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SUPPLEMENTARY SERVICE MANUAL

1. CMP sensor CTP switch Cylinder temp sensor IAT sensor MAP sensor 2 Pressure detect passage Rectifier amp regulator Over charging Exhaust manifold temp sensor Fuel injector f more than two items fail at once the self diagnostic indication appears according to priority order The indication repeats three times DF140 140Z GENERAL INFORMATION 11 TIGHTENING TORQUE Tightening Torque Important Fasteners THREAD TIGHTENING TORQUE DIAMETER N m kg m ITEM Cylinder head cover bolt 6 mm 11 1 1 8 mm 23 2 3 10 mm 70 7 0 8 mm 25 2 5 10 mm 56 5 6 Cylinder head bolt Crankcase bolt Conrod cap nut Camshaft housing bolt Camshaft timing sprocket bolt Timing chain guide bolt Intake manifold bolt nut Oil pressure switch Fuel delivery pipe nut Fuel delivery pipe plug union bolt Fuel return pipe bolt Low pressure fuel pump bolt Thermostat cover bolt Flywheel bolt Starter motor mounting bolt Oil filter stand Engine oil filter Engine oil drain plug Power unit mounting bolt Driveshaft housing bolt Upper mount nut Upper mount cover bolt Lower mount bolt nut Clamp bracket shaft nut Water pump case bolt Gearcase bolt Propeller shaft bearing housing bolt Pinion nut Propeller nut 12 DF140 140Z
2. 1 Horizontal slider 2 R Gear bearing housing 3 Shift rod center o Y gt Front direction Shifter yoke Shifter yoke Horizontal slider 84 DF140 140Z COUNTER ROTATION LOWER UNIT LEAKAGE CHECK Check for leakage of oil seal and O ring when applying speci fied pressure inside of the gearcase 09950 69511 Oil leakage tester Air pump Procedure 1 Install the test tool into the oil level hole 2 Connect the air pump to the tester 3 Rotate driveshaft and propeller shaft clockwise several times and then apply specified pressure for the test NOTE Apply low initial pressure of 20 40 0 2 0 4 kg cm 2 8 5 7 psi first then apply specified pressure Leakage test pressure 100 kPa 1 0 kg cm 14 2 psi CAUTION Do not exceed pressure of 110 kPa 1 1kg cm 15 6 psi or damage to oil seals will result 4 Once stabilized pressure should remain steady for at least 5 min If pressure does not fall sealing performance is correct WATER PUMP Impeller amp Case Place the dowel pins D under panel gasket and under panel into position Insert the key in the driveshaft and slide the impeller 5 onto driveshaft ensuring that key and keyway are aligned Install the pump case while rotating driveshaft clockwise to flex the impeller vanes in the correct direction Securely tight
3. NOTE Use a thinner pinion back up shim than the standard shim so that a clearance exists 3 Insert the driveshaft through the shimming gauge open ing and then install pinion gear and nut amp to the driveshaft tighten pinion nut V Pinion nut 120 N m 12 kg m 86 8 Ib ft 4 Install oil seal housing to shimming gauge with bolts 5 Depress and hold driveshaft so that driveshaft bearing is firmly seated in bearing outer race 62 DF140 140Z NORMAL ROTATION LOWER UNIT 6 Hold driveshaft against oil seal housing Q while measuring clearance B between gauge and flat edge of pinion gear with thickness gauge measured clearance plus shim is the total shim thickness to be used in gear housing reas sembly for correct pinion gear position FORWARD GEAR BACK UP SHIM ADJUSTMENT Follow the procedure below to adjust forward gear pinion gear Step to prior to adjustment 1 Correctly assemble driveshaft oil seal housing driveshaft forward gear pinion gear and related components See page 53 to 55 Do not install reverse gear at this time 2 Tighten pinion nut to specified torque V Pinion nut 120 N m 12 kg m 86 8 Ib ft Checking driveshaft thrust play 1 Affix gear adjusting gauge to drive shaft 09951 09511 Gear adjusting gauge 2 To check the driveshaft thrust play push the forward gear inward and fix it by hand Slowly push driveshaft downward then read th
4. Camshaft journal in 23 000 23 021 0 9055 0 9063 housing inside diameter 23 171 0 9122 26 000 26 021 1 0236 1 0244 26 171 1 0304 Camshaft journal outside 22 959 22 980 0 9039 0 9047 diameter 22 869 0 9004 25 934 25 955 1 0210 1 0219 25 844 1 0175 Camshaft runout 0 10 0 004 Cylinder head bore 0 025 0 066 0 0010 0 0026 to tappet clearance 0 150 0 0059 Tappet outer diamelef 30 959 30 975 1 2189 1 2195 Cylinder head bore in 31 000 31 025 1 2203 1 2215 6 DF140 1402 GENERAL INFORMATION DF140T DF140Z VALVE VALVE GUIDE Valve diameter in 33 1 2992 28 1 1024 Tappet clearance in 0 23 0 27 0 009 0 011 Cold engine condition 0 23 0 27 0 009 0 011 Valve seat angle 15 45 60 15 45 Valve guide to in 0 020 0 047 0 0008 0 0019 valve stem F clearance 0 070 0 0028 0 045 0 072 0 0018 0 0028 0 090 0 0035 Valve guide inside diameter in 6 000 6 012 0 2362 0 2367 Valve guide protrusion 13 5 0 5315 Valve stem 5 965 5 980 outside diameter 5 940 5 955 0 2348 0 2354 0 2339 0 2344 Valve stem end 0 14 0 0055 deflection 0 18 0 0071 Valve stem runout 0 05 0 0020 Valve head radial runout 0 08 0 0031 Valve head 1
5. PTT MOTOR RELAY UP CAUTION BUZZER A Le OVERHEAT OIL PRESSURE HIGH PRESSURE PTT MOTOR RELAY DN BATTERY VOLTAGE DIAGNOSIS OIL PRESSURE SWITCH FUEL PUMP MAP m 1 0kgf cm2 or less ON NEUTRAL SWITCH 6 BATTERY CHARGE COIL SENSOR ALTERNATOR Br N ON Gr ER OFF do ax CKP SENSOR CAP COMMUNICATION FUEL IJ CTORS M FF CONNECTOR L STARTER MOTOR METER ILLUMI i E l FUSE 30A FUSE 60A s ry n Gros 6 i i 2 E 1 2 Gr slola W W f gt B Y j a 3 Ww T CYLINDERTEMP 4 erg SENSOR a i ale H i Ar TIT Low H zoo s LT EC gy Ky W l sen STARTER MOTOR MAIN hew j RELAY RELAY Fer 9 8 IAC VALVE 7 7 f i i CMP SENSOR b RIG JED eer Gr IONITOI BUB 1 LB B TACHO G Y METER ar IAT SENSOR J PEBE PTTSWITCH up Q n EX MANITEMP 2 4 Hae B SENSOR Zo ee IGNITION COILS it a SWITCH ENGINE CONTROL MODULE E REMOTE CONTROL BOX E Lg R r 4 I 1 i dm m RECTIFIER amp 5 ae T REGULATOR 2 9 ela Hee es Ba bs Bind EM 8588855 Ss Seg 95 W TUBE is IGNITION SWITCH BHEE gt b F STOP G 6 E lo B 9 BATT W Ww i EP d IG Gr Gi START ER I 8 d BRE o Le Pont EMERGENCY STOP SWITCH 6 oBr EBr P P Lock plate IN RUN L o d LbI
6. 09944 09420 PTT cylinder cap tool Pull the trim rod piston assembly out of the trim cylinder i gt 30 0 140 1402 POWER TRIM AND TILT CLEANING AND INSPECTING Thoroughly wash all metal components with cleaning solvent and dry them with compressed air Arrange all components on a clean sheet of paper NOTE Do not lay PTT components out on a rag as dirt or lint may be transferred to these items which may cause possible system operating problems Inspect tilt rod and trim rod replace if damaged or bent Inspect the surface of tilt rod and trim rod for scores grooves or roughness Slight roughness may be removed with fine emery paper A badly scored or grooved rod must be replaced Inspect the PTT cap seal and O ring Replace if cuts nicks or excessive wear is found NOTE It is recommended that the O ring always be replaced once the tilt trim cylinder has been disassembled Inspect the shock valves spring rod and ball Replace if there are any signs of rust or pitting Inspect the cylinder bore for evidence of a rough or grooved surface Light honing may rectify slight surface roughness or scarring but a deeply scarred surface will require replacement of the tilt cylinder Inspect manual release valve for damage Inspect manual release valve O ring Replace if nicked or cut o oo s e o 009 O ring DF140 140Z POWER TRIM AND TILT 31 REASSEMBLY
7. 7 99000 22540 99000 25010 99000 25160 99000 31120 400 ml x 24 pcs 500 9 250 9 50 9 SUZUKI BOND 1104 SUZUKI BOND 1207B THREAD LOCK 1342 THREAD LOCK SUPER 1333 99104 33140 99000 31140 100 g 99000 31030 100 9 99000 32050 50 9 99000 32020 50 9 4 Stroke Motor Oil API SE SF SG SH SJ SAE 10W 40 NOTE Marked part No is in U S market only ENGINE CONTROL The specifications of engine control system such as ignition and fuel injection systems on model DF140 are basically the same as those on DF90 115 However the control specifications on DF140 differ from DF90 115 as shown below Idling Trolling speed Idling Trolling engine speed as controlled by IAC system e Idling Trolling engine speed 700 50 rpm AC duty ratio at idling trolling Approximately 30 NOTE To adjust idling trolling engine speed manually on DF140 use the same procedure as DF90 115 and adjust the speed to 700 50 rpm with the IAC valve duty set to 30 Ignition timing The ignition timing is controlled within the following range ac cording to the engine operating condition gnition timing advance range BTDC 5 45 gnition timing at idling trolling BTDC 10 x 5 Over revolution limter The over rev detecting speed is as follows DF140 6500 rpm SDS The database specially provided only for DF140 needs t
8. Bush Clamp Tilt lock lever PORT Lower shaft Tilt lock lever amp Rubber Bolt Bush Bonding wire Washer Spring Screw Steering bracket amp Link Tilt pin Washer Spring Nut Bush Bracket Washer DF140 140Z POWER TRIM AND TILT 25 POWER TRIM AND TILT PTT unit of DF140 is new design and unit is 3 cylinder two trim ram one tilt rod type SERVICE PROCEDURE OIL LEVEL To check the oil level Raised the engine to a full tilt position Lower the manual tilt lock lever D Remove the oil filler plug 2 If oil can be seen at filler plug level the unit is full If oil level is low refill with the recommended oil N gt Recommended oil Dexron III automatic transmission fluid or equivalent CAUTION To ensure consistent pump operation do not mix dif ferent types of oil 6 Reinstall oil filler plug AIR BLEEDING 1 Check that the manual release valve is tightened to the specified torque V Manual release valve 3 5 N m 0 36 kg m 2 6 Ib ft CAUTION Do not over tighten manual release valve Counterclockwise open Clockwise close 2 Operate the PTT switch raising and lowering the motor up and down full tilt position to full trim down position 4 to 5 times 3 Check oil level topping off if necessary 4 Reinstall oil filler plug 26 DF140 140Z POWER TRIM AND TILT POWE
9. FUEL amp OIL DF140T DF140Z Suzuki highly recommends that you use alcohol free unleaded gasoline with a minimum pump octane rating of 87 4 method or 91 Research method However blends of unleaded gasoline and alcohol with equivalent octane content may be used Engine oil SE SF SG SH SJ SAE10W 40 API classification Viscosity rating Engine oil amounts L US Imp qt 5 5 5 8 4 8 Oil change only 5 7 6 0 5 0 Oil filter change Gear oil SUZUKI Outboard Motor Gear Oil SAE 90 hypoid gear oil Gearcase oil capacity ml US Imp oz BRACKET Trim angle Number of trim position 1050 35 5 37 0 PTT system PTT system Maximum tilt angle LOWER UNIT Reversing system 75 Gear Transmission Forward Neutral Reverse Reduction system Bevel gear Gear ratio 12 23 1 92 Drive line impact protection Spline drive rubber hub Propeller shaft rotation when shift into forward Propeller xx Aluminum propeller Stainless steel propeller clockwise counterclockwise Blade x Diam in x Pitch in 13 1 2 x 15 14 x 17 14 19 14 21 14 23 14 18 14 20 14 22 14 24 3 3 3 3 3 3 3 3 3 X X X X X X X X X 4 0 140 1402 GENERAL INFORMATION Data DF140T DF140Z REDUCTION SYSTEM 1st reduction gear ratio 29 36 1 24 Crankshaft drive gear Driven gear 2nd reductio
10. T Lbl Lock plate OFF STOP OW OG BZ BI T BI Bry vB Ger j BI R Gr G ET G s Bi Feng WIRE COLOR B Black G Y Green with Yellow tracer n Br Brown G W Green with White tracer lo aja BI Blue Lg B Light green Black tracer TRIM SENDER Lg W Light green White tracer Gr Gray Lg Y Light green with Yellow tracer PTR MOTOR Lbl Light blue 0 B Orange with Black tracer nn El JOINT CONNECTOR Lg Light green O G Orange with Green tracer 41 alo Orange P B Pink with Black tracer up ah JJ tr Red with Green tracer BATTERY 12V 100AH DN UP R Red R G Red with Blue tracer W White Red with White tracer PTT SWITCH Y Yellow W Y White with Yellow tracer B G Black with Green tracer W R White with Red tracer B W Black with White tracer Y G Yellow with Green tracer B Y Black with Yellow tracer Yellow with White tracer DF140 140Z HOSE ROUTING 93 HOSE ROUTING Fuel hose protector 3 way joint to fuel delivery pipe Evaporation hose Vapor separator to cylinder head cover LE NR EE EAA j STE Fuel delivery pipe I j u AD d x an NE Water hose Fuel return pipe to 3 way joint Fuel return pipe Water hose 3 way joint to water return pipe 20620900000 Water hose 3 way joint to oil cooler Water hose 3 way joint to fuel return pipe Water hose Crankcase upper to 3
11. Crankshaft center journal runout 0 04 0 0016 Crankshaft journal 0 020 0 040 0 0008 0 0016 oil clearance 0 065 0 0026 Crankcase bearing holder inside diameter 62 000 62 018 2 4409 2 4417 Crankshaft journal outside diameter 57 994 58 012 2 2832 2 2839 Crankshaft journal outside diameter difference out of round and taper 0 01 0 0004 Crankshaft bearing thickness 1 990 2 006 0 0783 0 0790 Crankshaft thrust play 0 11 0 31 0 0043 0 0122 0 35 0 0138 Crankshaft thrust bearing thickness 2 425 2 475 0 0955 0 0974 DF140 140Z GENERAL INFORMATION 9 ELECTRICAL Ignition timing DF140T DF140Z Degrees at r min BTDC 5 BTDC 45 Over revolution limiter r min 6500 CKP sensor resistance at 20 C 168 252 CMP sensor resistance at 20 C Primary at 20 C 1 9 2 5 Ignition coil resistance Secondary No 2 No 3 18 34 including H T cord and spark plug cap kQ at 20 C e No 1 No 4 19 36 including H T cord and spark plug cap High tension cord resistance kQ m at 20 16 Battery charge coil resistance Q at 20 C 0 16 0 24 Battery charge coil output 12V Watt 480 Type NGK BKR6E Standard spark plug Gap mm in 0 7 0 8 0 028 0 031 Fuse amp rating
12. Replace if wear damage or other abnormal condition Inspect clutch dog shifter Replace if chipped worn or dam 2 aged p Inspect dog pin Replace if bent or worn des Inspect propeller shaft splines Replace if worn twisted or 7 damaged Inspect thrust bearing Replace bearing if pitted noisy or rough Inspect housing Replace if cracked or damaged Inspect forward gear bearing Replace bearing if pitted noisy or rough Inspect bearing Replace bearing if pitted noisy or rough Check condition of oil seal and O ring Replace the seals if nicked cut or worn 74 DF140 140Z COUNTER ROTATION LOWER UNIT Replacing propeller shaft oil seal 1 2 Remove the retaining ring and washer Q Extract the seals Q with oil seal remover 09913 50121 Oil seal remover CAUTION Do not reuse oil seal once removed Always use new oil seal 3 Apply Water Resistant Grease to the inner circumference of the housing Using an oil seal installer drive the two oil seals one at a time into the propeller shaft bearing housing The lipped portion of the seal must face towards the propel ler Apply Water Resistant Grease to the seal lips 99000 25160 Water Resistant Grease 5 Install washer and retaining ring SHIFT ROD GUIDE HOUSING COMPONENTS Inspect shift rod guide housing Replace if cracked or dam aged Inspect shifter yoke Replace if wear damage or
13. Main fuse 60 Sub fuse 30 A Recommended battery capacity 12V Ah kC 100 360 or larger Fuel injector resistance 1 valve resistance Q at 20 C 11 0 16 5 Q at 20 C IAT sensor Cylinder temp sensor Ex mani temp sensor Thermistor characteristic kQ at 25 C ECM main relay resistance at 20 C Starter relay coil resistance at 20 C PTT motor relay coil resistance STARTER MOTOR Max continuous time of use at 20 C 30 Motor output 1 4 STD 16 0 0 63 Brush length Limit 12 0 0 47 Commutator STD 0 5 0 8 0 02 0 03 undercut Limit 0 2 0 008 Commutator STD 1 14 outside diameter Limit 29 28 14 1 10 Commutator outside STD diameter difference 0 05 0 002 0 40 0 016 10 0 140 1402 GENERAL INFORMATION PTT MOTOR Brush length in 9 8 0 39 5 0 0 20 Commutator outside in 22 0 0 87 diameter in 20 4 0 80 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 FAIL SAFE SYSTEM ACTIVATING MAP sensor 1 YES CKP sensor LT UI YES IAC valve By pass air NO screw adjustment FAILED ITEM LAMP FLASHING PATTERN
14. 72 DF140 140Z COUNTER ROTATION LOWER UNIT INSPECTION NOTE If any component is worn excessively cracked defective or damaged in any way it must be replaced NOTE Thoroughly wash all metal components with cleaning solvent and dry with compressed air Wear safety grasses when using compressed air PROPELLER Inspect the propeller for bent chipped or broken blades Replace or repair propeller if in damaged condition Inspect propeller bush splines Replace or repair propeller if splines are worn or damaged Inspect propeller bush for deterioration or slipping Replace if necessary GEARCASE Inspect the gearcase Replace if cracked or damaged Visually check the pinion bearing Replace if pitted noisy or rough NOTE If removal and replacement are required see the DF90 115 service manual PINION BEARING section on page 9 7 REVERSE GEAR BEARING HOUSING RETAINER Inspect the reverse gear retainer and reverse gear bearing Z housing Replace if cracked or damaged Visually check each bearings Replace if pitted noisy or rough DF140 140Z COUNTER ROTATION LOWER UNIT 73 GEAR Inspect forward reverse and pinion gear teeth and engaging dogs Replace gears if damaged or worn Inspect forward gear thrust bearing Replace bearing if pit ted noisy or rough PROPELLER SHAFT COMPONENTS PROPELLER SHAFT BEARING HOUSING Inspect horizontal slider and connector pin
15. Assembly is reverse order of disassembly with special atten tion to following steps CAUTION Do not reuse O rings after removal always use new O rings Lubricate all components and O rings with PTT fluid before assembly Do not reuse PTT fluid always refill with new fluid TILT ROD When tightening the piston retaining nut on the tilt rod piston apply Thread lock 1342 to the threads Tighten the nut to specified torque 99000 32050 Thread Lock 1342 Q Piston retaining nut 100 N m 10 kg m 72 Ib ft Installing tilt rod piston Pour 100 ml of PTT fluid into cylinder Insert the free piston into cylinder and push it down to the bot tom of the cylinder Cylinder z Pour PTT fluid into the cylinder until it is topped off Insert the tilt rod piston into cylinder and thread the tilt cylinder Free piston Top OFF head by hand until fully seated Tighten the cylinder head to specified torque using special tool v Tilt cylinder head 160 N m 16 kg m 115 7 Ib ft 09944 09420 PTT cylinder cap tool 32 DF140 140Z POWER TRIM AND TILT TRIM ROD Pour PTT fluid into the trim cylinder until it is topped off Insert the trim rod piston assembly into cylinder and thread the trim cylinder head by hand until fully seated Tighten the trim cylinder head to specified torque using special tool V Trim cylinder head 78 N m 7 8 kg m 56 4 Ib ft 09944 09420 PTT cylinder cap too
16. GENERAL INFORMATION Tightening torque general bolt NOTE These values are only applicable when torque for a general bolt is not listed in the Important Fasteners table THREAD TIGHTENING TORQUE DIAMETER kg m Ib ft 3 0 5 0 ay 2 7 0 11 5 Conventional or 4 marked bolt 16 0 25 5 TYPE OF BOLT 1 5 3 0 y 4 5 7 0 11 0 14 5 Stainless steel bolt 24 5 29 5 2 0 4 5 6 0 8 5 13 0 20 0 7 marked or _ marked bolt 29 0 43 5 SPECIAL TOOLS 09900 00410 Hexagon wrench set B Hexagon socket included in 09900 00410 09900 20101 150 mm 09900 20102 200 mm Vernier calipers 09900 20202 Micrometer 25 50 mm DF140 140Z GENERAL INFORMATION 09900 00413 5 mm 09900 00414 6 mm Hexagon bit included in 09900 00410 09900 20203 50 75 mm 09900 20204 75 100 mm Micrometer A 09900 06107 B 09900 06108 Snap ring pliers 09900 20205 Micrometer 0 25 mm 09900 20508 Cylinder gauge set 09900 20605 Dial calipers 10 34 mm 09900 20803 Thickness gauge 09900 21304 Steel V block set 09900 20606 Dial gauge 09900 22302 0 051 0 125 mm 09900 22301 0 025 0 076 mm Plastigauge 09900 20701 Magnetic stand 09900 26006 Engine tachometer 17 18 09900 28403 Hydrometer 20 09912 58413 Fuel pressure gauge set 09921 29410 D
17. driveshaft and loosen the pinion nut 09921 29410 Driveshaft holder 48 DF140 140Z NORMAL ROTATION LOWER UNIT Unscrew the four 4 bolts D securing driveshaft oil seal hous ing 2 then remove oil seal housing and pinion shim 3 Lift out driveshaft assembly Remove the driveshaft collar washer wave washer 7 washer with tab amp and washer 9 from driveshaft Remove the pinion gear D Remove the forward gear and thrust bearing 3 Remove the bearing thrust washer and back up shim Remove the forward gear bearing housing Account for dowel pin DF140 140Z NORMAL ROTATION LOWER UNIT 49 Disassembly of propeller shaft components Slide propeller shaft away from reverse gear 3 and bearing housing assembly Account for the reverse gear back up shim Q and reverse gear thrust washer 4 To disassemble propeller shaft components refer to the follow ing a Remove horizontal slider 5 and forward gear thrust washer 6 b Remove the spring from the clutch dog shifter c Use special tool to push the dog pin 8 out of the clutch dog shifter 09922 89810 Shift pin remover d Remove the clutch dog shifter and connector pin 4 from propeller shaft Disassembly of shift rod components a Remove the circlip and washer p b Slide the shift rod 3 out of the shift rod guide housing 50 DF140 140Z NORMAL ROTATION
18. other ab normal condition Inspect O ring Replace if nicked cut torn or swollen Inspect oil seal Replace if nicked cut or worn Inspect shift rod splines Replace if worn twisted or dam aged Inspect detent ball Replace if wear damage or other abnor mal condition WATER PUMP AND RELATED ITEMS Inspect impeller Replace if vanes are cut torn or worn Inspect pump case Replace if cracked distorted or corroded Inspect under panel Replace if cracked distorted or corroded DF140 140Z COUNTER ROTATION LOWER UNIT 75 DRIVESHAFT OIL SEAL HOUSING Inspect housing Replace if cracked or damaged Check condition of oil seals Replace if nicked cut or worn Inspect O ring Replace if worn nicked or cut Replacing driveshaft oil seal 1 With the oil seal remover draw the two oil seals out of the driveshaft oil seal housing 09913 50121 Oil seal remover 2 Apply Water Resistant Grease to the inner circumference of the driveshaft oil seal housing 99000 25160 Water Resistant Grease 3 Grease the inner lips of the seal With the lips facing away from driveshaft bearing place seal in position and drive it into the oil seal housing Direction of water pump case DRIVESHAFT Inspect driveshaft splines Replace if worn twisted or damaged Inspect driveshaft bearing replace if pitted noisy or rough 76 0 140 1402 COUNTER ROTATION LOWER UNIT ASSEMBLY Assembly is rev
19. torque V Bearing housing bolt 20 N m 2 0 kg m 14 5 Ib ft RECHECKING DRIVESHAFT THRUST PLAY Recheck the driveshaft thrust play Driveshaft thrust play Approx 0 3 0 5 mm 0 012 0 020 in 09951 09511 Gear adjusting gauge CHECKING PROPELLER SHAFT THRUST PLAY See the GEARS SHIMMING AND ADJUSTMENT CHECK ING PROPELLER SHAFT THRUST PLAY section on page 91 SHIFT ROD GUIDE HOUSING Install the spring D and detent ball into shift rod guide housing Apply Water Resistant Grease to the shift rod oil seal Install shift rod and washer into the shift rod guide housing then secure it with the snap ring 6 DF140 140Z COUNTER ROTATION LOWER UNIT 83 NOTE Before install the shift unit Shift rod guide housing assembly be sure to put the horizontal slider in the neutral position Apply Water Resistant Grease to the shift rod guide housing O ring NOTE Before install the shift unit Shift rod guide housing assembly bring shifter yoke to the neutral position by turning shift rod right or left Install the shift rod guide housing assembly 7 by aligning the shifter yoke with the groove in the horizontal slider then tighten three 3 housing bolts securely e Shift the shift rod from Neutral through Forward and Reverse to check proper gear engagement Apply enough Water Resistant Grease on oil seal before putting seal cover 8 so that there is no space between them
20. water contaminates or metal Remove cotter pin 3 from propeller nut and remove propeller nut 4 Remove washer spacer 6 propeller and stopper 8 from the propeller shaft To prevent injury from propeller blades wear gloves and place a block of wood between the anti cavitation plate and the propeller blade tips to lock the propeller in place Loosen the four 4 bolts D then remove the water pump case Q 68 DF140 140Z COUNTER ROTATION LOWER UNIT Remove the impeller 3 impeller key pump under plate 4 and dowel pins Keep the impeller key for reuse and discard the plate gas ket Remove three 3 bolts and shift rod guide housing assem bly Remove the two 2 bolts D securing the propeller shaft bear ing housing to the gearcase Using special tools draw out the propeller shaft bearing hous ing Remove the propeller shaft and bearing housing assembly 09930 30102 Sliding hammer 09930 30161 Propeller shaft remover Hold the pinion nut securely then fit special tool to the driveshaft and loosen the pinion nut 09921 29410 Driveshaft holder DF140 140Z COUNTER ROTATION LOWER UNIT 69 Unscrew the four 4 bolts D securing driveshaft oil seal hous ing 2 then remove oil seal housing and pinion shim Lift out driveshaft assembly Remove the driveshaft collar washer wave washer 7 washer with tab amp a
21. way joint Water hose IN mani cover to 3 way joint Water hose IN mani cover to 3 way joint Water hose 3 way joint to pilot water tube Water hose 3 way joint to IN mani cover Water hose 3 way joint to crankcase lower Water hose 3 way joint to oil cooler Fuel hose protector 3 way joint to H Fuel filter High pressure fuel filter 3 way joint Clamp PATER b ceu I ZI T8678 Fh a m MES pf SATB ji L Yor BOEN i Ghz 0 e j REH ZITI Engine holder Prepared by SUZUKI MOTOR CORPORATION Marine amp Power Products Division November 2001 Manual No 99501 92J00 01E Printed in Japan SUZUKI MOTOR CORPORATION Printed in Japan x K2
22. 0 0 0394 thickness 0 7 0 0276 1 20 0 0472 0 7 0 0276 Valve seat mm in 1 1 1 3 0 0433 0 0512 contact width mm in 1 1 1 3 0 0433 0 0512 Valve spring free mm in 42 73 1 6823 length mm in 41 02 1 6150 Valve spring tension N kg Ibs 164 190 16 7 19 3 36 7 42 5 for 32 6 mm 1 28 in N kg Ibs 151 15 1 33 3 for 32 6 mm 1 28 in Valve spring squareness mm in 2 0 0 079 DF140 140Z GENERAL INFORMATION 7 DF140T DF140Z CYLINDER PISTON PISTON RING Cylinder distortion Limit in 0 05 0 0020 Piston to cylinder STD in 0 020 0 040 0 0008 0 0016 clearance Limit in 0 100 0 0039 Cylinder bore STD in 86 000 86 020 3 3858 3 3866 Cylinder measuring position in 50 1 969 from cylinder top surface Piston skirt diameter STD in 85 970 85 990 3 3846 3 3854 Piston measuring position in 26 5 1 043 from piston skirt end Cylinder bore wear in 0 10 0 039 Piston ring in 0 20 0 35 0 0079 0 0138 end gap in 0 70 0 0276 0 35 0 50 0 0138 0 0197 1 00 0 0394 Piston ring in Approx 11 6 0 4567 free end gap in 9 3 0 3661 Approx 11 5 0 4528 9 2 0 3622 Piston ring to in 0 030 0 070 0 0012 0 0028 groove in 0 12 0 0047 clearance 0 020 0 060 0 0008 0 0024 0 10 0 0039 Piston ring in 1 22 1 24 0 0480 0 0488
23. BLOCK The cylinder bore is different from DF90 115 The diameter for the cylinder of DF140 has become as the fol lowing Cylinder bore Standard 86 000 86 020 mm 3 3858 3 3866 in PISTON amp PISTON RING Piston and piston ring diameters are different from DF90 115 The dimension of piston has become as the following Piston skirt diameter Standard 85 970 85 990 mm 3 3846 3 3854 in The shape of piston ring is the same as DF90 115 1st ring Barrel face and nitrogen treatment 2nd ring Taper face with under cut and hard chrome plating NOTE 1st ring differs from 2nd ring in shape and color of surface con tacting cylinder wall Distinguish 1st ring from 2nd ring by referring to figure DF140 140Z POWER UNIT 21 2nd ring i 1st ring B 2nd ring p 22 DF140 140Z POWER UNIT CRANKSHAFT The crankshaft for DF140 is different from that for DF90 115 To identify the crankshaft for each different model check for the shape on the upper part of crankshaft tapered portion See right illustrations CONROD ASSEMBLY Conrod bolts and nuts are different between DF140 and DF90 115 However the conrod and cap of DF90 115 are used for DF140 Because the different conrod bolt is used for DF140 the torque for the conrod cap nuts of DF140 has become as the following V DF140 Conrod cap nut 40 N m 4 0 kg m 29 Ib ft NOTE Refer to table for the identifi
24. IT DF140Z model The counter rotation unit reverse gear is installed in the position where in the normal rotation unit the forward gear is located Likewise the counter rotation unit forward gear takes the position of normal rotation unit reverse gear This change of gear arrangement however does not affect the remote control lever operation because the shift rod and shifter yoke have been also modified to operate in the opposite direction 1 Forward gear 2 Reverse gear 3 Shift rod and shifter yoke C a n EX 15 tc a PROPELLER SELECTION FOR COUNTER ROTATION For counter rotation model newly designed stainless steel pro pellers are available as follows Suzuki highly recommend to use the genuine Suzuki counter Blade x Diam in x Pitch in 3 x 14 x 18 rotation propeller for the counter rotation model mr UM t Xo uem In case of twin installation always use on both engines the same size normal rotation and counter rotation propellers DF140 140Z COUNTER ROTATION LOWER UNIT 67 REMOVAL AND INSTALLATION Refer to the procedures in DF90 115 service manual Always disconnect the battery cable before removing lower unit DISASSEMBLY Place a drain pan under the oil drain plug Remove oil drain plug D first then oil level plug and allow gear oil to drain Inspect oil for
25. LOWER UNIT c Remove the detent ball and spring d Remove the pin and shifter yoke DF140 140Z NORMAL ROTATION LOWER UNIT 51 ASSEMBLY Assembly is reverse of disassembly with special attention to following steps Oil seal Q Shift rod guide housing Bolt Ball amp Spring D O ring Washer Circlip Seal cover Shift rod Yoke shifter Pin Horizontal slider Magneto Grommet Water pump case Pin Bolt Key Water pump impeller Pump case under panel Gasket Exhaust seal Exhaust seal plate amp Union Hose Nipple Gear case Bolt Bolt Pin Anode Washer Bolt amp Trim tab Bolt Screw Water filter PORT Water filter STBD F 54 Nm e 5 5 kg m 39 8 Ib ft 29 Wi 52 DF140 140Z NORMAL ROTATION LOWER UNIT 5 1 0 5 55 5 5 kg m 40 0 Ib ft 8 20 2 0 kg m Mio 14 5 lb ft 12 kg m 86 8 Ib ft 9 lt Propeller shaft Thrust washer 9 13 N m 1 3 kg m 9 5 Ib ft QD Reverse gear Shim amp Plug 3 O ring Gasket Bearing amp Bearing Propeller shaft bearing housing F gear bearing housing Bolt Driveshaft F gear bearing Bearing Oil seal Back up shim Oil seal Bolt Thrust washer Washer Oil seal housing F gear thrust bearing Retaining ring amp O ring Forward gear a
26. ND TILT TILT SYSTEM PRESSURE RELIEF 1 If engine speed exceeds approx 1500 RPM when operating in shallow water drive mode oil pressure will increase underneath the tilt piston The relief valve incorporated in the manual release valve will then open 2 The oil below the tilt piston will then flow to the reservoir through the relief valve 3 As the power of the engine continues to exert downward force on the tilt piston this will open Down check valve D thereby allowing oil from the reservoir to flow into the chamber above the tilt piston 4 In this way high internal pressure is relieved and the engine will slowly tilt downward until it reaches the highest position in the Trim range THERMAL EXPANSION RELIEF 1 High ambient temperature will through thermal expansion induce a build up of oil pressure inside the PTT unit 2 Expansion of the oil and the resulting high pressure will open the relief valve thereby providing unit protection by directing oil back to the reservoir Expanded oil in the tilt cylinder upper chamber will return to reservoir passing through impact relief valve De free piston check valve O thermal relief valve DF140 140Z POWER TRIM AND TILT 43 SHOCK ABSORBER CIRCUIT This incorporated safety feature is for protection of the gearcase and prevention of internal PTT pressure build up in the event of an impact 1 The pressure from a sudden impact will make impact relief val
27. OTATION LOWER UNIT LOWER UNIT Normal rotation model REMOVAL AND INSTALLATION Refer to the procedures in DF90 115 service manual Always disconnect the battery cable before removing lower unit DISASSEMBLY Place a drain pan under the oil drain plug Remove oil drain plug D first then oil level plug 2 and allow gear oil to drain Inspect oil for water contaminates or metal Remove cotter pin from propeller nut and remove propeller nut 3 Remove washer 4 spacer 5 propeller and stopper D from the propeller shaft To prevent injury from propeller blades wear gloves and place a block of wood between the anti cavitation plate and the propeller blade tips to lock the propeller in place Loosen the four 4 bolts D then remove the water pump case Q DF140 140Z NORMAL ROTATION LOWER UNIT 47 Remove the impeller 3 impeller key pump under plate and dowel pins Keep the impeller key for reuse and discard the plate gas ket Remove three 3 bolts and shift rod guide housing assem bly 2 Remove the two 2 bolts securing the propeller shaft bear ing housing to the gearcase Using special tools draw out the propeller shaft bearing hous ing Remove the propeller shaft and bearing housing assembly 09930 30102 Sliding hammer 09930 30161 Propeller shaft remover Hold the pinion nut securely then fit special tool to the
28. R TRIM AND TILT UNIT REMOVAL Raise the engine to the full tilt position and lower the manual tilt lock levers D During the following procedures the engine must be firmly secured and its weight fully supported See right Remove the tilt rod snap ring and push tilt cylinder upper shaft pin out Lower tilt rod to full down position and disconnect the battery cable Disconnect the PTT motor cable wire leads BI from the PTT relays Remove the PTT motor cable from engine lower cover Remove the tilt pin Remove the two STBD motor mounting bolts and the clamp bracket shaft nut DF140 140Z POWER TRIM AND TILT Remove the PTT cylinder lower shaft bolts Remove the two 2 bolts and anode 7 Slide the STBD clamp bracket 8 off the clamp bracket shaft then remove the PTT unit DISASSEMBLY NOTE Before disassembly wash the PTT body with a stiff bristle brush and hot soapy water to remove sand or dirt and dry the PTT body with compressed air Place the lower mounting eye of the PTT cylinder in a vise Tighten the vise only enough to secure the PTT unit do not over tighten NOTE To prevent damage to the PTT cylinder use wood blocks vise jaw protectors etc between the vise jaws and PTT compo nents before tightening vise Connect the PTT motor cable leads G Bl to battery and oper ate PTT motor until tilt piston rod is at maximum stroke full tilt up position Un
29. SUZUKI OUTBOARD MOTOR OM UU FOUR STROKE SUPPLEMENTARY SERVICE MANUAL 99501 92J00 01E FOREWORD This supplementary service manual describes service data and servicing procedures which differ from those of the DF90T 115T K1 models The entire manual should be thoroughly reviewed before any servicing is performed NOTE Refer to the DF90T 115T service manual P no 99500 90J00 01E for details which are not given in this supplementary service manual Use this supplement with the following service manual DF90T 115T Service manual P no 99500 90J00 01E CONTENTS GENERAL INFORMATION _____ SPECIFICATIONS ___ U U _ SERVICE DATA ____ Os TIGHTENING TORQUE UA SPECIAL TOOLS S B MATERIALS REQUIRED _ iG ENGINE CONTROL ____ oo A7 POWER UNIT _ 018 ENGINE OIL COOLER 8 e Removal installation 19 CAMSHAFT o CYLINDER BLOCK MEINEN PISTON amp PISTON RING 21 CRANKSHAFT sp ss 22 CONROD ASSEMBLY _ mn 22 MID UNIT esa ET POWER TRIM AND TILT ge ely 225 SERVICE PROCEDURE 2 OIL LEVEL AIR BLEEDING MN NU 25 POWER TRIM AND TILT UNIT ____ 26 REMOVAL 26 DISASSEMBLY Reg o y SS CLEANING AND INSPECTING 30 REASSEMBLY gt Te 4 PTT MOTOR zz v d INSTALLATION z 37 COMPONENT PARTS 39 OPERATION NM 39 LOWER UNIT Normal rotation model 46 REMOVAL AND INSTALLATION 46 DISASSEMBLY 46 ASSEMBLY I ar e
30. TER ROTATION LOWER UNIT 89 FORWARD GEAR BACK UP SHIM ADJUSTMENT Follow the procedure below to adjust forward gear Step to prior to adjustment 1 Correctly assemble reverse gear driveshaft oil seal hous ing driveshaft pinion gear and related components See page 78 80 2 Tighten pinion nut to specified torque V Pinion nut 120 N m 12 kg m 86 8 Ib ft 3 Correctly assemble forward gear forward gear bearing pro peller shaft propeller shaft thrust bearing and propeller shaft bearing housing and related components then install for ward gear propeller shaft bearing housing assembly into gearcase 4 Tighten both bearing housing retaining bolts to the speci fied torque NOTE Before installing special tool loosen the jam nuts securing the long bolts and then remove the plate from long bolts Screw long bolts into the 10 mm thread on propeller shaft bearing housing 5 Install the special toll to gearcase and then attach it to the propeller shaft as shown in the illustration 1 Jam nuts 2 Plate 1 09951 98721 Gear holder 6 Turn the bolt D counterclockwise and tighten until the pro peller shaft can rotate smoothly without play Do not over tighten Checking driveshaft thrust play a Affix gear adjusting gauge to driveshaft 09951 09511 Gear adjusting gauge b To check the driveshaft thrust play slowly push driveshaft downward then read the maximum play Driveshaf
31. TT switch is operated in the DOWN position the motor and gear pump will rotate in a counterclockwise direction 2 The oil pressure will open the Down check valve D and oil will be forced through the Down shuttle valve E When the oil reaches Up shuttle valve B the check valve will begin to open mechanically 3 The pressurized oil flows through Down check valve D and then enters the upper area of the tilt cylinder This thereby forces the tilt rod piston downward 4 When the swivel bracket contacts the trim rams this pressure forces the trim pistons downward and oil from the reservoir is then able to enter the area above both trim rod pistons 5 Oil from the lower area of the trim and tilt cylinders now returns to the pump through Up check valve 6 Throughout the tilt action operation range there is a difference in oil volume between the upper and lower chambers of the tilt cylinder and any surplus oil is therefore directed to the reservoir by means of the Down relief orifice E 7 Throughout trim operation range oil will be discharged from the bottom of all three cylinders and the pump will only supply oil to the tilt cylinder Excess oil is then vented to the reservoir through the Down relief orifice 8 To prevent damage from excessive oil pressure when all three rods are fully retraced this pressure is relieved through the Down relief orifice 42 DF140 140Z POWER TRIM A
32. UP SHIM ADJUSTMENT 1 Correctly assemble reverse gear bearing housing reverse gear thrust bearing reverse gear retainer reverse gear re verse gear spacer pinion gear driveshaft assembly oil seal housing and related components 2 Tighten pinion nut to specified torque V Pinion nut 120 N m 12 kg m 86 8 Ib ft 3 Install propeller shaft assembly and bearing housing as sembly without the forward gear then tighten bearing hous ing retaining bolts to the specified torque 4 Install the special tool to the bearing housing and then at tach it to the propeller shaft as shown 09951 98721 Gear holder NOTE 1 Jam nuts Before installing special tool loosen the jam nuts securing 2 Plate 1 the long bolts and then remove the plate from long bolts Screw long bolts into the 10 mm thread on propeller shaft bearing housing 5 Turn the bolt D clockwise and tighten until the propeller shaft can rotate smoothly without play Do not over tighten 6 Affix gear adjusting gauge to driveshaft 09951 09511 gear adjusting gauge 7 To check the driveshaft thrust play slowly push driveshaft downward then read the maximum play Driveshaft thrust play Approx 0 6 0 8 mm 0 024 0 031 in f thrust play is larger than the specified thickness of re verse gear back up shim must be increased f thrust play is smaller reverse gear back up shim thick ness must be decreased DF140 140Z COUN
33. ase until the bottom of shaft protrudes through center of pinion NOTE The washer tab must be located into groove on the gearcase Install bearing outer race and pinion shim 8 to driveshaft DRIVESHAFT OIL SEAL HOUSING Apply Water Resistant Grease to the driveshaft oil seal Xe 99000 25160 Water Resistant Grease CN Apply Water Resistant Grease to O ring then install the O ring RI zx into the groove on the driveshaft oil seal housing p Io 1 Install driveshaft oil seal housing on gearcase then tighten four 4 bolts securely 80 DF140 140Z COUNTER ROTATION LOWER UNIT PINION NUT Apply Thread Lock 1342 to the threads of the pinion nut before threading it onto the driveshaft Tighten nut to the specified torque V Pinion nut 120 N m 12 kg m 86 8 Ib ft 99000 32050 Thread Lock 1342 09921 29410 Driveshaft holder CHECKING DRIVESHAFT THRUST PLAY Before installing forward gear driveshaft thrust play should checked See the GEARS SHIMMING AND ADJUSTMENT CHECK ING DRIVESHAFT THRUST PLAY section on page 88 Driveshaft thrust play Approx 0 6 0 8 mm 0 024 0 031 in 09951 09511 Gear adjusting gauge PROPELLER SHAFT Slide the clutch dog shifter onto the propeller shaft NOTE For correct installation the side of the clutch dog shifter which must face towards reverse gear is marked with the letter R E V Insert the connector pin Q into propeller shaft Align
34. cation of the conrod bolt and cap nut DF140 0 90 115 Bolt length L 48 mm 46 mm Nut height H 9 5 mm 7 5 mm DF140 NL 50mm N MES oc DF90 115 h 38mm E MID UNIT Main components of DF140 are the same as those of DF90 115 but the followings are different Upper mount and Lower mount are different between DF90 115 and DF140 DF140 mounts are harder than those of DF90 115 To equip DF140 with new PTT unit the swivel and clamp brackets have been modified DF140 140Z MID UNIT 23 Upper mount DF90 115 DF140 Lower mount I D groove DF140 Groove DF90 115 No groove bracket Clamp bracket PTT unit 24 DF140 140Z MID UNIT CLAMP BRACKET SWIVEL BRACKET STEERING BRACKET When disassembling or reassembling the components refer to the construction diagram below E 43 4 3 kg m 31 0 Ib ft W R G s Clamp bracket STBD Oil seal Pi bracket PORT Washer Clamp bracket shaft 9 Shim Nut Lower mount bracket Washer Circlip Anode Bush G Screw Bolt Q9 Washer amp Washer PTT unit Grease nipple amp Pin 9 Bolt Q Screw Nut
35. de diameter Standard 22 mm 0 87 in Service limit 20 4 mm 0 80 in If measurement exceeds service limit replace armature Ensure that the mica insulator between the segments is un dercut to specified depth SEGMENT Commutator undercut Standard 1 6 1 9 mm 0 06 0 07 in CE Service limit 1 0 mm 0 04 in 7 If undercut is less than service limit cut to specified depth MICA NOTE D Commutator undercut Remove all particles of mica and metal using compressed air Wear safety grasses when using compressed air Brushes Check the length of each brush 09900 20101 Vernier calipers Brush length Standard 9 8 mm 0 39 in Service limit 5 0 mm 0 20 in If brushes are worn down to the service limit they must be re placed O ring Inspect the O ring between the PTT motor and PTT pump case Replace if cuts nicks or tears are found 36 0 140 1402 POWER TRIM AND TILT Assembly Assembly is reverse of disassembly with special attention to following steps Install armature to brush holder first When installing the armature exercise care not to break the brushes Match up previously scribed alignment marks When assembling field case to brush holder proceed by pull ing PTT motor cables out of field case Apply silicone seal to PTT motor cable holder and grom mets and install cable holder screw PTT motor installation Installation is reverse of removal
36. e maximum play Driveshaft thrust play Approx 0 4 0 6 mm 0 016 0 023 in e f thrust play is larger than the specified thickness of forward gear back up shim must be increased e f thrust play is smaller forward gear back up shim thickness must be decreased Checking and adjusting tooth contact pattern Pinion and Forward gear Check tooth contact pattern by using the following procedure 1 To assess tooth contact apply a light coat of Prussian Blue on the convex surface of forward gear DF140 140Z NORMAL ROTATION LOWER UNIT 2 Install propeller shaft and housing assembly minus reverse gear and internal components 3 Push propeller shaft inward and hold in position 4 Using driveshaft holder tool rotate the driveshaft 5 6 times 09921 29410 Driveshaft holder 5 Carefully pull out propeller shaft and housing to check tooth contact pattern Optimum tooth contact The optimum tooth contact is shown at right A shim adjustment may be necessary to obtain this contact pattern CAUTION The driveshaft thrust play should be checked when in creasing or decreasing the thickness of the shim to adjust tooth contact Example 1 Incorrect topside toe contact Correction measures Decrease thickness of forward gear shim Slightly increase pinion gear shim thickness CAUTION Do not set tooth contact in this position top side toe contact Damage and chipping o
37. ee LOWER UNIT GEARS SHIMMING AND ADJUSTMENT__________ 61 COUNTER ROTATION LOWER UNIT DF140Z 66 REMOVAL AND INSTALLATION 07 DISASSEMBLY o INSPECTION _ CNN ASSEMBLY 76 LOWER UNIT GEARS SHIMMING AND ADJUSTMENT Counter rotation model 86 WIRING DIAGRAM DAE C Q2 HOSE ROUTING 93 2 DF140 40Z2 GENERAL INFORMATION GENERAL INFORMATION SPECIFICATIONS These specifications are subject to change without notice Data Unit DIMENSIONS amp WEIGHT Overall length front to back in 779 30 7 Overall width side to side in 481 18 9 Overall height in 1611 63 4 Weight 186 0 410 without engine oil Transom height mm in type 539 20 mm in type PERFORMANCE kw PS 109 140 Recommended operating range r min 5600 6200 Idle speed r min 700 50 POWERHEAD Engine type 4 stroke DOHC Number of cylinders 4 Bore in 86 3 39 Stroke in 88 3 46 Total displacement cm cu in 2044 124 6 Compression ratio zT 9 7 Spark plug BKR6E Ignition system Full transistorized ignition Fuel supply system Multi point sequential electronic fuel injection Exhaust system Through prop exhaust Cooling system Water cooled Lubrication system Wet sump by trochoid pump Starting system Electric Throttle control Remote control DF140 140Z GENERAL INFORMATION 3
38. en the four 4 pump case bolts to the specified torque V Pump case bolt 20 N m 2 0 kg m 14 5 Ib ft DF140 140Z COUNTER ROTATION LOWER UNIT PROPELLER INSTALLATION Install propeller stopper onto propeller shaft then slide on the propeller Fit spacer 3 washer and nut then tighten nut to speci fied torque Push cotter pin 6 through nut and shaft then bend to secure 99000 25160 Water Resistant Grease v Propeller nut 55 N m 5 5 kg m 40 0 Ib ft GEAR OIL Fill the gearcase with specified gear oil for initial testing and recheck the level after 10 minutes Top up if necessary 99000 22540 Suzuki Outboard Motor Gear Oil 6 3 85 86 DF140 140Z COUNTER ROTATION LOWER UNIT LOWER UNIT GEARS SHIMMING AND ADJUSTMENT Counter rotation model If lower unit has been rebuilt or has had components replaced shimming for correct gear contact and backlash will have to be adjusted to ensure smooth reliable operation of gears Shim Washer amp Mounting position Numerical index item Available thickness mm Design specification Thickness mm Pinion gear back up shim 0 60 0 65 0 70 0 75 0 85 0 90 0 95 1 00 1 10 1 15 1 0 Forward gear back up shim 0 60 0 65 0 70 0 75 0 85 0 90 0 95 1 00 0 8 Propeller shaft thrust shim 0 60 0 70 0 80 0 90 1 00 1 05 1 10 1 15 1 0 Reve
39. erse of disassembly with special attention to following steps D Oil seal Shift rod guide housing Bolt Ball amp Spring O ring Washer Circlip Seal cover Shift rod Yoke shifter Pin Horizontal slider amp Magneto 49 Grommet Water pump case Pin Bolt Key Water pump impeller Pump case under panel Gasket Exhaust seal Exhaust seal plate Union Hose Nipple Gear case Bolt Bolt Pin Anode Washer Bolt Trim tab Bolt Screw Water filter PORT Water filter STBD 54 N m e 5 5 kg m 39 8 Ib ft bod ve W R Gs 8 13 1 3 kg m 9 5 Ib ft amp Driveshaft Oil seal Bolt Oil seal housing O ring Shim Bearing Washer Washer Wave washer Washer Driveshaft collar Plug Gasket Bearing Dowel pin DF140 140Z COUNTER ROTATION LOWER UNIT 77 20 2 0 kg m 14 5 Ib ft 9 120 12 kg m 69 86 8 Ib ft Gear OIL 9 Thrust washer Back up shim Thrust washer R gear bearing housing Bearing Bearing 9 Washer Back up shim Shim Thrust washer O ring Thrust bearing Bearing R gear retainer Propeller shaft bearing housing Bearing Bolt Reverse gear amp Bearing Pinion gear Oil seal Pinion nut Washer Spacer Retaining r
40. eshaft and propeller shaft clockwise several times and then apply specified pressure for the test NOTE Apply low initial pressure of 20 40 0 2 0 4 kg cm 2 8 5 7 psi first then apply specified pressure Leakage test pressure 100 kPa 1 0 kg cm 14 2 psi CAUTION Do not exceed pressure of 110 kPa 1 ikg cm 15 6 psi or damage to oil seals will result 4 Once stabilized pressure should remain steady for at least 5 min If pressure does not fall sealing performance is correct 60 DF140 140Z NORMAL ROTATION LOWER UNIT WATER PUMP Impeller amp Case Place the dowel pins D under panel gasket and under panel 3 into position Insert the key in the driveshaft and slide the impeller 5 onto driveshaft ensuring that key and keyway are aligned Install the pump case while rotating driveshaft clockwise to flex the impeller vanes in the correct direction Securely tighten the four 4 pump case bolts to the specified torque V Pump case bolt 20 N m 2 0 kg m 14 5 Ib ft PROPELLER INSTALLATION Install propeller stopper onto propeller shaft then slide on the propeller Fit spacer 3 washer 4 and nut then tighten nut to speci fied torque Push cotter pin 6 through nut and shaft then bend to secure 99000 25160 Water Resistant Grease V Propeller nut 55 N m 5 5 kg m 40 0 Ib ft GEAR OIL Fill the gearcase with specified gear oil fo
41. ew gentle outward taps 09930 30161 Propeller shaft remover 09930 30102 Sliding hammer 3 Affix gear adjusting gauge to driveshaft 09951 09511 Gear adjusting gauge 4 Push shaft downward and read maximum play Designate this measurement as play B 5 Compare play B to play A page 64 6 Reverse gear back up shim adjustment is correct if B is equal to A f B is less than A reduce reverse gear back up shim thickness DF140 140Z NORMAL ROTATION LOWER UNIT 65 CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions measure the propeller shaft thrust play If not within the following specification a shim ad justment is required Propeller shaft thrust play 0 2 0 4 mm 0 008 0 016 in NOTE Maintain the forward gear thrust washer at standard thickness 9 0 mm and adjust only the reverse gear thrust washer with shim Measurement step 1 Assemble gear adjusting gauge to the propeller shaft 09951 09511 Gear adjusting gauge 2 Push propeller shaft inward 3 Hold shaft in and set dial gauge pointer to zero 4 Slowly pull shaft outward and read the maximum thrust play on the dial f measurement is more than specification increase reverse gear thrust washer thickness f measurement is less than specification reduce re verse gear thrust washer thickness 66 DF140 140Z COUNTER ROTATION LOWER UNIT COUNTER ROTATION LOWER UN
42. f forward and pinion gear may result Example 2 Incorrect bottom side toe contact Correction measures Increase thickness of forward gear shim Slightly decrease pinion gear shim thickness CAUTION Do not set tooth contact in this position bottom side toe contact Chipping of pinion gear may result 63 Concave side Convex side PATTERN Optimum tooth contact approx 1 3 of tooth width approx 1 mm pa Convex side HEEL EXAMPLE OF INCORRECT Top side toe contact EXAMPLE OF INCORRECT Bottom side toe contact HEEL 64 DF140 140Z NORMAL ROTATION LOWER UNIT CHECKING DRIVESHAFT THRUST PLAY After obtaining optimum tooth contact driveshaft thrust play should be measured 1 Affix gear adjusting gauge to driveshaft 09951 09511 Gear adjusting gauge 2 Slowly push driveshaft downward Read the maximum play Designate this amount of play as A Driveshaft thrust play Approx 0 4 0 6 mm 0 016 0 023 in NOTE Driveshaft thrust play A must be known to adjust reverse gear shim RECHECKING DRIVESHAFT THRUST PLAY Reverse gear back up shim adjustment 1 After adjusting forward gear tooth contact pattern correctly assemble propeller shaft housing assembly reverse gear and related components See page 55 to 56 2 Screw sliding hammer assembly onto propeller shaft and strike a f
43. f forward gear shim Slightly increase pinion gear shim thickness CAUTION Do not set tooth contact in this position top side toe contact Damage and chipping of forward and pinion gear may result Concave side Convex side Tooth top Tooth bottom PATTERN Optimum tooth contact approx 1 3 of tooth width approx 1mm HEEL pu Xo Convex side EXAMPLE OF INCORRECT Top side toe contact DF140 140Z COUNTER ROTATION LOWER UNIT 91 Example 2 Incorrect bottom side toe contact Correction measures Increase thickness of forward gear shim Slightly decrease pinion gear shim thickness CAUTION Do not set tooth contact in this position bottom side toe contact Chipping of pinion gear may result CHECKING PROPELLER SHAFT THRUST PLAY After adjusting all gear positions measure the propeller shaft thrust play If not within the following specification a shim ad justment is required Propeller shaft thrust play 0 2 0 4 mm 0 008 0 016 in Measurement step 1 Assemble gear adjusting gauge to the propeller shaft 09951 09511 Gear adjusting gauge 2 Push propeller shaft inward 3 Hold shaft in and set dial gauge pointer to zero 4 Slowly pull shaft outward and read the maximum thrust play on the dial f measurement is more than specification increase propeller shaft thrust shim thickness
44. f measurement is less than specification reduce pro peller shaft thrust shim thickness EXAMPLE OF INCORRECT Bottom side toe contact 6 Zot 10 LAG INVH9VIG 9NIHIM INVH5VIG 5NIHIA ZOt L Ot L3
45. groove width in 1 51 1 53 0 0594 0 0602 2 51 2 53 0 0988 0 0996 Piston ring in 1 17 1 19 0 0461 0 0469 thickness in 1 47 1 49 0 0579 0 0587 Pin clearance in in 0 006 0 017 0 0002 0 0007 piston pin hole in 0 040 0 0016 Piston pin outside in 20 997 21 000 0 8267 0 8268 diameter in 20 980 0 8260 Piston pin hole in 21 006 21 014 0 8270 0 8273 diameter in 21 040 0 8283 Pin clearance in in 0 003 0 014 0 0001 0 0006 conrod small end in 0 05 0 002 Conrod small end 21 003 21 011 0 8269 0 8272 bore 8 DF140 140Z GENERAL INFORMATION CRANKSHAFT CONROD Conrod small end inside diameter Conrod big end oil 21 003 21 011 0 8269 0 8272 0 020 0 040 0 0008 0 0016 clearance 0 065 0 0026 Conrod big end inside diameter 47 000 47 018 1 8504 1 8511 Crank pin outside diameter 43 982 44 000 1 7316 1 7323 Crank pin outside diameter difference out of round and taper 0 010 0 0004 Conrod bearing thickness 1 484 1 502 0 0584 0 0591 Conrod big end side 0 100 0 250 0 0039 0 0098 clearance 0 350 0 0138 Conrod big end width Crank pin width 21 950 22 000 0 8642 0 8661 22 100 22 200 0 8700 0 8740
46. haft assembly down into the gearcase until the bottom of shaft protrudes through center of pinion NOTE The washer tab must be located into groove on the gearcase Install bearing outer race 2 and pinion shim 8 to driveshaft DRIVESHAFT OIL SEAL HOUSING Apply Water Resistant Grease to the driveshaft oil seal 99000 25160 Water Resistant Grease Apply Water Resistant Grease to O ring then install the O ring into the groove on the driveshaft oil seal housing Install driveshaft oil seal housing on gearcase then tighten four 4 bolts securely DF140 140Z NORMAL ROTATION LOWER UNIT 55 PINION NUT Apply Thread Lock 1342 to the threads of the pinion nut before threading it onto the driveshaft Tighten nut to the specified torque V Pinion nut 120 N m 12 kg m 86 8 Ib ft 99000 32050 Thread Lock 1342 09921 29410 Driveshaft holder CHECKING DRIVESHAFT THRUST PLAY Before installing reverse gear driveshaft thrust play should checked See the GEARS SHIMMING AND ADJUSTMENT CHECK ING DRIVESHAFT THRUST PLAY section on page 62 09951 09511 Gear adjusting gauge PROPELLER SHAFT Slide the clutch dog shifter 2 onto the propeller shaft NOTE For correct installation the side of the clutch dog shifter which must face towards reverse gear is marked with the letter Insert the connector pin Q into propeller shaft Align the holes in the shifter dog and connector pin and then slide t
47. he dog pin through both dog and connector pin Install the dog pin retaining spring ensuring that it fits snugly N into the groove on the dog shifter 5 56 DF140 140Z NORMAL ROTATION LOWER UNIT PROPELLER SHAFT BEARING HOUSING Assemble the propeller shaft in the following sequence forward thrust washer 5 reverse thrust washer D reverse gear 2 reverse gear back up shim and propeller shaft hous ing 99000 25160 Water Resistant Grease 99000 22540 Suzuki Outboard Motor Gear Oil Assemble horizontal slider 6 to connector pin Using special tools install the propeller shaft and housing as sembly in the gear case 09922 59410 Propeller shaft housing installer 09922 59420 Housing Installer Handle When the housing is fully seated tighten both retaining bolts to the specified torque V Bearing housing bolt 20 N m 2 0 kg m 14 5 Ib ft RECHECKING DRIVESHAFT THRUST PLAY Recheck the driveshaft thrust play This should not be less than previously checked If less re duce the number thickness of reverse gear back up shims 09951 09511 Gear adjusting gauge DF140 140Z NORMAL ROTATION LOWER UNIT 57 CHECKING PROPELLER SHAFT THRUST PLAY See the GEARS SHIMMING AND ADJUSTMENT CHECK ING PROPELLER SHAFT THRUST PLAY section on page 65 SHIFT ROD GUIDE HOUSING Install the spring D and detent ball into shift rod guide housing Apply Water Resistant Grease
48. inder lower shaft bolt 50 N m 5 0 kg m 36 0 Ib ft Install anode 5 then tighten bolts securely 38 DF140 140Z POWER TRIM AND TILT Apply Water Resistant Grease to tilt rod upper bushes then install bushes in tilt rod Operate the PTT motor to extend the PTT rod upward Align the tilt rod with the hole in the swivel bracket as the tilt rod extends 99000 25160 Water Resistant Grease Apply Water Resistant Grease to the PTT rod upper shaft then insert the shaft through the swivel bracket and tilt rod 99000 25160 Water Resistant Grease Secure the upper shaft with the snap ring 8 Route the PTT motor cable in through the lower cover and con nect the terminals to the PTT relays Cable routing see the WIRE HOSE ROUTING section DF140 140Z POWER TRIM AND TILT 39 COMPONENT PARTS PTT motor Oil reservoir Gear pump Pump manifold assy Filter Tilt rod Manual release valve Impact relief valve Down shuttle valve Free piston Trim rod Down check valve Up shuttle valve Up check valve Down relief orifice Down relief check valve Pump room orifice Tank room orifice Up relief valve 6 amp 698 Cylinder body When the manual valve is to be opened turn the manual release valve to the left about two turns When the oil level of the system should be checked inspect the reservoir by placing the motor in the maximum tilt up position OPERATION By moto
49. ing Connector pin amp Stopper Dog pin Propeller Clutch dog shifter Propeller bush Dog spring Spacer Propeller shaft Washer Forward gear Nut F gear thrust bearing Pin 78 DF140 140Z COUNTER ROTATION LOWER UNIT CAUTION Make sure that all parts used in assembly are clean and lubricated After assembly check parts for tightness and smoothness of operation Before final assembly be absolutely certain that all gear contact shim adjustments and tolerances are correct Failure to correctly adjust these areas will result in lower unit damage See the GEARS SHIMMING AND ADJUSTMENT section on page 86 REVERSE GEAR BEARING HOUSING Install dowel pin and R gear bearing housing in posi tion REVERSE GEAR Place R gear back up shim D and bearing thrust washer 2 in position Assemble the R gear thrust bearing S reverse gear retainer 4 and reverse gear then install reverse gear retainer as sembly 99000 22540 Suzuki Outboard Motor Gear Oil PINION GEAR Place pinion gear in gearcase DF140 140Z COUNTER ROTATION LOWER UNIT 79 DRIVESHAFT Assemble the washer D washer with the tab 2 wave washer 3 washer and driveshaft collar to the driveshaft After installing driveshaft collar fit the convex part of the col lar in the concave part of the driveshaft by turning collar Lower the driveshaft assembly down into the gearc
50. l PTT PUMP CASE Install five 5 O rings and orifice collars to PTT cylinder body NOTE Lubricate O rings with PTT fluid before installing PTT cylinder body Install PTT pump case then tighten three 3 screws to speci fied torque V PTT pump case screw 3 5 0 35 kg m 2 5 Ib ft MANUAL RELEASE VALVE Oil and install the manual release valve 1j Tighten the valve to specified torque Install snap ring 2 V Manual release valve 3 5 N m 0 36 kg m 2 6 Ib ft PTT MOTOR See the PTT Motor Installation section on page 36 RESERVOIR Install O ring and reservoir then tighten bolts to specified torque V Reservoir bolt 5 N m 0 5 kg m 3 5 Ib ft AIR BLEEDING Pour recommended PTT fluid in to reservoir until specified level Perform the air bleeding procedure For air bleeding see page 25 Orifice collar DF140 140Z POWER TRIM AND TILT PTT MOTOR Removal NOTE Before removing PTT motor wash the PTT body with a stiff bristle brush and hot soapy water to remove sand or dirt and dry the PTT body with compressed air Place the lower mounting eye of the PTT cylinder in a vise Tighten the vise only enough to secure the PTT unit do not over tighten NOTE To prevent damage to the PTT cylinder use wood blocks vise jaw protectors etc between the vise jaws and PTT compo nents before tightening vise Remove the four 4 screws securing the PTT motor to the PTT pu
51. mp Stopper amp Shim Pinion gear amp Propeller Bearing Pinion nut Propeller bush amp Washer Thrust washer amp Spacer Washer amp Connector pin Washer Wave washer Clutch dog shifter Nut Washer Dog pin Pin Driveshaft collar Dog spring amp Dowel pin DF140 140Z NORMAL ROTATION LOWER UNIT 53 CAUTION Make sure that all parts used in assembly are clean and lubricated After assembly check parts for tightness and smoothness of operation Before final assembly be absolutely certain that all gear contact shim adjustments and tolerances are correct Failure to correctly adjust these areas will result in lower unit damage See the GEARS SHIMMING AND ADJUSTMENT section on page 61 FORWARD GEAR BEARING HOUSING Install dowel pin and forward gear bearing housing FORWARD GEAR Place the forward gear back up shim D thrust washer for ward gear thrust bearing in position then install forward gear 99000 22540 Suzuki Outboard Motor Gear Oil PINION GEAR Place pinion gear in gearcase 54 DF140 140Z NORMAL ROTATION LOWER UNIT DRIVESHAFT Assemble the washer D washer with the tab 2 wave washer 3 washer 4 and driveshaft collar amp to the driveshaft After installing driveshaft collar fit the convex part of the col lar in the concave part of the driveshaft by turning collar Lower the drives
52. mp case Detach the PTT motor from PTT pump case Note the position of drive joint D and O ring and remove them PTT motor Disassembly For correct assembly scribe an alignment mark on the field case and brush holder Slide cable protector tube upward Remove the screw securing the motor cable holder D then slide motor cable holder and grommets out as shown in figure 33 34 DF140 140Z POWER TRIM AND TILT Remove the two 2 screws 3 securing the field case to the brush holder Slide the field case upward and away from the brush holder NOTE When separating field case from brush holder proceed by push ing PTT motor cables into brush holder side Disconnect PTT motor cables from brush holder Remove armature from field case Note the position of the O ring encircling the brush holder Inspection Armature and Commutator Check for continuity between the commutator and the armature core shaft Replace armature if continuity is indicated 09930 99320 Digital tester Tester range A Continuity Check continuity between the adjacent commutator segments Replace armature if no continuity is indicated T 2 DF140 140Z POWER TRIM AND TILT 35 Inspect the commutator surface If surface is gummy or dirty clean with 400 grit emery paper Measure commutator outside diameter 09900 20101 Vernier calipers Commutator outsi
53. n gear ratio 12 23 1 92 Lower unit gear Total reduction gear ratio 2 38 38 x 23 SERVICE DATA These service data are subject to change without notice Unit Data ni DF140T DF140Z POWERHEAD Recommended operating range r min 5600 6200 Idle speed r min 700 50 in gear 700 50 Cylinder compression kPa kg cm psi 1200 1600 12 16 171 228 Cylinder compression max difference between any three kPa kg cm psi 100 1 0 14 cylinders Engi il ssure _ 5 5 in ngine oil pre kPa kg om psi 440 490 4 5 5 0 64 71 at 3000 r min at normal operating temp Engine oil API classification SE SF SG SH SJ Viscosity rating SAE 10W 40 Engine oil amounts 5 5 5 8 4 8 Oil change L US Imp qt SEN 5 7 6 0 5 0 Oil filter change Thermostat operating C F 58 62 136 143 temperature Figures shown are guidelines only not absolute service limits DF140 140Z GENERAL INFORMATION 5 DF140T DF140Z Cylinder head distortion in 0 05 0 002 Manifold seating faces 0 10 0 004 distortion Cam height in 39 520 39 680 1 5560 1 5622 39 420 1 5520 39 320 39 480 1 5480 1 5543 39 220 1 5441 Camshaft journal oil clearance 0 020 0 062 0 0008 0 0024 0 120 0 0047 0 045 0 087 0 0018 0 0034 0 120 0 0047
54. nd washer 9 from driveshaft Remove the pinion gear Remove reverse gear 2 with reverse gear retainer and thrust bearing Remove the reverse gear from reverse gear retainer Remove the bearing thrust washer and back up shim 70 DF140 140Z COUNTER ROTATION LOWER UNIT Remove the reverse gear bearing housing 2 and dowel pin 8 Disassembly of propeller shaft components Slide propeller shaft away from forward gear and bearing housing assembly Remove the forward gear forward gear thrust bearing forward gear thrust washer 5 forward gear back up shim Remove the propeller shaft thrust washer 7 propeller shaft thrust bearing 8 bearing washer 9 and shim 10 from propel ler shaft bearing housing To disassemble propeller shaft components refer to the follow ing a Remove horizontal slider and spacer 2 b Remove the spring 43 from the clutch dog shifter DF140 140Z COUNTER ROTATION LOWER UNIT 71 c Use special tool to push the dog pin 4 out of the clutch dog shifter 09922 89810 Shift pin remover d Remove the clutch dog shifter 05 and connector pin from propeller shaft Disassembly of shift rod components a Remove the circlip and washer b Slide the shift rod 3 out of the shift rod guide housing c Remove the detent ball and spring d Remove the pin and shifter yoke
55. o be added to the Ver 4 currently used FLYWHEEL MAGNETO When installing the flywheel magneto apply a small amount of engine oil to the threads and seating face of the magneto bolt for lubrication so that the correct tightening torque specifica tion can be attained securely V Flywheel bolt 245 N m 24 5 kg m 177 Ib ft DF140 140Z ENGINE CONTROL 17 18 0 140 1402 POWER UNIT POWER UNIT ENGINE OIL COOLER To keep a engine oil temp properly and to show its optimum engine performance a engine oil cooler was installed The water flow to cool the engine oil is shown in the figure Water outlet Water gallery Engine oil cooler Engine oil filter Cylinder block Bottom side Water inlet PIPING gt A i To water il 1 return Intake Fuel return manifold Crank case pipe water jacket water Jacket d Oil To pilot hole cooler From engine holder Removal 1 Remove the STBD side lower cover 2 Using oil filter wrench to loosen the oil filter then remove engine oil filter and O ring 09915 47330 filter wrench 3 Disconnect both inlet 2 and outlet 33 water hoses from en gine oil cooler 4 Loosen oil filter stand then remove the oil filter stand and engine oil cooler assembly NOTE Use socket wrench to loose the
56. oil filter stand Installation 1 Install seal ring to oil cooler assembly 2 Place the engine oil cooler assembly to cylinder block NOTE When installing the oil cooler put a locating pin Q at the sur face of rib in the cylinder block as shown in the figure DF140 140Z POWER UNIT 19 20 DF140 140Z POWER UNIT 3 Install oil filter stand S then tighten filter stand to specified torque V Oil filter stand 40 N m 4 0 kg m 29 Ib ft Connect inlet and outlet water hoses to each fitting of engine oil cooler 4 Screw engine oil filter on by hand until the filter O ring contacts the mounting surface NOTE Before fitting oil filter be sure to oil O ring 5 Tighten the engine oil filter 3 4 turn from the point of contact with the mounting surface using an oil filter wrench 5 Engine oil filter 14 N m 1 4 kg m 10 Ib ft 3 4 turn CAMSHAFT The camshaft for DF140 was specially designed The height of the cam is different from DF90 115 Cam height Standard IN 39 520 39 680 mm 1 5560 1 5622 in EX 39 320 39 480 mm 1 5480 1 5543 in Service limit IN 39 420 mm 1 5520 in EX 39 220 mm 1 5441 in Camshaft identification The camshaft is distinguished by the mark at the top of shaft DF140 camshaft is marked as shown I D mark Mark DF140 3 DF115 2 DF90 1 CYLINDER
57. pin remover 09930 30161 Propeller shaft remover 09930 30102 Sliding hammer 09930 39411 Flywheel rotor remover SS 09930 39420 Rotor remover bolt 53 H 09930 48720 Flywheel holder 09930 76420 Timing light 09930 89240 4 pin connector test cord 56 09930 89260 Injector test cord A 09930 89950 44 pin test cord 09930 99320 Digital tester 09900 25002 Pocket tester Diagnostic harness 09932 89910 SDS adapter 09940 44120 Air pressure gauge 09940 44130 Attachment A 09950 69512 Gearcase oil leakage tester B Air pump 09951 09511 Gear adjusting gauge 09944 09420 PTT cylinder cap tool Pinion bearing installer and remover A 09951 59910 Pinion bearing installer shaft B 01107 08408 Bolt C 09951 39914 Pinion bearing plate D 09951 19420 Attachment A 18213 74F00 O sensor B 18498 99E40 Protector 09951 09010 Shimming gauge 16 DF140 140Z GENERAL INFORMATION 99954 53873 lt A 99954 53008 820 Stevens CD 77 99954 53883 Digital voltmeter Peak reading voltmeter Gear oil filler NOTE Marked part No is in U S market only MATERIALS REQUIRED SUZUKI OUTBOARD SUZUKI SUPER WATER RESISTANT SUZUKI SILICONE MOTOR GEAR OIL GREASE A GREASE SEAL A ESP 99000 25030 d
58. r initial testing and recheck the level after 10 minutes Top up if necessary 99000 22540 Suzuki Outboard Motor Gear Oil DF140 140Z NORMAL ROTATION LOWER UNIT 61 LOWER UNIT GEARS SHIMMING AND ADJUSTMENT Normal rotation model If lower unit has been rebuilt or has had components replaced shimming for correct gear contact and back lash will have to be adjusted to ensure smooth reliable operation of gears Shim Washer amp Mounting position Available thickness mm Numerical index item Thickness mm T7 0 60 0 65 0 70 0 75 0 80 0 85 0 90 0 95 1 00 1 05 1 0 1 10 1 15 Pinion gear back up shim Forward gear 0 60 0 65 0 70 0 75 0 80 back up shim 0 85 0 90 0 95 1 00 1 1 Forward gear thrust washer 39 Reverse gear 1 5 1 7 1 9 2 1 2 3 2 4 thrust washer 2 6 2 7 2 8 Reverse gear 1 0 1 1 1 2 1 3 1 4 1 5 1 6 back up shim PINION GEAR BACK UP SHIM ADJUSTMENT 1 Position the shimming gauge horizontally in a vise and 3 0d 6 tighten vise securely 09951 09010 Shimming gauge 2 Assemble the bearing outer race back up shim and driveshaft oil seal housing Q to the driveshaft
59. r operation the geared pump will be driven and by turning the motor to the right or to the left oil flow will change its direction and this causes up and down movements of the piston rod of the tilt cylinder and the trim rod of the trim cylinder 40 DF140 140Z POWER TRIM AND TILT TRIM amp TILT UP 1 When the PTT switch is operated in the UP position the motor and gear pump will rotate in a clockwise direction 2 Pressurized oil will open Up check valve and the oil will flow through Up shuttle valve B to the Down shuttle valve Following operation of valve Down check valve will open mechanically 3 Pressurized oil flows through the Up check valve to the bottom of the trim and tilt cylinders thereby pushing the trim and tilt pistons upward Residual oil in the upper area of the tilt cylinder is returned to the pump through Down check valve O Any oil in the area above both trim cylinder pistons will be returned to the reservoir Oil will then flow from the reservoir to the pump to stabilize the balance of the oil volumes When the engine is fully tilted up oil pressure will correspondingly increase in the lower chamber of the tilt and trim cylinders But to protect the PTT unit from excessively high pump pressure the Up relief valve G begins to open 4 5 6 7 ve a WH DF140 140Z POWER TRIM AND TILT 41 TILT DOWN TRIM IN 1 When the P
60. riveshaft holder 1 09912 58442 Fuel pressure gauge 2 2 09912 58432 Fuel pressure hose 3 09912 58490 3 way joint amp hose 19 Nu Deep socket wrench 21 s Oil seal remover 13 14 DF140 140Z GENERAL INFORMATION 09915 47330 Oil filter wrench 09915 64511 Compression gauge 09915 67010 Compression gauge hose attachment 09915 64530 Compression gauge hose 09915 77311 Oil pressure gauge 2r 09915 78211 Oil pressure gauge adapter 28 09916 10910 Valve lapper 29 09916 19030 Valve lifter 09916 14910 Valve lifter attachment 31 Solid pilot Neway N 120 6 0 09916 54910 Handle N 505 09916 22420 Valve seat cutter 60 Neway 114 09916 20620 Valve seat cutter 45 Neway 122 09916 20610 Valve seat cutter 15 Neway 121 36 09916 37810 Valve guide reamer 6 mm 09916 34542 Valve guide reamer handle 38 09916 38210 Valve guide reamer 0 11 mm 39 09916 46020 Valve guide remover 41 09916 49040 Tappet holder 42 09916 77310 Piston ring compressor 43 09916 84511 Tweezers 09917 47011 Vacuum pump gauge 09917 87810 Valve guide installer attachment 09917 98221 Valve guide stem seal installer attachment lt 09922 59410 Propeller shaft housing installer B 09922 59420 Housing installer handle DF140 140Z GENERAL INFORMATION 15 48 09922 89810 Shift lock
61. rse gear back up shim 0 8 0 9 1 0 1 1 1 2 1 3 1 4 D cls TS UB ey y NS 1 li Jj A Fe zE z m COLI ES XE gt ard XAN V N NA G X MN N SN DF140 140Z COUNTER ROTATION LOWER UNIT PINION GEAR BACK UP SHIM ADJUSTMENT 1 Position the shimming gauge horizontally in a vise and tighten vise securely 09951 09010 Shimming gauge 2 Assemble the bearing outer race D back up shim 2 and driveshaft oil seal housing Q to the driveshaft NOTE Use a thinner pinion back up shim than the standard shim so that a clearance B exists 3 Insert the driveshaft through the shimming gauge open ing and then install pinion gear and nut to the driveshaft tighten pinion nut V Pinion nut 120 N m 12 kg m 86 8 Ib ft 4 Install oil seal housing to shimming gauge with bolts 5 Depress and hold driveshaft so that driveshaft bearing is firmly seated in bearing outer race 6 Hold driveshaft against oil seal housing 3 while measur ing clearance B between gauge and flat edge of pinion gear with thickness gauge measured clearance plus shim 2 is the total shim thickness to be used in gear housing reassembly for correct pinion gear position HE Hi A 87 88 DF140 140Z COUNTER ROTATION LOWER UNIT REVERSE GEAR BACK
62. screw the fill plug and drain PTT oil into suitable container Remove the three 3 screws securing reservoir D then de tach the reservoir from cylinder body Note the position of O ring and remove it 27 28 DF140 140Z POWER TRIM AND TILT Remove the PTT motor assembly See page 33 Note the position of drive joint and O ring before remov ing them Remove the manual release valve snap ring then unscrew the manual release valve Remove the three 3 screws securing the PTT pump case then detach the PTT pump case from PTT cylinder body Note the position of O rings and orifices collars before remov ing them Orifice collar with ball valve B Orifice collar with filter and ball valve O Orifice collar Using special tool unscrew the PTT cylinder head 09944 09420 PTT cylinder cap tool DF140 140Z POWER TRIM AND TILT 29 Pull the tilt rod piston assembly out of the cylinder body Remove the free piston from the cylinder body Disassembly of tilt rod piston assembly Unscrew the piston retaining nut from the bottom of the tilt rod and remove the washer Carefully retain and account for four shock valves each com posed of spring rod and ball Remove the piston assembly and PTT cylinder head from the tilt rod by sliding them down and off the rod end Disassembly of trim rod piston assembly Using special tool unscrew the trim cylinder head
63. t thrust play Approx 0 3 0 5 mm 0 012 0 020 in f thrust play is larger than the specified thickness of forward gear back up shim must be increased f thrust play is smaller forward gear back up shim thickness must be decreased 90 DF140 140Z COUNTER ROTATION LOWER UNIT Checking and adjusting tooth contact pattern Pinion and Forward gear Check tooth contact pattern by using the following procedure A To assess tooth contact apply a light coat of Prussian Blue on the convex surface of forward gear B In accordance with step 1 6 assemble the lower unit then install the special tool Turn the bolt counterclockwise and tighten until the pro peller shaft can rotate smoothly without play Do not over tighten NOTE While assessing tooth contact place the clutch dog shifter to Neutral position 09951 98721 Gear holder C Using driveshaft holder tool rotate the driveshaft 5 6 times 09921 29410 Driveshaft holder D Carefully pull out propeller shaft and housing to check tooth contact pattern Optimum tooth contact The optimum tooth contact is shown at right A shim adjustment may be necessary to obtain this contact pattern CAUTION The driveshaft thrust play should be checked when in creasing or decreasing the thickness of the shim to adjust tooth contact Example 1 Incorrect topside toe contact Correction measures Decrease thickness o
64. the holes in the shifter dog and connector pin and then slide the dog pin through both dog and connector pin Install the dog pin retaining spring ensuring that it fits snugly into the groove on the dog shifter Install the spacer 6 to propeller shaft DF140 140Z COUNTER ROTATION LOWER UNIT 81 FORWARD GEAR PROPELLER SHAFT BEARING HOUSING Assemble the propeller shaft in the following sequence 99000 25160 Water Resistant Grease 99000 22540 Suzuki Outboard Motor Gear Oil a Apply Water Resistant Grease to O ring D then install the O ring into the groove on the propeller shaft bearing hous ing b Install shim bearing washer S propeller shaft thrust bearing propeller shaft thrust washer into propeller shaft bearing housing c Install F gear back up shim 2 F gear thrust washer 8 F gear thrust bearing and forward gear 10 to propeller shaft bearing housing d Slide propeller shaft into forward gear and propeller shaft bearing housing e Assemble horizontal slider 2 to connector pin To hold the correct bearing position pull propeller shaft back ward and then install propeller shaft and housing assembly in the gearcase NOTE To make the bearing housing fully seated in the gearcase tap the housing gently with plastic mallet 82 DF140 140Z COUNTER ROTATION LOWER UNIT When the housing is fully seated tighten both retaining bolts to the specified
65. to the shift rod oil seal Install shift rod and washer into the shift rod guide housing 5 then secure it with the snap ring NOTE Before install the shift unit Shift rod guide housing assembly be sure to put the horizontal slider in the neutral position Apply Water Resistant Grease to the shift rod guide housing O ring NOTE Before install the shift unit Shift rod guide housing assembly bring shifter yoke to the neutral position by turning shift rod right or left 1 Horizontal slider 2 F Gear bearing housing 3 Shift rod center Shifter yoke 58 DF140 140Z NORMAL ROTATION LOWER UNIT Install the shift rod guide housing assembly 2 by aligning the shifter yoke with the groove in the horizontal slider then tighten three 3 housing bolts securely e Shift the shift rod from Neutral through Forward and Reverse to check proper gear engagement Horizontal slider Shifter yoke Apply enough Water Resistant Grease on oil seal before put ting seal cover 8 so that there is no space between them DF140 140Z NORMAL ROTATION LOWER UNIT 59 LEAKAGE CHECK Check for leakage of oil seal and O ring when applying speci fied pressure inside of the gearcase 09950 69511 Oil leakage tester Air pump Procedure 1 Install the test tool into the oil level hole 2 Connect the air pump to the tester 3 Rotate driv
66. ve D open allowing oil from the upper area of the tilt cylinder to flow into the area between the tilt rod piston and the free piston The tilt rod will then extend 2 When the moment of impact has passed the PTT DOWN switch must be activated to return the engine to within the normal trim range When the switch is pressed the oil between the piston and free piston will be directed to the cylinder upper chamber via the return valve below the tilt piston 44 DF140 140Z POWER TRIM AND TILT MANUAL RELEASE CIRCUIT DOWN MODE 1 By opening the manual release valve the engine can be lowered manually to a running position Oil underneath the trim and tilt pistons will be directed through this valve into the area above the tilt rod piston 2 The volume of oil flowing from under the trim rod pistons will be larger than the area above the tilt rod piston can accommodate Excess oil therefore returns through the manual release valve to the reser voir DF140 140Z POWER TRIM AND TILT 45 MANUAL RELEASE CIRCUIT UP MODE 1 With the manual release valve f open the engine can also be raised manually to the fully tilted position 2 Oil from the upper chamber of the tilt cylinder will flow through valve into the lower chamber of the cylinder 3 The upward movement of the piston rod will increase the cylinder area beneath it thereby allowing oil from the reservoir to flow into this area 46 DF140 140Z NORMAL R
67. with special attention to fol lowing steps Ensure that the drive joint D is aligned and firmly inserted into the gear pump assembly Fit O ring 2 to PTT motor Check the level of PTT fluid contained in the PTT pump case If level is low add recommended PTT fluid until level with mating surface of PTT motor Ensure that the faces of the PTT motor and pump unit are free of dirt or debris When attaching the PTT motor to the PTT pump case en sure that the tip of armature shaft fits firmly into the drive joint Tighten the four 4 screws to specified torque V PTT motor screw 5 N m 0 5 kg m 3 6 Ib ft Pour recommended PTT fluid into reservoir until specified level Perform the air bleeding procedure For air bleeding see page 25 DF140 140Z POWER TRIM AND TILT 37 INSTALLATION Installation is reverse order of removal with special attention to the following steps Lower tilt rod to full down position Apply Water Resistant Grease to the tilt cylinder lower shaft and lower shaft bushes Install bushes and cylinder lower shaft 2 to PTT unit 99000 25160 Water Resistant Grease Place the PTT unit in position then install the clamp bracket Tighten the clamp bracket shaft nut to specified torque V Clamp bracket shaft nut 43 N m 4 3 kg m 31 0 Ib ft Tighten lower shaft bolts 4 pre coated with thread lock to specified torque 99000 32050 Thread Lock 1342 V Cyl

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