03 model SUPPLEMENTARY SERVICE MANUAL
Contents
1.2. u HOLIMS Lid iIlDROBS ITA THER P 1 H 34 HOLVINDAY H E H ____ HOSN3S T puna INVIW X3 1 a isi ns Pre 10 E HOLOIN 7 H H ede HALYVLS voe 3sna M 3i H VIL Hl ind aH to u HHwa i ni YOLVNYSLIV 1 o HOLIMS Hey _______ lt e Fom dala 19 SS ei ep Ede aua C Fe aisles HosNasdWo HOLOAPNI 1304 NOILVOINQIWINOO syueo jeuondo 7777 NO lt 5591 10 ui2 J6X0 330 HJ HOLIMS aunssaud 110 2 NO N EE 102 39HVHO AYALLVE 9 HOLIMS 1 1 HOSN3S SISONDVIG ADVLIOA AH311V8 HOLOIN H3lHVlS 515 E 55 AV14Y HOLOW 11 am 332719 NOILNVD AV 13H HOLOM D an HOLIMS HOSN3S dVIN 14 DF40 DF50 03 model WIRE ROUTING xoou 1150 sued 9115913 19 1 5 Ion Eni AOL MES PT 5 9262255 E
3. AR ToO CEED mw ES e qeo qns e qeo AW Dy mee c ejqeo ejoJ Ld CT h L5 D X Aejes 1010UJ M N dl Nils 4 D T 7 L jn 3 l _ an m 77 3 4 Sz CAS h NNA t see aS 114 E Z 2 TJS N PO y p Josues duie pjopuew 1Sneux3 OF deo 9Sn VOE DF40 DF50 K3 03 model 15 JOJOSUUOD u9IIMS d SYN YOUMS EN N Y S A 10 oefui jen ii oL 0 SD TT ojoef e 10159 Jon 4 Pils 8JIM peg J0joefur o z u Ne L4 Jojoefur JOY sec 10 99 01d esou 08095 peaj U9IIMS Josues 5 16 DF40 DF50 03 model 1981UO9 01100 Ped JOSU S exoeJg 105095 dV Jej 1261000 0 10 5
4. Aye peg 10100 ojeuDeuJ 1261000 O 104 Ped 08102 jou sseuJeu ut 06070 S770 deb uo Sieg pue Josues ueewjeq deb 4oeuo anbio paijioeds 1nu Buunoes pue JepJou sued 9119913 19147299Y YM 105095 Josues 1001000 0 JOU Ped 4 Josues j1sneux3 ueuM Jepui Ao pue Josues JO ueog o Josues dwa DF40 DF50 03 model 17 Starter motor ge j Tighten bolt with PTT relay ground wire battery cable ground wire and harness switch ground wire H Starter motor sub cable IAT sensor Engine wiring harness ms CIT S7 E Ignition coil 2 Clamp Position clip tabs inward engine side Prepared by SUZUKI MOTOR CORPORATION Marine amp Power Products Division July 2002 Manual No 99501 87J20 01E Printed in Japan SUZUKI MOTOR CORPORATION Printed in Japan
5. 8 50 Recommended operating range 5200 5800 5900 6500 Idle speed 850 50 in gear approx 850 POWERHEAD Engine type 4 stroke DOHC Number of cylinders _ 10080 DICE Compression ratio 10 Spark plu DOPREE Starting system Electric Throttle control Remote control Twist grip Remote control Twist grip DF40 DF50 03 model 3 oom om DFA0T DF40QH DFSOT SOWT DFSOWQH FUEL amp OIL Suzuki highly recommends that you use alcohol free unleaded gasoline with a minimum pump octane rating of 87 2 method or 91 Research method However blends of unleaded gasoline and alcohol with equivalent octane content may be used Engine oil API classification SE SF SG SH SJ Viscosity rating 10W 40 Engine oil amounts 2 2 2 3 1 9 Oil change only L US Imp qt 2 4 2 5 2 1 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil capacity ml US Imp oz 610 20 6 21 5 BRACKET Manual trim and gas Manual trim and gas i 3 PTT system 3 assisted tilt system assisted tilt system Number of trim position Adjustable PTT system PTT system Maximum tilt angle 73 LOWER UNIT Forward Neutral Reverse Propeller Blade x Diam in x Pitch in 9 S900 10 51000 11 51100 12 51200 13 81301 551300 14 51400 551400 15 51500 16 81600 551600 17 51700 5 Aluminum propelle
6. GUIDE Valve diameter LANLION 24 6 0 97 Tappet clearance DIE JN 0 18 0 24 0 007 0 009 Cold engine condition 0 18 0 24 0 007 0 009 angle 15 45 Valve guide to EGET 0 020 0 047 0 0008 0 0019 valve stem 0 045 0 072 0 0018 0 0028 diameter protrusion alio siem Ml EE 5 465 5 480 0 2152 0 2157 outside diameter 5 440 5 455 0 2142 0 2148 length Valve tem end deflection EX Limit 0 18 0 007 runout contact width Ey mm 1 65 2 05 Valve spring free mm 33 1 1 30 Vaive sping c lbs 97 113 9 7 11 3 21 4 24 9 for 28 5 mm 1 12 in N kg 165 89 8 9 19 6 for 28 5 mm 1 12 in Valve spring 6 DF40 DF50 03 model CYLINDER PISTON PISTON RING Oylinder measuring position 50 2 0 from cylinder top surface mm 70 970 70 990 2 7941 2 7949 Cylinder distortion Piston to cylinder clearance Oylinder bore Piston skirt diameter mm 19 0 7 from piston skirt end 0 02 0 06 0 001 0 002 m 0 02 0 06 0 001 0 002 mm me f rmem 0 006 0 018 0 0002 0 0007 17 996 18 000 0 7085 0 7087 18 006 18 014 0 7089 0 7092 0 003 0 015 0 0001 0 0006 18 003 18 011 0 7088 0 7091 Piston measuring ae Piston ring thickness Pin clearanc
7. SUZUKI OUTBOARD MOTOR Om 416 2 f FOUR STROKE For 03 model SUPPLEMENTARY SERVICE MANUAL DF40 50 K3 2003 MODEL FOREWORD This supplementary service manual describes the outline technical data and servicing procedures for the K3 2003 models outboard motor Please read and thoroughly familiarize yourself with this information before using it for your service activities NOTE Use this supplement with the following service manual DF40 50 Service Manual P no 99500 87J0 CONTENTS SPECIFICATIONS 2 SERVICE DATA 4 ECM MAIN RELAY 9 EXHAUST MANIFOLD TEMPERATURE SENSOR AND CYLINDER TEMPERATURE SENSOR 9 CYLINDER BLOCK 10 BUZZER 10 NEUTRAL SWITCH BRACKET 11 UNDER OIL SEAL HOUSING 11 FORWARD GEAR THRUST WASHER 11 EXHAUST CAM SHAFT 12 WIRING DIAGRAMS 13 WIRE ROUTING 14 2 DF4O DF50 03 model GENERAL INFORMATION SPECIFICATIONS oom om DF40T DF4OQH DFSOT SOWT DFSOWOH DIMENSIONS amp WEIGHT Overall length front to back mm in 756 29 8 852 33 5 756 29 8 852 33 5 Overall width side to side mm in 382 15 0 382 15 0 382 15 0 382 15 0 Overall height mm in 1263 49 7 1263 49 7 1390 54 7 1390 54 7 1390 54 7 1390 54 7 we Wem T sus wem _ s eu Ww we mem Du mmws 95e PERFORMANCE Maximum output kW PS 29 4 40 36
8. e in piston pin hole Piston pin outside diameter Piston pin hole diameter Pin clearance in conrod small end Conrod small end bore DF40 DF50 03 model 7 DF40T 40QH DFS50T SOWT SOWQH CRANKSHAFT CONROD Pome mm in 18 003 18 011 0 7088 0 7091 inside diameter 0 020 0 040 0 0008 0 0016 41 000 41 018 1 6142 1 6149 inside diameter tonis com S198 9800 4954 1490 982 38 000 1 4954 S198 9800 4954 1490 1 4961 diameter Crank pin outside diameter difference Limit in 0 010 0 0004 out of round and taper Conrod bearing in 1 486 1 502 0 0585 0 0591 thickness Conrod big side STD 0 100 0 250 0 0039 0 0098 in clearance Limit 0 350 0 0138 Crankshaft journal oil clearance 0 065 0 0026 STH mm in 49 000 49 018 1 9291 1 9298 holder inside diameter Crankshaft journal in 44 02000 44982 48000 7708 17 0000 45 000 1 7709 1 7717 outside diameter Crankshaft journal outside diameter Limit in 0 010 0 0004 difference out of round and taper Crankshaft bearing in 1 1999 2015 00787 0079 00000 2 015 0 0787 0 0793 thickness 0 11 0 31 0 012 ind e mm in 2 470 2 520 0 0972 0 0992 bearing thickness LOWER UNIT Design specification thickness for shim amp wash
9. er Pinion gear back up shim 1 0 0 as Forward gear back up shim Forward gear thrust washer Reverse gear thrust washer 8 DF40 DF50 03 model tem DF40T 40QH DFSOT 50WT 50WQH ELECTRICAL fuesen ignition coil resistance Battery charge coil resistance Battery charge coil output 12V Standard spark plug _ 0 8 0 9 0 031 0 035 Fuse amp rating Main Manfue 30 30 Hecommended battery Fuel injector resistance Q at 20 C 11 0 16 5 IAC valve resistance Q at 20 C 21 5 32 3 IAT sensor Cylinder temp sensor Ex mani temp sensor k Q at 25 C 1 8 2 3 Thermistor characteristic ECM main relay resistance Q at 20 C 80 120 Starter motor relay resistance Q at 20 C 3 5 5 1 PTT motor relay resistance Q at 20 C 3 0 4 5 STARTER MOTOR Max continuous time of use Motor output EE 3 E mm 0 5 0 8 0 02 0 03 Commutator outside m 0 05 0 002 diameter difference 0 40 0 016 Pinion to ring gear gap mm in 3 0 5 0 0 12 0 20 PTT MOTOR Brush length STO mmi _ 9 8 0 39 mm in 4 8 0 19 Commutator ELI mm in 22 0 0 87 outside diameter mm in 21 0 0 83 DF40 DF50 03 model 9 ECM MAIN RELAY 09930 99320 Digital tester Tester range Continuity 1 Disconnect ECM main relay from wi
10. model 11 NEUTRAL SWITCH BRACKET The neutral switch bracket has been changed to be secured with two bolt from the middle of 2002 year model NOTE When install a late type neutral switch bracket to the early cylin der secure the neutral switch bracket with one bolt In this case use the upper side bolt hole on the neutral switch bracket and apply Thread Lock 1342 to the bolt UNDER OIL SEAL HOUSING Before installing under oil seal housing apply grease to oil seal lip under oil seal housing and crankshaft 99000 25160 Water Resistant Grease FORWARD GEAR THRUST WASHER Available thickness 2 0 mm and 2 2 mm gt 2 0 mm only Early Late p L3 7 7 7 aN Forward gear thrust washer 12 DF40 DF50 03 model EXHAUST CAM SHAFT The shape of exhaust cam shaft and exhaust cam sprocket have been changed from the middle of 2002 year model Arrow mark Arrow mark 13 DF40 DF50 K3 03 model WIRING DIAGRAMS HV0Z AZL AH3 LIVS YOLOW Lld uazzna HOLIMS NOILINDI 7109 15 3 1nGOlN TOHLINOO 5 19 4 Ed AATWA OVI 1OHLINOO ALOWSY 38nl M 00 191 02 1 197 HOLIMS 15
11. r SS Stainless steel propeller X X X X X X X X X X X X These specifications are subject to change without notice 4 DF40 DF50 03 model SERVICE DATA POWERHEAD 5200 5800 5900 6500 850 50 in gear approx 860 kPa kg cm psi 1300 1600 13 16 185 228 Cylinder compression max kPa kg cm psi difference between any other 100 1 0 14 cylinders Engine oil pressure 300 380 3 0 3 8 43 54 at 4000 r min kPa kg cm psi at normal operating temp Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts US Imp 2 2 2 3 1 9 Oil change only 2 4 2 5 2 1 Oil filter change Thermostat operating temperature Figures shown are guidelines only not absolute service limits ENGINE OIL PUMP Radial clearance 0 31 0 012 0 15 0 006 CYLINDER HEAD CAMSHAFT 005 0002 distortion 37 530 37 690 1 4776 1 4839 38 230 38 390 1 5051 1 5114 37 640 1 4819 37 640 1 4819 Camshaft journal hous 23 000 23 021 0 9055 0 9063 ing inside ciameter 23171 0 9122 Camshaft diameter Limit 22 784 0 8970 4th 26 959 26 975 1 0614 1 0620 27 000 27 021 1 0630 1 0638 DF40 DF50 K3 03 model 5 Ooo DF40T 40QH DF50T 50WT 50WQH VALVE VALVE
12. re 2 Check continuity between terminal 1 and 2 each time 12 V is applied Connect positive side to terminal 4 and nega tive side to terminal ECM main relay ECM main relay function 12 V power Continuity CAUTION Be careful not to touch 12 V power supply wires to each other or with other terminals EXHAUST MANIFOLD TEMPERATURE SENSOR AND CYL INDER TEMPERATURE SENSOR The shape of temperature sensor has been changed from the middle of 2002 year model Dome shape O ring Tube color Gray h 12 mm The temperature sensor has been changed 2003 year model Change of connector Elimination of O ring Change of tube color Tube color Green pf p 9 mm NOTE Exhaust manifold temperature sensor does not contact with cool ing water from 2003 year model 10 DF40 DF50 03 model CYLINDER BLOCK Cylinder block has been changed because of the change of tem perature sensor Hole for exhaust temperature sensor Hole for cylinder temperature sensor 2002 12 2003 9 2002 12 BUZZER Buzzer in the remote control box side mount type has been changed in function and shape Early Late D E Buzzer has function for intermittent sound Buzzer has function for continuous sound ing itself ing only NOTE Buzzer sounding pattern when caution or the other system acti vates is the same as the pattern on 2002 DF40 DF50 03
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