/4 × 11 (M1101)



Installing a propeller with pitch either too high or too low will cause incorrect maximum engine speed, which may result in severe damage to the motor.

DF9.9 4 900 – 5 500 r/min DF15 5 400 – 6 000 r/min

Page 12

1-8 GENERAL INFORMATION

*SPECIFICATIONS

: These specifications are subject to change without notice.

47.0

48.0

Data

44.0

(97.0)

45.0

(99.2)

48.0

(105.6)

49.0

(107.8)

Item Unit

PRE-FIX 00992F 01502F

DIMENSIONS & WEIGHT

Overall length (front to back) Overall width (side to side)

Overall height S mm (in) 1 093 (43.0)

L mm (in) 1 220 (48.0)

Weight

Transom height [Trim position: 3]

PERFORMANCE

Maximum output kW (PS) 7.3 (9.9) 11.0 (15) Recommended operating

range Idle speed r/min 900 ± 50 In-gear idle speed r/min Approx. 820 – 920

S mm (in. type) 422 (15) L mm (in. type) 549 (20)

mm (in) 668 (26.3)

mm (in) 323 (12.7)

(lbs)

r/min 4 900 – 5 500 5 400 – 6 000

DF9.9

44.0

(97.0)

45.0

(99.2)

DF9.9E DF9.9R DF15 DF15E DF15R

48.0

(105.6)

49.0

(107.8)

(103.4)

(105.6)

47.0

(103.4)

48.0

(105.6)

POWER HEAD

Engine type 4-stroke SOHC Number of cylinders 2 Bore mm (in) 58.0 (2.28) Stroke mm (in) 57.0 (2.24) Total displacement cm Compression ratio :1 9.0 Spark plug NGK BKR6E Ignition system SUZUKI PEI (Digital CDI) Fuel supply system Carburetor (Number of carb.: 1) Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump Starting system Manual Electric Manual Electric Choke system (Enrichener system) Manual Throttle control

(cu. in) 302 (18.4)

Automatic

Twist grip

Remote

control

Manual

Twist grip

Automatic

Remote

control

Page 13

GENERAL INFORMATION 1-9

Item Unit

DF9.9

DF9.9E DF9.9R DF15 DF15E DF15R

Data

FUEL & OIL

Fuel

Engine oil API classification SE, SF, SG, SH, SJ

Viscosity rating SAE 10W-40

Engine oil amounts

L (US/lmp. qt)

1.0 (1.1/0.9): Oil change only

1.1 (1.2/1.0): Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil (SAE #90 hypoid gear oil) Gearcase oil amounts

ml (US/lmp. oz)

170 (5.7/6.0)

BRACKET

Trim angle Degrees 4 – 20 Number of tilt pin position 5 Maximum tilt angle Degrees 67

LOWER UNIT

Reversing system Gear Transmission Forward-Neutral-Reverse Reduction system Bevel gear Gear ratio 12 : 25 (2.083) Drive line impact protection Spline drive rubber hub Propeller Blade × Diam. (in) × Pitch (in)

3 × 9-1/4 × 7 3 × 9-1/4 × 8 3 × 9-1/4 × 9 3 × 9-1/4 × 10 3 × 9-1/4 × 11

Page 14

1-10 GENERAL INFORMATION

*SERVICE DATA *: These service data are subject to change without notice.

Item Unit

DF9.9

DF9.9E DF9.9R DF15 DF15E DF15R

Data

POWERHEAD

Recommended operation range

r/min 4 900 – 5 500 5 400 – 6 000

Idle speed r/min 900 ± 50 (in-gear: approx. 820 – 920) **Cylinder compression

kPa

(kg/cm

, psi)

550 – 850 (5.5 – 8.5, 78 – 120): With decompression system: DF9.9/15 820 – 1230 (8.2 – 12.3, 116 – 175): Without decompression system: DF9.9E/R, DF15E/R {Crank with recoil starter}

**Oil pressure [Oil temp. at 60 °C (140 °F)]

kPa

(kg/cm

, psi)

Min. 200 (2.0, 28)

Max. 500 (5.0, 71)

at 3 000 r/min

Engine oil API classification SE, SF, SG, SH, SJ

Viscosity rating SAE 10W-40

Engine oil amount

Thermostat operating temperature

L (US/lpm. qt))

°C (°F) 58 – 62 (136 – 144)

1.0 (1.1/0.9): Oil change only

1.1 (1.2/1.0): Oil filter change

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

CYLINDER HEAD/CAMSHAFT

Cylinder head distortion

Cam height

Camshaft journal oil clearance

Camshaft holder inside diameter

Camshaft journal outside diameter

Rocker arm shaft to rocker arm clearance

Rocker arm inside diameter

Rocker arm shaft outside diameter

Upper

Lower

Upper

Lower

Limit mm (in) 0.05 (0.002)

STD mm (in) 23.394 – 23.454 (0.9210 – 0.9234)

Limit mm (in) 23.294 (0.9171) STD mm (in) 23.397 – 23.457 (0.9211 – 0.9235) Limit mm (in) 23.297 (0.9172) STD mm (in) 0.020 – 0.062 (0.0008 – 0.0024) Limit mm (in) 0.100 (0.0039) STD mm (in) 25.000 – 25.021 (0.9843 – 0.9851)

STD mm (in) 23.000 – 23.021 (0.9055 – 0.9063)

STD mm (in) 24.959 – 24.980 (0.9826 – 0.9835)

STD mm (in) 22.959 – 22.980 (0.9039 – 0.9047)

STD mm (in) 0.016 – 0.045 (0.0006 – 0.0018) Limit mm (in) 0.060 (0.0024)

STD mm (in)

13.000 – 13.018

(0.5118 – 0.5125)

12.973 – 12.984

(0.5107 – 0.5112)

Page 15

GENERAL INFORMATION 1-11

Item Unit

VALVE/VALVE GUIDE

Valve diameter

Valve clearance (cold engine condition)

Valve guide to valve stem clearance

Valve guide inside diameter

Valve stem outside diameter

Valve guide protrusion

Valve stem deflection

Valve stem runout

Valve head radial runout

Valve head thickness

Valve seat contact width

Valve spring free length

Valve spring tension

IN STD mm (in) 26 (1.0)

EX STD mm (in) 22 (0.9)

IN STD mm (in) 0.18 – 0.22 (0.007 – 0.009)

EX STD mm (in) 0.18 – 0.22 (0.007 – 0.009)

STD mm (in) 0.010 – 0.037 (0.0004 – 0.0015) Limit mm (in) 0.070 (0.0028) STD mm (in) 0.035 – 0.062 (0.0014 – 0.0024) Limit mm (in) 0.090 (0.0035)

IN STD mm (in) 5.500 – 5.512 (0.2165 – 0.2170)

EX STD mm (in) 5.500 – 5.512 (0.2165 – 0.2170)

IN STD mm (in) 5.475 – 5.490 (0.2156 – 0.2161)

EX STD mm (in) 5.450 – 5.465 (0.2146 – 0.2152)

IN STD mm (in) 10.0 (0.39)

EX STD mm (in) 10.0 (0.39)

IN Limit mm (in) 0.16 (0.006)

EX Limit mm (in) 0.16 (0.006)

IN Limit mm (in) 0.05 (0.002)

EX Limit mm (in) 0.05 (0.002)

IN Limit mm (in) 0.03 (0.001)

EX Limit mm (in) 0.03 (0.001)

IN Limit mm (in) 0.5 (0.02)

EX Limit mm (in) 0.5 (0.02)

IN STD mm (in) 0.9 – 1.1 (0.035 – 0.043)

EX STD mm (in) 0.9 – 1.1 (0.035 – 0.043)

STD mm (in) 32.52 (1.280) Limit mm (in) 32.40 (1.276) STD N (kg, lbs) 90 (9.0, 19.8) for 28.5 mm (1.12 in) Limit N (kg, lbs) 76 (7.6, 16.8) for 28.5 mm (1.12 in)

DF9.9

Data

DF9.9E DF9.9R DF15 DF15E DF15R

Page 16

1-12 GENERAL INFORMATION

Item Unit

CYLINDER/PISTON/PISTON RING

Cylinder distortion

Piston to cylinder clearance

Cylinder bore

Cylinder measuring position

Piston skirt diameter

Piston measuring position

Wear on cylinder bore

Piston ring end gap

1st

2nd

Piston ring free end gap

1st

2nd

Piston ring to groove clearance

1st

2nd

Piston ring groove width

1st STD mm (in) 1.21 – 1.23 (0.0476 – 0.0484)

2nd STD mm (in) 1.21 – 1.23 (0.0476 – 0.0484)

Limit mm (in) 0.05 (0.002) STD mm (in) 0.0276 – 0.0425 (0.0011 – 0.0017) Limit mm (in) 0.100 (0.0039) STD mm (in) 58.000 – 58.015 (2.2835 – 2.2841)

mm (in) 50 (2.0) from cylinder top surface

STD mm (in) 57.965 – 57.980 (2.2821 – 2.2827)

mm (in) 15 (0.6) from piston skirt end

Limit mm (in) 0.055 (0.0022)

STD mm (in) 0.10 – 0.25 (0.004 – 0.010) Limit mm (in) 0.50 (0.020) STD mm (in) 0.10 – 0.25 (0.004 – 0.010) Limit mm (in) 0.50 (0.020) STD mm (in) Approx. 5.8 (0.23) Limit mm (in) 4.6 (0.18) STD mm (in) Approx. 7.4 (0.29) Limit mm (in) 5.9 (0.23) STD mm (in) 0.02 – 0.06 (0.001 – 0.002) Limit mm (in) 0.10 (0.004) STD mm (in) 0.02 – 0.06 (0.001 – 0.002) Limit mm (in) 0.10 (0.004)

Oil STD mm (in) 2.51 – 2.53 (0.099 – 0.100)

Piston ring thickness

Pin clearance in piston pin hole

Piston pin outside diameter

Piston pin hole diameter

1st STD mm (in) 1.17 – 1.19 (0.046 – 0.047)

2nd STD mm (in) 1.17 – 1.19 (0.046 – 0.047)

STD mm (in) 0.002 – 0.013 (0.0001 – 0.0005) Limit mm (in) 0.040 (0.0016) STD mm (in) 13.995 – 14.000 (0.5510 – 0.5512) Limit mm (in) 13.980 (0.5504) STD mm (in) 14.002 – 14.008 (0.5513 – 0.5515) Limit mm (in) 14.030 (0.5524)

DF9.9

Data

DF9.9E DF9.9R DF15 DF15E DF15R

Page 17

GENERAL INFORMATION 1-13

Item Unit

DF9.9

DF9.9E DF9.9R DF15 DF15E DF15R

Data

CRANKSHAFT/CONROD

Conrod small end inside diameter

Conrod big end oil clearance

Conrod big end inside diameter

Crank pin outside diameter

STD mm (in) 14.006 – 14.014 (0.5514 – 0.5517) Limit mm (in) 14.040 (0.5528) STD mm (in) 0.025 – 0.045 (0.0010 – 0.0018) Limit mm (in) 0.063 (0.0025)

STD mm (in) 29.025 – 29.034 (1.1427 – 1.1431)

STD mm (in) 28.989 – 29.000 (1.1413 – 1.1417)

Crank pin outside diameter

Limit mm (in) 0.010 (0.0004)

difference Conrod big end

side clearance

Conrod big end width

STD mm (in) 0.10 – 0.20 (0.004 – 0.008) Limit mm (in) 0.60 (0.024)

STD mm (in) 19.95 – 20.00 (0.785 – 0.787)

Crank pin width STD mm (in) 20.10 – 20.15 (0.791 – 0.793) Crankshaft thrust clearance Crankshaft length Crankcase length Crankshaft journal oil clearance

Limit mm (in) 0.60 (0.024)

STD mm (in) 126.8 – 126.9 (4.992 – 4.996)

STD mm (in) 127.0 – 127.1 (5.000 – 5.004)

STD mm (in) 0.020 – 0.047 (0.0008 – 0.0019)

Limit mm (in) 0.060 (0.0024) Crankshaft bearing holder inside

STD mm (in) 35.000 – 35.016 (1.3780 – 1.3786) diameter Crankshaft journal outside

STD mm (in) 31.989 – 32.000 (1.2594 – 1.2598) diameter Crankshaft journal outside diameter differ-

Limit mm (in) 0.010 (0.0004)

ence Crankshaft bearing thickness

STD mm (in) 1.486 – 1.494 (0.0585 – 0.0588)

Page 18

1-14 GENERAL INFORMATION

Item Unit

DF9.9

DF9.9E DF9.9R DF15 DF15E DF15R

Data

LOWER UNIT

Gearcase oil amounts ml

(US/lmp.oz)

170 (5.7/6.0)

Gear ratio 2.08 (12 : 25)

Preliminary gear shim & thrust washer

Pinion back up shim mm (in) 1.0 (0.04) Forward back up shim mm (in) 1.0 (0.04) Reverse back up shim mm (in) 1.0 (0.04) Forward thrust washer mm (in) 1.5 (0.06) Reverse thrust washer mm (in) 1.5 (0.06)

Initial selection-shim adjustment may be required.

CARBURETOR

Type KEIHIN BCM

II 23-11.5 BCMII 25-21

I.D. mark 94J2 94J3 94J6 94J7 Main jet # 70 115 Pilot jet # 38 40 Pilot screw

Turns open

PRE-SET

(1-7/8 ± 1/2)

PRE-SET

(2-7/8 ± 1/2)

Float height mm 13.5 ± 2 13.5 ± 2

Page 19

GENERAL INFORMATION 1-15

Item Unit

DF9.9

DF9.9E DF9.9R DF15 DF15E DF15R

Data

ELECTRICAL

Ignition timing Degrees

ATDC 5 – BTDC 30

Over revolution limiter r/min Approx. 6 500 Condenser charge coil

resistance

Ω at 20 °C 12.5 – 18.8 [G – B/R]

Pulser coil resistance Ω at 20 °C 148 – 222 [R/B – B] Ignition coil

Primary

Ω at 20 °C 0.2 – 0.4 [O – B] resistance (without spark

Secondary

kΩ at 20 °C 6.8 – 10.2 [H.T. cord – H.T. cord]

plug cap) Spark plug cap resistance kΩ at 20 °C 8 – 12 Battery charge coil resistance Battery charge coil output

(12V) Standard spark plug

Type NGK BKR6E

Gap mm (in) 0.7 – 0.8 (0.028 – 0.031)

Ω at 20 °C

Watt

0.9 – 1.3 (DF9.9E/15E, DF9.9/15)

0.3 – 0.4 (DF9.9R/15R) 80: Tiller handle model 120: Remote control model

Fuse amp rating A 20: Electric start model Recommended battery capacity (12V) Starter motor relay coil resistance

Ah (kC) 35 (126) or over: Electric start model

Ω at 20 °C 145 – 190: Electric start model

[R – Y]

STARTER MOTOR (only for Electric start model)

Max. continuous time of use

Motor output

Brush length

STD mm (in) 15.5 (0.61)

Sec. 30

kW 1.4

Limit mm (in) 9.5 (0.37)

Commutator undercut

Commutator outside diameter

Commutator outside diameter difference

STD mm (in) 0.5 – 0.8 (0.02 – 0.03)

Limit mm (in) 0.2 (0.01)

STD mm (in) 29.0 (1.14)

Limit mm (in) 28.0 (1.10)

STD mm (in) 0.05 (0.002)

Limit mm (in) 0.40 (0.016)

Page 20

1-16 GENERAL INFORMATION

PEAK VOLTAGE Requirements for peak voltage measurement

• Remove all spark plugs to eliminate the variables at cranking speed.

• Crank with recoil starter.

• Use a STEVENS peak voltage tester, Model CD-77.

• Use the 6-pin connector test cord (Part No. 09930-89920).

Tester probe

Testing sequence

connection

Peak voltage Tester range Remarks

+ (Red) - (Black)

1 CDI output Orange Black 128 V or over NEG 500

Condenser charge coil

output Pulser coil output

Battery charge coil out-

put

Green Black/Red 15 V or over POS 50

Red/Black

Black

(Ground)

0.8 V or over SEN 5

Red Yellow 5.6 V or over POS 50

• With ignition coil connected

• Use the 6-pin connector test cord.

With CDI unit disconnected

With rectifier

disconnected

Test 3

Pulser coil

Test 2

Condenser charge coil

Test 1

R/B

B/RGB/R

CDI unit

Ignition coil

Test 4

Battery charge coil

RYR

Page 21

TIGHTENING TORQUE

Tightening torque – Important fasteners

GENERAL INFORMATION 1-17

ITEM

Cylinder head cover bolt 6 mm 10 1.0 7.0 Cylinder head bolt 8 mm 27 2.7 20.0 Crankcase bolt 6 mm 14 1.4 10.0

Conrod cap bolt 7 mm 12 1.2 8.5 Oil pump bolt 6 mm 14 1.4 10.0 Oil pump gallery bolt 6 mm 14 1.4 10.0 Intake manifold bolt 8 mm 23 2.3 16.5 Carburetor mounting bolt 6 mm 10 1.0 7.0 Fuel pump bolt 6 mm 10 1.0 7.0 Thermostat cover bolt 6 mm 10 1.0 7.0 Valve adjusting lock nut 5 mm 11 1.1 8.0 Timing pulley nut 26 mm 50 5.0 36.0 Flywheel nut 14 mm 80 8.0 58.0 Spark plug — 27 2.7 19.5 Power unit mounting bolt and nut 8 mm 23 2.3 16.5 Driveshaft housing bolt 8 mm 23 2.3 16.5 Oil pressure switch — 13 1.3 9.5 Oil regulator 14 mm 27 2.7 19.5 Camshaft pulley bolt 6 mm 10 1.0 7.0 Engine oil drain plug 12 mm 13 1.3 9.5 Upper mount bolt 8 mm 23 2.3 16.5 Upper mount bracket bolt 8 mm 23 2.3 16.5 Lower mount cover bolt 8 mm 23 2.3 16.5 Lower mount bolt 8 mm 23 2.3 16.5 Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0 Shallow drive arm bolt 10 mm 25 2.5 18.0 Tiller handle cover bolt 8 mm 17 1.7 12.5 Water pump case bolt 8 mm 18 1.8 13.0 Gearcase bolt 8 mm 23 2.3 16.5 Propeller nut 12 mm 18 1.8 13.0 Propeller shaft bearing housing bolt 6 mm 8 0.8 6.0

THREAD

DIAM.

8 mm 25 2.5 18.0

TIGHTENING TORQUE

N·m kg-m lb-ft

Page 22

1-18 GENERAL INFORMATION

Tightening torque – General bolt

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

TYPE OF BOLT

THREAD

DIAMETER

TIGHTENING TORQUE

N·mkg-mlb-ft

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0 6 mm 4 – 7 0.4 – 0.7 3.0 – 5.0 8 mm 10 – 16 1.0 – 1.6 7.0 – 11.5

(Conventional or “4” marked bolt) 10 mm 22 – 35 2.2 – 3.5 16.0 – 25.5

5 mm 2 – 4 0.2 – 0.4 1.5 – 3.0 6 mm 6 – 10 0.6 – 1.0 4.5 – 7.0 8 mm 15 – 20 1.5 – 2.0 11.0 – 14.5

(Stainless steel bolt) 10 mm 34 – 41 3.4 – 4.1 24.5 – 29.5

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

(7 marked or marked bolt) 10 mm 40 – 60 4.0 – 6.0 29.0 – 43.5

Page 23

GENERAL INFORMATION 1-19

SPECIAL TOOLS

1. 2. 3. 4. 5.

09900-00413 (5 mm) 09900-00414 (6 mm)

09900-00415 (8 mm) 09900-00410 Hexagon wrench set

Hexagon bit (included

in 09900-00410)

09900-06108 Snap ring pliers

6. 7. 8. 9. 10.

09900-20101 (150 mm) 09900-20102 (200 mm) Vernier calipers

09900-20202 Micrometer (25 – 50 mm)

09900-20203 Micrometer (50 – 75 mm)

09900-20205

Micrometer

(0 – 25 mm)

09900-20530 Cylinder gauge set (40 – 100 mm)

09900-20602 Dial gauge

09900-20605 Dial calipers (10 – 34 mm)

11. 12. 13. 14. 15.

09900-22301 09900-20701 Magnetic stand

09900-20803 Thickness gauge

09900-21304 Steel “V” block set

Plastigauge

(0.025 – 0.076 mm)

09900-26006 Engine tachometer

16. 17. 18. 19. 20.

09900-28403 Hydrometer

09911-49310 Crankshaft holder

09913-50121 Oil seal remover

09915-64512

Compression gauge

09915-77311 Oil pressure gauge

Page 24

1-20 GENERAL INFORMATION

21. 22. 23. 24. 25.

09915-78211 Oil pressure gauge adapter

09916-10911 Valve lapper

09916-14510 Valve lifter

09916-14521 Valve lifter attachment

09916-20610 Valve seat cutter (15°) (N-121)

26. 27. 28. 29. 30.

09916-20620 Valve seat cutter (45°) (N-122)

09916-24440 Handle adapter (N-503-1)

09916-24450 Solid pilot (N-100-5.52)

09916-34542 Valve guide reamer handle

09916-34550 Valve guide reamer

 5.5 mm)

(

31. 32. 33. 34. 35.

09916-38210 Valve guide reamer

 11 mm)

(

09916-44910 Valve guide remover/installer

09916-54910 Handle (N-505)

09916-77310 Piston ring compressor

09916-84511 Tweezers

36. 37. 38. 39. 40.

09930-39210 09917-14910 Valve adjuster driver

09930-30104 Sliding hammer

Flywheel remover

attachment bolt

09930-39411 Flywheel remover

09930-48720 Flywheel holder

Page 25

GENERAL INFORMATION 1-21

41. 42. 43. 44. 45.

09930-49210 Flywheel holder attachment

09930-76420 Timing light

09930-99320 Digital tester

09930-89920 6-pin connector test cord

46. 47. 48. 49.

Pinion bearing installer and remover

09951-59910 Pinion bearing installer shaft A 09951-49910 Pinion bearing remover shaft B 09951-69910 Bearing C 01500-08403 Bolt D 09951-39914 Pinion bearing plate E 09951-19311 Attachment F 09951-79311 Spacer G 09951-29910 Nut H

09952-99310 hand air pump

09950-69512 Gearcase oil leakage tester

09951-09530 Gear adjusting gauge

50. 51. 52. 53.

09950-59320 Propeller shaft remover

09900-25010 Pocket tester

99954-53008-820* Digital voltmeter

NOTE: * Marked part No. is in U.S. market only

99954-53873* Stevens CD-77 Peak reading voltmeter

99954-53883* Gear oil filler

Page 26

1-22 GENERAL INFORMATION

MATERIALS REQUIRED

SUZUKI OUTBOARD MOTOR GEAR OIL

99000-22540 (400 ml × 24 pcs.)

THREAD LOCK “1342”

99000-32050 (50 g)

SUZUKI SUPER GREASE “A”

99000-25030* 99000-25011 (500 g)

THREAD LOCK SUPER “1333B”

99000-32020 (50 g)

WATER RESISTANT

GREASE

99000-25161

(250 g)

4-Stroke Motor Oil

API: SE, SF, SG, SH, SJ

SAE: 10W-40

SUZUKI SILICONE SEAL

99000-31120 (50 g)

SUZUKI BOND “1207B”

99104-33140* 99000-31140 (100 g)

NOTE: * Marked part No. is in U.S. market only

Page 27

PERIODIC MAINTENANCE

PERIODIC MAINTENANCE 2-1

CONTENTS

PERIODIC MAINTENANCE SCHEDULE .......................................................2- 2

PERIODIC MAINTENANCE CHART .....................................................2- 2

MAINTENANCE AND TUNE-UP PROCEDURES ..........................................2- 3

ENGINE OIL ...........................................................................................2- 3

ENGINE OIL FILTER ..............................................................................2- 4

GEAR OIL ...............................................................................................2- 5

LUBRICATION .......................................................................................2- 6

SPARK PLUG ........................................................................................2- 7

VALVE CLEARANCE ............................................................................2- 8

TIMING BELT .........................................................................................2-10

IDLE SPEED ...........................................................................................2-13

CARBURETOR ......................................................................................2-13

IGNITION TIMING ..................................................................................2-14

BREATHER AND FUEL LINE ................................................................2-14

FUEL FILTER .........................................................................................2-14

WATER PUMP/WATER PUMP IMPELLER ...........................................2-15

PROPELLER/NUT/PIN ...........................................................................2-15

ANODES AND BONDING WIRES .........................................................2-16

BATTERY ...............................................................................................2-17

BOLTS AND NUTS ................................................................................2-18

OIL PRESSURE ..............................................................................................2-19

CYLINDER COMPRESSION ...........................................................................2-21

TEST PROCEDURE ...............................................................................2-21

Page 28

2-2 PERIODIC MAINTENANCE

PERIODIC MAINTENANCE SCHEDULE

The chart below 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.

PERIODIC MAINTENANCE CHART

Interval

Item to be serviced Spark plug —— I R

Breather Hose and Fuel line

Engine oil R—R R Gear oil R—R R Lubrication —III Anodes and bonding wire —III Battery —III Bolts and nuts T—T T Engine oil filter R——R

Fuel filter

Valve clearance I——I

Timing belt

Carburetor I—I I Propeller nut and pin I—I I Water pump ——— I Water pump impeller ——— R Idle speed I——I Ignition timing ——— I

Initial 20 hrs.

or 1 month

IIII

—III

——— I

Every 50 hrs.

or 3 months

Replace every 2 years.

Replace every 400 hours or 2 years.

Replace every 4 years.

Every 100 hrs.

or 6 months

Every 200 hrs.

or 12 months

I: Inspect and clean, adjust, lubricate or replace, if necessary T: Tighten R: Replace

Page 29

MAINTENANCE AND TUNE-UP PROCEDURES

This section describes servicing procedures for each periodic maintenance requirement.

ENGINE OIL

Change initially after 20 hours (1 month) and every 100 hours (6 months).

NOTE: Engine oil should be changed while engine is warm.

1. Place outboard motor upright on a level surface.

2. Remove the motor cover.

3. Remove the oil filler cap 1.

PERIODIC MAINTENANCE 2-3

4. Place a container under engine oil drain plug 2, then

remove engine oil drain plug and gasket to drain engine oil.

5. Install new gasket and oil drain plug. Tighten engine oil drain plug to specified torque.

 Engine oil drain plug: 13 N·m (1.3 kg-m, 9.5 lb-ft) 

Do not re-use gasket once removed. Always use a new gasket.

Page 30

2-4 PERIODIC MAINTENANCE

6. Pour recommended engine oil into oil filler opening, then install the oil filler cap.

Necessary engine oil amount:

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)

Recommended oil:

• 4 stroke motor oil

• API classification SE, SF, SG, SH, SJ

• Viscosity rating SAE 10W-40

7. Start the engine and allow it to run for several minutes at idle speed. Turn off engine and wait for approx. two minutes.

8. Remove the oil level dipstick 3 and wipe it clean.

9. Reinsert the dipstick fully into the dipstick tube, then remove to check oil level.

10. Oil level should be between full level Max. mark (hole) and low level Min. mark (hole). If level is low, add recommended oil to full level hole (Max).

ENGINE OIL FILTER

Replace initially after 20 hours (1 month) and every 200 hours (12 months).

NOTE: When replacing engine oil filter, change engine oil at the same time. (For oil change, see pages 2-3 and 2-4.)

Necessary engine oil amounts:

Oil filter change: 1.1 L (1.2/1.0 US/Imp. qt)

Full level line

Low level line

1. Remove the motor cover.

2. Remove the side covers.

3. Remove the three (3) bolts securing the oil filter cap.

4. Remove the oil filter 1.

Page 31

PERIODIC MAINTENANCE 2-5

5. Assembly is reverse order of disassembly.



Do not re-use the O-rings once removed. Always use a new O-ring.

6. Start engine and allow it to run for several minutes at idle speed. Check that there are no leaks around filter cap.

7. Turn off engine, then recheck engine oil level.

GEAR OIL

Change initially after 20 hours (1 month) and every 100 hours (6 months).

1. Place the outboard motor upright on a level surface.

2. Place a container under the lower unit.

3. Remove lower gear oil drain plug 2 first, then remove gear oil level plug 1 and drain gear oil.

1. O-ring

2. Oil filter

3. O-ring

4. Spring

5. Filter cap

4. Fill with recommended gear oil through oil drain hole until oil just starts to flow out from oil level hole.

Gear oil amounts: 170 ml (5.7/6.0 US/Imp. oz)

Recommended oil:

SUZUKI OUTBOARD MOTOR GEAR OIL or SAE #90 HYPOID GEAR OIL

5. Install oil level plug before removing oil filler tube from drain hole.

6. Install oil drain plug.



Do not re-use gasket once removed. Always use a new gasket.

NOTE: To avoid a possible low gear oil level, recheck gear oil level 10 minutes after doing procedure in step 6. If oil level is low, add additional gear oil until level is correct.

Page 32

2-6 PERIODIC MAINTENANCE

LUBRICATION

Inspect every 50 hours (3 months).

Apply SUZUKI Water Resistant Grease to the following points.

 99000-25161: SUZUKI WATER RESISTANT GREASE

Throttle cable

Carburetor linkage

NSI cable

Swivel bracket

Clamp screw

Steering bracket

Propeller shaft

Page 33

SPARK PLUG

• Inspect every 100 hours (6 months).

• Replace every 200 hours (12 months).

Standard spark plug: NGK BKR6E



Only resistor (R) type spark plugs must be used with this engine. Using a non-resistor spark plug will cause ignition system malfunctions.

CARBON DEPOSIT

Inspect for a carbon deposit on spark plug base. If carbon is present, remove it with a spark plug cleaning machine or by carefully using a pointed tool.

PERIODIC MAINTENANCE 2-7

SPARK PLUG GAP

Measure spark plug gap with a thickness gauge. Adjust to within specified range if gap is out of specification.

Spark plug gap: 0.7 – 0.8 mm (0.028 – 0.031 in)

 09900-20803: Thickness gauge

CONDITION OF ELECTRODE/INSULATOR

Check the electrode and insulator condition. If the electrode is extremely worn or burnt, replace the spark plug. If the spark plug has a broken insulator, damaged threads, etc., replace the spark plug.



Confirm the thread size and reach when replacing the plug. If the reach is too short, carbon will be deposited on the threaded portion of the plug hole resulting in possible engine damage.

Gap

 Spark plug: 27 N·m (2.7 kg-m, 20.0 lb-ft)

Page 34

2-8 PERIODIC MAINTENANCE

VALVE CLEARANCE

Inspect initially after 20 hours (1 month) and every 200 hours (12 months).

1. Remove following parts:

• Motor cover

• Side covers

• Recoil starter

• Spark plugs

2. Disconnect the fuel hose 1 from fuel pump 2.

3. Remove the six bolts and cylinder head cover 3.

4. Rotate the flywheel clockwise to bring each piston to Top Dead Center (TDC) on compression stroke. Align each PUNCH mark on cam pulley with INDEX mark on cylinder head block.

PUNCH mark TDC cylinder number

1 No. 1 cylinder 2 No. 2 cylinder



Rotate the crankshaft in the normal running direction only (clockwise) to prevent water pump impeller damage.

NOTE:

• The piston must be at its TDC position on a compression

stroke to check or adjust valve clearance.

• The valve clearance specification is for COLD engine condi-

tion.

5. Insert the thickness gauge between valve stem end and valve adjusting screw on rocker arm.

 09900-20803: Thickness gauge

Valve clearance (cold engine condition):

IN. 0.18 – 0.22 mm (0.007 – 0.009 in) EX. 0.18 – 0.22 mm (0.007 – 0.009 in)

INDEX mark Punch mark

If measurement is out of specification, adjust valve clearance.

Page 35

ADJUSTMENT

6. Loosen valve adjusting lock nut 4.

7. Turn valve adjusting screw using the valve adjustment driver to bring valve clearance to within specification.

 09900-20803: Thickness gauge

09917-14910: Valve adjustment driver

8. Tighten valve adjusting lock nut while holding valve adjusting screw.

 Valve adjusting lock nut: 11 N·m (1.1 kg-m, 8.0 lb-ft)

PERIODIC MAINTENANCE 2-9

9. Recheck valve clearance.

10. Tighten the cylinder head cover bolts to specified torque.

 Cylinder head cover bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft) 

Do not re-use gasket once removed. Always use a new gasket.

Checking

• All parts removed have been returned to their original positions.

• Check hose routing.

Page 36

2-10 PERIODIC MAINTENANCE

TIMING BELT

• Inspect every 200 hours (12 months).

• Replace every 4 years.

If wear, crack or other damage is found, replace the timing belt.

1. Remove the motor cover.

2. Remove the recoil starter.

3. Remove the side covers.

4. Remove the spark plugs.

5. Remove the flywheel 1. (See page 3-9.)

 09930-48720: Flywheel holder

09930-49210: Flywheel holder attachment 09930-39411: Flywheel remover 09930-39210: Flywheel remover attachment bolt

6. Disconnect stop switch lead wire connector. Disconnect starter button lead wire connector.

7. Remove nut 1 and positive + battery cable 2, positive + battery charge cable 3 from the magnetic switch “B” terminal of starter motor. Disconnect the red lead wire 4 from starter motor magnetic switch “S” terminal.

Starter motor magnetic switch

Page 37

8. Loosen the port side bolt securing starter motor band.

9. Remove the four (4) bolts securing stator base 5.

Remove the two (2) bolts securing starter motor.

PERIODIC MAINTENANCE 2-11

10. Lift stator base from cylinder block and lay it on port side as shown figure.

11. Rotate the crankshaft to align the PUNCH mark on the timing pulley with the INDEX mark on the cylinder block.

 09911-49310: Crankshaft holder 

Rotate the crankshaft in the normal running direction (clockwise) to prevent water pump impeller damage.



Do not rotate the cam pulley with timing belt removed.

1. PUNCH mark “ ”

2. INDEX mark

Page 38

2-12 PERIODIC MAINTENANCE

12. Remove the timing belt from the cam pulley first, then from the timing pulley.



Do not rotate the crankshaft or the cam pulley before installing the belt; the following must be checked:

• The PUNCH mark on the timing pulley aligns with the INDEX mark on the cylinder block.

• Either of the PUNCH marks on the cam pulley aligns with the INDEX mark on the cylinder head block.

If the timing pulley or the cam pulley is rotated with the timing belt removed or installed but misaligned, this may cause the valves to become bent. If the alignment marks are not correctly matched, loosen the valve adjusting lock nuts and the valve adjusting screws fully to prevent valve damage. Then align the marks correctly by rotating the cam pulley clockwise.

13. Install the timing belt on the timing pulley first, then the cam pulley.



Always keep the timing belt away from any grease and oil.



The timing belt must be installed with the arrow mark on the timing belt toward the direction of rotation.

14. Make sure that either of the PUNCH marks on the cam pulley aligns with the INDEX mark on the cylinder head block when the PUNCH mark on the timing pulley aligns with the INDEX mark on the cylinder block.

1. Punch mark on cam pulley

2. INDEX mark on cylinder head

15. Install following parts.

• Stator base (See page 3-13.)

• Flywheel (See page 3-13.)

• Recoil starter (See page 5-8.)

• Side covers

• Spark plugs

16. Check wire routing. (See page 9-5 to 9-7.)

3. PUNCH mark

4. INDEX mark on cylinder block

Page 39

IDLE SPEED

Inspect initially after 20 hours (1 month) and every 200 hours (12 months).

Checking

1. Check throttle link mechanism and carburetor throttle valve for smooth operation.

2. Attach engine tachometer cord to the ignition coil high-tension cord.

 09900-26006: Engine tachometer

3. Start engine and allow to warm up.

NOTE: Check and/or adjust the idle speed after the engine speed has stabilized.

4. Check engine idle speed.

PERIODIC MAINTENANCE 2-13

Idle speed (in neutral gear): 850 – 950 r/min

Adjustment

If engine idle speed is out of specification, adjust engine speed as follows:

Turn the throttle stop screw 1.

• Turning clockwise: The engine speed becomes higher.

• Turning counterclockwise: The engine speed becomes lower.

CARBURETOR

Inspect initially after 20 hours (1 month) and every 100 hours (6 months).

If crack or other damage is found on carburetor body, lever, rod, connector, inlet manifold or silencer, replace.

Page 40

2-14 PERIODIC MAINTENANCE

IGNITION TIMING

Inspect every 200 hours (12 months).

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

1. Start and warm up the engine.

2. Attach the timing light to the No. 1 ignition coil high-tension cord.

 09930-76420: Timing light

09900-26006: Engine tachometer

3. Check the ignition timing while operating the engine at 1 000 r/min.

Ignition timing: Approx. ATDC 5° at 1 000 r/min

BREATHER AND FUEL LINE

• Inspect initially after 20 hours (1 month) and every 50 hours (3 months).

• Replace every 2 years.

If leakage, cracks, swelling or other damage is found, replace the breather line and/or the fuel line.

FUEL FILTER

• Inspect every 50 hours (3 months).

• Replace every 400 hours or 2 years.

If water accumulation, sediment, leakage, cracks or other damage is found, replace the fuel filter.

Page 41

WATER PUMP/WATER PUMP IMPELLER

WATER PUMP Inspect every 200 hours (12 months).

Inspect water pump case and under panel. Replace if wear, cracks, distortion or corrosion is found.

WATER PUMP IMPELLER Replace every 200 hours (12 months).

Inspect water pump impeller. Replace if vanes are cut, torn or worn.

PROPELLER/NUT/PIN

Inspect initially after 20 hours (1 month) and every 100 hours (6 months).

PERIODIC MAINTENANCE 2-15

• Inspect propeller for bent, chipped or broken blades. Replace propeller if damage noticeably affects operation.

• Inspect propeller splines. Replace propeller if splines are worn, damaged or twisted.

• Inspect propeller bush for slippage. Replace if necessary.

• Make sure that propeller nut is torqued to specification and cotter pin is installed securely.

Page 42

2-16 PERIODIC MAINTENANCE

ANODES AND BONDING WIRES

Inspect every 50 hours (3 months).

ANODES

If 2/3 of the anode has corroded away, replace the anode. The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness.



Never paint the anode.

NOTE: The anode securing bolt should be covered with SUZUKI SILICONE SEAL.

 99000-31120: SUZUKI SILICONE SEAL

BONDING WIRES

If breakage or other damage is found on the wire, replace the wire. If rust, corrosion, or other damage is found on terminal, clean with cleaning solvent or replace the wire.

Anode

Page 43

BATTERY

Inspect every 50 hours (3 months).



• Never expose battery to open flame or electric spark

as batteries generate gas which is flammable and explosive.

• Battery acid is poisonous and corrosive. Avoid con-

tact with eyes, skin, clothing and painted surfaces. If battery acid comes in contact with any of these, flush immediately with large amounts of water. If acid contacts the eyes or skin, get immediate medical attention.

• Batteries should always be kept out of reach of chil-

dren.

• When checking or servicing battery, disconnect the

negative (black) cable. Be careful not to cause a short circuit by allowing metal objects to contact battery posts and motor at the same time.

• Wear approved eye protection.

PERIODIC MAINTENANCE 2-17

Recommended battery:

12 V 35 AH (126 kC) or larger battery

CONNECTING BATTERY

Upon completion of the connection, lightly apply grease to the battery terminals.

How to connect:

1. Connect the positive (+) terminal first.

2. Connect the negative (–) terminal second.

How to disconnect:

1. Disconnect the negative (–) terminal first.

2. Disconnect the positive (+) terminal second.



If the battery leads are loose, incorrectly connected or reversed, the electrical system could be damaged.

Page 44

2-18 PERIODIC MAINTENANCE

BATTERY SOLUTION LEVEL CHECK

Battery solution level should be between UPPER level and LOWER level. If level is low, add distilled water only.



Once the battery has been initially serviced, NEVER add diluted sulfuric acid or battery damage will occur. Follow the battery manufacture’s instructions for specific maintenance procedures.

BATTERY SOLUTION GRAVITY CHECK

Measure the gravity of battery solution using a hydrometer.

 09900-28403: Hydrometer

Battery solution gravity: 1.28 at 20 °C

BOLTS AND NUTS

Inspect initially after 20 hours (1 month) and every 100 hours (6 months).

Check that all bolts and nuts listed below are tightened to their specified torque.

ITEM

Cylinder head cover bolt 6 mm 10 1.0 7.0 Cylinder head bolt 8 mm 27 2.7 20.0 Intake manifold bolt 8 mm 23 2.3 16.5 Carburetor mounting bolt 6 mm 10 1.0 7.0 Flywheel nut 14 mm 80 8.0 58.0 Power unit mounting bolt/nut 8 mm 23 2.3 16.5 Clamp bracket shaft nut 7/8-14 UNF 43 4.3 31.0 Tiller handle cover bolt 8 mm 17 1.7 12.5 Gearcase bolt 8 mm 23 2.3 16.5 Propeller nut 12 mm 18 1.8 13.0

THREAD

DIAMETER

N·m kg-m lb-ft

TIGHTENING TORQUE

Page 45

OIL PRESSURE

Oil pressure (at normal operating temp.):

200 – 500 kPa (2.0 – 5.0 kg/cm at 3000 r/min.

NOTE: The figure shown above is a guideline only, not an absolute service limit.

If oil pressure is lower or higher than specification, the following causes may be considered. (See page 6-45 for oil passage locations.)

Low oil pressure

• Clogged oil filter

• Leakage from oil passages

• Defective oil pump

• Defective oil pressure regulator

• Damage O-ring

• Combination of above items

, 28 – 71 psi)

PERIODIC MAINTENANCE 2-19

High oil pressure

• Using an engine oil of too high viscosity

• Clogged oil passage

• Clogged oil pressure regulator

• Combination of above items

TEST PROCEDURE

1. Check the engine oil level.

2. Remove the plate 1 by sliding it upward.

3. Remove CDI unit 2 from electric parts holder.

4. Remove the two (2) bolts 3 securing ignition coil.

5. Loosen screw and disconnect blue lead wire 4 from oil pressure switch 5. Remove the oil pressure switch.

Page 46

2-20 PERIODIC MAINTENANCE

6. Install oil pressure gauge adaptor into oil pressure switch hole in place of oil pressure switch.

 09915-77311: Oil pressure gauge

09915-78211: Oil pressure gauge adapter

7. Place CDI unit in position. Install ignition coil, then secure with bolts.

8. Attach the engine tachometer to ignition coil high-tension cord.

 09900-26006: Engine tachometer

9. Start engine and allow to warm up as follows:

Summer : 5 min. at 2 000 r/min Winter : 10 min. at 2 000 r/min

10. After warming up, shift into forward gear and increase engine speed to 3 000 r/min, then compare pressure indicated on gauge to specifications.

11. After testing, reinstall oil pressure switch. (See page 3-17.)

Page 47

CYLINDER COMPRESSION

Cylinder compression:

Standard:

550 – 850 kPa (5.5 – 8.5 kg/cm 820 – 1 230 kPa (8.2 – 12.3 kg/cm

Without decompression system (DF9.9E/R, DF15E/R) Max. difference between any other cylinders: 100 kPa (1.0 kg/cm

NOTE: Figures shown are guidelines only, not absolute service limits.

Low compression pressure can indicate one or more of the following:

• Excessively worn cylinder wall

• Worn piston or piston rings

• Stuck piston rings

• Poor seating of valves

• Ruptured or otherwise damaged cylinder head gasket

, 78 – 120 psi.): With decompression system (DF9.9/15)

, 116 – 175 psi.):

, 14 psi.)

PERIODIC MAINTENANCE 2-21

TEST PROCEDURE

1. Start engine and allow to warm up, then shut engine off.

2. Remove the STBD / PORT engine side lower cover.

3. Remove all spark plugs.

4. Install the compression gauge into the plug hole.

 09915-64512: Compression gauge

5. Disconnect the safety lanyard from the emergency stop

switch.



Disconnect the safety lanyard from the emergency stop switch prior to cranking the engine. This will prevent any residual fuel discharged from the cylinders from being ignited by a spark discharged from the spark plug cap.

6. Disconnect the remote control throttle cable from the throttle

lever. (R model)

7. • Move and hold the throttle lever in the full-open position.

(R model)

• Move and hold the throttle control grip in the full-open position. (Tiller handle model.)

8. While cranking the engine with the starter motor or recoil

starter, note the maximum compression pressure reading on the gauge for each cylinder.

9. Reinstall parts removed earlier. (spark plug, side lower

cover, etc.)

Page 48

IGNITION AND ELECTRICAL 3-1

IGNITION AND ELECTRICAL

CONTENTS

IGNITION SYSTEM........................................................................................3- 2

PRINCIPLES OF OPERATION ...............................................................3- 2

IGNITION TIMING CONTROL.................................................................3- 3

TROUBLESHOOTING ............................................................................3- 4

INSPECTION ...........................................................................................3- 5

REMOVAL/INSTALLATION....................................................................3- 9

CAUTION SYSTEM .......................................................................................3-14

OVER-REVOLUTION CAUTION SYSTEM.............................................3-14

LOW OIL PRESSURE CAUTION SYSTEM............................................3-15

TESTING OIL PRESSURE CAUTION SYSTEM ....................................3-16

REMOVAL AND INSTALLATION...........................................................3-17

BATTERY CHARGING SYSTEM ..................................................................3-18

OUTLINE .................................................................................................3-18

INSPECTION ...........................................................................................3-19

REMOVAL/INSTALLATION....................................................................3-22

ELECTRIC STARTER SYSTEM....................................................................3-23

OUTLINE .................................................................................................3-23

TROUBLESHOOTING ............................................................................3-25

INSPECTION ...........................................................................................3-26

STARTER MOTOR..................................................................................3-29

Page 49

3-2 IGNITION AND ELECTRICAL

IGNITION SYSTEM

PRINCIPLES OF OPERATION

A digital CDI (condenser discharge ignition) system is employed on the DF9.9/DF15. The condenser built in the CDI unit stores the electrical energy generated by the condenser charge coil. The electrical energy stored in the condenser is released to the ignition coil primary windings by the ignition timing signal calculated by the CDI microcomputer from the pulser coil signals.

SPECIFICATION

Ignition type CDI Advance Electronic microcomputer control Ignition timing ATDC 5° – BTDC 30°

Engine stop switch

Ignition coil

Condenser charge coil

Pulser coil

Neutral switch

Oil pressure switch



Power source circuit (Charging circuit) Power source circuit

Base signal circuit

Hardware ignition signal circuit

Software ignition signal control circuit

Input circuit

Output circuit

SCR

CPU

Caution lamp

Tachometer

Page 50

IGNITION AND ELECTRICAL 3-3

IGNITION TIMING CONTROL

Outline

The ignition timing varies based upon engine speed. The pulser coil monitor current engine speed and send signals to the CDI unit. Based on this signal, the CDI unit determines the optimum ignition timing and supplies voltage to the primary winding of the ignition coil.

CDI unit

Basic sensor

Pulser coil :

Informs CDI unit of engine speed and crankshaft angle.

Control mode When starting (at the time of cranking):

The ignition timing is fixed at ATDC 10° until the engine starts.

When operating (normal operation):

The ignition timing varies in the range of ATDC 5° – BTDC 30° according to the engine operating condition.

Ignition timing is determined by a digital map designed in relation to engine speed.

Signal

Ign.coil

Page 51

3-4 IGNITION AND ELECTRICAL

TROUBLESHOOTING

Perform the following ignition system tests when the engine is hard to start in order to determine if the cause is in the ignition or another system.

START

Check the spark condition.

No or weak sparks

Check if the spark plug is in good condition. (See page 2-7.)

Disconnect the engine stop switch lead wire connector. (Blue/Red, B).

No or weak sparks

Check the ignition coil resistance. (See page 3-7.) [Primary: 0.2 – 0.4 Ω] [Secondary: 6.8 – 10.2 kΩ]

Check the spark plug cap for any evidence of the high-tension leak.

The cause will not be in the ignition system.

Check the ignition timing by using the timing light. [ATDC 5˚ at 1 000 r/min]

Not good

Sparks

Out of spec.

Not good

Replace the spark plug with a new one.

Check and/or replace the engine stop switch. (See page 3-8.)

Replace the ignition coil.

Replace the spark plug cap.

Not good

Check the spark plug cap resistance. (See page 3-8.) [Cap resistance: 8 – 12 kΩ)]

Check the condenser charge coil resistance. (See page 3-5.) [Coil resistance: 12.5 – 18.8 Ω]

Check the pulser coil resistance. (See page 3-6.) [Coil resistance: 148 – 222 Ω]

Check the CDI unit. (See page 3-7.)

Out of spec.

Replace the condenser charge coil.

Out of spec.

Replace the pulser coil.

Out of spec.

Replace the CDI unit.

Page 52

INSPECTION



Always disconnect the battery cables from battery before commencing electrical resistance test.

CONDENSER CHARGE COIL OUTPUT  Peak Voltmeter Stevens CD-77

Tester range: POS 50

1. Disconnect the condenser charge coil lead wire connector.

2. Connect the tester probe to the coil lead wires as shown.

Tester probe connection

+ (Red) - (Black)

Green Black/Red

3. Remove the all spark plugs.

4. Crank with the recoil starter, then measure voltage.

IGNITION AND ELECTRICAL 3-5

Condenser charge coil output: 15 V or over

If measurement is out of specification, replace the condenser charge coil.

CONDENSER CHARGE COIL RESISTANCE

 09930-99320: Digital tester  Tester range: Ω (Resistance)

1. Disconnect the condenser charge coil lead wire connector.

2. Connect the tester probe to the coil lead wires as shown.

Tester probe connection

Probe Other probe

Green Black/Red

Condenser charge coil resistance: 12.5 – 18.8 Ω

If measurement is out of specification, replace the condenser charge coil.

Black/Red

Green

Page 53

3-6 IGNITION AND ELECTRICAL

PULSER COIL OUTPUT  Peak Voltmeter Stevens CD-77

Tester range: SEN 5

1. Disconnect the pulser coil lead wire connector.

2. Connect the tester probe to the coil lead wires as shown.

Tester probe connection

+ (Red) - (Black)

Red/Black Black (Ground)

3. Remove all spark plugs.

4. Crank with the recoil starter, then measure voltage.

Pulser coil output: 0.8 V or over

If measurement is out of specification, replace the pulser coil.

Red/Black

Black

PULSER COIL RESISTANCE

 09930-99320: Digital tester  Tester range: Ω (Resistance)

1. Disconnect the pulser coil lead wire connector.

2. Connect the tester probe to the coil lead wires as shown.

Tester probe connection

Probe Other probe

Red/Black Black (Ground)

Pulser coil resistance: 148 – 222 Ω

If measurement is out of specification, replace the pulser coil.

Red/Black

Black

Page 54

IGNITION COIL RESISTANCE

 09930-99320: Digital tester  Tester range: Ω (Resistance)

Primary side

1. Disconnect the ignition coil lead wire connector.

2. Connect the tester probe to the coil lead wires as shown.

Tester probe connection

Probe Other probe

Orange Black

Primary coil resistance: 0.2 – 0.4 Ω

If measurement is out of specification, replace the ignition coil.

Secondary side

1. Remove the spark plug caps from the high-tension cord.

2. Connect the tester probe to the high-tension cords as

shown.

IGNITION AND ELECTRICAL 3-7

Tester probe connection

Probe Other probe

High-tension cord Other High-tension cord

Secondary coil resistance: 6.8 – 10.2 kΩ

If measurement is out of specification, replace the ignition coil.

CDI UNIT OUTPUT

 09930-89920: 6 pin connector test cord  Peak Voltmeter Stevens CD-77

Tester range: NEG 500

1. Disconnect 6 pin wire harness connector from CDI unit

2. Connect the 6 pin test cord between CDI unit and wire har-

ness as shown in figure.

3. Connect the tester probe to the test cord lead wires as

shown.

Tester probe connection

+ (Red) - (Black)

Orange

{Test cord wire color: Black}

Engine body ground

CDI unit

Black

4. Remove all spark plugs.

5. Crank with the recoil starter, then measure voltage.

CDI unit output: 128 V or over

If measurement is out of specification, replace the CDI unit.

Page 55

3-8 IGNITION AND ELECTRICAL

SPARK PLUG CAP

 09930-99320: Digital tester  Tester range: Ω (Resistance)

Measure the spark plug cap resistance.

Tester probe connection

Probe Other probe

Cap end Other cap end

Spark plug cap resistance: 8 – 12 kΩ

If measurement is out of specification, replace the spark plug cap.

EMERGENCY & ENGINE STOP SWITCH

 09930-99320: Digital tester

 Tester range:  (Continuity)

Check continuity/infinity between the wiring leads under the condition shown below.

Tester probe connection

Probe Other probe

Blue/Red

Green (Note: 1)

Black

Switch condition Continuity Lock plate IN No Lock plate OUT Yes Lock plate IN & button depressed

(Note: 2)

Yes

Note 1: Remote control model Note 2: Tiller handle model

If out of specification, replace the engine stop switch.

Bl/R

(G)

Bl/R (G)

Page 56

REMOVAL/INSTALLATION

FLYWHEEL/BATTERY & CONDENSER CHARGE COIL/PULSER COIL

80 N·m (8.0 kg-m, 58.0 lb-ft)

IGNITION AND ELECTRICAL 3-9

1. Nut

2. Washer

3. Flywheel

4. Key

5. Battery & condenser charge coil

6. Pulser coil

7. Screw

8. Screw

9. Stator base

10. Bolt

11. Bolt

12. Dowel pin

NOTE: Clean flywheel and crankshaft mating surfaces with cleaning solvent.

REMOVAL

Before removing electrical parts:

• Disconnect battery cables from battery.

• Remove all spark plug caps from the spark plug.

NOTE: Motor depicted is electric start model.

[Flywheel]

1. Remove recoil starter. (See page 5-2.)

Page 57

3-10 IGNITION AND ELECTRICAL

2. Using special tools, loosen flywheel nut 2–3 turns.

 09930-48720: Flywheel holder

09930-49210: Flywheel holder attachment

NOTE: Do not remove flywheel nut at this time. This nut prevents damage to the crankshaft when using flywheel remover tools.

3. Using special tools, loosen flywheel from crankshaft.

 09930-39411: Flywheel remover

09930-39210: Flywheel remover bolt

4. Remove flywheel nut 1, washer 2, flywheel 3 and key 4.

[Battery & Condenser charge coil/Pulser coil]

5. Remove side covers. (See page 7-2.)

6. Disconnect stop switch lead wire connector 1. Disconnect starter button lead wire connector 2.

(Tiller handle model)

7. Remove nut and positive + battery cable 3, positive + battery charge cable 4 from the magnetic switch “B” terminal of starter motor. Disconnect the red lead wire 5 from starter motor magnetic switch “S” terminal.

1. Starter motor magnetic switch

Page 58

8. Loosen the PORT side bolt 6 securing starter motor band.

9. Remove the three (3) screws securing battery charge & con-

denser charge coil 7. Remove the two (2) screws securing pulser coil 8. Remove the six (6) bolts securing stator base 9.

IGNITION AND ELECTRICAL 3-11

10. Cut the cable ties 0 securing pulser coil wiring harness to

stator base.

11. Disconnect the 4-pin wiring harness connector from CDI unit.

12. Lift up and remove stator base from cylinder block.

13. Cut the cable ties securing coil wiring harness to stator base.

14. Disconnect battery charge coil lead wire connector from rectifier.

15. Remove the bolt A securing pulser coil GND lead wire.

16. Remove the battery & condenser charge coil.

Page 59

3-12 IGNITION AND ELECTRICAL

INSTALLATION

Installation is reverse order of removal with the special attention to the following steps.

Battery & Condenser charge coil/Pulser coil

• Secure coil lead wire with cable ties, then check that coil lead wire is routed properly and away from hot or rotating parts.

Wire routing

Pulser coil

Pulser coil ground lead wire/Bolt

Cable tie

Battery & Condenser charge coil

Cable tie

To PTC heater (R model)

Cable tie

Main wiring harness

Clamp

Manual starter model

Pulser coil ground lead wire/Bolt

Cable tie

Main wiring harness

Clamp

Electric starter model

Page 60

• Install stator base, then tighten stator base mounting bolts securely.

 Stator base mounting bolt:

8 mm 23 N·m (2.3 kg-m, 16.5 lb-ft) 6 mm 10 N·m (1.0 kg-m, 7.0 lb-ft)

• Apply Thread Lock 1342 to the coil mounting screws.

 99000-32050: THREAD LOCK 1342

IGNITION AND ELECTRICAL 3-13

Flywheel

• Clean flywheel and crankshaft mating surfaces with cleaning solvent.

• Tighten flywheel nut to specified torque.

 09930-48720: Flywheel holder

09930-49210: Flywheel holder attachment

 Flywheel nut: 80 N·m (8.0 kg-m, 58.0 lb-ft)

Final assembly check

Perform the following checks to ensure proper and safe operation.

• All parts removed have been returned to their original positions.

• Wire routing match’s service manual illustration. (See page 9-2 to 9-9.)

Page 61

3-14 IGNITION AND ELECTRICAL

CAUTION SYSTEM

The following two caution systems alert the operator when an abnormality occurs on the engine.

• OVER-REVOLUTION CAUTION

• LOW OIL PRESSURE CAUTION

Caution lamp

CAUTION TYPE

CAUTION

LAMP

CAUTION

BUZZER

(*)

OVER-REV

LIMITER

Over-revolution Yes No Yes Low oil pressure Yes Yes Yes

*: Remote control model only

■ LAMP CHECK

Two (2) seconds after starting engine:

• The caution lamp turns ON.

■ CAUTION BUZZER

On remote control model: The caution buzzer sounds when ignition switch is turned ON. Then it stops sounding when engine starts and the oil pressure switch turns OFF by reaching engine oil pressure at 15 kPa (0.15 kg/cm

, 2 psi).

OVER-REVOLUTION CAUTION SYSTEM

CONDITION:

The CDI unit controlled over revolution limiter will engage at the engine speeds shown below. Once engaged it will initiate an intermittent ignition signal to reduce engine speed.

Over revolution limiter: 6 500 r/min

ACTION:

• If the operator decreases engine speed to less than approximately 6 200 r/min within 10 seconds, the over-revolution caution control will be cancelled.

• If the engine is operated at a speed above 6 500 r/min for more than 10 seconds, the engine speed will be automatically lowered to approximately 3 000 r/min by intermittent ignition.

• During operation of the over-revolution caution control, the caution lamp is ON.

RESET:

To cancel the over-revolution caution control, close the throttle to reduce the engine speed below approximately 2 500 r/min for more than one second.

NOTE: In neutral gear, the preset maximum engine speed value before the over-revolution caution system activates is 4 000 r/min. In the operation of Neutral gear over-revolution caution system, the lamp does not light. To cancel the Neutral gear over-revolution caution control, close throttle completely for more than one second.

Page 62

LOW OIL PRESSURE CAUTION SYSTEM

IGNITION AND ELECTRICAL 3-15

CDI unit

LED output circuit

PPB

B/R

Caution lamp

Magneto

Condenser charge coil

Oil pressure switch

15 kPa (0.15 kg/cm

, 2 psi)

CONDITION:

Immediate activation of the system when the oil pressure switch turns “ON” due to an engine oil pressure drop below 15 kPa (0.15 kg/cm

, 2 psi).

ACTION:

• The caution lamp is on.

• The caution buzzer sounds. (For remote control model only.)

• The engine speed will be automatically reduced to approx. 2 000 r/min by intermittent ignition signals if the system is activated at 2 000 r/min or higher.

RESET:

• Stop the engine and check the engine oil level. Refill the engine oil to the correct level.

• The low oil pressure caution system is reset when the oil pressure is restored to over 15 kPa (0.15 kg/cm 2 psi) with approx. 1 500 r/min for 1.5 seconds.

If the engine oil level is correct, the following causes may be considered:

• Improper oil viscosity

• Malfunctioning oil pressure switch

• Clogged oil filter

• Worn oil pump relief valve

• Oil leakage from oil passage

• Excessive wear/damage of oil pump

Page 63

3-16 IGNITION AND ELECTRICAL

TESTING OIL PRESSURE CAUTION SYSTEM

To check the oil pressure caution circuit, follow the procedure below.

NOTE: Before checking the oil pressure caution circuit, make sure the engine oil pressure is within specification.

OIL PRESSURE SWITCH

a. Remove the blue lead wire from the oil pressure switch. b. Check the continuity between the switch terminal and the

engine body ground.

 09930-99320 : Digital circuit tester

 Tester range:  (Continuity)

During engine running Infinity At engine stop Continuity

Oil pressure switch

If measurement exceeds specification, replace oil pressure switch.

OIL PRESSURE CAUTION LAMP CIRCUIT

a. Remove the blue lead wire from the oil pressure switch. b. Start the engine. c. Touch the blue lead wire to the engine body ground. If the

caution lamp comes on, the oil pressure switch circuit and the oil pressure caution lamp are normal.

CAUTION LAMP

Check for illumination of the caution lamp.

1. Disconnect lamp lead wires from engine harness.

2. For tests using 1.5V power source (or battery), connect the lamp lead wire to the 1.5V power source (or battery) as shown below.



Do not use Battery larger than 2V.

Pink lead wire → Battery (+) Black lead wire → Battery (–)

Black

Pink

When 1.5 V applied → Lamp ON

If out of specification, replace the caution lamp.

Pink

Black

1.5V Battery

Page 64

REMOVAL AND INSTALLATION

OIL PRESSURE SWITCH Removal

1. Remove the plate 1 by sliding it upward.

2. Remove CDI unit 2 from electric parts holder.

3. Remove the two (2) bolts 3 securing ignition coil.

4. Loosen screw and disconnect blue lead wire from oil pressure switch.

5. Remove oil pressure switch from cylinder block.

IGNITION AND ELECTRICAL 3-17

INSTALLATION

Installation is reverse order of removal with special attention to the following steps.

• Before installing oil pressure switch, wrap screw threads with sealing tape then tighten switch to specified torque.

NOTE: Cut off any excess sealing tape from switch threads before installation.

 Oil pressure switch: 13 N·m (1.3 kg-m, 9.5 lb-ft)

• Start engine and check oil pressure switch for oil leakage.

• Reseal switch if oil leakage is found.



Sealing tape

Page 65

3-18 IGNITION AND ELECTRICAL

BATTERY CHARGING SYSTEM

OUTLINE

The battery charging system circuit is illustrated below. It is composed of the battery charge coil, the rectifier & regulator and the battery. The AC current generated from the battery charge coil is converted by the rectifier into regulated DC current which is used to charge the battery.

Manual start model

Magneto

Battery charge coil (12 V 80 W)

Receptacle plug

Battery (12 V)

Electric start model

Y-tube

R-tube

Starter motor

Fuse 20A

Rectifier & Regulator

------: Option

To starter button (Tiller handle model)

Magneto

PTC heater

Fuse 20A

Battery

To ignition switch (Remote control model)

Starter motor

relay

Rectifier & Regulator

Y/G

1. Battery charge coil 12 V 80 W (Tiller handle model) 12 V 120 W (Remote control model)

------ : Remote control model only

Page 66

INSPECTION

BATTERY CHARGE COIL OUTPUT  Peak Voltmeter Stevens CD-77

Tester range: POS 50

1. Disconnect battery charge coil wires from rectifier.

2. Remove all spark plugs.

3. Connect tester probe to battery charge coil lead wires as shown.

Tester probe connection

+ (Red) - (Black)

Red Yellow

4. Crank with the recoil starter.

Coil output: 5.6 V or over

If measurement is out of specification, replace the battery charge coil.

IGNITION AND ELECTRICAL 3-19

YellowRed

BATTERY CHARGE COIL RESISTANCE

 09930-99320: Digital tester  Tester range: Ω (Resistance)

1. Disconnect the battery charge coil wires from the rectifier.

2. Connect tester probe to battery charge coil lead wires as shown.

Tester probe connection

Probe Other probe

Red Yellow

Coil resistance:

0.9 – 1.3 Ω {80 W coil: DF9.9E/15E, DF9.9/15}

0.3 – 0.4 Ω {120 W coil: DF9.9R/15R}

If measurement is out of specification, replace the battery charge coil.

YellowRed

Page 67

3-20 IGNITION AND ELECTRICAL

RECTIFIER & REGULATOR

 09900-25010: Pocket tester  Tester range: ×1 kΩ (Resistance)

1. Disconnect all lead wires of rectifier & regulator.

2. Measure resistance between leads in the combinations shown.

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.

Rectifier & regulator resistance:

Remote control model Unit: Approx. kΩ

Tester probe + (Red)

Black White

Black 7 – 11 2 – 4 2 – 4 2 – 3 7 – 11

White

Yellow 1

Red

Yellow 2

Tester probe - (Black)

Yellow 3

∞

160 – 240

2 – 4

∞∞∞∞ ∞

∞ 0 ∞∞∞

Yellow 1

Red

Yellow 2 Yellow 3

∞∞∞

400 – 600 400 – 600

2 – 4

Tiller handle model Unit: Approx. kΩ

Tester probe + (Red)

Black White Yellow Red

Remote control model

Yellow 1

White

Tiller handle model

Red

Black

Yellow 3

Yellow 2

Black 7 – 11 2 – 4 2 – 4

White

(Black)

Yellow ∞ 2 – 4 ∞

Tester probe -

Red ∞ 2 – 4 ∞

∞

If measurement exceeds specification, replace rectifier & regulator.

∞∞

Yellow

White

Red

Black

Page 68

FUSE CASE/FUSE

 09930-99320: Digital tester  Tester range:  (Continuity)

Fuse

1. Remove the plate 1 by sliding it upward.

2. Remove the fuse from fuse case 2.

3. Inspect the fuse and replace with a new 20-amp fuse if needed.

IGNITION AND ELECTRICAL 3-21

Fuse

Fuse case

1. Disconnect battery cables from battery.

2. Disconnect white lead wire of rectifier from engine wire harness.

3. Check continuity between White lead wire 1 of engine wire harness and Red lead wire 2 of starter motor magnetic switch “B” terminal.

If no continuity is indicated, replace engine wire harness and/or fuse.

Starter motor magnetic switch

Page 69

3-22 IGNITION AND ELECTRICAL

REMOVAL/INSTALLATION

REMOVAL

Before removing electrical parts:

• Disconnect battery cables from battery.

• Disconnect spark plug cap from all spark plugs.

Battery & Condenser charge coil

• Remove flywheel (See page 3-9.)

• Remove the stator base and battery charge coil (See page 3-10.)

Rectifier & Regulator

• Remove the bolts securing stator base. (See page 3-10.)

• Lift stator base from cylinder block and lay it on port side as shown figure.

• Remove the screws securing the rectifier & regulator 1.

• Disconnect lead wire connectors.

INSTALLATION

Installation is reverse order of removal with special attention to the following steps.

• Battery & Condenser charge coil

• Install stator base and charge coil. (See page 3-12.)

• Wire routing

• Check wire routing. (See page 9-3 to 9-9.)

Page 70

IGNITION AND ELECTRICAL 3-23

ELECTRIC STARTER SYSTEM

OUTLINE

The starting circuit consists of the battery, starting motor, ignition switch (or starter button), neutral switch and related electrical wiring. These components are connected electrically as shown in figure below.

STARTING SYSTEM CIRCUIT

In the circuit shown in figure below, the magnetic switch coils 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.

For Tiller handle model

Hold-in coil

Plunger

Shift lever

Ring gear

Pinion & over-running clutch

Starter button

Neutral switch

W/R

W/RW/RW/R

Y/G Y/GY/G Y/G

Pull-in coil

Fuse 20A

Magnetic switch

Starter motor

Starter relay

Y/GY/G

Battery



Movable contact Stationary contact

Page 71

3-24 IGNITION AND ELECTRICAL

For Remote control model

Ignition switch

SUZUKI

Shift lever

Pinion & over-running clutch

FREEPUSH

IG OFF

PUSH TURN

Hold-in coil

Plunger

Ring gear

GND

STOP

BATT

START

B.Z

RESET

Pull-in coil

Fuse 20A

Magnetic switch

Starter motor

Starter relay

Y/GY/G

Battery

Neutral switch

Y/G Y/GY/G Y/G



Y/GY/G

Movable contact Stationary contact

Page 72

IGNITION AND ELECTRICAL 3-25

TROUBLESHOOTING

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.



If any abnormality is found, immediately disconnect battery cables from battery.

Engine does not start.

Does engine turn over with continued cranking?

YES

• Check pinion and over-

• Check starter magnetic

running clutch. (See page 3-35.)

switch. (See page 3-37.)

Does starter motor rotate?

YES

• Check battery for charging condition.

• Check battery terminals for connections and corrosion.

• Check 20A fuse and fuse case.

(See page 3-21.)

YES

Check for starter relay

• “Click” sound when turn-

ing ignition switch to “START”. (R model) Check for starter relay

• “Click” sound when

starter button depressed. (Tiller handle model) Is there “Click” sound?

YES

• Check function of neutral switch (See page 3-

27.)

• Check ignition switch

function. (See page 3-

26.)

• Check starter button function. (See page 3-26.)

• Check starter relay. (See page 3-27.)

• Check wiring system and connections between starter relay and ignition switch (or starter

button).

Does the flywheel rotate?

No (or turns slowly)

• Check battery for charging condition.

• Check battery terminals for connections and corrosion.

• Remove starter motor from engine.

• Does starter motor turn under no-load conditions by connecting battery + terminal to “M” terminal of starter motor and battery - terminal to the starter motor body.

YES

• The magnetic switch and / or connection is faulty. Replace it.

• Check the brush and

brush holder. (See page 3-34.)

• Check the armature coil. (See page 3-34.)

Page 73

3-26 IGNITION AND ELECTRICAL

INSPECTION

IGNITION SWITCH (Remote control model)

 09930-99320: Digital tester  Tester range:  (Continuity)

1. Disconnect the ignition switch from remote control wiring harness.

2. Check continuity between wiring leads at the key positions shown in the chart.

FREE

PUSH



(OFF)

(ON)

(START)

Key Position



OFF

START

FREE

PUSH

Black Green White Gray Brown Orange

Switch Lead Wires

: Continuity

If out of specification, replace ignition switch.

STARTER BUTTON (Tiller handle model)

 09930-99320: Digital tester  Tester range:  (Continuity)

1. Disconnect the starter button lead wire.

2. Check continuity between the wiring leads under the condition shown below.

Starter button not depressed

Starter button depressed

Tester probe connection

Probe Other probe

White/Red Brown

Continuity

Yes

Orange

Brown

White

W/R

Green

Gray

Not depressed

Black

Blue

Depressed

If out of specification, replace the starter button.

Page 74

IGNITION AND ELECTRICAL 3-27

NEUTRAL SWITCH

 09930-99320: Digital tester  Tester range:  (Continuity)

1. Disconnect neutral switch lead wire.

2. Check continuity/infinity between Yellow/Green and Brown lead wire while operating the shift lever or remo-con handle.

Neutral switch function:

Shift position Tester indicates

Neutral Continuity Forward Infinity Reverse Infinity

If out of specification:

•1st

• 2nd

Check switch position adjustment, readjust if necessary. Replace neutral switch.

NOTE: After installing neutral switch, check for proper correct function by operating remo-con handle or shift lever.

Forward

Neutral

Reverse

STARTER MOTOR RELAY

 09930-99320: Digital tester  Tester range:  (Continuity)

1. Remove the plate a by sliding it upward.

2. Remove CDI unit b.

3. Pull out relay c from electric parts holder, then disconnect

starter motor relay from wire.

4. Check continuity between terminal 1 and 2 each time 12 V is applied. Connect positive + side to terminal 4, and negative - side to terminal 3.

Starter motor relay function:

12 V power Continuity

Applied Yes

Not applied No



Be careful not to touch 12 V power supply wires to each other or with other terminals.

12 V

CONT

Page 75

3-28 IGNITION AND ELECTRICAL

5. Measure resistance between relay terminals 3 and 4.

 Tester range: Ω (Resistance)

Starter motor relay solenoid coil resistance:

145 – 190 Ω

If out of specification, replace starter motor relay.

Page 76

STARTER MOTOR

REMOVAL

Prior to removing starter motor:

• Disconnect battery cables from battery.

1. Remove the side covers. (See page 7-2.) Remove bolts and recoil starter 1. (See page 5-2.)

2. Remove the flywheel 2. (See page 3-9.)

 09930-48720: Flywheel holder

09930-49210: Flywheel holder attachment 09930-39411: Flywheel remover 09930-39210: Flywheel remover attachment bolt

IGNITION AND ELECTRICAL 3-29

3. Remove nut 3 and positive + battery cable 4, positive + battery charge cable 5 from the magnetic switch “B” terminal of starter motor. Disconnect the red lead wire 6 from starter motor magnetic switch “S” terminal.

4. Disconnect engine stop switch lead wire connector 7. Disconnect starter switch lead wire connector 8.

(Tiller handle model)

5. Remove the PORT side bolt 9 securing starter motor band.

1. Starter motor magnetic switch

Page 77

3-30 IGNITION AND ELECTRICAL

6. Remove the six (6) bolts securing stator base 0.

7. Lift up stator base, then remove starter motor A.

INSTALLATION

Installation is reverse order of removal with special attention to the following steps.

• Install starter motor and stator base, then tighten stator base mounting bolts securely.

 Stator base mounting bolt:

8 mm 23 N·m (2.3 kg-m, 16.5 lb-ft) 6 mm 10 N·m (1.0 kg-m, 7.0 lb-ft)

• Check wire routing. (See page 9-2 to 9-9.)

DISASSEMBLY

When overhauling starting motor, it is recommended that component parts be cleaned thoroughly. However, the yoke assembly, armature coil, over-running clutch assembly, magnetic switch assembly, and rubber or plastic parts should not be washed in a degreasing tank or with a grease dissolving solvent. These parts should be cleaned with compressed air or wiped with clean cloth.

NOTE: Before disassembling starting motor, be sure to put match marks at three locations (A, B and C) as shown in figure at right to avoid any possible component alignment mistakes.

Page 78

1. Remove nut 1 from magnetic switch, then disconnect the connecting wire 2.

2. Remove two bolts 3 securing magnetic switch.

3. Remove the magnetic switch 4.

IGNITION AND ELECTRICAL 3-31

4. Remove screws 5, long through bolts 6 and rear cover 7.

5. Remove thrust washer 8 with screwdriver.

6. Pull the brush spring 9 up to separate the brush from the surface of the commutator, then remove the brush holder 0.

Page 79

3-32 IGNITION AND ELECTRICAL

7. Remove the yoke A and armature B.

8. Remove the center cover plate C.

9. Remove the planetary gears D and internal gear E.

10. Remove the center bracket F (with shift lever H, pinion I and pinion shaft J) from front housing G.

11. Remove the shift lever H.

12. Push the pinion stopper K down, then remove stopper ring L. Remove the pinion stopper and pinion I.



Wear safety glasses when disassembling and assembling stopper ring.

NOTE: Using a screw-driver, pry off the stopper ring.

Page 80

13. Remove the E-ring M.

14. Remove the pinion shaft J, washers N and rubber ring O

from center bracket.

IGNITION AND ELECTRICAL 3-33

INSPECTION AND SERVICING Armature and Commutator

• Inspect the commutator surface. If surface is gummy or dirty, clean with #500 grit emery paper A.

• Measure commutator outside diameter.

 09900-20101: Vernier calipers

Commutator outside diameter:

Standard: 29.0 mm (1.14 in) Service limit: 28.0 mm (1.10 in)

If measurement exceeds service limit, replace armature.

• Check that mica (insulator) between the segments is undercut to specified depth.

Commutator undercut 1:

Standard: 0.5 – 0.8 mm (0.02 – 0.03 in) Service limit: 0.2 mm (0.01 in)

SEGMENT

If measurement exceeds service limit, cut to specified depth.

NOTE: Remove all particles of mica and metal using compressed air.

MICA

1 undercut

Page 81

3-34 IGNITION AND ELECTRICAL



Wear safety glasses when using compressed air.

• Check for continuity between the commutator and the armature core/shaft. Replace armature if continuity is indicated.

 09930-99320: Digital tester  Tester range:  (Continuity)

• Check for continuity between adjacent commutator segments. Replace armature if no continuity is indicated.

 09930-99320: Digital tester  Tester range:  (Continuity)

BRUSHES

Check the length of each brush.

Commutator

Shaft

Armature core

 09900-20101: Vernier calipers

Brush length:

Standard: 15.5 mm (0.61 in) Service limit: 9.5 mm (0.37 in)

If brushes are worn down to the service limit, they must be replaced.

BRUSH HOLDER

• Check brush holder continuity.

 09930-99320: Digital tester  Tester range:  (Continuity)

Brush holder continuity:

Tester probe connection Continuity

Brush holder positive + to Brush holder negative -

Brush holder positive + to Base plate (ground)

Brush

Base plate

Replace brush holder if the tester doesn’t show the above.

Page 82

BRUSH SPRING

Inspect brush spring for wear, damage or other abnormal conditions. Check the brush spring tension. Replace if necessary.

Brush spring tension

Standard: 15 – 18 N (1.5 – 1.8 kg, 3.3 – 4.0 lb)

SHIFT LEVER

Inspect shift lever for wear. Replace if necessary.

IGNITION AND ELECTRICAL 3-35

PINION AND OVER-RUNNING CLUTCH

• Inspect pinion for wear, damage or other abnormal conditions. Check that clutch locks up when turned in direction of drive and rotates smoothly in reverse direction. Replace if necessary.

• Inspect spline teeth for wear or other damage. Inspect pinion for smooth movement. Replace if necessary.

GEAR

• Inspect planetary gears and internal gear for wear, damage or other abnormal conditions. Replace if necessary.

Page 83

3-36 IGNITION AND ELECTRICAL

PINION SHAFT/PINION SHAFT BUSH

• Inspect pinion shaft for wear, damage or other abnormal conditions. Replace if necessary.

• Inspect pinion shaft bush for wear or other damage. Replace if necessary.

FRONT HOUSING

• Inspect front housing for wear, damage or other abnormal conditions. Replace if necessary.

• Inspect bush for wear or other damage. Replace if necessary.

ARMATURE SHAFT BUSH

Inspect bush for wear or other damage. Replace if necessary.

PLUNGER

Inspect plunger for wear or other damage. Replace if necessary.

Page 84

MAGNETIC SWITCH

Push in plunger and release. The plunger should return quickly to its original position. Replace if necessary.

Pull-in coil Open circuit Test

 09930-99320: Digital tester  Tester range:  (Continuity)

Check for continuity across magnetic switch “S” terminal and “M” terminal. If no continuity exists, the coil is open and should be replaced.

IGNITION AND ELECTRICAL 3-37

1. Plunger

1. Terminal “S”

2. Terminal “M”

3. Terminal “B”

Hold-in coil Open circuit Test

 09930-99320: Digital tester  Tester range:  (Continuity)

Check for continuity across magnetic switch “S” terminal and coil case. If no continuity exists, the coil is open and should be replaced.

Contact points Test

 09930-99320: Digital tester  Tester range:  (Continuity)

Put the plunger on the under side and then push the magnetic switch down. At this time, check for continuity between terminal “B” and terminal “M”. Continuity indicates proper condition. If no continuity exists, replace the magnetic switch and/or plunger.

Page 85

3-38 IGNITION AND ELECTRICAL

ASSEMBLY

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



When installing armature, use care to avoid breaking brushes.

When installing pinion shift lever, refer to figure in construction diagram for installation direction.

Construction diagram

7 N.m (0.7 kg-m,

5.1 lb-ft)

5.5 N.m (0.55 kg-m, 4.0 lb-ft)

Nut

Bolt

Magnetic switch

Gasket

Spring

Plunger

Torsion spring

Rubber packing

Shift lever

Front housing

Screw

Through bolt

Rear cover

Thrust washer

Brush holder

Yoke

Armature

Center cover plate

Internal gear

Planetary gear

Pinion shaft

Pinion

E-ring

Washer

Center bracket

Rubber ring

Stopper ring

Pinion stopper

Page 86

PERFORMANCE TEST



Each test must be performed within 3 – 5 seconds to avoid coil damage from overheating.



When performing the following test, be sure to connect the battery and the starting motor with a lead wire of the same size as original equipment used there.

IGNITION AND ELECTRICAL 3-39

PULL-IN/HOLD-IN TEST

Connect battery to magnetic switch as shown in figure.

• Check that plunger and pinion (over-running clutch) move outward. If plunger and pinion don’t move, replace magnetic switch.

NOTE: Before testing, disconnect brush lead from terminal “M”.

• While connected as above with plunger out, disconnect negative lead from terminal “M”. Check that plunger and pinion remain out. If plunger and pinion return inward, replace magnetic switch.

PLUNGER AND PINION RETURN TEST

Disconnect negative lead from switch/motor body. Check that plunger and pinion return inward. If plunger and pinion don’t return inward, replace magnetic switch.

1. Terminal “S”

2. Terminal “M”

3. Terminal “B”

4. Brush lead

Page 87

3-40 IGNITION AND ELECTRICAL

NO-LOAD PERFORMANCE TEST



Before performing following test, secure the starter motor to the test bench.

1. Connect battery and ammeter to starter motor as shown.

2. Check that starter rotates smoothly and steadily with pinion moving out. Check that ammeter indicates specified current.

No load current: Within 90 A at 11 V

Page 88

FUEL SYSTEM 4-1

FUEL SYSTEM

CONTENTS

PRECAUTION ON FUEL SYSTEM SERVICE ..............................................4- 2

GENERAL PRECAUTION.......................................................................4- 2

FUEL LINE.....................................................................................................4- 2

REMOVAL/INSTALLATION....................................................................4- 2

FUEL LEAKAGE CHECK PROCEDURE ...............................................4- 3

FUEL HOSE CONNECTION ...................................................................4- 3

CARBURETOR..............................................................................................4- 4

REMOVAL ...............................................................................................4- 4

INSTALLATION.......................................................................................4- 5

DISASSEMBLY .......................................................................................4- 6

CLEANING & INSPECTION....................................................................4- 9

REASSEMBLY ........................................................................................4-11

THROTTLE CONTROL .................................................................................4-13

INSTALLATION/ADJUSTMENT .............................................................4-13

FUEL PUMP...................................................................................................4-15

REMOVAL/INSTALLATION....................................................................4-15

DISASSEMBLY/REASSEMBLY .............................................................4-16

INSPECTION ...........................................................................................4-17

FUEL TANK ...................................................................................................4-18

DISASSEMBLY/REASSEMBLY .............................................................4-18

INSPECTION ...........................................................................................4-19

OPERATION ..................................................................................................4-20

CARBURETOR .......................................................................................4-20

Page 89

4-2 FUEL SYSTEM

PRECAUTION ON FUEL SYSTEM SERVICE

GENERAL PRECAUTION



Gasoline is extremely flammable and toxic. Always observe the following precautions when working around gasoline or servicing the fuel system.

• Disconnect battery cables except when battery power is required for servicing / inspection.

• 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 CO readily available for use.

• Always use appropriate safety equipment and wear safety glasses when working around 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.

2 fire extinguisher and

FUEL LINE

REMOVAL/INSTALLATION

Pay special attention to the following steps when removing or installing fuel hoses.



• Do not over bend (kink) or twist hoses when installing.

• When installing hose clamps (clips), 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.

• Extreme care should be taken not to cut, abrade or cause any other damage to hoses.

• Use care not to excessively compress hoses when tightening clamps.

NOTE:

• Check fuel hose routing. (See page 9-11 and 9-12.)

• Check for fuel leakage.

Page 90

FUEL LEAKAGE CHECK PROCEDURE

After performing any fuel system service, always be sure there is not fuel leakage by checking as follows.

1. Squeeze fuel primer bulb until you feel resistance.

2. Once pressurized, check all connections and components for any signs of leakage.

FUEL HOSE CONNECTION

Note that fuel hose connection varies with each type of pipe. Be sure to connect and clamp each hose correctly by referring to the figure.

FUEL SYSTEM 4-3

• For type “A” (short barbed end) pipe, hose must completely cover pipe.

• For type “B” (bent end) pipe, hose must cover straight part of pipe by 20 – 30mm (0.8 – 1.2 in.).

• For type “C” pipe, hose must fit up against flanged part of pipe.

“A”

“B”

“C”

Clamp (Clip)

Hose

Joint pipe

3 – 7 mm (0.1 – 0.3 in)

20 – 30 mm (0.8 – 1.2 in.)

3 – 7 mm (0.1 – 0.3 in.)

• For type “D” pipe, hose must cover pipe by 20 – 30 mm (0.8 –

1.2 in.).

“D”

3 – 7 mm (0.1 – 0.3 in.)

20 – 30 mm

3 – 7 mm (0.1 – 0.3 in.)

(0.8 – 1.2 in.)

Page 91

4-4 FUEL SYSTEM

CARBURETOR



Before servicing the fuel system, read and understand “PRECAUTION ON FUEL SYSTEM SERVICE” in the previous section.

REMOVAL

1. Remove the STBD side cover. (See page 7-2.)

2. Remove the two (2) bolts securing carburetor.

3. Remove the silencer case 1, carburetor 2 and insulator 3.

4. Detach the fuel hose 4 from carburetor inlet. Remove the throttle rod 5 from carburetor.

5. On tiller handle model: Unscrew the starter cable lock nut 6, then remove starter cable with starter plunger 7.

Page 92

FUEL SYSTEM 4-5

6. On remote control model: Disconnect the auto-enrichener lead wire connector.

INSTALLATION

Installation is the reverse order of removal with special attention to the following steps.



Do not re-use gasket, as sealing abilities will be insufficient. Air leakage will induce a lean air/fuel mix which will result in severe engine damage.

• On tiller handle model:

Install starter cable with starter plunger 1, then tighten the starter cable lock nut 2 securely.

1. Auto-enrichener

• Install insulator gasket 3, insulator 4, carburetor gasket 5, carburetor 6 and silencer case 7, then tighten carburetor mounting bolts 8 to specified torque.

 Carburetor mounting bolt: 10 N·m (1.0 kg-m, 7.0 lb-ft)

NOTE:

• When installing carburetor gasket, be sure that starter fuel passage is not obstructed.

• The projection of insulator must be faced to STBD and intake manifold sides.

Page 93

4-6 FUEL SYSTEM

Final assembly check

Perform the following checks to ensure proper and safe operation.

• All parts removed have been returned to their original positions.

• No fuel leakage is evident when fuel system is pressurized. (See page 4-3.)

DISASSEMBLY

NOTE: Carburetor depicted is carburetor with acceleration pump.

1. On remote control model:

Remove the screw 1 and the auto-enrichener 2 with plate

2. Remove the four (4) screws securing the top cover 4, then remove the cover and rubber gasket 5.

NOTE: On the carburetor with covered pilot screw: Do not remove the cover and adjust pilot screw.

Pilot screw/cover

Page 94

3. Remove the four (4) screws securing the float chamber 6, then remove the chamber and rubber gasket 7.

FUEL SYSTEM 4-7

4. Remove the screw 8 securing float pin. Account for float 9, float pin 0 and needle valve A.

Page 95

4-8 FUEL SYSTEM

5. Remove the main jet B and main nozzle C.

6. Remove the cap D and pilot jet E.

7. Remove the acceleration pump plunger F and spring G.

Page 96

CLEANING & INSPECTION

Clean thoroughly with cleaning solvent and compressed air before inspection.



Wear safety glasses when using compressed air to expel solvent, carburetor cleaner, etc.



Do not place any rubber, plastic and non-metallic parts in cleaning solvent, as severe damage or deterioration will result.

NOTE: Wire or small drill bits must not be used to clean carburetor orifices and jet.

FUEL SYSTEM 4-9

CARBURETOR BODY/TOP COVER

• Inspect the carburetor body and top cover. If cracks or other damage are found on any component, replace it.

• Clean the carburetor body and top cover so that there is no obstruction.

• Inspect the needle valve seat. Replace carburetor body if wear, damage, or other abnormal condition.

JET, NOZZLE

• Inspect the jet and nozzle. If cracks or other damage are found on the jet and nozzle, replace them.

• Clean the jet and nozzle thoroughly so that there is no obstruction.

NEEDLE VALVE ASSEMBLY

Inspect the needle valve assembly. If broken tips or wear are found on the needle valve assembly, replace it.

Page 97

4-10 FUEL SYSTEM

FLOAT

Inspect the float. If cracks or other damage are found on the float, replace it.

AUTO-ENRICHENER

Inspect the needle valve. If broken tips or wear are found on the needle valve, replace the auto-enrichener.

• Connect the positive + terminal of 12 V battery to Yellow lead and the negative - terminal to other yellow lead.

• Check that the auto-enrichener section (PTC heater built-in area) is heated in 5 minutes after the battery has been connected.

NOTE: To inspect the function, check for change of temperature from the cold condition.



Do not attempt to disassemble the auto-enrichener for the purpose of checking temperature.

PTC heater built-in area

12 V Battery

Page 98

REASSEMBLY

Reassembly is reverse order of disassembly with special attention to the following steps.

FUEL SYSTEM 4-11

CONSTRUCTION DIAGRAM

1. Carburetor body

2. Main nozzle

3. Main jet

4. Pilot jet

5. Cap

6. Float

7. Needle valve

8. Needle valve pin

9. Clip

10. Pin

11. Screw

12. Stop screw

13. Spring

14. Gasket

15. Float chamber

16. Drain screw

17. O-ring

18. U-ring

19. Top cover

20. Screw

21. Cable holder

22. Cable guide

23. Cable sealing cap

24. Starter valve

25. Spring

marked item: For DF9.9R/15R only. marked item: For DF15/E/R only. marked item: For Tiller handle model only.

26. O-ring

27. Drain hose

28. Clip

29. Plate

30. Screw

31. Starter assy

32. Clip

33. Cap

34. Plunger

35. Spring

36. Starter knob assy

37. Cable protector

33 32

7 8

4 5

2 3

FLOAT

Install the float (with float pin and needle valve), then secure float pin with the screw.

NOTE: After installing float, inspect for smooth movement of float.

Page 99

4-12 FUEL SYSTEM

CHECKING FLOAT HEIGHT

Measure the float height.

NOTE: Make sure that float weight is not applied to needle valve.

 09900-20101: Vernier calipers

Float height H: 13.5 ± 2 mm

ACCELERATION PUMP

Check that the acceleration pump plunger operates smoothly and together with the throttle lever when turned.

Page 100

THROTTLE CONTROL

INSTALLATION/ADJUSTMENT

TILLER HANDLE MODEL

FUEL SYSTEM 4-13

0 – 2 mm

(rib)

1. Fit two throttle cables, 1 and 2, both to the throttle drum 3 and the cable holder 4.

2. Adjust the length of throttle rod 5 to the specification below:

Throttle rod length L : 96 mm (3.78 in.)

3. Fit one end of the throttle rod 5 to the throttle lever 6 and other end to the carburetor throttle arm 7.

4. Turn the throttle control grip to its full open position.

Adjust the throttle cable 1 by turning the lock nuts 8 to the appropriate direction so that the stopper A on the throttle drum 3 can contact the stopper B on the cylinder block.

5. Return the throttle control grip to its completely closed position.

Adjust the throttle cable 2 by turning the lock nuts 9 to the appropriate direction so that the matching mark C can align with the rib D on the cylinder block.

6. With the throttle control grip in completely closed position, check that there are clearances, X and Y,

between the throttle drum and throttle control lever. Secure the throttle cables, 1 and 2, on the cable holder by tightening the lock nut.

7. Position the throttle control grip in full open position.

Check that there is 0 − 2 mm of clearance between the carburetor full open stopper E and the lever F

when the throttle drum stopper A and cylinder block stopper B are in contact.

Suzuki DF9, 9, DF15 Service Manual

Specifications and Main Features

Frequently Asked Questions

User Manual