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PRE-PRODUCTION ISSUE

1. LOW PRESSURE FUEL FILTER Inspect before every use Inspect every 50 hours 3 months Replace every 400 hours 2 years If leakage cracks or other damage is found replace the fuel fil ter Inspect and Cleaning A WARNING Stop the motor before cleaning the fuel filter Do not smoke and keep open flames and sparks away while working near any part of the fuel system 1 Turn the engine OFF 2 To remove the cover 1 pull the upper part outward then lift up 3 Disconnect the inlet hose and outlet hose 3 from fuel fil ter 4 Remove the fuel filter from filter bracket Remove the cap 6 then drain and clean fuel filter Install the cap then secure it with clamp 7 Install fuel filter to filter bracket properly Connect the fuel inlet and outlet hose to fuel filter then secure the fuel hoses to the fuel filter with the hose clamp 9 Restart the engine and check that there are no leaks around the fuel filter 10 Install the cover pd pL HIGH PRESSURE FUEL FILTER Replace every 1 000 hours SUZUKI recommends that replacing the high pressure fuel filter every 1 000 operating hours PERIODIC MAINTENANCE 2 19 P Ww LU ine 7 Pi
2. 50 dls 75 0 05 0 uci oo ef onore sooo eoo eo wo soe oo aa uz oo n ejr on prefere eee wo soo e prenne ee oe or oe ere oe eene 7 o2ueJeo o 88 C 0 1 9215 ullus epis LHYHO NOILO3T13S WIHS 13ddVL 2 16 PERIODIC MAINTENANCE IDLE SPEED gt gt Inspect initially after 20 hours 1 month and every pZ G 200 hours 12 months P i NOTE Before checking idle speed engine must be warmed SS e Check and or adjust idle speed after engine speed has stabi n lized 4 Before checking idle speed check throttle link mechanism throttle valve for smooth operation 3 Ln pica 1 1 ignition coil amp dum D 77 y f o 7 1 Remove bolt and 1 ignition coil 2 Connect special tool cord with plug cap adapter between No 1 ignition coil and spark plug 09930 89350 H T cord with plug cap adapter 3 Start engine and allow to warm up 4 Attach engine tachometer to the special tool 09900 26006 Engine tachometer 5 Check engine speed Idle speed in neutral gear 600 700 r min ADJUSTMENT If engine idle speed is out of specification the following adjust ment procedure must be performed 6 Remove the three 3 bolts and fuel hose guard 7 Shift into Neutral and close
3. 1 Depression chamber 2 Intake manifold 3 Rod 3 64 ENGINE CONTROL SYSTEM VACUUM PASSAGE INSPECTION 1 Disconnect vacuum hose 4 from vacuum switching valve 2 2 Start engine and it at idle speed Place a finger over vacuum hose end and engine vacuum is present 3 If vacuum is not present clean vacuum passage with com pressed air start engine and check again for vacuum CHECK VALVE Inspection 1 Remove check valve 7 2 Blow air moderate pressure through hose fitting on white side of check valve Air should not pass through valve from intake manifold white side to green side 3 Blow air low pressure through hose fitting on green side of check valve Air should pass through to white side 4 f air passes through valve in Step 2 or high pressure is required to cause air to pass in Step 3 replace check valve A WARNING DO NOT SUCK air through check valve Fuel vapor inside the valve is harmful 5 Install check valve NOTE The check valve is directional Refer to the figure for correct installation 4 To vacuum tank 5 From intake manifold assembly ENGINE CONTROL SYSTEM 3 65 VSV Vacuum switching valve 1 With ignition switch OFF disconnect connector from VSV 2 Check resistance between VSV terminals Resistance of VSV 37 44 Q 3 Disconnect two hoses from VSV 4 With 12 V applied between the VSV terminals check that port E connects to port F
4. joseu eT keja lt 184 94 UIEN 9 Jewod 1085095 ENGINE CONTROL SYSTEM 3 7 LOCATION OF SENSOR AND SWITCH Cylinder temp sensor SI ii 5 281 CU S 7 WA lt I e NAS NI MAP sensor IAC valve il pressure switch Oi B IAT sensor Fuel injector High pressure fuel pump Shift position sensor Neutral switch 3 8 ENGINE CONTROL SYSTEM CMP sensor 22 DF175 CMP sensor 1 DF150 175 Ignition coil Cylinder RID censor Fuse box Fuse box STD MAIN SPARE MAIN STARTER RELAY RELAY roo oe d CDSTARTER PTT SW CMP VSV VVT Q a COIL INJECTOR ECM F P ISOLATOR PS SENSOR AND SWITCH CKP Crankshaft Position SENSOR There is one 1 CKP sensor installed below the flywheel rotor When the reluctor bars on the flywheel pass the sensor a signal voltage pulse is generated and sent to the ECM This is the fundamental signal used to judge engine speed and crankshaft angle There are 34 reluctor bars spaced 10 degr
5. CN O N N CN LO CN CN O CN LO CN LO LO CN LO CN O LO N CN LO lt CN CN O CN CN cv 0 8 0 CN O CN N LO N CN O N N CN LO CN CN O CN LO CN LO LO CN LO CN O LO N CN LO st CN CN O CN CN LO CN CN 260 660 CN LO CN N O CN CN LO CN CN O CN LO CN LO LO CN LO CN O LO N st CN LO st CN CN O CN CN LO CN CN O CN CN CN c 0 8c 0 N eo CN CN CN LO N N N N 26 0 52 0 O CN CN CN LO CN O N O CN CN LO N CN N CN LO CN N O N N CN LO CN N O CN LO CN LO LO CN LO CN LO CN b 3 CN ez 262 losz osz 08c oc us fuu ji LO CN CN 292 092 092 9 046 OSE Sve OVE GEC EES OES 566 9 Va ze m mm v mm O CN CN
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7. 8 4 _ 4 sensor 022 Ignition 4 __ sensor 1 Approx 0 3 Vor5 V 2 Approx 0 3 5 V Ignition switch ON 8 w Ignition switch Ex manifold temp sensor 0 14 4 75 V Ignition switch ON Lo W Cylinder temp sensor 0 14 4 75 V Ignition switch ON Shift position sensor Approx 4 V Ignition switch ON Shift in Forward Approx 0 6 V Ignition switch ON Shift in Reverse 0 20 4 58 V Ignition switch ON B 13 Model distinction Approx 5 V Ignition switch ON DF150 only Approx 2 V Ignition switch ON Shift in Neutral Approx 5 V ____ Ignition switch ON __4 R i 15 BI R Emergency stop switch Approx 11 V Ignition switch ON Stop switch plate IN Approx 0 V Ignition switch ON Stop switch plate OUT Approx 0 7 V Ignition switch ON Stop switch plate IN Engine stopped shift into NEUTRAL Ground for ECM main relay ______ 2 5 Ignition switch Shift into FORWARD or REVERSE Br Neutral Cranking switch Approx 10 V While engine cranking NN Oil pressure switch Approx 5 V While engine running P B Gr Y O Y 22 PC communication Approx 12 V 24 Ml Buzzer cancel Approx 12 V Ignition switch ON Approx 0 V Engine stopped Ignition switch ON 16 Br Y Throttle position sensor Approx 3 8 V Ignition switch ON Throttle WO
8. 1 Bonens T T Inspect and clean adjust lubricate or replace if necessary T Tighten Replace NOTE OIL CHANGE SYSTEM e Refer to page 3 44 for function and operation e See page 2 5 for reset information PERIODIC MAINTENANCE 2 3 MAINTENANCE AND TUNE UP PROCEDURES This section describes servicing procedures for each periodic maintenance requirement ENGINE OIL ENGINE OIL FILTER ENGINE OIL LEVEL CHECK Inspect oil level before every use Place outboard motor upright on a level surface Remove motor cover Remove oil level dipstick and wipe it clean Reinsert dipstick fully into dipstick tube then remove to check oil level WANI D Oil level dipstick 5 Oil level should be between full level Max mark hole and low level Min mark hole If level is low add recommended oil to full level Max mark Recommended oil 4 stroke motor oil API classification SE SF SG SH SJ FC W Classification SE SF SG SH SJ Viscosity rating SAE 10W 40 NUMA FC W 10W 40 Full level line 2 4 PERIODIC MAINTENANCE ENGINE OIL CHANGE ENGINE OIL FILTER REPLACEMENT ENGINE OIL Change initially after 20 hours 1 month and every 100 hours 6 months ENGINE OIL FILTER Replace initially after 20 hours 1 month and every 200 hours 12 months NOTE e Engine oil should be changed while engine is warm
9. NOTE 1 This value will change according to the current engine speed ENGINE CONTROL SYSTEM 3 43 OPERATING HOUR INDICATION SYSTEM When the ignition switch is initially turned ON from OFF the MONITOR TACHOMETER ECM tests the caution system by turning on all four lamps in the monitor tachometer and sounding the caution buzzer for an ini tial two seconds For the next three seconds the ECM indicates the total operat ing hours using a combination of the tachometer needle and REV LIMIT lamp flash 22 9 7000 r min TEMP REV CHECK ENGINE lt LIMIT The total operating hours displayed are those of actual engine D operation not ignition switch ON time CHART OF TOTAL OPERATING HOURS INDICATION MONITOR TACHOMETER Total operating Needle 1 REV LIMIT lamp 2 indication flashing 90 NO 500 r min 600 r min No 5 400 r min 500 r min 600 r min 1 040 1 5 400 r min 1550 h i i One lamp flash corresponds to 500 hours 1050h 500 r min i 1540h 5 400 r min 3 44 ENGINE CONTROL SYSTEM OIL CHANGE REMINDER SYSTEM Action This system informs the operator it is time to change ENGINE Starting operation OIL based on the recommended maintenance schedule When Lea the total motor operating hours have reached the prepro indication 3J Canesllaten grammed hours the OIL lamp will flash and the buzze
10. SYSTEM STRUCTURE 1 INPUT CONTROL OUTPUT sensor switch ECM actuator etc CKP sensor Fuel injection system Fuel injector CMP sensor 1 Ignition system Ignition coil Idle air control system IAC valve CMP sensor 2 VVT system Oil control valve MAP sensor Fuel pump system High pressure fuel pump IAT sensor Cylinder temp sensor Multi stage induction system VSV Vacuum switching valve Exhaust manifold temp sensor Caution system Caution Buzzer Throttle position sensor Self diagnostic system Neutral switch Monitor tachometer Fail safe system Shift position sensor Operating hour indication system Oil changing reminder system Oil pressure switch Emergency stop switch Starter motor relay Ignition switch Start in gear protection system Starter motor Starter motor relay control system O2 sensor Optional O2 feedback system ENGINE CONTROL SYSTEM 3 3 SYSTEM STRUCTURE 2 DF150 175 15 5 AA pu ADO paddinbe jou si 0G LAC s 1 SIHOJUL eq 1snuJ 105095 20 4osues qVIN 10595 2 Josues 20 105095 IVI 5 4 Josues Y pjojluew P ie youms dois 1 r Jeoue g zd 5 911044 EE S
11. When performing tests related to fuel injector operation eRelieve fuel pressure in line See page 5 3 Disconnect high pressure fuel pump wire connector located on fuel vapor separator CAUTION Always turn ignition switch OFF and disconnect battery cables when wires are being dis connected or connected Hold and pull connector pieces when disconnecting Do not pull wires NOTE e The self diagnostic codes memory in ECM will remain even if battery is disconnected e As each terminal voltage is affected by battery voltage use a full charged battery e Make sure all ground points have good electrical contact e Make sure all wires cables are securely connected 26 PIN amp 34 PIN TEST CORD This test cord is used when checking the circuit for voltage etc and connected between ECM and the wiring harness To measure connect the tester probe to the relevant terminal of the test cord 09930 89340 26 pin amp 34 pin test cord 34 pin test cord 26 pin test cord White connector _ Epson Near ote pase Wire harness ae arses Po XXX Black connector 2 3145 6 7 e e White connector Black connector Ez e 3 48 ENGINE CONTROL SYSTEM INSPECTION FOR ECM CIRCUIT VOLTAGE ECM cannot be bench checked It is strictly prohibited to connect any tester voltmeter or ohmmeter to
12. FUEL INJECTOR OPERATING SOUND CRANKING 1 Disconnect all ignition coil connectors 2 Touch a sound scope or long blade screw driver to fuel injec tor body as shown 3 Crank engine and check for injector operating sound Injector operating sound Click FUEL INJECTOR OPERATING SOUND INDIVIDUAL 1 Disconnect fuel injector wire and connect test cord 09930 89260 Injector test cord A 2 Connect Gray wire to body ground 3 Momentarily touch Black Yellow wire to starter motor mag netic switch terminal connected to battery positive terminal and check for injector operating sound Injector operating sound Click Connecting fuel injector to battery positive for more than a few seconds may cause injector overheating and possible injector solenoid failure 3 54 ENGINE CONTROL SYSTEM FUEL INJECTOR OPERATING SIGNAL 34 test cord CE THE E 26 pin test cord White connector d sero o 9 4414 Black connector Black connector 5 White connector Wire harness Starter motor magnetic switch B terminal l Pe LL LLLLLLLEBS LAX White connector Black connector 34 pin test cord 09930 89340 26 pin amp 34 pin test
13. LO co CN co CN dee 676 1022 896 992 692 096 846 92 ES 0Sc 8 Svc Eve OVE 862 SEC 8c 88 2 52 2 22 21022 yoddey 9215 ullus JUISI apis LHVHO 2371386 WIHS LaddVL PERIODIC MAINTENANCE 2 15 0 eq 9215 Or z a 921 5 juesaJg 00218 sez 26210621882 982 282 1082 1812 460 060 SI 1edde 00 862 Sez 5 882 08218 2 672 2 2 68 0 8 0 31d NVX3 00 86z 262 062 8 2 282108218 2 5 2 212 022 892 780 090 e UOZOY 9215 wys 1uesaJd 006 86 962 262 062 882 582 6 872 972 222 022 892 592 292 670 470 uunjoo Yoel 00 86 962 262 062 882 282 282 082 8 27210221892 9592 292 092 1852 2 0 02 0 8215 ullus jueseJd 1 adde ec 62 062 882 98188 08 8 2 522 uz oza 892 592 lt 92 092 862 lt 652 5 lt 2 690 S9 0 882 982 8 2 92 2 ozz z 9z 09z 8Sz 952 292 052 872 90 090 afer o cff proh feo veu or ma pea sez se cz zl ez ozz sez ee one os ee e os ve ae eve or oo e oc vro ovo peep 3
14. Wire continuity connection failure CHART 4 SELF DIAGNOSTIC CODE 2 3 IAT sensor START Ignition switch OFF Check IAT sensor resistance IAT sensor failure Is result OK See page 3 51 Possible cause ECM failure Wire continuity connection failure CHART 5 SELF DIAGNOSTIC CODE 4 2 CKP sensor START Ignition switch OFF Check CKP sensor resistance CKP sensor failure Is result OK See page 3 51 Possible cause ECM failure Wire continuity connection failure CHART 6 SELF DIAGNOSTIC CODE 2 4 CMP sensor START Ignition switch ON e CMP sensor failure Check CMP sensor signal Wire continuity connection failure Is result OK See page 3 57 Possible cause ECM failure e Wire continuity connection failure 3 74 ENGINE CONTROL SYSTEM CHART 7 SELF DIAGNOSTIC CODE 2 2 Air intake system START Ignition switch ON gt Check throttle position sensor output voltage change Is result OK See page 3 59 NO Ignition switch OFF Check MAP sensor IAC valve for air YES leakage Check intake manifold for air leakage Is result OK Possible cause e ECM failure Throttle position sensor failure Air intake system failure CHART 8 SELF DIAGNOSTIC CODE 3 2 MAP sensor 2 START Ignition switch ON Check MAP sensor output voltage change Is result OK See page 3 58 YES Possible cause Clogged pressure
15. 100 1 0 14 ence between cylinders kg cm psi Engine oil pressure kPa 400 600 4 0 6 0 57 85 at 3 000 r min kg cm psi at normal operating temp Engine oil API classification SE SF SG SH SJ or NMMA FC W classification SE SF SG SH SJ Viscosity rating SAE 10W 40 or NUMA FC W 10W 40 Engine oil amounts 8 0 8 5 7 0 Oil change only 8 5 9 0 7 5 filter change Thermostat operating temperature C F 58 62 136 144 Figures shown are guidelines only not absolute service limits GENERAL INFORMATION 1 13 DF150T Z DF175T Z CYLINDER HEAD CAMSHAFT Cylinder head distortion 0 03 0 001 Manifold seating faces dis 0 10 0 004 tortion Cam height in 42 520 42 680 44 420 44 580 IN 1 6740 1 6803 1 7488 1 7551 42 420 1 6701 44 320 1 7449 42 420 42 580 44 420 44 580 1 6701 1 6764 1 7488 1 7551 42 320 1 6661 44 320 1 7449 Camshaft journal oil 0043 00085 00017 00089 043 0 085 0 0017 0 0033 clearance housing inside di 26 000 26 021 1 0286 1 0244 000 000 26 021 1 0236 1 0244 ousing inside diam eter Limit in Camshaft journal out 25936 25 957 102 1 0219 936 25 957 1 0211 1 0219 33 959 33 975 3370 1 3376 34 000 34 025 1 3386 1 3396 1 14 GENERAL INFORMATION em DF150T Z DF175T Z V
16. 4 6 V signal Fuel injector No operation signal from the ECM Throttle position sensor No signal Receiving an out of range 0 2 4 8 V signal Shift position sensor No signal Receiving an out of range 0 2 4 8 V signal During two crankshaft rotation 4 signals are not input to ECM VVT advance There is a large difference between the target advance angle and the Neutral switch While the shift sensor outputs the forward or reverse signal the ECM ont Model discrimination There is discrepancy between the ECM memory storage and the model discrimination terminal 13 terminal open DF150 e No 13 terminal short circuit DF175 Oil control valve OCV not operating ENGINE CONTROL SYSTEM 3 41 NOTE 1 MAP sensor These conditions will be caused by IAC valve failure incorrect O ring M by pass air screw adjustment IAC valve is always closed NG by pass air is too low ECM controls the IAC valve duty to dom increase to maintain the idling trolling speed specified 2 This condition will be caused by clogged pressure detect pas sage in intake manifold 3 42 ENGINE CONTROL SYSTEM FAIL SAFE SYSTEM The fail safe system is closely related to the self diagnostic system When an abnormality occurs in a sensor signal the ECM ignores the out of range signal and assumes a pre programmed
17. A 1104 99000 25030 99000 22540 99000 25010 99000 25160 99000 31120 99000 31030 400 x 24 pcs 500 g 100 g SUZUKI BOND THREAD LOCK THREAD LOCK 4 Stroke Motor Oil 1207B 1342 SUPER 1333B 99104 33140 99000 31140 99000 32050 99000 32020 API SE SF SG SH SJ 100 g 50 g 50 g SAE 10W 40 NOTE Marked part No is in U S market only PERIODIC MAINTENANCE 2 1 PERIODIC MAINTENANCE CONTENTS PERIODIC MAINTENANCE SCHEDULE 2 2 PERIODIC MAINTENANCE CHART _ 2 2 MAINTENANCE AND TUNE UP PROCEDURES 2 3 ENGINE OIL ENGINE OIL FILTER uuo Rouen aaa 2 3 MN 2 6 LUBRICATION qe 2 7 SPARK PLUG entere recon ene non mee 2 8 CLEARANCE aa 2 9 IDEE SPEED nii 2 16 IGNITION Mal i cue napana Ar a Eaa 2 17 BREATHER AND FUEL LINE wi a 2 18 LOW PRESSURE FUEL FILTER 2 19 HIGH PRESSURE FUEL FILTER iini 2 19 WATER PUMPAWATER PUMP IMPELLER 2 20 PROPELLER NU COTTER PIN i riii ie tert edie 2 20 BONDING WIRES 2 20 Pr ep 2 21
18. NO 7 8 9 30 NO TERMI WIRE NAL COLOR CIRCUIT 31 Br R OCV 2 ee 33 Variable intake control VSV Rev Limit lamp 36 No 2 Fuel injector Gr Y Ignition coil 34 35 e 9 2 No 1 Ignition coil BIW Lg R No 4 Ignition coil 7 8 0 3 4 5 6 8 9 0 3 Ground for power Ground for power Ground for ECM BW No 2 Ignition coil B B 5 Lg 54 No 1 Fuelinjector 55 6 2 57 valve 4 8 3 9 G W CHECK ENGINE lamp TEMP lamp 2 i UJ Ol JJ 2 3 6 ENGINE CONTROL SYSTEM ECM INTERNAL STRUCTURE D 4osues ZO CHW gt G6 ou 4 B 5 96 99 09 Canons NOO OK 6S 10199lu cit 10joefu L4 Jojoefu oums 401 uoi 3 1 gH eJnssaJd IO 61 m 19159 99 Josues 89 uonoutisip Josues 8 Josues amp 1A2 105098 HIS Josues H 91 4 2 do o 7 AV T3H keja D 19 48 5 87 5 yolims
19. 09900 00413 5 mm 09900 00414 6 mm 09900 00415 8 mm 09900 06107 Hexagon bit included 09900 06108 09900 00410 Snap ring pliers 09900 20205 Micrometer 0 25 mm 09916 99311 Flywheel holder 09900 20803 Thickness gauge 09900 21304 Steel V block set 09900 20101 150 mm 09900 20102 200 mm Vernier calipers 09900 20605 Dial calipers 10 34 mm 09900 22302 0 051 0 125 mm 09900 22301 0 025 0 076 mm Plastigauge GENERAL INFORMATION 1 23 09912 58413 Fuel pressure gauge set 09910 39610 1 09912 58442 Fuel pressure gauge 09900 26006 09900 28403 Piston pin remover 2 09912 58432 Fuel pressure hose Engine tachometer Hydrometer and installer 3 09912 58490 3 way joint amp hose 09951 09310 09913 50121 Gear adjust spring 09921 29410 09915 47341 09915 64512 Oil seal remover Driveshaft holder Oil filter wrench Compression gauge AK gt d lt gt 09915 67010 09915 78211 Compression gauge Oil pressure gauge 09916 10911 hose attachment adapter Valve lapper 09916 24450 Solid pilot 09916 14521 N 100 5 52 09916 22420 09916 19030 Valve lifter attach Solid pilot 09916 54910 Valve seat cutter 60 Valve lifter ment Neway N 150 5 5 Handle N 505 N 114 1 24 GENERAL INFORMATION 09917 47011 Vacuum pump gauge 09930 30104 Sliding hammer 09916 34542 Valve guide reamer handle 09916 77310 09916 57330 Piston ring com Valve guide install
20. 1 22 MATERIALS AE QUIRED opu eee eee 1 26 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 mes sages highlighted by these signal words A WARNING 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 judgment 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
21. 46 terminal or to body ground 4 Crank engine and measure voltage Ignition coil operating signal Approx 5 V 3 56 ENGINE CONTROL SYSTEM IGNITION COIL ASSEMBLY 09930 99320 Digital tester Tester range DCV See chart for range NOTE The ignition coil power transistor and high tension lead are an integral part of the coil internal circuit Using resistance mea surements to check for a defect on either the primary or second ary coil is not possible 1 Turn ignition key OFF 2 Disconnect ignition coil connector 3 Check for continuity between GND terminal on the wiring harness side connector and the engine body ground 4 Turn the ignition key to ON position Check for battery volt age by measureing between the BAT terminal and terminal on the wiring harness side connector 5 Connect the wiring harness connector to the ignition coil and measure the ignition operating signal See page 3 55 6 If any failure exists check for open circuit short circuited battery short circuited lead and connectors contact condi tion for each circuit 7 fthere is no spark even with the wiring harness and spark plug in sound condition perform inspection again using an ignition coil that is known to be in good condition new or used from another cylinder that is operating properly 8 If there is still no spark even with the wiring harness spark plug and ignition coil in sound condition replace the ECM an
22. 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 PROPELLERS An outboard motor is designed to develop its rated power within a specified engine speed range The maximum rated power delivered by the DF150 175 models are shown below Recommended full 02150 5 000 6 000 r min throttle speed range DF175 5 500 6 100 r min 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 Counter rotation models Blade x Dia in x Pitch in x 15 and 1 2 17 x 15 and 1 2 17 x 15 and 1 4 19 x 15 and 1 4 19 15 21 14 and 3 4 23 14 and 1 2 25 14 and 1 2 27 16 17 16 18 1 2 16 20 16 21 1 2 16 23 16 24 1 2 16 26 X x 15 21 14 and 3 4 23 14 1 2 25 14 1 2 27 16 17 16 18 1 2 16 20 16 21 1 2 16 23 16 24 1 2 16 26 16 27 1 2 Installing a propeller with pitch either too high or too low will cause 9 00 0 0 X X X X X X X X X X X 0 X X X X X X X X X X X X X X X X X X X X X X X incorrect maximum engine speed which may result in severe dam age to the motor NOTE In the case of twin installation always use the same size right hand rotation and
23. NOTE After installing shift position sensor check for proper correct function by operating remo con handle 1 Shift position sensor 2 Adjust screw 3 Clutch lever Power source voltage Shift position B B W Sensor Out put voltage Shift position sensor OIL PRESSURE SWITCH NOTE Before checking the oil pressure switch make sure the engine oil pressure is within specification 1 Remove the blue lead wire from oil pressure switch 2 Check the continuity between the switch terminal and engine body ground 09930 99320 Digital tester Tester range amp Continuity infinity Engine stopped Continuity If measurement exceeds specification replace oil pressure switch 3 Reinstall parts removed earlier ECM MAIN RELAY 09930 99320 Digital tester Tester range amp Continuity 1 Disconnect ECM main relay from fuse box 2 Check continuity between terminal D and each time 12 V is applied Connect positive probe to terminal and negative probe to terminal 3 ECM main relay function 12 V power Continuity Applied Not applied noo Do not touch 12 V power supply wires to each other or with other terminals ENGINE CONTROL SYSTEM 3 61 aT Y 2 5 5 3 62 ENGINE CONTROL SYSTEM IAC VALVE 1 2 Disconnect connector from IAC valve Check each coil of IAC valve for resistanc
24. RESISTANCE TABLE TERMINAL FOR TESTER STANDARD RESISTANCE PROBE CONNECTION at 20 C CKP sensor 4 R B to 49 B W 168 2520 Fuel injector 1 54 O B to Terminal NOTE 1 Fuel injector No 2 36 B Br to Terminal NOTE 1 Fuel injector 3 28 R W to Terminal NOTE 1 Fuel injector No 4 53 Lg to Terminal NOTE 1 IAC valve 2 56 R Y to Terminal NOTE 3 OCV Oil control valve 31 Br R to Terminal NOTE 3 VSV Vacuum switching valve 33 Gr G to Terminal NOTE 3 IAT sensor 25 Lg B to 49 B W 0 32 F 5 3 6 6 Cylinder temperature sensor 9 Lg W to 49 B W 25 77 F 1 8 2 3 50 C 122 F 0 73 0 96 Ex manifold temperature sensor 8 V W to 49 B W 75 C 135 F 0 33 0 45 Thermistor characteristic ECM main relay 17 to Terminal NOTE 2 145 190 9 ENGINE CONTROL SYSTEM 3 53 COMPONENT INSPECTIONS HIGH PRESSURE FUEL PUMP 6 SEC OPERATING SOUND 1 Install the emergency stop switch lock plate in position 2 Shift into Neutral 3 Turn ignition switch ON and check for fuel pump operating sound Fuel pump operating sound Sounds for approx 6 seconds only NOTE Fuel pump operating sound is low because pump is inside 1 separator vapor separator If you cannot hear pump sound clearly use a sound scope or long blade screw driver
25. a a a 2 22 BALANCER CHAN 2 23 BOLTS AND NUTS ee esi 2 24 FUEL MIXTURE CHECK O2 FEEDBACK 2 24 OIL FHESSURE eee MES 2 25 SUR vk Causa 2 27 ENGINE VACUUM it aruit 2 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 Initial 20 hrs or Every 50 hrs Every 100 hrs Every 200 hrs to be serviced 1 month 3 months or 6 months or 12 months Spark plug __ I R Replace fuel hose every 2 years aum o 02 gp o p Po Replace every 2 years Engine oil NOTE Anodes amp Bonding wires Battery Fuel mixture check O2 feedback Engine oil filter lm onimng ______ 1 iese 1 Waterpump 1 Waerpumpimpeler RH 2 Propellernut amp pin i
26. counter rotation propellers on both engines GENERAL INFORMATION 1 7 1 8 GENERAL INFORMATION POWERHEAD DIRECTION OF ROTATION This outboard motor is designed with a L H left hand rotation powerhead utilizing an offset crankshaft This design has the advantage of reducing the size of the motor and keeping the overall motor s weight closer to the boat tran som and therefore closer to the boat C G center of gravity Rotation of the driveshaft is accomplished through a crankshaft drive gear and a driveshaft driven gear These gears are located beneath the powerhead in the same oil bath location as the camshaft chain As the rotational direction of the driven gear will be opposite of the drive gear a left hand rotation powerhead design was adopted to retain a conventional standard rotation right hand propeller shaft output CYLINDER NUMBER Cylinder number is as mentioned in the right figure SPECIFICATIONS GENERAL INFORMATION 1 9 These specifications are subject to change without notice DF150T DF150Z DF175T DF175Z PRE FIX DIMENSIONS amp WEIGHT Overall length front to back Overall width side to side Overall height Weight without engine oil Transom height PERFORMANCE Maximum output Recommended operating range Idle speed POWER HEAD Engine type Number of cylinders Bore Stroke Total displacement Compression ratio Spark plug Ignition syst
27. duty Rectifier amp regulator 0 8 ms OFF Sensor switch Ignition Time switch Battery Fuel pump 1 ms 1cycle CONTROL MODES BEFORE START For 6 seconds after the ignition switch is turned ON the pump is controlled to operate at 100 duty in order to initially pressurize the high pressure line WHEN CRANKING The pump is controlled to operate at 50 100 duty Duty change depends on cylinder temperature WHEN RUNNING NORMAL OPERATION The pump is controlled to operate at 50 100 duty based on the current engine speed and battery volt age ENGINE CONTROL SYSTEM 3 25 AIR INTAKE COMPONENTS Air after entering through the silencer case passes through the throttle body and flows into the surge tank where it is then distributed to the cylinder intake manifold Intake manifold pressure monitored by the MAP sensor is an indirect measure of the intake air amount When the throttle is fully closed the main supply of intake manifold air necessary to sustain engine idle passes through the by pass air passage To maintain engine idle speed at specification the ECM controlled IAC valve supplies a regulated amount of additional air through the IAC idle air control passage C Air flow 1 Throttle body 2 AC valve 3 By pass air screw 4 Intake manifold 5 Throttle position sensor 6 MAP sensor 7 AT sensor 8 Air intake silencer 9 VSV TH
28. 0 0012 0 0020 Clanktase PANN 70 000 70 018 2 7559 2 7566 inside diameter nc Mp mm in 64 982 65 000 2 5583 2 5591 diameter Crankshaft journal outside diameter difference out of Limit mm in 0 010 0 0004 round and taper 2 2 Peeing AMICK 2 497 2 512 0 0983 0 0989 Crankshaft thrust play ani 0 11 0 31 0 004 0 012 2 425 2 475 0 0955 0 0974 thickness GENERAL INFORMATION 1 17 m DF150T Z DF175T Z ELECTRICAL at r min idm 0 7 0 8 0 028 0 031 Recommended battery capacity 12V 100 360 or larger Fuel injector resistance Q at 20 Fuse amp rating Main fuse 60 Starter motor 30 A Ignition coil Injector ECM 30 PTT switch 10 IAC CMP VSV VVT 10 Isolator 30 5 10 14 IAC valve resistance Q at 20 25 34 IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor KQ at 25 C 1 8 2 3 characteristic ECM main relay coil resistance Q at 20 C 145 190 C C Starter motor relay coil resistance Q at 20 145 190 PTT motor relay coil resistance Q at 20 25 37 1 18 GENERAL INFORMATION STARTER MOTOR Brush length 16 0 0 63 12 0 0 47 Commutator undercut 0 5 0 8 0 02 0 03 in 0 2 0 01 Commutator outside diame in 29 0 1 14 ter in 28 0 1 10 Commutator outside diame in 0 05 0 002 ter
29. 000 r min or higher Caution lamps TEMP lamp lights continuously REV LIMIT lamp lights continuously during engine speed rev limiter activation Sounds in a series of long 1 5 sec beeps RESET Close throttle completely and then shift into neutral System reset will occur when cylinder temperature drops below the limits shown below However the sys tem may be activated again unless the cause for overheat such as insufficient water is removed Reset temperature Condition 1 A 86 C 187 F Maximum temperature 86 C 187 F Condition 2 Temperature rise vs Time Approx 84 C 183 F ENGINE CONTROL SYSTEM 3 37 LOW BATTERY VOLTAGE CAUTION SYSTEM CONDITION 1 System activated when battery voltage decreases to less than 9 volts for 30 seconds CONDITION 2 System activated if battery voltage is less than 2 V for more than 2 seconds with the ignition switch turned ON and engine not running ACTION Engine speed No engine speed limiter is activated Caution lamp CHECK ENGINE lamp lights continuously Sounds in a series of long 1 5 sec beeps RESET CONDITION 1 This caution system is automatically reset when battery voltage increases to more than 9 volts Refrain from using electrical equipment requiring high amperage such as hydraulic trim tabs hydraulic jack plate etc after this caution is activated CONDITION 2 For the caution system to engage under
30. Center Crankshaft position Camshaft position Close Throttle position Direct Current Double Over Head Camshaft Engine Control Module Exhaust Idle Air Control Intake Air Temperature Intake Manifold absolute pressure Oil control valve Port Power Trim amp Tilt Shift Position Sensor Starboard Throttle Position Sensor Vacuum switching valve Variable Valve Timing GENERAL INFORMATION 1 1 GENERAL INFORMATION CONTENTS WAHNING CAUTION NOTE 1 2 GENERAL PRECAUTIONS 1 2 IDENTIFICATION NUMBER 1 4 FUEL AND OIL 1 5 GASOLINE RECOMMENDATION 1 5 ENGINE OIL M 1 5 ENGINE BREAK IN 1 6 WARM UP RECOMMENDATION 1 6 THROTTLE RECOMMENDATION 1 6 PROPELLERS sicuri DIE EE dI IC 1 7 POWERHEAD DIRECTION OF ROTATION 1 8 CYLINDER NUMBER 2000 ae 1 8 SPECIFICA HONS 1 9 SERVICE E DID OD E eee 1 12 TIGHTENING TORQUE tee eee 1 20 SPECIAL TOOLS
31. Compression gauge 09915 64530 Compression gauge hose 09915 67010 Compression gauge hose attachment 6 Disconnect remote control throttle cable from throttle lever Move and hold throttle lever in full open position 8 While cranking engine with starter motor note maximum compression pressure reading on gauge for each cylinder 9 Reinstall parts removed earlier spark plugs ignition coils etc N PERIODIC MAINTENANCE 2 27 1 Compression gauge 2 Compression gauge hose 3 Compression gauge hose attachment 2 28 PERIODIC MAINTENANCE ENGINE VACUUM CHECK Engine vacuum is required for proper operation of the Multi Stage Induction system used on the DF150 amp DF175 Engine vacuum is also an indicator of general engine condition 1 Warm up engine to normal operating temperature Make sure engine idle speed is within specification Stop engine and disconnect vacuum outlet hose from check valve Connect special tools vacuum gauge hose and 3 way joint between engine vacuum hose and check valve 09915 67311 Vacuum Gauge 09918 08210 Hose joint 09355 35754 601 Hose 09367 04002 3 way joint Start engine and run at idle speed Vacuum reading on gauge should be within specification Vacuum specification idle speed at 759 8 mmHg sea level 61 71 kPa 457 533 mmHg 18 21 inHg If vacuum is not within specification further testing leak down test compression test etc and evaluation of
32. In valve Retard Crank angle Valve overlap ENGINE CONTROL SYSTEM 3 33 OCV Oil Control Valve The OCV is used to regulate oil flow and is installed on the lower camshaft housing RETARD OPERATION Retard operation When the duty ratio of the ECM is small the OCV spool valve is Advance chamber Engine oil pressure Retard as d pushed away from the coil by spring force and engine oil pres sure is applied to the retard chamber Engine oil remaining in the advance chamber is drained out through the spool valve L ad lt AEA SE Spool valve Spring ADVANCE OPERATION When the duty ratio of the ECM is large the spool valve is pulled towards the coil by magnetic force compressing the spring and applying engine oil pressure to the advance chamber side Engine oil remaining in the retard chamber side is drained out through the spool valve RETAINING OPERATION When the duty ratio of the ECM is medium the OCV coil mag netic and return spring forces are equal This positions the spool valve between the advance and retard chamber closing both oil passages INTAKE CAM TIMING SPROCKET ASSY Inside the intake cam timing sprocket assembly VVT actuator there are separate advance and retard chambers formed by a partition of the rotor The rotor moves inside the housing as engine oil pressure is applied to the advance or retard chamber The intake cam timing sprocket is
33. The throttle shaft is interlocked with the TPS shaft This sensor is a variable resistor changing resistance Ohms in accordance with the throttle opening The varying resistance value is converted to voltage and input to the ECM Based on the TPS voltage the ECM calculates the idle position and throttle opening and determines the control modes of vari ous controls systems Idle air control VVT system control Fuel injection control system etc NEUTRAL SWITCH The neutral switch is installed on the throttle lever holder and used to detect the shift position This switch is ON in neutral and OFF in forward or reverse Based on the switch shift position signal input the ECM per forms the following controls When the shift is in forward or reverse at the time of engine start no power is supplied to starter motor relay preventing starter motor engagement Start in gear protection See page 3 45 SPS Shift Position Sensor The SPS is installed on the throttle lever holder and detects the shift position The clutch lever is interlocked with the SPS shaft This sensor is a variable resistor that changes resistance ohms in accordance with the shift position The varying resistance value is converted to voltage and input to the ECM Based on the SPS voltage the ECM calculates and determines the change of shift position and executes the following controls When the shift is in neutral fuel injection
34. When replacing engine oil filter change engine oil at the same time Place outboard motor upright on a level surface Remove oil filler cap Place a container under engine oil drain plug Remove engine oil drain plug and gasket to drain engine oil p Dm 1 Oil filler cap 5 ENGINE OIL FILTER REPLACEMENT NOTE For engine oil change only go to step 6 To replace engine oil filter 1 Remove STBD side cover See page 7 2 2 Using oil filter wrench to loosen the oil filter then remove filter and O ring 09915 47341 Oil filter wrench NOTE Before fitting new oil filter be sure to oil O ring W 3 Screw new filter on by hand until filter O ring contacts the mounting surface 4 Tighten filter 3 4 turn from point of contact with mounting surface using an oil filter wrench 9 Engine oil filter 14 N m 1 4 kg m 10 0 Ib ft 3 4 turn 5 Install STBD side cover 6 Install new gasket and oil drain plug Tighten engine oil drain plug to specified torque Q Engine oil drain plug 13 N m 1 3 kg m 9 5 Ib ft To avoid water entry into oil pan or oil leakage into the environment do not reuse gasket once removed Always use a new gasket 7 Pour recommended engine oil into oil filler opening then install oil filler cap Engine oil amounts Oil change only 8 0 L 8 5 7 0 US Imp qt Oil filter change 8 5 L 9 0 7 5 US Imp qt 8 To reset oil change reminder system s opera
35. an example for ignition at 10 TDC 1 Cyl EEK ____ TDC EK TDC In ED TDC 2 EK ET CKP sensor signal signal CMP 1 sensor 2 EA signal VVT 180 Spark timing Ig coil 1 Ig coil 2 Ig coil 3 Ig coil 4 Cm Compression Ep Explosion Ex Exhaust In Intake Top Dead Center CONTROL MODE WHEN CRANKING The ignition timing is fixed at BTDC 5 until the engine starts WHEN IDLING TROLLING The ignition timing is controlled within the range of 5 5 to provide stable engine operation at the specified idling trolling speed WHEN RUNNING NORMAL OPERATION The ignition timing ranges between BTDC 5 26 depending on current engine operating conditions ENGINE CONTROL SYSTEM 3 19 ELECTRONIC FUEL INJECTION SYSTEM The fuel injection system used by the DF150 DF175 is a speed density multi point sequential electronic fuel injection type The fuel injection system is composed of the fuel line components air intake components and components for system control ECM sensors switches etc FUEL INJECTION CONTROL SYSTEM OUTLINE Sensors are mounted at precise locations on the motor to monitor the current conditions of engine operation and send signals to the ECM Based on these signals the ECM determines the optimum fuel injection time duration fuel amount fuel injection timing multi point seque
36. because IAC valve condition depends ECM con trol See page 3 40 If IAC valve has failed Fast idle function warm up mode wont operate
37. detect passage CHART 9 SELF DIAGNOSTIC CODE 1 5 Ex mani temp sensor START Ignition switch OFF Check Ex manifold temp sensor resistance Is result OK See page 3 51 YES Possible cause ECM failure Wire continuity connection failure MAP sensor failure ECM failure e Wire continuity connection failure Ex manifold temp sensor failure ENGINE CONTROL SYSTEM 3 75 CHART 10 SELF DIAGNOSTIC CODE 4 3 Fuel injector START Ignition switch gt Check 28 36 53 54 terminal voltage e ECM failure Is result OK See page 3 48 e Wire continuity connection failure YES lt Ignition switch ON gt fail Check fuel injector operating signal Em i a tion fail Is result OK See page 3 54 ire continuity connection failure YES lt lgnition switch gt Check fuel injector operating sound individual Is result OK See page 3 53 YES Fuel injector failure Possible cause e ECM failure e Wire continuity connection failure CHART 11 SELF DIAGNOSTIC CODE 2 1 Throttle position sensor START lt lgnition switch ON gt Check throttle position sensor output Throttle position sensor failure voltage change Wire continuity connection failure Is result OK See page 3 59 Possible cause ECM failure Wire continuity connection failure CHART 12 SELF DIAGNOSTIC
38. engine condition is required Possible causes of incorrect engine vacuum e Piston ring leakage Incorrect valve timing Poor valve valve seat valve guide condition e Intake leakage Cylinder head gasket leakage Restricted exhaust 2 Checkevalve 222 To vacuum tank Valve ENGINE CONTROL SYSTEM 3 1 ENGINE CONTROL SYSTEM CONTENTS ENGINE CONTROL SYSTEM 3 2 SYSTEM STRUCTURE cian avid ia 3 2 SYSTEM STRUCTURE 2 unii etur ates ceca 3 3 COMPONENTS FOR SYSTEM CONTROL 3 4 ENGINE CONTROL MODULE 3 4 CONNECTOR TERMINALS LAYOUT 3 5 ECM INTERNAL STRUCTURE nunE SE REERR E EERURRERRNE 3 6 LOCATION OF SENSOR AND SWITCH 3 7 SENSOR AND SWITCH ec 3 9 IGNITION SYSTEM incisis euer eaten Eva xa asec 3 16 IGNITION CONTROL SYSTEM 1111 eere eren naa nna naanza 3 17 ELECTRONIC FUEL INJECTION SYSTEM 3 19 FUEL INJECTION CONTROL SYSTEM 3 19 FUEL DELIVERY SYSTEM COMPONENTS 3 21 HIGH PRESSURE FUEL PUMP CONTRO
39. gap 0 75 mm 0 030 in aT gt DA ow lar Te E Check to ensure that all removed parts are back in original position Check wire routing See page 11 4 to 11 10 ENGINE CONTROL SYSTEM 3 69 CMP SENSOR REMOVAL 1 Disconnect CMP sensor lead wire connector at sensor 2 Remove bolt CMP sensor and sensor cover INSTALLATION Installation is reverse order of removal e Install CMP sensor and sensor cover then tighten sensor mounting screw securely Connect sensor lead wire connector to CMP sensor IAC VALVE REMOVAL 1 Remove flywheel See page 3 66 2 Disconnect IAC valve lead wire connector at IAC valve 3 Remove screws and IAC valve INSTALLATION Installation is reverse order of removal Install IAC valve then tighten mounting screws securely Connect IAC valve lead wire connector to IAC valve Check to ensure that all removed parts are back in original position 3 70 ENGINE CONTROL SYSTEM OIL PRESSURE SWITCH REMOVAL 1 Remove the ring gear cover and air intake silencer case 1 See page 6 2 2 Remove the three bolts and fuel hose guard 2 3 Loosen screw 3 and disconnect blue lead wire 4 from switch 4 Remove oil pressure switch from cylinder block INSTALLATION Installation is reverse order of removal with special attention to the following steps Before installing oil pressure switch wrap screw threads with sealing tap
40. is controlled to pre vent engine speed from exceeding 3 000 r min e After shifting into forward or reverse from neutral the IAC valve is controlled to increase intake air for 0 1 second to pre vent unstable engine idle or stalling tT hrottle Si 2 WENN i T ECM MAIN RELAY The ECM main relay is installed in the fuse box When ener gized by turning the ignition switch ON a circuit is formed which supplies battery voltage to the ECM fuel injector ignition coil IAC valve CMP sensor high pressure fuel pump OCV Oil con trol valve and VSV Vacuum switching valve CRANKING SWITCH SIGNAL The ECM detects the engine being started by the position of ignition switch key When the ignition key is turned to ST posi tion a voltage 12 V signal is input to the ECM The ECM in turn controls the actuators for ignition fuel injection IAC etc to the starting mode With the key is turned to IG position after the engine has been started the input voltage becomes approx 1 4 V ENGINE CONTROL SYSTEM 3 13 main relay nme 2 Ruse boxe 1 Ignition switch 2 Neutral switch 3 To starter motor relay 3 14 ENGINE CONTROL SYSTEM SUB BATTERY CABLE ECM POWER SOURCE LINE The ECM is battery dependent and must be provided with its own dedicated 12V power supply The electri cal circuits which provide this supply are 1 The sub battery cable to the white le
41. mechanical components power unit lower unit etc are normal NOTE For troubleshooting of Starter motor will not run see page 4 13 CHART 1 SELF DIAGNOSTIC CODE 3 4 MAP sensor START lt Ignition switch ON gt NO Check 14 terminal voltage ECM failure Is result OK See page 3 49 YES lt Ignition switch gt NO Check 12 terminal voltage 5 result OK See page 3 58 MAP sensor failure YES Possible cause e ECM failure e Wire continuity connection failure CHART 2 SELF DIAGNOSTIC CODE 3 1 IAC system START Ignition switch OFF gt ON gt YES Possible case Check IAC valve operation Is result OK See page 3 62 Incorrectly by pass air screw adjustment IAC passage failure Ignition switch OFF Check IAC valve resistance Is result OK See page 3 62 IAC valve failure Ignition switch ON gt Check 55 56 57 58 terminal voltage Wire continuity connection failure e ECM failure 5 result OK See page 3 48 Possible cause IAC valve failure mechanical ECM failure e Wire continuity connection failure ENGINE CONTROL SYSTEM 3 73 CHART 3 SELF DIAGNOSTIC CODE 1 4 Cylinder temp sensor START Ignition switch OFF NO Check cylinder temp sensor resistance Cylinder temp sensor failure Is result OK See page 3 51 Possible cause ECM failure
42. temperature change gradient temperature rise VS time Resistance Temperature EXHAUST MANIFOLD TEMPERATURE SENSOR The exhaust manifold temperature sensor is installed on the a exhaust manifold and used to detect exhaust manifold tempera S BBN EXimanifold temp sensor ture This sensor is the same type as the cylinder temperature sen sor and inputs a signal to the ECM as a voltage value This signal is also used to detect engine over heat IAT Intake Air Temperature SENSOR The IAT sensor is installed on the air intake silencer case and used to detect the intake air temperature This sensor is the same type as the cylinder temperature sen sor and inputs a signal to the ECM as a voltage value This signal is used to compensate the fuel injection time dura tion 7 E 2 intake silencer cases MAP Manifold Absolute Pressure SENSOR 7 The sensor is installed on the intake manifold and used to detect the intake manifold pressure also detects the barometric pressure before starting the engine This sensor inputs the intake manifold pressure to the ECM as a voltage value This input signal is used as the fundamental signal to determine T fuel injection time duration ignition timing etc p AA 3 12 ENGINE CONTROL SYSTEM TPS Throttle Position Sensor The TPS is installed on the throttle body and detects the degree of throttle opening
43. this condition possibilities such as deteriorated battery poor battery cable connection battery switch in OFF condition etc must be inspected To cancel the caution system activation for these conditions check all power source related items and elim inate the problem 3 38 ENGINE CONTROL SYSTEM SELF DIAGNOSTIC SYSTEM The self diagnostic system alerts the operator when an abnor MONITOR TACHOMETER mality occurs in a signal from sensor switch etc When the system is activated the CHECK ENGINE lamp flashes lights intermittently according to each code pattern along with a buzzer sound When engine is running the buzzer sounds a series of short 0 2 sec beeps When engine is not running the buzzer sounds according to each code pattern but not simultaneous with the lamp flash The buzzer sound activated by the self diagnostic system can Tw CHECK ENGINE lamp be temporally canceled by pushing the ignition key in PRIORITY CODE PATTERN FOR SELF DIAGNOSTIC SYSTEM OPERATION PRIORITY FAILED ITEM CODE PATTERN _ a 2 n valve By pass air screw adjustment ore JUULIL NN ARMIN NN 5 ee vw 5 wem BILL sensor 2 manifold temp 1 5 n nnnnm YES sensor TT ON emewm s ws _ hs _ 16 E E 41 1 ON NM T code wire NOTE 2 TL 18 amp regulator _ ON Over charging NOTE
44. uous 90 OVI 11 P 17 once 2 5 105095 Jojoefur jen 4 191009 eJnsseud YOUMS uous 10595 49111 ONY eunsseJd uonisod gius x SSS jen 3 4 ENGINE CONTROL SYSTEM COMPONENTS FOR SYSTEM CONTROL ENGINE CONTROL MODULE ECM The ECM sends signals to control the actuators based on the information inputs from each sensor switch Major controls are as follows NAME OF CONTROL DESCRIPTION Fuel injection control Controls fuel injection amount and timing Ignition control Controls ignition timing Idle air control Controls idling trolling speed by adjusting intake air amount through IAC valve VVT system Controls intake cam valve timing through Oil control valve Fuel pump control Controls high pressure fuel pump drive Multi stage induction system e Changing the length of intake manifold pipes according to engine Caution system control e Informs operator of abnormal engine condition Controls engine speed Self diagnostic system control Informs operator of sensor switch malfunction Fail safe system control e Allows operation with back up system during sensor switch mali Total operating ho
45. value for the failed sensors This allows the engine to continue running under the fail safe condition PRE PROGRAMMED VALUE FOR FAIL SAFE SYSTEM PRE PROGRAMMEDVALUE MAP sensor 1 260 760 mmHg M 2 30 inHg The control takes place accor dance with the engine speed NOTE 1 CMP sensor Based on signals from CKP sensor a Failed with engine running Normal ignition timing Normal sequential fuel injection e VVT advance is fixed at the most retarded angle b Failed prior to engine start The ignition timing fixed at BTDC 10 degree 1 simultaneous injection for all cylinders per 2 crankshaft rotations e VVT advance is fixed at the most retarded angle is executed with the maximum engine speed as 2 000 r min 60 140 F 113 60 C 140 F Shift position sensor The shift position Fwd Neu Rev is detected with the neutral switch signal e The IAC control follows the forward gear map VVT advance e VVT advance is fixed at the most retarded angle e The ECM cyclically outputs the drive and stop signals for the OCV and when the difference between the VVT s target advance angle and the actual advance angle has come to the normal range the diagnostic code display is canceled Model discrimination e The original model discrimination is retained NOTE There is no back up system for the ECM itself The engine will stop if it has failed
46. 0 r min is controlled by IAC idle air control system If engine speed does not return to specification passage may be clogged or IAC system may not be operating correctly See IDLE AIR CONTROL SYSTEM section on page 3 26 NOTE Trolling speed in gear idle speed is same as idle speed IGNITION TIMING Inspect every 200 hours 12 months NOTE Before checking the ignition timing make sure idle speed is adjusted within specification 1 Start the engine and allow to warm up 2 Attach the timing light cord to the No 1 ignition coil primary wire 09930 76420 Timing light 3 Check the ignition timing while operating the engine in neu tral gear at 1 000 r min Ignition timing Approx BTDC 10 at 1 000 r min bus PERIODIC MAINTENANCE 2 17 dedi I D rer n ae or 2 1 d exea ide P s a SP A Len 4 E if gt gt EN passlainscrew ______ 2 18 PERIODIC MAINTENANCE 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 hose and or fuel line
47. 1 ore ENGINE CONTROL SYSTEM 3 39 NOTE f more than two items fail at once the self diagnostic indication appears according to priority order The indication repeats three times f the failed item remains the self diagnostic indication appears again after turning the ignition switch ON e After correcting failed item the self diagnostic indication appears until the ECM receives the proper signal with the engine running For cylinder temp sensor exhaust manifold temp sensor or IAT sensor the self diagnostic indication will be canceled after corrective action by turning the ignition switch ON The ECM will require 10 20 seconds after turning the ignition switch ON to cancel the self diagnostic indication NOTE 1 This self diagnostic indication may not display be canceled by turning the ignition switch ON because the ECM detects only battery voltage not charging output Under this condition the buzzer will not sound a 1 1 code However if the rectifier amp regulator have failed the self diagnostic indication will again appear after starting the engine NOTE 2 The diagnostic code for model discrimination is displayed when a failure either open or short circuit exists in No 13 terminal of the wiring harness connector When this code is displayed the first check should be for a failure in the wiring harness When this code is displayed do not replace the ECM Replacing the E
48. 118 N m 11 8 kg m 85 5 Ib ft 3 Dowel pin 4 CKP sensor 5 Bolt 6 CMP sensor 7 Bolt Clean flywheel and crankshaft mating surfaces with cleaning solvent 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 SEAL Apply SUZUKI SILICONE SEAL torque Apply oil Use the engine oil unless oth Apply THREAD LOCK 1342 erwise specified OCK 13 Apply molybdenum oil solution Mixture of engine oil and SUZUKI Apply THREAD LOCK SUPER 13338 MOLY PASTE in a ratio of 1 1 Apply SUZUKI OUTBOARD MOTOR GEAR OIL Measure in DC voltage range Apply SUZUKI SUPER GREASE Measure in resistance range Apply SUZUKI MOLY PASTE 99000 25140 Measure in continuity test range Apply SUZUKI WATER RESISTANT GREASE Use peak voltmeter Stevens CD 77 Apply SUZUKI BOND 1104 Use special tool Apply SUZUKI BOND 120787 ABBREVIATIONS Abbreviations used in this service manual are as follows BTDC CKP CMP CTP DC DOHC ECM EX Ex IAC IAT IN In MAP OCV PORT PTT SPS STBD TPS VSV VVT Before Top Dead
49. ALVE VALVE GUIDE Valve diameter 35 9 1 4 0 4 Cold engine condition Valve guide to valve 0 020 0 047 0 0008 0 0019 stem clearance pany in 0 070 0 0028 mm 0 045 0 072 0 0018 0 0028 5 500 5 512 0 2165 0 2170 N m in 11 4 11 8 0 45 0 46 Valve stem outside 5 465 5 480 0 2152 0 2157 Valve stem deflection 0 14 0 006 eve stem neu eae 0 05 0 002 Valve head radial IN Valve spring tension 147 173 15 0 17 7 33 1 39 0 for 31 1 mm 1 22 in 136 13 9 30 6 for 31 1 mm 1 22 in GENERAL INFORMATION 1 15 DF150T Z DF175T Z CYLINDER PISTON PISTON RING ST u amp m 5 1 16 GENERAL INFORMATION DF150T Z DF175T Z CRANKSHAFT CONROD 21 968 21 979 0 8649 0 8653 diameter Conrod big end oil clearance 0 045 0 063 0 0018 0 0025 200 00081 57 000 57 018 2 2441 2 2448 Crank pin outside diameter 53 982 54 000 2 1253 2 1260 Crank pin outside diameter difference out of round and Limit in 0 010 0 0004 taper nu 1 482 1 497 0 0583 0 0589 Crank Crank width in 23 100 23 200 0 9094 0 9134 Crankshaft center journal 0 04 0 002 runout Crankshaft journal oil clear 0 030 0 050
50. CM may cause improper execution of the self diagnostic for model discrimination possibly leading to engine trouble 3 40 ENGINE CONTROL SYSTEM CONDITION FOR SELF DIAGNOSTIC SYSTEM OPERATION FAILED ITEM CONDITION MAP sensor 1 No signal With engine running Receiving an out of range 37 860 mmHg 1 46 33 86 inHg 0 50 4 84 V signal With engine running IAC valve operates at 90 duty or higher when ECM receives fully closed position signal from throttle position sensor NOTE 1 IAC valve By pass air screw adjustment Cylinder temp sensor No signal Receiving an out of range 46 to 170 C 114 8 338 F 0 10 4 6 V signal IAT sensor No signal Receiving out of range 46 to 169 C 114 8 336 2 F 0 10 4 6 V signal e During one crankshaft rotation 34 signals are not input to ECM During two crankshaft rotation 10 signals are not input to the ECM Air intake system During the receiving input of the complete close signal from the throttle position sensor the engine operates at an abnormally high speed Criterion 2 100 r min MIN MAP sensor 2 Receiving unchanging signal regardless engine speed change Pressure detect passage NOTE 2 Rectifier Regulator Receiving 16 volts or higher signal Over charging Exhaust manifold temp sensor No signal Receiving an out of range 46 to 170 C 114 8 338 F 0 10
51. CODE 1 2 Shift position sensor START Ignition switch gt Check shift position sensor output voltage e Shift position sensor failure change Wire continuity connection failure Is result OK See page 3 60 Possible cause ECM failure e Wire continuity connection failure 3 76 ENGINE CONTROL SYSTEM CHART 13 SELF DIAGNOSTIC CODE 2 6 CMP sensor VVT START Ignition switch ON gt fail Check CMP sensor VVT signal Em E tion fail Is result OK See page 3 57 ire continuity connection failure Possible cause e ECM failure e Wire continuity connection failure CHART 14 SELF DIAGNOSTIC CODE 5 2 VVT advance START lt lgnition switch ON gt Check 20 23 terminal voltage ECM power source battery battery ECM power source voltage switch sub battery cable etc failure Is result OK See page 3 48 lt lgnition switch gt and or gasket failure Is result OK See page 3 62 Possible cause ECM failure e Wire continuity connection failure OCV oil passage failure VVT actuator failure CHART 15 SELF DIAGNOSTIC CODE 3 3 Neutral switch START Ignition switch OFF Check neutral switch function Is result OK See page 4 15 YES Neutral switch failure Possible cause e ECM failure Wire short circuit Shift position sensor lever damage E
52. L SYSTEM 3 24 AIR INTAKE COMPONENTS prp 3 25 IDLE AIR CONTROL SYSTEM eo uk EE 3 26 MULII STAGE INDUCTION 3 29 DUU i 3 29 3 29 SYSTEM OPERATION i nto pacta dea pax ancha been 3 30 VVT Variable Valve Timing SYSTEM 1 Leer rennen 3 32 CAUTION SYSTEM Oc EEO 3 34 OVER REVOLUTION CAUTION SYSTEM erre nnne 3 34 LOW OIL PRESSURE CAUTION SYSTEM 3 35 OVERHEAT CAUTION a Seance ene 3 36 LOW BATTERY VOLTAGE CAUTION SYSTEM 3 37 SELF DIAGNOSTIC SYSTEM 2 3 38 PRIORITY CODE PATTERN FOR SELF DIAGNOSTIC SYSTEM OPERATION eee ees 3 38 CONDITION FOR SELF DIAGNOSTIC SYSTEM OPERATION 3 40 FAIL SAFE 3 42 PRE PROGRAMMED VALUE FOR FAIL SAFE SYSTEM 3 42 OPERATING HOUR INDICATION SYSTEM 3 43 OIL CHANGE REMINDER SYSTEM sana anna aaa u n aan uana 3 44 STA
53. NGINE CONTROL SYSTEM 3 77 CHART 16 SELF DIAGNOSTIC CODE 4 1 Model discrimination START lt Ignition switch gt Check CMP sensor 1 2 signal e Is result OK See 3 57 e Wire continuity connection failure YES Possible cause 13 terminal wiring harness connector open circuit DF 150 No 13 terminal connector short circuit DF175 CHART 17 SELF DIAGNOSTIC CODE 6 2 OCV START Ignition switch OFF Check OCV operation OCV failure Is result OK See page 3 62 YES Ignition switch OFF Check OCV resistance OCV failure Is result OK See page 3 62 YES Possible cause ECM failure e Wire continuity connection failure CHART 18 SELF DIAGNOSTIC CODE 1 1 Over charging START lt Individual check Check rectifier amp regulator resistance T 1 Rectifier amp regulator failure amp regulator failure Is result OK See page 4 8 YES lt Engine running gt Check 20 terminal voltage at idle speed Is result 16 V or over See page 3 48 Possible cause e ECM failure e Wire continuity connection failure NOTE This self diagnostic code indication may be canceled by turning ignition switch ON because ECM detects battery voltage NOTE 1 It is difficult to check rectifier amp regulator completely Before replacing with new one check if its ground point has good electrica
54. PRE PRODUCTION ISSUE SUZUKI OUTBOARD MOTOR Om io JL y m FOUR STROKE SERVICE MANUAL FOREWORD This manual contains an introductory description of the SUZUKI DF 150 175 Outboard motors and pro cedures for inspection service and overhaul of their AAA GENERAL INFORMATION General knowleage information is not included Please read the GENERAL INFORMATION section PERIODIC MAINTENANCE to familiarize yourself with basic information con cerning this motor Read and refer to the other ENGINE CONTROL SYSTEM sections in this manual for information regarding proper inspection and service procedures ENGINE ELECTRICAL This manual will helo you better understand these outboard motors assisting you in providing your customers with optimum and quick service GROUP INDEX FUEL SYSTEM e 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 15 intended for use by techni cians who already possess the basic knowl LOWER UNI T edge and skills to service SUZUKI outboard LEOBDIECTOTSTOTE EOTETIS TO motors Persons without such knowledge and skills Should not attempt to service SUZUKI out bo
55. RATION Shift position High pressure E Fuel injection Ignition SAP Starter motor Fuel pump Forward Reverse 2 YES NO 2 YES NO 2 YES 52 2 If itis in neutral judged by the ECM according to ON signal from the neutral switch ye Mca SAO SI 3 46 ENGINE CONTROL SYSTEM O2 FEEDBACK SYSTEM After extended usage the engine components may become deteriorated or worn This might make the A F air fuel mixture ratio incorrect which could affect exhaust emissions To correct the A F an O2 sensor must be temporally installed in the exhaust manifold This sensor is used to measure the concentration of oxygen in the exhaust gas at engine speeds of 3 000 4 000 and 5 000 r min The ECM uses the input data from the O2 sensor to correct the compensation coefficient of the fuel injection duration map within the ECM itself Feedback Informs ECM of concentration of oxygen in exhaust gas lt 4 18213 74200 02 For fuel mixture check 02 feedback operation procedure refer to Suzuki Diagnostic System Operation Manual ENGINE CONTROL SYSTEM 3 47 INSPECTION PRECAUTION ON SYSTEM INSPECTION A WARNING To prevent any unexpected engine start perform the following before proceeding with any CRANKING tests When performing tests not related to fuel injector operation eDisconnect all fuel injector wire connectors
56. ROTTLE BODY The throttle body assembly consists of the main bore throttle valve by pass air passage by pass air screw and TPS Throttle position sensor The throttle body adjusts the intake air amount with the throt tle valve which is connected to the throttle lever linkage The TPS installed on the throttle body informs of throttle valve opening angle NOTE n Do not try to adjust or remove any of the throttle body compo nent parts Throttle position sensor throttle valve throttle stop screw etc These components have been factory adjusted to precise speci fications gt OSS ATN i 2 Mihrottleiposition sensor 3 26 ENGINE CONTROL SYSTEM BY PASS AIR SCREW PASSAGE _ Since the throttle valve is almost fully closed when idling trolling the main flow of air necessary to maintain idling trolling speed passes through the by pass air passage The by pass air screw controls the flow of air through the pas sage and provides a means of partially adjusting the total amount of air necessary for idling trolling NOTE See page 2 16 for the by pass air screw adjustment procedure IAC VALVE PASSAGE The IAC valve is a stepper motor type mounted on the intake manifold Its purpose is to control the amount of intake air flowing from the IAC passage The IAC valve consists of a stepper motor rod valve and other parts As the stepper motor is controlled by signals from
57. RT IN GEAR PROTECTION SYSTEM 3 45 O2 FEEDBACK SYSTEM tas uu cs TE 3 46 stmt 3 47 PRECAUTION ON SYSTEM INSPECTION 3 47 26 PIN amp 34 PIN ep ee 3 47 INSPECTION FOR ECM CIRCUIT VOLTAGE 3 48 INSPECTION FOR RESISTANCE 3 51 COMPONENT INSPECTIONS nane rn aaa na ania nuu aaa uu aaa 3 53 MUETESTAGE INDUCTION 3 63 3 66 FLYWHEEL 3 66 CH SENSOR antice iet 3 68 gt 3 69 AC VABVES 3 69 OIL PRESSURE SWITCH ias 3 70 3 71 IHOUBLESHOOTING eee 3 72 3 2 ENGINE CONTROL SYSTEM ENGINE CONTROL SYSTEM STRUCTURE The DF150 DF175 models employ an integrated control system which performs the control functions for fuel injection ignition idle trolling speed idle air etc through the ECM Engine Control Module
58. T Approx 0 7 V Ignition switch ON Throttle FCT Approx 0 V Ignition switch ON Key not pushed in Lg B 0 04 4 46 gnition switch ON 3 50 ENGINE CONTROL SYSTEM WIRE STANDARD TERMINAL COLOR CIRCUIT VOLTAGE CONDITION REMARKS Lose qoc o 4 2 522 EN 5 __ _____ _____ 3 Fuel injector Approx 12 V Ignition switch ON 28 E B Br No 2 Fuel injector Approx 12 V Gr Y No 3 Ignition coil Approx O V 3 37 O Ignition switch ON 29 NE fe o 11 Approx 12 V row ej Variable intake control Approx 12 V Ignition switch ON VSV REV LIMIT lamp Tachometer 36 0 _ A 9 40 41 Ignition switch ON A No 1 Ignition coil BIW Approx 0 V Ignition switch ON amp Approx OV Approx OV B R High pressure fuel pump Approx 0 V Stop switch plate IN Shift in Neutral Ignition switch ON A O Ignition switch ON 6 sec after ignition switch ON While engine running Approx 12 V Engine stopped Ignition switch ON stop switch plate IN Shift in Neutral Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON Ignition switch ON No 4 Fuel injector No 1 Fuel injector Approx 12 V IAC valve 1 Approx 12 V orO V IAC va
59. TE Before installing the flywheel magneto wipe the crankshaft and flywheel clean Before tightening flywheel bolts make sure the fly wheel dowel pin hole and crankshaft dowel pin align or severe damage may result Apply THREAD LOCK 1342 to flywheel bolts before installing Tighten flywheel bolts to specified torque To lock flywheel use special tool as shown in figure Q Flywheel bolt 118 11 8 kg m 85 3 Ib ft 09916 99311 Flywheel holder 99000 32050 THREAD LOCK 1342 e After installing flywheel and torquing bolts to specification check air gap between CKP sensor and flywheel reluctor bars Air gap 0 75 mm 0 030 in Check to ensure that all removed parts are back in original position 3 68 ENGINE CONTROL SYSTEM CKP SENSOR REMOVAL Prior to removing CKP sensor Disconnect battery cables from battery 1 Remove flywheel See page 3 66 2 Remove the electric parts holder See page 4 30 3 Disconnect CKP sensor lead wire connector in electric parts holder 4 Remove two 2 screws D and sensor 2 INSTALLATION Installation is reverse order of removal with special attention to the following steps Apply THREAD LOCK 1342 to the sensor mounting screws 99000 32050 THREAD LOCK 1342 Install sensor with air gap of 0 75 mm between sensor and reluctor bar on flywheel then tighten sensor mounting screws securely Air
60. ad wire in the remote control extension harness to the ignition switch When the ignition switch is turned ON battery power passes from the white lead wire through the igni tion switch contacts to the gray output lead wire to the No 23 terminal of ECM NOTE Ensure battery cable connections are clean and secure Failure at the battery connection will cause incorrect operation of the ECM and starter motor cranking sys tem 2 The engine wiring harness to the main relay When the ECM main relay is energized by turning the igni tion switch ON a circuit is formed which supplies battery voltage to the No 20 terminal of ECM BATTERY Main battery cable Starter motor 30 60 amp fuse fuse E ECM main relay p Sub battery cable 15 amp fuse a A Battery 9 T Gr O2 SENSOR Optional item The O2 sensor is installed in the exhaust manifold only when the O2 feedback operation is performed This sensor is a zirconia element platinum plated which changes output voltage depending on the oxygen concentration difference between its internal and external surfaces The volt age change reflects the concentration of the oxygen in the exhaust gas and is used to perform the O2 feedback operation The terminal voltage change 0 1 V is dependent on the con centration of oxygen in the exhaust gas This detected voltage value therefore represents the oxygen con
61. al second If the battery leads are loose incorrectly connected or reversed the electrical system could be damaged 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 spe cific maintenance procedures BATTERY SOLUTION GRAVITY CHECK Measure the gravity of battery solution using a hydrometer Battery solution gravity 1 28 at 20 C 09900 28403 Hydrometer BALANCER CHAIN Replace every 1 600 hours SUZUKI recommends replacing the balancer chain chain ten sioner and chain guide every 1 600 hours For balancer chain replacement procedure see the POWER UNIT TIMING CHAIN BALANCER CHAIN section on page 6 31 or 6 44 PERIODIC MAINTENANCE 2 23 UPPER LEVEL LOWER LEVEL gt 2 24 PERIODIC MAINTENANCE 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 THREAD TIGHTENING TORQUE ina ImwETER 8mm Power unit mounting T Gearcase pe FUEL MIXTURE CHECK 02 FEEDBACK Perform every 2 years To perform fuel mixture check O2 feedback operation a bat tery powered personal c
62. an ECM which has been disconnected from the engine wiring harness 09930 89340 26 pin amp 34 pin test cord 09930 99320 Digital tester Tester range DCV See chart for range 1 Turn ignition switch OFF 2 Connect the 26 pin amp 34 pin test cord between ECM and wire harness as shown in figure 3 Turn ignition switch ON 4 Connect the tester probe Black to body ground and measure voltage according to the CIRCUIT VOLTAGE TABLE 34 pin test cord White connector b v d DXDT Black connector Black connector 26 REDD o 26 pin test cord White connector 26 pin test cord X XX e s ro r eps White connector Black connector 34 pin test cord XXX fool XX White connector Black connector ENGINE CONTROL SYSTEM 3 49 CIRCUIT VOLTAGE TABLE 9 000000 0006000600 009000000 000000000 FRONT VIEW WIRE STANDARD TERMINAL COLOR CIRCUIT VOLTAGE CONDITION REMARKS 1 Starter relay control Approx 1 3 V Ignition switch ON Shift in Neutral stop switch plate OUT switch plate IN 2 BG 02 Feedback AA 2
63. ard engines by relying on this manual only and should contact an authorized SUZUKI outboard motor dealer A WARNING 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 man POWER UNIT MID UNIT POWER TRIM AND TILT LOWER UNIT Standard rotation Right hand model oS OP WIRE HOSE ROUTING ual Improper repair may result in injury to the mechanic and may render the engine unsafe for the boat operator and passengers NOTE This manual is compiled based on 2006 K6 model COPYRIGHT SUZUKI MOTOR CORPORATION 2005 Marine amp Power Products Division HOW 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 ser vice information such as the tightening torque lubrication and locking agent points Example 1 Flywheel bolt 2 Flywheel E Q
64. but not to the filter section 5 Without voltage applied to the VSV terminals check that port E connects to the filter section but not to port F VSV AIR PASSAGE CONTINUITY Passage continuity between ports VSV electrical power Filter section L __ Poweron PowerOFF Q O Air passage NOTE Before removing hoses to check VSV mark each hose for posi tion to ensure correct hose connection on assembly 3 66 ENGINE CONTROL SYSTEM REMOVAL INSTALLATION FLYWHEEL 1 Flywheel bolt 2 Flywheel 3 Dowel pin 4 CKP sensor 5 Bolt REMOVAL Prior to removing flywheel Disconnect battery cables from battery 1 Remove ring gear cover and air intake silencer case See page 6 2 2 To lock the flywheel 1 when removing attaching bolts use special tool shown in figure Use screws and threaded holes on top of cylinder to attach special tool 09916 99311 Flywheel holder E 9 118 N m 11 8 kg m 85 5 Ib ft Ov 09 T Clean flywheel and crankshaft mating surfaces with cleaning solvent ENGINE CONTROL SYSTEM 3 67 3 Remove eight 8 flywheel bolts 4 Remove flywheel 1 dowel 3 INSTALLATION Installation is reverse order of removal with special attention to the following steps Install dowel pin 3 Install flywheel 1 onto crankshaft making sure to align dowel pin hole NO
65. centration The terminal voltage decreases when the oxygen concentration is high and increases when it is low NOTE As the Zirconia element is not conductive below 250 C the O2 sensor will not function properly until the engine is at normal operating temperature NOTE Zirconia element The zirconia element produces a potential difference voltage when there is a difference in the oxygen concentration of the gases which contact the two sides of the element Since the inner surface of the Zirconia element inside the sen sor is exposed to atmospheric air and the outer surface exposed to the exhaust gas there is a difference in oxygen con centration on each side and thus a difference in the potential generated ENGINE CONTROL SYSTEM 3 15 Zirconia element Housing 3 16 ENGINE CONTROL SYSTEM IGNITION SYSTEM The ignition system used by the DF150 DF175 is a fully transistorized electronic microcomputer timing advanced type This system is totally battery powered with the ECM controlling all ignition timing functions The ignition system is composed of the ignition coil spark plug and components for system control ECM sensor switch etc When the ignition switch is ON battery voltage 12 V is applied to the circuit as shown in the illustration The ECM determines the optimum ignition timing and duration of current flowing through the ignition coil pri mary winding based on the signals received from various
66. cessive wear damage of oil pump NOTE The low oil pressure caution system is reset when the oil pressure is restored to over 1 0 kg cm with approx 1 000 r min or less engine speed operation However the engine must be stopped and checked immediately once the system is activated 3 56 ENGINE CONTROL SYSTEM OVERHEAT CAUTION CONDITION 1 Maximum temperature Immediate activation of system when e Cylinder temperature reaches 120 C 248 F e Exhaust manifold temperature reaches 114 C 237 2 F CONDITION 2 Temp rise vs Time Immediate activation of system when e The average temperature difference during three consecutive 10 second measurement periods of the cyl inder temperature sensor at engine speeds of 500 r min or higher exceeds the limits as shown below Temperature range Temperature difference 88 99 C 190 210 F Approx 8 C 46 F 99 C 210 F Approx 1 5 C 35 F e The average temperature difference during three consecutive 10 second measurement periods of the exhaust manifold temperature sensor at engine speeds of 500 r min or higher exceeds the limits as shown below Temperature range Temperature difference 80 95 C 176 203 F Approx 14 C 57 2 F 95 203 F Approx 1 7 C 35 F ACTION Engine speed Automatically reduced to approx 3 000 r min by intermittent fuel injection and ignition signals if the system is activated at 3
67. cord Peak voltmeter Stevens CD 77 Tester range NEG 50 1 Disconnect all ignition coil connectors 2 Connect test cord between ECM and wire harness as shown in figure then turn ignition switch ON 3 Connect the tester probe Black to starter motor mag netic switch terminal connected to battery positive terminal as shown in figure 4 Connect the tester probe Red to each terminal Voltage Wire color Injector Terminal engine harness Peak voltage reading NEG level for peak voltmeter 5 Crank engine and measure voltage Fuel injector operating signal 6 10 V ENGINE CONTROL SYSTEM 3 55 IGNITION COIL OPERATING SIGNAL 34 pin test cord White connector FS aaa Ga 404142 575859 Lad Black connector yA M Te KX KD NC White connector rJ iy 26 pin test cord _ tL White connector 7 Black connector 34 pin test cord 09930 89340 26 pin amp 34 pin test cord Peak voltmeter Stevens CD 77 Tester range SEN 50 1 Connect test cord between ECM and wire harness as shown in figure then turn ignition switch ON 2 Connect the tester probe Red to each terminal Wire color Ignition coil Terminal engine sores Lg R 3 Connect the tester probe Black to No
68. d perform inspection again CMP SENSOR SIGNAL 09930 89340 26 pin amp 34 pin test cord 09930 99320 Digital tester Tester range DCV See chart for range 1 2 3 No 1 No 2 VVT 5 Turn ignition switch OFF Remove CMP sensor See page 3 69 Connect the 26 pin amp 34 pin test cord between ECM and wire harness as shown in figure Connect the tester probe Red to each terminal Wire color Terminal engine harness CMP sensor 5 7 Connect the tester probe Black to No 49 terminal or to body ground Turn ignition switch ON Measure the voltage when the tip of a steel screwdriver is brought near and then pulled away from the sensor tip When screwdriver is brought near Approx 5 V When screwdriver is pulled away Approx 0 3 V If the voltage does not change in the above test check wire harnesses for open and short If wire harnesses in good condition replace CMP sensor and recheck ENGINE CONTROL SYSTEM 3 57 26 pin test cord XXX White connector 34 pin test cord Black connector 3 58 ENGINE CONTROL SYSTEM MAP SENSOR OUTPUT VOLTAGE CHANGE 09917 47011 Vacuum pump gauge 09930 89340 26 pin amp 34 pin test cord 09930 99320 Digital tester Tester range DCV See chart for range 1 Remove flywheel See page 3 66 2 Remove the three bolts and fuel hose guard 3 Re
69. de cover may be separated from the power unit body by inserting and turning a 10 mm bolt to function as a screw jack 1 Screw jack 2 Anode coven CAUTION Never paint the anode NOTE The anode securing bolt should be covered with SUZUKI SILI CONE SEAL 99000 31120 SUZUKI SILICONE SEAL 2 22 PERIODIC MAINTENANCE BATTERY Inspect every 50 hours 3 months A WARNING 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 medi cal attention Batteries should always be kept out of reach of chil dren When checking or servicing the battery disconnect the negative black cable Be careful not to cause a short circuit by allowing metal objects to contact the battery posts and the motor at the same time Wear approved eye protection Recommended battery 12 V 100 AH 360 kC or larger CONNECTING BATTERY Upon completion of connection lightly apply grease to battery terminals How to connect 1 Connect positive terminal first 2 Connect negative terminal second How to disconnect 1 Disconnect negative terminal first 2 Disconnect positive termin
70. difference za 0 40 0 016 PTT MOTOR Brush length in 9 8 0 39 Commutator outside diame in 22 0 0 87 mm in 21 0 0 83 SELF DIAGNOSTIC SYSTEM INDICATION When the abnormality occurs in a signal from sensor switch etc the CHECK ENGINE lamp on the moni tor tachometer flashes lights intermittently according to the each code pattern with buzzer sounding PRIORITY FAIL SAFE SYSTEM FAILED ITEM CODE LAMP FLASHING PATTERN ACTIVATINC MAP sensor 1 n yes IAC valve By pass air 3 4 on hnn n wA screw adjustment off Cylinder temp sensor Air intake system 2 2 a MAP sensor 2 4 0 101 NO Pressure detect passage off Exhaust manifold temp 1 5 on sensor off GENERAL INFORMATION 1 19 TES CMP sensor VVT 2 6 9 5 2 5 on Neutral switch 3 3 om Model discrimination Oil control valve 6 2 Rectifier regulator Over charging If more than two items fail at once the self diagnostic indication appears according to priority order The indication repeats three times 1 20 GENERAL INFORMATION TIGHTENING TORQUE Tightening torque Important fasteners ms THREAD TIGHTENING TORQUE DIAMETER Nm kgm 6mm n 11 Cylinder head bolt 12mm 86 86 8620 63 Camshaft housing bolt Oil pump bolt 23 VVT model 78 7 8 56 0 model EX camshaft timing spr
71. e Terminals Resistance 5 4 JI and 2 2 4 25 34 CQ 6 and If out of specification replace IAC valve 3 4 Remove IAC from intake manifold See page 3 69 Connect connector to IAC valve When the ignition switch is turned ON and OFF check that the rotary valve turns to open and returns to closed If the valve does not turn check the wiring harness for conti nuity between ECM and IAC valve and connector contact condition OCV Oil control valve 1 2 Remove OCV See 3 71 Check for operating sound ticking sound when battery volt age applied to and removed from the terminals of oil control valve Check resistance between the two OCV terminals resistance 6 0 8 0 Q ENGINE CONTROL SYSTEM 3 63 MULTI STAGE INDUCTION SYSTEM INSPECTION e Ensure the depression chamber rod pulls the shut off valves to the complete close position after engine start m mS 1 Depression chamber 2 Intake manifold e Ensure the shut off valve return spring returns the shut off valves to the full open position when the engine is turned off 1 Depression chamber 2 Intake manifold 3 Rod DEPRESSION CHAMBER 09917 47011 Vacuum pump gauge e Ensure the shut off valve fully close when vacuum is applied A to the depression chamber with a vacuum pump tool EA EU ms 4 2 10 OA
72. e impact protection Spline drive rubber hub Propeller shaft rotation when shift into forward DF150T 175T Clockwise DF150Z 175Z Counterclockwise 3 X X X X X X KX XXXXXxx x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x 3 x Blade x Dia in x Pitch in 15 and 1 2 17 15 and 1 4 19 15 21 14 and 3 4 23 14 1 2 25 14 1 2 27 16 17 16 18 1 2 16 20 16 21 1 2 16 23 16 24 1 2 16 26 16 27 1 2 GENERAL INFORMATION 1 11 00 150 1502 7 DF175Z Propeller Counter rotation models Blade x Dia in 15 and 1 2 15 and 1 4 15 14 and 3 4 14 and 1 2 14 1 2 16 16 16 16 16 16 16 42 CO REDUCTION SYSTEM x Pitch 17 19 21 23 25 27 17 18 and 1 2 20 21 and 1 2 23 24 and 1 2 26 1st reduction gear ratio Crankshaft drive gear Driven gear 30 36 1 20 2nd reduction gear ratio Lower unit gear 12 25 2 08 Total reduction gear ratio 2 50 36 30 x 25 12 1 12 GENERAL INFORMATION SERVICE DATA These service data are subject to change without notice POWERHEAD Hecommended operating range 5 000 6 000 5 500 6 100 Idle speed 650 50 in gear Approx 650 Cylinder compression kPa 1 100 1 700 11 17 156 242 kg cm psi Cylinder compression max differ kPa
73. e then tighten switch to specified torque NOTE Cut off any excess sealing tape from switch threads before installation V Oil pressure switch 13 N m 1 3 kg m 9 5 lb ft e Install the ring gear cover and air intake silencer case Start engine and check oil pressure switch for oil leakage Reseal switch if oil leakage is found 1 Sealing tape i rcm o o m at 1 j Sn yyy ENGINE CONTROL SYSTEM 3 71 OCV Oil control valve REMOVAL 1 To remove the cover 0 pull the upper part outward then lift up 2 Disconnect OCV lead wire connector at OCV 3 Remove the four 4 bolts securing OCV then remove OCV and discard OCV gasket INSTALLATION Installation is reverse order of removal with special attention to the following steps e Install gasket and OCV then tighten bolts securely NOTE Position the OCV gasket tab as shown at right CAUTION J Do not reuse the OCV gasket always replace with new one V bolt 12 N m 1 2 kg m 8 6 Ib ft Check to ensure that all removed parts are back in original position 3 72 ENGINE CONTROL SYSTEM TROUBLESHOOTING Before starting troubleshooting read and follow the PRECAUTION ON SYSTEM INSPECTION section on page 3 47 In this section troubleshooting procedures are based on the assumption that Low pressure fuel system and
74. ected via hose to the vacuum tank the other side is connected via hose to the depression chamber The VSV receives operating signals from the ECM When the ECM signals OFF the VSV releases vacuum to the atmosphere When the ECM signals ON the VSV supplies vacuum to the depression chamber DEPRESSION CHAMBER The depression chamber is designed to open close the shut off valve When vacuum is applied to the depression chamber the rod in the chamber is pulled in closing the shut off valve When vacuum is not applied to the chamber the rod returns to the original position opening the shut off valve ENGINE CONTROL SYSTEM 3 29 3 30 ENGINE CONTROL SYSTEM SYSTEM OPERATION This system is operated by the vacuum created during engine operation and controlled by the ECM To operate the system open close the shut off valve to change the intake tract the intake manifold check valve vacuum tank VSV and depression chamber are connected with hoses as shown in the illustration A rod is used to connect the shut off valve and depression chamber for opening and closing the valve 0 09 2 0 09 c a 098 N N LOW amp MID SPEED RANGE When engine speed is below the preset value the ECM gen erates a signal to turn the VSV ON applying vacuum to the depression chamber which closes the shut off valve With the valve closed during the engines low to mid speed range inta
75. ees apart followed by a 20 degree index space During one crankshaft rotation 34 signals are input to the ECM CMP Camshaft Position SENSOR 1 CMP sensor 1 is mounted on the cylinder head cover with trigger vanes pressed onto the end of the exhaust camshaft This sensor detects piston position Signals received from this sensor are also used by the ECM to determine sequential fuel injection and ignition control e The CMP sensor contains a Hall Effect semiconductor and a magnet The semiconductor generates a voltage in proportion to the line of magnetic force passed through it When a trigger vane on the camshaft reluctor aligns with the sensor internal magnet a large amount of magnetic force is generated allow ing a high voltage to pass through the semiconductor When the trigger vane moves away from the sensor no magnetic force is generated and low voltage passes through the semi conductor These generated voltages are rectified to create ON high voltage amp OFF low voltage signals to the ECM The ten camshaft trigger vanes provide ten high voltage sig nals from CMP sensor to ECM during one camshaft rotation two rotations of crankshaft ENGINE CONTROL SYSTEM 3 9 ed is 2 Hall Effect semiconductor sensor r High voltage Low voltage 3 10 ENGINE CONTROL SYSTEM ECM cylinder identification Cy
76. em Fuel supply system Exhaust system Cooling system Lubrication system Starting system Throttle control 150012 150012 1750F 175012 mm in 839 33 0 mm in 519 20 4 mm in 1841 72 5 kg 105 211 465 2 kg 105 215 474 0 mm in type 500 20 mm in type 627 25 110 150 129 175 5 000 6 000 5 500 6 100 650 50 in gear Approx 650 4 stroke DOHC 97 3 82 97 3 82 1 GK 2067 1749 Full transistorized ignition Multi point sequential electronic fuel injection Through prop exhaust Water cooled Wet sump by trochoid pump Electric Remote control 1 10 GENERAL INFORMATION Has EN DFis0T Drisoz DFizsT 071752 FUEL amp OIL Fuel 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 Engine oil API classification SE SF SG SH SJ or NMMA FC W classification SE SF SG SH SJ Viscosity rating SAE 10W 40 or NMMA FC W 10W 40 Engine oil amounts 8 0 8 5 7 0 Oil change only SUZUKI Outboard Motor Gear Oil SAE 490 hypoid gear oil Gearcase oil capacity ml US Imp oz 1 100 37 2 38 7 BRACKET Trim angle 0 21 PTT system Number of trim position system LOWER UNIT Drive lin
77. en lift up valve 8 Remove tappet holder and tighten camshaft housing bolts to specified torque Q Camshaft housing bolt 12 1 2 kg m 8 7 Ib ft D Special tool 2 Tappet 3 Camshaft 9 Recheck tappet clearance NOTE After completing tappet clearance adjustment and securing camshaft housing bolts inspect tappet clearance again REASSEMBLY After checking and adjusting all valves reinstall parts removed earlier Installation is reverse order of removal Cylinder head cover Install the cylinder head cover See page 6 13 NOTE Examine cylinder head cover gasket for damage Always replace gasket if sealing performance is suspect 1 Head cover gasket PERIODIC MAINTENANCE 2 13 Tighten cylinder head cover bolts to specification V Cylinder head cover bolts 11 N m 1 1 kg m 8 0 Ib ft OCV Oil control valve Install gasket and OCV and then tighten bolts securely NOTE Position the OCV gasket tab as shown the right Do not reuse OCV gasket Always replace with new one V OCV bolt 12 N m 1 2 kg m 8 7 Ib ft FINAL ASSEMBLY CHECK All parts removed have been returned to their original posi tions Check hose and wire routing See page 11 4 to 11 17 Check oil leakage 2 14 PERIODIC MAINTENANCE pjoo 1 4 1 002 862 962 262 062 882 9826821 660 880 062 pesn eq 0 ezis
78. er pressor A 09922 59410 Propeller shaft 09917 98221 housing installer 09916 56011 Valve guide stem B 09922 59420 09916 37320 Valve guide reamer 10 5 mm 09916 84511 Tweezers 09922 89810 Valve guide installer seal installer attach Housing installer Shift lock pin attachment handle 09930 30161 09926 29310 Propeller shaft Driveshaft housing 09951 99310 remover remover Gear holder remover 09945 79310 PTT cable extension 09930 76420 Timing light 09930 99320 Digital tester 09951 09511 Gear adjusting gauge 09944 09420 PTT cylinder cap tool 09930 89220 3 pin connector test 09932 79910 Diagnostic harness 09932 89910 SDS adapter 09940 44121 Air pressure gauge 09952 09310 Back lash indicator 09930 89350 H T cord adapter 09917 49610 Vacuum pump adapter 09952 99310 Hand air pump GENERAL INFORMATION 1 25 09940 44130 Attachment 09900 25002 Pocket tester 09917 29610 Scissors gear alignment tool set 09930 89340 26 pin amp 34 pin test cord 09950 69512 Gearcase oil leakage A 18213 74F00 O2 sensor B 18498 99E70 Protector 1 26 GENERAL INFORMATION 99954 53873 Stevens CD 77 99954 53008 820 Peak reading volt 99954 53883 Digital voltmeter meter Gear oil filler NOTE Marked part No is in U S market only MATERIALS REQUIRED SUZUKI OUTBOARD SUZUKI SUPER WATER RESISTANT SUZUKI SILICONE SUZUKI BOND MOTOR GEAR OIL GREASE
79. ffect and Fast idle function the by pass air screw must be adjusted to provide IAC valve operation at approx 10 5 duty at the engine idling trolling specification See page 2 16 for the by pass air screw adjustment procedure MULTI STAGE INDUCTION OUTLINE The multi stage induction system is designed to improve the intake efficiency by changing the intake tract volume in accor dance with the engine speed This system improves low and mid range torque and increases power output at the higher rom ranges SYSTEM COMPOSITION The intake manifold assembly provides air for the low mid range intake tract and high speed range tracts Mounted on the intake manifold are throttle body VSV Vacuum Switching Valve vac uum tank depression chamber for operating the system and the shut off valve for switching the intake tract System connection components include one check valve and hose to form the vac uum passage VACUUM TANK The vacuum tank stores vacuum created during engine opera tion The vacuum tank purpose is to supply a stable vacuum to the depression chamber under the varying vacuum conditions normally occurring within the intake manifold thereby making it possible to control the shut off valve accurately A hose and check valve connects one side of the vacuum tank to the intake manifold The other side of the tank is connected to the VSV with a hose VSV Vacuum Switching Valve One side of the VSV is conn
80. g angle Sensor output voltage FCT position Approx 0 7 V WOT position Approx 3 8 V NOTE 26 pin test cord Do not try to adjust or remove any of the throttle body compo nent parts Throttle position sensor throttle valve throttle stop screw etc These components have been factory adjusted to precise speci fications 7 f out of specification check wire harnesses for open and 34 pin test cord short If wire harnesses are in good condition replace throt tle body and recheck Black connector 3 60 ENGINE CONTROL SYSTEM SHIFT POSITION SENSOR 09930 99320 Digital tester 09930 89220 3 pin test cord Tester range DCV See chart for range 1 Turn ignition switch OFF 2 Connect 3 pin test cord between shift position sensor and wire harness as shown in figure 3 Turn the ignition switch ON 4 Connect tester probe as shown in the illustration and check for sensor power source voltage Sensor power source voltage Approx 5 V 5 Connect tester probe as shown in the illustration Check for sensor output voltage while operating remo con handle Sensor output voltage Shift position Output voltage Approx 4 1 V Approx 23 Approx 0 8 V If out of specification 1st Check remo con cable adjustment readjust if necessary 2nd Check wire harnesses for open and short If wire harnesses are in good condition replace shift position sensor and recheck
81. he fuel vapor separator chamber VALVE CLOSED VALVE OPENED below 250 kPa over 250 kPa To Fuel vapor separator chamber Fuel return From Delivery line FUEL INJECTOR The fuel injector is an electromagnetic valve operated by a sig nal from the ECM When the injection signal is supplied to the fuel injector the solenoid coil is energized pulling up the plunger This opens the injector valve and injects fuel Because the fuel pressure is kept constant the amount of fuel injected is determined by the amount of time duration the valve is open S ICE WM I 1 Filter 2 Solenoid coil 3 Ball valve 4 Terminal Ei 3 24 ENGINE CONTROL SYSTEM HIGH PRESSURE FUEL PUMP CONTROL SYSTEM OUTLINE To supply the optimum fuel amount the ECM controls the fuel pump drive duty cycle a repeated ON OFF signal at a specified rate 1 000 times a second Based on engine speed and battery voltage the ECM determines the optimum duty repeating ON time rate within a cycle and sends this signal to the fuel pump CKP sensor Informs ECM of engine speed Battery voltage Ignition switch Informs ECM of START signal Cylinder temp sensor Informs ECM of cylinder temperature Duty cycle signal for fuel pump Battery example 80 duty charge coil F time 1 Fuel pump x 100
82. hould be SAE or NUMA FC W 10W 40 If SAE or FC W 10W 40 motor oil is not available select an alternative according to the chart at right GENERAL INFORMATION 1 5 20W ERE EN 40 15W 50 ENGINE OIL 30 20 10 0 10 20 30 40 22 4 14 32 50 68 86 104 1 6 GENERAL INFORMATION ENGINE BREAK IN The first 10 hours are critically important to ensure correct run ning of either a brand new motor or a motor that has been recon ditioned or rebuilt How the motor is operated during this time will have direct bearing on its life 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 the first 15 minutes operate the engine in gear at idling speed During the remaining 1 hour and 45 minutes operate the engine in gear at less than 1 2 half throttle 3 000 r min NOTE The throttle may be briefly opened beyond the recommended setting to plane the boat but must be reduced to the recom mended setting immediately after planning 2 NEXT 1 HOUR Operate the engine in gear at less than 3 4 three quarter throttle 4 000 r min 3
83. ic inspection when valve mechanism is serviced when camshafts are disturbed by removing them for inspection CHECKING AND ADJUSTING TAPPET CLEARANCE 1 remove the cover 0 pull the upper part outward then lift up 2 Remove following parts Engine side lower cover See page 7 2 Ring gear cover and air intake silencer case See page 6 2 gnition coils Spark plugs 3 Remove the cylinder head cover See page 6 11 2 10 PERIODIC MAINTENANCE 4 Rotate crankshaft counterclockwise to bring cam nose verti cal to shim surface 5 Measure tappet clearances by inserting thickness gauge between cam and shim surface Tappet clearance cold engine condition IN 0 23 0 27 mm 0 009 0 011 in EX 0 30 0 34 mm 0 012 0 013 in 09900 20803 Thickness gauge This is a left hand LH rotation powerhead Rotate crankshaft counterclockwise to prevent water pump impeller damage NOTE e Rotate crankshaft and measure clearance for each tappet respectively by bringing cam nose vertical to shim surface All tappet clearances can be measured during two crankshaft rotations 6 If out of specification adjust tappet clearance by changing shim ADJUSTMENT Tappet clearances are adjusted by replacing tappet shim 1 With cam nose vertical to valve turn tappet cut away towards center of cylinder head as shown in figure 2 Rotate crankshaft to open lift up valve and
84. ke air is supplied through the low mid speed intake tract only In this operating mode intake air speed is boosted and com bined with the inertia effect to the long intake tract increases low and mid speed range engine torque Preset value DF150 approx 4 700 r min DF175 approx 4 800 r min 1 Intake manifold 2 Throttle body 3 VSV 4 Check valve 5 Depression chamber 6 Vacuum tank LOW amp MID SPEED Air flow gt Shut off valve closed ENGINE CONTROL SYSTEM 3 31 HIGH SPEED RANGE HIGH SPEED When the engine speed is above the preset value the ECM generates a signal to turn the VSV OFF and vacuum is no longer applied to the depression chamber Without vacuum the shut off valve return spring returns and holds the valve in its normal open position In this operating mode intake air is supplied to the engine through the high speed intake tract only This enlarges the intake tract volume improves intake inertia and efficiency which increases the engines output power Shut off valve opened Air flow gt 3 32 ENGINE CONTROL SYSTEM VVT Variable Valve Timing SYSTEM The VVT system is designed to continuously vary intake valve timing to best fit the engines current ating condition The intake cam timing sprocket assembly VVT actuator is located at the front end of the intake cam shaft The timing sprocket internal rotor is operated by engine oil pressure Since the
85. l 5 Bearing Air flow State 1 State 2 State 3 6 Stator Pole shifting Rotor rotation 7 Rotor 8 IAC valve 9 Throttle valve 3 28 ENGINE CONTROL SYSTEM CONTROL MODE BEFORE START The IAC valve is initialized at 70 opening position when engine is not running Ignition switch OFF WHEN CRANKING The IAC valve is controlled to operate at approx 40 100 duty Duty change depends on cylinder temperature AFTER START FAST IDLE FUNCTION The IAC valve is controlled to operate at approx 10 70 duty until the timer set according to cylinder temperature at cranking expires then decrease duty gradually to reach the set rpm at idle WHEN IDLING TROLLING The IAC valve is controlled so that engine speed is stable at the idling trolling speed specified During this period the IAC valve has a duty of approx 10 but will vary slightly as idling trolling conditions change WHEN RUNNING NORMAL OPERATION The IAC valve is controlled to operate at 10 70 duty dependent on current engine conditions WHEN DECELERATING DASH POT EFFECT When the throttle valve is suddenly returned to full close and the throttle position sensor signal changes to fully closed the IAC valve operates at a controlled gradual return to idle troll operating duty to prevent engine stalling or unstable running NOTE Due to the limited intake air flow from the IAC passage and in order to effectively use both the Dash pot e
86. l contact 3 78 ENGINE CONTROL SYSTEM CHART 19 ENGINE CRANKED BUT NOT START OR STOPS SHORTLY AFTER STARTING Before starting the troubleshooting make sure that There is no self diagnostic code indication Emergency stop switch plate 15 set in place START Ignition switch gt Ignition switch failure Check 23 terminal voltage e Wire continuity connection 5 result OK See page 3 48 failure YES Ignition switch gt Check 20 terminal voltage ECM main relay failure Spark plug failure 5 result OK See page 3 48 Ignition switch OFF lt Cranking gt Individual check Check fuel injector resistance Check ignition spark using Check if spark plug See page 3 51 timing light P no 09930 is in good condition Is result OK 76420 Is result OK Is there light flashing Ignition switch ON lt Cranking gt Check ignition coil Check 54 36 28 53 terminal Check ignition coil operating condition voltage See page 3 48 signal See page 3 55 See page 3 56 Is result OK Is result OK Is result OK lt Cranking gt Check fuel injector operating Tri rit ne ae Ignition coil failure signal See page 3 54 Is result OK failure Fuel injector failure Ignition switch gt Check 52 terminal voltage Ignition switch gt Check high pressure fuel pump 6 sec operating sound See page 3 53 Is resul
87. l pressure gauge 09915 78211 Oil pressure gauge adapter 6 Install the ring gear cover and air intake silencer case 7 Start engine and allow to warm up as follows Summer 5 at 2 000 r min Winter 10 min at 2 000 r min 8 After warming up shift into forward gear and increase engine speed to 3 000 r min then compare pressure indi cated on gauge to specifications 9 After testing reinstall oil pressure switch See page 3 70 CHECK ENGINE 7000 r min TEMP REV F lt LIMIT CYLINDER COMPRESSION Cylinder compression Standard 1 100 1 700 kPa 11 17 kg cm 156 242 psi Max difference between cylinders 100 kPa 1 0 kg cm 14 psi NOTE Figures shown are guidelines only not absolute service limits Low compression pressure can indicate one or more of follow ing Excessively worn cylinder wall Worn piston or piston rings e Stuck piston rings Poor seating of valves Ruptured or otherwise damaged cylinder head gasket TEST PROCEDURE 1 Start engine and allow to warm up then shut engine off 2 Disconnect all fuel injector connectors at fuel injector 3 Disconnect all ignition coil connectors 4 Remove the bolts securing the ignition coil then remove all ignition coils and spark plugs 5 nstall compression gauge hose attachment into spark plug hole then connect compression gauge hose to gauge hose attachment and compression gauge 09915 64512
88. led in the proper order and orientation Be sure to use special tools where instructed Make sure that all parts used in assembly are clean and also lubricated when specified When use of a certain type of lubricant bond or sealant is specified be sure to use the speci fied 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 tight ening 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 scre
89. linders are identified by a calculation combined from two signals one from the CKP sensor and one from the CMP sensor TDC ___ ____ i 05 TDC 3Cyl _ TDC In CEE TDC 2 EK EET 34 signals crankshaft 1 rotation CKP signal CMP sensor 6 signals CMP sensor 4 signals CMP sensor 1 signal 360 Crankshaft 1 rotation 60 360 Crankshaft 1 rotation CMP sensor 2 7 VVT signal 360 120 Cm Compression Ep Explosion Ex Exhaust In Intake Top Dead Center CMP Camshaft position SENSOR 2 For DF175 model CMP sensor 2 is mounted on the cylinder head cover with trigger vanes pressed onto the end of the intake camshaft This sensor detects camshaft position e This sensor is the same type as the CMP sensor 1 and inputs signals to ECM This signal is used to control intake camshaft valve timing through OCV Oil control valve ENGINE CONTROL SYSTEM 3 11 CYLINDER TEMPERATURE SENSOR The cylinder temperature sensor is installed on the cylinder top side and used to detect the cylinder temperature This is a thermistor type sensor resistance of which changes depending on temperature and inputs a signal to the ECM as a voltage value This signal is used to compensate the fuel injec tion time duration ignition timing etc This sensor is also used to detect engine over heat as the ECM detects both the temperature and
90. lve 2 Approx 12 V or0 V 57 W BI IAC valve 4 Approx 12 V orO V Approx 12 V 55 O 58 IAC valve 3 Approx 12 V or0 V CHECK ENGINE lamp TEMP lamp When 12 V is displayed at No 55 57 terminal 0 zero V is displayed at No 58 56 terminal Con versely V is displayed at No 55 57 terminal 12 V will be displayed at No 58 56 terminal co Lg O B W B R Y R G G W G Y O ENGINE CONTROL SYSTEM 3 51 INSPECTION FOR RESISTANCE 09930 99320 Digital tester Tester range Resistance See chart for range NOTE Make sure ignition switch is always OFF when measuring resis lance 1 Turn ignition switch OFF 2 Disconnect battery cables from battery 3 Disconnect wire harness connector from ECM 4 Connect the tester probes to terminal wire harness side and measure resistance according to the RESISTANCE TABLE 000000000 000000000 0000000 0000000 Wire harness NOTE 17 Disconnect ECM main relay from fuse box and connect tester probe to relay terminal of fuse box side NOTE 2 Disconnect remote control wire harness and connect tester probe to terminal 8 White wire White lead wire 3 52 ENGINE CONTROL SYSTEM NOTE 3 Disconnect 10 amp IAC CMP fuse from fuse box and connect tester probe to fuse terminal of fuse box side
91. move bolts and MAP sensor from intake manifold 4 Install MAP sensor into special tool 09917 49610 Vacuum pump adaptor 5 Connect vacuum pump gauge with hose to MAP sensor 26 pin test cord special tool as shown in figure 6 Turn ignition switch ON 7 While applying negative pressure vacuum to MAP sensor measure 12 terminal voltage See page 3 48 and 3 49 for v DOPPIX White MAP sensor output voltage change Negative pressure 0 40 80 kPa kg cm mmHg 0 0 0 4 300 0 8 600 12 terminal 4 00 2 42 0 84 voltage V at 759 8 mmHg 29 91 inHg 1013 hPa barometric pressure ENGINE CONTROL SYSTEM 3 59 8 If out of specification check wire harnesses for open and short If wire harnesses are in good condition replace MAP sensor and recheck TPS Throttle position sensor 09930 99320 Digital tester 09930 89340 26 pin amp 34 pin test cord Tester range DCV See chart for range 1 Turn ignition switch OFF 2 Connect the 24 pin amp 34 pin test cord between ECM and wire harness as shown in figure Connect tester probe D Red to No 16 terminal 4 Connect tester probe Black to No 49 terminal or to body ground 5 Turn the ignition switch ON x 6 Check for sensor output voltage Slowly move the throttle lever to open and check if voltage changes linearly within specification according to throttle valve openin
92. nal 3 injection signal 4 injection signal Injection Start Timing 275 Ex stroke ai Injection time duration Cm Compression Ep Explosion Ex Exhaust In Intake Top Dead Center CONTROL MODE BEFORE START When the ignition switch is turned ON the ECM receives a MAP sensor signal indicating the static baro metric pressure of the intake manifold This signal is used to compensate the fuel injection map for altitude WHEN CRANKING Fuel is simultaneously injected to all cylinders according to the Start up mode map in relation to crankshaft angle AFTER START FAST IDLE FUNCTION The fuel injection amount is controlled to remain increased until the timer set according to cylinder tempera ture at the time of engine start expires WHEN IDLING TROLLING The fuel injection amount is controlled to maintain a stable engine speed at the specified idle trolling rom WHEN ACCELERATING The fuel injection amount is controlled to increase WHEN DECELERATING The fuel injection amount is controlled to decrease The fuel injection is also cut off on very rapid engine deceleration ENGINE CONTROL SYSTEM 3 21 FUEL DELIVERY SYSTEM COMPONENTS The fuel delivery system is composed of the low pressure fuel line components fuel tank filter pump fuel vapor separator high pressure fuel pump high pressure fuel filter fuel pressure regulator located in the fuel vapor separa
93. nme fuel filter 2 20 PERIODIC MAINTENANCE WATER PUMP WATER PUMP IMPELLER WATER PUMP Inspect every 200 hours 12 months Inspect water pump case inner sleeve and under panel Replace if wear cracks distortion or corrosion is found WATER PUMP IMPELLER Replace every 200 hours 12 months SUZUKI recommends that replacing the water pump impeller every 200 hours 12 months Inspect water pump impeller Replace if vanes are cut torn or worn PROPELLER NUT COTTER PIN Inspect initially after 20 hours 1 month and every 100 hours 6 months Inspect propeller for bent chipped or broken blades Replace propeller if damage noticeably affects operation e 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 BONDING WIRES Inspect every 50 hours 3 months If breakage or other damage is found on bonding wire replace the wire e If rust corrosion or other damage is found on terminal clean with cleaning solvent or replace wire PERIODIC MAINTENANCE 2 21 ANODES Inspect every 50 hours 3 months ANODES If 2 3 of zinc anode has corroded away replace anode The anode should be periodically cleaned with a wire brush to ensure maximum effectiveness NOTE The ano
94. ntial timing and controls the injector operating signals accordingly Fuel injection start timing is set at a constant of ATDC 275 on the exhaust stroke Basic sensors ECM MAP sensor CKP sensor amount is determined by a digital map designed in relation to intake manifold Compensating sensors pressure engine Cylinder temperature sensor speed Informs ECM of cylinder temperature Exhaust manifold temperature sensor Informs ECM of exhaust manifold temperature IAT sensor Informs ECM of intake air temperature TPS Throttle position sensor Informs ECM of throttle opening angle MAP sensor Informs ECM of barometric pressure at time of engine start Battery voltage Constantly monitored by the ECM Others CMP sensor Informs ECM of camshaft angle A Shift position sensor M Informs ECM of shift position neutral or in gear Injector Fuel amount compensation Multi point sequential timing 11111 Battery charge J Sensor switch signal input Rectifier amp mir regulator 30A fuse 60A fuse Au e ABA fuse Ignition switch Battery Injector 3 20 ENGINE CONTROL SYSTEM FUEL INJECTION TIMING CHART 1 Cyl 3 Cyl 4 Cyl 2 Cyl CKP sensor signal CMP sensor 1 A 0 ___ signal CMP sensor 2 signal VVT 1 injection signal 2 injection sig
95. o 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 7 To check the gear oil level a Remove the oil level plug b If oil can be seen at oil level plug level the unit is full c If oil level is low re fill with gear oil through oil level hole d Install oil level plug 3 Oil level plug PERIODIC MAINTENANCE 2 7 LUBRICATION Inspect every 50 hours 3 months Apply SUZUKI Water Resistant Grease to the following points 99000 25160 SUZUKI WATER RESISTANT GREASE Throttle cable link Throttle body cable Propeller shaft Swivel bracket 2 8 PERIODIC MAINTENANCE SPARK PLUG Inspect every 100 hours 6 months Replace every 200 hours 12 months Standard spark plug NGK BKR6E CAUTION Only resistor R type spark plugs must be used with this engine Using a non resistor spark plug will cause ignition and fuel injection system malfunctions REMOVAL Disconnect ignition coil connector then remove the bolt securing the ignition coil Remove the ignition coil and spark plug 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 SPARK PLUG GAP Measure spark plug gap with a thickness gauge Adjust to
96. oat system that maintains a constant fuel level inside the separator chamber As the fuel level decreases fuel flows into the vapor separator from the low pressure fuel pump The function of this unit is to separate vapors from fuel delivered by the low pressure fuel pump or fuel returned from the fuel pressure regulator This vapor is routed through the evaporation hose connecting the vapor separator cover to the crankcase HIGH PRESSURE FUEL PUMP The high pressure fuel pump is an integral type in which the pump mechanism is located within the fuel vapor separator To supply the optimum fuel amount the pump is driven by the duty cycle signal from ECM Fuel outlet Evaporation Needle valve Valve seat High pressure Float fuel pump Chamber Suction filter 7 4m Fuel return Fuel pressure regulator Fuel drain ENGINE CONTROL SYSTEM 3 23 FUEL PRESSURE REGULATOR The fuel pressure regulator is located in the fuel vapor separator The regulator s function in the system is to maintain a constant fuel pressure relative to the injector while the engine is operating The regulator diaphragm chamber is open to the fuel vapor separator chamber to keep the pressure bal anced Fuel pressure adjusted by the regulator is constantly maintained higher than the pressure in the fuel vapor separator chamber by approx 250 kPa 2 55 kg cm 36 3 psi By pass fuel is returned to t
97. ocket IN camshaft timing sprocket Chain tensioner adjusterbot _____ emm 1 11 so _ Oilpressureswich 95 _ Fuel delivery pipe Fuel delivery pipe union bol 4 14 19 Engine oil drain plug UNF 43 Water pump case bol Driveshaft seal housing 30 109 725 GENERAL INFORMATION 1 21 ITEM THREAD TIGHTENING TORQUE DIAMETER Nm kgm _ bolt 2mm 83 83 60 Propeller shaft bearing housing 1050 Propeller Tightening torque General bolt NOTE These value are only applicable when torque for a general bolt is not listed in the Important Fasteners table THREAD TIGHTENING TORQUE Se DIAMETER Nm kgm bt _ 02 04 15 30 Q 04 07 30 50 2 10 16 1 0 1 6 7 0 11 5 Conventional or 4 marked bolt 22 35 2 3 3 5 16 0 25 5 2 02 04 15 30 zi 06 10 45 74 2 15 20 15 20 110 145 Stainless steel bolt 34 41 3 4 4 1 24 5 29 5 08 06 20 45 ay 08 12 60 85 18 28 1 8 2 8 13 0 20 0 7 marked _ marked bolt 40 60 4 0 6 0 29 0 43 5 1 22 GENERAL INFORMATION SPECIAL TOOLS 09900 00410 a 09900 00411 Hexagon socket included in Hexagon wrench set 09900 00410 09900 20202 Micrometer 25 50 mm 09900 20602 Dial gauge 09900 20203 50 75 mm 09900 20204 75 100 mm Micrometer 09900 20701 Magnetic stand
98. omputer and the Suzuki Diagnostic Sys tem software hardware must be used For fuel mixture check O2 feedback operation refer to Suzuki Diagnostic System Operation Manual NOTE See O2 FEEDBACK SYSTEM section on page 3 46 before starting O2 feedback operation PERIODIC MAINTENANCE 2 25 OIL PRESSURE Oil pressure at normal operating temp 400 600 kPa 4 0 6 0 kg cm 57 85 psi at 3000 r min NOTE The figure shown above is a guideline only not an absolute ser vice limit If oil pressure is lower or higher than specification the following causes may be considered See page 6 108 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 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 three 3 bolts and fuel hose guard 1 3 Remove the ring gear cover and air intake silencer case 2 See page 6 2 4 Loosen screw and disconnect blue lead wire 3 from oil pressure switch 4 the oil pressure switch 2 26 PERIODIC MAINTENANCE 5 Install oil pressure gauge adaptor into oil pressure switch hole in place of oil pressure switch 09915 77311 Oi
99. part of the sprocket housing assembly Since the rotor and intake camshaft are bolted together when the rotor moves inside the housing a change of phase angle takes place in the relative position between the intake camshaft and intake cam timing sprocket The rotor has a spring pressured lock pin which engages with the housing when spring force is greater than oil pressure locking the rotor in the most retarded position This prevents a change of phase angle between the intake camshaft and intake cam timing sprocket when the engine oil pressure is low at engine start When the engine is started and the engine oil pressure is applied to the advance chamber the lock pin is forced up com pressing the return spring releasing the rotor and allowing the VVT actuator to function Advance chamber 3 54 ENGINE CONTROL SYSTEM CAUTION SYSTEM The following four caution systems alert the operator when an MONITOR TACHOMETER abnormality occurs on the engine OVER REVOLUTION CAUTION LOW OIL PRESSURE CAUTION OVERHEAT CAUTION LOW BATTERY VOLTAGE CAUTION OVER REV LIMITER 3 000 r min CAUTION CAUTION CAUTION TYPE LAMP BUZZER 7 REV LIMIT lamp 2 lamp 3 TEMP lamp 4 CHECK ENGINE lamp Overrevolution 60 Low pressure _ ves Yes Overnet 9 Yes Yes Low battery voltage Yes OVER REVOLUTION CAUTION SYSTEM CONDITION The ECM con
100. r will P PD 2 72 4 begin a series of double beeps if engine is not running but igni i Y tion switch is ON The above mentioned indication will repeat Indication Cancellation until the activated system is manually cancelled 73 Indication gt Cancellation NOTE o 4 This system will activate up to 2 100 hour s operation Y Indication Cancellation INDICATION OF SYSTEM ACTIVATION Buzzer OIL lamp Hepeat SEE Lapse of initial 20 hour s operation 0 3 sec paces ON ON Lapse of 80 hour s operation gt Lapse of 100 hour s operation OFF OFF When performing cancellation before 0 3 sec 0 3 sec system activation Ign switch ENGINE START gt RUNNING ON Buzzer OFF ON Oil Lamp OFF Indicator check No relation to OIL CHANGE REMINDER SYSTEM CANCELLATION Procedure 1 Turn the ignition key to ON position 2 Pull out the emergency stop switch plate 1 3 Pull up the emergency stop switch knob 2 three times in ten seconds A short beep will be heard if cancellation is suc cessfully finished 4 Turn the ignition key to OFF position 5 Set switch plate in original position NOTE e Canceling of the system activation is possible regardless of whether or not the engine oil has been replaced Once the system has operated however SUZUKI strongly recommends that the engine oil be replaced before canceling the
101. rotor and intake camshaft is bolted together the rotor and camshaft move together Varying the intake valve timing is accomplished by changing the intake camshaft phase angle relative to the intake cam timing sprocket using pressurized engine oil applied to the rotor through an ECM controlled oil control valve The oil control valve OCV directs engine oil pressure to the advance chamber or retard chamber inside the intake cam timing sprocket assembly VVT actuator The oil control valve operates on a duty cycle controlled by the ECM he ECM determines the optimum valve timing advance angle under various operating conditions based on engine speed throttle opening and cylinder wall temperature These input values are then used to control the position of the oil control valve OCV The ECM also detects the actual advance angle from the CMP sensor inputs to perform feedback control and accurately maintain the target advance angle VVT actuator Rotation direction CMP sensor Ex camshaft In camshaft eon Retard Advance E I CKP sensor Drain Crank ECM a position aS Throttle opening angle Cmm 1 Throttle sensor Target Cylinder temp sensor Cylinder temp advance Oil control valve OCV Cam position KI Oil pan Manifold pressure Actual valve a timing Engine oil pressure Signal Advance 40 movable angle Valve lift Ex valve
102. sensors The ECM interrupts the base current of the power transistor inside the ignition coil thereby controlling current flow ignition to the primary winding of ignition coil In this way a mutual induction high voltage occurs in the ignition coil secondary side and spark is generated ENGINE CONTROL SYSTEM 3 17 IGNITION CONTROL SYSTEM OUTLINE Sensors at specific points on the engine monitor current engine conditions and send signals to the ECM Based on these signals the ECM determines the optimum ignition timing and releases voltage to the ignition coils ECM Basic sensors MAP sensor Informs ECM of intake manifold pressure Ignition timing is determined by a digital map designed in relation to Compensating sensors Cylinder temperature sensor Informs ECM of cylinder temperature Throttle position sensor Informs ECM of throttle opening angle Shift position sensor Informs ECM of shift position and change Switch Ignition switch Informs ECM of START signal Spark plug SPECIFICATION Ignition system Full transistorized ignition Electronic microcomputer control BTDC 5 BTDC 26 DF150 CKP sensor intake manifold pressure and engine speed Informs ECM of engine speed and crankshaft angle Ignition timing compensation Ignition timing BTDC 5 BTDC 26 DF175 1 3 4 2 3 18 ENGINE CONTROL SYSTEM IGNITION TIMING CHART The following chart is
103. speed The transistor driving the IAC is inside the ECM and turns ON OFF when a signal command is received from the CPU This signal operates the stepper motor inside the IAC valve causing it to be driven equal to the number of command signal steps Through this procedure the system is able to attain a very precise target idling trolling speed The stepper motor rotates by means of magnetic attraction between the stator and rotor More specifi cally shifting the stator excitation in State 1 of the illustration below to that in State 2 will develop a magnetic torque to cause the rotor to rotate and then stabilize in State 3 The illustration below shows the operating principle of a simple stepper motor This example differs slightly from the 2 phase excitation method used in the actual application This operation is repeated equal to the number of command signal steps from the ECM resulting in rotation of the rotor With the screw shaft installed this rotation is con verted to a linier motion of the valve pintle that changes the volume of IAC air flow Battery voltage is applied to the center tap of each coil through the ECM main relay when the ignition switch is turned on Each coil end connects to one of the ECM terminals 1 4 The terminal voltage at ECM terminals IAC 1 4 is 1 V MAX when current flows and battery voltage at all other times 12 V T Gr valve 1 Valve pintle 2 Screw shaft 3 Rotor 4 Coi
104. system activation Even if the engine oil has been replaced with the system not operating it is still necessary to perform the cancellation ENGINE CONTROL SYSTEM 3 45 START IN GEAR PROTECTION SYSTEM Control by Neutral switch A switch to detect neutral gear position is located on the throttle lever holder and operated by the clutch con trol lever This ON OFF type switch is ON in neutral and OFF in forward or reverse On starting the engine the ECM detects the shift position using the neutral switch When the neutral switch is OFF the ECM does not provide starter motor relay operating signal Control by Shift position sensor A shift position sensor is installed on the throttle lever holder and detects the shift position This sensor is a variable resistor that changes resistance in accordance with the shift position The resistance changes increase decrease the voltage signal output from the sensor to the ECM Based on the sensor voltage the ECM calculates and detects shift position On starting the engine the ECM does not provide an injector operating signal when a shift lever in gear position is detected Operation by Neutral switch on engine starting OPERATION hift positi Fuel pump YES YES YES Forward Reverse 1 YES 1 YES 1 YES 8 1 If it is in neutral judged by the ECM according to the shift position sensor signal Operation by Shift position sensor on engine starting OPE
105. t OK e ECM failure See page 3 48 Is result OK YES e High pressure fuel pump failure e Wire continuity connection failure ENGINE CONTROL SYSTEM 3 79 CHART 20 UNSTABLE IDLING TROLLING OR ENGINE TENDS TO STALL Ignition switch gt Check shift position sensor output voltage change See page 3 60 Is result OK Shift position sensor failure NOTE 1 e Wire continuity connection failure Ignition switch gt Check throttle position sensor output voltage change See page 3 59 Is result OK e Throttle position sensor failure NOTE 2 e Wire continuity connection failure Possible cause e Incorrect by pass air screw adjustment NOTE 3 IAC valve failure NOTE 3 IAC passage failure clogged etc NOTE 3 e Spark plug failure Ignition coil failure e ECM failure Wire continuity connection failure Failure of high pressure fuel system components Fuel injector clog stuck valve etc Fuel pressure regulator incorrect regulated pressure etc Fuel pump clogged suction filter leakage in tank etc Fuel filter clog etc Hose clog kink leakage etc NOTE 1 If shift position sensor has failed while engine running engine will tend to stall when shifting into gear NOTE 2 If throttle position sensor has failed engine will tend to stall when decelerating NOTE 3 e The self diagnostic code 3 1 not be indicated
106. the ECM valve position changes will increase or decrease the air flow through the IAC passage IDLE AIR CONTROL SYSTEM OUTLINE The ECM controls the position of the valve to regulate a portion of the intake air flow to the intake man ifold This system is used for the following purposes To keep idling trolling at specified speed To improve drivability when decelerating Dash pot effect To improve engine starting and warm up performance Fast idle function The sensors switch shown below monitor current engine condition and send signals to the ECM Based on these signals the ECM determines the IAC valve opening necessary to achieve the target engine revolution and outputs the signal for actuating the stepper motor inside the IAC valve The rotor of the stepper motor then turns in an amount equal to the steps of the signal supplied from the ECM moving the valve via a screw shaft CKP sensor Informs ECM of engine speed MAP sensor Informs ECM of intake manifold pressure Throttle position sensor Informs ECM of throttle opening angle Cylinder temp sensor Informs ECM of cylinder temperature Shift position sensor Informs ECM of shift position and change Li IAC valve ENGINE CONTROL SYSTEM 3 27 IAC VALVE The IAC valve uses a stepper type motor The IAC valve is installed on the intake manifold The IAC valve controls the volume of bypass air to stabilize the idling trolling
107. the throttle fully this will cause a full close throttle signal to be input to the ECM ES 8 the IAC valve duty to constant 10 turn the ignition key from to START five times within ten seconds At this time the caution buzzer will sound to notify that IAC duty is in fixed mode NOTE b The ignition key operation to set the IAC valve into the fixed 1 E a cel guard mode should be performed with the engine running at idle While IAC valve duty 15 at a fixed 10 duty the caution buzzer will sound in a repeating pattern of 0 5 second on with an inter val of 3 seconds off e The 10 fixed mode of IAC valve duty will continue for 5 utes after which it will automatically cancel 9 During this fixed mode of IAC duty adjust engine speed to 650 50 r min by turning by pass air screw Turning air screw counterclockwise Engine speed will increase Turning air screw clockwise Engine speed will decrease 10 When finished adjusting the idle speed opening the throttle will automatically cancel the IAC fixed mode NOTE The fixed mode of IAC can also be canceled manually by shift ing to Forward or Reverse or raising the engine speed changes the TPS full close throttle signal to OFF 11 Return the throttle to full close and check engine speed It should now be stable at 600 700 r min NOTE Idling trolling speed of 600 70
108. the water and on a boat ensure that the necessary safety equipment is on board Such equipment includes flotation aids for each person fire extin guisher 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 well ventilated and that you follow all of the material manufacturer s instructions Never use gasoline as a cleaning solvent To avoid getting burned do not touch the engine engine oil or exhaust system during or shortly after engine operation 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 con tacts 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 fit tings related to the system for leaks Carefully adhere to the battery handling instructions laid out by the battery supplier GENERAL INFORMATION 1 3 If parts replacement is necessary replace the parts with Suzuki Genuine Parts or their equiv alent When removing parts that are to be reused keep them arranged in an orderly manner so that they may be reinstal
109. then remove camshaft housing bolts where shim is to be replaced 3 Install special tool with camshaft housing bolts as shown in figure 09916 69310 Tappet holder Cut section of the tappet Shim 3 Plug hole Camshaft housing bolt 2 Plug hole 4 Rotate top of 90 degree counterclockwise and remove shim from cut away at tappet Two tappets can be adjusted at the same time Do not put your finger between camshaft and tappet while the tappet is being held with the tappet holder e Use a magnet to remove and install shim When installing shim identification mark on the shim should face down towards tappet 5 After removing shim measure thickness of original shim and determine correct thickness of shim for proper tappet clear ance as calculated by following formula 09900 20205 Micrometer IN side A 0 25 mm EX side A B C 0 32 mm A Correct thickness of shim for proper tappet clearance mm B Thickness of original shim mm C Original tappet clearance mm ED No LD LD ny mm mm mm 228 278 220 250 280 225 253 283 225 255 285 228 258 268 230 260 290 233 263 293 235 265 295 238 268 298 240 270 300 243 27a 0 Magnet PERIODIC MAINTENANCE 2 11 1 Removed shim 2 12 PERIODIC MAINTENANCE 6 Install shim Identification number should face down towards tappet 7 Rotate crankshaft to be op
110. tion time to zero cancellation 1 Turn ignition key to ON position 2 Pull out emergency stop switch plate 1 3 Pull up emergency stop switch knob three times in ten seconds A short beep will be heard if cancellation is suc cessfully finished 4 Turn ignition key to OFF position then set emergency stop switch plate in original position NOTE See OIL CHANGE REMINDER SYSTEM section on page 3 44 9 Start engine and allow it to run for several minutes at idle speed Check oil filter for oil leakage Turn off engine and wait for approx two minutes then recheck engine oil level PERIODIC MAINTENANCE 2 5 Full level line Low level line 2 6 PERIODIC MAINTENANCE GEAR OIL Change initially after 20 hours 1 month and every 100 hours 6 months 1 Place outboard motor upright on a level surface 2 Place a container under the lower unit 3 Remove lower gear oil drain plug first then remove air vent plug and drain gear oil D Air vent plug 2 Oil drain plug 4 Fill with recommended gear oil through oil drain hole until oil just starts to flow out from air vent hole Gear oil amount 1 100 ml 37 2 38 7 US Imp oz Recommended oils SUZUKI OUTBOARD MOTOR GEAR OIL or SAE 90 HYPOID GEAR OIL 5 Install air vent plug before removing oil filler tube from drain hole 6 Install oil drain plug Do not re use gaskets once removed Always use a new gasket NOTE T
111. tor delivery pipe fuel injector and hoses Fuel is supplied through the primer bulb low pressure fuel filter and low pressure fuel pump to the fuel vapor separator Fuel flow from the fuel vapor separator is pressurized by the high pressure fuel pump and supplied through the high pressure fuel filter and fuel delivery pipe to the fuel injectors The pressure regulator maintains fuel pressure in the feed line between the high pressure fuel pump and fuel injector This pressure maintained at a constant level is higher than the pressure in the vapor separator chamber When fuel feed line pressure exceeds vapor separator chamber pressure by more than approx 250 kPa 2 55 kg cm 36 3 psi the valve in the fuel pressure regulator will open and return the excess fuel to vapor separator chamber Pressurized fuel enters into the intake ports through the fuel injector based on the sequential signals sup plied from the ECM Low pressure fuel filter Primer bulb 650609 5 oS To crankcase SS 4 YA S may Fuel vapor separator q 6 e Fuel tank Low pressure fuel pump CD High pressure fuel pump 2 High pressure fuel filter 3 Fuel cooler 4 Fuel delivery pipe 5 Fuel injector 6 Evaporation hose Ss Pale Intake manifold Throttle body 3 22 ENGINE CONTROL SYSTEM FUEL VAPOR SEPARATOR The fuel vapor separator incorporates a fl
112. trolled over revolution limiter will engage at the engine speeds shown below Once engaged it will initiate an intermittent fuel injection signal to reduce engine speed Over revolution limiter DF150 6 200 r min DF175 6 300 r min ACTION Engine speed Automatically reduced to approx 3 000 r min by intermittent fuel injection signal Caution lamp REV LIMIT lamp lights continuously Caution buzzer No buzzer sounds RESET Close throttle to reduce engine speed below approx 3 000 r min for one second ENGINE CONTROL SYSTEM 3 35 LOW OIL PRESSURE CAUTION SYSTEM CONDITION Immediate activation of system when the oil pressure switch is turned ON due to an engine oil pressure drop below 100 kPa 1 0 kg cm 14 psi ACTION Engine speed Automatically reduced to approx 1 000 r min by intermittent fuel injection signal if the system is activated at 1 000 r min or higher Caution lamps OIL lamp lights continuously REV LIMIT lamp lights continuously during engine speed rev limiter activation Sounds in a series of long 1 5 sec beeps RESET Stop engine and check engine oil level Refill engine oil to the correct level if below the low oil mark If the engine oil level is correct the following causes may be considered oil viscosity Malfunctioning oil pressure switch Clogged oil strainer or oil filter Worn oil pump relief valve Oil leakage from the oil passage Ex
113. ur indication Informs operator of total operating time ee NN Oil changing reminder system e Informs operator of for replacing engine oil on the basis of the Start in gear protection system Prevents engine start when shift is positioned in forward or reverse f Pren enone aart in mim _ otarter motor relay control Prevents starter motor operation when engine is already operating meri mim t _ Controls and performs O2 feedback operation using optional O2 sen sor NOTE Information related to the Caution system Self Diagnostic System Total operating hour indication system and O2 feedback system is retained in ECM memory ENGINE CONTROL SYSTEM 3 5 ECM CONNECTOR TERMINALS LAYOUT 2 gt oo FRONT VIEW TERMI WIRE NAL COLOR Starter relay control O2 Feedback CMP sensor 1 CMP sensor 2 VVT Ex manifold temp sensor Lg W Cylinder temp sensor Shift position sensor w Br IAT sensor No 3 Fuel injector BG _ Xm zo ho 0 1 2 23 24 25 6 no Po 2 E 0 gt lt NO LP 5 2 9 10 a 14 15 16 18 19 20 28 24 _ 25 26 27
114. w 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 bat teries To protect the Earth s natural resources properly dispose of used motor parts 1 4 GENERAL INFORMATION 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 SUZUKI 17501 ZUKI MOTOR ADE IN JAPAN FABRIOJE AU JAPON SERIAL NUMBER ENGINE SERIAL NUMBER A second engine serial number plate is pressed into a boss on the cylinder block 34 Serial humber plate 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 91 Research method However blends 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 CAUTION If leaded gasoline is used engine damage may result Use only unleaded gasoline ENGINE OIL Use only oils that are rated SE SF SG SH or SJ under the API American Petroleum Institute classification system or NMMA FC W classification system The viscosity rating s
115. 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 Inspect electrode for a worn or burnt condition If it is extremely worn or burnt replace spark plug Also be sure to replace spark plug if it has a broken insulator damaged thread etc 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 PERIODIC MAINTENANCE 2 9 INSTALLATION Installation is reverse order of removal V Spark plug 28 N m 2 8 kg m 20 0 Ib ft TAPPET CLEARANCE Inspect every 200 hours 12 months The tappet clearance specification is different for intake and exhaust valves Too small a tappet clearance may reduce engine power too large a tappet clearance increases valve noise and hastens valve and seat wear When the tappets are set to the specified clearance the engine will run without excessive noise from the valve mechanism and will deliver full power In this engine the tappet clearance is increased or decreased by replacing the shim disc made of a special wear resistant material fitted to the top of the tappet Using the proper tools provides for easy removal and installation of the shim disc Tappet clearance adjustment should be checked and adjusted during scheduled period

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